SJ45T Service Manual

MODELS SJ 40T SJ 45T
Service Manual
Telescopic Boom Series
Part No. 143844AE September 2010

USE THE SERIAL NUMBER OF YOUR MACHINE
TO DETERMINE THE CORRECT MANUAL TO USE
Manual Part # 143844AD 143872AB
Release Date June 2008 September 2010
SJ 40T 98000521 & Below 98000522 & Above
MODELS
SJ 45T Use Not Used
Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, 60174 USA
Phone: 630-262-0005
Toll Free: 1-800-275-9522
Fax: 630-262-0006
Email: service@skyjack.com
Parts (North America)

Toll Free: 1-800-965-4626
Toll Free Fax: 1-888-782-4825
Email: parts@skyjack.com
Parts & Service (Europe) Unit 1 Maes Y Clawdd, Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK
Phone: +44-1691-676-235
Fax: +44-1691-676-238
Email: info@skyjackeurope.co.uk
Skyjack Asia Pacific

Singapore
Phone: +65-6449-3710
Fax: +65-6449-7690
Email: skyjack@singnet.com.sg
SERVICE AND MAINTENANCE
Table of Contents
Section 1 - Scheduled Maintenance

Table of Contents
Section 2 - Maintenance Tables

List of Tables
Section 3 - System Component Identification and Schematics

Table of Contents
Section 4 - Troubleshooting
Troubleshooting
Section 5 - Procedures
Table of Contents
Telescopic Boom Series SKYJACK, Page 3

The Safety Alert Symbol identifies important
safety messages on aerial platforms, safety This Safety Alert Symbol means attention!
signs in manuals or elsewhere. When you
see this symbol, be alert to the possibility of Become alert! Your safety is involved.
personal injury or death. Follow the instructions
in the safety message.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.
important
IMPORTANT indicates a procedure essential for safe operation and which,
if not followed, may result in a malfunction or damage to the aerial platform.
SKYJACK, Page 4 Telescopic Boom Series

1
Section 1
scheduleD maintenance
Table of Contents
Operator’s Responsibility for Maintenance
Aerial Platform Definition...............................................................................................................................................7
Purpose of Equipment..................................................................................................................................................7
Use of Equipment.........................................................................................................................................................7
Manuals.........................................................................................................................................................................7
Operator........................................................................................................................................................................7
Service Policy and Warranty.........................................................................................................................................7
Optional Accessories....................................................................................................................................................7
Scope of this Manual....................................................................................................................................................8
Operator Safety Reminders..........................................................................................................................................8
Electrocution Hazard....................................................................................................................................................9
Safety Precautions......................................................................................................................................................10
Maintenance and Inspection Schedule......................................................................................................................13
Owner’s Annual Inspection Record............................................................................................................................13
Replacement Parts......................................................................................................................................................13
Maintenance and Service Safety Tips........................................................................................................................13
Hydraulic System & Component Maintenance and Repair.......................................................................................14
Maintenance Hints......................................................................................................................................................14
Service and Maintenance

About this Section.......................................................................................................................................................15
Service Bulletins..........................................................................................................................................................15
Maintenance and Inspection......................................................................................................................................15
Maintenance Instructions............................................................................................................................................15
Schedule Maintenance Inspections

1.1 Scheduled Maintenance Inspections...............................................................................................................18
1.2 Function Tests..................................................................................................................................................28
Tables
1.1 Owner’s Annual Inspection Record.................................................................................................................16
1.2 Maintenance and Inspection Checklist............................................................................................................17

Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Aerial Platform Definition

A mobile device that has an adjustable position platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK Telescopic Boom Series (Models SJ 40T, 45T, 61T & 66T) aerial platform is designed to transport
and raise personnel, tools and materials to overhead work areas
Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level,
compacted surface. It can be driven over uneven terrain only when the platform is fully lowered.
Manuals
Operating
The operating manual is considered a fundamental part of the aerial platform. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the aerial platform at all times.
Service & Maintenance

The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.
All information in this manual should be read and understood before any attempt is made to service the machine.
The updated copy of the manuals are found on the company’s website: www.skyjack.com.
Operator
The operator must read and completely understand both this operating manual and the safety panel label located on
the platform and all other warnings in this manual and on the aerial platform. Compare the labels on the aerial platform
with the labels found within this manual. If any labels are damaged or missing, replace them immediately.
Service Policy and Warranty

SKYJACK warrants each new SJT series work platform to be free of defective parts and workmanship for the first
24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or
labor. Contact SKYJACK Service Department for warranty statement extensions or exclusions.
Optional Accessories
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under “Standard
and Optional Features” in Table 2.1 of the operating manual. Operating instructions for these options (if equipped)
are located in Section 2 of the operating manual.
For non-standard components or systems, contact the SKYJACK Service Department at
North America & Asia: Europe:

( : 800 275-9522 ( : 44-1691-676-235
7 : 630 262-0006 7 : 44-1691-676-239
Include the model and serial number for each applicable aerial platform.

Operator’s Responsibility for Maintenance Section 1 - Scheduled Maintenance
Scope of this Manual

a. This manual applies to the ANSI/SIA, CSA, AS and CE versions of the Telescopic Boom aerial platform models
listed on Table 2.1 of the operating manual.
- Equipment identified with “ANSI” meets the ANSI/SIA A92.5-2006 standard.

- Equipment identified with “CSA” meets the CSA B354.4-02 standard.
- Equipment identified with “AS” meets the AS 1418.10-2004 standard.
- Equipment identified with “CE” meets the requirements of the Machinery Directive 98/37/EC and the EMC
Directive 2004/108/EC.
b. CSA (Canada), AS (Australia) and CE (Europe)

Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this aerial platform.
c. ANSI/SIA (United States)

Operators are required by the current ANSI/SIA A92.5 standards to read and understand their responsibilities
in the manual of responsibilities before they use or operate this aerial platform.
WARNING
Failure to comply with your required responsibilities in the use and operation of the aerial platform
could result in death or serious injury!
Operator Safety Reminders

A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to
follow simple and fundamental safety rules and precautions.
You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this aerial platform
is mandatory. The following pages of this manual should be read and understood completely before operating the
aerial platform.
Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety
devices to protect your eyes, ears, hands, feet and body.
Any modifications from the original design are strictly forbidden without written permission from SKYJACK.

Electrocution Hazard
This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from energized
power lines and parts as listed below. The operator must allow for the platform to sway, rock or sag. This aerial
platform does not provide protection from contact with or proximity to an electrically charged conductor.
Per ANSI A92.5-2006 8.10(7)

“The operator shall perform only the work for which he or she is qualified, in compliance with all applicable safety
related work practices intended to prevent electric shock covered by the Code of Federal Regulations (CFR) 1910.333.
The operator’s level of competence shall be established only by persons qualified to do so. Operators shall
maintain the appropriate minimum approach distance (MAD) from energized power lines and parts covered by
CFR 1910.333 (c).”
Unqualified persons must maintain a minimum approach distance of 10 feet from any energized power line up to
50 kV. Energized power lines over 50 kV require a greater minimum approach distance to be maintained. Refer to
CFR 1910.333.
As per CSA B354.4-02

“The operator shall maintain the minimum safe approach distance (MSAD) from energized conductors at all times
in accordance with the authority having jurisdiction.”
Refer to CFR 1910.333 or the authority having jurisdiction.
DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING.

DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS.
DANGER
Avoid Power Lines
Minimum Safe Approach Distance

ANSI/SIA A92.6-2006 CE Guidance Note
and CSA B354.2-01 Requirements “Avoidance of danger from overhead lines”
Voltage Range Minimum Safe Approach Distance
(Phase to Phase) (Feet)
0 to 300V Avoid Contact
Over 300V to 50KV 10
Adhere strictly to the governmental rulings
Over 50KV to 200KV 15
and regulations applicable in your country.
FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!
60023AD

Safety Precautions
Know and understand the safety precautions before going on to next section.
WARNING
Failure to heed the following safety pre- • DO NOT operate aerial platform
cautions could result in tip over, falling, during lightning or storms.
crushing, or other hazards leading to
death or serious injury.
• KNOW all national, state or territorial/provincial

and local rules which apply to your aerial platform • DO NOT drive elevated near
and jobsite. depressions or holes of any
type, loading docks, debris,
• TURN main power disconnect switch off when drop-offs and surfaces that
leaving the aerial platform unattended. Remove may affect the stability of the
the key to prevent unauthorized use of the aerial aerial platform.
platform.
• DO NOT drive or elevate the
• WEAR all the protective clothing and personal aerial platform if it is not on a
safety devices issued to you or called for by job firm level surface.
conditions.
• Elevated driving must only
• DO NOT wear loose clothing, be done on a firm level sur-
dangling neckties, scarves, face.
rings, wristwatches or other
jewelry while operating this aer- • If operation in areas with
ial platform . holes or drop-offs is abso-

lutely necessary, elevated

driving shall not be allowed.
Position the aerial platform hor-
izontally only with the platform
• AVOID entanglement with fully lowered. After ensuring
ropes, cords or hoses. that all 4 wheels or outriggers (if equipped) have
contact with level firm surface, the aerial platform
can be elevated. After elevation, the drive func-
tion must not be activated.
• AVOID falling. Stay within the

boundaries of the guardrails.
• AVOID soft, uneven surfaces.
• DO NOT raise the platform in

windy or gusty conditions. Do
not increase the lateral surface • DO NOT ascend or descend a
area of the platform. Increasing grade steeper than 45% (2WD
the area exposed to the wind & 4WD). Boom elevated driving
will decrease aerial platform must only be done on firm level
stability. surfaces.

Safety Precautions (Continued)

• DO NOT operate an aerial • ENSURE that there are no

platform that has ladders, personnel or obstructions in
scaffolding or other devices the path of travel, including
mounted on it to increase its blind spots.
size or work height.
• DO NOT lower the platform unless the area below

is clear of personnel and obstructions.
• DO NOT exert side forces on
aerial platform while elevated.
• DO NOT use the aerial

platform as a crane. It is
prohibited. • DO NOT use boom to push, pull other objects or
to lift the chassis.
• DO NOT sit, stand or climb on

the guardrails. It is prohibited.
• DO NOT raise the aerial

• BE AWARE of overhead platform while it is on a
obstructions or other possible truck, forklift or other device
hazards around the aerial or vehicle.
platform when driving or lifting.
• STUNT driving and
horseplay are prohibited.
• ENSURE ALL tires are in good condition and lug

• BE AWARE of crushing nuts are properly tightened.
hazards. Keep all body parts
inside platform guardrail. • DO NOT alter or disable limit switches or other
safety devices.
• DO NOT use the aerial platform without guardrails,

locking pins and the entry gate in place.
• BE AWARE of blind spots when • DO NOT exceed the rated capacity of the
operating the aerial platform. aerial platform. Do make sure the load is evenly
distributed on the platform.

Safety Precautions (Continued)

• DO NOT attempt to free a snagged platform with

WARNING
lower controls until personnel are removed from
the platform. Entering and exiting the aerial platform
should only be done using the three
• DO NOT position the aerial platform against an- points of contact.
other object to steady the platform.
• Use only equipped access openings.
• DO NOT place materials on the guardrails or • Enter and exit only when the aerial
materials that exceed the confines of the guardrails platform is in the fully retracted position.
unless approved by Skyjack.
• Do use three points of contact to enter and exit
Fall Protection the platform. Enter and exit the platform from
All occupants of this aerial platform must wear personal the ground only. Face the aerial platform when
fall protection equipment. entering or exiting the platform.
As per the ANSI A92.5-2006 standard, “Principal fall • Three points of contact means that two hands
protection is provided by the guardrail system. The user and one foot or one hand and two feet are in
shall direct and monitor the operator to ensure that all contact with the aerial platform or the ground at
components of the guardrail system are in place. The all times during entering and exiting.
user shall direct and monitor the occupants of the work
platform to ensure that they wear a personal fall arrest WARNING
system to protect against the potential effects of ejection
An operator should not use any aerial
or a fall restraint system to prevent a free fall.”
platform that:
Fall restraint and fall arrest systems are defined within
• does not appear to be working properly.
the ANSI A92.5 Manual of Responsibilities shipped with
• has been damaged or appears to have worn or
this aerial platform.
missing parts.
• has alterations or modifications not approved by
Skyjack recommends the use of a fall restraint system
the manufacturer.
to keep an occupant within the confines of the platform,
• has safety devices which have been altered or
and thus not expose the occupant to any fall hazard
disabled.
requiring a fall arrest.
• has been tagged or blocked out for non-use or
repair.
CSA B354.4-02 requires the use of a fall arrest system,
therefore Canadian users must use personal fall arrest
Failure to avoid these hazards could re-
protection as opposed to fall restraint.
sult in death or serious injury.
All personal fall protection equipment must comply
with applicable governmental regulations and must Jobsite Inspection
be inspected and used in accordance with the • Do not use in hazardous locations.
manufacturer’s recommendations. • Perform a thorough jobsite inspection prior to
operating the aerial platform, to identify potential
All personal fall protection equipment must be attached hazards in your work area.
only to approved anchorage points within the platform • Be aware of moving equipment in the area. Take
of the aerial platform. appropriate actions to avoid collision.

Maintenance and Inspection Schedule Maintenance and Service Safety Tips

The actual operating environment of the work platform Maintenance and repair should only be performed by
governs the use of the maintenance schedule. The personnel who are trained and qualified to service this
inspection points covered in Table 1.2. Maintenance aerial platform.
and lnspection Checklist, indicates the areas of the
aerial platform to be maintained or inspected and at All maintenance and service procedures should be
what intervals the maintenance and inspections are to performed in a well lighted and well ventilated area.
be performed.
Anyone operating or servicing this aerial platform
Owner’s Annual Inspection Record must read and completely understand all operating
It is the responsibility of the owner to arrange quarterly instructions and safety hazards in this manual and
and annual inspections of the aerial platform. Table 1.1. operating manual.
Owner’s Annual lnspection Record is to be used for
recording the date of the inspection, owner’s name, All tools, supports and lifting equipment to be used
and the person responsible for the inspection of the must be of proper rated load and in good working order
work platform. before any service work begins. Work area should be
kept clean and free of debris to avoid contaminating
Replacement Parts components while servicing.
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and All service personnel must be familiar with employer
dimensions different from original parts will affect and governmental regulations that apply to servicing
stability of the aerial platform and must not be used this type of equipment.
without manufacturer’s consent.
Keep sparks and flames away from all flammable or
All replacement tires must be of the same size and load combustible materials.
rating as originally supplied tires; to maintain safety and
stability of aerial platform. Properly dispose of all waste material such as lubricants,
rags, and old parts according to the relative law
Consult SKYJACK’s Service Department for optional provisions obtaining in the country.
tires specifications and installation.
Before attempting any repair work, turn Battery
Disconnect Switch to “ ” off position.
WARNING Preventive maintenance is the easiest and least

Any unit that is damaged or not operating expensive type of maintenance.
properly must be immediately tagged and
removed from service until proper repairs
are completed.

Scheduled Maintenance Inspections Section 1 - Scheduled Maintenance
Hydraulic System & Component 7. All hydraulic components must be disassembled

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

Section 1 - Scheduled Maintenance Scheduled Maintenance Inspections
About this Section Maintenance Instructions

This section contains the maintenance and inspection This manual consists of four schedules to be done for
schedule that is to be performed. maintaining on an aerial platform. Inspection schedule
frequency is shown below:
References are made to the procedures in Section 5
that outline detailed step-by-step instructions for checks Inspection Schedule
and replacements. Daily A
Frequently A+B
Service Bulletins Annually A+B+C
Before performing any scheduled maintenance Bi-annually A+B+C+D
inspection procedure, refer to service bulletins found in
our web site: www.skyjackinc.com for updates related • Make copies of the maintenance and inspection
to service and maintenance of this aerial platform. checklist to be used for each inspection.
• Check the schedule on the checklist for the type of
inspection to be performed.
Maintenance and Inspection • Place a check in the appropriate box after each
Death or injury can result if the aerial platform is not kept inspection procedure is completed.
in good working order. Inspection and maintenance • Use the maintenance and inspection checklist and
should be performed by competent personnel who step-by-step procedures in Section 5 to perform
are trained and qualified on mantenance of this aerial these inspections.
platform. • If any inspection receives a fail, tag and remove the
aerial platform from service.
warning • If any aerial platform component(s) has been
Failure to perform each procedure as pre- repaired, an inspection must be performed again
sented and scheduled may cause death, before removing the tag. Place a check in the repair
serious injury or substantial damage. column.
Note Legend
Preventive maintenance is the easiest and P = Pass
least expensive type of maintenance. F = Fail
R = Repaired
• Unless otherwise specified, perform each
maintenance procedure with the aerial platform in
the following configuration:
- Aerial platform parked on a flat and level

surface
- Disconnect the battery by turning the main
power disconnect switch to “ ”off position.
• Repair any damaged or malfunction components

before operating aerial platform.
• Keep records on all inspections.

Table 1.1 Owner’s Annual Inspection Record
Model Number: ____________________________ Serial Number: ____________________________
Recording
Date
Recording
1 2 3 4 5 6 7 8 9
Year #
Owner’s
Name
Inspected
By
60564AA
As described earlier in this section, this decal is located on the control compartment cowling. It must be completed after an annual
inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 13 months.

Table 1.2 MAINTENANCE AND INSPECTION CHECKLIST
Serial Number:
Model:
Hourmeter Reading: Name (Printed):
Date:
Time: Signature:
Each item shall be inspected using the the appropriate section of the Skyjack service manual.
As each item is inspected, write the apropriate grade in the box.
INSPECTION FREQUENCY Inspection Schedule
DAILY Daily A
P - PASS FREQUENTLY Frequently* A+B
F - FAIL ANNUALLY Annually* A+B+C
R - REPAIRED BI-ANNUALLY Bi-annually* A+B+C+D
Other Other* A+B+C+D+E
Schedule P F R Schedule P F R
Schedule Maintenance Inspections Boom A, B, C
Labels A Cylinder A, B, C
Limit Switches A, B Wear Pads A, B, C
Engine Compartment Power Track A, B, C
Main Power Disconnect Switch A, B Cables (61T/66T) A, B, C, E
Battery A, B Special Options (If Equipped)
Swing Drive Motor A, B, C Hydraulic Generator A
Turret Rotation Gear A, B, C Battery Warmer/Hydraulic Oil Heater A
Rotary Manifold A, B Welder A
High Pressure Filter A, B, C Work Light A
Hydraulic Pumps A, B Flashing Amber Light A
Muffler and Exhaust A, B Glazier Tray A
Engine Pivot Tray A, B Arctic Weather Package A
Engine Oil Level A, B Function Tests
Engine Air Filter A, B, C Test Main Power Disconnect Switch A, B
Engine Fuel Leaks A, B, C Base Control Console
Control Compartment Test Emergency Stop A, B
Base Control Console A, B Test Function Enable Switch
A, B
Hydraulic Tank A, B & All Boom Functions
Hydraulic Oil A, B, D Test Platform Self-leveling A, B
Hydraulic Return Filter A, B, C Test Tilt Sensor A, B
Brake and Main Manifolds A, B, C Test Emergency Power A, B
Emergency Power Unit A, B Test Base/Off/Platform Switch A, B
Fuel Tank A, B, C Platform Control Console
Fuel Tank Leaks A, B Test Load Sensing System - CE A, B
Base Test Footswitch A, B
Turret Transportation Lock A, B Test Engine Enable Switch - CE A, B
Drive Axle A, B, C Test Emergency Stop A, B
Oscillating Axle Assembly A, B, C Test Steering A, B
Steer Cylinder Assembly A, B Test Driving Function A, B
Tie Rod A, B Test Driving Speed A, B
Wheel/Tire Assembly A, B, C Test Emergency Power A, B
Manuals A, B Test Horn A, B
Platform Assembly A, B Test Brakes A, B
Platform Control Console A, B Test Oscillating Axles A, B
Rotary Actuator A, B, C Test Cables (61T/66T) A, B
Jib (If Equipped) A, B 114AD
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.7 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every three months or 150 hrs. Refer to Section 1.0 of this manual.
C - Perform Scheduled Maintenance Inspection every year. Refer to Section 1.0 of this manual.
D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1.0 of this manual.
E - For other Perform Scheduled Maintenance Inspection intervals, Refer to Section 5.0 of this manual.
* - Refer to Skyjack's website @ www.skyjack.com for latest service bulletins prior to performing quarterly or yearly inspection.
Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy.

Platform Control
Console
Platform
Railing
Manuals
Platform
Footswitch Assembly
1.1 Scheduled Maintenance Inspections Perform a visual inspection around the following
Begin the scheduled maintenance inspections by areas:
checking each item in sequence for the conditions listed • hydraulic tank filter, fittings, hoses, emergency
in this section. power unit and turret/base surface
• engine compartment fittings, hoses, main
WARNING pump, filter and turret/base surface
• all hydraulic cylinders
To avoid injury, do not operate an aerial • all hydraulic manifolds
platform until all malfunctions have been • the underside of the turret
corrected. • the underside of the base
• ground area under the aerial platform
WARNING
1.1-1 Labels
To avoid possible injury, ensure aerial
Refer to the labels section in the operating manual and
platform power is off during visual and
ensure that all labels are in place and are legible.
daily maintenance inspections.
1.1-2 Limit Switches
Electrical
Ensure limit switches are properly secured and no signs
Maintaining electrical components is essential to good
of visible damage and movement is not obstructed.
performance and service life of aerial platform.
Detecting limit switch malfunction is essential to safe
aerial platform operation.
Perform a visual inspection around the following
areas:
Visually inspect all limit switch located inside the turret
• boom to platform cable harness
and under the power track. Inspect for the following:
• engine compartment electrical panel
• engine wiring harness
• broken or missing actuator arm
• rotary manifold wiring
• missing fasteners
• loose wiring
Hydraulic
Maintaining hydraulic components is essential to good
performance and service life of the aerial platform.

Typical SJ 40T/45T shown

(for model 61T/66T, see note below) Muffler
Air Filter
Hydraulic
High Pressure Pumps
Filter
Swing Drive Motor
Battery
Main Power Disconnect Switch Engine
1.1-3 Engine Compartment

WARNING
Ensure all compartment latches are secure and in
proper working order. Battery acid is extremely corrosive
- Wear proper eye and facial protec-
• Main Power Disconnect Switch tion as well as appropriate protective
(see right side for 61T/66T) clothing. If contact occurs, immedi-
-- Turn main power disconnect switch to ately flush with cold water and seek
“ ” off position. medical attention.
1. Check battery case for damage.
-- Ensure there are no loose or missing
parts and there is no visible damage. 2. Clean battery terminals and cable ends
-- Ensure all cables are secure and switch thoroughly with a terminal cleaning tool
is in proper working condition. or wire brush.
• Battery 3. Ensure all battery connections are tight.

Proper battery condition is essential to good
engine performance and operational safety. 4. If applicable, check battery fluid level. If
Improper fluid levels or damaged cables and plates are not covered by at least 1/2”
connections can result in engine component (13 mm) of solution, add distilled or
damage and hazardous conditions. demineralized water.
WARNING 5. Replace battery if damaged or incapable

of holding a lasting charge.
Explosion hazard. Keep
flames and sparks away. Do
not smoke near batteries. WARNING
Use original or manufacturer-approved
parts and components for the aerial
platform.


(for model 61T/66T, see note below) Muffler
Air Filter
Hydraulic
High Pressure Pumps
Filter
Swing Drive Motor
Battery
Main Power Disconnect Switch Engine
• Swing Drive Motor -- Ensure all fittings and hoses are properly
-- Ensure there are no loose or missing tightened and there is no evidence of
parts and there is no visible damage. hydraulic leakage.
-- Ensure all bolts are properly tightened. • Muffler and Exhaust
-- Ensure muffler and exhaust system are
-- Ensure all fittings and hoses are properly properly secured, with no evidence of
tightened and there is no evidence of damage.
hydraulic leakage.
• Engine Pivot Tray
C - Annual Inspection -- Ensure there are no loose or missing
-- For motor oil replacement procedure, parts and no visible damage to the engine
refer to Section 5. pivot tray. Ensure that each tray-securing
• Turret Rotation Gear bolt is in place.
-- Ensure there are no loose or missing • Engine Oil Level
parts and there is no visible damage. -- Maintaining the engine components
• Rotary Manifold is essential to good performance and
-- Ensure all hoses are properly tightened service life of the aerial platform.
and there is no evidence of hydraulic
leakage. WARNING
Beware of hot engine components.
• High Pressure Filter (40T/45T)
(see Control Compartment for 61T/66T)
Check oil level on dipstick
-- Ensure housing is secure and shows no
-- Oil level should be in the “safe” zone.
visible damage or leakage.
Add oil as needed. Refer to Table 2.8b
• Hydraulic Pumps for recommended oil type.
B - Frequent Inspection
parts and there is no visible damage.
-- For recommand oil change, refer to
-- Ensure all bolts are properly tightened. engine manual

Hydraulic Return
Hydraulic Tank
Brake Manifold
Main Manifold
Base Control Emergency Power Fuel Tank

Console Unit
• Engine Air Filter • Enigne Fuel Filter

-- Ensure there are no loose or missing -- Ensure there are no loose or missing
parts and there is no visible damage. parts and there is no visible damage.
B - Frequent Inspection C - Annual Inspection
-- For engine air filter maintenance -- For engine fuel filter replacement
procedure, refer to engine manual. procedure, refer to engine manual.
C - Annual Inspection 1.1-4 Control Compartment
-- For engine air filter replacement -- Ensure all compartment latches are secure
procedure, refer to engine manual. and in proper working order.
• Engine Fuel Leaks • Base Control Console
-- Ensure that there no fuel leaks at -- Ensure all switches are returned to their
engine. neutral positions.
DANGER -- Ensure there are no loose or missing

parts and there is no visible damage.
Engine fuels are combustible. Inspect
the aerial platform in an open, well- • Hydraulic Tank
ventilated area away from heaters, -- Ensure hydraulic filler cap is secure.
sparks and flames. Always have an
-- Ensure tank shows no visible damage
approved fire extinguisher within easy
and no evidence of hydraulic leakage.
reach.
• Hydraulic Oil
-- Ensure shutoff valve, hoses and fittings -- Be sure that the boom is in the stowed
show no visible damage and no evidence position, and then visually inspect the
of fuel leakage. sight gauge located on the side of the
hydraulic oil tank.
--

Hydraulic Return
Hydraulic Tank
Brake Manifold
Main Manifold
Base Control Emergency Power Fuel Tank

Console Unit
-- The hydraulic oil level should be between • Fuel Tank

the minimum and maximum marks on the
sight glass. Add oil as needed. Refer to IMPORTANT
Table 2.8b for recommended oil type. Before using your aerial platform en-
sure there is enough fuel for expected
C - Annual Inspection use.
-- For hydraulic oil replacement procedure,
refer to Section 5. -- Ensure fuel filler cap is secure.
• Hydraulic Return Filter -- Ensure tank shows no visible damage
-- Ensure filter element is secure. and no evidence of fuel leakage.
-- Ensure there are no signs of leakage or • Fuel Tank Leaks
visible damage. -- Ensure that there no fuel leaks at tank.
• Brake and Main Manifolds
-- Ensure all fittings and hoses are properly DANGER
tightened and there is no evidence of Engine fuels are combustible. Inspect
hydraulic leakage. the aerial platform in an open, well-
ventilated area away from heaters,
-- Ensure there are no loose wires or
sparks and flames. Always have an
missing fasteners.
approved fire extinguisher within easy
• Emergency Power Unit reach.
parts and there is no visible damage. -- Ensure fuel tank, shutoff valve, hoses and
fittings show no visible damage and no
-- Ensure there are no loose wires or evidence of fuel leakage.
missing fasteners.
-- Ensure all fittings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.

Overhead View
Tie Rod
Oscillating
Turret Rotation
Limit Switch Cylinder
Gear
Assembly
Drive Axle
Wheel/Tire
Assembly
Rotary
Manifold
Steer Cylinder
Assembly
1.1-5 Base • Tie Rod

• Turret Transportation Lock parts, tie rod end studs are locked and
-- Ensure turret transportation lock is there is no visible damage.
unlocked, there are no loose or missing
parts and there is no visible damage. • Wheel/Tire Assembly
-- The aerial platform is either equipped
• Drive Axle with air tires or foam-filled tires. Tire
-- Ensure drive axle is properly secured, and/or wheel failure could result in an
there are no loose or missing parts, all aerial platform tip over. Component
fittings and hoses are properly tightened damage may also result if problems are
and there is no evidence of hydraulic not discovered and repaired in a timely
leakage. fashion.
• Oscillating Cylinder Assembly WARNING
-- Ensure oscillating cylinder assembly is
properly secured, there are no loose An over-inflated tire can explode and
or missing parts, all fittings and hoses may cause death or serious injury.
are properly tightened and there is no
evidence of hydraulic leakage. -- Check all tire treads and sidewalls for
cuts, cracks, punctures and unusual
Note wear.
Oscillating axle is locked when aerial
platform is in work mode. Refer to -- Check each wheel for damage and
Diagram 2.5 Axle Oscillation Diagrams. cracked welds.
-- Check each lug nut for proper torque to
• Steer Cylinder Assembly ensure none are loose.
-- Ensure steer cylinder assembly is properly
secured, there are no loose or missing To maximize stability, it is essential to maintain
parts, all fittings and hoses are properly proper pressure in all air-filled tires.
tightened and there is no evidence of -- Check each tire with an air pressure
hydraulic leakage. gauge and add air as needed.
• Refer to Table 2.5 for wheel/tire specifications.

Platform Control
Console
Platform
Railing
Manuals
Platform
Footswitch Assembly
1.1-6 Manuals 1.1-8 Platform Control Console

Ensure a copy of operating manual, and other -- Ensure all switches/controllers are returned
important documents are enclosed in manual to neutral and are properly secured.
storage box.
-- Ensure there are no loose or missing parts
-- Check to be sure manual storage box is and there is no visible damage.
present and in good condition.
-- Ensure manuals are legible and in good 1.1-9 Rotatory Actuator
condition. -- Ensure there are no loose or missing parts
and there is no visible damage.
-- Always return manuals to the manual storage
box after use. -- Ensure all bolts and pins are properly
tightened.
1.1-7 Platform Assembly
-- Ensure there are no loose or missing parts -- Ensure all hoses are properly tightened and
and there is no visible damage. there is no evidence of hydraulic leakage.
-- Ensure all fasteners are securely in place. 1.1-10 Jib (If Equipped)
-- Ensure there are no loose or missing parts
-- and there is no visible damage.
-- Ensure all railings are properly positioned -- Ensure all bolts and pins are properly
and secured. tightened.
-- Ensure gate is in good working order. -- Ensure all hoses are properly tightened and
there is no evidence of hydraulic leakage.
-- Ensure footswitch is in good working order
and has not been modified, disabled or
blocked.

SJ 45T
Wear Pad
Boom
Jib
Rotary Actuator Wear Pad
Power Track
Lift Cylinder
1.1-11 Boom • Hoses

-- Ensure there are no loose or missing parts -- Ensure all hoses are properly tightened
and there is no visible damage. and there is no evidence of hydraulic
leakage.
-- Ensure all bolts and pins are properly
tightened. • Power Track
-- Ensure there are no visible cracks in welds parts and there is no visible damage.
or structure and there are no signs of
deformation. • Cables (61T/66T)
-- Ensure all hoses are properly tightened and parts with no signs of visible damage.
there is no evidence of hydraulic leakage.
-- Ensure that nuts are not loose and are
• Cylinders locked together.
-- Ensure all cylinders are properly secured
and there is no evidence of leakage. -- Ensure that there are no gaps between
springs. For cable tension repair, refer
• Wear Pads to Section 5.
-- Ensure all bolts are tight, there is no
visible damage to the wear pads and that
no parts are missing.
With Gaps No Gaps
Cable Disc Springs

Battery Warmer/ Flashing Amber Light Hydraulic Generator

Hydraulic Oil Heater
03
Work Light Welder
Glazier
Tray
1.1-12 Special Options • Work Light (If Equipped)

-- Ensure lamps are properly secured with
• Hydraulic Generator (If Equipped) no signs of visible damage.
parts with no signs of visible damage. -- Ensure mounting bracket is properly
secured.
-- Ensure all hoses are properly tightened
and there is no evidence of hydraulic -- Ensure there are no loose wires or
leakage. missing fasteners.
• Battery Warmer/Hydraulic Oil Heater • Flashing Amber Light (If Equipped)

(If Equipped) -- Ensure lamp is properly secured with no
-- Ensure battery warmer/hydraulic oil signs of visible damage.
heater cord is properly secured with no • Glazier Tray (If Equipped)
signs of visible damage and hydraulic -- Ensure tray, strap, foam supports and
leakage. cover bumpers are properly secured with
• Welder (If Equipped) no signs of visible damage.
-- Ensure welder and welder tray are • Arctic Weather Package (If Equipped)
properly secured. -- Ensure battery/hydraulic oil/engine oil
-- Ensure there are no loose or missing heater plug is properly secured with no
parts and there is no visible damage. signs of visible damage and hydraulic
leakage.
-- Ensure there are no loose wires or
missing fasteners.

Function Tests - ANSI/CSA/AS Section 1 - Scheduled Maintenance
Base Control
Console
Start/Emergency
Power Switch
Emergency
Base/Off/Platform Key Stop
Switch
1.2 Function Tests 1.2-1 Test Main Power Disconnect Switch

Function tests are designed to discover any malfunctions
before aerial platform is put into service. The operator 1. In engine compartment, turn main power
must understand and follow step-by-step instructions disconnect switch to “ ” off position.
to test all aerial platform functions. Result: Aerial platform functions should not
operate.
IMPORTANT
Never use a malfunctioning aerial 2. In engine compartment, turn main power
platform. If malfunctions are discovered, disconnect switch to “ ” on position.
aerial platform must be tagged and
placed out of service. Repairs to aerial Note
platform may only be made by a qualified Close all cowlings before proceeding to
service technician. next item.
After repairs are completed, operator must perform a 1.2-2 Base Control Console
pre-operation inspection and a series of function tests
again before putting aerial platform into service.
1. On platform control console, pull out “ ”
emergency stop button.
Prior to performing function tests, be sure to read
and understand Section 2.10 - Start Operation of the
operating manual. 2. On base control console, pull out “ ” emergency
stop button.
Note
All-function motion alarm should sound 3. Turn base/off/platform key switch to “ ” base
while operating any boom and drive position.
function.
4. Start engine by selecting “ ” start position from
start/emergency power switch.

Section 1 - Scheduled Maintenance Function Tests - ANSI/CSA/AS
Base Control
Console
Start/Emergency
Power Switch
Emergency
Switch
• Test Emergency Stop • Test Platform Self-leveling
1. Push in “ ” emergency stop button. 1. Lower boom to stowed position.

Result: Engine should shut down and
aerial platform functions should not 2. Adjust platform to a level position using
operate. platform leveling switch.
2. Pull out “ ” emergency stop button and 3. Raise “ ” and lower “ ” main
restart engine. boom through a full cycle.
Result: Platform should remain level at all
• Test Function Enable Switch and All time.
Boom Functions
• Test Tilt Sensor
WARNING
Tilt Sensor A
Ensure that there are no personnel or
1. Move the aerial platform on to a slope not
obstructions in test area and there is
greater than 5°.
sufficient room for boom to swing.
1. Do not hold “ ” function enable switch 2. Extend “ ” fly boom approximately

to either side. Attempt to activate each 12 in. (30 cm).
boom and platform switch. Result: Platform alarm should sound, tilt
Result: All boom and platform functions warning light should come on and all drive
should not operate. functions should not operate.
2. Hold “ ” function enable switch to either

side and activate each boom and platform
function.
Result: All boom and platform functions
should operate as selected.

Base Control
Console
Start/Emergency
Power Switch
Emergency
Switch
Tilt Sensor B Note

1. Open control cowling. To conserve battery power, test each
function through a partial cycle.
2. Locate tilt sensor on top of
control box. WARNING
3. Extend “ ” fly boom Ensure that there are no personnel or
approximately 30 cm (12 in.). obstructions in test area and there is
Turn engine off. Press down sufficient room for boom to swing.
one side of tilt sensor until
level bubble is no longer in
the center. 3. On base control console, pull out “ ”
Result: Platform alarm should sound, tilt emergency stop button.
warning light should come on and all drive
functions should not operate. 4. For CE, turn base/off/platform key switch
to “ ” platform position.
• Test Emergency Power
1. On base control console, push in
5. Select “ ” emergency power position
“ ” emergency stop button to turn from start/emergency power switch and
engine off. activate each boom function.
Result: All selected functions should
2. On platform control console, push in “ ” operate.
emergency stop button.
For CE
caution 6. Turn base/off/platform key switch to “ ”
When operating on auxiliary power, do base position.
not operate more than one function at a
time to avoid overloading 12-Volt auxil- 7. Select “ ” emergency power position
iary pump motor. Do not use emergency from start/emergency power switch and
power unit continuously for more than activate each boom function.
two minutes. Result: All selected functions should
operate.

Base Control
Console
Start/Emergency
Power Switch
Emergency
Switch
6. On platform control console, select “ ”

NOTE
start position from start/emergency power
The emergency power unit has two-
switch and until engine starts.
minute duty cycle.
7. Dismount from platform.
• Test Base/Off/Platform Switch
8. On base control console, attempt to
1. Ensure “ ” emergency stop button is activate each boom and platform switch
pulled out. while holding function enable switch.
Result: All boom and platform functions
2. Start engine. should not operate while holding function
enable switch.
3. On base control console, turn base/off/
platform key switch to “ ” off position. 9. Push in “ ” emergency stop button to
Result: Engine should shut down and turn engine off.
aerial platform functions should not
operate.
10. Pull out “ ” emergency stop button.
4. On base control console, turn base/off/
platform key switch to “ ” platform
position.
WARNING
Ensure that you maintain three points
of contact to mount/dismount plat-
form.
5. Enter platform and close gate.

Platform Control Emergency Stop Drive/Steer

Console Controller
Tie-off Point
Tie-off Point
Footswitch
1.2-3 Platform Control Console

Result: After four seconds of time elapses,
WARNING the red light and audible alarm pulse two
Ensure that you maintain three points of times. This indicates the system is active
contact to mount/dismount platform. and there are no faults.
1. Enter platform and close gate. • Test Footswitch
WARNING 1. Pull out “ ” emergency stop button.
DO NOT operate any control on platform 2. Do not start engine.

control console without proper fall pro-
tection secured to designated location
3. Select generator on/off switch to “ ” off
in platform. Failure to avoid this hazard
position (if equipped).
could result in death or serious injury!
4. Depress and hold footswitch and attempt
WARNING
to start engine by selecting “ ” start
Ensure that there are no personnel or position from start/emergency power
obstructions in test area and that there is switch.
sufficient room for boom to swing. Result: Engine should not start.
• Test Load Sensing System - CE 5. Without depressing footswitch, try to start

engine.
1. Push in “ ” emergency stop button. Result: Engine should start.

Start/Emergency
Horn Power Switch Drive/Steer
Controller
6. W ith engine running and without 4. Start engine.

depressing footswitch, test each boom
and platform function. • Test Emergency Stop
Result: Aerial platform functions should
not operate. 1. Ensure engine is running.
NOTE 2. Push in “ ” emergency stop button.

The emergency power unit has two- Result: Engine should shut down and
minute duty cycle. aerial platform functions should not
operate.
NOTE
A 15-second anti-tiedown feature • Test Steering
deactivates footswitch when operator
depresses it for 15 seconds without
activating any function.
• Test Engine Enable Switch - CE 2. Start engine by selecting “ ” start

position from start/emergency power
1. Ensure engine is running. switch.
2. Select “ ” off position from engine 3. Depress and hold footswitch.

enable switch.
Result: Engine should shut down and 4. Press rocker switch on top of drive/steer
platform control console is disabled.
controller to “ ” left and “ ” right.
3. Select “ ” on position from engine enable Result: Steer wheels should turn left and
switch. right.
Result: Platform control console is
enabled.

Start/Emergency
Controller
• Test Driving Function

4. Extend “ ” fly boom approximately
1. Ensure path of intended motion is clear. 12 in. (30 cm) and then slowly move drive/
steer controller to full drive position.
2. Ensure boom is in stowed position and fly Result: The maximum achievable drive
boom fully retracted. speed should be significantly less than
3. Depress and hold footswitch. stowed drive speed.
4. Slowly move drive/steer controller in • Test Emergency Power
“ ” forward or “ ” reverse direction caution

until aerial platform begins to move, and When operating on auxiliary power, do
then return handle to center position. not operate more than one function
Result: Aerial platform should move in at a time to avoid overloading 12-Volt
forward or reverse direction, and then auxiliary pump motor. Do not use emer-
come to a stop. gency power unit continuously for two
minutes.
• Test Driving Speed
Note
1. Depress and hold footswitch. To conserve battery power, test each
function through a partial cycle.
2. Raise “ ” main boom approximately
1. On platform control console, push in
14 ft. (4 m) and then slowly move drive/
steer controller to full drive position. “ ” emergency stop button to turn
Result: The maximum achievable drive engine off.
speed should be significantly less than
stowed drive speed. 2. Pull out “ ” emergency stop button.
3. Lower boom to stowed position. 3. Depress and hold footswitch.

Start/Emergency
Controller
2. Ensure boom is in stowed position.

4. Select “ ” emergency power position
from start/emergency power switch and
3. Depress and hold footswitch and drive
activate each function control handle or
switch.
Result: All boom and steer functions aerial platform first “ ” forward then “ ”
should operate. Drive functions should reverse at full speed.
not operate.
4. Remove your foot from footswitch.
NOTE Result: Aerial platform should come to an
The emergency power unit has two- instant and abrupt stop. If aerial platform
minute duty cycle. does not stop immediately, or if aerial
platform pulls to one side while stopping,
• Test Horn do not operate aerial platform until brake
adjustments have been checked.
1. Push “ ” horn pushbutton.
Result: Horn should sound.
• Test Brakes
WARNING
Brakes will engage instantly when you
release footswitch, causing aerial plat-
form to stop immediately.
1. Move aerial platform to a firm level surface

to ensure similar traction on left and
right.

Function Tests - CE Section 1 - Scheduled Maintenance
Oscillating Axle Unlocked Oscillating Axle Locked
• Test Oscillating Axles • Test Cables (61T/66T)
WARNING 1. Raise the main boom to approximately

horizontal.
DO NOT operate any control on plat-
form control console without proper 2. Extend and retract the boom sections.
fall protection secured to designated Result: There should be no delay in the
location in platform. Failure to avoid this movement of the fly boom section.
hazard could result in death or serious
injury!
1. Extend fly boom 12 in. (30 cm) while on a

firm level ground.
Result: The steer axles should be
locked.
2. Drive one of the steer tires up onto a

6 in. (15 cm) block or curb.
Result: An appropriate tilt of the aerial
platform chassis should occur.
3. Retract fly boom while in tilt position.

Result: The steer axles should unlock and
the aerial platform chassis should level
itself to ground.

Section 2
maintenance tables and diagrams
Table of Contents
Tables
2.1 Standard Hose Numbering System...................................................................................................................2
2.2 Aerial Platform Torque Specifications................................................................................................................4
2.3 Axles Torque Specifications...............................................................................................................................5
2.4 Axles Maintenance Intervals...............................................................................................................................6
2.5 Tire Specifications..............................................................................................................................................7
2
2.6 Floor Loading Pressure......................................................................................................................................8
2.7 Hydraulic Specifications.....................................................................................................................................9
2.8 Specifications and Features.............................................................................................................................10
Diagrams
2.1 Dimension and Reach Diagram - SJ 40T.........................................................................................................12
2.5 Axle Oscillation Diagrams................................................................................................................................16

Service and Maintenance Section 2 - Maintenance Tables and Diagrams
Table 2.1 Standard Hose Numbering System
H1104 0081 2
FITTING LENGTH IN
ARRANGEMENT LENGTH OF HOSE IN FRACTIONS (1/4”
(See Schedule WHOLE INCHES INCREMENTS) I.E.
HOSE SIZE
Below) 1=1/4”
(See Chart
2=1/2”
Below)
3=3/4”
Using the number above as an example (H1104 0081 2). 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 03 04 06 08 10 12 16 20 24 32 40 48 56 64
ID 3/16” 1/4” 3/8” 1/2” 5/8” 3/4” 1” 1-1/4” 1-1/2” 2” 2-1/2” 3” 3-1/2” 4”
Fitting Arrangement Schedule (Continued on the following page)
S.A.E. Hose
Hose Prefix Hose End Fitting Hose End Fitting
Specification
H01 FEMALE, 37º JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H02 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R13
H03 FEMALE, 37º JIC, SWIVEL 45º, FEMALE, 37º JIC, SWIVEL 100R17
H05 FEMALE, 37º JIC, SWIVEL LONG 90º, FEMALE, 37º JIC, SWIVEL 100R17
H06 FEMALE, 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 100R17
H07 LONG 90º, FEMALE, 37º JIC, SWIVEL LONG 90º, FEMALE, 37º JIC, SWIVEL 100R17
H10 FEMALE, 37º JIC, SWIVEL MALE PIPE THREAD FITTING 100R17
H11 FEMALE, 37º JIC, SWIVEL MEDIUM 90º, FEMALE, 37º JIC, SWIVEL 100R13
H12 SHORT 90º, FEMALE, 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 100R17
H13 FEMALE, 37º JIC, SWIVEL REUSABLE MALE PIPE THREAD FITTING 300 PSI
H14 REUSABLE MALE PIPE THREAD FITTING NO FITTING 300 PSI
H15 REUSABLE, FEMALE, 37º JIC, SWIVEL REUSABLE, FEMALE, 37º JIC, SWIVEL 300 PSI

Section 2 - Maintenance Tables and Diagrams Service and Maintenance
Table 2.1 Standard Hose Numbering System (Continued)
Fitting Arrangement Schedule (Continued from the previous page)
S.A.E. Hose
Hose Prefix Hose End Fitting Hose End Fitting
Specification
H16 NO FITTING NO FITTING 100R4
H17 NO FITTING NO FITTING 300 PSI
H18 REUSABLE, FEMALE, 37º JIC, SWIVEL NO FITTING 300 PSI
H19 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R13
H21 FEMALE, 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 100R2AT
H22 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R2AT
H23 FEMALE, 37º JIC, SWIVEL LONG 90º, FEMALE, 37º JIC, SWIVEL 100R2AT
H26 SHORT 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17
H27 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17
H29 45º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17
H30 MEDIUM 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17
60589AA

Table 2.2 Aerial Platform Torque Specifications
Location Description Torque (ft-lb) Torque (Nm)

Base
Trunnion Mount BOLT, Hex head (3.4"-10 x 4.5", Grade 8) 210 285
Rear Axle Mount BOLT, Hex head (M20 x 2.5 120mm, Grade 10.9) 210 285
Oscillating axle Mount BOLT, Hex head (M20 x 2.5 120mm, Grade 10.9) 280 380
Lockout Cylinder Pin BOLT, Hex head (3/8"-16 x 1", Grade 5) 23 31
Swing Drive Motor BOLT, Hex head (3/4"-10 x 2", Grade 8) 280 380
Rotation Gear (40T / 45T) BOLT, Hex head (5/8"-11 x 4.5", Grade 8) 205 278
Rotation Gear (61T / 66T) BOLT, Hex head (3/4"-10 x 5", zinc, Grade 5) 280 380
Hydraulic Drive Motor BOLT, Hex head (M14 x 2 x 30mm, ZP, Grade 8.8) 80 108
Wheel Nut NUT, Wheel 247-302 335-410
Turret
Rotation Gear (40T / 45T) BOLT, Hex head (5/8"-11 x 4.5", Grade 8) 205 278
Rotation Gear (61T / 66T) BOLT, Hex head (3/4"-10 x 4", zinc, Grade 5) 280 380
Engine (40T/45T)
Deutz Engine Mount BOLT, Hex head (1/2"-13 x 3.75", Grade 5) 55 75
Coupling Assembly (Deutz) BOLT (M10) 29-33 39-45
Muffler NUT 40 55
GM Engine Mount NUT, Hex head (1/2"-13, Grade 5) 50 68
Cylinders
Lift ROD NUT 425 576
Extension (61T/66T) ROD NUT 300 407
Extension (40T/45T)
Master
Slave ROD NUT 350 475
Jib
Axle Lockout
Lift Cylinder Bracket BOLT, Hex head (3/4"-10 x 2.5", Grade 5) 210 285
(40T/45T) BOLT, Hex head (3/4"-10 x 2.5", Grade 8) 200 271
Master Cylinder Pin
SCREW, Socket head cap (1/2"-13 x 1", nylon, patch, zinc) 80 108
(40T/45T)
Platform
BOLT, Hex head, patch (3/8"-16 x 7/8", zinc, Grade 8) 35 48
Rotary Mount
BOLT, Hex head (1"-8 x 10.5", zinc, Grade 8) 480 569
Rotary Manifold BOLT, Hex head (1/2"-13 x 2", Grade 8) 80 108
Rotary Actuator BOLT, Hex head (3/4"-10 x 3", Grade 8) 210 285
BOLT, Hex head patch (ZP, M16 x 1.5 x 4.5", Grade 8.8) 130 177
Load Cell Mounting (CE)
BOLT, Hex head (1/2"-13 x 2.25", Grade 8) 80 108
Special Options (If equipped)
Generator Support (40T/45T) BOLT, Hex head (1/2"-13 x 2", Grade 8) 55 75
Oil Cooler Support (40T/45T) BOLT, Hex head (1/2"-13 x 2", Grade 8) 55 75
60580AJ

Table 2.3 Axles Torque Specifications
Type of Bolt
8.8 10.9 12.9
Size of Bolt Normali Normali Normali
Loctite 270 Loctite 270 Loctite 270
Loctite 242 Loctite 242 Loctite 242
(Nm) (Nm) (Nm)
(Nm) (Nm) (Nm)
M6 x 1 9.5-10.5 10.5-11.5 14.3-15.7 15.2-16.8 16.2-17.8 18.1-20.0
M8 x 1.25 23.8-26.2 25.6-28.4 34.2-37.8 36.7-40.5 39.0-43.0 43.7-48.3
M10 x 1.5 48-53 52-58 68-75 73-81 80-88 88-97
M12 x 1.75 82-91 90-100 116-128 126-139 139-153 152-168
Course Pitch
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263

M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2.5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2.5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2.5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3.5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
M8 x 1 25.7-28.3 27.5-30.5 36.2-39.8 40.0-44.0 42.8-47.2 47.5-52.5

M10 x 1.25 49.4-54.6 55.2-61.0 71.5-78.5 78.0-86.0 86.0-94.0 93.0-103.0
M12 x 1.25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1.5 86-95 94-104 120-132 133-147 143-158 159-175
M14 x 1.5 143-158 157-173 200-222 219-242 238-263 261-289
Fine Pitch
M16 x 1.5 214-236 233-257 302-334 333-368 361-399 394-436

M18 x 1.5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1.5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1.5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082
60571AA
Note: 1 Nm = 0.7376 ft-lb
Screw-locking, Sealing and Lubricating Materials
Loctite 242
• Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength lock-
ing. Before using it, completely remove any lubricant by using the specific activator.
Loctite 270
• Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength lock-
ing. Before using it, completely remove any lubricant by using the specific activator. To remove parts, it may
be necessary to heat them at 80˚C approx.

Table 2.4 Axles Maintenance Intervals
Operation Frequency Lubricants
Differential monthly
Check Levels
Planetary reduction every 200 hours
SAE85W90 (API GL4 - MIL L-2105)
Differential every 800 hours *
With additives for oil-bath brakes
Oil Change Planetary reduction every 1000 hours *
Self-locking
every 700 * &
differential gear
Operation Member Conditions Frequency Lubricants

Normal work monthly
Greasing Articulations MOLIKOTE
Awkward work weekly
Adjustments and Checks
Unit Operation Frequency Service Brake Circuit

Negative Brake Adjustment every 1000 hours *
Only for mineral oil use, e.g., ATF Dexron II.
Service Brake Adjustment every 500 hours Make sure that master cylinder seals are
suitable for mineral oil.
Wheel Nuts Tightening every 200 hours
* Initially after 100 working hours
& When it starts sounding noisy
Gear Box Lubricant Intervals
Check levels monthly
Oil change once at 50 hours after every 1000 hours
Screw/bolt tighten every 200 hours
Lubricant SAE 90 oil API GL3
Torque Wrench Settings (Nm)

Size of Screw 8G/8.8 10K/10.9 12K/12.9
M4 2.9 4.1 -
M6 10 14 -
M8 25 35 -
M12 49 69 -
M10 x 1.25 - 73 -
M12 86 120 -
M14 135 190 -
M14 x 1.5 - - 250
M16 210 295 -
A18 325 - -
60572AA
Note: 1 Nm = 0.7376 ft-lb

Table 2.5 Tire Specifications
SJ 40T/45T SJ 61T/66T
Tire Size 12" x 16.5" (30.5 cm x 41.9 cm) 15" x 19.5" (38.1 cm x 49.5 cm)
Pressure 65 psi (448.2 kPa) 95 psi (655 kPa)
Tire Ply Rating 10 16
Wheel Nuts Torque 290 ft-lb (393.2 Nm) 290 ft-lb (393.2 Nm)
60565AD-ANSI
WARNING
Intermixing tires of different types or using tires of types other than those originally supplied with
this equipment can adversely affect stability. Therefore, replace tires only with the exact original
Skyjack-approved type. Failure to operate with matched approved tires in good condition may
result in death or serious injury.
IMPORTANT
For proper function of each axle differential, all four wheels must have same tire size installed at
all times. Failure to comply with this requirement will reduce the life of the differentials and reduce
overall mobility of aerial platform.

Table 2.6 Floor Loading Pressure
Total Aerial Platform Total Aerial Platform Load

MODEL Weight Wheel LCP OUP
lb. kg lb. kg psi kPa psf kPa
SJ 40T (Standard configuration) 15,550 7,053 7,775 3,527 136 937.7 283 13.6
SJ 66T (Standard configuration) 27,800 12,610 14,240 6,459 145 1,001.0 304 14.6
60562AD-ANSI
Standard Configuration (40/45T)= 4WD + Oscillating Axle + 12" x 16.5" (30.5 cm x 41.9 cm) Air Tires
Standard Configuration (61/66T) = 4WD + Oscillating Axle + 15"X19.5" (38.1cm x 49.5 cm) Air Tires
Total Aerial Platform Weight = Weight + platform capacity
LCP – Locally Concentrated Pressure – is a measure of how hard the aerial platform tire tread presses on the area in direct contact with the
floor. The floor covering (tile, carpet, etc.) must be able to withstand more than the indicated values above.
OUP – Overall Uniform Pressure – is a measure of the average load the aerial platform imparts on the whole surface projected directly
underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values above.
40/45T: Foam tires option will add approximately 800 lb. (362.9 kg) to total aerial platform weight and 200 lb. (91 kg) to max. wheel load.
OUP will increase by 5% and LCP will increase by approx. 68%.
61/66T: Foam tires option will add approximately 1364 lb. (616 kg) to total aerial platform weight and 340 lb. (154 kg) to max wheel load.
OUP will increase by 5% and LCP will increase by approx 18%.
Welder option will add approximately 350 lb. (158.8 kg) to total aerial platform weight and 175 lb. (79.4 kg) to max. wheel load.
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or
architect for that particular structure.
Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP):
Foot Print Area = Tread Contact Area Base Area = Length x Width
Maximum Wheel Load Aerial Platform Weight + Capacity

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

Table 2.7 Hydraulic Specifications
SJ 40T / 45T SJ 45T SJ 61T / 66T SJ 66T

DESCRIPTION
ANSI CE ANSI CE
2.8 CIR 2.8 CIR
Displacement - 2600 rpm 46 CC 46 CC
30 gpm @ 2600 rpm 30 gpm @ 2600 rpm
Drive Pump Pressure 5000 psi 345 bar 4350 psi 300 bar
Drive Pump
Specifications
Charge Pump Displacement 0.85 CIR 13.9 CC 0.85 CIR 13.9 CC

Pump
Charge Pump Pressure 313 psi 22 bar 313 psi 22 bar
1.83 CIR / 1.83 CIR /

Displacement - Static 30 CC 30 CC
System 20.6 gpm @ 2600 rpm 20.6 gpm @ 2600 rpm
Pump
System Pump Pressure 2175 psi 150 bar 3000 psi 207 bar
Charge Pump Filter 50 psi 9 m/35 25 psi 9 m/35
Filter
High Pressure Filter 87 psi 10 m/25 87 psi 10 m/25
Specifications
Return Filter 25 psi 10 m/60 25 psi 10 m/60
1.55 CIR / 0.88 CIR /

Displacement - Low 25 CC 14.4 CC
Drive 15.2 gpm @ 2600 rpm 15.2 gpm @ 2600 rpm
Specifications
Motor 2.32 CIR / 2.32 CIR /

Displacement - High 38 CC 38 CC
Motor
22.8 gpm @ 2600 rpm 22.8 gpm @ 2600 rpm

4 CIR / 4 CIR /
Motor Displacement 65.56 CC 65.56 CC
Swing 39.4 gpm @ 2600 rpm 39.4 gpm @ 2600 rpm
Motor
Maximum Swing Pressure 1400 psi 96 bar 1400 psi 96 bar
Bore 2.5 in. 6.4 cm 2.5 in. 6.35 cm
Rod Diameter 1.5 in. 3.8 cm 3.5 in. 8.89 cm

Extension
Cylinder
Stroke 175 in. 4.45 m 167 in. 4.45 m
Maximum Boom Pressure 1500 psi 103 bar 3000 psi 207 bar
Bore 4 in. 10.2 cm 6 in. 15.24 cm

Specifications
Cylinder
Rod Diameter 3 in. 7.6 cm 3 in. 7.6 cm

Lift
Cylinder
Stroke 60.52 in. 1.54 m 44.28 in. 1.12 m
Maximum Lift Pressure 2175 psi 150 bar 3000 psi 207 bar
Differential Area 3.07 in. 7.8 cm 3.07 in. 7.8 cm
Steering
Steering Cylinder Stroke 4.32 in. 10.9 cm 4.32 in. 10.9 cm
Cylinder
Maximum Steering Pressure 2175 psi 150 bar 2175 psi 150 bar
For other component specifications, refer to hydraulic schematic.

60590AC

Table 2.8a Specifications and Features
MODEL SJ 40T SJ 45T SJ 61T SJ 66T
Maximum Load Capacity 650 lb. (295 kg) 500 lb (227 kg) 500 lb (227 kg) 500 lb (227 kg)
Platform
Total Platform Length (Outside) 96 in. (243.8 cm) 96 in. (243.8 cm) 96 in. (243.8 cm) 96 in. (243.8 cm)
Size
Total Platform Depth (Outside) 36 in. (91.4 cm) 36 in. (91.4 cm) 36 in. (91.4 cm) 36 in. (91.4 cm)
Working 44 ft. (13.4 m) 48 ft. (14.6 m) 65 ft. (19.8 m) 70 ft. (21.3 m)
Platform Elevated 40 ft. (12.4 m) 45 ft. (13.7 m) 61 ft. (18.6 m) 66 ft. (20.1 m)
Height
Drive driveable at all heights driveable at all heights
Turret 7 ft. 10 in. (2.4 m) 7 ft. 10 in. (2.4 m) 8 ft. 5 in. (2.6 m) 8 ft. 5 in. (2.6 m)
Overall with platform 25 ft. 5 in. (7.7 m) 28 ft. 10 in. (8.8 m) 30 ft. 4 in. (9.2 m) 33 ft. 11 in. (10.3 m)
Length
Base and tires 12 ft. 3 in. (3.7 m) 12 ft. 3 in. (3.7 m) 11 ft. 5 in. (3.5 m) 11 ft. 5 in. (3.5 m)
Outside std. tires 7 ft. 6 in. (2.3 m) 7 ft. 6 in. (2.3 m) 8 ft. (2.4 m) 8 ft. (2.4 m)
Width
Turret 7 ft. 4 in. (2.2 m) 7 ft. 4 in. (2.2 m) 7 ft. 6 in. (2.3 m) 7 ft. 6 in. (2.3 m)
Weight (with air tires) 14,900 lb. (6,759 kg) 15,850 lb. (7,189 kg) 23,800 lb. (10,796 kg) 27,300 lb. (12,383 kg)
Weight
Weight (with foam-filled tires) 15,700 lb. (7,121 kg) 16,650 lb. (7,552 kg) 25,200 lb. (11,431 kg) 28,700 lb. (13,018 kg)
Platform Rotation 170 degrees 180 degrees 170 degrees 180 degrees
Horizontal Reach 34 ft. (10.4 m) 39 ft. 9 in. (12.1 m) 51 ft. 3 in. (15.6 m) 57 ft. (17.4 m)
Wheelbase 8 ft. (2.4 m) 8 ft. (2.4 m) 8 ft. (2.4 m) 8 ft. (2.4 m)
Turret Rotation 360 degrees continuous 360 degrees continuous
Turret Tailswing 3 ft. 1 in. (94 cm) 3 ft. 1 in. (94 cm) 3 ft. 11 in. (145 cm) 3 ft. 11 in. (145 cm)
Gradeability (torque equivalent to) 45% 45% 45% 45%
Ground Clearance Between Wheels 11 in. (28 cm) 11 in. (28 cm) 16 in. (41 cm) 16 in. (41 cm)
2WD 7 ft. 7 in. (2.3 m) 7 ft. 7 in. (2.3 m) 9 ft. 3 in. (2.8 m) 9 ft. 3 in. (2.8 m)
Turning Radius
Inside
4WD 9 ft. (2.7 m) 9 ft. (2.7 m) 9 ft. 3 in. (2.8 m) 9 ft. 3 in. (2.8 m)
2WD 17 ft. (5.2 m) 17 ft. (5.2 m) 16 ft. 7 in. (5.0 m) 16 ft. 7 in. (5.0 m)
Outside
4WD 18 ft. 7 in. (5.7 m) 18 ft. 7 in. (5.7 m) 16 ft. 7 in. (5.0 m) 16 ft. 7 in. (5.0 m)
System Voltage 12 VDC 12 VDC
Type Lead Acid Lead Acid

Battery
Cold Cranking Amperes 800 A 800 A
Main boom up 30 - 40 seconds (approx.) 45 - 60 seconds (approx.)
Main boom down 30 - 40 seconds (approx.) 45 - 60 seconds (approx.)

Operating Times
Fly boom extend 30 - 40 seconds (approx.) 60 - 70 seconds (approx.)
Fly boom retract 30 - 40 seconds (approx.) 60 - 70 seconds (approx.)
Jib up 20 - 30 seconds (approx.) 20 - 30 seconds (approx.)
Jib down 14 - 24 seconds (approx.) 14 - 24 seconds (approx.)

Turret rotate - counterclockwise 360°
70 - 110 seconds (approx.) 83 - 120 seconds (approx.)
(fully stowed)
Platform rotate - full 10 - 20 seconds (approx.) 10 - 20 seconds (approx.)
Speeds
Drive Speed (maximum-stowed) 4.5 mph (7.2 km/h) 4.5 mph (7.2 km/h)
Driving
Drive Speed (maximum-elevated) 0.5 mph (0.8 km/h) 0.5 mph (0.8 km/h)
60629AA-ANSI

Table 2.8b Specifications and Features
MODEL SJ 40T SJ 45T SJ 61T SJ 66T

Engine Type Deutz D2011L03i Deutz D2011L04i
RPM Settings 1600 Low / 2100 / 2675 High 1600 Low / 2100 / 2675 High
Gross Intermittent HP 36 kW / 48 Hp 48 kW / 65 Hp
Horsepower @ 2600 rpm (intermittent) 34 kW / 45 Hp 48 kW / 65 Hp
Fuel Type Diesel
Fuel Tank Capacity 45 gal (170.3 L)
Engine - Deutz
Standard Oil 0°F to 115°F

SAE 15W-40 API CF/CG/CH-4
Factory Fill (- 18°C to +45°C)
Cold Lube Oil - 20°F to 90°F

Ambient SAE 5W-30 API CF/CG/CH-4
Option (- 29°C to +32°C)
Temperature
Arctic Lube Limits - 40°F to 115°F
SAE 0W-40 API CF/CG/CH-4
Oil Option (- 40°C to +45°C)
Apporved
See Engine Manual
Alternates
Lube Oil Sump Capacity 1.45 gal (5.5 L) 2.64 gal (10.0 L)
Engine Type 3.0L GM Dual Fuel

RPM Settings 900 Low / 1600 / 2675 High
Gross Intermittent HP 46 kW / 62 Hp
Horsepower @ 2600 rpm (intermittent) 45 kW / 60 Hp
Fuel Type - Dual Gasoline/Propane
Fuel Tank Capacity 45 gal (170.3 L)
Standard Oil - 40°F to 115°F
Engine - GM
Ambient SAE 5W-30 API SL

Factory Fill (- 40°C to +45°C)
Temperature
Apporved Limits See Engine Manual
Alternates
Lube Oil Capacity 1.19 gal (4.5 L)
Standard - 20°F to 115°F
Ambient GM 50/50 Extended Life Coolant
Coolant (- 29°C to +45°C)
Arctic Temperature
Limits - 40°F to 115°F
Coolant GM 60/40 Extended Life Coolant
(- 40°C to +45°C)
Option
Coolant Capacity 3.0 gal (11.4 L)
Hyd Cooler 100°F to 115°F

Oil cooler option recommended
Option (+38°C to +45°C)
Standard -15°F to 100°F

Shell Tellus T46
Factory Fill (-26°C to +38°C)
Hydraulic Oil
Arctic Ambient
- 40°F to 100°F Esso/Mobil UNIVIS HVI 26
Oil Temperature
(- 40°C to +38°C) Petro-Canada HYDREX EXTREME
Option Limits
-15°F to 100°F
Mobilfluid 424, Esso UNIVIS N46, Chevron Rycon MV
Apporved (-26°C to +38°C)
Alternates Mobil DTE 13M, Esso UNIVIS N22
- 40°F to 80°F
(- 40°C to +27°C) Petro-Canada HYDREX MV Arctic 15
Hydraulic Tank Capacity 59 gal (223.3 L)
60628AA-ANSI

Diagram 2.1 Dimension and Reach Diagram - SJ 40T
Reach Diagram - 40T
Dimensions - 40T

Reach Diagram - 45T
Dimensions - 45T

61 T Reach Diagram
Feet (meters)
75
(22.86)
70
(21.34)
65
(19.81)
60
(18.29)
55
(16.76)
50
(15.24)
45
(13.72)
40
(12.19)
35
(10.67)
30
(9.14)
25
(7.62)
20
(6.10)
15
(4.57)
10
(3.05)
5
(1.52)
-5
(-1.52)
-10
(-3.05)
-10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
(-3.05) (-1.52) (1.52) (3.05) (4.57) (6.10) (7.62) (9.14) (10.67) (12.19) (13.72) (15.24) (16.76) (18.29)
Reach Diagram - 61T

Dimensional Diagram 61T
(2.41 m) (15.63 m)
(1.20 m)
(18.67 m)
(2.43 m) (2.43 m)
(0.92 m)
(2.56 m)
(2.44 m)
(1.18 m)
(9.24 m)
Dimensions - 61T

Feet (meters)
75
(22.86)
70
(21.34)
65
(19.81)
60
(18.29)
55
(16.76)
50
(15.24)
45
(13.72)
40
(12.19)
35
(10.67)
30
(9.14)
25
(7.62)
20
(6.10)
15
(4.57)
10
(3.05)
5
(1.52)
-5
(-1.52)
-10
(-3.05)
-10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
(-3.05) (-1.52) (1.52) (3.05) (4.57) (6.10) (7.62) (9.14) (10.67) (12.19) (13.72) (15.24) (16.76) (18.29)
Reach
Reach Diagram - 66T
Diagram - SJ 66T
(2.41 m) (17.37 m)
(20.12 m) (1.20 m)
(2.43 m) (2.43 m)
(0.92 m)
(2.56 m)
(1.18 m) (2.44 m)
(10.34 m)
Dimensions - 66T
SJ 66T Dimensions

Diagram 2.5 Axle Oscillation Diagrams
WARNING
Do not raise the platform in work mode if it is not on a firm level surface.
Axle oscillation free (travel mode) - drive speed 4.5 mph max.
Axle oscillation locked (work mode) - drive speed 0.5 mph max.
Axle Oscillation - No Jib Boom
Axle oscillation free (travel mode) - drive speed 4.5 mph max.
Axle oscillation locked (work mode) - drive speed 0.5 mph max.
Axle Oscillation - Jib Boom

AD
Section 3
System component idenTification and schematics
Table of Contents
Charts
3.1 Hydraulic Symbol Chart...................................................................................................................................3
3.2 Electrical Symbol Chart...................................................................................................................................4
3.3 Wire Number and Color Code.........................................................................................................................5
Parts List
3.4 Hydraulic Schematic Parts List . .....................................................................................................................7
3.5 Electrical Component Parts List....................................................................................................................10
Diagrams and Schematics

3.6 Rotary Manifold and Port Identifications.......................................................................................................13
3.7 Brake Manifold and Port Identifications.........................................................................................................14
3.8 System Pump and Port Identifications..........................................................................................................15
3.9 Drive Pump and Port Identifications..............................................................................................................16
3.10 Drive Motor and Port Identifications..............................................................................................................17
3
3.11 Jib Valve and Port Identifications...................................................................................................................18
3.12 No Jib Valve and Port Identifications.............................................................................................................19
3.13 Axle Lockout Valve and Port Identifications..................................................................................................20
3.14 Main Manifold and Port Identifications..........................................................................................................21
3.15 Main Harness Wiring Diagram.......................................................................................................................24
3.16 ECU Engine Wiring Diagram (Deutz Diesel Engine).....................................................................................25
3.17 Engine Interface Harness (GM Dual Fuel Engine)........................................................................................26
3.18 Glow Plug Harness........................................................................................................................................27
3.19 Harnesses .....................................................................................................................................................28
3.20 Platform Control Cable Harnesses................................................................................................................29
3.21a Limit Switch Connections (ANSI/CSA)..........................................................................................................30
3.21b Limit Switch Connections (CE)......................................................................................................................31
3.22 Harness Connection Assemblies..................................................................................................................32
3.23 Load Sensing Cable Connection (CE)..........................................................................................................33
3.24 Deutz Diesel Engine Battery Cable Locations (CE)......................................................................................34
3.25 Hydraulic Schematic Diagram.......................................................................................................................35
3.26 Platform Control Console Diagram (ANSI/CSA SJ 45T - Deutz Diesel Engine)...........................................36
3.27 Platform Control Console Diagram (ANSI/CSA SJ 40T - Deutz Diesel Engine)...........................................37
3.28 Platform Control Console Diagram (CE SJ 45T - Deutz Diesel Engine).......................................................38
3.29 Platform Control Console Diagram (ANSI/CSA SJ 45T - GM Dual Fuel Engine).........................................39
3.30 Platform Control Console Diagram (ANSI/CSA SJ 40T - GM Dual Fuel Engine).........................................40
3.31 Base Control Console Diagram (ANSI/CSA SJ 45T - Deutz Diesel Engine)................................................41
3.32 Base Control Console Diagram (ANSI/CSA SJ 40T - Deutz Diesel Engine)................................................43
3.33 Base Control Console Diagram (CE SJ 45T - Deutz Diesel Engine)............................................................45
3.34 Base Control Console Diagram (ANSI/CSA SJ 45T - GM Dual Fuel Engine)..............................................46
3.35 Base Control Console Diagram (ANSI/CSA SJ 40T - GM Dual Fuel Engine)..............................................47
3.36 Electrical Schematic Diagram (ANSI/CSA - Deutz Diesel Engine)...............................................................48
3.37 Electrical Schematic Diagram (CE SJ 45T - Deutz Diesel Engine)...............................................................50
3.38 Electrical Schematic Diagram (ANSI/CSA - GM Dual Fuel Engine)............................................................51
3.39 Interface & Engine Electrical Schematic - GM Dual Fuel Engine ...............................................................52
3.40 Engine Harnesses - GM Dual Fuel Engine....................................................................................................53

Models SJ 40T & 45T
143844
AD
Table of Contents (Continued)
Special Options
3.41 Flashing Amber Light Connection.................................................................................................................55
3.42 Generator Control Valves and Port Indentifcations.......................................................................................56
3.43 Generator and Oil Cooler Harness Connections..........................................................................................57
3.44 Generator Wire Kit Connections....................................................................................................................58
3.45 Generator and Oil Cooler Connection Locations..........................................................................................59
3.46 12 kW Generator Connection Assembly.......................................................................................................60
3.47 12 kW Generator Connection Locations.......................................................................................................61

Models SJ 40T & 45T
143844
Section 3 - System Component Identification and Schematics Service and Maintenance
3.1 Hydraulic Symbol Chart
VARIABLE
LINE CROSSING DISPLACEMENT SHUTTLE VALVE VELOCITY FUSE
PUMP
ACCUMULATOR, SINGLE ACTING

LINE JOINED HAND PUMP GAS CHARGED CYLINDER
HYDRAULIC CUSHION DOUBLE ACTING

TANK RELIEF VALVE CYLINDER CYLINDER
DOUBLE ACTING
HYDRAULIC PRESSURE
PRESSURE DOUBLE
FILTER WITH REDUCING
SWITCH RODDED
BYPASS VALVE
CYLINDER
ELECTRIC MOTION SPRING APPLIED

MOTOR FIXED ORIFICE CONTROL VALVE HYDRAULIC
RELEASED
BRAKE
ADJUSTABLE FLOW DIVIDER BRAKE

ENGINE FLOW CONTROL COMBINER CYLINDER
FIXED
DISPLACEMENT COUNTER ROTARY
CHECK VALVE BALANCE VALVE ACTUATOR
PUMP
THREE POSITION
VARIABLE BI DIRECTIONAL
FOUR WAY
DISPLACEMENT HYDRAULIC
OIL COOLER VALVE COIL
PROPORTIONAL
HYDRAULIC MOTOR MOTOR
SERIES TWO POSITION THREE POSITION

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

TWO WAY TWO POSITION FOUR WAY FOUR WAY
NORMALLY THREE WAY VALVE CLOSED CENTER PROPORTIONAL
OPEN VALVE CLOSED PORT
PRESSURE PILOT LINES Dashed

MAIN LINES Solid
TRANSDUCER
SERVO

Models SJ 40T & 45T
143844
Service and Maintenance Section 3 - System Component Identification and Schematics
3.2 Electrical Symbol Chart
CIRCUITS CROSSING LIMIT SWITCH

NO CONNECTION HOURMETER KEY SWITCH
LIMIT SWITCH
CIRCUITS LIGHT FOOT SWITCH
CONNECTED CLOSED
LIMIT SWITCH
HYDRAULIC
BATTERY TOGGLE SWITCH
VALVE COIL
PROPORTIONAL LIMIT SWITCH

GROUND HYDRAULIC PUSH BUTTON
VALVE COIL
SILICON
ELECTRIC CONTROLLED
FUSE ROTARY SWITCH
MOTOR RECTIFIER
CIRCUIT PRO IMITY

HORN LIMIT SWITCH
BREAKER SWITCH
EMERGENCY CAM OPERATED PNP

VOLT METER STOP BUTTON LIMIT SWITCH TRANSISTOR
CAPACITOR RESISTOR NPN

TILT SWITCH
TRANSISTOR
SINGLE POLE
POTENTIOMETER LEVEL SENSOR SINGLE THROWN VACUUM
RELAY SWITCH
SINGLE POLE DOUBLE POLE DOUBLE POLE TEMPERATURE

DOUBLE THROW SINGLE THROW DOUBLE THROW SWITCH
RELAY RELAY RELAY
TRIPLE POLE
DOUBLE THROW DIODE RHEOSTAT
RELAY

Models SJ 40T & 45T
143844
3.3 Wire Number and Color Code
WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE

WIRE COLOR
NO. COLOR NO. NO. COLOR NO. COLOR NO. COLOR
00 WHT 20 ORG/BLU 44 YEL/WHT 67 ORG/BRN 92 GRN SHLD
000 WHT 21 WHT/RED 45 YEL/ORG 68 GREY 93 BLK SHLD
B1 BLU/PINK 23 BLK/WHT 46 RED/BLK 69 WHT/GRN 95 YEL/GREY
01 PUR/BLK 24 BLU/BLK 47 PUR/ORG 70 ORG/PINK 96 WHT/GREY
02 WHT 25 BRN/BLK 48 YEL/GREY 71 RED/ORG 97 ORG/GREY
03 GRN/PUR 26 BLU/YEL 49 GRN/RED 72 RED/BRN 98 RED SHLD
04 RED/YEL 27 RED/BLK/WHT 50 BRN 73 RED/PINK 98A BLK SHLD
GRN/
05 PUR 28 GRN 51 BLK/GRN 74 99 BLK/GREY
GREY
06 29 GREY/ORG 52 GRN/BLU 75 GREY/PUR 103 BLK/PUR
07 RED 30 RED/GRN 53 BRN/RED 76 BRN/BLU 104 GRN/ORG
08 PUR/WHT 31 RED/WHT 54 PUR/RED 77 BRN/GREY 105 GRN/BRN
09 YEL 32 GRN/BLK 55 YEL/PUR 78 RED/BLU 106 GRN/PINK
10 BLU/WHT 33 GRN/WHT 56 YEL/BLK 79 BRN/PUR 107 BLK/BLU

GREY/
11 WHT/ORG 34 ORG/BLK 57 BRN/GRN 80 WHT 108 YEL/BRN
RED/YEL/
12 35 ORG/WHT 58 WHT/PUR 81 GREY/BLK 109 GRN/YEL
BLK
13 ORG 36 RED/PUR 59 YEL/BLU 82 BRN/WHT 110A BLU
WHT/RED/
14 BLK 37 60 WHT/BLU 83 BLU/GREY 110B BRN
BLK
WHT/BLK/
15 BLU 38 ORG/RED 61 GREY/BRN 84 111 GREY/GRN
PUR
16 WHT/BLK 39 BLK/RED 62 GREY/RED 85 GREY/BLU 112 BLU/ORG
17 BLU/GRN 40 BLU/RED 63 GREY/YEL 86/87 PUR/BLU 113 BLU/BRN
18 GRN/BLU 41 BLU/PUR 64 WHT/BRN 88 BLK/ORG 114 YEL/RED
19 ORG/GRN 42 PINK 65 YEL/PINK 90 RED/GREY 115 WHT/PUR
22 PUR/GRN 43 WHT/YEL 66 ORG/YEL 91 RED SHLD 118 PUR/PINK
This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire
numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red.

Models SJ 40T & 45T
143844
3.4 Hydraulic Schematic Parts List AB

Index Skyjack
Qty. Description
No. Part No.
2H-21A 141408 1 VALVE, Pressure dump

2H-42 141418 1 VALVE, Control (Flow enable)
3H-15 141486 1 VALVE, Control (Drive pump control reverse)
3H-16 141486 1 VALVE, Control (Drive pump control forward)
3H-26 141435 1 VALVE, Control (Brake apply)
3H-45 141435 1 VALVE, Control (2 speed motor)
3H-65 139093 1 VALVE, Control (Axle lockout)
3H-V1 N/A 1 VALVE, Control (Pressure compensator)
3H-V2 N/A 1 VALVE, Control (Load sense compensator)
4H-13 141430 1 VALVE, Control (Boom lower)
4H-14 141430 1 VALVE, Control (Boom raise)
4H-23A 141410 1 VALVE, Control (Steering right)
4H-24A 141410 1 VALVE, Control (Steering left)
4H-32 141417 1 VALVE, Control (Boom rotation left)
4H-33 141417 1 VALVE, Control (Boom rotation right)
4H-34 141421 1 VALVE, Control (Jib lower)
4H-35 141421 1 VALVE, Control (Jib raise)
4H-36 141421 1 VALVE, Control (Platform rotate left)
4H-37 141421 1 VALVE, Control (Platform rotate right)
4H-38 141430 1 VALVE, Control (Boom retract)
4H-39 141430 1 VALVE, Control (Boom extend)
4H-40 141421 1 VALVE, Control (Platform leveling down)
4H-41 141421 1 VALVE, Control (Platform leveling up)
C1 138500 1 CYLINDER (Boom lift)
C2 138501 1 CYLINDER (Boom extension)
C3 138502 1 CYLINDER (Platform leveling - master)
C4 138503 1 CYLINDER (Platform leveling - slave)
C5 138504 1 CYLINDER (Jib lift)
C6 141046 1 CYLINDER (Front axle steering - 4WD)
C7 138171 1 CYLINDER (Axle lockout)
C8 138171 1 CYLINDER (Axle lockout)
C9 141083 1 CYLINDER (Front axle steering - 2WD)
CB1 141407 1 VALVE, Counterbalance (Main control)
CB2 141407 1 VALVE, Counterbalance (Main control)
CB3 144570 1 VALVE, Counterbalance (Swing drive)
CB4 144570 1 VALVE, Counterbalance (Swing drive)
CB5 701827 1 VALVE, Counterbalance (Boom lift)
CB6 141453 1 VALVE, Counterbalance (Boom extension)
CB7 141453 1 VALVE, Counterbalance (Boom extension)
CB8 710088 1 VALVE, Counterbalance (Platform leveling - slave)
CB9 710088 1 VALVE, Counterbalance (Platform leveling - slave)
CB10 701827 1 VALVE, Counterbalance (Jib lift)
CB11 701827 1 VALVE, Counterbalance (Jib lift)
CB12 141399 1 VALVE, Counterbalance (Platform rotary actuator)
CB13 141399 1 VALVE, Counterbalance (Platform rotary actuator)
CB14 104569 1 VALVE, Counterbalance (Axle lockout cylinder)
Parts list continued on following page.

Models SJ 40T & 45T
143844
3.4 Hydraulic Schematic Parts List (Continued) AC

Index Skyjack
Qty. Description
No. Part No.
Parts list continued from previous page.

CV1 141404 1 VALVE, Check (Main control valve - P1)
CV2 141405 1 VALVE, Check (Main control valve - P2)
CV3 141406 1 VALVE, Check (Main control valve - steer)
CV7 141406 1 VALVE, Check (Main control valve - DSV1)
CV10 141406 1 VALVE, Check (Main control valve - CB2)
CV11 141406 1 VALVE, Check (Main control valve - CB1)
CV12 141406 1 VALVE, Check (Main control valve - PP)
CV13 138406 1 VALVE, Check (Generator option)
CV14 141444 1 VALVE, Check (Brake valve - 247 psi spring)
CV15 N/A 1 VALVE, Check (EPU)
CV16 139205 1 VALVE, Check (Brake valve hand pump)
DSV1 141416 1 VALVE, Differential sensing (Swing)
DSV2 141416 1 VALVE, Differential sensing (Lift)
DSV3 141416 1 VALVE, Differential sensing (Extend)
EPU 706921 1 EMERGENCY POWER UNIT
F1 138398 1 FILTER, Charge pump (9 micron abs, 50 psi bp)
F2 139148 1 FILTER, high pressure (10 micron abs, 87 psi bp)
F3 138404 1 FILTER, return (10 micron abs, 25 psi bp)
GCV1 138405 1 VALVE, Generator control (110/120V Generator option)
GCV2 138989 1 VALVE, Generator control (Welder Generator option)
M1 138118 1 MOTOR, Drive (2 speed)
M2 138280 1 MOTOR, Turret rotation
M3 144419 1 MOTOR, Hydraulic (110/120V Generator option)
M4 146075 1 MOTOR, Hydraulic (Welder Generator option)
OR1 141420 1 ORIFICE, 0.078” (Main control valve)
OR6 141443 1 ORIFICE, 0.073” (Brake valve)
OR7 144120 1 ORIFICE (Generator LS)
P1 138116 1 PUMP, Drive
P1A N/A 1 PUMP, Charge
P2 138117 1 PUMP, System
PR1 141438 1 VALVE, Control (Pressure reducing)
QD1 122420 1 QUICK DISCONNECT (CE)
Parts list continued on following page.

Models SJ 40T & 45T
143844
3.4 Hydraulic Schematic Parts List (Continued) AC

Index Skyjack
Qty. Description
No. Part No.
Parts list continued from previous page.
RA1 138232 1 ACTUATOR, Platform rotary

RA2 138280 1 ACTUATOR, Turret rotation swing drive
RV1 141287 1 VALVE, Relief (Drive pump)
RV4 141440 1 VALVE, Relief (Brake)
RV5 N/A 1 VALVE, Relief (EPU)
RV6 141403 1 VALVE, Relief (Main control swing drive)
RV7 141403 1 VALVE, Relief (Main control boom extend)
RV8 146015 1 VALVE, Relief (Main control clipping)
SV1 141439 1 VALVE, Shuttle (Brake valve)
SV2 141441 1 VALVE, Shuttle (Brake valve - M1 / M2)
SV3 141414 1 VALVE, Shuttle (Main control valve - RA / RB)
SV4 141414 1 VALVE, Shuttle (Main control valve - LA / LB)
SV5 141414 1 VALVE, Shuttle (Main control valve - EA / EB)
SV6 146014 1 VALVE, Shuttle (Boom rotation)
SV7 138394 1 VALVE, Shuttle (Generator option)
V1 141436 1 VALVE, Control (Brake release override)
V2 141442 1 VALVE, Control (Loop flush)
V3 141437 1 VALVE, Control (Brake hand pump)

Models SJ 40T & 45T
143844
3.5 Electrical Component Parts List AC
SUPPLY (B+) (Common)
CONTROL (B+) GROUND (B-)
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Qty. Description
No. Part No.
01CR 127131 1 RELAY, 12 Volt 40 Amp (e-pump)

08BCR 127131 1 ENABLE RELAY, 12 Volt 40 Amp
08CR 127131 1 RELAY, 12 Volt 40 Amp (engine start interlock)
09CR 127131 1 RELAY, 12 Volt 40 Amp (engine power on)
17ACR1 127131 1 RELAY, 12 Volt 40 Amp (steering reversal)
17ACR2 127131 1 RELAY, 12 Volt 40 Amp (steering reversal)
21CR 127131 1 RELAY, 12 Volt 40 Amp (dump valve)
49CR 127131 1 RELAY, 12 Volt 40 Amp (horn)
51CR 127131 1 RELAY, 12 Volt 40 Amp (drive enable)
51CR1 127131 1 RELAY, 12 Volt 40 Amp (tilt alarm)
54ACR 138844 1 RELAY, 12 Volt 80 Amp (SPST)
57ACR 127131 1 RELAY, 12 Volt 40 Amp (anti restart)
57BCR 127131 1 RELAY, 12 Volt 40 Amp (anti restart)
57BCR1 127131 1 RELAY, 12 Volt 40 Amp (engine start)
59CR 127131 1 RELAY, 12 Volt 40 Amp (optional axle lock)
60CR 127131 1 RELAY, 12 Volt 40 Amp (system power)
78CR 127131 1 RELAY, 12 Volt 40 Amp (high idle)
79CR 127131 1 RELAY, 12 Volt 40 Amp (low idle)
81CR 127131 1 RELAY, 12 Volt 40 Amp (optional light)
107CR 127131 1 RELAY, 12 Volt 40 Amp (level interlock)
2H-21A 143970 1 COIL, 12 Volt (Dump valve)
2H-42 143966 1 COIL, 12 Volt (Proportional flow enable)
Parts list continued on the following page.

Models SJ 40T & 45T
143844
3.5 Electrical Component Parts List AE

Index Skyjack
Qty. Description
No. Part No.
2H-85 143967 1 COIL, 12 Volt (Optional generator valve)

3H-45 143970 1 COIL, 12 Volt (Motor 2-speed valve)
3H-26 143970 1 COIL, 12 Volt (Brake valve)
3H-65 143966 1 COIL, 12 Volt (Optional axle lock valve)
4H-13 143964 1 COIL, 12 Volt (Boom down valve)
4H-14 143964 1 COIL, 12 Volt (Boom up valve)
3H-15 143965 1 COIL (Reverse drive valve)
3H-16 143965 1 COIL (Forward drive valve)
4H-23A 143968 1 COIL, 12 Volt (Right steer valve)
4H-24A 143968 1 COIL, 12 Volt (Left steer valve)
4H-32 143964 1 COIL, 12 Volt (Left turret rotate valve)
4H-33 143964 1 COIL, 12 Volt (Right turret rotate valve)
4H-34 143969 1 COIL, 12 Volt (Platform level down valve)
4H-38 143964 1 COIL, 12 Volt (Telescope in valve)
4H-39 143964 1 COIL, 12 Volt (Telescope out valve)
4H-41 143969 1 COIL, 12 Volt (Platform level up valve)
A1 138225 1 JOYSTICK, Boom/turret
A2 138224 1 JOYSTICK, Drive/steer
A3 138226 1 CONTROLLER, Speed control selector
B1 703719 1 BATTERY, 12V (wet)
B2 144527 1 BATTERY, 12V (450 CCA) (CE)
BP1 103057 1 BEEPER, 4-28 VDC Slow pulsing (Platform control console)
BP2 103056 1 BEEPER, 7.5-16 VDC (Base control console)
BP3 144387 1 ALARM, Overload (CE)
CB1 117325 1 CIRCUIT BREAKER, 15 Amp
DXX 102921 AR DIODE
FU1 138848 1 FUSE, 50 Amp
FU2 121504 1 FUSE, 20 Amp (If equipped)
FS1 136119 1 SWITCH, Low fuel
H1 102850 1 HORN, 12 Volt
LB2 143971 1 LIGHT, Optional strobe
LB4 138806 1 LIGHT, Optional chassis
LB5 138806 1 LIGHT, Optional chassis
LS1 133075 1 LIMIT SWITCH, High drive tilt override NO, held closed
LS2 133075 1 LIMIT SWITCH, Direction sensing, NC held open
LS3 138719 1 LIMIT SWITCH, Fly, NO, held closed (SJ 45T)
138720 1 LIMIT SWITCH, Fly, NO, held closed (SJ 40T)

Models SJ 40T & 45T
143844
3.5 Electrical Component Parts List (Continued) AD

Index Skyjack
Qty. Description
No. Part No.
M1 706921 1 PUMP, Emergency

PL1 138228 1 MODULE, Lower indicating (Base control console)
PL2 138229 1 MODULE, Upper indicating (Platform control console)
PL3 137785 1 SWITCH, LED block (Emergency stop) (Base control console)
PL4 137785 1 SWITCH, LED Block (Emergency stop) (Platform control console)
R1 139088 1 RESISTOR, (6 OHM 25 watt) (ANSI/CSA)
144523 1 RESISTOR, (7 OHM 25 watt) (CE)
R2 139089 1 RESISTOR, (12 OHM 25 watt) (SJ 45T)
139196 1 RESISTOR, (15 OHM 25 watt) (SJ 40T)
R3 139080 1 RESISTOR, (30 OHM 3 Watt, wire wound)
R4 139080 1 RESISTOR, (30 OHM 3 Watt, wire wound)
R5 143952 1 RESISTOR, (51 OHM 2 Watt)
R6 144523 1 RESISTOR, (680 OHM 1 watt, axial lead 2%) (CE)
S1 119725 1 SWITCH, Main power disconnect
108714 1 LEVER, Locking
S2 138277 1 KEYSWITCH, Base/off platform
S3 137783 2 NC CONTACT, Emergency stop (Base control console)
S4 137783 2 NC CONTACT, Emergency stop (Platform control console)
S5 138278 1 SWITCH, Ignition/emergency pump toggle (Base control console)
S6 138278 1 SWITCH, Ignition/emergency toggle (Platform control console)
S7 102853 1 SWITCH, Function enable toggle (Base control console)
S8 102853 1 SWITCH, Diagnose toggle (Base control console)
S9 102853 1 SWITCH, Diagnose toggle (Base control console)
S10 115747 1 SWITCH, Throttle toggle (Platform control console)
S11 138721 1 ASSEMBLY, Footswitch
S12 138278 1 SWITCH, Boom up/down toggle (Base control console)
S13 102853 1 SWITCH, Turret rotate toggle (Base control console)
S14 102853 1 SWITCH, Telescope in/out toggle (Base control console)
S15 102853 1 SWITCH, Platform leveling toggle (Base control console)
S16 102853 1 SWITCH, Platform rotate toggle (Base control console)
S17 102853 1 SWITCH, Jib up/down toggle (Base control console) (SJ 45T)
S18 102853 1 SWITCH, Telescope in/out toggle (Platform control console)
S19 102853 1 SWITCH, Platform leveling toggle (Platform control console)
S20 102853 1 SWITCH, Platform rotate toggle (Platform control console)
S21 102853 1 SWITCH, Jib up/down toggle (Platform control console) (SJ 45T)
S22 115747 1 SWITCH, Electrical generator
S23 137782 1 NO SPRING CONTACT, Horn (Platform control console) (ANSI/CSA)
102853 1 SWITCH, Horn (Platform control console) (CE)
S24 115574 1 SWITCH, Optional lights (Platform control console)
S25 137782 1 NO SPRING CONTACT, Engine enable (Platform control console) (CE)
S48 115574 1 SWITCH, Drive torque toggle (Platform control console)
TS1 139014 1 SWITCH, Tilt (5°/ 5°)
TT1 103336 1 HOUR METER
X22 138576 1 PORT, Diagnose
X23 138575 1 CONNECTOR, Engine

Models SJ 40T & 45T
143844
3.6 Rotary Manifold and Port Identifications
Port 7
To Drive Pump
Port 8
To Drive Pump
Port 9
To Hydraulic Tank
Port 2
To Axle Lockout Valve
Port 1
To Main Manifold
Port 3
Port 5
To Hydraulic Tank
To Main Manifold
Port 6 Port 4
To Brake Manifold To Brake Manifold
Port 8
Port 4
To Drive Motor
To Brake Cylinder
Port 1
To Steer Cylinder
Port 5 Port 3
To Steer Cylinder To Axle Lockout Cylinder*
Port 6
Port 2 To Drive Motor
To Axle Lockout Cylinder
Port 7
Port 9
To Drive Motor
To Drive Motor
M139167AA_S3

Models SJ 40T & 45T
143844
3.7 Brake Manifold and Port Identifications
T
To Return Line Filter
CV14
Check Valve RV4
Relief Valve
M2
To Drive Pump
LS
M1 To Main Manifold
To Drive Pump
SV1
V3 Shuttle Valve
Hand Pump Release
V2
Loop Flush Valve
SV2
Shuttle Valve
V1
Brake Release Override Valve
PR1
Pressure Reducing Valve
2 SPD
To Rotary Manifold
OR6
Orifice
BR
To Rotary manifold
3H-45
2 Speed Valve
3H-26
Brake Valve
M139131AA_S3

Models SJ 40T & 45T
143844
3.8 System Pump and Port Identifications
Port B
To High Pressure Filter
3H-V2
Load Sense Adjusting Stem
3H-V1
Pressure Compensator
Adjusting Stem
LS
To Main Manifold
S
To Shut-off Valve
L1
To Hydraulic Tank
(For pressure adjustment, refer to section 5) M138117AA_S3

Models SJ 40T & 45T
143844
3.9 Drive Pump and Port Identifications
S
To Shut-off Valve
M1 L1
To Brake Manifold To Hydraulic Tank
D
To Charge Filter
E
To Charge Filter
V4
Bypass Valve
M2
To Brake Manifold
RV3
Charge Pump Relief Valve
A
To Rotary Manifold
B
To Rotary Manifold
(For pressure test, refer to section 5) M138116AA_S3

Models SJ 40T & 45T
143844
3.10 Drive Motor and Port Identifications
B
To Rotary Manifold
A
To Rotary Manifold
L1
To Rotary Manifold
X1
To Rotary Manifold
M138118AA_S3

Models SJ 40T & 45T
143844
3.11 Jib Valve and Port Identifications
4H-37 4A-34
Platform Right Rotate Valve Jib Down Valve
4H-36 4A-35
Platform Left Rotate Valve Jib Up Valve
2B
To Jib Cylinder
2A
1B
To Bulkhead
To Jib Cylinder
(Bracket Weldment)
1A
To Bulkhead
(Bracket Weldment)
3(P)
4(T)
To Bulkhead
To Bulkhead
(Main Boom)
(Main Boom)
M138120AA_S3

Models SJ 40T & 45T
143844
3.12 No Jib Valve and Port Identifications
4H-37
Platform Right Rotate Valve
4H-36
Platform Left Rotate Valve
2A
To Bulkhead
(Bracket Weldment)
1A
To Bulkhead
(Bracket Weldment)
3(P)
To Bulkhead
(Main Boom)
4(T)
To Bulkhead
(Main Boom)
M138395AA

Models SJ 40T & 45T
143844
3.13 Axle Lockout Valve and Port Identifications
2 3H-65
To Rotary Manifold Axle Lockout Valve
1
To Charge Filter
3
To Rotary Manifold
M139133AA_S3

Models SJ 40T & 45T
143844
3.14a Main Manifold and Port Identifications AD
A B C D E F G H
SA
To Rotary Manifold
SB
To Rotary Manifold RA
P1 To Swing Drive Motor
To High Pressure Filter W
GP1 (CE) LA
P2 Test Port To Lift Cylinder
To Emergency Power Unit RB
To Swing Drive Motor
BLS
To Brake Manifold LB
To Lift Cylinder
LS
To System Pump PLA X
(without Generator option) To Bulkhead (Turret)
PLB
To Bulkhead (Turret)
EB
To Bulkhead (Turret)
GP2 (ANSI/CSA) EA
Test Port LS To Bulkhead (Turret)
Y
To System Pump
(with generator option)
PP
To Bulkhead (Main Boom)
LS
To Generator Option
T
To Return Line Filter
Z
M139132AD-S3

Models SJ 40T & 45T
143844
3.14b Main Manifold and Electrical Identifications AB
A B C D E F G H
4H-23A
Right Steer Valve
4H-24A
Left Steer Valve W
4H-33
Turret Rotate Right Valve
2H-21A X
Dump Valve 4H-13
Boom Down Valve
4H-32
4H-39
Turret Rotate Left Valve
Boom Extend Valve
4H-14
Boom Up Valve 2H-42
Flow Enable Valve Y
4H-38
Boom Retract Valve 4H-40
Manual Level Down Valve
4H-41
Manual Level Up Valve
M139132AD-S3

Models SJ 40T & 45T
143844
3.14c Main Manifold and Hydraulic Identifications AB
A B C D E F G H
CV1
Pump Check Valve CV6
Check Valve V
CV2
DSV1
Emergency Power Check Valve
Differential Sensing
DSV2
OR1
Differential Sensing Valve
Steer Orifice
DSV3
Differential Sensing Valve
W
OR5
Level Orifice
SV3
Shuttle Valve
RV8
System Relief Valve
SV5 X
CV5 Shuttle Valve
Check Valve CB2
RV6 Counterbalance Valve
Boom Rotation Relief Valve CB1
SV4 Counterbalance Valve
Shuttle Valve SV7
RV7 Shuttle Valve
Boom Extension Relief Valve OR4 Y
Orifice
OR2 CV7
Orifice Check Valve
OR3 CV8
Orifice Check Valve
CV4 CV9
Check Valve Check Valve
CV3 CV10 CV12
Check Valve Check Valve Check Valve Z
CV11
Check Valve
M139132AD-S3

Models SJ 40T & 45T
143844
3.15 Main Harness Wiring Diagram AD
A B C D E F G H
02
V
108 EMERGENCY PUMP

03 108 - YELLOW/BROWN AXLE LOCK VALVE
14 GA.
2
PIN 1 - 65 YELLOW/PINK
1 2
MAIN POWER PIN 2 - 02 WHITE (SPLICE #3)

03 - GREEN PURPLE
12 GAUGE
ABCD X
BRAKE VALVE
1
PIN 1 - 26 BLUE/YELLOW
1
PIN 2 - 02 WHITE SPLICE #3)
2
)
2
DRIVE PUMP EDC MOTOR TORQUE
BATTERY (B-) PIN A - 16 WHITE/BLACK PIN 1 - 45 YELLOW/ORANGE
00 - WHITE PIN B - 02 WHITE (SPLICE #3) PIN 2 - 02 WHITE SPLICE #3)
12 GAUGE PIN C - 02 WHITE (SPLICE #3) 2
00
PIN D - 15 BLUE
PLATFORM LEVEL DOWN
02
PIN 1 - 40 BLUE/RED PIN 1 - 00 - WHITE [12 GA.]
1
2
PIN 2 - 02 WHITE (SPLICE #2)
1 2
13
PROPORTIONAL FLOW ENABLE PIN 2 - 03 - GREEN/PURPLE [12 GA.]
PLATFORM LEVEL UP PIN 3 - 13 - ORANGE
2
2
1
1 2 1 2
PIN 1 - 42 PINK PIN 1 - 41 BLUE/PURPLE PIN 4 - 14 - BLACK

FUEL LEVEL SWITCH PIN 2 - 02 WHITE (SPLICE #2) Y
PIN 2 - 02 WHITE (SPLICE #2) PIN 5 - 21A - WHITE/RED
PIN 1 - 55 YELLOW/PURPLE
PIN 2 - 02 WHITE SPLICE #3) TELESCOPE OUT PIN 6 - 23A - BLACK/WHITE
TELESCOPE IN PIN 7 - 24A - BLUE/BLACK
12
PIN 1 - 39 BLACK/RED PIN 1 - 38 ORANGE/RED
24
2
PIN 8 - 26 - BLUE/YELLOW
1 2
1
1 2
PIN 2 - 02 WHITE (SPLICE #2) PIN 2 - 02 WHITE (SPLICE #2)

PIN 9 - 65 - YELLOW/PINK
02
PIN 10 - 32 - GREEN/BLACK
BOOM DOWN BOOM UP PIN 11 - 33 - GREEN/WHITE
PIN 1 - 13 ORANGE PIN 1 - 14 BLACK PIN 12 - 38 - ORANGE/RED
2
1
1 2 1 2
PIN 2 - 02 WHITE (SPLICE #2) PIN 2 - 02 WHITE (SPLICE #1) PIN 13 - 39 - BLACK/RED
PIN 14 - 40 - BLUE/RED
TURRET ROTATE LEFT PIN 15 - 41 - BLUE/PURPLE
TURRET ROTATE RIGHT
2
PIN 1 - 32 GREEN/BLACK PIN 16 - 42 - PINK
PIN 1 - 33 GREEN/WHITE
2
1 2
1
PIN 2 - 02 WHITE (SPLICE #1) PIN 17 - 45 - YELLOW/ORANGE

PIN 2 - 02 WHITE (SPLICE #1)
STEER LEFT PIN 18 - 55 - YELLOW/PURPLE
STEER RIGHT PIN 19 - 108 - YELLOW/BROWN [14 GA.] Z
2
PIN 1 - 24A BLUE/BLACK
1 2
1
1 2
PIN 1 - 23A BLACK/WHITE PIN 2 - 02 WHITE (SPLICE #1) PIN 20 - 15 - BLUE

PIN 2 - 02 WHITE (SPLICE #1) PIN 21 - 16 - WHITE/BLACK
DUMP VALVE PIN 22 - 02 - WHITE (SPLICE #1) [14 GA.]
2
1 2
PIN 1 - 21A WHITE/RED PIN 23 - 02 - WHITE (SPLICE #2) [14 GA.]

PIN 2 - 02 WHITE (SPLICE #1) PIN 24 - 02 - WHITE (SPLICE #3) [14 GA.]
M139132AD-S3

Models SJ 40T & 45T
143844
3.16 ECU Engine Wiring Diagram (Deutz Diesel Engine)
A B C D E F G H
00A 00A - L=25.00"
02 02 - L=7.00" V
PIN 1 - 02 - WHITE 11 11 - L=13.00"
PIN 2 - 106 - GREEN/PINK 54A 54A - L=9.00"
PIN 3 - 96 - WHITE/GREY
PIN 4 - 76 - BROWN/BLUE
PIN 5 - 74 - GREEN/GREY 57C 57C - L=32.00"
PIN 6 - PLUGGED
74 74 - L=10.00"
PIN 7 - PLUGGED
PIN 8 - PLUGGED 76 76 - L=10.00"
PIN 9 - PLUGGED 77 77 - L=10.00"
84 84 - L=16.00" W
PIN 10 - 105 - GREEN/BROWN
PIN 11 - 104 - GREEN/ORANGE
PIN 12 - PLUGGED
PIN 13 - PLUGGED
90 90 - L=29.00"
PIN 14 - 54A - PURPLE/RED 96 96 - L=16.00"

PIN 15 - 84 - WHITE/BLACK/PURPLE
PIN 16 - PLUGGED
PIN 17 - 103 - BLACK/PURPLE
PIN 1 - 77 - BROWN/GREY
PIN 4 - 57C - BROWN/GREEN [12 GA.]
99 99 - L=31.00"
PIN 18 - 99 - BLACK/GREY PIN 10 - 11 - WHITE/ORANGE
PIN 19 - PLUGGED 103 103 - L=9.50"
PIN 11 - 00A - WHITE X
PIN 20 - PLUGGED 104 104 - L=6.00"
PIN 21 - 90 - RED/GREY
PIN 22 - PLUGGED 105 105 - L=6.00"
PIN 23 - JUMPER TO PIN 24 106 106 - L=6.00"
PIN 24 - JUMPER TO PIN 23
PIN 25 - PLUGGED
M138708AA

Models SJ 40T & 45T
143844
3.17 Engine Interface Harness (GM Dual Fuel Engine) AD
A B C D E F G H
ENGINE CONNECTOR 2 PIN 1 - 02 WHITE

PIN E - 02 WHITE PIN 2 - 54A PURPLE/RED
2
305
PIN 3 - 57A BROWN/GREEN
300
PIN J - 78 RED/BLUE FUEL PUMP (+) FUEL PUMP (-)
6
PIN K - 79 BROWN/PURPLE 3056 BLACK 3002 WHITE PIN 4 - 11 WHITE/ORANGE
PINS (A,B,C,D,F,G,H,L,M,N,P,R&S) - N/U PIN 5 - 76 BROWN/BLUE
PIN 6 - 77 BROWN/GREY
PIN 7 - 78 RED/BLUE
PIN 8 - 79 BROWN/PURPLE W
PINS 9, 10, 11, 12 - N/U
ENGINE CONNECTOR 2
BACK VIEW
BACK VIEW
1 12
2 11
DEUTSCH
3 10
4 9
5 8
6 7
X
ENGINE CONNECTOR 1
BACK VIEW
ENGINE CONNECTOR 1
PIN A - 54A PURPLE/RED
PIN B - 77 BROWN/GREY Y
PIN C - 3002 WHITE
PIN D - 3056 BLACK
PIN F - 57A BROWN/GREEN
PIN G - 76 BROWN/BLUE
PIN H - 11 WHITE/ORANGE
PINS (E,J,K,L,M,N,P,R&S) - N/U
M144265AC_S3

Models SJ 40T & 45T
143844
3.18 Glow Plug Harness
A B C D E F G H
TO AIR BOX
LEFT CYLINDER
RELAY
SOCKET
DETAIL
CENTRE CYLINDER RIGHT CYLINDER

W
SOCKET #87
54A
11
BASE CONTROL
BOX TERMINAL
BLACK - 54A STRIP X
WHITE - 11
03
6 AWG
TO ENGINE STARTER
M138849AB

Models SJ 40T & 45T
143844
3.19 Harnesses AD
A B C D E F G H
JIB VALVE HARNESS LIMIT SWITCH ASSEMBLY (IF EQUIPPED)

(REFER TO 3.21 FOR OTHER ASSEMBLIES)
JIB DOWN
PIN 1 - 34 ORANGE/BLACK
PIN 2 - 02 WHITE
2
1
2
G
1 2
2
3
1 2
JIB UP W
G
SOCKET 1 - 34 ORANGE/BLACK PIN 1 - 35 ORANGE/WHITE
SOCKET 2 - 35 ORANGE/WHITE PIN 2 - 02 WHITE
SOCKET 3 - 02 WHITE
SOCKET 4 - 02 WHITE SOCKET 1 - BLUE
SOCKET G - N/C
SOCKET 2 - BROWN
SOCKET 3 - N/C
SOCKET G - N/C
ROTATE VALVE HARNESS FOOTSWITCH HARNESS
ROTATE CCW
PIN 1 - 37 WHITE/RED/BLACK
PIN 2 - 02 WHITE
2
1
G
1 2
1
Y
2
3
1 2
PIN 1 - 36 RED/PURPLE
ROTATE CW
PIN 2 - 37 WHITE/RED/BLACK
G
PIN 1 - 36 RED/PURPLE
PIN 3 - 02 WHITE
PIN 2 - 02 WHITE
PIN 4 - 02 WHITE
PIN G - N/C PIN 1 - 04A BLACK
PIN 2 - 08A WHITE
PIN 3 - N/C
PIN G - N/C
M138717AB M138719AB M138721AB

Models SJ 40T & 45T
143844
3.20 Platform Control Cable Harnesses AD
A B C D E F G H
BASE PLATFORM
POSITION 1 - PURPLE/BLACK POSITION 1 - PURPLE/BLACK
POSITION 2 - WHITE POSITION 2 - WHITE V
POSITION 3 - WHITE POSITION 3 - WHITE
POSITION 4 - RED POSITION 4 - RED
POSITION 5 - RED POSITION 5 - RED
POSITION 6 - PURPLE/WHITE POSITION 6 - PURPLE/WHITE
POSITION 7 - YELLOW POSITION 7 - YELLOW
POSITION 8 - BLUE/WHITE POSITION 8 - BLUE/WHITE
POSITION 9 - RED/YELLOW/BLACK POSITION 9 - RED/YELLOW/BLACK
POSITION 10 - ORANGE POSITION 10 - ORANGE
POSITION 11 - BLACK POSITION 11 - BLACK
POSITION 12 - BLUE POSITION 12 - BLUE
POSITION 13 - WHITE/BLACK POSITION 13 - WHITE/BLACK
POSITION 14 - BLUE/GREEN POSITION 14 - BLUE/GREEN
POSITION 15 - ORANGE/BLUE POSITION 15 - ORANGE/BLUE
POSITION 16 - BLACK/WHITE POSITION 16 - BLACK/WHITE
POSITION 17 - BLUE/BLACK POSITION 17 - BLUE/BLACK W
POSITION 18 - BLUE/YELLOW POSITION 18 - BLUE/YELLOW
POSITION 19 - RED/BLACK/WHITE
MALE POSITION 19 - RED/BLACK/WHITE
POSITION 20 - GRAY/ORANGE POSITION 20 - GRAY/ORANGE
POSITION 21 - GREEN/BLACK POSITION 21 - GREEN/BLACK
POSITION 22 - GREEN/WHITE POSITION 22 - GREEN/WHITE
POSITION 23 - ORANGE/BLACK POSITION 23 - ORANGE/BLACK
POSITION 24 - ORANGE/WHITE POSITION 24 - ORANGE/WHITE
MALE
BASE PLATFORM
POSITION 1 - RED/PURPLE POSITION 1 - RED/PURPLE
POSITION 2 - WHITE/RED/BLACK POSITION 2 - WHITE/RED/BLACK
POSITION 3 - ORANGE/RED POSITION 3 - ORANGE/RED
POSITION 4 - BLACK/RED POSITION 4 - BLACK/RED
POSITION 5 - BLUE/RED POSITION 5 - BLUE/RED
POSITION 6 - BLUE/PURPLE POSITION 6 - BLUE/PURPLE
POSITION 7 - PINK POSITION 7 - PINK
POSITION 8 - BLUE/WHITE/BLACK POSITION 8 - BLUE/WHITE/BLACK
POSITION 9 - YELLOW/ORANGE POSITION 9 - YELLOW/ORANGE
POSITION 10 - GREEN/RED POSITION 10 - GREEN/RED
POSITION 11 - YELLOW/PURPLE POSITION 11 - YELLOW/PURPLE Y
POSITION 12 - BROWN/GREEN POSITION 12 - BROWN/GREEN
POSITION 13 - YELLOW/BLUE POSITION 13 - YELLOW/BLUE
POSITION 14 - WHITE/BLUE POSITION 14 - WHITE/BLUE
POSITION 15 - GREEN/GRAY POSITION 15 - GREEN/GRAY
POSITION 16 - BROWN/BLUE POSITION 16 - BROWN/BLUE
POSITION 17 - RED/BLUE POSITION 17 - RED/BLUE
POSITION 18 - BROWN/PURPLE POSITION 18 - BROWN/PURPLE
POSITION 19 - GRAY/BLACK POSITION 19 - GRAY/BLACK
POSITION 20 - GRAY/BLUE POSITION 20 - GRAY/BLUE
POSITION 21 - PINK/WHITE
FEMALE POSITION 21 - PINK/WHITE
POSITION 22 - PINK/PURPLE POSITION 22 - PINK/PURPLE
POSITION 23 - BLUE/WHITE/RED POSITION 23 - BLUE/WHITE/RED
POSITION 24 - BLUE/WHITE/YELLOW POSITION 24 - BLUE/WHITE/YELLOW
Z
FEMALE
M138758AA1

Models SJ 40T & 45T
143844
3.21a Limit Switch Connections (ANSI/CSA) AD
A B C D E F G H
LS3-BLK/WH
LS3-BLACK
BLACK/WHITE BROWN
NC NO
BLACK BLUE
W
LS3 - @ BOOM
(6" EXTEND)
51 / 59
(IF EQUIPPED)
09
09
17
29
BASE CONTROL
LS1-BLACK
LS1-BLK/WH
LS2-BLK/WH
LS2-BLACK
BOX TERMINAL
STRIP X
BLACK BROWN
LS2 - @
NC NO UPPER TURRET
BLACK/WHITE BLUE
BLACK/WHITE
NC
BLACK
Y
BLUE
BROWN
NO
LS1 - @
SWIVEL
Z
M143993AB

Models SJ 40T & 45T
143844
3.21b Limit Switch Connections (CE) AD
A B C D E F G H
LS3-BLK/WH
BROWN
LS3-BLACK
BLACK/WHITE
NC NO
BLACK BLUE
162 / 59
LS3 - @ BOOM
(6" EXTEND) W
29
09
09
17
BASE CONTROL
BOX TERMINAL LS2 - @ TURRET
X
LS1-BLACK
LS1-BLK/WH
LS2-BLK/WH
LS2-BLACK
STRIP (15 DEGREES)

BLACK/WHITE BROWN
NC NO
BLACK BLUE
Y
BLACK/WHITE
NC
BLACK
BLUE
BROWN
NO
LS1 - @
SWIVEL
Z
M144462AB

Models SJ 40T & 45T
143844
3.22 Harness Connection Assemblies AB
A B C D E F G H
(LOWER COIL)
W
38/02
14/02
32/02
(UPPER COIL)
2
41/02
34/02 35/02
2
65/02
2 2 2
23A/02
2
37/02 36/02
2
40
(U /02
PP 2
ER
CO
IL)
2
X
2 2
45/02
26/02
2
2
2
Y
(LOWER COIL)
2
/02
24A/02
2
21A
2 2 2
42/02
39/02
13/02
33/02
BOTTOM VIEW
M139163AA M139192AA

Models SJ 40T & 45T
143844
3.23 Load Sensing Cable Connection (CE) AC
A B C D E F G H
2
4
3
24
23
22
21
20
19
18
17
16
15
14
13
24P-MALE
PLUG B
12
11
10
9
8
7
6
5
4
3
2
1
82/118
60/04
02
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
PLUG A
10
11
12
1
1
2
3
4
5
6
7
8
9
GREEN/YELLOW
PLATFORM CONTROL CONSOLE

Z
M144463AB

Models SJ 40T & 45T
143844
3.24 Deutz Diesel Engine Battery Cable Locations (CE) AC
A B C D E F G H
X
2/0
Y
2/0
TO STARTER POST
2/0
2/0
00
NOTE: BATTERY BOOTS NOT SHOWN.

M144571AA

Models SJ 40T & 45T
143844
3.25 Hydraulic Schematic Diagram AE
A B C D E F G H
OPTION - 12000 WATT GENERATOR (WELDER OPTION) ST2 - STEEL TUBE (BEHIND TANK-MIDDLE)
LS SAE04 BULKHEAD LOCATIONS
2 BULKHEAD #2 POWER TRACK CARRIER ASSEMBLY #1 - AT REAR OF TURRET (BY COUNTERWEIGHT)

#2 - BOTTOM OF MAIN BOOM - REAR
SAE12 OUT M4 IN SAE12 SAE06 SAE06
#3 - TOP OF FLYBOOM - AT TIP
GCV2 2H-85 #4 - ON NO-JIB MOUNTING BRACKET
GENERATOR SAE06 SAE06
V
SAE08 GEN CONTROL
VALVE
SAE06 SAE06
C1
12kW HYDRAULIC GENERATOR C3 C2 BOOM LIFT SAE06 SAE06
208 VAC - 3 PHASE PLATFORM LEVELING BOOM EXTENSION C4 C5
CYLINDER
1 MASTER CYLINDER CYLINDER PLATFORM LEVELING JIB LIFT
3.25"BORE 2.50"BORE 4.00"BORE SLAVE CYLINDER CYLINDER
1.50"ROD 1.50"ROD 3.00"ROD
60.52"STROKE 3.25"BORE 3.00"BORE
SAE12 12.06"STROKE 175.00"STROKE
TO 1.50"ROD 2.00"ROD
11.63"STROKE 31.58"STROKE
ST3 FROM TO RA2
F2 SV7 BOOM ROTATION
SWING DRIVE
(T45 ONLY)
OPTION - 3500 WATT, 110V GENERATOR
ST2 - STEEL TUBE (BEHIND TANK-MIDDLE) M2 RA1
PLATFORM ROTARY
- PLUG ACTUATOR
CB7 CB6
1000 PSI 1000 PSI BR2
OUT 3:1
3:1
DISPL: 239CC
CB4 CB3
SAE12 OUT M3 IN SAE08 LS SAE04
1000 1000
OR7 PSI
GCV1 PSI
GENERATOR 8 GPM
SAE08 GEN CONTROL

VALVE 2H-85
CB5 SV6
3000 PSI
3.5kW HYDRAULIC GENERATOR
SAE06
SAE06
SAE06
SAE06
SAE06
SAE06
3:1
117 VAC - 60 CYCLE
IN
CB12 CB13
W
CB8 CB9 CB10 CB11
BULKHEAD #1 3000 PSI 3000 PSI 3300 PSI 3300 PSI
3000 PSI 3000 PSI
3:1 3:1 3:1 3:1 3:1 3:1
ST3 - STEEL TUBE
SAE06
SAE06
SAE04
SAE04
BEHIND TANK (LOWER) SAE08
SAE06
SAE06
SAE06
SAE06
SAE06
SAE06
SAE06
SAE06
SAE04
SAE04
SAE12 GENERATOR
BULKHEAD BULKHEAD
NO GENERATOR MB3 PLA PLB EA EB LA LB RA RB SA SB #3 #4
NOTE C BRAKE VALVE
SAE12
SAE08
V2 SV5 SV4 SV3 STEERING
SAE06
SAE06
SAE04
SAE04
SAE04
SAE04
LOOP FLUSH VALVE VALVE
M2 M1 SAE04 CB2 CB1 OR4 OR3 OR2
3000 3000 CV6 CV5
OPTION - PSI PSI
HYDRAULIC 2B 1B 2A 1A
OC1 CV14 OR6 4H-33 4H-32
SAE04
OIL COOLER
Ø0.073 4H-14 RIGHT LEFT
4H-39 4H-38 4H-13
IN OUT UP DOWN
V3 SV2 RV7
BRAKE HAND BLS
SAE04
RELIEF
PUMP VALVE RV6 4H-23A 4H-24A 4H-34 4H-35 4H-37 4H-36
PR1 4H-41 4H-40 RIGHT LEFT
(STANDARD WITH UP 1500 RELIEF DOWN UP RIGHT LEFT
PRESS. REDUCING DOWN
GENERATOR) PSI VALVE NOTE A
VALVE-450 PSI OR1
CV11 CV10 DSV2 DSV1
3H-45 LS CV8 1400 SAE06 3(P) x
2 SPEED VALVE SV7 OR5 CV9 CV7 CV4 CV3
DSV3 PSI
SAE12
SAE12
LS LS SAE06 4(T) x
SV1 PLS 2H-21A
2-SPD CV12
SAE04
DUMP
SAE04
PLATFORM ROTATE AND JIB VALVE
VALVE
T45 ONLY
PP P1
3H-26 NOTE 2H-42 CV1
SAE12
BRAKE B FLOW RV8 TO
VALVE ENABLE
0-800 PSI 2900 BULKHEAD #4
VALVE P2
SAE06
GAUGE
X
PSI CV2
SAE04
V1 SAE12 T x 3 1
BRAKE RELEASE
x
OVERRIDE
RV4 MAIN CONTROL VALVE ASSEMBLY OPTION - CE GP1 GLS GP2
RELIEF VALVE BRG RV5
QD1 SYSTEM PRESSURE
500 PSI RELIEF 4H-37 4H-36
QUICK DISCONNECT CV15
TP4 VALVE RIGHT LEFT
2500 PSI
T BR
GENERATOR 2(P)
SAE08 GENERATOR ONLY GENERATOR AND NO GENERATOR TO
SAE08 EMERGENCY BULKHEAD #2
POWER UNIT 4(T)
SAE12 NO GENERATOR
ST1 - STEEL TUBE SAE06 SAE04 GENERATOR ONLY NO GENERATOR
PLATFORM ROTATE VALVE
BEHIND TANK (TOP) T40 ONLY
12VDC
MOTOR
C6 (4WD)
SAE04
C9 (2WD)
25 F1 FRONT AXLE
F3 PSI CHARGE PUMP STEERING CYLINDER
RETURN LINE FILTER ROTARY
SAE08
FILTER CV16 (9 MICRON ABS) MANIFOLD
(10 MICRON ABS) HAND PUMP
SAE04
SUCTION 50 PSI
ASSIST TP3 PORT #1
STEER RIGHT
SAE04
PORT #2
P1 LOCKOUT PILOT
DRIVE PUMP
SAE06 SAE04
Y
(46 CC/2.8 CIR)
(30 GPM @ 2600 RPM) PORT #3
LOCKOUT TANK
SAE06
SAE06
PCP
SAE10
SAE10
PUMP DISPL CONTROL PORT #4

BRAKE
3H-15 = REVERSE
M1
3H-16 = FORWARD SAE06 SAE06 (25 CC/1.55 CIR)
DRIVE MOTOR CB17
M1 PORT #5 (38 CC/2.32 CIR) 2000 PSI
SAE12
DRIVE DIRECTIONAL VALVE D E P2 STEER LEFT 10:1 C7

4H-V1 TP2 SAE10 SYSTEM PUMP SAE04 SAE04 B
(30 CC/1.83 CIR) F2
L1 HI PORT #6 CB16
A (20.6 GPM @ 2600 RPM) 2 SPEED SHIFT
PRESSURE 2000 PSI
SAE12
10:1
FILTER SAE06 SAE06
(10 MICRON ABS) X1
DIESEL OR RV1
PORT #7 L1 AXLE LOCKOUT CYLINDERS
DUAL FUEL RELIEF DRIVE FORWARD
ENGINE VALVE 3.00"BORE
5000 PSI S B SAE12 A
SAE12 SAE12
SAE04
V4 3H-V1 3H-V2 2.00"ROD
BYPASS PRESSURE LOAD SENSE CB15
P1A PORT #8 4.00"STROKE
VALVE COMPENSATOR COMPENSATOR DRIVE REVERSE 2000 PSI
CHARGE RV3 2175 PSI 87 PSI 10:1
RV2 275 PSI
PUMP RELIEF SAE12 SAE12
RELIEF
VALVE
SAE12
VALVE C8
313 PSI 5000 PSI PORT #9
SAE06
MOTOR DRAIN CB14
2000 PSI
SAE08 10:1
B
SAE08
TP1
Z
L1 S NOTE: SYSTEM PUMP IS FLANGE MOUNTED LS
M2 ENERGIZED TO FLOAT
TO REAR OF DRIVE PUMP SAE04
SAE12
SAE16
SAE04 3H-65
SAE06
SAE06
SAE20
PORT PLUGS:
1 NOTE: SPRING CAVITY DRAIN LINES HAVE

NOTE A: - PLUGGED WHEN GENERATOR OPTION ADDED 3
SHUT-OFF 2 BEEN REMOVED FOR CLARITY: ALL COUNTER BR1
NOTE B: - PLUGGED WHEN NO GENERATOR USED BALANCE, RELIEF, LOAD SENSE, AND REAR AXLE SAHR
VALVE
PRESSURE COMPENSATING VALVES AFFECTED BRAKE CYLINDER
NOTE C: - PLUGGED WHEN OIL COOLER ONLY ADDED (NO GENERATOR)
SAE06
AXLE LOCKOUT
VALVE
M143950AH1
Telescopic Boom Series NOTE: To determine the correct electrical schematic that resembles your aerial platform, SKYJACK, Page 35
Models SJ 40T & 45T refer to the “Table Of Contents” frond at the beginning of this section.
143844
3.26 Platform Control Console Diagram (ANSI/CSA SJ 45T - Deutz Diesel Engine) AD
A B C D E F G H
Serial Breakdown A1 JOYSTICK S20-ROT S19-LEV S18-TELE S21-JIB A2 JOYSTICK
Reference Chart JUMPER
Model Serial Number 41 38A 35

RED (+) POWER 04 (RED/YELLOW) 90A 08 08 08
SJ-45T 98000481 & Below BLK (-) GROUND 02 (WHITE)

40 39A 34
08
37
36
WHT (X)
BLU (Y)
X-SIGNAL
Y-SIGNAL
RED
BLUE
09A (YELLOW)
02 (WHITE)
POWER
GROUND
RED
BLK
V
02 BLACK D-SIGNAL YEL
24 (BLUE/BLACK) LEFT WHT/RED
23 (BLACK/WHITE) RIGHT WHT/YEL
PL2
GREEN SIGNAL
A B C D E F G H
PURPLE POWER
A3
WHITE NEUTRAL
S10- S48-
S6-IGNITION
THROT TORQ
02
WHITE
GREEN
D04
-2
WHITE WHITE
SUP
59
02
08
02
27
76
55
74
PURPLE
78 57
02
02 08 59 04 20D
04
S4-E STOP
PURPLE
01
GREEN
79 45
S23-HORN W
02
04
07A
49 04
04
07A
04
49
04
04
4
04
02
02
12
10
12
10
76
55
JUMPER
74
49
02
34
35
36
37
02
59
17ACR2
04A
02 SUPP 37
37
02 SUPP 36
36
X
02 SUPP 35
34 35
02 SUPP
34
23
24
04
17A
23A
24
23
08
59
60
40
41
57A
17ACR1
79
78
76
74
60
59
57A
49
55
42
41
40
39
38
36
45
37
24
23
22
21
20
19
18
17
16
15
14
13
24P-MALE
24A
02
GREEN
20D/24
20D/40
20D/41
20D/23
04A
34A/34
34A/35
36A/36
36A/37
02
08B
60/04
12
11
10
27
34
35
36
37
59
60
02
04
02
02
08
08BCR
9
8
7
6
5
4
3
2
1
D-SIG
02
23
13
14
15
16
17
18
19
20
21
22
24
24P-FEMALE
08
04
02
20D
20D
20D
34A
36A
59
37
10
11
12
1
2
3
4
5
6
7
8
9
08CR
36
D20
B
35
23A
24A
16
17
20
26
27
29
32
33
34
35
34
08
07A
07A
09A
01
02
02
10
12
13
14
15
37
36
04
20D
20B
27
57A
02
57
20
R3=30
23A
24A
02
24 1 04
08
08CR1
13 04
R4=30
02
25 2 04
14 04
02
26 3 PURPLE
15 17
D-SIG
27 4 17A
20D
16 08A
X-SIG
28 5 20B
02
17
20
39A
Y-SIG
29 6 08B
18 38A
GREEN
30 7 26
19 32
59
31 8 13
20 42
36A
32 9
21
Z
39
34A
33 10 33
BP1 22 14
16
34 11 38
OCM PLUG 23 15
+ 35 12 90A
34-BLACK 02-WHITE 36-BLACK 02-WHITE 29-BLACK 04A-BLACK
1 3 1 3 1 3 1 3
60
35-RED 02-GREEN 37-RED 02-GREEN 59-WHITE 08A-WHITE
_ 27 2 G 2 G 2 2
4P-MALE 4P-FEMALE 3P-MALE 3P-FEMALE

4" PIGTAIL TYP.
M143985AB
SKYJACK, Page 36 NOTE: To determine the correct electrical schematic that resembles your aerial platform, Telescopic Boom Series
refer to the “Table Of Contents” found at the beginning of this section. Models SJ 40T & 45T
143844
3.27 Platform Control Console Diagram (ANSI/CSA SJ 40T - Deutz Diesel Engine) AD
A B C D E F G H
Serial Breakdown A1 JOYSTICK S20-ROT S19-LEV S18-TELE A2 JOYSTICK

Model Serial Number 41 38A

RED (+) POWER 04 (RED/YELLOW) 90A 08 08
SJ-40T 98000481 & Below BLK (-) GROUND 02 (WHITE)

40 39A
V
08
37
36
WHT (X) X-SIGNAL RED
09A (YELLOW) POWER RED
BLU (Y) Y-SIGNAL BLUE 02 (WHITE) GROUND BLK
PL2
GREEN SIGNAL
A B C D E F G H
PURPLE POWER
A3
WHITE NEUTRAL
S10- S48-
S6-IGNITION
02
THROT TORQ
WHITE
GREEN
D04
-2
WHITE WHITE
SUP
59
02
08
02
27
76
55
74
PURPLE
78 57
02
02 08 59 04 20D
04
S4-E STOP
PURPLE
01
GREEN
S23-HORN
79 45
W
02
04
07A
49 04
04
07A
04
49
04
04
4
04
02
02
12
10
12
10
76
55
JUMPER
74
49
02
36
37
02
59
17ACR2
04A
02 SUPP 37
37
02 SUPP 36
X
36
23
24
04
17A
23A
24
23
08
59
60
40
41
57A
17ACR1
79
78
76
74
60
59
57A
49
55
42
41
40
39
38
36
45
37
24
23
22
21
20
19
18
17
16
15
14
13
24P-MALE
24A
02
GREEN
20D/24
20D/40
20D/41
20D/23
04A
34A/34
34A/35
36A/36
36A/37
02
08B
60/04
12
11
10
27
34
35
36
37
59
60
02
04
02
02
08
08BCR
9
8
7
6
5
4
3
2
1
D-SIG
02
23
13
14
15
16
17
18
19
20
21
22
24
24P-FEMALE
08
04
02
Y
20D
20D
20D
34A
36A
59
37
10
11
12
1
2
3
4
5
6
7
8
9
08CR
36
D20
B
23A
24A
16
17
20
26
27
29
32
33
08
07A
07A
09A
01
02
02
10
12
13
14
15
37
36
04
20D
20B
27
57A
02
57
20
R3=30
23A
24A
02
24 1 04
08
08CR1
13 04
R4=30
02
25 2 04
14 04
02
26 3 PURPLE
15 17
D-SIG
27 4 17A
20D
16 08A
X-SIG
28 5 20B
02
17
20
39A
Y-SIG
29 6 08B
18 38A
GREEN
30 7 26
19 32
59
31 8 13
20 42
32 9
Z
36A
21 39
34A
33 10 33
BP1 22 14
16
34 11 38
23 15
+ 35 12 90A
36-BLACK 02-WHITE 29-BLACK 04A-BLACK
1 3 1 3 1 3
60
37-RED 02-GREEN 59-WHITE 08A-WHITE
_ 27
OCM PLUG 2 G 2 2
4P-FEMALE 3P-MALE 3P-FEMALE

4" PIGTAIL TYP.
M143983AB
Models SJ 40T & 45T refer to the “Table Of Contents” found at the beginning of this section.
143844
3.28 Platform Control Console Diagram (CE SJ 45T - Deutz Diesel Engine) AC
A B C D E F G H
A1 JOYSTICK S20-ROT S18-TELE S21-JIB A2 JOYSTICK

JUMPER
38A 35
RED (+) POWER 04 (RED/YELLOW) 08 08 08
39A 34
V
BLK (-) GROUND 02 (WHITE)
08
37
36
PL2
GREEN SIGNAL
A B C D E F G H
PURPLE POWER
A3
WHITE NEUTRAL
S10- S48-
S23- S6-IGNITION
THROT TORQ
HORN 02
OPTION OPTION GREEN

WHITE
D04
02A
-2
WHITE WHITE
SUP
59
08
02
27
76
55
74
49 04
PURPLE
78 57
02
04
S25-ENGINE 08 59 04 20D
PURPLE
01
GREEN
49 79 45
S4-E STOP ENABLE W
02
04
07A 04A 04A 04
04A
07A
04A
04
04
3
JUMPER
04A
02
02
12
10
12 10
76
55
74
49
02
34
35
36
17ACR2
02
37
02
04A
02 SUPP 37
37
02 SUPP 36
36
X
02 SUPP 35
34 35
02 SUPP
34
23
24
17A
23A
24
23
04
08
59
60
57A
17ACR1
37 D37A 37A
36 D36A 36A
79
78
76
74
60
59
57A
36A
37A
49
55
42
39
38
45
02
24
23
22
21
20
19
18
17
16
15
14
13
24A
02
24P-MALE
08B
GREEN
08BCR
20D/24
20D/40
20D/41
20D/23
04A
34A/34
34A/35
36A/36
36A/37
82/118
02
60/04
12
11
10
36
27
34
35
37
59
60
02
02
02
02
04
08
9
8
7
6
5
4
3
2
1
D-SIG
02
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
08
04
02
02
20D
20D
20D
34A
36A
59
Y
08CR
37
10
11
12
1
2
3
4
5
6
7
8
9
36
D20
08
35
23A
24A
34A
35A
16
17
20
26
27
32
33
34
15
07A
07A
09A
01
02
02
10
12
13
14
37
D34A
D35A
36
04
34
35
20D
20B
57A
02
57
27
20
02
R3=30
23A
08
08CR1
24A
02
24 1 04
13 04
R4=30
02
25 2 04
20D
14 04
02
26 3 PURPLE
15
02
17
20
D-SIG
27 4 17A
16 08A
X-SIG
28 5 20B
17 39A
BP3
Y-SIG
29 6 08B
82
18 38A
02
82CR
GREEN
30 7 26
+
19 32
118
02A 59
31 8 13
02
_
20 42
36A
32 9
21 39
34A
33 10 33
Z
02
22 14
16
34 11 38
BP1 23 15
+ OCM PLUG 35 12 34-BLACK 02-WHITE 36-BLACK 02-WHITE 04A-BLACK

1 3 1 3 1 3
60
35-RED 02-GREEN 37-RED 02-GREEN 08A-WHITE
_ 27
2 G 2 G 2
4P-MALE 4P-FEMALE
3P-FEMALE
4" PIGTAIL TYP.
M144381AB
143844
3.29 Platform Control Console Diagram (ANSI/CSA SJ 45T - GM Dual Fuel Engine)
A B C D E F G H
Serial Breakdown A2 JOYSTICK
A1 JOYSTICK S20-ROT S19-LEV S18-TELE S21-JIB
Model Serial Number 41 38A 35

90A 08 08 08
SJ-45T
RED (+) POWER 04 (RED/YELLOW)
98000481 & Below 40 39A 34

V
08
37
36
PL2
GREEN SIGNAL
A B C D E F G H PURPLE POWER
A3
S26-
WHITE NEUTRAL
S10- S48-
S6-IGNITION
FUEL THROT TORQ
02
WHITE
GREEN
D04
WHITE WHITE
SUP
59
-2
08
02
27
76
55
04
PURPLE
78 57
02
60 08 59 04 20D
02
S4-E STOP
PURPLE
01
GREEN
74
S23-HORN
79 45
W
02
04
07A
49 04
04
07A
04
49
04
04
4
04
02
02
12
10
12
10
60
76
55
JUMPER
74
49
02
34
35
36
37
02
59
17ACR2
04A
02 SUPP 37
37
02 SUPP 36
36
X
02 SUPP 35
02 SUPP 34 35 60
34
23
24
04
17A
23A
24
23
08
59
60
40
41
57A
17ACR1
79
78
76
74
60
59
57A
49
55
42
41
40
39
38
36
45
37
24
23
22
21
20
19
18
17
16
15
14
13
24P-MALE
24A
02
GREEN
20D/40
20D/41
20D/23
20D/24
04A
34A/34
34A/35
36A/36
36A/37
02
08B
60/04
12
11
10
34
35
36
37
59
60
27
02
02
02
04
08
08BCR
9
8
7
6
5
4
3
2
1
D-SIG
02
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
08
04
02
20D
20D
20D
34A
36A
59
Y
37
10
11
12
1
2
3
4
5
6
7
8
9
08CR
36
D20
B
35
23A
24A
16
17
20
26
27
29
32
33
34
35
34
08
07A
07A
09A
01
02
02
10
12
13
14
15
37
36
04
20D
20B
27
57A
02
57
20
R3=30
23A
24A
02
24 1 04
08
08CR1
13 04
R4=30
02
25 2 04
14 04
02
26 3 PURPLE
15 17
D-SIG
27 4 17A
20D
16 08A
X-SIG
28 5 20B
02
17
20
39A
Y-SIG
29 6 08B
18 38A
GREEN
30 7 26
19 32
59
31 8 13
20 42
36A
32 9
21 39
33 10
Z
34A 33
BP1 22 14
16
34 11 38
23 15
+ 35 12 90A
34-BLACK 02-WHITE 36-BLACK 02-WHITE 29-BLACK 04A-BLACK
OCM PLUG 1 3 1 3 1 3 1 3
60
35-RED 02-GREEN 37-RED 02-GREEN 59-WHITE 08A-WHITE
_ 27 2 G 2 G 2 2
4P-MALE 4P-FEMALE 3P-MALE 3P-FEMALE

4" PIGTAIL TYP.
M144152AA
143844
3.30 Platform Control Console Diagram (ANSI/CSA SJ 40T - GM Dual Fuel Engine) AD
A B C D E F G H
Serial Breakdown A1 JOYSTICK A2 JOYSTICK
S20-ROT S19-LEV S18-TELE
Model Serial Number 41 38A

RED (+) POWER 04 (RED/YELLOW) 90A 08 08
SJ-40T 98000481 & Below 40 39A
V
08
37
36
09B (YELLOW) POWER RED
PL2
GREEN SIGNAL
A B C D E F G H
PURPLE POWER
A3
S10- S48-
WHITE NEUTRAL
S26- S6-IGNITION
FUEL 02
THROT TORQ
WHITE
GREEN
D04
WHITE WHITE
SUP
59
-2
08
02
27
76
55
04
PURPLE
78 57
02
60 08 59 04 20
02
S4-E STOP
PURPLE
01
GREEN
74 79 45
S23-HORN W
02
04
07A
49 04
04
07A
04
49
04
04
4
04
02
02
12
10
12
10
60
76
55
74
JUMPER
49
02
36
37
02
59
17ACR2
04A
02 SUPP 37
37
02 SUPP 36
36
X
60
23
24
04
17A
23A
24
23
08
59
60
40
41
57A
17ACR1
79
78
76
74
60
59
57A
49
55
42
41
40
39
38
36
45
37
24
23
22
21
20
19
18
17
16
15
14
13
24P-MALE
24A
02
GREEN
04A
34A/34
34A/35
36A/36
36A/37
02
08B
60/04
12
11
10
34
35
36
37
59
60
27
02
02
02
04
08
08BCR
20/24
20/40
20/41
20/23
9
8
7
6
5
4
3
2
1
D-SIG
02
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
08
04
02
34A
36A
59
20
20
20
Y
37
10
11
12
1
2
3
4
5
6
7
8
9
08CR
36
D20
B
23A
24A
16
17
20
26
27
29
32
33
08
07A
07A
09A
01
02
02
10
12
13
14
15
37
36
04
20
20B
27
57A
02
57
09A
R3=30
23A
24A
20
02
24 1 04
08
08CR1
13 04
R4=30
02
25 2 04
14 04
02
26 3 PURPLE
15 17
D-SIG
27 4 17A
09B
16 08A
X-SIG
28 5 20B
09A
02
17 39A
Y-SIG
29 6 08B
18 38A
GREEN
30 7 26
19 32
59
31 8 13
20 42
36A
32 9
21 39
33 10
Z
34A 33
BP1 22 14
16
34 11 38
23 15
+ 35 12 90A
36-BLACK 02-WHITE 29-BLACK 04A-BLACK
1 3 1 3 1 3
60
37-RED 02-GREEN 59-WHITE 08A-WHITE
_ 27 OCM PLUG 2 G 2 2
4P-FEMALE 3P-MALE 3P-FEMALE

4" PIGTAIL TYP.
M144150AA
143844
3.31a Base Control Console Diagram (ANSI/CSA SJ 45T - Deutz Diesel Engine) AD
A B C D E F G H
Serial Breakdown Reference Chart
49
38
39
40
41
Model Serial Number Reference

59
55
60
42 74
79 37
980143 & Below Figure 3.31a

78 36
45 76
SJ-45T
57A
980144 & 98000481 Figure 3.31b V
79
78
76
74
60
59
PLUG B
57A
55
49
45
42
41
40
39
38
37
36
24
23
22
21
20
19
18
17
16
15
14
13
(NEAR DOOR)
24P-MALE
TS1
H1
LEVEL
HORN
49A
12
11
10
9
8
7
6
5
4
3
2
1
SENSOR
02
(NEAR BACKPLATE)
- +
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
10
11
12
1
2
3
4
5
6
7
8
9
PLUG A
07A-14ga
07A-14ga
23A
24A
16
17
20
26
27
29
32
33
34
35
09A
01
02
02
10
12
13
14
15
YELLOW
GREEN
WHITE
09
02
28
W
09A
49
01CR 09CR 21CR 49CR 51CR 51CR1 SPARE
03-12ga
05-14ga
02-14ga
09-14ga
09-14ga
54A
21A
49A
09-14ga
09-14ga
00-12ga
09-14ga
03A-14ga
108
01
02
02
21
02
02
51
02
51
02
27
02
02
03A-14ga
03-12ga
76
09-14ga
57ACR 57BCR 57BCR1 60CR 78CR 79CR 59CR 103
78
79
76
S8 CB3 CB2 CB1

DIAGNOSE
X
103
103
57C
00A
54A
57B
57A
57B
57B
57B
57A
57A
07-14ga
09-14ga
59
99
90
65
TT1-HOURMETER
SUPP
60
02
02
02
02
02
02
TURRET HARNESS
PLUG
R2=12Ω (45T)
R2=15Ω (40T)
35A 37A
24 12 38
02-14GA
77
02
23 11 33
02-14GA
22 10 32
37A
37A
02-14GA
21 9 65
16
20 8 26
15
24A
-1
-1
D36
D37
19 7
18 6
108
23A S17-JIB S15-LEVEL S5-START
S16-ROT
55
36
37
21A D34 35A
17 5 34 34 -1 40 01
45
16 4 14
42 20A 20A 10 12
15 3 13
35A
41 35 35
D35
41 57A
20A
36
37
-1
14 2 03-12GA
54A
X22
40
13 1 00-12GA
01
10
02
02
02
28
59
39
A R5=51
B
54A
54A
103
K
01
09
09
11
13
14
17
20
21
29
32
33
38
39
40
41
55
74
76
77
02
02
02
02
02
104
23A
24A
S14-TELE S12-BOOM
60
60
45
51
51
L
S7-ENABLE
24P-FEMALE
S13-TUR
106
105
10
20A
20A
38 13
Y
20A 20A 20A 20C
39 14
20C
20A
32
33
D01
-2
01 01
S2-KSW
S3-E STOP
H
G F E D C B A
05 10
1
X1
R1=6Ω
35A
42
2 X2
20
07 02
07
54A
54A
74
55
76
96
84
77
07A 12
D20
A
20A
07-14ga
20A
02
20
BLACK RED
BP2
23A
23A
24A
Z
24A
45
45
00A
99
11 TO DEUTZ EDC HARNESS 54A 74 02 84
57C 76 96
105 90 77
104 103
106
M143984AA
143844
3.31b Base Control Console Diagram (ANSI/CSA SJ 45T - Deutz Diesel Engine) AD
A B C D E F G H
49
38

39
40
41
59
55
60
Model Serial Number Reference 42

79
78
74
37
36
45 76

57A
SJ-45T PLUG B
79
78
76
74
60
59
57A
V
55
49
45
42
41
40
39
38
37
36
980144 & 98000481 Figure 3.31b
24
23
22
21
20
19
18
17
16
15
14
13
(NEAR DOOR)
24P-MALE
TS1
H1
LEVEL
HORN
49A
12
11
10
9
8
7
6
5
4
3
2
1
SENSOR
02
(NEAR BACKPLATE)
- +
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
10
11
12
1
2
3
4
5
6
7
8
9
PLUG A
07A-14ga
07A-14ga
23A
24A
16
17
20
26
27
29
32
33
34
35
09A
01
02
02
10
12
13
14
15
YELLOW
GREEN
WHITE
09
02
28
W
09A
49
03-12ga
05-14ga
02-14ga
09-14ga
09-14ga
54A
21A
49A
09-14ga
09-14ga
09-14ga
00-12ga
03A-14ga
108
01
02
02
21
02
02
51
02
51
02
27
02
02
03A-14ga
03-12ga
76
09-14ga
107CR 57ACR 57BCR 57BCR1 60CR 78CR 79CR 59CR 103
107
90B
78
79
76
S8 CB3 CB2 CB1

DIAGNOSE
X
57B
57A
57A
103
103
57C
00A
54A
57B
57A
57B
57B
07-14ga
09-14ga
59
99
20A
90
02
65
TT1-HOURMETER
SUPP
60
02
02
02
02
02
TURRET HARNESS
02
PLUG
35A 37A
24 12 38 R2=12O
02-14GA 77 02
23 11 33
02-14GA
22 10 32
-1
-1
D36
D37
02-14GA
21 9 65
16
20 8
15
26
S17 S15-
19 7 24A
18 6
108
23A -JIB LEVEL S5-IGNITION
S16-ROT
55
36
37
21A D34 35A
17 5 34 34 -1 40 01
45
16 4 14
42 20A 90B 10 12
15 3 13
35A
41 35 35
D35
41 57A
20A
36
37
-1
14 2 03-12GA
54A
X22
40
13 1 00-12GA
01
10
02
02
02
28
59
39
A R5=51
B
54A
54A
103
K
S12
01
09
09
11
13
14
17
20
21
29
32
33
38
39
40
41
55
74
76
77
02
02
02
02
02
104
23A
24A
S14-TELE
60
60
45
51
51
L
-BOOM
S7-ENABLE
24P-FEMALE
S13-TUR
106
105
10
20A
20A
38 107 13
Y
20A 20A 20C
39 14 107
20C
20A
32
33
D01
-2
01 01
S2-KSW
S3-E STOP
H
G F E D C B A
05 10
1 X1
R1=6Ω
35A
42
2 X2
20 07 02
07
54A
54A
74
55
76
96
84
77
07A 12
D20
A
20A
07-14ga
20A 20A
02
20
BLACK RED
BP2
23A
23A
24A
Z
24A
45
45
00A
99
11
TO DEUTZ EDC HARNESS 54A 74
76
02 84
96
57C
105 90 77
104 103
106
143844
3.32a Base Control Console Diagram (ANSI/CSA SJ 40T - Deutz Diesel Engine) AD
A B C D E F G H
49
38
39
40
41
Model Serial Number Reference

59
55
60
42 74
79 37

78 36
45 76
SJ-40T
57A
980173 & 98000481 Figure 3.32b V
79
78
76
74
60
59
PLUG B
57A
55
49
45
42
41
40
39
38
37
36
24
23
22
21
20
19
18
17
16
15
14
13
(NEAR DOOR)
24P-MALE
TS1
H1
LEVEL
HORN
49A
12
11
10
9
8
7
6
5
4
3
2
1
SENSOR
02
(NEAR BACKPLATE)
- +
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
10
11
12
1
2
3
4
5
6
7
8
9
PLUG A
07A-14ga
07A-14ga
23A
24A
16
17
20
26
27
29
32
33
09A
01
02
02
10
12
13
14
15
YELLOW
GREEN
WHITE
09
02
28
W
09A
49
03-12ga
05-14ga
02-14ga
09-14ga
09-14ga
54A
21A
49A
09-14ga
09-14ga
09-14ga
00-12ga
03A-14ga
108
01
02
02
21
02
02
51
02
51
02
27
02
02
03A-14ga
03-12ga
76
09-14ga
57ACR 57BCR 57BCR1 60CR 78CR 79CR 59CR 103
78
79
76
S8 CB3 CB2 CB1

DIAGNOSE
X
57B
57A
57A
103
103
57C
00A
54A
57B
57A
57B
57B
07-14ga
09-14ga
59
99
90
65
TT1-HOURMETER
SUPP
60
02
02
02
02
02
TURRET HARNESS
02
PLUG
35A 37A
24 12 38 R2=15Ω
02-14GA 77 02
23 11 33
02-14GA
22 10 32
-1
-1
D36
D37
02-14GA
21 9 65
16
20 8
15
26
S15-
19 7 24A
18 6
108
23A LEVEL S5-IGNITION
S16-ROT
55
36
37
17 5 21A
45 40 01
16 4 14
42 20A 10 12
15 3 13
41 41 57A
20A
36
37
14 2 03-12GA
54A
X22
40
13 1 00-12GA
01
10
02
02
02
28
59
39
A R5=51
B
54A
54A
103
K
S12
01
09
09
11
13
14
17
20
21
29
32
33
38
39
40
41
55
74
76
77
02
02
02
02
02
104
23A
24A
S14-TELE
60
60
45
51
51
L
-BOOM
S7-ENABLE
24P-FEMALE
S13-TUR
106
105
10
20A
20A
38 13
20A 20A 20A 20C
39 14
Y
20C
20A
32
33
D01
-2
01 01
S2-KSW
S3-E STOP
H
G F E D C B A
05 10
1 X1
R1=6Ω
35A
42
2 X2
20
07 02
07
54A
54A
74
55
76
96
84
77
07A 12
D20
A
20A
07-14ga
20A
02
20
BLACK RED
BP2
23A
23A
24A
24A
45
45 Z
TO DEUTZ EDC HARNESS

00A 11 54A 74 02 84
99 76 96
57C
105 90 77
104 103
106
M143982AA
143844
3.32b Base Control Console Diagram (ANSI/CSA SJ 40T - Deutz Diesel Engine) AD
A B C D E F G H
49

38
39
40
41
59
55
Model Serial Number Reference 42

79
60
74
37
78 36
45

76
57A
SJ-40T PLUG B
79
78
76
74
60
59
980173 & 98000481 Figure 3.32b
57A
55
49
45
42
41
40
39
38
37
36
V
24
23
22
21
20
19
18
17
16
15
14
13
(NEAR DOOR)
24P-MALE
TS1
H1
LEVEL
HORN
49A
12
11
10
9
8
7
6
5
4
3
2
1
SENSOR
02
(NEAR BACKPLATE)
- +
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
10
11
12
1
2
3
4
5
6
7
8
9
PLUG A
07A-14ga
07A-14ga
23A
24A
16
17
20
26
27
29
32
33
09A
01
02
02
10
12
13
14
15
YELLOW
GREEN
WHITE
09
02
28
W
09A
49
03-12ga
05-14ga
02-14ga
09-14ga
09-14ga
54A
21A
49A
09-14ga
09-14ga
00-12ga
09-14ga
03A-14ga
108
01
02
02
21
02
02
51
02
51
02
27
02
02
03A-14ga
03-12ga
76
09-14ga
107
90B
78
79
76
S8 CB3 CB2 CB1

DIAGNOSE
57B
X
57A
57A
103
103
57C
00A
54A
57B
57A
57B
57B
07-14ga
09-14ga
59
99
20A
90
02
65
TT1-HOURMETER
SUPP
60
02
02
02
02
02
TURRET HARNESS
02
PLUG
35A 37A
24 12 38 R2=15Ω
02-14GA 77 02
23 11 33
02-14GA
22 10 32
-1
-1
D36
D37
02-14GA
21 9 65
16
20 8
15
26
S15-
19 7 24A
18 6
108
S16-ROT
55
36
37
17 5 21A
45 40 01
16 4 14
42 90B 10 12
15 3 13
41 41 57A
20A
36
37
14 2 03-12GA
54A
X22
40
13 1 00-12GA
01
10
02
02
02
28
59
39
A R5=51
B
54A
54A
103
K
S12
01
09
09
11
13
14
17
20
21
29
32
33
38
39
40
41
55
74
76
77
02
02
02
02
02
104
23A
24A
S14-TELE
60
60
45
51
51
L
-BOOM
S7-ENABLE
24P-FEMALE
S13-TUR
106
105
10
20A
20A
38 107 13
20A 20A 20C
39 14 107
Y
20C
20A
32
33
D01
-2
01 01
S2-KSW
S3-E STOP
H
G F E D C B A
05 10
1 X1
R1=6Ω
35A
42
2 X2
20
07 02
07
54A
54A
74
55
76
96
84
77
07A 12
D20
A
20A
07-14ga
20A 20A
02
20
BLACK RED
BP2
23A
23A
24A
Z
24A
45
45
TO DEUTZ EDC HARNESS

00A 11 54A 74 02 84
99 76 96
57C
105 90 77
104 103
106
M143982AB
143844
3.33 Base Control Console Diagram (CE SJ 45T - Deutz Diesel Engine) AD
A B C D E F G H
Serial Breakdown 49
38
39
Reference Chart 162A

59
55
161 60
Model Serial Number

42 74
79 37A
78 36A
45 76
57A
SJ-45T 98000521 & Below

V
162A
161
79
78
76
74
60
59
57A
37A
36A
PLUG B
55
49
45
42
39
38
24
23
22
21
20
19
18
17
16
15
14
13
(NEAR DOOR)
24P-MALE
TS1
H1
LEVEL
HORN
49A
12
11
10
9
8
7
6
5
4
3
2
1
SENSOR
02
(NEAR BACKPLATE)
- +
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
10
11
12
1
2
3
4
5
6
7
8
9
PLUG A
07A-14ga
07A-14ga
23A
24A
34A
35A
16
17
20
26
27
32
33
09A
01
02
02
10
12
13
14
15
YELLOW
GREEN
WHITE
09
02
28
W
09A
27
49
03-12ga
05-14ga
02-14ga
09-14ga
54A
21A
49A
09-14ga
09-14ga
03A-14ga
108
00-12ga
162
162
01
02
02
21
02
02
51
02
51
02
02
02
03A-14ga
03-12ga
76
09-14ga
107
90B
78
79
76
S8 CB3 CB2 CB1

DIAGNOSE
X
57B
57A
57A
103
103
57C
00A
54A
57B
57A
57B
57B
07-14ga
09-14ga
59
99
20A
90
02
65
TT1-HOURMETER
SUPP
60
02
02
02
02
02
02
TURRET HARNESS
PLUG
59
42 37B
24 12 38 R2=12Ω
02-14GA 77 02
23 11 33
02-14GA
22 10 32
D36A
D37A
-1
-1
02-14GA
21 9 65
16
20 8
15
26
S17 S15- S5-IGNITION
19 7 24A
-JIB LEVEL
R6=680
108 161
18 6 23A
S16-ROT
55
36A
37A
21A D34A 42 01A
17 5 34A 34A -1 40 01A
45
16 4 14 12A
42 20A 90B 10 12A
15 3 13
42
41 35A 35A
D35A
41 57A
20A
36A
37A
-1
03-12GA
162A
14 2
D12
54A
X22
40
D01A
01
10
02
02
02
28
59
59
00-12GA
-2
13 1
39 R5=51
D01A
54A
54A
103
A
01
09
09
11
13
14
17
20
21
29
32
33
38
39
40
41
55
74
76
77
02
02
02
02
02
162
K B
S12
23A
24A
104
162
162
60
60
45
51
51
24P-FEMALE
L
S14-TELE -BOOM S13-TUR
106
105
10
20A
20A
Y
S7-ENABLE
38 107 13
D108
20A 20A 20C
39 14 107
20C
20A
32
33
108
D01
-2
01 01
S2-KSW
S3-E STOP
H
G F E D C B A
05 10
1 X1
R1=7Ω
2 X2
20
07 02
07
54A
54A
74
55
76
96
84
77
07A 12
D20
A
20A
07-14ga
20A 20A
20C
23A 07A D07 12A
23A -A
D108
-1
24A
24A
45
108
45
00A 11
TO DEUTZ EDC HARNESS 74
54A 02 84
99 76 96
57C
105 90 77
104 103
106
M144380AC
143844
3.34 Base Control Console Diagram (ANSI/CSA SJ 45T - GM Dual Fuel Engine) AD
A B C D E F G H
49
38
39
40
41
59
55
60
42 11
79 37
78 36
45 76
57A
79
78
76
11
60
59
V
57A
55
49
45
42
41
40
39
38
37
36
24
23
22
21
20
19
18
17
16
15
14
13
PLUG B
(NEAR DOOR)
24P-MALE
TS1
H1
LEVEL
HORN
49A
12
11
10
9
8
7
6
5
4
3
2
1
SENSOR
02
(NEAR BACKPLATE)
- +
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
PLUG A
10
11
12
1
2
3
4
5
6
7
8
9
07A-14ga
07A-14ga
23A
24A
16
17
20
26
27
29
32
33
34
35
09A
01
02
02
10
12
13
14
15
YELLOW
GREEN
WHITE
09
28
02
W
09A
49
03-12ga
05-14ga
02-14ga
09-14ga
09-14ga
54A
21A
49A
09-14ga
09-14ga
09-14ga
00-12ga
03A-14ga
108
01
02
02
21
02
02
51
02
51
02
27
02
02
03A-14ga
03-12ga
59CR 60CR 107CR
59
09-14ga
CB3 CB2 CB1
07-14ga
09-14ga
TT1-HOURMETER
X
SUPP
20A
90B
107
59
65
02
60
02
02
TURRET HARNESS
PLUG
35A 37A
24 12 38 R2=12O
02-14GA 77 02
23 11 33
02-14GA
22 10 32
D36
D37
02-14GA
-1
-1
21 9 65
16
20 8
15
26
S17 S15-
19 7 24A
18 6
108
23A -JIB LEVEL S5-IGNITION
S16-ROT
55
36
37
21A D34 35A
17 5 34 34 -1 40 01
45
16 4 14
42 20A 90B 10 12
15 3 13
35A
41 35 35
D35
-1 41 57A
36
37
20A
14 2 03-12GA
40
13 1 00-12GA
01
10
02
02
02
28
59
39
R5=499
54A
54A
103
S12
01
09
09
11
13
14
17
20
21
29
32
33
38
39
40
41
55
74
76
77
02
02
02
02
02
23A
24A
S14-TELE
60
60
45
51
51
-BOOM
S7-ENABLE
24P-FEMALE
S13-TUR
10
20A
20A
38 107 13
20A 20A 20C
39 14 107 20A
32
33
20C
Y
D01
-2
01 01
S2-KSW
S3-E STOP
H
G F E D C B A
05 10
1 X1
R1=6ohm
35A
42
2 X2
20
07 02
07
54A
54A
55
76
77
07A 12
D20
A
20A
07-14ga
20A
02
20
BLACK RED
BP2
23A
23A
PIN 1 - 02 WHITE
24A
24A
45
PIN 2 - 54A PURPLE/RED
45 PIN 3 - 57A BROWN/GREEN
PIN 4 - 11 WHITE/ORANGE
BACK VIEW PIN 5 - 76 BROWN/BLUE Z
PIN 7 - 78 RED/BLUE
12 1 PIN 8 - 79 BROWN/PURPLE
11 2 PIN 9 - N/U
DEUTSCH
78 11
02
77 10 3
79
54A 76
9 4
PIN 10 - N/U
8 5 PIN 11 - N/U
7 6 PIN 12 - N/U
M144151AC
143844
3.35 Base Control Console Diagram (ANSI/CSA SJ 40T - GM Dual Fuel Engine) AD
A B C D E F G H
Serial Breakdown 49
38
Reference Chart
39
40
41
59
55
Model Serial Number

60
42 11
79 37
78 36
45 76
SJ-40T 98000521 & Below

57A
79
78
76
11
60
59
57A
55
49
45
42
41
40
39
38
37
36
24
23
22
21
20
19
18
17
16
15
14
13
(NEAR DOOR)
PLUG B
24P-MALE
TS1
H1
LEVEL
HORN
49A
12
11
10
9
8
7
6
5
4
3
2
1
SENSOR
02
(NEAR BACKPLATE)
- +
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
PLUG A
10
11
12
1
2
3
4
5
6
7
8
9
07A-14ga
07A-14ga
23A
24A
16
17
20
26
27
29
32
33
09A
01
02
02
10
12
13
14
15
YELLOW
GREEN
WHITE
09
28
02
W
09A
49
03-12ga
05-14ga
02-14ga
09-14ga
09-14ga
54A
21A
49A
09-14ga
09-14ga
00-12ga
09-14ga
03A-14ga
108
01
02
02
21
02
02
51
02
51
02
27
02
02
03A-14ga
03-12ga
59CR 60CR 107CR
59
09-14ga
CB3 CB2 CB1
07-14ga
09-14ga
TT1-HOURMETER
SUPP
20A
90B
107
59
65
02
60
02
02
TURRET HARNESS
PLUG
35A 37A
38
24 12 R2=15ohm
02-14GA 77 02
23 11 33
02-14GA
22 10 32
D36
D37
02-14GA
-1
-1
21 9 65
16
20 8
15
26
S15-
19 7 24A
18 6
108
S16-ROT
55
36
37
17 5 21A
45 40 01
16 4 14
42 90B 10 12
15 3 13
41 41 57A
36
37
20A
14 2 03-12GA
40
13 1 00-12GA
01
10
02
02
02
28
59
39
R5=499
54A
54A
103
S12
01
09
09
11
13
14
17
20
21
29
32
33
38
39
40
41
55
74
76
77
02
02
02
02
02
23A
24A
S14-TELE
60
60
45
51
51
-BOOM
S7-ENABLE
24P-FEMALE
S13-TUR
10
20A
20A
38 107 13
20A 20A 20C
39 14 107
Y
20A
32
33
20C
D01
-2
01 01
S2-KSW
S3-E STOP
H
G F E D C B A
05 10
1 X1
R1=6ohm
35A
42
2 X2
20
07 02
07
54A
54A
55
76
77
07A 12
D20
A
20A
07-14ga
20A
02
20
BLACK RED
BP2
23A
23A
PIN 1 - 02 WHITE
24A
24A
45
PIN 2 - 54A PURPLE/RED
45 PIN 3 - 57A BROWN/GREEN
PIN 4 - 11 WHITE/ORANGE
PIN 5 - 76 BROWN/BLUE
Z
BACK VIEW
PIN 7 - 78 RED/BLUE
12 1 PIN 8 - 79 BROWN/PURPLE
11 2 PIN 9 - N/U
DEUTSCH
78 11
02
77 10 3
79
54A 76
9 4
PIN 10 - N/U
8 5 PIN 11 - N/U
7 6 PIN 12 - N/U
M144149AB
143844
Model
SJ-45T
SJ-40T
SKYJACK, Page 48
S4 S2
EMERGENCY KEY SWITCH S3
07A RED 07A EMERGENCY
STOP BASE/OFF/PLATFORM S1
POSITION 4-A STOP 1
DISCONNECT
04 SWITCH B1
07A 07A RED 07A 07A RT CB1 15 AMP
07 05 05 03 00 2 BATTERY
POSITION 5-A CTR
Serial Number
980143 & Below

980172 & Below
10 12 12 RED/YELLOW/BLACK LEFT PL3 CB2 15 AMP

12 12 10 02 00 00 3
980144 & 98000481

980173 & 98000481
POSITION 9-A
10 BLUE/WHITE 108CR 4
10
03A CB3 15 AMP 03 03
PL4 POSITION 8-A
TO 2ND CONTACT M1 5
A
AT LINE 115 01CR 108 EMERGENCY PUMP

01 02 6
09 108 86CR 7
FU2 03B 86A
M OPTIONAL OIL COOLER
TSW1 15A 8
09 86
S24
OPTIONAL 9
LIGHTS 02
10
04 81 09CR X23-ENGINE CONNECTOR 57CCR
S5 09 02
03 11
IGNITION/E-PUMP M STARTER
SWITCH 57C 4 57C
03A 54A 54A 12
Reference
01
Figure 3.36a
Figure 3.36a
Figure 3.36b
Figure 3.36b
S6
IGNITION/E-PUMP 12 E-PUMP 13
SWITCH 10 PS1
START 57ACR 11 ENGINE OIL PR.
E-PUMP 01 01 00A 00A 00A 14
PURPLE/BLACK ANTI-RESTART
20D POSITION 1-A
04 15
START 57 57A BROWN/GREEN 57A 57A 57A 57B 02
POSITION 12-B 03 16
08 02 57BCR1 A ALTERNATOR
77 1 77
07 09 09 57B 17
08CR
04 D04 60 D01-2 D10 D01 10
11 FU1 18
S23 60 60 60 02 57BCR 02 50A
WHITE/BLUE
HORN SWITCH POSITION 14-B 19
49CR 11A
60CR
04 49 GREEN/RED 49 49 02 54ACR 20 COLD START RELAY
POSITION 10-B 11B
H1 54A 21 GLOW PLUGS (3)
08 HORN TO ECU
D5.1, PIN 3
PL2 02 02 09 49A 02 22
WHITE
TT HORN
08 POSITION 2-A TT1 23
HOURMETER HOURMETER
02 02 02 WHITE 02 02
FOOTSWITCH 24
POSITION 3-A ECU
27 FS1 LOW
TILT CONNECTOR D5.2 25
FUEL SWITCH
R5=51 ohm (LOCATED ON ECU R.H.S.)
55 02 FUEL LEVEL INDICATOR
26
B
76 76 BROWN/BLUE 76 ENGINE CONTROLLER

ENGINE FAULT 02 1 27
POSITION 16-B X22-DIAG PORT
55 55 YELLOW/PURPLE 55
LOW FUEL B 106 2 28
POSITION 11-B
74 74 GREEN/GRAY 74
GLOW PLUG L 105 10 29 DIAGNOSTIC CONNECTOR
POSITION 15-B PL1
04B
10 77 K 104 11 30
S7
D04
54A A 54A 31
04 BP1 FUNCTION ALTERNATOR
TILT ENABLE 32
84 84 15
OIL PRESS.
60 ALARM 27 20A
96 96 3 33
COOLANT TEMP.
76 76 34
ENGINE FAULT
55 35
LOW FUEL
74 74 5 36
GLOW PLUG
54A 37
54A 54A 14 38
S10 DIAGNOSE
THROTTLE 39
SWITCH 78 SWITCH
78 2600 RPM 78 RED/BLUE
S8 40
08 D08 POSITION 17-B
79 2100 RPM 79 BROWN/PURPLE 79 76 4
POSITION 18-B 41
27 RED/BLACK/WHITE 27 27 103 103 42

17
POSITION 19-A
43
LS3
FLY IN LS 51 02 79
44
79CR LOW IDLE RELAY N=2100 RPM
NORMALLY OPEN
HELD CLOSED 51CR1 78 2100RPM
99 18 45
78CR HIGH IDLE RELAY N=2600 RPM
59 59 29 LS2 HIGH DRIVE
TILT OVERRIDE 2600RPM
90 21 46
29 TS1
NORMALLY OPEN LEVEL
C
JMPR 23 47
HELD CLOSED SENSOR
29 29 GRAY/ORANGE 29 29 09 09 02 BOOM TURRET LIMIT SWITCHES
POSITION 20-A 24 48
S48
DRIVE TORQUE
49
SWITCH 51CR
D28 51
28 02 02 TILT RELAY
45 YELLOW/ORANGE 45 50
LOW TORQUE 45
POSITION 9-B
D59 51
59 59 YELLOW/BLUE 59 59
POSITION 13-B 52
08
53
09 09 09A 54
D85-1 S11 TILT OUTPUT ENABLE
FOOT 55
08A SWITCH
56
3H-45
45
57 MOTOR 2-SPEED VALVE
04 JMPR2 04A SUPPR. (COIL ON = HIGH SPEED)
58
WITH OPTIONAL GENERATOR 08CR1 D20A 2H-21A
08 09 09 21A 02
REMOVE JMPR2 & JMPR3 59 DUMP VALVE
S22 20D 20 ORANGE/BLUE 20 20 JMPR3 21 21CR 02 DUMP VALVE RELAY
ELECTRICAL 60
POSITION 15-A
GENERATOR 04A
04 61
2H-85
85 GRAY/BLUE 85 D20 D85-2 85 02
62 OPTIONAL GENERATOR VALVE
85 POSITION 20-B
63
TO 2ND CONTACT
AT LINE 78 64
08 04 20 02
65 OPTIONAL STROBE LIGHT
LB2
08B 02
20 20 02 66
ALL MOTION ALARM
08BCR
BP2 67
OCM-VALVE DRIVER
D
68
81CR
81 GRAY/BLACK 81 02 OPTIONAL LIGHT RELAY
08A 16 69
POSITION 19-B LB4
08B 09 09 81A 81A 02 OPTIONAL CHASSIS LIGHTS (2)
6 70
SUPPR. 81A 02
04 1 26 02
71
09
04 2 31 LB5
59 59 72
R4=30 ohm 3H-16
04 13 34 16 16 WHITE/BLACK 16 16 73 FORWARD DRIVE VALVE
POSITION 13-A 3H-15
04 14 23 15 R3=30 ohm 15 15 15
BLUE 74 REVERSE DRIVE VALVE
POSITION 12-A 3H-26
7 26 26 BLUE/YELLOW 26 26 02 75 BRAKE VALVE
BOOM/TUR POSITION 18-A
A2 04 X 28 5 D20B N.C. HELD OPEN LS1
20B 76
BOOM/TURRET Vbat Xaxis WITH ENGINE OVER DIRECTION
JOYSTICK SENSING 59CR
Y 29 15 17 17 BLUE/GREEN 17 STEERING AXLE 59 02
Yaxis 77
POSITION 14-A 3H-65
02 25 S22 FROM 65 65 OPTIONAL AXLE LOCK RELAY
DRIVE 09 02 78
Gnd GEN'R LN 62 09A YELLOW 09A OPTIONAL AXLE LOCK VALVE
A1 27 D Vbat 09A (09B) SUPPR.
Output POSITION 7-A 79 (COIL ON = FLOATING AXLE)
DRIVE/STEER
JOYSTICK
02 80
Gnd 17ACR1
17A
81
SPEED D24
A3 C 30 24 24
SPEED CTRL. C Left 82 STEER DIRECTIONAL RELAY
SELECTOR 02 24 23 24A 24A 24A 4H-24A
23 BLUE/BLACK 02 83 LEFT STEER VALVE
R Right
POSITION 17-A
L 3 SUPPR.
L 84
STEER DIRECTIONAL RELAY
D23 23A 23A 23A 4H-23A
BLACK/WHITE 02 RIGHT STEER VALVE
85
POSITION 16-A
IN 38A 18 SUPPR.
S18 86
08 UP 14
TELESCOPE
IN/OUT 39A 17 4 17A 17A 20A
S12 87
OUT 20C
DN 13 MAIN LIFT
17ACR2
UP/DOWN 88
E
89
90
22 14 14 BLACK 14 14 14 4H-14
BOOM UP VALVE
POSITION 11-A 91
8 13 13 ORANGE 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 10-A 92
3.36a Electrical Schematic Diagram (ANSI/CSA - Deutz Diesel Engine)
20D 93
LT
S13
20A 20C 94
TURRET
RT ROTATE
R1=6 ohm 95
19 32 32 32 32 4H-32
GREEN/BLACK 32 TURRET ROTATE LEFT VALVE
POSITION 21-A 96
10 33 33 GREEN/WHITE 33 33 33 4H-33
TURRET ROTATE RIGHT VALVE
POSITION 22-A 97
98
IN
20A S14
99
TELESCOPE
OUT RET/EXT
100
11 38 38 ORANGE/RED 38 38 38 4H-38
TELESCOPE IN VALVE
POSITION 3-B 101
21 39 39 BLACK/RED 39 39 39 4H-39
TELESCOPE OUT VALVE
102
refer to the “Table Of Contents” found at the beginning of this section.
POSITION 4-B
103
104
20A UP 41 S15
105
PLATFORM
DN 40 LEVELING
106
D41 41 41 41 4H-41
S19 UP 41 BLUE/PURPLE PLATFORM LEVEL UP VALVE
12 90A POSITION 6-B 107
MANUAL 40 40 4H-40
BLUE/RED 40 PLATFORM LEVEL DOWN VALVE
LEVELING DN 40 108
POSITION 5-B
D40
NOTE: To determine the correct electrical schematic that resembles your aerial platform,
109
F
110
20 42 42 PINK 42 42 2H-42
PROPORTIONAL FLOW ENABLE
POSITION 7-B 111
FROM S2
33 34A AT LINE 3
112
S2
32 36A KEY SWITCH 113
BASE/OFF/PLATFORM
R2=12 ohm (45T) 114
R2=15 ohm (40T)
36 36 36 D36-1 37A 35A RT 115
LT 36 RED/PURPLE PLATFORM LEFT
S20 CTR
08 POSITION 1-B
PLATFORM 37 D36 02 SUPPR. 02 4H-36 LT 42 116
20A LEFT
ROTATE RT
02 02 4H-37 S16 RT 117
PLATFORM
SUPPR. D37-1
D37 37 WHITE/RED/BLACK 37 ROTATE 37 118 PLATFORM RIGHT
POSITION 2-B
119
120
35 35 ORANGE/WHITE 35 35 D35-1 35A 121

S21 UP JIB UP
08 POSITION 24-A
JIB D35 02 SUPPR. 02 122
34 4H-35 UP
UP/DOWN DN 20A
02 02 4H-34 S17 123
DN
SUPPR. JIB UP/DOWN D34-1
TB-45 ONLY D34 34 ORANGE/BLACK 34 34 35A 124 JIB DOWN
POSITION 23-A
125
126
HYDRAULIC
GENERATOR 127
OPTION 128
OPTIONAL GENERATOR
129
110A 110A 110A 110A
WHITE
CB4 15 AMP 130
110B BLACK 110B 110B 110B 110C
G
M F
GND GND 131 110V PLATFORM POWER
GREEN
NOTE: WITH HYDRAULIC GENERATOR OPTION
MALE AND FEMALE PLUGS ARE CONNECTED 132
133
134
135
CB5 50 AMP WELDER
WHITE WHITE ORANGE 136 OPTIONAL WELDER GENERATOR
GENERATOR
RED RED RED 3Ø 137
F OPTION
BLACK BLACK BLACK 138
GREEN GREEN GREEN
139
110A WHITE
CB4 15 AMP
110B 110C
F
NOTE: WITH WELDER GENERATOR OPTION

MALE AND FEMALE PLUGS ARE CONNECTED
H
M138222AD
Z
Y
X
V

Models SJ 40T & 45T
AD
143844
143844
Model
SJ-45T
S4
EMERGENCY
STOP
07A RED 07A
S2
KEY SWITCH
BASE/OFF/PLATFORM
S3
EMERGENCY
SJ-40T
POSITION 4-A S1
STOP 1
DISCONNECT
04 SWITCH B1
07 05 05 03 00 2 BATTERY
POSITION 5-A CTR
12 12 3
Models SJ 40T & 45T

10 02 00 00
POSITION 9-A
10
03A CB3 15 AMP 03 03
PL4 POSITION 8-A
TO 2ND CONTACT M1 5

AT LINE 115 01CR 108 EMERGENCY PUMP
01 02 6
Serial Number
86CR 7
980143 & Below
980172 & Below
09 108
FU2 03B 86A
TSW1 8
980144 & 98000481
980173 & 98000481
09 86 20A
S24
OPTIONAL 9
LIGHTS 02
A
10
04 81 09CR X23-ENGINE CONNECTOR 57CCR
S5 09 02
03 11
IGNITION/E-PUMP M STARTER
SWITCH 57C 4 57C
03A 54A 54A 12
S6 01
IGNITION/E-PUMP 12 E-PUMP 13
SWITCH 10 PS1
START 57ACR 11 ENGINE OIL PR.
E-PUMP 01 01 00A 00A 00A 14
20D POSITION 1-A
04 15
START 57 57A 57A 57A 57B 02
BROWN/GREEN 57A
POSITION 12-B 03 16
77 1 77
Reference
57B
Figure 3.36a
Figure 3.36a
07 09 09 17
Figure 3.36b
Figure 3.36b
08CR
04 D04 60 D01-2 D10 D01 10
11 FU1 18
S23 60 60 60 02 57BCR 02 50A
WHITE/BLUE
49CR 11A
60CR
POSITION 10-B 11B
08 HORN
TO ECU
PL2 02 02 09 49A 02 D5.1, PIN 3 22
WHITE
TT HORN
HOURMETER HOURMETER
02 02 02 WHITE 02 02
FOOTSWITCH 24
POSITION 3-A ECU
27 FS1 LOW
FUEL SWITCH
R5=51 ohm (LOCATED ON ECU R.H.S.)
55 02 FUEL LEVEL INDICATOR
26
LOW FUEL B 106 2 28
POSITION 11-B
74 74 GREEN/GRAY 74
POSITION 15-B PL1
04B
10 77 K 104 11 30
B
S7
D04
54A A 54A 31
04 BP1 FUNCTION ALTERNATOR
TILT ENABLE 32
84 84 15
OIL PRESS.
60 ALARM 27 20A
96 96 3 33
COOLANT TEMP.
76 76 34
ENGINE FAULT
55 35
LOW FUEL
74 74 5 36
GLOW PLUG
54A 37
54A 54A 14 38
S10 DIAGNOSE
THROTTLE 39
SWITCH 78 SWITCH
S8 40
POSITION 18-B 41
27 RED/BLACK/WHITE 27 27 103 103 42

17
POSITION 19-A
43
LS3
FLY IN LS 51 02 79
44
NORMALLY OPEN
HELD CLOSED 51CR1 78 2100RPM
99 18 45
78CR HIGH IDLE RELAY N=2600 RPM
TILT OVERRIDE 2600RPM
90 21 46
29 TS1
NORMALLY OPEN LEVEL
JMPR 23 47
HELD CLOSED SENSOR
POSITION 20-A 24 48
S48
DRIVE TORQUE
49
SWITCH 51CR
D28 51
28 02 02 TILT RELAY
LOW TORQUE 45
POSITION 9-B
D59 51
C
POSITION 13-B 52
08
53
09 09 09A 54
FOOT 55
08A SWITCH
56
3H-45
45
58
08 09 09 21A 02
ELECTRICAL 60
POSITION 15-A
GENERATOR 04A
04 61
2H-85
85 GRAY/BLUE 85 D20 D85-2 85 02
85 POSITION 20-B
63
TO 2ND CONTACT
AT LINE 78 64
08 04 20 02
LB2
08B 02
20 20 02 66
ALL MOTION ALARM
08BCR
BP2 67
OCM-VALVE DRIVER
68
81CR
08A 16 69
POSITION 19-B LB4
6 70
SUPPR. 81A 02
04 1 26 02
71
09
04 2 31 LB5
59 59 72
D
R4=30 ohm 3H-16

POSITION 13-A 3H-15
04 14 23 15 R3=30 ohm 15 15 15
POSITION 12-A 3H-26
20B 76
Yaxis 77
POSITION 14-A 3H-65
DRIVE 09 02 78
DRIVE/STEER
JOYSTICK
02 80
Gnd 17ACR1
17A
81
SPEED D24
A3 C 30 24 24
SELECTOR 02 24 23 24A 24A 24A 4H-24A
R Right
POSITION 17-A
L 3 SUPPR.
L 84
D23 23A 23A 23A 4H-23A
85
POSITION 16-A
IN 38A 18 SUPPR.
S18 86
08 UP 14
TELESCOPE
IN/OUT 39A 17 4 17A 17A 20A
107 S12 87
OUT
MAIN LIFT
17ACR2 107
20C UP/DOWN 88
DN 13
89
90
22 14 14 BLACK 14 14 14 4H-14
BOOM UP VALVE
POSITION 11-A 91
8 13 13 ORANGE 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 10-A 92
E
20D 93
LT
S13
20A 20C 94
TURRET
RT ROTATE
R1=6 ohm
95
19 32 32 32 32 4H-32
POSITION 21-A 96
33 33 33 4H-33
3.36b Electrical Schematic Diagram (ANSI/CSA - Deutz Diesel Engine)
10 33 GREEN/WHITE 33 TURRET ROTATE RIGHT VALVE

POSITION 22-A 97
98
IN
20A S14
99
TELESCOPE
OUT RET/EXT
100
11 38 38 ORANGE/RED 38 38 38 4H-38
TELESCOPE IN VALVE
POSITION 3-B 101
21 39 39 BLACK/RED 39 39 39 4H-39
TELESCOPE OUT VALVE
POSITION 4-B 102
103
107CR
107 02
104 LEVEL INTERLOCK RELAY
20A UP 41 S15
90B 105
PLATFORM
DN 40 LEVELING
106
D41 41 41 41 4H-41
MANUAL 40 40 4H-40
LEVELING DN 40 108
POSITION 5-B
D40
109
110
20 42 42 PINK 42 42 2H-42
POSITION 7-B 111
FROM S2
33 34A AT LINE 3
112
S2
BASE/OFF/PLATFORM
F
R2=12 ohm (45T) 114

R2=15 ohm (40T)
36 36 36 D36-1 37A 35A RT 115
S20 CTR
08 POSITION 1-B
20A LEFT
ROTATE RT
02 02 4H-37 S16 RT 117
PLATFORM
SUPPR. D37-1
POSITION 2-B
119
120
35 35 ORANGE/WHITE 35 35 D35-1 35A 121

S21 UP JIB UP
08 POSITION 24-A
JIB D35 02 SUPPR. 02 122
34 4H-35 UP
UP/DOWN DN 20A
02 02 4H-34 S17 123
DN
POSITION 23-A
125
126
HYDRAULIC
GENERATOR 127
OPTION 128
OPTIONAL GENERATOR
129
110A 110A 110A 110A
WHITE
CB4 15 AMP 130
110B BLACK 110B 110B 110B 110C
M F
GND GND 131 110V PLATFORM POWER
GREEN
133
134
G
135
CB5 50 AMP WELDER
GENERATOR
RED RED RED 3Ø 137
F OPTION
GREEN GREEN GREEN
139
110A WHITE
CB4 15 AMP
110B 110C
F

H
M138222AF
Z
Y
X
V
SKYJACK, Page 49
AD
SJ 45T
Model
SKYJACK, Page 50
S25 S4 S2 B2
S3 00
ENGINE EMERGENCY KEY SWITCH
ENABLE STOP BASE/OFF/PLATFORM S1
POSITION 4-A STOP 1
DISCONNECT
04 SWITCH B1
04A 07A 07A RED 07A 07A RT CB1 15 AMP
05
Reference Chart
07 05 03 00 2 BATTERY
POSITION 5-A CTR
Serial Breakdown

12 12 10 02 00 00 3
POSITION 9-A
10
Serial Number
03A CB3 15 AMP 03 03

PL4 POSITION 8-A
M1 5
98000521 & Below
01CR 108 EMERGENCY PUMP

01 02 6
09 108 86CR 7
A
TO 81CR 03 FU2 03B 86A

D07A @ LINE 70 TSW1 8
09 86 20A
S24
OPTIONAL 9
LIGHTS D12
02
D01A 10
04 81 S5
IGNITION/E-PUMP 09CR X23-ENGINE CONNECTOR 57CCR
09 02
SWITCH 03 11
M STARTER
01A 4
03A 54A 54A 57C 57C 12
12A E-PUMP
S6
IGNITION/E-PUMP 10 13
SWITCH PS1
57ACR 11 ENGINE OIL PR.
E-PUMP 01 01 START 00A 00A 00A 14
20D POSITION 1-A
04 15
START 57 57A BROWN/GREEN 57A 57A 57A 57B 02
POSITION 12-B 03 16
77 1 77
07 09 57B 17
08CR D01-2 D10 D01A-2 D01
04 D04 60 10
11 FU1 18
S23 60 60 60 02 57BCR 02 50A
WHITE/BLUE
49CR 11A
60CR
POSITION 10-B 11B
08 HORN
TO ECU
PL2 02 02 09 49A 02 D5.1, PIN 3 22
WHITE
TT HORN
HOURMETER HOURMETER
02 02 02 WHITE 02 02
FOOTSWITCH 24
POSITION 3-A ECU
27 FS1 LOW
FUEL SWITCH
02A R5=51 ohm (LOCATED ON ECU R.H.S.)
OVERLOAD 55 02 FUEL LEVEL INDICATOR
26
LOW FUEL
B
B 106 2 28
POSITION 11-B
74 74 GREEN/GRAY 74
POSITION 15-B PL1
04B
10 77 K 104 11 30
S7
FUNCTION
D04
54A A 54A 31
04 BP1 ENABLE ALTERNATOR
TILT 84 84 15 32
D108 OIL PRESS.
60 ALARM 27 20A 108
96 96 3 33
COOLANT TEMP.
D108-1 76 76 34
ENGINE FAULT
20C 55 35
LOW FUEL
74 74 5 36
GLOW PLUG
54A 37
54A 54A 14 38
S10 DIAGNOSE
THROTTLE 39
SWITCH 78 SWITCH
S8 40
POSITION 18-B 41
02A 02 27 27
27 RED/BLACK/WHITE 103 103 17 42
82 02 POSITION 19-A
43
162
BP3 82CR
51 02 79
D118 OVERLOAD 44
118 ALARM 02
51CR1 78 2100RPM
99 18 45
LS3 LS2 HIGH DRIVE 78CR HIGH IDLE RELAY N=2600 RPM
FLY IN LS TILT OVERRIDE 2600RPM
PLATFORM LOAD SENSOR 90 46
(HI DRIVE SHOWN) (HI DRIVE SHOWN) TS1 21
LEVEL
JMPR 23 47
SENSOR
118 4 1 60 59 wh bk 29 bk/wh bk 09 09 02 BOOM TURRET LIMIT SWITCHES
24 48
82 5 7 02 02
C
49
162A 3 2 161 161 161 161 JMPR4 D28 51 51CR
PINK/WHITE 28 02 02 TILT RELAY
POSITION 21-B 50
D59 51
162A 162A 162A D162 162 09A
PINK/PURPLE
POSITION 22-B 52
162A
08 53
R6=680 ohm
54 PLATFORM OVERLOAD CUT-OUT
D85-1 S11
FOOT 55
08A SWITCH
56
3H-45
45
58
08 162 162 21A 02
S22 20D 20 ORANGE/BLUE 20 20 JMPR3 21 21CR 02 60 DUMP VALVE RELAY
ELECTRICAL
GENERATOR POSITION 15-A
04A
04 61
2H-85
85 GRAY/BLUE 85 D20 D85-2 85 02
85 POSITION 20-B
S48 63
DRIVE TORQUE
SWITCH 64
TO 2ND CONTACT D59-2 20 02
AT LINE 78 45 LOW TORQUE 45 YELLOW/ORANGE 45 65 OPTIONAL STROBE LIGHT
POSITION 9-B LB2
08 04
59 59 YELLOW/BLUE 59 59 20 20 02 66
OPTIONAL ALL MOTION ALARM
08B 02 POSITION 13-B
BP2 67
08BCR OCM-VALVE DRIVER
68
81CR
81 GRAY/BLACK 81 81 02 OPTIONAL LIGHT RELAY
08A 16 69
POSITION 19-B LB4
FROM 03 FU3 03C 81A 81A 02 OPTIONAL CHASSIS LIGHTS (2)
D
08B 6
LINE 7 70
15A
04 SUPPR. 81A 02
1 26 02
71
04 2 31 09 LB5
59 59 72
R4=30 ohm 3H-16
POSITION 13-A 3H-15
04 14 23 15 R3=30 ohm 15 15 15
POSITION 12-A 3H-26
20B 76
Yaxis 77
POSITION 14-A 3H-65
DRIVE 09 02 78
DRIVE/STEER
JOYSTICK
02 80
Gnd 17ACR1
17A
81
SPEED D24
A3 C 30 24 24
SELECTOR 02 24 23 24A 24A 24A 4H-24A
R Right
POSITION 17-A
L 3 SUPPR.
L 84
D23 23A 23A 23A 4H-23A
85
POSITION 16-A
IN 38A 18 SUPPR.
S18 86
08 UP 14
TELESCOPE
IN/OUT 39A 17 4 17A 17A 20A
107 S12 87
OUT
MAIN LIFT
17ACR2 107
20C UP/DOWN 88
DN 13
89
90
22 14 14 14 14 4H-14
E
BLACK 14 BOOM UP VALVE

POSITION 11-A 91
8 13 13 ORANGE 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 10-A 92
93
LT
3.37 Electrical Schematic Diagram (CE SJ 45T - Deutz Diesel Engine)
S13
20A 20C 94
TURRET
RT ROTATE
R1=7 ohm 95
19 32 32 32 32 4H-32
POSITION 21-A 96
10 33 33 GREEN/WHITE 33 33 33 4H-33
POSITION 22-A 97
98
IN
20A S14
99
TELESCOPE
OUT RET/EXT
100
11 38 38 ORANGE/RED 38 38 38 4H-38
TELESCOPE IN VALVE
POSITION 3-B 101
21 39 39 BLACK/RED 39 39 39 4H-39
TELESCOPE OUT VALVE
POSITION 4-B 102
103
107CR
107 02
20A UP 41 S15
90B 105
PLATFORM
DN 40 LEVELING
106
41 4H-41
PLATFORM LEVEL UP VALVE
12 107
40 4H-40
PLATFORM LEVEL DOWN VALVE
108
109
110
20 42 42 PINK 42 42 2H-42
POSITION 7-B 111
F
33 34A 112
32 36A 113
114
R2=12 ohm
36 D36A 36A 36A D36A-1 37B 115
LT 36A RED/PURPLE PLATFORM LEFT
S20 08 POSITION 1-B
PLATFORM 37 D36 4H-36 02 LT 116
SUPPR. 20A
ROTATE RT
4H-37 02 S16 RT 117
SUPPR. PLATFORM
D37A-1
D37 37A WHITE/RED/BLACK 37A ROTATE 37A 118 PLATFORM RIGHT
POSITION 2-B
D37A
119
120
35 D35A 35A ORANGE/WHITE 35A 35A D35A-1 42 121

S21 UP JIB UP
08 POSITION 24-A
JIB D35 02 122
34 4H-35 UP
UP/DOWN DN SUPPR. 20A
4H-34 02 S17 123
SUPPR. DN
JIB UP/DOWN D34A-1
D34 34A ORANGE/BLACK 34A 34A 42 124
HYDRAULIC JIB DOWN
POSITION 23-A
D34A 125
GENERATOR
OPTION 126
OPTIONAL GENERATOR
127
110A 110A 110A 110A
WHITE
CB4 15 AMP 128
110B BLACK 110B 110B 110B 110C
M F
GND 129 110V PLATFORM POWER
GREEN GND
131
132
G
133
CB5 50 AMP WELDER
GENERATOR
RED RED RED 3Ø 135
F OPTION
GREEN GREEN GREEN 137
110A WHITE 138
CB4 15 AMP 139

110B 110C
F

H
M144335AC
Z
Y
X
V

Models SJ 40T & 45T
143844
AD
SJ
143844
Model
S2
40T / 45T
S4
S3
Models SJ 40T & 45T

EMERGENCY KEY SWITCH 1
STOP BASE/OFF/PLATFORM S1
POSITION 4-A STOP 2
DISCONNECT
04 SWITCH B1
07 05 05 03 00 3 BATTERY
POSITION 5-A CTR
Reference Chart

Serial Breakdown

12 12 10 02 00 00 4
POSITION 9-A
10 BLUE/WHITE 5
10
03A CB3 15 AMP 03
PL4 POSITION 8-A
Serial Number
TO 2ND CONTACT 6
AT LINE 115 01CR 108CR
98000481 & Below
01 02
03 7
M1
A
09 108 108 8 EMERGENCY PUMP

S24
OPTIONAL 09CR 9
LIGHTS 09 02
10
04 81 03A 54A 86CR
S5 FU2 03B 86A
M 11
IGNITION/E-PUMP TSW1 OPTIONAL OIL COOLER
SWITCH 09 86 20A
12
S6 01
IGNITION/E-PUMP 12 E-PUMP 02 13
SWITCH 10
START
E-PUMP 01 PURPLE/BLACK 01 14
20D POSITION 1-A
04 15
START 57 57A BROWN/GREEN 57A 57A
57ACR
POSITION 12-B 03 15A 16
08 02 M STARTER
07 09 09 17
08CR
04 D04 60 D01-2 D10 D01
18
S23 60 WHITE/BLUE 60 60 02 02 60A
03 ALTERNATOR
HORN SWITCH POSITION 14-B A 19
60CR 49CR
04 49 GREEN/RED 49 49 02 20
POSITION 10-B
H1 21
08 HORN
PL2 02 02 09 49A 02 22
WHITE
HORN
08 POSITION 2-A
INTERFACE 23
CONNECTOR 1
02 02 02 WHITE 02 02
FOOTSWITCH 24
POSITION 3-A
27
(LT BLUE/PINK)
TILT 57A 1-J 25 START COMMAND

R5=51 ohm
26
76 76 BROWN/BLUE 76 FS1 LOW
ENGINE FAULT 27
POSITION 16-B FUEL SWITCH
55 55 YELLOW/PURPLE 55 55
LOW FUEL 28
POSITION 11-B FUEL LEVEL INDICATOR
B
29
PL1
04B
10 30
(PURPLE)
77 77 77 1-B
S7
D04
54A 1-D 31 HOURMETER
04 BP1 FUNCTION ALTERNATOR TT
ENABLE TT1 FUEL PUMP +
TILT 32
HOURMETER FP
60 ALARM 27 20A
1-C 33
FUEL PUMP -
S26 76 76 1-G 34
FUEL SELECT ENGINE FAULT ENGINE FAULT (MIL)
SWITCH 35
55
LOW FUEL
60 74
74 PROPANE 74 GREEN/GRAY 36
POSITION 15-B
54A 54A 1-A 37
ENGINE ON (VSW)
38
S10 74 1-H
39 FUEL SELECT (HI = PROPANE)
THROTTLE (LOW = GASOLINE)
SWITCH 78 2600 RPM 78 RED/BLUE 78
08 D08 POSITION 17-B 40
79 1600 RPM 79 BROWN/PURPLE 79
POSITION 18-B 41
INTERFACE
27 RED/BLACK/WHITE 27 27 42
CONNECTOR 2
POSITION 19-A
78 2-J 43
LS3 HIGH IDLE N=2600 RPM
FLY IN LS 51 02 44
79 2-K
NORMALLY OPEN LOW IDLE N=1600 RPM
HELD CLOSED 51CR1 02 2-E 45
TILT OVERRIDE 46
29 TS1
NORMALLY OPEN LEVEL
47
HELD CLOSED SENSOR
GM EFI ENGINE
POSITION 20-A 48
S48
DRIVE TORQUE
49
SWITCH 51CR
D28 51
28 TILT RELAY
C
LOW TORQUE 45
POSITION 9-B
D59 51
POSITION 13-B 52
08
53
09 09 09A 54
FOOT 55
08A SWITCH
56
3H-45
45
58
08CR1 D20A 2H-21A
WITH OPTIONAL GENERATOR 08 09 09 21A 02 59 DUMP VALVE
REMOVE JMPR2 & JMPR3
ELECTRICAL 60
POSITION 15-A
GENERATOR 04A
04 61
2H-85
85 GRAY/BLUE 85 D20 D85-2 85 02
85 POSITION 20-B
63
TO 2ND CONTACT
AT LINE 78 64
08 04 20 02
LB2
08B 02
20 20 02 66
ALL MOTION ALARM
08BCR
BP2 67
OCM-VALVE DRIVER
68
81CR
08A 16 69
POSITION 19-B LB4
6 70
SUPPR. 81A 02
04 1 26 02
71
D
09
04 2 31 LB5
59 59 72
R4=30 ohm 3H-16
POSITION 13-A 3H-15
04 14 23 15 R3=30 ohm 15 15 15
POSITION 12-A 3H-26
20B 76
Yaxis 77
POSITION 14-A 3H-65
DRIVE 09 02 78
A1 27 D 09A (09B) SUPPR.
Output Vbat POSITION 7-A 79 (COIL ON = FLOATING AXLE)
DRIVE/STEER
JOYSTICK
02 80
Gnd 17ACR1
17A
81
SPEED D24
A3 C 30 24 24
SELECTOR 02 24 23 24A 24A 24A 4H-24A
R Right
POSITION 17-A
L 3 SUPPR.
L 84
D23 23A 23A 23A 4H-23A
85
POSITION 16-A
IN 38A 18 SUPPR.
S18 86
08 UP 14
TELESCOPE
IN/OUT 39A 17 4 17A 17A 20A
107 S12 87
OUT
MAIN LIFT
17ACR2 107
20C UP/DOWN 88
DN 13
89
90
22 14 14 BLACK 14 14 14 4H-14
BOOM UP VALVE
POSITION 11-A 91
8 13 13 ORANGE 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 10-A 92
E
20D 93
LT
S13
20A 20C 94
TURRET
RT ROTATE
R1=6 ohm 95
19 32 32 32 32 4H-32
3.38 Electrical Schematic Diagram (ANSI/CSA - GM Dual Fuel Engine)
POSITION 21-A 96
10 33 33 GREEN/WHITE 33 33 33 4H-33
POSITION 22-A 97
98
IN
20A S14
99
TELESCOPE
OUT RET/EXT
100
11 38 38 ORANGE/RED 38 38 38 4H-38
TELESCOPE IN VALVE
POSITION 3-B 101

21 39 39 BLACK/RED 39 39 39 4H-39
TELESCOPE OUT VALVE
POSITION 4-B 102
103
107CR
107 02
20A UP 41 S15
90B 105
PLATFORM
DN 40 LEVELING
106
D41 41 41 41 4H-41
MANUAL 40 40 4H-40
LEVELING DN 40 108
POSITION 5-B
D40
109
110
20 42 42 PINK 42 42 2H-42
POSITION 7-B 111
FROM S2
33 34A AT LINE 3
112
S2
F
BASE/OFF/PLATFORM
R2=12 ohm (45T) 114
R2=15 ohm (40T)
36 36 36 D36-1 37A 35A RT 115
S20 CTR
08 POSITION 1-B
20A LEFT
ROTATE RT
02 02 4H-37 S16 RT 117
PLATFORM
SUPPR. D37-1
POSITION 2-B
119
120
35 35 ORANGE/WHITE 35 35 D35-1 35A 121

S21 UP JIB UP
08 POSITION 24-A
JIB D35 02 SUPPR. 02 122
34 4H-35 UP
UP/DOWN DN 20A
02 02 4H-34 S17 123
DN
POSITION 23-A
125
126
HYDRAULIC
GENERATOR 127
OPTION 128
OPTIONAL GENERATOR
129
110A 110A 110A 110A
WHITE
CB4 15 AMP 130
110B BLACK 110B 110B 110B 110C
M F
GND 131 110V PLATFORM POWER
GREEN GND
133
134
G
135
CB5 50 AMP WELDER
GENERATOR
RED RED RED 3Ø 137
F OPTION
GREEN GREEN GREEN 139
110A WHITE
CB4 15 AMP
110B 110C
F

H
M138223AB
Z
Y
X
V
SKYJACK, Page 51
AD
SKYJACK, Page 52
GM EFI DUAL FUEL ENGINE
ECU1
R (TAN/DK GREEN)
8 (TAN/DK GREEN) AUX ANA PD 1 1 ECU
(TWIST WIRES 10 TURNS (360 DEG)/FOOT FULL LENGTH)
P (RED/BLACK)
25 (RED/WHITE) SPEED + 2
A
N (RED/WHITE)
26 (RED/BLACK) SPEED - 3
CONNECTOR 2
M (TAN/BLACK)
44 (TAN/BLACK) AUX DIG 3 4
L (TAN/RED)
43 (TAN/RED) AUX DIG 2 5
H (DK BLUE/YELLOW)
46 (DK BLUE/YELLOW) AUX ANA PU 1 6
G (YELLOW/DK BLUE)
47 (YELLOW/DK BLUE) AUX ANA PU 2 7
F (TAN)
87 (TAN) AUX PWM 2 8
D (GRAY)
58 (GRAY) TACH 9
B (WHITE/BROWN)
78 (WHITE/BROWN) PWM 5 RECIRC 10
78 J (GRAY/ORANGE)
52 (GRAY/ORANGE) GOV 2 11
79 K (GRAY/DK BLUE)
51 (GRAY/DK BLUE) GOV 1 12
C (BROWN/WHITE)
77 (BROWN/WHITE) PWM 5 13
02 E (BLACK)
B
69 (BLACK) GND TEMP 14
S (PINK/DK GREEN)
81 (BLACK) GND TEMP 15
CPS1
A (UNUSED) CRANKSHAFT
A 22 (WHITE/PURPLE) CRANK - 16
POSITION SENSOR
B 21 (PURPLE/WHITE) CRANK + 17
CPS2
A 23 (GRAY/BROWN) CAM+ 18 CAMSHAFT
POSITION SENSOR
B 24 (PURPLE/ORANGE) CAM- 19
C 20
GI1-1
61 (BROWN/LT BLUE) INJ 1 LS 21 GAS INJECTOR
CYLINDER #1
GI1-4
63 (BROWN/YELLOW) INJ 3 LS 22 GAS INJECTOR
CYLINDER #4
GI1-2
64 (BROWN/WHITE) INJ 4 LS 23 GAS INJECTOR
CYLINDER #2
GI1-3
62 (BROWN/LT GREEN) INJ 2 LS 24 GAS INJECTOR
CYLINDER #3
IGC1
C
(YELLOW) A 25 IGNITION COIL
B 26
IGM1
D B 31 (YELLOW) SPK COIL 1A 27 IGNITION MODULE
A C 28
OXS1
C D 72 (BLACK/WHITE) EGOH 1 29 OXYGEN SENSOR
PRE-CAT
B A 1 (DK GREEN/ORANGE) EGO 1 30

(RED) (PINK/DK GREEN) OXS2
A B 2 (DK GREEN/WHITE) EGO 2 31 OXYGEN SENSOR
POST-CAT
F10
C D 73 (BLACK/YELLOW) EGOH 2 32
FUSE 15A
IGNITION
71 (WHITE/LT BLUE) RELAY 33 POWER RELAY
2002CR
F8
79 (RED/TAN) VBAT 34
FUSE 20A
ECM
60 (RED/TAN) VBAT 35
TPS1
B A 40 (TAN/WHITE) ECT 36 ENGINE COOLANT
D
TEMPERATURE SENSOR
TPS2
B A 41 (WHITE/RED) EGT 37 LPG TEMPERATURE
SENSOR
MS1
1 2 39 (YELLOW/GRAY) IAT 38 M.A.P. SENSOR
3 4 7 (LT GREEN) MAP 39

RA1
2 1 83 (TAN/ORANGE) DBW - 40 THROTTLE
ACTUATOR
3 4 82 (PINK/WHITE) DBW + 41
1 (BLACK/LT GREEN)
5 6 (LT BLUE/DK BLUE) TPS 2 42
2 (LT GREEN/RED)
6 5 (PURPLE/LT BLUE) TPS 1 43
3 (DK GREEN)
55 (DK GREEN) PC TX 44
DIAGNOSTIC
(RED/LT BLUE)
4 (ORANGE)
56 (ORANGE) PC RX 45
PRV1 F9 GPS1
8 (BLUE/WHITE) GASOLINE
1 7 A B 48 (LT GREEN/WHITE) (FRT) AUX ANA PU 3 46
FUSE 10A PRESSURE SENSOR
7 (BLUE/PINK) EPR
3 C D 54 (WHITE/LT GREEN) (FRP) AUX AND PUD 1 47 PROPANE
E
REGULATOR/VAPORIZER
2 6 13 (WHITE/ORANGE) CAN TERM + 48

3.39 Interface & Engine Electrical Schematic - GM Dual Fuel Engine
(WHITE)
P (BLUE/WHITE)
14 (BLUE/PINK) CAN 1 + 49
N (BLUE/PINK)
15 (BLUE/WHITE) CAN 1 - 50
L (BLACK/LT GREEN)
20 (BLACK/LT GREEN) 5V RTN 51
CONNECTOR 1
M (LT GREEN/RED)
19 (LT GREEN/RED) 5V EXT 1 52
S (LT GREEN/PURPLE)
49 (LT GREEN/PURPLE) 5V EXT 2 53
R (LT GREEN/BLACK)
50 (LT GREEN/BLACK) 5V RTN 54
K (DK BLUE/ORANGE)
9 (DK BLUE/ORANGE) FPP1 55
J (PURPLE/YELLOW)
10 (PURPLE/YELLOW) FPP2/IVS 56
E (DK BLUE) MAIN ENGINE

88 (DK BLUE) AUX PWM 1 57
SWITCH
3002 C (BLACK/RED)
FP 86 (BLACK/RED) AUX PWM 3 58 FUEL PUMP
F
(PINK/YELLOW) (RED)
OPS1
85 (PINK/YELLOW) AUX PWM 3 RECIR 59 ENGINE START
SWITCH
3056 F11
D (PINK/YELLOW) OIL PRESSURE
53 (LT BLUE) OIL PRES 60
FUSE 15A SWITCH
FUEL PUMP
84 (TAN/BLACK) FPUMP 61 FUEL PUMP
RELAY
56CR 2P-56
57A PROPANE LOCKOFF
75 (WHITE/BLACK) EGOH 4 62
SOLENOID
77 11 H (TAN/BROWN)
42 (TAN/BROWN) AUX DIG 1 63 GAS/PROPANE
SELECTOR SWITCH
76 76 G (GREEN/YELLOW) CHECK ENGINE
80 (GREEN/YELLOW) MIL 64
LIGHT
57ACR
57A F (LT BLUE/PINK)
89 (PINK/BLACK) (STARTER) AUX PWM4 65 STARTER RELAY
F7 (WHITE)
54A 54A A (PINK)
45 (PINK/TAN) VSW 66
FUSE 5A
F12 32BCR
VSW
67 ENGINE STARTER
FUSE 15A SOLENOID
11 STARTER
M 68 ENGINE STARTER
EL. MOTOR
(RED/TAN)
77 B (PURPLE) 69
G
(RED)
02 70
F13 S IG
78 71
G ALTERNATOR
FUSE 60A
79 ALTERNATOR
72
TO MAIN TO BATTERY
DISCONNECT GROUND
H
M138223AE1
Z
Y
X
V

Models SJ 40T & 45T
143844
AD
3.40 Engine Harnesses - GM Dual Fuel Engine AD
A B C D E F G H
GPS1
OXS2
OXS1 V
2P-56
TPS2
MS1
TPS1
OPS1
W
IGC1
IGM1
X
CPS1
F8
F12
57ACR
F10
CPS2 F7
Y
F13
F9
2002CR
RA1
56CR
PRV1
F11
GI1-4 GI1-3 GI1-2 GI1-1
M138223AD_2
143844
3.41 Flashing Amber Light Connection AB
A B C D E F G H
PIN 2-WHITE
PIN 1-BLACK
W
20
02
2
BLACK - 20 WHITE - 02 X
BASE CONTROL
PIN 1-RED
PIN 2-BLACK CONSOLE TERMINAL
STRIP
M144026AA_S3

Models SJ 40T & 45T
143844
3.42 Generator Control Valves and Port Indentifcations AB
A B C D E F G H
3500W Generator 12kW Generator (Welder option)
8 GPM W
OUT
Flow Regulator
To Pressure Tube
2
To Pressure Tube
1
To Main Manifold
LS X
To Shuttle Valve
IN
To Main Manifold
Y
2H-85
Generator Valve
2H-85
Generator Valve
M138405AA_S3 M138989AA_S3

Models SJ 40T & 45T
143844
3.43 Generator and Oil Cooler Harness Connections AD
A B C D E F G H
BASE CONTROL CONSOLE BLACK - 85
TOP VIEW V
RELAY SOCKET
51CR1 86CR 86A

01CR
85
R5=51
86
02
03B
21
03B
86A
86
WHITE - 02
57ACR 79CR
W
BASE CONTROL CONSOLE

09
09
X
TO GENERATOR SOCKET 1 - BLACK
VALVE SOCKET 2 - WHITE
1
JUMPER
GREEN
U2 V2
TO EMERGENCY PUMP Y
POWER STUD 03 V1 W1
WHITE
09
TO TEMPERATURE SWITCH PIN 1 - BLACK BLK JUMPER
CONNECTOR PIN 2 - WHITE
1
TO COOLER FAN PIN 1-PURPLE/BLUE

1
CONNECTOR PIN 2-WHITE

00 TO UNDER COOLER MOUNTING BOLT
110V GENERATOR CABLE (ANSI/CSA)
Z
GENERATOR TERMINAL CONSOLE
M144106AA M144107AB

Models SJ 40T & 45T
143844
3.44 Generator Wire Kit Connections AC
A B C D E F G H
38A 35
08 08 08 TO DRIVE
24
20
13
JOYSTICK
TOP OF CABINET
39A 34
S19-LEV S18-TELE S21-JIB
NEAR DOOR
S20-ROT W
S22- S10- S48-
12
1
GEN S6-IGN
THROT TORQ
85 78 57
09A 04 08C 04
09B 04A 79
X
04A
85
24
13
20
04A
12
04
10
85
02
R5=51
Y
17
20
20
21
29
23A
60
21
12
1
7
09A
PLATFORM CONTROL CONSOLE BASE CONTROL CONSOLE

GENERATOR WIRE KIT GENERATOR WIRE KIT
Z
M144108AB M144109AB

Models SJ 40T & 45T
143844
3.45 Generator and Oil Cooler Connection Locations AB
A B C D E F G H
COOLER MOUNTING BOLT
03
Z
110V GENERATOR CABLE GENERATOR VALVE
OIL COOLER POWER
HARNESS HARNESS
M144106AA_LOC M144107AA_LOC

Models SJ 40T & 45T
143844
3.46 12 kW Generator Connection Assembly AC
A B C D E F G H
WHITE WHITE - JUMPER

V
ORANGE
RED
BLACK
BLACK - JUMPER
GREEN
ON ON
NEUT
WHITE
GND
15 50
OFF OFF
GREEN
BLACK
RED
GREEN ORANGE
RED WHITE
VIEW UNDER GENERATOR COVER BLACK RED
BLACK WHITE BLACK
Y
Y X WHITE
Z G
GREEN
Z
LOCATED ON PLATFORM
M144088_144089AB

Models SJ 40T & 45T
143844
3.47 12 kW Generator Connection Locations AC
A B C D E F G H
CABLE ASSEMBLY
CABLE X
110V GENERATOR CABLE

GENERATOR VALVE
HARNESS
M144163AC

Models SJ 40T & 45T
143844
Section 4
Troubleshooting Information
Table of Contents
Introduction...................................................................................................................................................................3
Electrical System
4.1-1 All Controls Inoperative....................................................................................................................................4
4.1-2 No Power To Platform......................................................................................................................................4
4.1-3 No Power to Base............................................................................................................................................5
4.1-4 Engine Will Not Crank from Base....................................................................................................................5
4.1-5 Engine Will Not Crank from Platform...............................................................................................................5
4.1-6 Engine Will Not Crank from Platform or Base (Deutz Diesel).........................................................................6
4.1-7 Engine Cranks but Will Not Start (Deutz Diesel).............................................................................................7
4.1-8 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel)..........................................................7
4.1-9 Engine Cranks but Will Not Start (GM Dual Fuel)...........................................................................................8
4.1-10 Glow Plug Circuit Inoperative........................................................................................................................10
4.1-11 All Base Control Console Inoperative............................................................................................................11
4.1-12 No Main Boom Down or Turret Rotate from Base Control Console.............................................................11
4.1-13 No Boom Up from Base Control Console.....................................................................................................12
4.1-14 No Boom Down from Base Control Console................................................................................................12
4.1-15 No Turret Rotate Left from Base Control Console.........................................................................................12
4.1-16 No Turret Rotate Right from Base Control Console......................................................................................13
4.1-17 No Telescope Retract From Base Control Console......................................................................................13
4.1-18 No Telescope Extend From Base Control Console......................................................................................13
4.1-19 No Platform Rotate Left From Base Control Console...................................................................................14
4
4.1-20 No Platform Rotate Right from Base Control Console..................................................................................14
4.1-21 No Platform Rotate Left or Right from Base Control Console.......................................................................15
4.1-22 No Jib Up from Base Control Console..........................................................................................................15
4.1-23 No Jib Down from Base Control Console.....................................................................................................16
4.1-24 No Jib Up Or Down From Base Control Console.........................................................................................16
4.1-25 No Manual Platform Level Up From Base Control Console..........................................................................16
4.1-26 No Manual Platform Level Down From Base Control Console.....................................................................17
4.1-27 No Manual Platform Level Up From Platform Control Console....................................................................17
4.1-28 No Manual Platform Level Down From Platform Control Console...............................................................18
4.1-29 All Controls Inoperative From Platform Control Console..............................................................................18
4.1-30 No Boom Up From Platform Control Console..............................................................................................19
4.1-31 No Boom Down From Platform Control Console..........................................................................................20
4.1-32 No Turret Left from Platform Control Console...............................................................................................20
4.1-33 No Turret Right from Platform Control Console............................................................................................21
4.1-34 No Telescope In from Platform Control Console...........................................................................................22
4.1-35 No Telescope Out from Platform Control Console........................................................................................22
4.1-36 No Platform Rotate or Jib Function from Platform Control Console.............................................................23
4.1-37 No Platform Rotate Left from Platform Control Console...............................................................................23
4.1-38 No Platform Rotate Right from Platform Control Console............................................................................24
4.1-39 No Jib Up from Platform Control Console....................................................................................................24
4.1-40 No Jib Down from Platform Control Console................................................................................................24
4.1-41 Mid Throttle Inoperative.................................................................................................................................25
4.1-42 High Throttle Inoperative...............................................................................................................................26
4.1-43 Brake will not Release...................................................................................................................................26
SJ 40T & SJ 45T SKYJACK, Page

143844
Service and Maintenance Section 4 - Troubleshooting Information
Table of Contents (Continued)
4.1-44 No Drive and Steer........................................................................................................................................27

4.1-45 No Forward Drive...........................................................................................................................................27
4.1-46 No Reverse Drive...........................................................................................................................................28
4.1-47 No High Speed Drive.....................................................................................................................................28
4.1-48 No Elevated Drive..........................................................................................................................................29
4.1-49 No Left Steer..................................................................................................................................................30
4.1-50 No Right Steer................................................................................................................................................30
4.1-51 Direction Sensing Inoperative.......................................................................................................................31
4.1-52 Steer Direction Sensing Inoperative..............................................................................................................31
Hydraulic System
4.2-1 All Controls Inoperative..................................................................................................................................32
4.2-2 All Boom Functions Inoperative.....................................................................................................................32
4.2-3 No Main Boom Up.........................................................................................................................................32
4.2-4 No Main Boom Down....................................................................................................................................32
4.2-5 No Turret Rotate Left......................................................................................................................................33
4.2-6 No Turret Rotate Right...................................................................................................................................33
4.2-7 No Boom Extend...........................................................................................................................................34
4.2-8 No Boom Retract...........................................................................................................................................34
4.2-9 No Jib Up.......................................................................................................................................................34
4.2-10 No Jib Down..................................................................................................................................................35
4.2-11 No Platform Rotation Right............................................................................................................................35
4.2-12 No Platform Rotation Left...............................................................................................................................35
4.2-13 Platform will not Level Down.........................................................................................................................36
4.2-14 Platform will not Level Up..............................................................................................................................36
4.2-15 Brake will not Release...................................................................................................................................36
4.2-16 Brake will not Engage....................................................................................................................................37
4.2-17 No Drive Forward or Reverse........................................................................................................................37
4.2-18 No Forward Drive...........................................................................................................................................37
4.2-19 No Reverse Drive...........................................................................................................................................37
4.2-20 No High Speed Drive.....................................................................................................................................38
4.2-21 No Right Steer................................................................................................................................................38
4.2-22 No Left Steer..................................................................................................................................................38
4.2-23 Axle Will Not Oscillate....................................................................................................................................38
4.2-24 Axle Will Not Lock..........................................................................................................................................39
Load Sensing System

4.3-1 Green Power LED is not Flashing.................................................................................................................40
4.3-2 Load Cell red Alarm LED is ON (with platform empty).................................................................................40
4.3-3 Red Error LED is ON......................................................................................................................................40
4.3-4 Load Cell red Alarm LED is OFF (with platform overloaded)........................................................................40
4.3-5 Platform Indicator Light does not turn ON....................................................................................................40
4.3-6 Audible Alarm does not turn ON...................................................................................................................40
4.3-7 Boom and Drive Functions are Enabled (with boom extended)...................................................................40
SKYJACK, Page SJ 40T & SJ 45T

143844
Section 4 - Troubleshooting Information Service and Maintenance
Introduction
The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble
which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information
will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and
deficiencies that may occur. If a specific trouble is not listed, isolate the major component in which the trouble oc-
curs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem.
The content of this section is separated into “probable cause” and “remedy.” The information preceded by a num-
ber represents the “probable cause.” The following line, noted by a dash represents the “remedy” to the “probable
cause” directly above it. See example below for clarification.
1. Probable Cause
- Remedy

143844
Electrical System
NOTE
All tests should be performed with boom over non-steering axle.
4.1-1 All Controls Inoperative

1. Battery disconnected or discharged.
- Connect battery or recharge.
2. Loose or broken wire #03 from battery to circuit breaker CB1.
- Check continuity. Replace if defective.
3. Circuit breaker CB1 tripped or defective.
- Reset breaker, check for defective wiring. Replace if defective.
4. Loose or broken wire #05 from circuit breaker CB1 to base emergency stop switch S3.
5. Open or defective base emergency stop switch S3.
- Close switch. Replace if defective.
6. Loose or broken wire #07 from base emergency stop switch S3 to base key S2.
7. Open or defective key select switch S2.
8. Loose or broken wire #60 from base terminal block to relay 60CR.
9. Loose or broken wire #07 from base emergency stop switch S3 to relay 60CR.
10. Loose or broken wire #02 from relay 60CR to base terminal block.
11. Defective relay 60CR.
- Check relay. Replace if defective.
13. Loose or broken wire #02 from base terminal block to circuit breaker CB2.
14. Circuit breaker CB2 tripped or defective.
- Reset breaker, check for defective wiring. Replace if defective.
15. Loose or broken wire #00 from circuit breaker CB2 to battery negative.
4.1-2 No Power To Platform

1. Open or defective key select switch S2.
2. Loose or broken wire #07A from key select switch S2 to plug A pins # 4 & 5 in bsae control console.
3. Loose or broken wire #07A from plug A pins # 4 & 5 in platform control console to platform emergency
stop switch S4.
4. Open or defective platform emergency stop switch S4.
- Check switch. Replace if defective.

143844
Electrical System (Continued)
4.1-3 No Power to Base

1. Open or defective base key switch S2.
- Select base position on key switch. Check continuity through base key switch. Replace if
defective.
2. Loose or broken wire #12 from base key switch S2 to start switch S5.
3. Loose or broken wire #12 from base key switch S2 to base connector plug A pin #9.
4. Loose or broken wire #12 in boom cable A or its connectors.
- Check for continuity between pins #9 on cable A. Check for loose or corroded connections on
cable connectors. Replace if wire is defective.
5. Loose or broken wire #12 from plug A pin #9 to emergency stop switch S4 in platform control
console.
6. Open or defective emergency stop switch S4.
- Check switch is in on position. Check continuity through switch. Replace if defective.
7. Loose or broken wire #10 from emergency stop switch S4 to plug A pin #8.
9. Loose or broken wire #10 from plug A pin #8 to base terminal block.
10. Loose or broken wire #10 from base terminal block to emergency stop switch S3.
11. Loose or broken wire #10 from emergency stop switch S3 to enable switch S7.
12. Loose or broken wire #10 from enable switch S7 to start switch S5.
4.1-4 Engine Will Not Crank from Base

1. Loose or broken wire #10 from enable switch S7 to base start switch S5.
2. Loose or broken wire #57A from base start switch S5 to relay 57ACR.
3. Defective base start switch S5.
- Check start button. Replace if defective.
4.1-5 Engine Will Not Crank from Platform
NOTE
Engine will not crank from platform with footswitch depressed.
1. Loose or broken wire #4 from emergency stop switch S4 to start switch S6.
2. Defective start switch S6.
- Check continuity through switch. Replace if defective.
3. Loose or broken wire #57 from start switch S6 to relay 08CR.

143844

- Check continuity through contacts of relay. Replace if defective.
5. Loose or broken wire #57A from relay 08CR to plug B pin #12.
6. Loose or broken wire #57A in boom cable B or its connectors.
- Check for continuity between pin #12 on cable B. Check for loose or corroded connections
on cable connectors. Replace if wire is defective.
7. Loose or broken wire #57A from plug B pin #12 to relay 57ACR in base control console.
4.1-6 Engine Will Not Crank from Platform or Base (Deutz Diesel)
1. Loose or broken wire #57A at relay 57ACR (2 places).
- Check for connections at relay. Check for voltage on relay (2 places).
2. Loose or broken wire #57A from relay 57ACR to relay 57BCR.
3. Loose or broken wire #00A from X23 engine connector pin #11 to relay 57ACR.
4. Loose or broken wire #00A from X23 engine connector pin #11 to engine oil pressure switch.
5. Defective relay 57ACR.
7. Loose or broken wire #03A from circuit breaker CB3 to relay 09CR.
8. Tripped or defective circuit breaker CB3.
- Reset circuit breaker. Check continuity through circuit breaker. Replace if defective.
9. Loose or broken wire #3 from circuit breaker CB3 to turret harness plug pin #2.
12. Loose or broken wire #54A from relay 09CR to base terminal block.
13. Loose or broken wire #54A from base terminal block to relay 57BCR1.
14. Defective contacts in relay 57BCR1.
- Check continuity between wires #54A and #57C when cranking. If no continuity, replace
relay.
15. Loose or broken wire #57C from relay 57BCR1 to X23 engine connector pin #4.
16. Loose or broken wire #57C from X23 engine plug to start solenoid 57CCR.
17. Loose or broken starter cable #03 from disconnect switch S1 to start solenoid 57CCR.
18. Defective start solenoid 57CCR.
- Check solenoid. Replace if defective.
19. Defective starter motor.
- Check starter motor. Replace if defective.

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4.1-7 Engine Cranks but Will Not Start (Deutz Diesel)

1. Loose or broken wire #57B from relay 57ACR to relay 57BCR (2 places).
- 57BCR maintains power for start circuit before engine starts and after oil pressure switch opens
to relay 57BCR1. Check wire #57B for continuity. Replace if defective.
2. Loose or broken wire #57A from relay 57ACR to relay 57BCR.
3. Loose or broken wire #02 from base terminal block to relay 57BCR.
4. Defective relay 57BCR.
5. Glow plug circuit not operating.
- See “Glow Plug Circuit Inoperative” in this section.
6. No fuel in fuel tank or fuel line obstructions.
- Check fuel level and flow through lines. Fill or repair if necessary.
NOTE
For other engine related problems, consult engine manufacturer’s
manual.
4.1-8 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel)
1. Loose or broken wire #54A from base terminal block TB1 to engine harness plug.
2. Loose or broken wire #54A from engine harness plug to GM engine connector 1.
3. Loose or broken pink wire from GM engine connector 1 to fuse F7.
4. Defective fuse F7.
- Check fuse. Replace if defective
5. Loose or broken pink/tan wire from fuse F7 to ECU connector pin #45.
- Check continuity. Replace if defective
6. Loose or broken red wire from battery positive to ECU fuse F8.
- Check fuse. Replace if defective.
8. Loose or broken red/tan wire from fuse F8 to ECU connector pin #60 and pin #79.
9. Loose or broken black wire from engine ground to ECU connector pin #69 and #81.
10. Loose or broken light blue/pink wire from GM engine connector 1 to relay 57ACR.
11. Loose or broken pink/black wire from ECU connector pin #89 to relay 57ACR.
13. Loose or broken red wire from battery positive to starter fuse F12.
15. Loose or broken red/tan wire from fuse F12 to relay 57ACR.

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16. Loose or broken white wire from relay 57ACR to start solenoid 32BCR.
17. Defective starter solenoid 32BCR.
- Check solenoid. Replace if defective.
18. Loose or broken battery cable from starter solenoid 32BCR to starter motor.
19. Defective starter motor.
- Check motor. Repair or replace if defective.
4.1-9 Engine Cranks but Will Not Start (GM Dual Fuel)
NOTE
For additional engine troubleshooting refer to diagnostic trouble codes
for use with the check engine light.
1. Loose or broken red wire from battery positive to relay 2002CR.

2. Loose or broken red/tan wire from ECU fuse F8 to relay 2002CR.
3. Loose or broken white/ light blue wire from ECU connector pin #71 to relay 2002CR.
5. Loose or broken pink/dark green wire from relay 2002CR to ignition fuse F10.
7. Loose or broken pink/dark green wire from fuse F10 to ignition coil IGC1 pin #A.
8. Loose or broken yellow wire from ignition coil IGC1 pin #B to ignition module IGM1.
9. Defective ignition coil IGC1.
- Check coil for spark. Replace if defective.
10. Loose or broken pink/dark green wire from fuse F10 to ignition module IGM1 pin #A.
11. Loose or broken black wire from ignition module IGM1 pin #C to engine ground.
12. Loose or broken yellow wire from ignition module IGM1 pin #B to ECU connector pin #31.
13. Defective ignition module IGM1.
- Check module for operation. Replace if defective.
14. Loose or broken pink/dark green wire from fuse F10 to gas injectors GI-1, GI-2, GI-3 and GI-4.
15. Loose or broken pink/white wire from ECU connector pin #82 to throttle actuator RA1.
16. Loose or broken tan/orange wire from ECU connector pin #83 to throttle actuator RA1.
17. Loose or broken light green/red wire from ECU connector pin #19 to throttle actuator RA1.

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18. Loose or broken black/light green wire from ECU connector pin #20 to throttle actuator RA1.
19. Loose or broken light blue/dark blue wire from ECU connector pin #6 to throttle actuator RA1.
20. Loose or broken purple/light blue wire from ECU connector pin #5 to throttle actuator RA1.
Fuel Related Problems

(Gasoline Only)
21. Loose or broken pink/tan wire from fuse F7 to fuel pump relay 56CR.
22. Loose or broken red wire from battery positive to fuel pump relay 56CR.
23. Loose or broken tan/black wire from ECU connector pin #84 to fuel pump relay 56CR.
24. Defective fuel pump relay 56CR.
25. Loose or broken pink/yellow wire from fuel pump relay 56CR to fuse F11.
27. Loose or broken pink/yellow wire from fuse F11 to fuel pump FP.
28. Defective fuel pump FP.
- Check fuel pump by putting 12 volts and a ground to it. Replace if defective.
29. Loose or broken wire #3002 from fuel pump FP to GM engine connector 1.
30. Loose or broken black/red wire from GM engine connector to ECU connector pin #86.
(Propane Only)
NOTE
The fuel select switch is defaulted to gasoline. The engine will run on
gasoline if propane is selected from the switch and either the switch
is bad or a wire is loose or broken from the switch. This is providing
there is nothing wrong on the gasoline side of the system. Disconnect
fuel pump to test propane side.
31. Loose or broken wire #60 from platform terminal block to fuel select switch S26.
32. Defective fuel select switch S26.
- Check switch. Replace if defective.
33. Loose or broken wire #11 from fuel select switch S26 to plug B pin #15 in platform control console.
34. Loose or broken wire #11 in boom cable B or its connectors.
- Check continuity between pins #15 on cable B. Check for loose or corroded connections on
35. Loose or broken wire #11 from plug B pin #15 to engine harness plug.

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36. Loose or broken wire #11 from engine harness plug to GM engine connector 1.
37. Loose or broken tan/brown wire from GM engine connector 1 to ECU connector pin #42.
38. Loose or broken pink/tan wire from fuse F7 to propane lock off 2P-56.
39. Loose or broken white/black wire from ECU connector pin #75 to propane lock off 2P-56.
40. Defective propane lock off 2P-56.
- Check lock off. Replace if defective.
41. Loose or broken pink/dark green wire from fuse F10 to fuse F9.
43. Loose or broken red/light blue wire from fuse F9 to propane regulator PRV1.
44. Loose or broken black wire from engine ground to propane regulator PRV1.
4.1-10 Glow Plug Circuit Inoperative

1. Defective glow plug fuse FU1 50 amp.
2. Loose or broken wire #03 from start solenoid 57CCR to fuse holder FU1.
3. Loose or broken wire #11A from fuse holder FU1 to relay 54ACR.
4. Loose or broken wire #11B from relay 54ACR to glow plugs.
5. Loose or broken wire #54A from base terminal strip to relay 54ACR.
6. Loose or broken wire #11 from base terminal block to relay 54ACR.
8. Defective glow plugs.
- Check glow plugs. Replace if defective.
NOTE
For other glow plug related problems, consult engine manufacturer’s
manual.
SKYJACK, Page 10 SJ 40T & SJ 45T

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4.1-11 All Base Control Console Inoperative

1. Loose or broken wire #10 from base emergency stop switch S3 to function enable switch S7.
2. Defective enable switch S7.
- Check continuity through switch when activated. Replace if defective.
3. Loose or broken wire #20A from function enable switch S7 to basket rotation switch S16.
4. Loose or broken wire #20A from telescope switch S14 to diode D20A.
5. Open or defective diode D20A.
- Check diode. Replace if defective.
6. Loose or broken wire #20 from diode D20A to base terminal block.
7. Missing or broken jumper JMPR3 on base terminal block between wires #20 and #21.
- Check for jumper. Replace if missing or broken.
NOTE
Jumper is removed if equipped with generator option.
12. Loose or broken wire #21A from relay 21CR to turret harness plug pin #5.
13. Loose or broken wire #21A from turret harness plug pin #5 to dump valve 2H-21A.
14. Loose or broken wire #02 from dump valve 2H-21A to turret harness plug.
15. Defective dump valve coil 2H-21A.
- Check continuity and resistance through coil. Replace if defective.
4.1-12 No Main Boom Down or Turret Rotate from Base Control Console
1. Loose or broken wire #20A from function enable switch S7 to resistor R1.
2. Open resistor R1.
- Check resistor for 6 ohms. If no resistance found, replace resistor.
3. Loose or broken wire #20C from resistor R1 to turret rotate switch S13 and boom down switch S12.
SJ 40T & SJ 45T SKYJACK, Page 11

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4.1-13 No Boom Up from Base Control Console

1. Loose or broken wire #20A from function enable switch S7 to boom switch S12.
2. Defective boom switch S12.
- Check continuity through switch while activating up function between wires #20C and #14.
Replace switch if no continuity.
3. Loose or broken wire #14 from boom switch S12 to base terminal block.
4. Loose or broken wire #14 from base terminal block to turret harness plug pin #4.
5. Loose or broken wire #14 from turret harness plug pin #4 to boom up valve 4H-14.
6. Loose or broken wire #02 from turret harness plug to boom up valve 4H-14.
7. Defective boom up coil 4H-14.
4.1-14 No Boom Down from Base Control Console

1. Loose or broken wire #20C from resistor R1 to boom down switch S12.
2. Defective boom switch S12.
- Check continuity through switch while activating down function between wires #20C and #13.
If no continuity found, replace switch.
3. Loose or broken wire #13 from boom down switch S12 to base terminal block.
5. Loose or broken wire #13 from turret harness plug pin #3 to boom down valve 4H-13.
6. Loose or broken wire #02 from turret harness plug to boom down valve 4H-13.
7. Defective boom down coil 4H-13.
4.1-15 No Turret Rotate Left from Base Control Console

1. Loose or broken wire #20C from resistor R1 to turret rotate switch S13.
2. Defective turret rotate switch S13.
- Check continuity through switch while activating rotate left function between wires #20C and
#32. If no continuity found, replace switch.
3. Loose or broken wire #32 from turret rotate switch S13 to base terminal block.
5. Loose or broken wire #32 from turret harness plug pin #10 to turret rotate left valve 4H-32.

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6. Loose or broken wire #02 from turret harness plug to turret rotate left valve 4H-32.
7. Defective turret rotate left valve coil 4H-32.
4.1-16 No Turret Rotate Right from Base Control Console

1. Loose or broken wire #20C from resistor R1 to turret rotate switch S13.
2. Defective turret rotate switch S13.
- Check continuity through switch while activating rotate right function between wires #20C and
3. Loose or broken wire #33 from turret rotate switch S13 to base terminal block.
5. Loose or broken wire #33 from turret harness plug pin #10 to turret rotate right valve 4H-33.
6. Loose or broken wire #02 from turret harness plug to turret rotate right valve 4H-33.
7. Defective turret rotate right valve coil 4H-33.
4.1-17 No Telescope Retract From Base Control Console

1. Loose or broken wire #20A from function enable switch S7 to telescope switch S14.
2. Defective telescope switch S14.
- Check continuity through switch while activating retract function between wires #20A and #38.
3. Loose or broken wire #38 from telescope switch S14 to base terminal block.
5. Loose or broken wire #38 from turret harness plug pin #12 to telescope retract valve 4H-38.
6. Loose or broken wire #02 from turret harness plug to telescope retract valve 4H-38.
7. Defective telescope retract valve coil 4H-38.
4.1-18 No Telescope Extend From Base Control Console

1. Loose or broken wire #20A from function enable switch S7 to telescope switch S14.
- Check continuity through switch while activating extend function between wires #20A and #39.
3. Loose or broken wire #39 from telescope switch S14 to base terminal block.

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5. Loose or broken wire #39 from turret harness plug pin #13 to telescope extend valve 4H-39.
6. Loose or broken wire #02 from turret harness plug to telescope extend valve 4H-39.
7. Defective telescope extend valve coil 4H-39.
4.1-19 No Platform Rotate Left From Base Control Console

1. Loose or broken wire #20A from function enable switch S7 to platform rotate switch S16.
2. Defective platform rotate switch S16.
- Check continuity through switch while activating rotate left function between wires #20A and
3. Open or defective diode D36-1.
4. Loose or broken wire #37A from diode D36-1 to resistor R2.
5. Loose or broken wire #36 from platform rotate switch S16 to base connector plug B pin #1.
- Check for continuity between pins #1 on cable B. Check for loose or corroded connections on
7. Loose or broken wire #36 plug B pin #1 to platform terminal block.
8. Loose or broken wire #36 from platform terminal block to platform rotate left valve 4H-36.
9. Loose or broken wire #02 from platform terminal block to platform rotate left valve 4H-36.
10. Defective platform rotate left valve coil 4H-36.
4.1-20 No Platform Rotate Right from Base Control Console

1. Loose or broken wire #20A from function enable switch S7 to platform rotate switch S16.
- Check continuity through switch while activating rotate right function between wires #20A and
5. Loose or broken wire #37 from platform rotate switch S16 to base connector plug B pin #2.
7. Loose or broken wire #37 plug B pin #2 to platform terminal block.

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8. Loose or broken wire #37 from platform terminal block to platform rotate right valve 4H-37.
9. Loose or broken wire #02 from platform terminal block to platform rotate right valve 4H-37.
10. Defective platform rotate right valve coil 4H-37.
4.1-21 No Platform Rotate Left or Right from Base Control Console

- Check resistor for 12 ohms (45T) or 15 ohms (40T). If no resistance found, replace resistor.
2. Loose or broken wire #35A from resistor R2 to base key switch S2.
- Select base control on switch. Check continuity through switch. Replace if defective.
4. Loose or broken wire #42 from base key switch S2 to turret harness plug pin #16.
5. Loose or broken wire #42 from turret harness plug pin #16 to proportional flow enable valve 2H-42.
6. Loose or broken wire #02 from turret harness plug to proportional flow enable valve 2H-42.
7. Defective proportional flow enable valve coil 2H-42.
4.1-22 No Jib Up from Base Control Console

1. Loose or broken wire #20A from function enable switch S7 to jib switch S17.
2. Defective jib up switch S17.
- Check continuity through switch while activating jib up function between wires #20A and #35.
5. Loose or broken wire #35 from jib up switch S17 to base connector plug A pin #24.
- Check for continuity between pins #24 on cable A. Check for loose or corroded connections
7. Loose or broken wire #35 from plug A pin #24 to platform terminal block.
8. Loose or broken wire #35 from platform terminal block to jib up valve 4H-35.
9. Loose or broken wire #02 from platform terminal block to jib up valve 4H-35.
10. Defective jib up valve coil 4H-35.

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4.1-23 No Jib Down from Base Control Console

1. Loose or broken wire #20A from function enable switch S7 to jib switch S17.
2. Defective jib down switch S17.
- Check continuity through switch while activating jib down function between wires #20A and
5. Loose or broken wire #34 from jib down switch S17 to base connector plug A pin #23.
7. Loose or broken wire #34 from plug A pin #23 to platform terminal block.
8. Loose or broken wire #34 from platform terminal block to jib down valve 4H-34.
9. Loose or broken wire #02 from platform terminal block to jib down valve 4H-34.
10. Defective jib down valve coil 4H-34.
4.1-24 No Jib Up Or Down From Base Control Console

1. Loose or broken wire #35A from resistor R2 to base key switch S2.
- Select base control console on switch. Check continuity through switch. Replace if defective.
6. Defective proportional flow enable valve coil 2H-42.
4.1-25 No Manual Platform Level Up From Base Control Console

1. Loose or broken wire #20A from function enable switch S7 to platform level switch S15.
2. Defective platform level switch S15.
- Check continuity through switch while activating level up function between wires #20A and
#41. If no continuity found replace switch.
3. Loose or broken wire #41 from platform level switch S15 to base terminal block.
4. Loose or broken wire #41 from base terminal block to turret harness pin plug pin#15.
5. Loose or broken wire #41 from turret harness pin plug pin#15 platform level up valve 4H-41.

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6. Loose or broken wire #02 from turret harness pin plug platform level up valve 4H-41.
7. Defective platform level up valve coil 4H-41.
8. Loose or broken wire #41 from base terminal block to base connector plug B pin #6.
10. Loose or broken wire #41 from plug B pin #6 to platform terminal block.
11. Open diode D41 located in platform terminal block.
4.1-26 No Manual Platform Level Down From Base Control Console

1. Loose or broken wire #20A from function enable switch S7 to platform level switch S15.
- Check continuity through switch while activating level down function between wires #20A and
3. Loose or broken wire #40 from platform level switch S15 to base terminal block.
4. Loose or broken wire #40 from base terminal block to turret harness pin plug pin #14.
5. Loose or broken wire #40 from turret harness pin plug pin #14 platform level down valve 4H-40.
6. Loose or broken wire #02 from turret harness pin plug platform level down valve 4H-40.
7. Defective platform level down valve coil 4H-40.
8. Loose or broken wire #40 from base terminal block to base connector plug B pin #5.
10. Loose or broken wire #40 from plug B pin #5 to platform terminal block.
4.1-27 No Manual Platform Level Up From Platform Control Console
NOTE
This function times out after 15 seconds when operating this
function only.
1. Loose or broken wire #90A from valve driver pin #12 to platform level switch S19.

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- Check continuity through switch while activating level up function between wires #90A and
3. Loose or broken wire #41 from platform level switch S19 to platform terminal block.
4.1-28 No Manual Platform Level Down From Platform Control Console
NOTE
function only.
1. Loose or broken wire #90A from valve driver pin #12 to platform level switch S19.
- Check continuity through switch while activating level down function between wires #90A and
3. Loose or broken wire #40 from platform level switch S19 to platform terminal block.
4.1-29 All Controls Inoperative From Platform Control Console

1. Open or defective emergency stop switch S4.
- Pull emergency switch out. Check continuity through switch. Replace if defective.
2. Loose or broken wire #4 from emergency stop switch S4 to platform terminal block.
3. Loose or broken jumper wire #4 on emergency stop switch S4.
4. Loose or broken pin jumper between #04 and #04A on platform terminal block (without generator
option only).
5. Loose or broken wire #04 from platform terminal block to generator switch S22 (generator option
only).
6. Generator switch S22 in generator mode or is open or defective (generator option only).
- Select OFF mode on generator switch. Check continuity through switch from #04 to #04A.
Replace if defective.
7. Loose or broken wire #04A from generator switch S22 to platform terminal block (generator option
only).
8. Loose or broken wire #04A from platform terminal block to footswitch S11.
9. Open or defective footswitch S11.
- Check continuity through switch while activating footswitch function between wires #04A and
#08A. If no continuity found replace switch.

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10. Loose or broken wire #08A from footswitch S11 to valve driver pin #16.
11. Loose or broken wire #04 from platform terminal block to valve driver pin #1, 2, 13 & 14.
12. Loose or broken wire #02 from platform terminal block to valve driver pin #24, 25 & 26.
13. No output on pin #16 of the valve driver to wire #08B.
- Check pin #6 for 12 volts. If no voltage present with foot on footswitch check section 5 for valve
driver test procedure.
14. Loose or broken wire #08B from valve driver pin #6 to relay 08BCR.
15. Loose or broken wire #02 from platform terminal block to relay 08BCR.
16. Loose or broken wire #04 from platform terminal block to relay 08BCR.
17. Loose or broken wire #08 from relay 08BCR to platform terminal block.
18. Defective relay 08BCR.
19. Loose or broken wire #08 or #02 from platform terminal block to relay 08CR1.
20. Loose or broken wire #20D from platform terminal block to relay 08CR1.
21. Loose or broken wire #20 from 08CR1 relay to plug A pin #15 in platform control console.
22. Defective relay 08CR1.
4.1-30 No Boom Up From Platform Control Console

1. Loose or broken wire #04 from platform terminal block to joystick controller A1.
3. No output on y-axis of joystick controller A1.
- Refer to joystick test procedure in section 5.
4. Loose or broken wire “Y” from joystick controller A1 to valve driver pin #29.
6. No output on pin #22 of the valve driver to wire #14.
- Check pin #22 for minimum 3.5 volts. If no voltage present with foot on footswitch check section
5 for valve driver test procedure.
7. Loose or broken wire #14 from valve driver pin #22 to plug A pin #11 in platform control console.
9. Loose or broken wire #14 from base connector plug A pin #11 to base terminal block.

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11. Loose or broken wire #14 from turret harness plug pin #4 to boom up valve 4H-14.
12. Loose or broken wire #02 from turret harness plug to boom up valve 4H-14.
13. Defective boom up valve coil 4H-14.
4.1-31 No Boom Down From Platform Control Console

3. No output on y-axis of joystick controller A1.
4. Loose or broken wire “Y” from joystick controller A1 to valve driver pin #29.
11. Loose or broken wire #13 from turret harness plug pin #3 to boom down valve 4H-13.
12. Loose or broken wire #02 from turret harness plug to boom down valve 4H-13.
13. Defective boom down valve coil 4H-13.
4.1-32 No Turret Left from Platform Control Console

3. No output on x-axis of joystick controller A1.
4. Loose or broken wire “X” from joystick controller A1 to valve driver pin #28.

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11. Loose or broken wire #32 from turret harness plug pin #10 to turret left valve 4H-32.
12. Loose or broken wire #02 from turret harness plug to turret left valve 4H-32.
13. Defective turret left valve coil 4H-32.
4.1-33 No Turret Right from Platform Control Console

3. No output on x-axis of joystick controller A1.
4. Loose or broken wire “X” from joystick controller A1 to valve driver pin #28.
11. Loose or broken wire #33 from turret harness plug pin #11 to turret right v alve 4H-33.

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12. Loose or broken wire #02 from turret harness plug to turret right valve 4H-33.
13. Defective turret right valve coil 4H-33.
4.1-34 No Telescope In from Platform Control Console
NOTE
Toggle switch controls are speed controlled through a speed control
selector A3.
1. Loose or broken wire #08 from platform terminal block to telescope switch S18.
- Check continuity through switch while activating in function between wires #08 and #38A.
3. Loose or broken wire #38A from telescope switch S18 to valve driver pin #18.
6. Loose or broken wire #38 from valve driver pin #11 to plug B pin #3 in platform control console.
8. Loose or broken wire #38 from base connector plug B pin #3 to base terminal block.
10. Loose or broken wire #38 from turret harness plug pin #12 to telescope in valve 4H-38.
11. Loose or broken wire #02 from turret harness plug to telescope in valve 4H-38.
12. Defective telescope in valve coil 4H-38.
4.1-35 No Telescope Out from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to telescope switch S18.
- Check continuity through switch while activating out function between wires #08 and #39A.
3. Loose or broken wire #39A from telescope switch S18 to valve driver pin #17.

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8. Loose or broken wire #39 from base connector plug B pin #4 to base terminal block.
10. Loose or broken wire #39 from turret harness plug pin #13 to telescope out valve 4H-39.
11. Loose or broken wire #02 from turret harness plug to telescope out valve 4H-39.
12. Defective telescope out valve coil 4H-39.
4.1-36 No Platform Rotate or Jib Function from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to rotate wwitch S20 and jib switch S21.
5. Loose or broken wire #42 from base connector plug B pin #7 to base key switch S2.
9. Defective proportional flow enable valve 2H-42.
4.1-37 No Platform Rotate Left from Platform Control Console

- Check continuity through switch while activating rotate left function between wires #08 and
#36.
2. Loose or broken wire #36 from platform rotate switch S20 to platform terminal block.
3. Loose or broken jumper wire #36 on platform terminal block.

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4. Open or defective diode D36 in platform terminal block.

5. Loose or broken wire #36A from platform terminal block to valve driver pin #32.
6. Loose or broken wire #36 or #02 from platform terminal block to rotate left valve 4H-36.
7. Defective rotate left valve coil 4H-36.
4.1-38 No Platform Rotate Right from Platform Control Console

- Check continuity through switch while activating rotate right function between wires #08 and
#37.
2. Loose or broken wire #37 from platform rotate switch S20 to platform terminal block.
6. Loose or broken wire #37 or #02 from platform terminal block to rotate right valve 4H-37.
7. Defective rotate right Valve coil 4H-37.
4.1-39 No Jib Up from Platform Control Console

1. Defective jib switch S21.
- Check continuity through switch while activating jib up function between wires #08 and #35.
2. Loose or broken wire #35 from jib switch S21 to platform terminal block.
6. Loose or broken wire #35 or #02 from platform terminal block to jib up valve 4H-35.
7. Defective jib up valve coil 4H-35.
4.1-40 No Jib Down from Platform Control Console

1. Defective jib switch S21.
- Check continuity through switch while activating jib down function between wires #08 and
#34.
2. Loose or broken wire #34 from jib switch S21 to platform terminal block.

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6. Loose or broken wire #34 or #02 from platform terminal block to jib down valve 4H-34.
7. Defective jib down valve coil 4H-34.
4.1-41 Mid Throttle Inoperative

1. Loose or broken wire #08 from platform terminal block to throttle switch S10.
2. Defective throttle switch S10.
- Check continuity through switch while activating mid throttle function between wires #08 and
3. Loose or broken wire #79 from throttle switch S10 to plug B pin #18 in platform control console.
4. Loose or broken wire #79 in Cable B or its connectors.
- Check for continuity between pins #18 on cable B. Check for loose or corroded connections
(Deutz Diesel Only)

5. Loose or broken wire #79 from base plug B pin #18 to relay 79CR.
7. Loose or broken wire #99 from relay 79CR to ECU connector pin #18.
9. Loose or broken wire #103 from base terminal block to ECU connector pin #17.
(GM Engine Only)

11. Loose or broken wire #79 from base plug B pin #18 to engine harness plug.
- Check continuity. Replace if defective
13. Loose or broken gray/dark blue wire from GM engine connector to ECU connector pin #51.
14. Loose or broken purple/light blue wire from ECU connector pin #5 to throttle actuator RA1.
15. Defective throttle actuator RA1.
- Check actuator. Replace if defective.

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4.1-42 High Throttle Inoperative

1. Loose or broken wire #08 from platform terminal block to throttle switch S10.
2. Defective throttle switch S10.
- Check continuity through switch while activating high throttle function between wires #08 and
3. Loose or broken wire #78 from throttle switch S10 to plug B pin #17 in platform control console.
4. Loose or broken wire #78 in Cable B or its connectors.
(Deutz Diesel Only)

5. Loose or broken wire #78 from base plug B pin #17 to relay 78CR.
7. Loose or broken wire #90 from relay 78CR to ECU connector pin #21.
9. Loose or broken wire #103 from base terminal block to ECU connector pin #17.
(GM Engine Only)

11. Loose or broken wire #78 from base plug B pin #17 to engine harness plug.
13. Loose or broken gray/orange wire from GM engine connector 2 to ECU connector pin #52.
14. Loose or broken light blue/dark blue wire from ECU connector pin #6 to throttle actuator RA1.
15. Defective throttle actuator RA1.
- Check actuator. Replace if defective.
4.1-43 Brake will not Release

1. No output on pin #7 from valve driver to wire #26 when operating a drive function.
2. Loose or broken wire #26 from valve drive pin #7 to plug A pin #18 in platform control console.
3. Loose or broken wire #26 in Cable A or its connectors.
4. Loose or broken wire #26 from base plug A pin #18 to turret harness plug pin #8.

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5. Loose or broken wire #26 or #02 from turret harness plug to brake valve 3H-26.
6. Defective brake valve coil 3H-26.
4.1-44 No Drive and Steer
NOTE
Aerial platform will not drive or steer if it is tilted and off limit
switches.
1. Loose or broken wire #51 or #02 from base terminal block to relay 51CR.
4. Loose or broken wire #09A from relay 51CR to base plug A pin #7.
5. Loose or broken wire #09A in cable A or its connectors.
6. Loose or broken wire #09A from plug A pin #7 to drive joystick A2 in platform control console.
7. Loose or broken wire #02 from platform terminal block to drive joystick A2.
4.1-45 No Forward Drive

1. No output on “D” when forward is selected on drive joystick A2.
- See drive joystick test procedure in section 5.
2. Loose or broken wire ”D-signal” from drive joystick A2 to valve driver pin #27.
3. No output from valve driver pin #34 to wire #16.
- Check pin #34 for minimum 2 volts. If no voltage present with foot on footswitch check section
4. Loose or broken wire #16 from valve driver pin #34 to resistor R4.
- Check resistor for 30 ohms. If no resistance found replace resistor.
6. Loose or broken wire #16 from resistor R4 to plug A pin #13 in platform control console.
7. Loose or broken wire #16 in cable A or its connectors.
9. Loose or broken wire #16 or #02 from turret harness plug to forward drive valve 3H-16.
10. Defective forward drive valve coil 3H-16.

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4.1-46 No Reverse Drive

1. No output on “D” when forward is selected on drive joystick A2.
- See drive joystick test procedure in section 5.
2. Loose or broken wire ”D-signal” from drive joystick A2 to valve driver pin #27.
3. No output from valve driver pin #23 to wire #15.
- Check pin #23 for minimum 2 volts. If no voltage present with foot on footswitch check section
4. Loose or broken wire #15 from valve driver pin #23 to resistor R3.
- Check resistor for 30 ohms. If no resistance found replace resistor.
6. Loose or broken wire #15 from resistor R3 to plug A pin #12 in platform control console.
9. Loose or broken wire #15 or #02 from turret harness plug to reverse drive valve 3H-15.
10. Defective reverse drive valve coil 3H-15.
4.1-47 No High Speed Drive

NOTE
Aerial platform must be level and boom must be below 15 degrees
and fully retracted for high speed drive.
1. Loose or broken wire #09 from base terminal block to limit switch LS2.
2. Open or defective limit switch LS2.
- Ensure boom is below 15 degrees. Adjust switch if required. Check continuity through switch.
Replace if required.
3. Loose or broken wire #29 from limit switch LS2 to base terminal block.
4. Loose or broken wire #29 from limit switch LS2 to base plug A pin #20.
6. Loose or broken wire #29 from plug A pin #20 to limit switch LS3 in platform control console.
- Ensure boom is fully retracted. Adjust switch if required. Check continuity through switch.
Replace if defective.
8. Loose or broken wire #59 from limit switch LS3 to platform terminal block.
9. Loose or broken wire #59 from platform terminal block to plug B pin #13.

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11. Loose or broken wire #59 from base plug B pin #13 to base terminal block.
12. Open or defective diode D59 in base terminal block.
13. Loose or broken wire #59 from platform terminal block to valve driver pin #31.
14. Defective valve driver channel input for high drive enable.
- See section 5 for test procedure on valve driver.
15. Loose or broken wire #59 from platform terminal block to torque switch S48.
16. Open or defective torque switch S48.
- Check continuity through switch while activating low torque function between wires #59 and
17. Loose or broken wire #45 from torque switch S48 to plug B pin #9 in platform control console.
18. Loose or broken wire #45 in cable B or its connectors.
19. Loose or broken wire #45 from plug B pin #9 in base terminal block.
21. Loose or broken wire #45 or #02 from turret harness plug to 2 speed valve 3H-45.
22. Defective 2 speed valve 3H-45.
4.1-48 No Elevated Drive

NOTE
Aerial platform must be level to drive elevated.
1. Loose or broken wire #09 or #02 from base terminal block to level sensor TS1.
2. Misadjusted, no output or defective level sensor TS1.
- Adjust level sensor if required. Check for 12 volts on wire #28 with drive activated. If no voltage
present or if defective, replace level sensor.
3. Loose or broken wire #28 from level sensor TS1 to base terminal block.
4. Open or defective diode D28 in base terminal block.

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4.1-49 No Left Steer

NOTE
function only.
1. Loose or broken wire #24 from drive joystick A2 to platform terminal block.
3. Loose or broken wire #24 from platform terminal block to relay 17ACR1.
4. Defective N/C contacts in relay 17ACR1.
5. Loose or broken wire #24A from relay 17ACR1 to plug A pin #17 in platform control console.
6. Loose or broken wire #24A in boom cable A or its connectors.
7. Loose or broken wire #24A from base plug A pin #17 in base terminal block.
8. Loose or broken wire #24A from base terminal block to turret harness plug pin #7.
9. Loose or broken wire #24A or #02 from turret harness plug to left steer valve 4H-24A.
10. Defective left steer valve coil 4H-24A.
4.1-50 No Right Steer

NOTE
function only.
1. Loose or broken wire #23 from drive joystick A2 to platform terminal block.
3. Loose or broken wire #23 from platform terminal block to relay 17ACR2.
4. Defective N/C contacts in relay 17ACR2.
5. Loose or broken wire #23A from relay 17ACR2 to plug A pin #16 in platform control console.
6. Loose or broken wire #23A in boom cable A or its connectors.
7. Loose or broken wire #23A from base plug A pin #16 to base terminal block.
8. Loose or broken wire #23A from base terminal block to turret harness plug pin #6.

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9. Loose or broken wire #23A or #02 from turret harness plug to right steer valve 4H-23A.
10. Defective left steer valve coil 4H-23A.
4.1-51 Direction Sensing Inoperative

1. Loose or broken wire #09 from base terminal block to limit switch LS1.
- Adjust limit switch if required. Check continuity through switch. Replace if defective.
3. Loose or broken wire #17 from limit switch LS1 to base terminal block.
4. Loose or broken wire #17 from base terminal block to base plug A pin #14.
6. Loose or broken wire #17 from base plug A pin #14 to valve driver pin #15 in platform control
console.
7. Defective valve driver channel input for direction sense enable.
- See section 5 for test procedure on valve driver.
4.1-52 Steer Direction Sensing Inoperative

1. No output on valve driver pin #4 to wire #17A.
2. Loose or broken wire #17A from valve driver pin #4 to relays 17ACR1 and 17ACR2.
3. Loose or broken wire #02 from platform terminal block to relays 17ACR1 and 17ACR2.
4. Defective relays 17ACR1 and 17ACR2.
NOTE
If only one relay is bad and one is OK, you will have steer in one di-
rection only.

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Hydraulic System
4.2-1 All Controls Inoperative

1. Broken or defective drive pump shaft or coupling.
- Check pump shaft and coupling. Replace if defective.
2. Hydraulic oil level low.
- Check oil level. Fill to proper level.
4.2-2 All Boom Functions Inoperative

1. Open or defective dump valve 2H-21A.
- Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as
required.
2. Stuck or defective relief valve RV8.
- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as
required.
3. System pump P2 out of adjustment or is defective.
- Refer to section 5 for pump set up procedure. Replace if defective.
4. Defective load sense adjusting valve 3H-V2.
- Check valve. Replace if defective.
5. Defective pressure compensator valve 3H-V1.
6. Plugged or defective high pressure filter F2.
- Check filter. Replace if plugged or defective.
4.2-3 No Main Boom Up

1. Stuck or defective lift up valve 4H-14.
- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective shuttle valve SV4.
required.
3. Stuck or defective check valve CV8.
required.
4. Stuck or defective counterbalance valve CB5.
- Clean valve. Check O-rings on valve. Repair or replace valve as required.
5. Defective lift cylinder C1.
- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-4 No Main Boom Down

1. Stuck or defective lift down valve 4H-13.
required.
required.
5. Defective lift cylinder C1.

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Hydraulic System (Continued)
4.2-5 No Turret Rotate Left

1. Stuck or defective rotate left valve 4H-32.
required.
required.
- Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as
required.
required.
7. Turret rotate brake BR2 not releasing.
- Inspect brake for worn seals or broken components. Repair and replace as necessary.
8. Worn or defective swing drive motor M2.
-
4.2-6 No Turret Rotate Right
1. Stuck or defective rotate right valve 4H-33.
required.
required.
required.
required.
7. Turret rotate brake BR2 not releasing.
- Inspect brake for worn seals or broken components. Repair and replace as necessary.
8. Worn or defective swing drive motor M2.

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4.2-7 No Boom Extend

1. Stuck or defective boom extend valve 4H-39.
required.
required.
required.
6. Defective extension cylinder C2.
4.2-8 No Boom Retract

1. Stuck or defective boom extend valve 4H-38.
required.
required.
required.
6. Defective extension cylinder C2.
-
4.2-9 No Jib Up
1. Stuck or defective proportional flow enable valve 2H-42.
required.
required.
3. Stuck or defective jib up valve 4H-35.
5. Defective jib cylinder.

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4.2-10 No Jib Down

required.
required.
3. Stuck or defective jib down valve 4H-34.
5. Defective jib cylinder.
-
4.2-11 No Platform Rotation Right
required.
required.
3. Stuck or defective rotate right valve 4H-37.
5. Defective rotary actuator RA1.
- Check actuator. Repair or replace as necessary.
-
4.2-12 No Platform Rotation Left
required.
required.
3. Stuck or defective rotate left valve 4H-36.
5. Defective rotary actuator RA1.
- Check actuator. Repair or replace as necessary.

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4.2-13 Platform will not Level Down

1. Stuck or defective platform level down valve 4H-40.
required.
3. Stuck or defective counterbalance valve CB2 or counterbalance valve CB8.
4. Defective leveling cylinder C3 or slave cylinder C4.
4.2-14 Platform will not Level Up

1. Stuck or defective platform level up valve 4H-41.
required.
3. Stuck or defective counterbalance valve CB1 or counterbalance valve CB9.
4. Defective leveling cylinder C3 or slave cylinder C4.
4.2-15 Brake will not Release

required.
2. Defective or misadjusted pressure reducing valve PR1.
required.
3. Stuck or defective brake valve 3H-26.
required.
required.
5. Defective or misadjusted relief valve RV4.
required.
6. Stuck or defective brake release override valve V1.
7. Bypassing or defective brake hand pump V3.
8. Bypassing or defective brake cylinder BR1.

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4.2-16 Brake will not Engage

1. Brake return spring or defective cylinder.
- Check cylinder. Repair or replace as necessary.
2. Brake valve 3H-26 stuck in shifted position.
3. Brake in axle out of adjustment.
- See section 5 for brake adjustment procedure.
4.2-17 No Drive Forward or Reverse

1. Brake not releasing.
- See “brake will not release” in this section.
2. Defective or misadjusted charge pump relief valve RV3.
required.
3. Plugged or defective charge pump filter F1.
- Check filter. Replace if plugged or defective.
4. Worn charge pump P1A.
- Check pump. Replace if defective.
5. Defective pump displacement control 3H-15 and 3H-16.
- Check control. Replace if defective.
6. Open bypass valve V4.
- Close bypass valve.
7. Drive directional valve 4H-V1 stuck in neutral position.
8. Worn drive pump P1.
- Check pump. Replace if defective.
9. Worn or defective drive motor M1.
- Check motor. Replace if defective.
4.2-18 No Forward Drive

1. Defective pump displacement control 3H-16.
2. Defective or misadjusted drive relief valve RV1.
- See section 5 for drive pump set up procedures.
4.2-19 No Reverse Drive

1. Defective pump displacement control 3H-15.
2. Defective or misadjusted drive relief valve RV2.
- See section 5 for drive pump set up procedures.

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4.2-20 No High Speed Drive

1. Stuck or defective 2 speed valve 3H-45.
required.
2. Defective shift spool in drive motor M1.
- Check motor. Repair or replace if necessary.
4.2-21 No Right Steer

1. Stuck or defective right valve 4H-23A.
2. Stuck or defective check valve CV5 or CV6.
required.
required.
4. Defective steer cylinder C6 for 4WD or C9 for 2WD.
4.2-22 No Left Steer

1. Stuck or defective left steer valve 4H-24A.
2. Stuck or defective check valve CV5 or CV6.
required.
required.
4. Defective steer cylinder C6 for 4WD or C9 for 2WD.
4.2-23 Axle Will Not Oscillate

NOTE
Axle will only oscillate when boom is fully retracted and is no greater
than 15 degress above horizontal.
1. Stuck or defective axle lockout valve 3H-65.

- Clean valve. Replace if defective.
2. One or more counterbalance valves (CB14, CB15, CB16 or CB17) failed to shift or is defective.

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4.2-24 Axle Will Not Lock

NOTE
Axle is in constant float if boom is fully retacted and is below 15 de-
grees of elevation.
1. Axle lockout valve 3H-65 is stuck in shifted position or is defective.

required.
2. Blocked tank port #3 in rotary manifold.
- Ensure port #3 in rotary manifold free flows back to tank.
3. Bypassing or defective axle cylinders C7 and C8.
4. Counterbalance valves (CB14, CB15, CB16 or CB17) out of adjusment or are defective.

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Load Sensing System - CE
4.3-1 Green Power LED is not Flashing

1. Loose or broken wires #60 and #02 at platform terminal block.
- Check for connections. Check for voltage (12V).
2. Load cell has lost its calibration.
- Refer to calibration procedure for recalibration of load cell.
4.3-2 Load Cell red Alarm LED is ON (with platform empty)

4.3-3 Red Error LED is ON

1. Open safety contact circuit.
- Check for connections with wires #161 and #162A at platform terminal block and base terminal
block. Check resistor R6 for 680 ohms.
4.3-4 Load Cell red Alarm LED is OFF (with platform overloaded)
4.3-5 Platform Indicator Light does not turn ON

1. Defective lamp.
- Check lamp. Replace if defective.
3. Load cell circuit not operating.
- Check for connections with wire #02A at pilot light strip and relay 82CR, and wire #82 at
platform terminal block and relay 82CR.
4. Defective load cell.
- Defective if 0V is measured between wire #82 and #02 from platform terminal block.
4.3-6 Audible Alarm does not turn ON

1. Defective alarm BP3.
- Check alarm. Replace if defective.
2. Open or defective diode D118.
3. Load cell circuit not operating.
- Check for connections with wires #02A and #118 at platform terminal block.
4. Defective load cell.
- Defective if 0V is measured between wire #118 and #02 from platform terminal block.
4.3-7 Boom and Drive Functions are Enabled (with boom extended)
1. “Fly IN” limit switch LS3 is not operating properly.
- Check for voltage (0V) between wires #59 and #02 from platform terminal block. If 12V is
measured, check for proper actuation of limit switch. Readjust limit switch if necessary.
2. Defective load cell. Safety contact remains closed.
- Check for voltage (0V) between wires #162A and #02 from base terminal block. Defective if
12V is measured.

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Section 5
Procedures
Table of Contents
General..........................................................................................................................................................................3
Safety and Workmanship..............................................................................................................................................3
Platform
5.1-1 Human Machine Interface (HMI)..........................................................................................................3
5.1-2 User Interface Keys..............................................................................................................................4
OCM Character Functions Charts.......................................................................................................4
OCM Operating Values Chart..............................................................................................................5
5.1-3 How to View OCM Operation...............................................................................................................6
5.1-4 How to Unlock and Modify OCM Settings...........................................................................................6
5.1-5 OCM Pin Voltage Reference................................................................................................................7
Boom
5.2-1 Check Wear Pads..............................................................................................................................11
5.2-2 Shimming Wear Pads........................................................................................................................11
5.2-3 Cable Carrier Repair..........................................................................................................................11
5.2-4 Cable Tension (61T/66T)....................................................................................................................11
5.2-5 Inspection and Replacement of Boom Cables (61T/66T).................................................................12
5.2-6 Installing Cables.................................................................................................................................14
Turret
5.3-1 Check and Replace High Pressure Filter..........................................................................................16
5.3-2 Adjust Turret Rotation Gear Backlash................................................................................................16
5.3-3 Check Swing Drive Motor Gearbox Oil..............................................................................................17
5.3-4 Change Swing Drive Motor Oil..........................................................................................................17
5.3-5 Battery Replacement.........................................................................................................................17
5.3-6 Bolt Torque Procedure.......................................................................................................................18
5.3-7 Electronic Tilt Switch Setup Procedure.............................................................................................19
Tilt Switch Replacement....................................................................................................................19
Reprogramming Existing Tilt Switch..................................................................................................21
Test and Verify Tilt Circuit...................................................................................................................22
Deutz Diesel Engine

5.4-1 Replace Engine Oil and Filter............................................................................................................23
5.4-2 Replace Fuel Filter.............................................................................................................................24
5.4-3 Replace Air Filter................................................................................................................................24
5
5.4-4 Check Engine Belt.............................................................................................................................24
5.4-5 Check Oil Cooler................................................................................................................................24
GM Dual Fuel Engine

5.5-1 GM Map and IAT Sensor (3.0L GM Engine)......................................................................................25
5.5-2 LPG Temperature Sensor (3.0L GM Engine).....................................................................................26

Service and Maintenance Section 5 - Procedures
List of Procedures (Continued)

5.5-3 Throttle Actuator (3.0L GM Engine)...................................................................................................27
5.5-4 Engine Coolant Temperature Sensor (3.0L GM Engine)...................................................................28
5.5-5 ECU Pin Reference Chart (3.0L GM Engine).....................................................................................29
5.5-6 Fuse Block Layout (3.0L GM Engine)................................................................................................30
Hydraulic Tank
5.6-1 Change Hydraulic Tank Filter.............................................................................................................31
5.6-2 Change Hydraulic Oil.........................................................................................................................31
Manifold and Hydraulic Pumps

5.7-1 Hydraulic Brake Pressure Adjustment...............................................................................................32
5.7-2 Hydraulic Standby Pressure Adjustment...........................................................................................33
5.7-3 Hydraulic High Pressure Adjustment................................................................................................34
5.7-4 Hydraulic System Relief Valve Adjustment........................................................................................35
5.7-5 Test Charge Pump Pressure on Drive Pump.....................................................................................36
5.7-6 Test Forward Drive Pressure on Drive Pump.....................................................................................36
5.7-7 Test Reverse Drive Pressure on Drive Pump.....................................................................................37
Axles
5.8-1 Change Oil in Rear Axle(including Front Axle - 61T/66T)..................................................................38
5.8-2 Change Oil in Front Axle (4WD) (40T/45T)........................................................................................38
5.8-3 Check Oil Level in Torque Hub..........................................................................................................38
5.8-4 Check Oil Level in Axle Gearbox.......................................................................................................39
5.8-5 Change Oil in Axle Gearbox..............................................................................................................39
5.8-6 Bleeding Oscillating Axle Cylinders...................................................................................................39
Grease Points
5.9-1 Lubrication.........................................................................................................................................40
Grease Turret Rotation Bearing.........................................................................................................40
Grease Turret Rotation Gear..............................................................................................................40
Grease Cylinder Brackets (40T/45T).................................................................................................41
Grease Drive Axle..............................................................................................................................42
Grease Drive Shaft.............................................................................................................................42
Options
5.10-1 Load Sensing System - CE................................................................................................................44
Verify Proper Operation of the Load Sensing System.......................................................................45
Calibration of Load Sensing System (with “Teach In” Handset).......................................................46

Section 5 - Procedures Service and Maintenance
General
The following information is provided to assist you in the use and application of servicing and maintenance procedures
contained in this chapter.
Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support
is provided.
Platform
5.1-1 Human Machine Interface (HMI)
Maintaining proper calibration is essential for good performance of the aerial platform.
1. Ensure aerial platform is on a firm level surface, and is in stowed position and engine is off.
2. On base control, turn base/off/platform key switch to “ ” platform position.

3. Pull out ” ” emergency stop button.
WARNING
Ensure that you maintain three points of contact to mount/dismount platform.
3. Enter platform and close gate.

WARNING
DO NOT operate any control on platform control console without proper fall protection secured
to designated location in platform. Failure to avoid this hazard could result in death or serious
injury!
WARNING
Ensure that there are no personnel or obstructions in test area and that there is sufficient room
for boom to swing.
4. At platform control, open the cover of the console to access the OCI-1 console.
The OCI-1 has an integrated multi segment, two line display with membrane keys that allow it to be used as the
main interface to system controls and adjustments. the Human Machine Interface (referred to as the HMI) will serve
as your window into the application software to allow the operator to monitor/adjust the following information;
- Active Function Being Used

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

5.1-2 User Interface Keys
MENU 1.0-1 <MENU> enters a new menu screen and/or

1.0 SELECT
1.0-2 <SELECT> select the flashing item.
1.1-1 <MINUS> decreases an adjustable parameter such as

---- ramp time.
1.1
1.1-2 <DOWN> selects the previous item in the current menu’s
list.
1.2-1 <PLUS> increases an adjustable parameter.

1.2
+ 1.2-2 <UP> selects the next item in the current menu’s list.
SAVE 1.3-1 <SAVE> saves the new data to EEPROM (permanent

1.3
memory storage).
---- Simultaneously press <UP> and <DOWN> will reset the HMI to
1.4
+ menu screen 0.
OCM Character Functions Charts
OCM Keypad Function Attribute

Keys Short Form THRESH Threshold
Menu/Select (M/S) RAMPDN Ramp Down
▼/- (-) RAMPUP Ramp Up
▲/+ (+) LOWRNG Low Range
Save/Exit (S/E) MAXOUT Maximum Output
60584AA
OCM Function (Channel) Names

DRIVE REV Fn01A Drive Reverse
DRIVE FWD Fn01B Drive Forward
ROTATE L Fn02A Turret Rotate Left
ROTATE R Fn02B Turret Rotate Right
BOOM DOWN Fn03A Main Boom Down
BOOM UP Fn03B Main Boom Up
FLY IN Fn04A Boom Telescope Retract
FLY OUT Fn04B Boom Telescope Extend
PROP FLOW Fn05A Jib and Platform Rotate
PROP FLOW Fn05B Unused Channel
60585AA

OCM Operating Values Chart
Input Expected Value Description

AI 1 0.5V to 8.5V Drive Joystick
AI 2 0.5V to 8.5V Turret Rotation Joystick
AI 3 0.5V to 8.5V Boom Elevation Joystick
AI 4 0.5V to 7.5V Flow Enable Rotary Potentiometer
DI 1 0 or 1 Direction Reverse Limit Sw.

DI 2 0 or 1 Footswitch Actuated
DI 3 0 or 1 Telescope Out Toggle Switch
DI 4 0 or 1 Telescope In Toggle Switch
DI 5 0 or 1 Jib Toggle Enabled
DI 6 0 or 1 Platform Rotation Toggle Enabled
DI 11 0 or 1 High Speed Drive Enable Limit Switch
Adjustable
Output Description
Parameter
PWM 1 25 to 75% Drive Reverse
PWM 2 25 to 75% Drive Forward
PWM 3 21 to 35% Turret Rotate Left
PWM 4 21 to 35% Turret Rotate Right
PWM 5 21 to 35% Main Boom Down
PWM 6 38 to 47% Main Boom Up
PWM 7 0 to 100% Jib and Platform Rotate
PWM 11 40 to 48% Boom Telescope Retract
PWM 12 45 to 70% Boom Telescope Extend
Output Expected Value Description

DOUT 1 0 or 1 Steering Reverse Relay
DOUT 2 0 or 1 Load Sense Valve Enable
DOUT 3 0 or 1 Footswitch Actuated Indicator
DOUT 4 0 or 1 Holding Brake OFF (Energize to release)
DOUT 5 0 or 1 Manual Platform Level Enable
60583AB

5.1-3 How to View OCM Operation

As a joystick or toggle switch is being activated, the OCM screen will display the active function and % output.
Also, the following procedure will allow monitoring of all input and output channels:
Press M/S, <ENTER PASSWORD> is displayed

Press +, two times until <IO TEST> is flashing
Press M/S, <Di> page is displayed, channels Di1 to Di5
Press +, channels Di6 to Di10 are displayed
Press +, channel Di11 is displayed
Press M/S, <Ai> page is displayed, channels Ai1 to Ai3
Press +, channels Ai4 to Ai6 are displayed
Press M/S <Do> page is displayed, channels Do1 to Do5
Press +, channels Do6 to Do8 are displayed
Press M/S, <PWM> page is displayed, channels PWM1 and PWM 2
Press +, channels PWM3 and PWM4 are displayed
Press M/S, <VDD POWER SUPPLY> is displayed
Press M/S, <8v SENSOR SUPPLY> is displayed
Press S/E, two times to return to <RUN MODE>
See OCM Operating Values Chart on page 5 for operating valves for the previous observations.
5.1-4 How to Unlock and Modify OCM Settings

Press +, Part Number and Serial Number are displayed
Press + again, <UNLOCK SETUP?> is displayed
Press M/S, <ENTER PASSWORD> is displayed
Press + until “7” is flashing in first column
Press M/S
Press + until “5” is flashing in second column
Press M/S
Press + until “5” is flashing in third column
Press M/S, <SETUP UNLOCKED PRESS - OR +> is flashing
Press +, <SET DRIVE TIMER PRESS SELECT> is flashing
Press S/E, <RUN MODE: NORMAL> is displayed
Press M/S, <ADJUST> is flashing
Press M/S, <DRIVE REV THRESH> is flashing
Press + or - to toggle through the functions
Press M/S, <THRESH> is flashing
Press + or - to toggle through THRESH/MAXOUT/LOWRNG/RAMPUP/RAMPDN
When <LOWRNG> is flashing, press M/S, <XX.X%> is flashing
Press + or - to increase or decrease the value
Press S/E to Save the value
Press S/E to exit THRESH/MAXOUT/LOWRNG/RAMPUP/RAMPDN
Press S/E to exit function screen
Press S/E to enter RUN MODE
Cycle power to the OCM with the E-Stop to re-enable password protection.

5.1-5 OCM Pin Voltage Reference
1 12
13 23
24 35
All voltages given are with OCM controller at maximum % adjustable settings.
All voltages should be tested with key on, engine off and foot switch depressed.
All tests should be performed with platform over drive axle, boom fully stowed and on flat level surface.
Pin 1 - 12 volt input from wire 4.

Test between pin 1 and 02 wire.

Pin 3 - 8 volt output (purple wire) to boom speed controller.

7.5 volts= speed control in circuit.
Pin 4 - Turret position. 12 volt output on wire 17A to relays 17ACR1 and 17ACR2 for directional sensing.
0 volts= Platform over drive axle.
12 volts= Platform over steer axle.
Pin 5 - 12 volt output on wire 20B to load sense dump valve when any function selected.
Test between pin 5 and 02 wire while selecting a function.
Pin 6 - 12 volt output on wire 08B to boom function enable relay 08BCR.
Pin 7 - 12 volt output on wire 26 to brake valve 3H-26 to release brakes.

Pin 8 - Boom down selected. Proportional output on wire 13 to boom down valve 4H-13.
0 volts to 4.85 volts depending on position of joystick. Threshold= 1.5 volts.
Test between pin 8 and 02 wire while operating boom down.
Pin 9 - Not used.

Pin 10 - Turret rotate right selected. Proportional output on wire 33 to turret rotate right valve 4H-33.
0 volts to 5 volts depending on position of joystick. Threshold= .5 volts.
Test between pin 10 and 02 wire while operating turret rotate right.
Pin 11 - Telescope in selected. Proportional output on wire 38 to telescope in valve 4H-38.

0 volts to 4.65 volts depending on boom speed control potentiometer.
Threshold= .95 volts.
Test between pin 11 and 02 wire while operating telescope in.
Pin 12 - 12 volt output on wire 90A to manual platform level switch.

No voltage will be present if boom up or down function is activated.


Pin 15 - Turret position. 12 volt input from wire 17 (limit switch LS1).
0 volts= Platform over drive axle.
12 volts= Platform over steer axle.
Test between 15 and 02 wire.
Pin 16 - Foot switch activated. 12 volt input from wire 08A.

Pin 17 - Telescope out selected. 12 volt input from wire 39A.

Pin 18 - Telescope in selected. 12 volt input from wire 38A.

Pin 19 - Turret rotate left selected. Proportional output on wire 32 to turret rotate left valve 4H-32.
0 volts to 5 volts depending on position of joystick. Threshold= .5 volts.
Test between pin 19 and 02 wire while operating turret rotate left.
Pin 20 - Platform rotate or jib function selected. Proportional output on wire 42

to proportional flow enable valve 2H-42.
0 volts to 3.85 volts while operating platform rotate depending on boom speed control
potentiometer position. Threshold= 2.3 volts.
0 volts to 9 volts while operating jib function depending on boom speed
control potentiometer position. Threshold= 2.3 volts.
Pin 21 - Telescope out selected. Proportional output on wire 39 to telescope out valve 4H-39.
0 volts to 6.8 volts depending on boom speed control potentiometer
position. Threshold= .95 volts.
Test between pin 21 and 02 wire while operating telescope out.
Pin 22 - Boom up selected. Proportional output on wire 14 to boom up valve 4H-14.

0 volts to 6.3 volts depending on joystick position. Threshold= 1.5 volts.
Test between pin 22 and 02 wire while operating boom up.

Pin 23 - Reverse drive selected. Proportional output on wire 15 to reverse drive valve 3H-15.
Test between pin 23 and 02 wire while operating reverse drive.
Pin 24 - Battery negative. Wire 02.
Pin 27 - Accelerator input. Wire D from drive joystick controller.

Neutral position= 4.2 volts to 4.8 volts.
Forward function= 4.9 volts to 8.5 volts.
Reverse function= 4.1 volts to .5 volts.
Pin 28 - Turret rotate input. Wire X from boom joystick controller.

Rotate right function= 4.9 volts to 8.5 volts.
Rotate left function= 4.1 volts to .5 volts.
Pin 29 - Boom elevation input. Wire Y from boom joystick controller.

Boom up function= 4.9 volts to 8.5 volts.
Boom down function= 4.1 volts to .5 volts.
Pin 30 - Accelerator input. Signal wire (green wire) from boom speed controller.
Proportional voltage. .5 volts= slow speed up to 7.5 volts= fast speed.
Test between pin 30 and 02 wire while operating telescope in/out, jib up/down or basket rotate.
Pin 31 - 12 volt input from wire 59. From LS2 boom elevation limit switch and LS3 telescope limit switch.
12 volts= full speed. 0 volts= creep speed (one or more limit switches open).
Pin 32 - Platform rotate enable. 12 volt input from wire 36A.

Pin 33 - Jib function enable. 12 volt input from wire 34A.

Pin 34 - Forward drive selected. Proportional output on wire 16 to forward drive valve 3H-16.
Test between pin 34 and 02 wire while operating forward drive.
Pin 35 - Not used.

Boom 5.2-3 Cable Carrier Repair

The cable carrier can be repaired by simply using a
5.2-1 Check Wear Pads screwdriver. Each crossbar can be snapped off from
1. Ensure aerial platform is on a firm level either side of the chain either by hand or by using the
surface and is in stowed position. screwdriver as a lever. New crossbars may be installed
by snapping links together.
2. Start engine from base control console.
3. Raise main boom to a comfortable working
height (chest high), and then extend fly
boom approximately 1 foot (30 cm). Female Side
4. Measure the thickness of each wear pad and
replace wear pad if it is less than 7/16 inches
(11 mm)
5. If wear pad is within specified thickness,
shim as necessary.
Male Side
5.2-2 Shimming Wear Pads
1. Ensure aerial platform is on a firm level
surface and is in stowed position. Crossbar
2. Raise main boom to a comfortable working

height (chest high) and extend fly boom until Cable Carrier Assembly
wear pad are accessible.
3. Loosen wear pad fasteners. 5.2-4 Cable Tension (61T/66T)
4. Shim as necessary to obtain zero to 1. Loosen outer nut.
1/32”clearance and zero drag. 2. Tighten inner nut until no gaps are shown in
between springs.
3. Tighten same nut with half a turn.
Fly Boom 4. Tighten outer nut to secure inner nut.
5. Repeat step 1-4 for all cable ends with
gaps.
Inner Nut Disc Springs

1/32” Feeler Outer Nut
Gauge Cable
Shim With Gaps No Gaps

Wear Pad
Cable Disc Springs
Shim & Feeler Gauge
6. Extend and retract fly boom through the

entire range of motion and observe for loose
points.
Note
Always maintain squareness between the
boom’s outer and inner tubes.

5.2-5 Inspection and Replacement of Boom 7. Loosen all four cables at anchor points.
Cables (61T/66T) 8. Remove all fasteners on flanges.
This inspection procedure involves completely removing
the boom cable from the boom arm assembly and 9. Remove cable support weldment flanges
visually inspecting the cable for wear and tear, and with 2 long bolts (minimum 2” long) and tap
then replacing boom cable if necessary. This inspection out pin.
precedure must be done once at the start of the first 7th
year of boom cable life, and then every 2 years if boom
cable is not replaced.
1. Ensure aerial platform is on flat level

ground.
2. Raise/lower boom to horizontal level.
3. Extend/Retract boom to align flanges with
boom holes.
10. Remove extension cylinder flange pins from

boom.
4. Install alignment bracket using side upper

wear pad bolt holes.
11. Remove link pin of link weldment at turret

end of boom.
5. Turn engine off. Add a support underneath

boom. Leave a 2” gap between boom and
support.
6. Remove center cowling from turret.
12. Lift up link weldment to access hydraulic

hoses. Disconnect hydraulic hoses from
extension cylinder, cap hoses and plug
cylinder manifold connections.
13. Remove hydraulic hoses from link weldment
bracket.
14. Slowly pull out extension cylinder assembly
from the rear of turret until cylinder end
passes boom counterweight.

15. Remove link pin of link weldment at cylinder

end.
19. Continue to pull out cylinder to about 2/3 of

Warning the way.
Carefully lift link weldment from boom. 20. Pull cable support weldment past mid boom
pulleys.
16. Remove upper cable from anchor points at CAUTION
turret end of boom.
Avoid cable entanglement with other
components while removing extension
cylinder.
21. Remove mid boom pulleys from boom.
17. Pull out extension cylinder, along with upper

cables, to about 1/3 of the way.
CAUTION
22. Remove lower cables from anchor points at
Avoid cable entanglement with other platform end.
components while removing extension
cylinder.
18. Remove mid boom cable stops from mid

boom.

23. Remove extension cylinder and cables from

boom.
CAUTION
Slightly lift mid boom at turret end to al-
low lower cables to be pulled out from
underneath of boom.
24. Lower extension cylinder onto suitable

supports.
25. Remove cable stop and cables from
extension cylinder pulley. 5. Align lower cables to mid boom pulleys and
attach cable stops to mid boom pulleys.
26. Replace old cables with new cables and

reattach cable stop.
5.2-6 Installing Cables 6. Feed lower cables further into boom and
1. Lift extension cylinder and position it to be secure at anchor points.
inserted at turret end of boom.
2. Slightly lift mid boom and feed lower cables
between mid and main boom weldment from
turret end of boom to platform end.
3. Attach mid boom pulleys to mid boom.
CAUTION
Avoid cable entanglement with other
components while inserting extension
cylinder.
4. Orient the cable support weldment to proper
position and push extension cylinder rod
7. Insert extension cylinder 2/3 of the way, and
end and cable support past the mid boom
then attach upper cables to anchor points at
pulleys.
turret end of boom.

15. Remove alignment bracket.

16. Tighten cable anchors to reduce slack.
8. Fully insert extension cylinder into boom.
9. Install extension cylinder flange pins.
10. Install cable support weldment flange pins.
11. Install link pin of link weldment at cylinder
end.
12. Lift up link weldment to access cylinder

manifold.
13. Attach hydraulic hoses through link weldment
bracket and reconnect hoses to cylinder
manifold.
14. Install link pin of link weldment at turret end
of boom.

Turret
5.3-1 Check and Replace High Pressure Filter

2. Inspect filter restriction indicator gauge. (The
filter should be operating with the gauge Swing Drive Motor
pointing to the green area. If it is in the red
area, the filter needs to be replaced)
3. Turn engine off.
4. Place a suitable container under filter.
Mount Fastener
Head
Adjustment Bolt & Nut

Filter
Swing Drive Assembly
Housing
2. Loosen mounting fasteners on the swing
drive motor.
3. Push the swing drive motor towards the
Bolt turret as close as possible. (this will push
the rotation gear into the rotation bearing)
v High Pressure Filter 4. Loosen lock nut on adjustment bolt.
5. Using a 30 mm box wrench, loosen bolt and 5. Tighten adjustment bolt clockwise until it
remove high pressure filter housing from contacts the plate of gearbox.
filter head.
6. Turn adjustment bolt ½ turn counterclockwise,
6. Remove high pressure filter from filter head then tighten lock nut on adjustment bolt.
and install a new high pressure filter.
7. Pull swing drive motor away from turret until
7. Apply hydraulic oil to the o-ring on the high it contacts the adjustment bolt.
pressure filter housing.
8. Tighten mounting fasteners on swing drive
8. Reinstall filter and re-tighten bolt. For torque motor.
specification, refer to section 2.
7. Rotate turret through an entire rotation and
check for a smooth rotation of the turret.
5.3-2 Adjust Turret Rotation Gear Backlash
The swing drive motor is located in the engine com-
partment.
Note
The adjustment of the backlash must be
performed on a flat level surface.

surface.

5.3-3 Check Swing Drive Motor Gearbox Oil • Change Brake Oil
1. Remove gearbox fill plug. 1. Remove plug at fill port.
2. Place suitable container under drain port.
2. Check oil level (oil level should be slightly 2. Remove plug at drain port to drain the oil.
below the plug, see below). Add oil if needed.
For oil specification, Refer to section 2. 3. Reinstall the drain plug.
4. Refill brake with hydraulic oil (2.7oz, VG32)
5. Reinstall plug at fill port.
5.3-5 Battery Replacement

1. Turn main power disconnect switch to off
Fill to here position.
Battery Anchor Plate
Gearbox Fill Port Nuts
5.3-4 Change Swing Drive Motor Oil

Battery Rods
Note
Oil change must be performed on a flat
level surface.
Battery Pad
Brake Fill
Port
Gearbox Fill
Brake Drain Port
Port 1 Battery Assembly
Gearbox Drain
Port 2. Remove positive and negative connector
from battery.
3. Remove the battery.
4. Replace battery pad if needed.
Gearbox Ports 5. Replace and secure the battery.
• Change Gearbox Oil 6. Clean terminal posts and clamps of battery,
1. Remove plug at fill port. and apply acid-free and acid-resistant
2. Place suitable container under drain port. grease.
3. Remove plug at drain port to drain the oil. 7. Re-connect battery with the positive and
negative connector cables. (Ensure the
4. Reinstall the drain plug.
clamps make good contact)
5. Refill gearbox with oil (32oz, 80W90)
6. Reinstall plug at fill port.

5.3-6 Bolt Torque Procedure Turret Rotation Gear Bolt Torque Sequence
Maintaining proper torque is essential to safe aerial plat- 1. Ensure aerial platform is on a firm level
form operation. Improper bolt torque could result in an surface and is in stowed position.
unsafe operating condition and component damage. 2. Turn main power disconnect switch to off
position.
Rotary Actuator Bolt Torque Sequence
1. Ensure aerial platform is on a firm level 3. Set the torque wrench to 100 ft.ib (140 ft.Ib
surface and is in stowed position. for 61TT/66T) and tighten mounting bolts in
a cross pattern sequence.
2. Turn main power disconnect switch to off 1
position. 20 5
16 9
3. Set the torque wrench to 17 ft.Ib and 20
1
5
12 13
tighten mounting bolts in a cross pattern 16
14
18 22 4
8
9
sequence. 8 12 6
10 12
16 13
17
18 22 4 20
2 14 8
10 12
48 23 17
3
6 16
1 19
2
120
15 5
4
18 23 73
8 5 11 9
19 7 13 1
3 21 17
14 15 5
18 11 7
11 9
7 13
10 3 21 17 15
14 11
4 3 6 19
2
10 15
6 19
2
7
6
2
Bolt Torque Sequence (40T/45T)
Bolt Torque Sequence 20

1
5
4. Set torque wrench to 35 ft.Ib and tighten 16

20
1
5
9
mounting bolts with the same sequence. 12 16 1 2 3 9

13 13
24
5. Torque the center bolt to 480 ft.lb. 23 2
14
12 1 3
13 13
24 15
22 17
8
23 14
12 7
22 15 17
8
4 11 8 3
12 7
10 9
4 11 8 3
18 7
18 19
10 9
17 20
18 7
18 16 21 19
14 11
6 5 4
17 20
16 21
14 11
10 6 4 15
5
6 19
10 2 15
6 19
2
Bolt Torque Sequence (61T/66T)
4. Set torque wrench to 205 ft.Ib (280 ft.Ib for

61T/66T) and tighten mounting bolts with
the same sequence.

5.3-7 Electronic Tilt Switch Setup Procedure

The following information is supplied for replacement
or reprogramming of the electronic tilt switch. Also in-
cluded are test and verification instructions. Follow the
appropriate procedures below.
Tilt Switch Replacement
Y AXIS
X AXIS
7. Install new switch to mount and connect switch
plug to 4 pin connector.
NOTE
The tilt circuit is only powered when controls
are powered up.
7. Turn main disconnect switch to “ ” ON position.
8. Turn base/off/platform key switch to “ ” base

position.
9. Pull out “ ” all emergency stop buttons.

1. Ensure aerial platform is parked on a firm level
10. Verify switch is powered. (Red or green LED will
surface.
be continually blinking)
2. Fully lower platform and retract fly boom.
3. Chock or block wheels to keep the aerial platform

from rolling forward or backward. Red LED Red LED
Green LED Green LED
4. Push in “ ” emergency stop buttons and turn
main disconnect switch to “ ” off position. 11.
Program the Tilt Switch
5. Disconnect tilt switch from 4 pin connector. a. Press and release the set up button 3 times.
Observe LED flash codes as shown below.
Note
Ensure part number of old and new tilt b. Only the red LED will
switch are the same. blink for 4 seconds.
Red LED
6. Remove old tilt switch from mount. Green LED

c. Both LEDs will f. The green LED

flash for 1 second. will turn on solid.
Results: The switch is Red LED Results: The switch Red LED
learning the new zero Green LED is ready for normal Green LED
position. operation.
d. Both LEDs will turn 12. Turn main disconnect switch to “ ” off position
on solid for 1 second.
Results: The new zero Red LED
13. Push in “ ” emergency stop buttons.
Green LED
position has been
learned. 14. Remove chock or wheel blocks.
e. The green LED will flash and then the 15. Proceed to Test and Verify Tilt Circuit - Telescopic
red LED will turn on solid for 2 seconds. Booms.
Red LED Red LED

Green LED Green LED
Results: The switch is verifying the new zero

position.

Reprogramming Existing Tilt Switch b. Both LEDs will flash.
Set up button is located on this Red LED

Light Indicators face next to harness Green LED
IMPORTANT
Step “c” must be completed within
R
Gre ed LE
en
LE
D a 5 second period or the switch will
D
automatically exit program mode and
return to normal operation using previously
stored data.
c. Press and release set up button 3 times.
d. If 5 second period has expired prior

completion, repeat Step “a”, “b” and “c”.
1. Ensure aerial platform is parked on a firm level
surface. e. Observe program delay
/ stabilization time. (Only
2. Fully lower platform and retract fly boom. the red LED will blink for Red LED
4 seconds) Green LED
3. Chock or block wheels to keep the aerial platform

from rolling forward or backward. f. Both LEDs will
flash for 1 second.
NOTE Results: The switch is Red LED
The tilt circuit is only powered when controls learning the new zero Green LED
are powered up. position.
4. Turn main disconnect switch to “ ” ON position. g. Both LEDs will turn

on solid for 1 second.
Red LED
5. Pull out “ ” all emergency stop buttons. Results: The new Green LED
zero position has been
6. Turn base/off/platform key switch to “ ” base learned.
position.
h. The green LED will flash and then the
7. Verify switch is powered. (Red or green LED will red LED will turn on solid for 2 seconds.
be continually blinking)
Red LED Red LED

Green LED Green LED
Red LED Red LED

Green LED Green LED
Results: The switch is verifying the new zero
8. position.
Reprogram the Tilt Switch
i. The green LED
a. Press and hold the set
will turn on solid.
up button for 3 seconds.
Results: The switch Red LED
Results: Both LEDs will Red LED
is ready for normal Green LED
be OFF. Green LED
operation.

Test and Verify Tilt Circuit

9. Turn main disconnect switch to “ ” off
position. Set up button is located on this
Light Indicators face next to harness
10. Push in “ ” emergency stop buttons.
11. Remove chock or wheel blocks.
12. Proceed to Test and Verify Tilt Circuit - Telescopic R

Gre ed LE
Booms. en
LE
D
D
Operations of Tilt Switch

The following describes the LED’s and what they in-
dicate.
Illuminated whenever both tilt

axes are within the specified
degrees of the zero/ home
learned position.
Green LED
Flashes when transitioning in
or out of tilt angle limits, but
built in time delay has not fully
occurred.
Illuminated whenever tilt on one
or more axes is more than the
Red LED
specified degrees out from the
zero/ home position.
On together, no blinking when
Green & Red LED
fault detected.
Tilt Circuit Test
1. Refer to section 2 for test tilt sensor procedure.

Deutz Diesel Engine 4. Pull locking pin down and swing the engine
Maintaining the engine components is essential to good tray away from the turret until it locks in
performance and service life of the aerial platform. place.
5. Place suitable container under engine.
5.4-1 Replace Engine Oil and Filter
6. Remove oil drain plug and allow all engine
Periodic replacement of the engine oil and filter is es-
oil to drain into container.
sential to good engine performance.
7. Install oil drain plug with new seal ring and
NOTE tighten firmly.
Perform this operation after warming the 8. Remove oil filter and catch any escaping
engine to normal operating temperature. oil.
9. Clean inside the filter head.
CAUTION
10. Add clean engine oil to oil filter.
Beware of hot engine components. 11. Apply a thin layer of engine oil to the new oil
Contact with hot engine components filter gasket.
may cause severe burns.
12. Install filter and tighten it by hand.
CAUTION 13. Clean up any oil that may have spilled during
this procedure.
When draining hot oil, there is a risk of
14. Refill engine with new oil as per specifications
scalding. Do not let used oil run into
(Refer to engine manual).
the soil, rather collect it in a container.
Dispose of this in accordance with en- 15. Swing engine tray back to its original
vironmental regulations. position.
16. Reinstall bolts to engine tray.
1. Ensure aerial platform is on a firm level 17. Start engine from base control console and
surface. allow engine to run for 30 seconds then stop
2. Allow engine to warm up. the engine.
3. Remove bolts from engine tray. 18. Check for oil leakage.
19. Check engine oil level on dipstick and add
oil if needed.
Note
Refer to your national/local regulations
on how to dispose of used filter and oil.

5.4-2 Replace Fuel Filter 5.4-4 Check Engine Belt

1. Remove bolts from engine tray. The aerial platform will not operate properly with a
2. Pull locking pin down and swing the engine loose or defective belt. Continuous usage may cause
tray away from the turret until it locks in component damage.
place.
3. Close fuel shut-off valve. WARNING
4. Place suitable container under engine. Do not inspect while the engine is run-
ning. Remove the key to secure from
5. Remove fuel filter and catch any escaping
operation.
fuel.
6. Clean any dirt from filter carrier sealing
CAUTION
surface.
7. Apply a thin layer of oil or diesel fuel to Beware of hot engine components.
rubber gasket of new fuel filter. Contact with hot engine components
may cause severe burns.
8. Install fuel filter and tighten it by hand then
tighten filter cartridge with final half-turn. 1. Inspect the engine belt for:
9. Clean up any fuel that may have spilled • cracking
during this procedure. • glazing
10. Open fuel shut-off valve. • separation
• breaks
11. Check for fuel leakage.
12. Swing engine tray back to its original 2. For correct tension of engine belt, refer to
position. engine manual.
13. Reinstall bolts to engine tray.
5.4-5 Check Oil Cooler
1. Remove cover from the side of engine.
Note
2. Inspect oil cooler for leaks and physical
Refer to your national/local regulations
damage.
on how to dispose of used filter and oil.
3. Clean oil cooler of any kind of debris.
5.4-3 Replace Air Filter 4. Reinstall cover.
Engine specifications require that this procedure be
performed more often if dusty conditions exist. Refer
to engine manual.
CAUTION
Perform this procedure with the engine
off.
1. Remove mounting fasteners from air filter

canister and remove end cap.
2. Remove filters from inside of canister.
3. Clean inside of canister and gasket with a
dry cloth.
4. Insert new filters inside of canister.
5. Reinstall end cap.

GM Dual Fuel Engine

Maintaining the engine components is essential to good performance and service life of the aerial platform.
5.5-1 GM Map and IAT Sensor (3.0L GM Engine)
BLK/LT GRN
1 SENSOR GROUND
YEL/GRY 5 VOLTS
2 INTAKE AIR TEMPERATURE SIGNAL (IAT)
LT GRN/RED
3 5 VOLTS
4 LT GRN
MANIFOLD ABSOLUTE PRESSURE SIGNAL
(MAP)
IAT Sensor Resistance

TEMPERATURE TOLERANCE ±10%
°F OHMS
248 110
239 125
221 162
203 214
185 284
167 383
149 522
131 721
104 1,200
77 2,063
50 3,791
23 7,419
-4 15,614
-22 26,854
-31 35,763
-40 48,153
60597AA

5.5-2 LPG Temperature Sensor (3.0L GM Engine)
A WHITE/RED
5 VOLTS
BLK/LT GREEN
B
SENSOR GROUND
TEMPERATURE SENSOR
Temperature Sensor RESISTANCE
Resistance
DEGREES F OHMS
220 153.7
200 214.6
190 255.4
180 305.5
170 367.3
160 444.1
140 660.6
120 1008
100 1582
80 2554
70 3284
60 4259
40 7357
20 13214
0 24705
-20 48300
-40 99318
60596AA

5.5-3 Throttle Actuator (3.0L GM Engine)
DBW+ PNK/WHT
4
MOTOR
DBW- TAN/ORG
1
TPS1 SIGNAL PPL/LT BLU

6
SENSOR GROUND BLK/LT GRN

2
TPS1 SIGNAL LT BLU/DK BLU

5
5 VOLTS
3 LT GRN/RED

5.5-4 Engine Coolant Temperature Sensor (3.0L GM Engine)
A TAN/WHITE
5 VOLTS
BLK/LT GREEN
B
SENSOR GROUND
TEMPERATURE SENSOR
Temperature Sensor RESISTANCE
Resistance
F OHMS
242.4 101
231.9 121
211.6 175
201.4 209
181.9 302
163.1 434
144.9 625
127.4 901
102.4 1,556
78.9 2,689
49.9 5,576
23.5 11,562
-5.7 28,770
-21.7 49,715
-30.8 71,589
-40 99,301
60595AA

5.5-5 ECU Pin Reference Chart (3.0L GM Engine)
61 75 76 90
31 45 46 60 LOCK TAB
1 15 16 30
Diagnostics Diagnostics
Pin # Wire Color Description Pin # Wire Color Description
1 DK GRN/ORN EGO1 Signal 46 DK BLU/YEL Not used
2 DK GRN/WHT EGO2 Signal 47 YEL/DK BLU Not used
3 EMPTY 48 LT GRN/WHT Output to gasoline temp sensor
4 EMPTY 49 LT GRN/PPL Not used
5 PPL/LT BLUE Throttle position 1 signal 50 LT GRN/BLK Not used
6 LT BLU/DK BLU Throttle position 2 signal 51 GRY/DK BLU Mid throttle input
7 LT GRN MAP Signal 52 GRY/ORN High throttle input
8 TAN/DK GRN Not Used 53 LT BLU Input from oil pressure switch
9 DK BLU/ORN Not Used 54 WHT/LT GRN Signal from gasoline pressure sensor
10 PPL/YEL Not Used 55 DK GRN To diagnostic connector (PC)
11 EMPTY 56 ORN To diagnostic connector (PC)
12 EMPTY 57 EMPTY
13 WHT/ORN Connected to pin #14 below 58 GRY Not used
14 BLU/PNK CAN + to propane regulator 59 EMPTY
15 BLU/WHT CAN – from propane regulator 60 RED/TAN Battery positive
16 EMPTY 61 BRN/LT BLU To injector #1
17 EMPTY 62 BRN/LT GRN To injector #3
18 EMPTY 63 BRN/YEL To injector #4
19 LT GRN/RED 5 volt + from ECU to sensors 64 BRN/WHT To injector #2
20 BLK/LT GREEN 5 volt – to ECU from sensors 65 EMPTY
21 PPL/WHT +V from crank position sensor 66 EMPTY
22 WHT/PPL -V from crank position sensor 67 EMPTY
23 GRY/BRN +V from camshaft position sensor 68 EMPTY
24 PPL/ORN -V from camshaft position sensor 69 BLK Ground from engine block
25 RED/WHT Not used 70 EMPTY
26 RED/BLK Not used 71 WHT/LT BLU Negative supply to power relay 2002CR
27 EMPTY 72 BLK/WHT EGO 1 Heater ground
28 EMPTY 73 BLK/YEL EGO 2 Heater ground
29 EMPTY 74 EMPTY
30 EMPTY 75 WHT/BLK Negative supply to propane lock off
31 YEL Output to igition module 76 EMPTY
32 EMPTY 77 BRN/WHT Not used
33 EMPTY 78 WHT/BRN Not used
34 EMPTY 79 RED/TAN Battery positive
35 EMPTY 80 GRN/YEL To check engine light (MIL)
36 EMPTY 81 BLK Ground from engine block
37 EMPTY 82 PNK/WHT Positive to throttle actuator motor
38 EMPTY 83 TAN/ORN Negative from throttle actuator motor
39 YEL/GRY Output to IAT (part of MAP) 84 TAN/BLK Negative supply to fuel pump relay 56CR
40 TAN/WHT Output to TPS1 85 PNK/YEL Fuel pump excite wire
41 WHT/RED Output to TPS2 86 BLK/RED Negative supply to fuel pump
42 TAN/BRN Propane selected 87 TAN Not used
43 TAN/RED Not used 88 DK BLU Not used
44 TAN/BLK Not used 89 PNK/BLK Negative supply to starter relay 57ACR
45 PNK/TAN 12 volt input 90 EMPTY
60594AB

5.5-6 Fuse Block Layout (3.0L GM Engine)
2002CR 56CR 57ACR

POWER FUEL STARTER
RELAY PUMP RELAY
RELAY
EMPTY F7 F8
5 AMP 20 AMP
VSW ECU
F11 F10
EMPTY 15 AMP 15 AMP
FUEL PUMP IGNITION
F9 F12
10 AMP 15 AMP
F13 60A ALT EPR STARTER

Hydraulic Tank 5.6-2 Change Hydraulic Oil

Maintaining the hydraulic components and hydraulic oil 1. Ensure aerial platform is on a firm level
at the proper level are essential to good performance surface and is in stowed position.
and service life of the aerial platform. 2. Allow hydraulic oil to warm up.
5.6-1 Change Hydraulic Tank Filter
position.
surface, is in stowed position and engine is 4. Place suitable container under the hydraulic
off. tank.
2 Place suitable container under the hydraulic 5. Remove oil drain plug and allow all hydraulic
tank filter. oil to drain into container.
3. Remove oil filter and catch any escaping 6. Install oil drain plug with new seal ring and
oil. tighten firmly.
4. Clean inside the filter head. 7. Refill hydraulic tank with new oil as per
specifications. (Refer to section 2 of this
5. Apply a thin layer of clean hydraulic oil to
manual)
the new oil filter gasket.
8. Check for leakage.
6. Install filter and tighten firmly.
9. Clean up any oil that may have spilled during
7. Clean up any oil that may have spilled during
this procedure.
this procedure.
10. Check hydraulic oil level. (The hydraulic oil
level should be at or slightly above the top
9. Check for leakage. mark on the sight gauge)
Note Note
Refer to your national/local regulations Refer to your national/local regulations
on how to dispose of used filter and oil. on how to dispose of used filter and oil.
Note
Samples of hydraulic oil should be drawn
from the reservoir and tested annually.
These samples should be taken when the
oil is warmed through normal operation
of the system. The sample should be
analyzed by a qualified lubrication
specialist to determine if it is suitable for
continued use. Oil change intervals will
depend on the care used in keeping the
oil clean, and the operating conditions.
Dirt and/or moisture cotamination will
dictate that the oil should be changed
more often. Under normal use and
operating conditions, the hydraulic oil
should be changed every two years.
Refer to Table 1.2 of this manual.

Manifold and Hydraulic Pumps 6. Stop aerial platform and adjust pressure
relief valve 1/4 turn at a time by turning
5.7-1 Hydraulic Brake Pressure Adjustment either clockwise to increase pressure or
Maintaining accurate hydraulic brake pressure is impor- counterclockwise to decrease pressure.
tant when it comes to safe aerial platform operation. 7. Repeat step 5 and 6 until brake pressure is
achieved (500 psi).
8. Locate brake system pressure reducing
surface and is in stowed position.
valve and turn valve gently counterclockwise
2. Locate brake system pressure reducing to initial position.
valve and turn valve gently clockwise until it
9. Drive aerial platform forward or reverse.
bottoms out.
(Pressure gauge reading should be
Note 450 psi)
Remember to keep track of how many
10. Stop aerial platform and adjust pressure
revolutions turned.
reducing valve 1/4 turn at a time by turning
either clockwise to increase pressure or
Brake Pressure Relief Valve
counterclockwise to decrease pressure.
11. Repeat step 9 and 10 with brake system
Pressure Gauge pressure reducing valve until brake pressure
Brake Release is achieved (450 psi).
Hand Pump
Brake Release
Brake System Pressure Override Valve
Reducing Valve
Brake Manifold
3. Locate brake pressure relief valve.
WARNING
Ensure that there are no personnel or
obstructions in test area and there is suf-
ficient room for boom to swing.
4. Start engine from platform control console

and extend boom slightly to achieve low
speed drive.
5. Drive aerial platform forward or reverse.
(Pressure gauge reading should be
500 psi)

5.7-2 Hydraulic Standby Pressure Adjustment 5. Locate set screw and adjusting stem on
1. Locate GP Port on main manifold and System Pump.
remove the cap.
Cap
Hose
Pressure Gauge
Set Screw Adjusting Stem
GP Port Main Manifold
System Pump
6. L o o s e n s e t s c r e w h a l f a t u r n
counterclockwise.
7. Adjust system pump pressure by turning
Main Manifold and Pressure Gauge adjusting stem either clockwise to increase
pressure or counterclockwise to decrease
pressure.
2. Connect a pressure gauge (600 psi) to GP
Port. 8. Tighten set screw after pressure is set to
275 psi. (You must steer fully in one direction
3. Start engine from base control console and
to activate pressure reading on gauge.)
let it run for 2-5 minutes.
9. Turn engine off.
4. Check reading on gauge (standard pressure
should be 275 psi) and follow the next steps 10. Remove pressure gauge from GP Port and
for adjusting pressure if needed. cap the port.

5.7-3 Hydraulic High Pressure Adjustment 5. Locate set screw and adjusting stem on
1. Locate GP Port on main manifold and System Pump.
remove the cap.
Cap
Hose
Pressure Gauge
GP Port Main Manifold Set Screw Adjusting Stem
System Pump
6. L o o s e n s e t s c r e w h a l f a t u r n
counterclockwise.
Main Manifold and Pressure Gauge 7. Adjust system pump pressure by turning
adjusting stem either clockwise to increase
2. Connect a pressure gauge (5000 psi) to GP pressure or counterclockwise to decrease
Port. pressure.
8. Tighten set screw after pressure is set to
WARNING
2175 psi (40T/45T), or 3000 psi (61T/66T).
Do not activate any controls during
9. Turn engine off.
procedure to protect gauge.
10. Remove pressure gauge from GP Port and
cap the port.
4. Steer fully to one direction and then check
reading on gauge. Standard pressure
should be 2175 psi (40T/45T), or 3000 psi
(61T/66T). Follow the next steps for adjusting
pressure if needed.

5.7-4 Hydraulic System Relief Valve 6. Locate system relief valve (RV8).
Adjustment
1. To adjust the system relief valve (RV8), you System Relief
are required to temporarily adjust the high Valve
pressure setting on the system pump to
3000 psi. Refer to Procedure 5.7-3.
2. Locate GP Port on main manifold and
remove the cap.
Cap
Hose
System Relief Valve
7. Loosen lock nut on system relief valve.

Turn adjusting stem clockwise to increase
pressure and counterclockwise to decrease
Pressure Gauge
pressure.
GP Port Main Manifold 8. Tighten lock nut on sustem relief valve once
2900 psi (40T/45T), or 3200 psi (61T/66T) is
observed on the gauge. (You must steer fully
in one direction to activate pressure reading
on gauge.)
9. R e s e t s y s t e m p u m p t o 2 1 7 5 p s i
Main Manifold and Pressure Gauge (40T/45T), or 3000 psi (61T/66T). Refer to
Procedure 5.7-3.
3. Connect a pressure gauge (5000 psi) to GP
Port.
5. Steer fully to one direction and then check
reading on gauge. Standard pressure
(61T/66T). Follow the next steps for adjusting
pressure if needed.

5.7-5 Test Charge Pump Pressure on Drive 5.7-6 Test Forward Drive Pressure on Drive
Pump Pump
Note
1. Locate test port beside charge pressure Make sure charge pump pressure test is
filter. completed first.
1. Locate test port 1 on the drive pump.
Test Port
Charge Pressure Filter Test Port 1
2. Connect a pressure gauge (600 psi) to test Drive Pump

port.
3. Start engine from base control console. 2. Connect a pressure gauge (10000 psi) to
4. Check reading on gauge (standard pressure test port 1.
should be 313 ±10% psi.)
WARNING
3. Start engine from platform control console.

4. Unplug brake solenoid power cable (26) on
brake valve.
5. Activate drive function slowly forward with
engine at high speed. Wheels should not
turn.
RV3 Note
Charge Pump Activating drive function too fast will stall
Relief Valve the engine.
Drive Pump
6. Check reading on gauges Standard pressure
5. Replace charge pump relief valve (RV3) if should be 5000 psi (40T/45T), or 4350 psi
pressure is not achieved. (61T/66T). Go to step 8 if pump pressure is
achieved.
6. Repeat steps 2, 3, and 4 after charge pump
relief valve is replaced. 7. Replace pump if pressure is not achieved.
7. if pressure still not in range, repair or replace 8. Turn engine off.
the pump as necessary. 9. Remove pressure gauge from port, cap
the port and re-plug brake solenoid power
cable.

5.7-7 Test Reverse Drive Pressure on Drive

Pump
Note
Make sure charge pump pressure test is
completed first.
1. Locate test port 2 on the drive pump.
Test Port 2
Drive Pump
2. Connect a pressure gauge (10000 psi) to

test port 2.
WARNING

3. Start engine from platform control console.

4. Unplug brake solenoid power cable (26) on
brake valve.
5. Activate drive function slowly reverse with
engine at high speed. Wheels should not
turn.
Note
Activating drive function too fast will stall
the engine.
6. Check reading on gauges Standard pressure

(61T/66T). Go to step 8 if pump pressure is
achieved.
7. Replace pump if pressure is not achieved.
8. Turn engine off.
9. Remove pressure gauge from port, cap
the port and re-plug brake solenoid power
cable.

Axles 5. Remove drain plug to allow oil to drain into

container.
5.8-1 Change Oil in Rear Axle
(including Front Axle - 61T/66T)
position.
3. Place suitable container under the axle
4. Remove fill plug. Fill/Check Port
5. Remove all three drain plugs to allow oil to Drain Port
drain into container.
Front Axle
FIll Port
6. Reinstall drain plug.
Check Port
Note
Axle is filled when oil is leaking from the
check port.
7. Refill axle with new oil as per specifications.

(Refer to section 2 of this manual)
Drain Ports
8. Reinstall fill/check plug.
Rear Axle (shown)
6. Reinstall all drain plugs. 5.8-3 Check Oil Level in Torque Hub
1. Drive the aerial platform to rotate the hub
7. Remove check plug. until the plug is located at 90 degrees.
Note 2. Remove the plug and check the oil level.

Axle is filled when oil is leaking from the The oil level should be even with the
check port. bottom of the plug hole. Add oil if needed.
For oil specification, Refer to section 2 for
8. Refill axle with new oil as per specifications. specifications.
(Refer to section 2 of this manual)
9. Reinstall both fill and check plugs.
5.8-2 Change Oil in Front Axle (4WD) (40T/45T)

position.
3. Place suitable container under the axle. Drive Torque Hub
Fill and Check Drain
4. Remove fill plug.

5.8-4 Check Oil Level in Axle Gearbox 7. Refill gearbox with new oil as per
1. Remove plug 1 from gear box. specifications. (Refer to section 2 of this
manual)
2. Check oil level. Oil level should be even with 8. Reinstall fill/check plug.
the bottom of plug hole 1. Add oil if needed.
(Refer to section 2 for specifications). 5.8-6 Bleeding Oscillating Axle Cylinders
If the axle oscillation system is not operating properly,
the stability of the aerial platform is compromised and
it may tip over.
Items you will need before starting:

• oil container
• hose lines (to reach from bleeders to bucket)
• 10” high ramp
1
1. Locate bleeders on either side of the axle
Gearbox
cylinder.
5.8-5 Change Oil in Axle Gearbox 3. Start bleeding from one side of the aerial
1. Ensure aerial platform is on a firm level platform that will be driven up the ramp.
surface and is in stowed position. 4. Hook up hose line to top bleeder and keep
2. Turn main power disconnect switch to off bottom bleeder capped.
position. 5. Ensure bleeder hose drains oil into container
3. Place suitable container under the when aerial platform is driving.
gearbox. 6. Drive aerial platform up and down the ramp
4. Remove fill plug. until only a continuous stream of fluid is
being released from the bleeders.
5. Remove drain plug to allow oil to drain into
container. 7. Repeat step 6 with the otherside.
8. Ensure bleeders are capped.
Fill/Check Port Drain Port

Gearbox
6. Reinstall drain plug.
Note
Gearbox is filled when oil is leaking from
the check port.

Grease Points
5.9-1 Lubrication
Maintaining proper lubrication is essential for good performance and service life of the aerial platform. If the bearing
and gear of the aerial platform are improperly greased, it could result in component damage.
WARNING
Ensure that there are no personnel or obstructions in maintenance area and there is suffi-
cient room for boom to swing.
Grease Turret Rotation Bearing

1. Ensure aerial platform is on a firm level surface and is in stowed position.
2. Open control compartment and locate grease fitting beside the hydraulic tank.
3. Pump grease into the turret rotation bearing and continue pumping until new lube appears continuously
around the grease seal lip. (Refer to the Race column in the Table below)
4. Rotate the turret in increments of 4 to 5 inches (10 to 13 cm) at a time, and repeat step 3 until the entire
bearing has been greased.
Grease Turret Rotation Gear

1. Apply grease to each tooth of the drive gear, located under the turret. (Refer to the Gear column in the
Table below)
GREASE
Recommended Grease Type

Model
Race Gear
Mobil Mobillux EP2 Mobil Mobiltac C
Texaco Multifax EP2 Texaco Crater 2X or 3X
SJ40T / 45T
Sun Prestige 742 EP Sun Gear Compound 407
SJ61T / 66T
Shell Alvania EP2 Shell Cardium EP
Exxon Ronex WB Exxon Surrett Fluid 30
To Turret Rotation Bearing
Turret Rotation Gear
61T/66T Turret 40T/45T Turret

WARNING
Ensure that there are no personnel or obstructions in maintenance area and there is suffi-
cient room for boom to swing.
Grease Cylinder Brackets (40T/45T)

2. Open control compartment and locate grease fitting beside the hydraulic tank.
3. Pump grease into the four grease fitting. (Refer to the Table below)
*GREASE
Model Recommended Grease Type
Mobil Mobillux EP2

Texaco Multifax EP2
SJ40T / 45T Sun Prestige 742 EP
Shell Alvania EP2
Exxon Ronex WB
* Refer to Service and Maintenance manual for greasing

frequency and procedures.
To Master Cylinder Bracket
*GREASE
Model To Lift Cylinder

Recommended Bracket
Grease Type
Mobil Mobiltac C
Texaco Crater 2X or 3X
SJ40T / 45T Sun Gear Compound 407
Shell Cardium EP
Exxon Surrett Fluid 30

40T/45T Turret

Grease Drive Axle

2. Open axle cover plate and locate grease fitting. (see diagram below)
3. Pump grease into the grease fittings. (Refer to the Table below)
Grease Drive Shaft

1. Locate the grease fittings on the drive shaft and pump grease. (Refer to the Table below)
*GREASE
Model Recommended Grease Type
Mobil Mobillux EP2

Texaco Multifax EP2
SJ40T / 45T
Sun Prestige 742 EP
SJ61T / 66T
Shell Alvania EP2
Exxon Ronex WB

Grease Fitting
*GREASE Grease Fitting
Grease Fitting Model Recommended Grease Type
Mobil Mobiltac C
Texaco Crater 2X or 3X
SJ40T / 45T
Sun Gear Compound 407
SJ61T / 66T
Shell Cardium EP
Exxon Surrett Fluid 30

Grease frequency
Fitting and procedures.
Grease Fitting
Drive Axle

Options
5.10-1 Load Sensing System - CE

The Skyjack boom platform overload sensing system is based on load cell or electronic scale technology. The deck
steel structure is isolated from the aerial platform. The load cell is permanently bolted between the deck and the
rotary actuator mount. The load cell will only respond to the vertical component of the load in the platform. There
are four external bolted connections that serve as a redundant back up system for the load cell connection. The
system is first calibrated with an empty platform to set the tare weight to zero. The following steps of the process
set the overload limit as regulated by applicable safety standards for Mobile Elevated Work Platforms.
Aerial Platform
(Rotary Actuator Mount)
Error LED
Alarm LED Deck
Interface Connector
Zero/Tare LED
Power LED
External Bolts Load Cell Permanent Bolts
Bottom View of Deck
Load Cell
LED Display
“T” Label
Overload Light
“4” Button
Platform Control Console

Indicator Module “Teach in” Handset
(Service only)
Error LED - Continously on when system error
Alarm LED - Continously on when platform is overload or has base contact
Interface Connector - Storage of limit valve (“Teach in” handset connects here)
Orange LED - Continously on when tare value is zero ± 15kg
Green LED - Flashes slowly on when system powered and calibrated
NOTE
When power is turned on and after a four second time period elapses, the overload light and audible
alarm will pulse two times. This indicates the system is active and there are no faults.

Verify Proper Operation of the Load Sensing System
Overload Status Chart
Indicator Load Cell Audible Aerial Platform

Weight
Light LED Display Alarm Functions
Error - OFF Error - OFF

Alarm - OFF Alarm - ON (red)
Error - OFF Error - OFF
Zero/Tare - ON (orange) Zero/Tare - OFF
Alarm - OFF Alarm - ON (red)
Power - FLASHING (green) Power - FLASHING (green)
(Zero) OFF Zero/Tare - ON (orange) Zero/Tare - OFF ENABLED
OFF
Power - FLASHING (green) Power - FLASHING (green)
Error - OFF
Alarm - FLASHING (red)
Error - OFF
Zero/Tare - OFF
Power - FLASHING (green)
Error - OFF- OFF
Zero/Tare Error - OFF
(Work Mode Power--OFF
Alarm FLASHING (green) Alarm - ON (red)
@ 244+) FLASHING Zero/Tare - ON (orange) PULSING
Zero/Tare - OFF
Power - FLASHING (green) Power - FLASHING (green) DISABLED
Error - OFF
Zero/Tare - OFF
(Travel Mode Power - FLASHING (green)
FLASHING PULSING ENABLED
@ 244+)
1. Ensure aerial platform is on firm level ground.
2. Fully “ ” retract and “ ” lower boom.

3. Turn engine “ ” off.
4. Ensure both ” ” emergency stops are pulled out and platform engine enable switch is in “ ” on
position.
Result: Overload indicator light and audible alarm will pulse two times.
5. Ensure platform is unloaded and is free from any surface contact.
Result: Green power LED is flashing, orange LED is ON, red alarm LED is OFF and red error LED is
OFF.
6. Place a 244kg load on platform.
Result: Platform indicator light is flashing, load cell red alarm LED is ON, and audible alarm is
pulsing.
7. On base control console, start engine and extend boom by > 300mm.
Result: All drive and boom function are disabled.
8. Remove load from platform.
Result: All drive and boom function are enabled and all warning indicators are OFF.
Note
Refer to section 4 for load sensing system troubleshooting.

Calibration of Load Sensing System (with “Teach In” Handset)
WARNING
Do not interrupt system power and rest your hand or foot on platform during this procedure.
1. Ensure aerial platform is on firm level ground.
2. Fully “ ” retract and “ ” lower boom.

3. Turn engine “ ” off.
4. Ensure both “ ” emergency stops are pulled out and platform engine enable switch is in “ ” on
position.
Result: Overload indicator light and audible alarm pulse two times.
5. Ensure platform is unloaded and is free from any surface contact.
6. Remove cap from load cell interface connector.
7. Connect “Teach in” handset to interface connector.
Result: The “T” label on handset will flash at a high frequency of 5Hz. If not, recheck that power is on
and handset is properly connected.
WARNING
Do not disconnect handset at any point of the following steps until instructed.
8. On “Teach in” handset, depress “4” button for four seconds.

Result: The “T” label on handset will light on constantly and then flash at a lower frequency of
1.25Hz.
9. Add a test load of 244kg onto the center of platform.
10. Depress “4” button for four seconds.
Result: The “T” label on handset will go from flashing to constantly on.
11. Disconnect “Teach in” handset from interface connector.
12. Wait for four seconds and then add a test load exceeding 244kg to test load sensing system.
Result: On platform control console, the overload light will flash and an audible alarm will pulse.
13. Remove test load from platform.
Result: Green power LED is flashing, orange LED is ON, red alarm LED is OFF, audible alarm is OFF
and red error LED is OFF.
14. Re-cap interface connector and place provided “calibrated” label over interface connector.

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www.skyjack.com

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MODELS SJ 40T SJ 45T

Part No. 143844AE September 2010

Parts (North America)

Skyjack Asia Pacific

Section 1 - Scheduled Maintenance

Section 2 - Maintenance Tables

Section 3 - System Component Identification and Schematics

Telescopic Boom Series SKYJACK, Page 3

SKYJACK, Page 4 Telescopic Boom Series

Service and Maintenance

Schedule Maintenance Inspections

Telescopic Boom Series SKYJACK, Page 5

Aerial Platform Definition

Service & Maintenance

Service Policy and Warranty

For non-standard components or systems, contact the SKYJACK Service Department at

North America & Asia: Europe:

Telescopic Boom Series SKYJACK, Page 7

Scope of this Manual

- Equipment identified with “ANSI” meets the ANSI/SIA A92.5-2006 standard.

b. CSA (Canada), AS (Australia) and CE (Europe)

c. ANSI/SIA (United States)

Operator Safety Reminders

SKYJACK, Page 8 Telescopic Boom Series

Per ANSI A92.5-2006 8.10(7)

As per CSA B354.4-02

Refer to CFR 1910.333 or the authority having jurisdiction.

DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING.

Minimum Safe Approach Distance

Telescopic Boom Series SKYJACK, Page 9

• KNOW all national, state or territorial/provincial

lutely necessary, elevated

• AVOID falling. Stay within the

• DO NOT raise the platform in

SKYJACK, Page 10 Telescopic Boom Series

Safety Precautions (Continued)

• DO NOT operate an aerial • ENSURE that there are no

• DO NOT lower the platform unless the area below

• DO NOT use the aerial

• DO NOT sit, stand or climb on

• DO NOT raise the aerial

• ENSURE ALL tires are in good condition and lug

• DO NOT use the aerial platform without guardrails,

Telescopic Boom Series SKYJACK, Page 11

Safety Precautions (Continued)

• DO NOT attempt to free a snagged platform with

SKYJACK, Page 12 Telescopic Boom Series

Maintenance and Inspection Schedule Maintenance and Service Safety Tips

WARNING Preventive maintenance is the easiest and least

Telescopic Boom Series SKYJACK, Page 13

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

SKYJACK, Page 14 Telescopic Boom Series

About this Section Maintenance Instructions

- Aerial platform parked on a flat and level

• Repair any damaged or malfunction components

Telescopic Boom Series SKYJACK, Page 15

Table 1.1 Owner’s Annual Inspection Record

Model Number: ____________________________ Serial Number: ____________________________

SKYJACK, Page 16 Telescopic Boom Series

Model Number: Serial Number:

Other Other* A+B+C+D+E