Skyjack Service Manual Sj1256 Ths

SERVICE
MANUAL
SJ1044 TH, SJ1044 THS,
SJ1056 TH, SJ1056 THS,
SJ1256 THS
TELEHANDLERS
230790ABA
August 2021
ANSI
SJ1044 TH/THS: 87 210 168 & Above
SJ1056 TH/THS: 87 312 009 & Above
SJ1256 THS: 87 410 638 & Above
Please refer to the website (www.skyjack.com) for other

Serial Numbers, most recent Technical Manuals and USB
software.
Skyjack Service Center Parts & Service (Europe)

3451 Swenson Ave. St. Charles, Unit 1 Maes Y Clawdd
Illinois, 60174 USA Maesbury Road Industrial Estate
Phone: 630-262-0005 Oswestry, Shropshire SY10 8NN UK
Toll Free: 1-800-275-9522 Phone: +44-1691-676-235
Fax: 630-262-0006 Fax: +44-1691-676-238
Email: service@skyjack.com E-mail: info@skyjackeurope.co.uk
Parts (North America) Skyjack Brasil

Toll Free: 1-800-965-4626 Alameda Júpiter, 710
Toll Free Fax: 1-888-782-4825 Loteamento American Park Empresarial
E-mail: parts@skyjack.com Indaiatuba, SP, Brasil 13347-653
Tel: +55 19 3936 0132
Skyjack Australia Pty Ltd.
Unit 1, 35 Honeycomb Drive
Eastern Creek
New South Wales 2766
Australia
Tel: +61 (0) 2 9854 0700
Fax: +61 (0) 2 9854 0777
THIS SAFETY ALERT SYMBOL MEANS ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED.
The Safety Alert Symbol identifies important safety

messages on telehandlers, safety signs in manuals
or elsewhere. When you see this symbol, be alert to
the possibility of personal injury or death. Follow the
instructions in the safety message.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert
against unsafe practices.
IMPORTANT
IMPORTANT indicates a procedure essential for
safe operation and which, if not followed, may
result in a malfunction or damage to the telehandler.
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA
3
Notes
230790ABA SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS
4
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 1 – Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.1 Read and Heed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-1 Telehandler Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-2 Purpose of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-3 Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-4 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-5 Service Policy and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-6 Operator Safety Reminders, Warnings and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-1 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-2 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-3 Maintenance and Service Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Hydraulic System & Component Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3-1 Maintenance Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 About this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4-1 Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4-2 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4-3 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Scheduled Maintenance Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5-1 Labels - A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5-2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5-3 Mirrors - A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5-4 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5-5 Cylinders - A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5-6 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5-7 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5-8 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5-9 Boom - A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5-10 Lifting Attachment - A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5-11 Grease Fittings - B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5-12 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.6 Function Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 2 – Maintenance Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.1 Standard and Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Recommended Fluids/Lubrications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5
2.4 Tire/Wheel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.6 Standard Hose Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.7 Torque Specifications for Fasteners (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.8 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.9 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.10 Air Conditioner Temperature/Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.11 Floor loading pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 41

3.1 Electrical Symbol Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2 Hydraulic Symbol Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3 Electrical Components Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4 Hydraulic Components Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5 Hydraulic Pump and Return Filter Ports Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6 Steering Control Unit Ports Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.7 Service Brake Actuator (Brake Pedal) Ports Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.8 Auxiliary Block Ports Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.9 Joystick Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.10 Premium Joystick Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.11 Premium Joystick Manifold Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.12 Rear Axle Stabilization Manifold Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.13 Outrigger Manifold Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.14 Anti-Cavitation Relief Valve (SJ1256 THS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.15 Major Components Identification and Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.16 Main Manifold Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.17 Enclosed Cab Harness & Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.18 Glow Plug Harness & Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.19 Road Lights Harness & Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.20 Work Lights Harness & Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.21 Boom Lights Harness & Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.22 Beacon Light Harness & Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.23 RAS System Schematic and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.24 Elevate Telematics Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.25 A/C Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.26 Transmission Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.27 Console Harness and Layout 74 HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.28 Console Harness Wiring Diagram 74HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.29 Console Harness and Layout 107 HP - THS Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.30 Console Harness Wiring Diagram 107 HP - THS Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.31 Engine Harness 74 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.32 Engine Harness 74 HP Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.33 Engine Harness Diagram 107 HP - THS Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6
3.34 Engine Harness Wiring Diagram 107 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.35 Chassis Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.36 Chassis Harness Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.37 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.38 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH. . . . . . . . . . . . . . . . . . . . . 88
3.39 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.40 Electrical Schematic 107 HP, Premium Joystick- SJ1044 TH & SJ1056 TH . . . . . . . . . . . . . . . . . . . . 94
3.41 Electrical Schematic - SJ1256 THS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.42 Hydraulic Schematic - SJ1044 TH/THS & SJ1056 TH/THS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.43 Hydraulic Schematic, Premium Joystick - SJ1044 TH/THS & SJ1056 TH/THS . . . . . . . . . . . . . . . . 101
3.44 Hydraulic Schematic - SJ1256 THS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.45 Hydraulic Schematic for Premium Joystick- SJ1256 THS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.2-1 Engine Will Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.2-2 Engine Cranks But Will Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2-3 All Electrical Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2-4 Park Brake Will Not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.2-5 Transmission Will Not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2-6 No Forward Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2-7 No Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2-8 No 1st Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.2-9 No 2nd Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.2-10 No Boom Up, Front Steer Mode Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2-11 Front Steer Mode Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2-12 No 4W (Round) Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2-13 No Crab Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2-14 No Boom Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.2-15 Frame Will Not Tilt Over 40° With Boom Below 40° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.2-16 No Frame Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.2-17 RAS remains fully locked (RAS indicator remains illuminated) . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.2-18 RAS remains locked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.2-19 Function Does Not Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.2-20 Outriggers inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.3 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3-1 All Controls inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3-2 No Boom Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3-3 No Carriage Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.3-4 No Frame Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.3-5 No Aux. functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.3-6 Hard or No Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7
4.3-7 Park Brake will not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.3-8 Park Brake Will Not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.3-9 Service Brake Will Not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.3-10 Outriggers Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.1-1 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.1-2 Engine and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.2 10 Hour or Daily Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2-1 Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2-2 Check Coolant Level, Radiator and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2-3 Check Transmission Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2-4 Check Air Cleaner Restriction and Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2-5 Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.2-6 Drain Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.2-7 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.2-8 Check Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.2-9 Check Tire Pressure and Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.2-10 Check Seat Belt and Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.2-11 Check Windshield Washer Fluid Level and Wiper Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.3 50 Hour or Weekly Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.3-1 Check Fork Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.4 250 Hour or Quarterly Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.4-1 Check Lug Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.4-2 Check Oil Level in Axle Differential Planetary wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.4-3 Check Oil level in Axle differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.4-4 Replace Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.4-5 Change Engine Fuel filter and Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.4-6 Clean Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.4-7 Torque Axle Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.4-8 Inspect Boom Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.4-9 Check Boom Slide Pad Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.4-10 Check Boom Chains Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.4-11 Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.4-12 E-chain and Hoses Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.4-13 Grease Axle Pivot Bearings and King Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.4-14 Grease Drive Shaft U-joints and slip joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.4-15 Grease Frame Level Pivot Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.4-16 Grease Boom Pivot and Boom Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.4-17 Grease Bottom Front & Top Rear Slide Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.5 1000 Hour or Annual Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.5-1 Change Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8
5.5-2 Change Hydraulic Oil and Clean Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.5-3 Change Axle Differential Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.5-4 Change Axle Planetary Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.5-5 Change Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.5-6 Change Transmission Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.5-7 Inspect Boom Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.5-8 Inspect RAS System (Rear Axle Stabilization) Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.6 Non-Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.6-1 Boom Hoses and Sheaves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.6-2 Boom Chains Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.6-3 Slide Pads Replacement Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.6-4 TH Boom Mount Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.6-5 Hydraulic Pressure Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.6-6 Hydraulic Pump Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.6-7 T12000 Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.6-8 Deutz Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.6-9 Starter Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.6-10 Bleeding Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5.6-11 Cable Track Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.6-12 Carrier Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5.7 Electronic Tilt Switch Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5.7-1 Tilt Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5.7-2 Reprogramming Existing Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.7-3 Test and Verify Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
5.8 Park Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.9 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.10 A/C Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9
Notes
10
Section 1 – Scheduled Maintenance
1.1 Read and Heed 1.1-5 Service Policy and Warranty
SKYJACK warrants each new product to be free
SKYJACK is continuously improving and expanding
of defective parts and workmanship for the first 2
product features on its equipment, therefore,
years or 3000 hours, whichever occurs first. Any
specifications and dimensions are subject to change
defective part will be replaced or repaired by your
without notice.
local SKYJACK dealer at no charge for parts or labor.
In addition, all products have a 5 year structural
1.1-1 Telehandler Definition warranty. Contact the SKYJACK Service Department
A material handler designed primarily as a fork truck for warranty statement extensions or exclusions.
with a pivoting telescopic boom which enables it to
pick and place loads at distances as well as various 1.1-6 Operator Safety Reminders,
lift heights.
Warnings and Precautions
Operator safety is SKYJACK’s priority. The operator
1.1-2 Purpose of Equipment should comply with all applicable safety-related
The SKYJACK telehandlers are designed to lift, handle reminders, warnings and precautions found in
and transport agricultural or industrial products by the Operating Manual. They should be read and
means of specific attachments. understood completely before operating the
telehandler.
1.1-3 Use of Equipment
The telehandler is a highly maneuverable, mobile
work station. Lifting, handling and driving must be on
a flat, level, compacted surface. It can be driven over
uneven terrain only when boom is fully lowered.
1.1-4 Manual
Operating Manual: The operating manual is
considered a fundamental part of the telehandler. 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 telehandler 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.
11
Section 1 – Scheduled Maintenance Maintenance and Inspection Schedule
1.2 Maintenance and 1.2-3 Maintenance and Service Safety

Tips
Inspection Schedule Maintenance and repair should only be performed by
The actual operating environment of the work platform personnel who are trained and qualified to service this
governs the use of the maintenance schedule. The Telehandler.
inspection points covered in Table 1.2. Maintenance
All maintenance and service procedures should be
and lnspection Checklist, indicates the areas of the
performed in a well lighted and well ventilated area.
telehandler to be maintained or inspected and at what
intervals the maintenance and inspections are to be Anyone operating or servicing this Telehandler
performed. must read and completely understand all operating
instructions and safety hazards in this manual and
1.2-1 Owner’s Annual Inspection Record operating manual.
It is the responsibility of the owner to arrange quarterly All tools, supports and lifting equipment to be used
and annual inspections of the telehandler. Table 1.1. must be of proper rated load and in good working
Owner’s Annual lnspection Record is to be used for order before any service work begins. Work area
recording the date of the inspection, owner’s name, should be kept clean and free of debris to avoid
and the person responsible for the inspection of the contaminating components while servicing.
work platform. Ensure personnel are clear from under unsupported
components/systems that are at risk of movement
1.2-2 Replacement Parts during maintenance.
Use only original replacement parts. Parts such All service personnel must be familiar with employer
as batteries, wheels, railings, etc. with weight and and governmental regulations that apply to servicing
dimensions different from original parts will affect this type of equipment.
stability of the Telehandler and must not be used
without manufacturer’s consent. Keep sparks and flames away from all flammable or
combustible materials.
All replacement tires must be of the same size and
load rating as originally supplied tires; to maintain Properly dispose of all waste material such as
safety and stability of Telehandler. lubricants, rags, and old parts according to the
relative law provisions obtaining in the country.
Consult SKYJACK’s Service Department for optional
tires specifications and installation. Before attempting any repair work, disconnect the
main power conenctors.
WARNING Keep personnel clear of components, systems or
unsupported loads that may move unexpectedly
Any unit that is damaged or not operating properly during maintenance procedures.
must be immediately tagged and removed from
service until proper repairs are completed. Preventive maintenance is the easiest and least
expensive type of maintenance.
12
Hydraulic System & Component Maintenance and Repair Section 1 – Scheduled Maintenance
1.3 Hydraulic System & 7. All hydraulic components must be disassembled

in spotlessly clean surroundings. During
Component Maintenance disassembly, pay particular attention to
the identification of parts to assure proper
and Repair reassembly. Clean all metal parts in a clean
The following points should be kept in mind when mineral oil solvent. Be sure to thoroughly clean
working on the hydraulic system or any component: all internal passages. After the parts have been
dried thoroughly, lay them on a clean, lint-free
WARNING surface for inspection.
8. Replace all O-rings and seals when overhauling
Escaping fluid from a hydraulic pressure leak can
any component. Lubricate all parts with clean
damage your eyes, penetrate the skin and cause
hydraulic oil before reassembly. Use small
serious injury. Use proper personal preotection at
amounts of petroleum jelly to hold O-rings in
all times.
place during assembly.
1. Any structure has limits of strength and 9. Be sure to replace any lost hydraulic oil when
durability. To prevent failure of structural parts of completing the installation of the repaired
hydraulic components, relief valves which limit component, and bleed any air from the system
pressure to safe operating values are included in when required.
the hydraulic circuits. 10. All hydraulic connections must be kept tight. A
2. Tolerance of working parts in the hydraulic loose connection in a pressure line will permit
system is very close. Even small amounts of dirt the oil to leak out or air to be drawn into the
or foreign materials in the system can cause system. Air in the system can cause damage
wear or damage to components, as well as to the components and noisy or erratic system
general faulty operation of the hydraulic system. operation.
Every precaution must be taken to assure
absolute cleanliness of the hydraulic oil. 1.3-1 Maintenance Hints
3. Whenever there is a hydraulic system failure Three simple maintenance procedures have the
which gives reason to believe that there are greatest effect on the hydraulic system performance,
metal particles or foreign materials in the system, efficiency and life. Yet, the very simplicity of them may
drain and flush the entire system and replace the be the reason they are so often overlooked. They are
filter cartridges. A complete change of oil must simply these:
be performed under these circumstances. 1. Change filters annually. The filters will need
4. Whenever the hydraulic system is drained, to be changed more often depending on the
check the magnets in the hydraulic reservoir for operating conditions. Dirty, dusty, high moisture
metal particles. If metal particles are present, environments may cause the hydraulic system
flush the entire system and add a new change to be contaminated more quickly.
of oil. The presence of metal particles also may 2. Maintain a sufficient quantity of clean hydraulic
indicate the possibility of imminent component oil of the proper type and viscosity in the
failure. A very small amount of fine particles is hydraulic reservoir.
normal.
3. Keep all connections tight.
5. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic
oil reservoir, and fill the reservoir only through
the filter opening. The use of cloth to strain the
oil should be avoided to prevent lint from getting
into the system.
6. When removing any hydraulic component,
be sure to cap and tag all hydraulic lines
involved. Also, plug the ports of the removed
components.
13
Section 1 – Scheduled Maintenance About this Section
1.4 About this Section 1.4-3 Maintenance Instructions

This manual consists of four schedules to be done for
This section contains the maintenance and inspection
maintaining on an Telehandler. Inspection schedule
schedule that is to be performed.
frequency is shown below:
References are made to the procedures in Section
5 that outline detailed step-by-step instructions for Issue or Symptom
checks and replacements.
Perform PDI prior to each
1.4-1 Service Bulletins PDI/Frequent B
delivery, or Frequent
Before performing any scheduled maintenance Inspection every 3 months
inspection procedure, refer to service bulletins found or 150 hours.
in our web site: www.skyjackinc.com for updates Perform Scheduled
related to service and maintenance of this Telehandler. Annual B+C Maintenance Inspections
every year.
1.4-2 Maintenance and Inspection
Perform at time sensitive
Death or injury can result if the Telehandler is not kept Additional *
maintenance intervals.
in good working order. Inspection and maintenance
should be performed by competent personnel who
are trained and qualified on mantenance of this ▪ Make copies of the maintenance and inspection
Telehandler. checklist to be used for each inspection.
▪ Check the schedule on the checklist for the type
WARNING of inspection to be performed.
Failure to perform each procedure as presented ▪ Place a check in the appropriate box after each
and scheduled may cause death, serious injury or inspection procedure is completed.
substantial damage. ▪ Use the maintenance and inspection checklist
and step-by-step procedures in Section 1 to
perform these inspections.
NOTE If any inspection receives a fail, tag and remove
Preventive maintenance is the easiest and least
▪
the Telehandler from service.
expensive type of maintenance.
▪ If any Telehandler component(s) has been
▪ Unless otherwise specified, perform each repaired, an inspection must be performed again
maintenance procedure with the Telehandler in before removing the tag. Place a check in the
the following configuration: repair column.
▪ Telehandler parked on a flat and level surface Legend
▪ Disconnect the batteries by disconnecting the Pass P
main power connectors.
▪ Repair any damaged or malfunction Fail F
components before operating Telehandler.
Repaired R
▪ Keep records on all inspections.
Not applicable N/A
14
About this Section Section 1 – Scheduled Maintenance
Table 1.1 MAINTENANCE AND INSPECTION CHECKLIST
Serial Number:
Model:
Hourmeter Reading: Operator's Name (Printed):
Date:
Time: Operator's Signature:
Each item shall be inspected using the appropriate section of the Skyjack operating manual.
As each item is inspected, write the appropriate grade in the box.
INSPECTION FREQUENCY Inspection Schedule
P - PASS  DAILY Daily A
F - FAIL  WEEKLY or 40 HOURS Weekly or 50 Hours A+B
R - REPAIRED  QUARTERLY OR 250 HOURS Quarterly or 250 Hours A+B+C
 ANNUALLY or 1000 HOURS Annually or 1000 Hours A+B+C+D
Schedule P F R Schedule P F R
Schedule Maintenance Inspections Boom
Labels A Main pins and bushings C,D
Electrical A subcarriage pins and bushings C,D
Mirrors A Rollers and Tracks C,D
Hydraulic A Slide Pads B,C,D
Cylinders A,B,C,D Chain(s) A,C
Frame Boom Angle Indicator A
Wheel/Tire Assembly A Proximity Sensors A
Air-filled Tires A Lifting Attachment(s) A
Foam-filled Tires A Forks A
Battery and Cables A Fork Bars and Locks A
Hydraulic Tank A Quick Attach apron A
Hydraulic Oil A,D Grease Fittings
Engine Intake Air Filter A,B,C Grease Fittings on Frame C
Tilt Switch A,B,C,D Grease Fittings on Boom Assembly C
Drive Axles Operator's Cab
Hub Oil D Seat A
Differential Oil D Pedals A
Pinion Seal A Manual A
Inner and Outer Shaft Seals A Operator's Cab Controls A
Hub Seals A Function Tests
King Pins C,D Operator's Cab Controls
Check Drive Shafts and U-Joints C,D Test Starter Operation A
Axle Mounting Pins and Bushings C,D Test Horn A
Axle Housing A Test Lights (If Equipped) A
Steer Cylinder Assembly A Test Boom and Attachment Functions A
Steer Linkage A Test Frame Leveling and Level Indicator A
Engine Compartment Test Frame Leveling and Boom Interlock A
Engine Oil A,C Test Accelerator Pedal A
Engine Coolant Level A Test Reverse Alarm, Driving & Service Brake A
Fuel Leaks A Test Steering A
Belts and Hoses A Test Positive Shut-off Valve (if equipped) A
Fuel Tank A Test Parking Brake A
Change Fuel Filter A,C Test Outriggers (If Equipped) A
Drain Fuel/Water Separator C,D 256D
Change Oil Filters A,C

Charge Accumulators (if equipped) A
Transmission
Operate and Check Shifting A
Check for Leaks A
Change Transmission Oil D
Change Oil Filter D
Hydraulic Pump A
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.8 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every week or 40 hrs. Refer to Section 1 of this manual.
C - Perform Scheduled Maintenance Inspection every 3 months or 250 hours. Refer to Section 1 of this manual.
D - Perform Scheduled Maintenance Inspection every year or 1000 hours. Refer to Section 1 of this manual.
Note: Make a copy of this page or visit the Skyjack web site: www.skyjack.com for a printable copy.
15
Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections
Forks/Lifting
Boom Assembly Attachment
Engine
Compartment Operator’s
Cab
Side-View
Frame
Mirror
1.5 Scheduled Maintenance 1.5-2 Electrical

Maintaining the electrical components is essential to
Inspections good performance and service life of the telehandler.
Before performing the visual and daily maintenance ▪ Ensure proper operation of all gauges.
inspections, ensure that the telehandler is parked on a
▪ Inspect the following areas for chafed, corroded
firm level surface.
and loose wires:
Begin the visual and daily maintenance inspections
by checking each item in sequence for the conditions
▪ boom wiring harnesses - A
listed in this section. ▪ frame wiring harnesses - A
▪ cab wiring harnesses - A
Ensure electrical devices are properly secured with no
WARNING signs of visible damage. Ensure there are no loose or
To avoid injury, do not operate a telehandler until missing parts.
all malfunctions have been corrected.
1.5-3 Mirrors - A
Ensure mirrors are properly secured with no signs of
WARNING visible damage.
To avoid possible injury, ensure telehandler power
is off during your visual and daily maintenance 1.5-4 Hydraulic
inspections. Maintaining the hydraulic components is essential to
good performance and service life of the telehandler
Perform a visual inspection and check for leaks around
NOTE the following areas:
While performing visual and daily inspections hydraulic tank, filter(s), fittings, hoses, pump, and
in different areas, be aware to also inspect all
▪
frame surface
switches, electrical and hydraulic components.
▪ all hydraulic cylinders - A
▪ all hydraulic manifolds - A
1.5-1 Labels - A
▪ underside of the frame - A
Refer to the labels section in this manual and determine
that all labels are in place and are legible. ▪ ground area under the telehandler - A
16
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance
Rear Axle Frame Level

Assembly Cylinder
Wheel/Tire
Assembly
Front & Rear

Lug Nut Drive Shafts
1.5-5 Cylinders - A ▪ Air-filled Tires - A

Ensure all cylinders are properly secured and there is To safeguard maximum stability, achieve optimum
no evidence of leakage. telehandler handling and minimize tire wear, it is
essential to maintain proper pressure in all air-filled
Grease weekly and check pins and bushings to ensure
tires. Refer to tire pressure label.
there is no evidence of damage.
Refer to section 5.3 for greasing procedure.
▪ Check each tire with an air pressure gauge and
add air as needed.
1.5-6 Frame
Wheel/Tire Assembly - A
WARNING
▪
Tire and/or wheel failure could result in a telehandler An improperly inflated tire may cause death or serious
tipover. Component damage may also result if injury.
problems are not discovered and repaired in a timely
fashion. ▪ Foam-filled Tires - A
Tire condition can vary significantly depending on
▪ Check all tire treads and sidewalls for cuts or telehandler use, job site environment and preventative
cracks that expose the cord plies.
maintenance measures. Inspect tires periodically and
▪ Check for punctures, holes and unusual wear. pay extra attention to the following:
▪ Check each wheel rim for damage and cracked
welds. Check for punctures or holes. Ensure they do not
▪
▪ Check each lug nut for proper torque to ensure exceed 1 inch in diameter.
none are loose. Refer to section 5.4-1 for torque
procedure. IMPORTANT
Do not intermix foam-filled and air-filled tires.
WARNING
If any tire does not meet the criteria outlined
above, remove telehandler from service and
replace wheel/tire immediately.
17
Battery
Front Axle
Assembly
▪ Drive Axles - A
Ensure drive axles are properly secured, there are WARNING
no loose or missing parts, all fittings and hoses are Battery acid is extremely corrosive - Wear proper
properly tightened and there is no evidence of oil eye and facial protection as well as appropriate
leakage. protective clothing. If contact occurs, immediately
▪ Steer Cylinder - A flush with cold water and seek medical attention.
Ensure steer cylinders are properly secured, there
1. Check battery case for damage.
are no loose or missing parts, all fittings and hoses
are properly tightened and there is no evidence of 2. Clean battery terminals and cable ends
hydraulic oil leakage. thoroughly with a terminal cleaning tool or wire
brush.
▪ Planetary Wheel Ends - C
3. Ensure all battery connections are tight.
Check the planetary wheel ends oil level and add as
4. If applicable, check battery fluid level. If plates are
required. Ensure there is no evidence of oil leakage.
not covered by at least 1/2” (13 mm) of solution,
▪ Axle Differential - C add distilled or demineralized water.
Check the axle differential oil level and add as required. 5. Replace battery if damaged or incapable of
Ensure there is no evidence of oil leakage. holding a lasting charge.
▪ Battery - A
Proper battery condition is essential to good engine WARNING
performance and operational safety. Improper fluid
Use original or manufacturer-approved parts and
levels or damaged cables and connections can result in
components for the telehandler.
engine component damage and hazardous conditions..
WARNING
Explosion hazard. Keep flames and sparks away.
Do not smoke near batteries.
18
▪ Engine Intake Air Filter - A WARNING

▪ Ensure there are no loose or missing parts and Engine fuels are combustible. Inspect the
there is no visible damage. telehandler in an open, well-ventilated area away
from heaters, sparks and flames. Always have an
▪ Ensure air cleaner vaccuator valve is free from approved fire extinguisher within easy reach.
dirt or dust by squeezing the valve lips.
▪ Check air cleaner service indicator and replace Refer to section 5.4-5 for fuel filter replacement
filter element if needed. Refer to section 5.2-4 procedure
▪ Fuel Tank -A ▪ DEF Tank (if equipped) - A
IMPORTANT IMPORTANT
Before using your telehandler ensure there is Before using your telehandler ensure there is
enough fuel for expected use. enough Diesel Exhaust Fluid for expected use.
▪ Ensure fuel filler cap is secure. ▪ Ensure tank cap is secure.

▪ Ensure tank shows no visible damage and no ▪ Ensure DEF tank shows no visible damage
evidence of fuel leakage. and no evidence of leakage.
▪ Fuel Leaks - A ▪ Hydraulic Oil Tank
Failure to detect and correct fuel leaks will result in an ▪ Ensure hydraulic filler cap is secure.
unsafe condition. An explosion or fuel fire may cause ▪ Ensure tank shows no visible damage and no
death or serious injury. evidence of hydraulic leakage.
Perform a visual inspection around the following
areas:
▪ hoses and fittings
▪ fuel pump
▪ fuel filter
▪ fuel tank
19
Radiator
Fill Cap
Hydraulic
Oil Pump
Fan Belts
Fuel Filter
Transmission
Oil Dipstick
Fuel/Water
Engine Engine
Separator
Oil Filter Oil Dipstick
▪ Hydraulic Oil - A, D ▪ Engine Coolant -A

▪ Be sure that the boom is in the lowered and
stowed position, and then visually inspect the WARNING
sight gauge located at the rear of the hydraulic
oil tank. Pressurized fluid present in radiator. Never open
radiator cap when hot. Always open fill cap slowly.
▪ Add clean hydraulic oil as required. Refer to
section 5.5-2 for hydraulic oil change.
▪ Check coolant level on radiator.
1.5-7 Engine Compartment ▪ Add coolant as required.
Refer to section 5.5-5 for engine coolant change
Ensure compartment cover is secure and in proper
procedure.
working order.
▪ Belts - A
WARNING ▪ Ensure belts are in good working condition

and have correct tension. Replace if belts are
Beware of hot engine components. cracked, frayed, or have chunks of material
missing. Refer to service manual for proper
▪ Engine Oil Level on dipstick - A, C replacement procedure.
▪ Maintaining the engine components is essential ▪ Hydraulic Pump - A
to good performance and service life of the
telehandler.
▪ Ensure there are no loose or missing parts and
there is no visible damage.
▪ Oil level should be between the “L” low and “H” ▪ Ensure all bolts are properly tightened.
high marks. Add oil as needed. Refer to section
5.4-4 for oil replacement procedure. ▪ Ensure all fittings and hoses are properly
tightened and there is no evidence of hydraulic
oil leakage.
▪ Fuel/Water Separator “ ” - C, D
Ensure there are no loose or missing parts and
there is no visible damage.
▪ Ensure all fittings and hoses are properly
tightened and there is no evidence of fuel leaks.
20
Boom Angle
Switch
Fork Carriage
Attatchment
▪ Drain water by opening water drain plug at ▪ Boom Angle Switches - A

bottom of filter. Close tightly after inspection. ▪ Ensure boom angle switches are properly
Refer to section 5.4-5 for fuel/water separator secured with no signs of visible damage.
replacement procedure ▪ Slide Pads - B, C, D
▪ Ensure all bolts are tight, there is no visible
1.5-8 Transmission damage to the slide pads and that no parts are
Ensure transmission shifter is working properly and missing.
there is no evidence of damage. ▪ Chain - A, C
▪ Check oil level on dipstick “ ”-D ▪ Ensure there are no loose or missing parts and
▪ With park brake engaged and transmission there is no visible damage
shifter in “N” Nuetral position, start engine. ▪ Boom Angle Indicator - A
▪ Oil level should be in the ‘safe’ zone. Add oil as ▪ Ensure all bolts are tight, and there is no visible
needed. Refer to section 5.5-6 for transmission damage and indicator swings freely.
oil change procedure.
1.5-10 Lifting Attachment - A
1.5-9 Boom - A ▪ Ensure there are no loose or missing parts and
▪ Ensure there are no loose or missing parts and there is no visible damage.
there is no visible damage. ▪ Ensure attachment is properly positioned and
▪ Ensure all bolts and pins are properly tightened. secured. (refer to Section 2.13 for attachments
▪ Ensure there are no visible cracks in welds or installation and operation).
structure and there are no signs of deformation.
▪ Ensure all hoses are properly tightened and
there is no evidence of hydraulic leakage.
21
Operator’s Cab
Multi-Function Operator’s
Joystick Seat
Transmission
Shifter
Manual
10h / 50h
Storage Box
Daily & Weekly

Maintenance Chart
1.5-11 Grease Fittings - B

▪ Maintaining properly greased components is WARNING
essential for good performance and service life Do not modify, drill or alter the operator’s cab in
of the telehandler. If components are improperly any way.
greased, it could result in component damage.
Refer to section 5.2 for greasing procedures. ▪ Seat - A
▪ Ensure seat is properly secured with no sign of
visible damage.
WARNING
▪ Ensure seat belt is working properly with no
Ensure that there are no personnel or obstructions sign of visible damage.
in maintenance area. ▪ Pedals - A
▪ Greasing intervals are based on average ▪ Ensure brake and accelerator pedals are
telehandler usage. Use of telehandler may vary secure, no loose or missing parts, no sign
significantly and greasing frequency must be of visible damage and movements are not
adjusted to obtain maximum service life. obstructed.
Refer to the Daily and Weekly Maintenance ▪ Manual - A
▪
Chart located inside operator’s cab for grease ▪ Check to be sure manual storage box is present
points location and service intervals. and in good condition.
▪ Ensure a copy of operating manual, and other
1.5-12 Operator’s Cab important documentation are enclosed in
▪ Rollover and Falling Object Protective manual storage box.
Structure (ROPS/FOPS) - B ▪ Ensure manual is legible and in good condition.
▪ Ensure there is no visible damage. ▪ Always return manual to the manual storage
box after use.
22
Operator’s Cab
Multi-Function
Joystick
Operator’s
Seat
Steering
Wheel
Transmission Manual
10h / 50h
Shifter Storage Box
Accelerator &
Brake Pedals
Daily & Weekly
Maintenance Chart
▪ Operator’s Cab Controls - A
WARNING
Ensure that you maintain three points of contact to
mount/dismount the cab.
Use the steps of telehandler to access operator’s cab.

▪ Ensure door and windows (if equipped) are
secure and in proper working order.
▪ Ensure steering wheel is secured with no sign of
visible damage.
▪ Ensure all switches and controls are properly
secured with no sign of visible damage.
▪ Ensure all switches and controls are returned
to their neutral position and movements are not
obstructed.
▪ Ensure capacity charts are in place and are
legible.
WARNING
Do not operate the telehandler if capacity charts
are missing or not legible.
23
Section 1 – Scheduled Maintenance Function Tests
1.6 Function Tests

Function tests are designed to discover any
malfunctions before the Telehandler is put into service.
The operator must understand and follow step-by-step
instructions to test all telehandler functions.
IMPORTANT
Never use a malfunctioning telehandler. If
malfunctions are discovered, telehandler must
be tagged and placed out of service. Repairs
to telehandler may only be made by a qualified
service technician.
▪ After repairs are completed, operator must
perform a pre-operation inspection and a
series of function tests again before putting
telehandler into service.
▪ Prior to performing function tests, be sure to
read and understand the “Start Operation”
section of the operating manual.
▪ For function test that are to be performed,
please refer to the operating manual that
corresponds to the correct serial number. Found
there will be detailed instructions for which
tests to perform, as well as how to properly and
successfully perform them.
NOTE
All-function motion alarm should sound while
operating any boom and drive function
24
Section 2 – Maintenance Tables
25
Section 2 – Maintenance Tables Standard and Optional Equipment
Table 2.1 Standard and Optional Equipment

MODELS SJ1044 TH/THS SJ1056 TH/THS
Standerd Equipment
Diesel Engine * *
Four-wheel drive * *
Three-Speed Transmisson * *
Three-Mode Steering * *
Open Operator's Cab * *
Spring-applied Hydraulically Released Parking Brake * *
Operator horn * *
Reverse/Backup alarm * *
Engine Block Heater * *
Hydraulic Test Port(s) * *
Air Filled Tires * *
Rear Axle Stabilization System (RAS) * *
Frame Leveling System * *
48" / 60" / 72" QA 10K Fork Carriages * *
Lifting Hook * *
Outriggers - *
Optional Equipment
Outriggers * -
SCR System * *
Enclosed Operator's Cab * *
Enclosed Operator's Cab with A/C * *
Flashing Beacon * *
Four-Wheel Fenders * *
Positive Air Shut-off System * *
Foam Filled Tires * *
Reserve Brak System * *
Road/Work/Boom Lights * *
Premium Multi-functional Joystick * *
48" / 60" / 72" Side-Tilt Fork Carriages * *
72" Swing Carriage * *
2 ft. Jib Boom * *
1.75 Cu. Yd. Bucket Loader Attachment * *
12 ft. Truss Boom * *
15 ft. Truss Boom * *
1340AA
26
Model SJ1256 THS
Standard Equipment
48" / 60" / 72" QA 12K Fork Carriages *
Air Filled Tires *
Diesel Engine *
Engine Block Heater *
Four-wheel drive *
Frame Leveling System *
Lifting Hook *
Open Operator's Cab *
Operator horn *
Outriggers *
Rear Axle Stabilization System (RAS) *
Reverse/Backup Alarm *
SCR System *
Spring-applied Hydraulically Released Parking Brake *
Three-Speed Transmisson *
Three-Mode Steering *
Optional Equipment
1.75 Cu. Yd. Bucket Loader Attachment *
12 ft. Truss Boom *
15 ft. Truss Boom *
2 ft. Jib Boom *
48" / 60" / 72" Side-Tilt Fork Carriages *
72" Swing Carriage *
Back-up Sensor/ Back-up Camera and Sensor *
Enclosed Operator's Cab *
Enclosed Operator's Cab with A/C *
Fire Extinguisher *
Flashing Beacon *
Foam Filled Tires *
Four-Wheel Fenders *
Pintle Hitch *
Positive Air Shut-off System *
Premium Multi-function Joystick *
Reserve Brake System *
Road/Work/Boom Lights *
1230AA
27
Table 2.2 Specifications and Features
MODEL SJ1044 TH/THS SJ1056 TH/THS
Standard Engine
Type Deutz 3.6L Tier 4 Final
Cylinders 4
Horsepower @ 2300 RPM 74 HP
Capacity 219 cu.in. (3600 cm3)
Torque @ 1300 RPM 286 lb. ft (387 N-m)
Idle Speed* 1100 - 1150 RPM
Fuel type Diesel
Optional Engine
Type Deutz 3.6L Tier 4 Final
Cylinders 4
Capacity 219 cu.in. (3600 cm3)
Torque @ 1300 RPM 288 lb. ft (390 N-m)
Idle Speed* 1100 - 1150 RPM
Fuel type Diesel
Transmission
Type Powershift with soft shift
Powershift Speeds forward 3
Speeds reverse 3
Type Continuously Variable Transmission - Two Range Powershift
CVT Speeds forward 2
Speeds reverse 1
Travel Speeds
Range 1 0-4 mph (1-7 km/h)
Powershift Range 2 5-8 mph (8-13 km/h)
Range 3 9-15 mph (14-24 km/h)
CVT Range 0-14 mph (0-23 km/h)
Electrical
Negative ground 12 Volts
Alternator 60 Amps
Battery 900 Amps
Backup Alarm 107 DBM
Dimensions
Wheelbase 133 in. (337.82 cm)
Overall width 8 ft. 6 in. (259.1 cm)
Overall height 8 ft. 3 in. (246.84 cm) 8 ft. 5 in. (248.8 cm)
Overall length (less forks) 20 ft. 9 in. (632.7 cm) 22 ft. 6 in. (685.6 cm)
Ground clearance 19 in. (48.26 cm)
Maximum weight without attachment 30,922 lb (14,026 kg) 33,482 lb (15,188 kg)
Turn radius (inside) 73 in. (185.4 cm)
Turn radius (outside) 173 in (439.4 cm)
Boom
Number of sections 3 4
Maximum lift height 44 ft. 3 in. (13.48 m) 56 ft. 3 in. (17.15 m)
Maximum forward reach 29 ft. 4 in. (8.94 m) 42 ft. 2 in. (12.85 m)
Standard Forks (Standard Tapered Forks) "2.25 in. x 5 in. x 48 in.
Carriage rollback 20°
Carriage forward tilt 92.5°
* Engine Idle Speed is measured with 5% droop when in gear. 1341AB
** Add 400 lb (181.437 kg) to the maximum weight for machines with CVT
28
Model SJ1256 THS
Standard Engine
Type Deutz 3.6 L Tier 4 Final
Cylinders 4
Capacity 219 cu in (3600 cm3)
Torque @ 1300 RPM 288 lb ft (390 N-m)
Idle Speed* 1100 – 1150 RPM
Fuel type Diesel
Transmission
Type Powershift with soft shift
Speeds forward 3
Speeds reverse 3
Travel Speeds
Range 1 0–4 mph (1–7 km/h)
Range 2 5–8 mph (8–13 km/h)
Range 3 9–15 mph (14–24 km/h)
Electrical
Negative ground 12 Volts
Alternator 60 Amps
Battery 900 Amps
Backup Alarm 107 DBM
Dimensions
Wheelbase 133 in (337.8 cm)
Overall width 8 ft 6 in (259.1 cm)
Overall height 8 ft 7 in (261.6 cm)
Overall length (less forks) 22 ft 10 in (697 cm)
Ground clearance 19 in (48.3 cm)
Maximum weight without attachment 33,482 lb (15,188 kg)
Turn radius (inside) 73 in (185.4 cm)
Turn radius (outside) 173 in (439.4 cm)
Boom
Number of sections 4
Maximum lift height 56 ft 3 in (17.15 m)
Maximum forward reach 42 ft 4 in (12.90 m)
Standard Forks 2.25 in x 5 in x 48 in (standard tapered forks)
Carriage rollback 20°
Carriage forward tilt 92.5°
* Engine idle speed is measured with 5% droop when in gear. 1231AA
29
Table 2.3 Recommended Fluids/Lubrications
Models SJ1044 TH/THS & SJ1056 TH/THS
Engine
Ultra Low Sulfur Diesel (EN 590, ASTM D975)

Fuel Type
or Biodiesel B20
Fuel Tank Capacity 35 gal (132 L)
Recommended Oil Type SAE 15W40
Engine Oil Capacity 9.5 Quart (9.0 L)
Coolant Type (Standard) COOLANT-ANTIFREEZE 50/50 PREMIX *
Coolant Type(Cold Weather Option) COOLANT-ANTIFREEZE 60/40 PREMIX *
Coolant Tank Capacity 4.2 gal (16 L)
DEF (if equipped) Diesel Exhaust Fluid (DEF)
DEF Tank Capacity 2.4 gal (9.4 L)
Transmission
Oil Type ATF Dexron III
Powershift
Capacity 14.2 Quart (13.5 L)
CVT Case: Dropcase:
Oil Type
CVT VALVOLINE INVARITORC 205 ATF DEXRON III
Capacity 18 L 0.90 L
Axles
Differential SAE 80W/90 LS
Front Axle Capacity 13.7 Quart (13 L)
Rear Axle Capacity 8.2 Quart (7.8 L)
Planetary Wheel Ends SAAE 80W/90
Capacity 2 Quart (1.89 L)
Hydraulic Oil
Standard Factory Fill ATF Dexron III
Type ATF Dexron III or Equivalent
Tank Capacity 43.85 gal (166 L)
Grease Points
Type EP2 Grease
* Refer to engine manufacturer’s manual 1348AE
WARNING
Do not mix hydraulic oil of different types or use
oils of types other than those originally supplied
with this equipment. Doing so can severely
damage hydraulic components. A full hydraulic oil
system flush must be performed prior to adding a
new type of hydraulic oil. Consult Skyjack service
department.
30
Model SJ1256 THS
Engine
Fuel Type Ultra Low Sulfur Diesel (EN 590, ASTM D975) or Biodiesel B20
Fuel Tank Capacity 35 gal (132 L)
Recommended Oil Type SAE 15W40
Engine Oil Capacity 9.5 quart (9.0 L)
Coolant Type (Standard) COOLANT-ANTIFREEZE 50/50 PREMIX *
Coolant Type (Cold Weather Option) COOLANT-ANTIFREEZE 60/40 PREMIX *
Coolant Tank Capacity 4.2 gal (16 L)
DEF Diesel Exhaust Fluid (DEF)
DEF Tank Capacity 2.4 gal (9.4 L)
Transmission
Oil Type ATF DEXRON III
Powershift
Capacity 14.2 quart (13.5 L)
CVT Case: Dropcase:

Oil Type
CVT VALVOLINE INVARITORC 205 ATF DEXRON III
Capacity 18 L 0.90 L
Axles
Differential SAE 80W/90 LS
Front Axle Capacity 14.8 quart (14 L)
Rear Axle Capacity 14.8 quart (14 L)
Planetary Wheel Ends SAAE 80W/90
Capacity 2 quart (1.89 L)
Hydraulic Oil
Standard Factory Fill ATF Dexron III
Type ATF Dexron III or Equivalent
Tank Capacity 43.85 gal (166 L)
Grease Points
Type EP2 Grease
* Refer to manufacturer’s manual. 1233AE
WARNING
Do not mix hydraulic oil of different types or use
oils of types other than those originally supplied
with this equipment. Doing so can severely
damage hydraulic components. A full hydraulic oil
system flush must be performed prior to adding a
new type of hydraulic oil. Consult Skyjack service
department.
31
Table 2.4 Tire/Wheel Specifications
Models SJ1044 TH/THS & SJ1056 TH/THS
"Wheel
"Ply
FILL Size Pressure Nuts
Rating"
Torque"
PRIMEX G3000 AIR 80 PSI (552 Kpa)
FOAM -
GALAXY GIRAFFE XLW AIR 14.00 X 24 TG 80 PSI (552 Kpa)
16
FOAM G-2 -
PRIMEX DNRZ II AIR 99 PSI (683 Kpa) "442 ft.-lb.
FOAM - (600 Nm)"
50.787 X 8.5 X
SOLIDAIR - N/A -
13.00 X 24
SOLIDBOSS - 50 X 13.00 X 24 N/A -
BLACKSTONE FOAM 14.000 X 24 - 16
1347AA
Model SJ1256 THS

Ply Wheel Nuts
Fill Size Pressure
Rating Torque
Air 80 psi (552 kPa)
Galaxy Giraffe XLW 14.00 × 24 TG G-2 16
Foam -
442 ft-lb (600 Nm)
SOLIDBOSS - 14.00 × 24 - -
BLACKSTONE Foam 14.00 × 24 - 16
1232AA
WARNING
Do not use tires other than those specified for this
machine. Do not mix different types of tires. Tires
other than those specified can adversely affect
stability. Failure to operate with matched, approved
tires in good condition can result in death or
serious injury. Replace tires with the exact,
Skyjack-approved types only.
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 telehandler.
32
Table 2.5 Pressure Settings
SJ1044 TH/THS - SJ1056 TH/THS - SJ1256 THS

System Component Test Port Pressure Value 10K Pressure Value 12K
Pilot Oil Pressure GP2 400 PSI 400 PSI
Tilt Comp./Carriage Tilt Port Relief - 3300 PSI 3900 PSI
System
Standby Pressure (Load Sense) GP1 450 PSI 450 PSI
Maximum Pressure GP1 3250 PSI 3900 PSI
Steering
Maximum RV2 2600 PSI 2600 PSI
Brakes
Service Brake PS2 900 PSI 900 PSI
1339AA
NOTE
All pressures to be checked with engine running
at idle unless specified otherwise.
NOTE
Service brake pressure is variable. The value
provided above is the maximum nominal value.
33
Table 2.6 Standard Hose Numbering System
H1104 0081 2
FITTING LENGTH IN FRACTIONS

ARRANGEMENT LENGTH OF HOSE IN (1/4" INCREMENTS)
(See Schedule Below) WHOLE INCHES 1=1/4"
HOSE SIZE
2=1/2"
(See Chart Below)
3=3/4"
Using the number above as an example,

H1104 0081 2, this hose requires a 37° JIC female NOTE
swivel fitting on one end, and a medium length 90° JIC Hose ends and hose must be from same
female swivel fitting for the other end. The hose must manufacturer per S.A.E. J1273 Nov. ‘91, Sections
meet or exceed the S.A.E. 100R13 hose specification, 3.10 and 4.2. Hose ends and hose must be of the
and be a total of 81-1/2" long. same size i.e. #4 size fittings must be used with
#4 size hose.
Hose Size Chart
Size 03 04 06 08 10 12 16 20 24 32 40 48 56 64
ID 3/16" 1/4" 3/8" 1/2" 5/8" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 3-1/2" 4"
Fitting Arrangement Schedule

S.A.E.
Hose Prefix Hose End Fitting Hose End Fitting
Hose Specification
H01 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H03 FEMALE, 37° JIC, SWIVEL 45°, FEMALE, 37° JIC, SWIVEL 100R17
H05 FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R17
H06 FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R17
H07 LONG 90°, FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R17
H10 FEMALE, 37° JIC, SWIVEL MALE PIPE THREAD FITTING 100R17
H11 FEMALE, 37° JIC, SWIVEL MEDIUM 90°, FEMALE, 37° JIC, SWIVEL 100R13
H12 SHORT 90°, FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R17
H13 FEMALE, 37° JIC, SWIVEL REUSABLE MALE PIPE THREAD FITTING 300 PSI
H14 REUSABLE MALE PIPE THREAD FITTING NO FITTING 300 PSI
H15 REUSABLE FEMALE, 37° JIC, SWIVEL REUSABLE FEMALE, 37° JIC, SWIVEL 300 PSI
H16 NO FITTING NO FITTING 100R4
H17 NO FITTING NO FITTING 300 PSI
H18 REUSABLE, FEMALE, 37° JIC, SWIVEL NO FITTING 300 PSI
H19 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R13
H20 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R4
34
Fitting Arrangement Schedule
S.A.E.
Hose Prefix Hose End Fitting Hose End Fitting
Hose Specification
H21 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R2AT
H22 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R2AT
H23 FEMALE, LONG 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R2AT
H24 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R13
H30 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H32 SHORT 45°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H57 SHORT 45°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R13
H58 FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R13
MEDIUM 90°, FEMALE, SAE ORFS,
H59 FEMALE, SAE ORFS, SWIVEL 100R13
SWIVEL
H66 FEMALE, 37° JIC, SWIVEL NO FITTING 100R4
H71 LONG 90°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R15
35
Table 2.7 Torque Specifications for Fasteners (US)
Torque SAE 2 SAE 5 SAE 8 Torque SAE 2 SAE 5 SAE 8
Size Size
Type Dry Lubed Dry Lubed Dry Lubed Type Dry Lubed Dry Lubed Dry Lubed
(in-lb) (5) (4) (8) (6) (12) (9) ft-lb 70 55 110 80 150 110
4-40 9/16-12
Nm 0.6 0.5 0.9 0.7 1.4 1.0 Nm 95 75 149 108 203 149
(in-lb) (6) (5) (9) (7) (13) (10) ft-lb 80 60 120 90 170 130
4-48 9/16-18
Nm 0.7 0.6 1.0 0.8 1.5 1.1 Nm 108 81 163 122 230 176
(in-lb) (10) (8) (16) (12) (23) (17) ft-lb 100 75 150 110 220 170
6-32 5/8-11
Nm 1.1 0.9 1.8 1.4 2.6 1.9 Nm 136 102 203 149 298 230
(in-lb) (12) (9) (18) (13) (25) (19) ft-lb 110 85 180 130 240 180
6-40 5/8-18
Nm 1.4 1.0 2.0 1.5 2.8 2.1 Nm 149 115 244 176 325 244
(in-lb) (19) (14) (30) (22) (41) (31) ft-lb 175 130 260 200 380 280
8-32 3/4-10
Nm 2.1 1.6 3.4 2.5 4.6 3.5 Nm 237 176 353 271 515 380
(in-lb) (20) (15) (31) (23) (43) (32) ft-lb 200 150 300 220 420 320
8-36 3/4-16
Nm 2.3 1.7 3.5 2.6 4.9 3.6 Nm 271 203 407 298 569 434
ft-lb 170 125 430 320 600 460
(in-lb) (27) (21) (43) (32) (60) (45) 7/8-9
10-24 Nm 230 169 583 434 813 624
Nm 3.1 2.4 4.9 3.6 6.8 5.1
ft-lb 180 140 470 360 660 500
(in-lb) (31) (23) (49) (36) (68) (51) 7/8-14
10-32 Nm 244 190 637 488 895 678
Nm 3.5 2.6 5.5 4.1 7.7 5.8
ft-lb 250 190 640 480 900 680
(in-lb) ft-lb (66) (50) 8 (75) 12 9 1-8
1/4-20 Nm 339 258 868 651 1220 922
Nm 7.5 5.6 11 8.5 16 12
ft-lb 270 210 710 530 1000 740
(in-lb) ft-lb (76) (56) 10 (86) 14 10 1-12
1/4-28 Nm 366 285 963 719 1356 1003
Nm 8.6 6.3 14 9.7 19 14
ft-lb 280 210 730 540 1020 760
ft-lb 11 8 17 13 25 18 1-14
5/16-18 Nm 380 285 990 732 1383 1030
Nm 15 11 23 18 34 24
ft-lb 350 270 800 600 1280 960
ft-lb 12 9 19 14 25 20 1 1/8-7
5/16-24 Nm 475 366 1085 813 1735 1302
Nm 16 12 26 19 34 27
ft-lb 400 300 880 660 1440 1080
ft-lb 20 15 30 23 45 35 1 1/8-12
3/8-16 Nm 542 407 1193 895 1952 1464
Nm 27 20 41 31 61 47
ft-lb 500 380 1120 840 1820 1360
ft-lb 23 17 35 25 50 35 1 1/4-7
3/8-24 Nm 678 515 1519 1139 2468 1844
Nm 31 23 47 34 68 47
ft-lb 550 420 1240 920 2000 1500
ft-lb 32 24 50 35 70 55 1 1/4-12
7/16-14 Nm 746 569 1681 1247 2712 2034
Nm 43 33 68 47 95 75
ft-lb 670 490 1460 1100 2380 1780
ft-lb 36 27 55 40 80 60 1 3/8-6
7/16-20 Nm 908 664 1979 1491 3227 2413
Nm 49 37 75 54 108 81 ft-lb 750 560 1680 1260 2720 2040
ft-lb 50 35 75 55 110 80 1 3/8-12
1/2-13 Nm 1017 759 2278 1708 3688 2766
Nm 68 47 102 75 149 108 ft-lb 870 650 1940 1460 3160 2360
1 1/2-6
ft-lb 55 40 90 65 120 90 Nm 1180 881 2630 1979 4284 3200
1/2-20
Nm 75 54 122 88 163 122 ft-lb 980 730 2200 1640 3560 2660
1 1/2-12
Nm 1329 990 2983 2224 4827 3606
NOTE: Lubed includes lubricants such as lubrizing, oil, grease, and some uncured thread lockers. Refer to the specific 1374AB
thread locker manufacturer’s instructions for specific torque adjustments.
36
Table 2.8 Torque Specifications for Fasteners (Metric)
Torque 8.8 10.9
Size
Type Dry Lubed Dry Lubed
(in-lb) (54) (41) (78) (59)
M5 x 0.80
Nm 6.1 4.6 8.8 6.7
(in-lb) (92) (69) (133) (99)
M6 x 1.00
Nm 10.4 7.8 15 11.2
(in-lb) (156) (116) (222) (167)
M7 x 1.00
Nm 17.6 13.1 25.1 18.9
(in-lb) (225) (169) (333) (242)
M8 x 1.25
Nm 25.4 19.1 37.6 27.3
ft-lb 37 28 53 40
M10 x 1.50
Nm 50 38 72 54
ft-lb 65 49 93 69
M12 x 1.75
Nm 88 66 126 94
ft-lb 104 78 148 111
M14 x 2.00
Nm 141 106 201 150
ft-lb 161 121 230 172
M16 x 2.00
Nm 218 164 312 233
ft-lb 222 167 318 238
M18 x 2.50
Nm 301 226 431 323
ft-lb 314 235 449 337
M20 x 2.50
Nm 426 319 609 457
ft-lb 428 321 613 460
M22 x 2.50
Nm 580 435 831 624
ft-lb 543 407 776 582
M24 x 3.00
Nm 736 552 1052 789
ft-lb 796 597 1139 854
M27 x 3.00
Nm 1079 809 1544 1158
ft-lb 1079 809 1543 1158
M30 x 3.50
Nm 1463 1097 2092 1570
ft-lb 1468 1101 2101 1576
M33 x 3.50
Nm 1990 1493 2849 2137
ft-lb 1886 1415 2699 2024
M36 x 4.00
Nm 2557 1918 3659 2744
NOTE: Lubed includes lubricants such as lubrizing, oil, grease, and some uncured thread lockers. 1375AC
Refer to the specific thread locker manufacturer’s instructions for specific torque adjustments.
37
Table 2.9 Torque Specifications for Hydraulic Couplings & Hoses
Hydraulic Coupling Torque Chart
O-Ring Port Connectors
Steel Ports Non-ferrous Ports
SAE Size
ft-lb Nm ft-lb Nm
4 14-16 20-22 9-10 12-13
6 24-26 33-35 15-16 20-21
8 50-60 68-78 30-36 41-47
10 72-80 98-110 43-48 60-66
12 125-135 170-183 75-81 102-110
16 200-220 270-300 120-132 162-180
20 210-280 285-380 126-168 171-228
24 270-360 370-490 162-216 222-294
32 - - - -
Hose End Torque Chart Hose End Torque Chart

for JIC for Flat-Face O-Ring Seal (Steel)
Size Steel Brass Size Torque Specification
ft-lb Nm ft-lb Nm ft-lb Nm
Dash Frac. Dash Frac.
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
-4 1/4" 10 11 13 15 5 6 6.75 9 -4 1/4" 10 12 14 16
-6 3/8" 17 19 23 26 12 15 17 20 -6 3/8" 18 20 24 27
-8 1/2" 34 38 47 52 20 24 27.66 33 -8 1/2" 32 40 43 54
-10 5/8" 50 56 69 76 34 40 46.33 55 -10 5/8" 46 56 60 75
-12 3/4" 70 78 96 106 53 60 72.33 82 -12 3/4" 65 80 90 110
-16 1" 94 104 127 141 74 82 100.5 111 -14 1" 65 80 90 110
-20 1 1/4" 124 138 169 188 75 83 101.5 113 -16 1 1/4" 92 105 125 240
-24 1 1/2 156 173 212 235 79 87 107 118 -20 1 1/2 125 140 170 190
-32 2" 219 243 296 329 158 175 214 237 -24 2" 150 180 200 245
1276AA
38
2.10 Air Conditioner Temperature/Pressure Chart
R-134a Temperature/Pressure Chart

Ambient Temperature °F (°C) Low Pressure Gauge High Pressure Gauge
65 °F (18 °C) 25-35 psi (172-241 kPa) 135-155 psi (931-1069 kPa)
70 °F (21 °C) 35-40 psi (241-276 kPa) 145-160 psi (1000-1103 kPa)
75 °F (24 °C) 35-45 psi (241-310 kPa) 150-170 psi (1034-1172 kPa)
80 °F (27 °C) 40-50 psi (276-345 kPa) 175-210 psi (1207-1448 kPa)
85 °F (29 °C) 45-55 psi (310-379 kPa) 225-250 psi (1551-1724 kPa)
90 °F (32 °C) 45-55 psi (310-379 kPa) 250-270 psi (1724-1862 kPa)
95 °F (35 °C) 50-55 psi (345-379 kPa) 275-300 psi (1896-2068 kPa)
100 °F (38 °C) 50-55 psi (345-379 kPa) 315-325 psi (2172-2241 kPa)
105 °F (41 °C) 50-55 psi (345-379 kPa) 330-335 psi (2275-2310 kPa)
110 °F (43 °C) 50-55 psi (345-379 kPa) 340-345 psi (2344-2379 kPa)
Interpreting Pressure Readings

Low Pressure Gauge High Pressure Gauge Action Required
In Range In Range A/C working properly
Low Low Add refrigerant
Need service, possibly blockage of the
Low High
expansion valve or orifice tube
Need service, possibly faulty
High Low
compressor
High High System overcharged.*
*It is illegal to vent R-134a refrigerant into the atmosphere.
39
2.11 Floor loading pressure
Weights Pressures
Max weight per LCP** OUP**
MEWP
Models wheel/outrigger
Weight pad
kg lb kg lb kPa psi kg/m2 psf
Min* 12837 28300 4173 9200 290 42 1050 215

SJ1044 TH
Max* 17373 38300 6441 14200 441 64 1421 291
Min* 15150 33400 4037 8900 276 40 1240 254

SJ1056 TH
Max* 19686 43400 7938 17500 545 79 1611 330
Min* 16738 36900 4808 10600 331 48 1372 281

SJ1256 TH
Max* 22181 48900 8981 19800 614 89 1816 372
2180AA
* Min: Minimum MEWP weight (Unloaded platform, no options/attachments)
Max: Maximum MEWP weight (Platform loaded to capacity with options/attachments)
Wheel is the weight that can be experienced on one wheel.

Note: This is more than 25% of the machine weight due to possible weight distribution over the machine and platform.
** LCP: Local Concentrated Pressure is a measure of how hard the MEWP presses on the area in direct contact with the floor/tire.
OUP: Overall Uniform Pressure is a measure of the average load the MEWP imparts on the whole surface directly underneath the
chassis. This has been calculated by dividing the MEWP weight by the overall floor area occupied by the MEWP (on wheels).
Note: The floor covering (e.g., tile, carpet, etc.) or the structure (e.g., beams) of the operating surface must
be able to withstand more than the values indicated above.
Locally Concentrated Pressure (LCP) Overall Floor Load (OFL)
Foot Print Area identified by test Base Area = Length x Width
Wheel Load Weight of MEWP + Capacity
LCP = OFL =
Foot Print Area Base Area
60
40
20
Foot Print Area
Base Width
Base Length
40
Section 3 – System Component
Identification and Schematics
41
Section 3 – System Component Identification and Schematics Electrical Symbol Chart
Table 3.1 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 PROXIMITY
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
42
Hydraulic Symbol Chart Section 3 – System Component Identification and Schematics
Table 3.2 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
VARIABLE BI DIRECTIONAL
DISPLACEMENT HYDRAULIC
OIL COOLER VALVE COIL
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

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

MAIN LINES Solid
TRANSDUCER
SERVO
43
Section 3 – System Component Identification and Schematics Electrical Components Parts List
3.3 Electrical Components Parts List

Index Skyjack
Qty. Description
No. Part No.
60CR 9-921734 1 RELAY, Power Relay

11CR 9-165029 1 RELAY, Glow Plug
56ACR 9-156200 1 RELAY, Fuel Pump
403ACR 9-931298 1 RELAY, Positive Air Shutoff
19CR 9-931298 1 RELAY, Boom Up
222CR 9-931298 1 RELAY, Frame Level Enable
224CR 9-931298 1 RELAY, Carriage Tilt Enable
5JCR 9-931298 1 RELAY, Brake Lamp
77CR 9-931298 1 RELAY, Engine Running
212CR 9-931298 1 RELAY, Boom Angle
65CR 9-931298 1 RELAY, Frame Level Disable
28CR 9-931298 1 RELAY, Boom Raise Disable
28LCR 9-931298 1 RELAY, Frame Left Enable
28RCR 9-931298 1 RELAY, Frame Right Enable
05CR 9-931298 1 RELAY, Park Brake Release
255CR 9-931298 1 RELAY, Rear Wiper
258CR 9-931298 1 RELAY, Front Wiper
258ACR 9-931298 1 RELAY, Top Wiper
250ACR 9-931298 1 RELAY, Left Turn Signal
251ACR 9-931298 1 RELAY, Right Turn Signal
223ACR 9-931298 1 RELAY, RAS Restric Mode Enable
220CR 9-931298 1 RELAY, RAS Drive/Brake
F1 9-156203 1 FUSE, Ignition/ Power (10A)
F2 9-156203 1 FUSE, Transmission/Back-up Alar/ Park Brake (10A)
F3 9-156203 1 FUSE, Steer Select/Gauge/Transmission Temp (10A)
F4 9-156203 1 FUSE, Frame/Carriage Enable (10A)
F5 9-156203 1 FUSE, Rear Axle Lock (10A)
F6 9-156202 1 FUSE, Auxilliary Hydraulics (5A)
F7 9-156203 1 FUSE, Horn/Beacon Option (10A)
F8 9-156204 1 FUSE, Power port (15A)
F9 9-156202 1 FUSE, Rear wiper (5A)
F10 9-156203 1 FUSE, Outriggers (10A)
F11 9-156203 1 FUSE, Work lights (10A)
F12 9-156204 1 FUSE, Road lights (15A)
F13 9-156202 1 FUSE, Turn/Hazard/Brake lights (5A)
F14 9-156203 1 FUSE, Boom lights (10A)
F15 9-156203 1 FUSE, Front & Top Wiper (10A)
F16 - - Not used.
44
Electrical Components Parts List Section 3 – System Component Identification and Schematics
Index Skyjack
Qty. Description
No. Part No.
F17 9-156202 1 FUSE, Fan/Interior Light (5A)

F18 9-156164 1 FUSE, Blower motor (30A)
F20 9-156203 1 FUSE, Heater Valve & A/C (10A)
F19 9-156203 1 FUSE, Frame Level Interlock (10A)
F21 9-156164 1 FUSE, SCR Control (30A)
F22 9-156204 1 FUSE, After SCR CAT (15A)
F23 9-156202 1 FUSE, Prior SCR CAT (5A)
F24 9-156204 1 FUSE, DEF Level (5A)
F25 9-156164 1 FUSE, ECM (30A)
F26 9-121504 1 FUSE, Fuel Pump (20A)
F27 9-165031 1 FUSE, Glow Plug (100A)
SW1 9-926721 1 SWITCH, Ignition
SW2 9-191454 1 SWITCH, Park brake
SW3 - - Not used.
SW4 9-191457 1 SWITCH, Steer mode
SW5 9-196995 1 SWITCH, Frame level (Joystick)
SW6 9-405339 1 SWITCH, Horn switch (button)
SW7 9-196995 1 SWITCH, Carriage Tilt (Joystick)
SW8 9-191680 1 SWITCH, Fan
SW9 9-191455 1 SWITCH, positive shutoff
SW10 9-191455 1 SWITCH, boom lights
SW11 9-191457 1 SWITCH, work lights+
SW12 9-191457 1 SWITCH, turn signal
SW13 9-191658 1 SWITCH, Interior light
SW14 9-191459 1 SWITCH, rear washer/wiper
SW15 9-197031 1 SWITCH, Auxiliary Extend
SW16 9-197031 1 SWITCH, Auxiliary Retract
SW17 - - Not used.
SW18 9-191491 1 SWITCH, A/C
SW19 9-191457 1 SWITCH, Road lights
SW20 - - Not used.
SW21 9-191458 1 SWITCH, LH outrigger
SW22 9-191458 1 SWITCH, RH Outrigger
SW23 9-191455 1 SWITCH, Hazard lights
SW24 9-191459 1 SWITCH, Washer/wiper front/top
D05J 9-102921 1 DIODE, Console harness
D26B 9-102921 1 DIODE, Console harness
D60 9-102921 1 DIODE, Console harness
D252-1 9-102921 1 DIODE, Console harness
D252A-1 9-102921 1 DIODE, Console harness
D252A-2 9-102921 1 DIODE, Console harness
45
Section 3 – System Component Identification and Schematics Electrical Components Parts List
Index Skyjack
Qty. Description
No. Part No.
D221 9-102921 1 DIODE, Chassis Harness

D15 9-102921 1 DIODE, Engine Harness
D250 9-102921 1 DIODE, Road light Harness
D251 9-102921 1 DIODE, Road light Harness
D60-1 9-102921 1 DIODE, Console harness
D15A 9-102921 1 DIODE, Console harness
- 9-190547 2 SENSOR, Inductive proxi - mm
- 9-166700 2 SENSOR, Pressure
2H-19A 9-159821 1 COIL, #8
2H-57 9-159821 1 COIL, #8
2H-221 9-159821 1 COIL, #8
2H-28 9-159821 1 COIL, #8
2H-28A 9-159821 1 COIL, #8
4H-223 9-159821 1 COIL, #8
4H-223-1 9-159821 1 COIL, #8
4H-47 9-159821 1 COIL, #8
4H-47-1 9-159821 1 COIL, #8
3H-26 9-168057 1 COIL, #10
4H-217 9-168057 1 COIL, #10
4H-218 9-168057 1 COIL, #10
46
Hydraulic Components Parts List Section 3 – System Component Identification and Schematics
3.4 Hydraulic Components Parts List

Index Skyjack
Qty. Description
No. Part No.
ACC1 9-400947 1 ACCUMULATOR, Diaphragm (if equipped)

ACC2 9-400947 1 ACCUMULATOR, Diaphragm (if equipped)
C1 9-190027 1 CYLINDER, Front steer
C1 9-205013 1 CYLINDER, Front steer - SJ1256 THS
C2 9-190028 1 CYLINDER, Rear steer
C2 9-205032 1 CYLINDER, Rear steer - SJ1256 THS
C3 9-190038 1 CYLINDER, Lift - 150B
C3 9-205058 1 CYLINDER, Lift - SJ1256 THS
C4 9-190038 1 CYLINDER, Lift - 150B
C4 9-205058 1 CYLINDER, Lift - SJ1256 THS
C5 9-190045 1 CYLINDER, Extend - 115B
C5 9-205061 1 CYLINDER, Extend 130B - TH1056 - SJ1256 THS
C6 9-190040 1 CYLINDER, Tilt comp - 120B
C6 9-205789 1 CYLINDER, Tilt comp 120B - SJ1256 THS
C7 9-190043 1 CYLINDER, Fork tilt - 120B
C7 9-205788 1 CYLINDER, Fork tilt - 120B - SJ1256 THS
C8 9-191832 1 CYLINDER, RAS
C9 9-190041 1 CYLINDER, Frame level - 115B
C9 9-205063 1 CYLINDER, Frame level - 115B - SJ1256 THS
C10 9-191123 1 CYLINDER, TH Outriggers
C10 9-205064 1 CYLINDER, TH Outriggers - SJ1256 THS
C11 9-191123 1 CYLINDER, TH Outriggers
C11 9-205064 1 CYLINDER, TH Outriggers - SJ1256 THS
C12 9-190025 1 CYLINDER, Front Axle
C12 9-205013 1 CYLINDER, Front Axle - SJ1256 THS
CB1 9-199472 1 VALVE, Counter-balance - 4200PSI
CB1 9-206179 1 VALVE, Counter-balance -230/120 - SJ1256 THS
CB2 9-206180 1 VALVE, Counter-balance -150 - SJ1256 THS
CB3 9-191813 1 VALVE, Counter-balance - 4000PSI - SJ1056 TH/THS
CB3 9-199473 1 VALVE, Counter-balance - 3900PSI - SJ1044 TH/THS
CB3 9-206182 1 VALVE, Counter-balance -310/70 - SJ1256 THS
CB4 9-206233 1 VALVE, Counter-balance - 290 - SJ1256 THS
47
Section 3 – System Component Identification and Schematics Hydraulic Components Parts List
Index Skyjack
Qty. Description
No. Part No.

CB12 9-191816 1 VALVE, Counter-balance -3700 PSI - SJ1256 THS
CB13 9-191816 1 VALVE, Counter-balance -3700 PSI - SJ1256 THS
CV1 9-166066 1 VALVE, Check
CV2 9-171412 1 VALVE, Check - SJ1256 THS
CV13 9-191806 1 VALVE, Check disc
EC1 9-191799 1 PRESSURE COMPENSATOR
EC1 9-206188 1 PRESSURE COMPENSATOR - SJ1256 THS
F1 9-157907 1 FILTER ELEMENT, Hydraulic spin-on
F2 9-191484 1 FILLER BREATHER, 1PSI
JS1 9-190356 1 JOYSTICK, Hydraulic
JS1 9-922265 1 JOYSTICK, Hydraulic
MB1 9-169031 1 MANIFOLD, Main
MB1 9-205190 1 MANIFOLD, Main - SJ1256 THS
MB2 9-169033 1 MANIFOLD, Auxiliary
MB2 9-205202 1 MANIFOLD, Auxiliary - SJ1256 THS
MB3 9-190357 1 MANIFOLD, Reserve brake
MB4 9-198734 1 MANIFOLD, RAS
48
Hydraulic Components Parts List Section 3 – System Component Identification and Schematics
Index Skyjack
Qty. Description
No. Part No.
MB5 9-169034 1 MANIFOLD, Outrigger

MB5 9-205191 1 MANIFOLD, Outrigger - SJ1256 THS
MB6 9-206115 1 MANIFOLD, RV4-1 - SJ1256 THS
MB7 9-213232 1 MANIFOLD, Premium Joystick (Option)
OR1 9-191807 1 PLUG, Orifice
OR3 9-206178 1 PLUG, Orifice - SJ1256 THS
OSM1 9-406450 1 MOTOR, Steering wheel
P1 9-190263 1 PUMP, Hydraulic
P1 9-205221 1 PUMP, Hydraulic - SJ1256 THS
PR1 9-191798 1 SWITCH, Pressure reducing/relieving
PR2 9-220518 1 SWITCH, Pressure reducing/relieving - SJ1256 THS
PS1 9-191810 1 SWITCH, Pressure 450 PSI
PS2 9-927724 1 SWITCH, Pressure brake light
PS3 9-191800 1 SWITCH, Pressure 350 PSI - SJ1256 THS
RV1 9-191802 1 VALVE, Relief
RV2 238579 1 VALVE, Relief
RV3 9-221887 1 VALVE, Relief anti-cavitation
RV4 9-191804 1 VALVE, Relief anti-cavitation
RV4-1 9-206093 1 VALVE, Relief anti-cavitation - SJ1256 THS
SV1 9-197301 1 VALVE, Shuttle
SW 9-197304 1 SWITCH, Pressure 1500 PSI
V1 9-191794 1 VALVE, Proportional-pilot operated
V1 9-206190 1 VALVE, Proportional-pilot operated - SJ1256 THS
V2 9-191793 1 VALVE, Proportional, pilot operated
V5 9-191795 1 VALVE, Solenoid 4W3P
49
Section 3 – System Component Identification and Schematics Hydraulic Components Parts List
Index Skyjack
Qty. Description
No. Part No.

V10 9-171796 1 VALVE, Solenoid cartridge
V11 9-102626 1 VALVE, Solenoid cartridge spool
V12 9-926370 1 VALVE, Brake
V13 9-191801 1 VALVE, Piloted 2W N.O.
V13 9-206192 1 VALVE, PILOTED 2-WAY SPOOL. - SJ1256 THS
V14 9-205813 1 VALVE PROPORTIONAL AUX. 12K - SJ1256 THS
V15 9-166038 1 VALVE, 2 way, normally closed spool
V15 9-206194 1 VALVE, SOLENOID CARTRIDGE, 2-WAY - SJ1256 THS
V18 9-197302 1 VALVE, Pressure unloading
V19 9-197303 1 VALVE, Low flow 2 way, normally closed
V20 9-168056 1 VALVE, 2W2P - SJ1256 THS
V21 9-199466 1 VALVE, SOLENOID POPPET 2W N.C. - SJ1256 THS
V22 9-168056 1 VALVE, 2W2P - SJ1256 THS
V27 9-213997 COIL, DROP IN -EHPR98-T33 12VDC (Option)
V28 9-213997 COIL, DROP IN -EHPR98-T33 12VDC (Option)`
50
Hydraulic Pump and Return Filter Ports Identification Section 3 – System Component Identification and Schematics
3.5 Hydraulic Pump and Return Filter Ports Identification
Port L
To Hyd. Tank
Pressure
Compesator
Adjuster
Load Sense
Compesator
Adjuster
Port X to Port LS
Port S on Main Manifold
Port P to Port P12
To Hyd. Tank on Main Manifold
Inlet
Outlet
Return Filter
M190807-1 M191415AA-S1
51
Section 3 – System Component Identification and Schematics Steering Control Unit Ports Identification
3.6 Steering Control Unit Ports Identification
Port L to Port L
on Front Axle
Steering Cylinder
Port T to Port STT
on Main Manifold
Port LS to Port STLS

on Main Manifold
Port P to Port CF
on Main Manifold
Port LS to Port Steer

on Optional Reserve
Brake Manifold
Port R to Por ORBR

on Main Manifold
M191585-SM
52
Service Brake Actuator (Brake Pedal) Ports Identification Section 3 – System Component Identification and Schematics
3.7 Service Brake Actuator (Brake Pedal) Ports Identification
Port T to Port DR1

on Main Manifold
Port P to Port A1 on
optional Reserve
Brake Manifold
Port P to Port A1
Port P to Port SB
on optional Reserve
on Main Manifold
Brake Manifold
M191582-SM
53
Section 3 – System Component Identification and Schematics Auxiliary Block Ports Identification
3.8 Auxiliary Block Ports Identification
Port A
to Bulkhead #7
Port AUX. LS
to Port AUX LS
Port B on Main Manifold
to Bulkhead #7
Port AUX T
4H-233
to Port AUX T
Solenoid Valve
Port AUX EF1 on Main Manifold
to Port AUX EF1
on Main Manifold
M190791AB-S1
54
Joystick Port Identifications Section 3 – System Component Identification and Schematics
3.9 Joystick Port Identifications
MACHINE
FRONT
“4”
“1” “P”
“T”
“2” “3”
Port 2 to Port J2
on Main Manifold
Port P to Port PS
on Main Manifold
Port 1 to Port J1
on Main Manifold
Port T to Port DR2

on Main Manifold
Port 3 to Port J3
on Main Manifold
Port 4 to Port J4
on Main Manifold
M190356-1
55
Section 3 – System Component Identification and Schematics Premium Joystick Port Identifications
3.10 Premium Joystick Port Identifications
MACHINE
FRONT
"3"
"2" "P" "4"
"1" "T"
Port 2 to Port J2
on Main Manifold
Port P to Port PS
on Main Manifold
Port 1 to Port J1
on Main Manifold
Port T to Port DR2

on Main Manifold
Port 3 to Port J3
on Main Manifold
Port 4 to Port J4
on Main Manifold
M1344040201_JS
56
Premium Joystick Manifold Port Identifications Section 3 – System Component Identification and Schematics
3.11 Premium Joystick Manifold Port Identifications
Port D to tee fitting DR1

on Main Manifold
3H-40
Carriage Down
3H-41
Carriage Up
Port A
to Carriage Down Port
on Main Manifold
Port B
to Carriage Up Port
Port D to tee fitting GP2
on Main Manifold
on Main Manifold
213749AA-SM
57
Section 3 – System Component Identification and Schematics Rear Axle Stabilization Manifold Port Identification
3.12 Rear Axle Stabilization Manifold Port Identification
2H-65
RAS Restrict
2H-221-1 2H-221-2 2H-221-3

RAS Unlock RAS Unlock RAS Unlock
2H-65
RAS Restrict
RV6
Relief Valve
Port RAST
to Port RAST
on Main Manifold
2H-65
RAS Restrict
Port RASP RV7

to Port RASP Relief Valve
on Main Manifold
CV15
Check Valve
M198734AB-S1
58
Outrigger Manifold Port Identifications Section 3 – System Component Identification and Schematics
3.13 Outrigger Manifold Port Identifications
V25 V26
4H-227 4H-225
& &
4H-228 4H-226
Port R1 to Port R
on Right Outrigger Port E1 to Port E
Cylinder on Right Outrigger
Cylinder
Port OUTT EF2

to Port OUTT
Port OUTT LS on Main Manifold
to Port OUTT LS
on Main Manifold
Port R2 to Port R
Port E2 to Port E on Left Outrigger
on Left Outrigger Cylinder
Cylinder
Port DR4 to Port DR4

on Main Manifold
M191835-S
59
Section 3 – System Component Identification and Schematics Anti-Cavitation Relief Valve (SJ1256 THS Only)
3.14 Anti-Cavitation Relief Valve (SJ1256 THS Only)
RV4-1
Anti-Cavitation
Relief Valve
Port P2 to Port T2
on Main Manifold
Port P1 to Port CA
on Main Manifold
M206115AA
60
3.15 Major Components Identification and Location
A B C D E F G H
MB1 CB3 & CB4

Main Manifold Counter Balance
Valves
V
C7 C5
Tilt Compensation/ Telescope
Slave Cylinder Cylinder
MB4
R.A.S.
Manifold
C8
Rear Stabilization CB5
Cylinder Counter
Balance
F2 Valve
Tank Filler
Breather
W
P1
MB3
Hydraulic CB1 & CB2
Optional Reserve
Pump Counte Balance
Brake Manifold
Valves
F1
C3 & C4
Hydraulic
Boom Lift
Return Filter
Cylinders
Frame
Angle
Sensor
X
MB5
MB2 Outrigger
Auxiliary Manifold Manifold
C6
Carriage Tilt
JS1 Cylinder
Joystick
OSM1
Steering Control
Unit
C2 Y
Rear Steer
Cylinder
C9
Frame Level C10
Cylinder Left Outrigger
Cylinder
C11
CB6 & CB7 Right Outrigger
Counter Balance Cylinder
Valves
C1 Z
Front Steer V12
Cylinder Service Brake
Actuator (Pedal)
M190530-Major Components
61
3.16 Main Manifold Port Identification
A B C D E F G H
GP1 Port RCR to Port R

on Rear Axle Steer
Port J2 to Port 2 Cylinder
on Main Manifold
V
OR2
Port RCR to Port L

GP3 on Rear Axle Steer
Cylinder
Port CB to
Bulkhead #3
Port LB to Port CB2

Port CA to on Left Boom Lift
Bulkhead #3 Cylinder
W
Port DR2 to Port T
on Joystick
Port CA to
Bulkhead #3
Port LA to Port CB1
(SJ1256 THS)
on Left Boom Lift 2H-28A
Cylinder Frame Left Enable
Port CA to Solenoid Valve
Port P1 on
RV4-1 Valve OR4
OR3
(SJ1256 THS) X
RV3 Anti-Cavitation PR2

Relief Valve Pressure
Reducing Valve V13
(SJ1256 THS) Pilot Valve
RV4
Anti-Cavitation
Relief Valve PS2 Switch
(Cavity Plug on SJ1256 THS)
Port T1 to Port F1
on Return Filter Y
CV11
Check Valve
Port P12 to Port P
on Hydraulic Pump Port CF to Port P
on optional Reserve
PR1 Brake Manifold
Pressure Reducing
Valve Port CF to Port P Port TB to
on Steering Control Bulkhead #4 Port J1 to Port 1 2H-28B
Unit Port BR1 to Port A on Joystick Frame Right Enable
on Brake Pedal Solenoid Valve
Port TA to Port FB to Port CB7 Z
EC1 on Frame Level
Bulkhead #4
Pressure Cylinder
Compensator Port FA to Port CB6
on Frame Level
Cylinder
M169032AF-S1-12k
62
A B C D E F G H
Port J3 to Port 3 Port J3 to Port 3

Port ORBR to Port R on Joystick on Joystick
on Steering Control
Unit
V
Port FCR to Port R

on Front Axle Steer
Cylinder
2H-221
Frame Speed Port RAST to RAST
Solenoid Valve on Main Manifold
W
Port PS1 to Port Port PB to
On Joystick Park Brake on
Port RASP to RASP
Front Axle
on Main Manifold
Port OUTT to
Port OUTT EF2 on
Outrigger Manifold
CV10
Check Valve
Port T2 to Port P2 on
RV4-1 Valve
Port DR1 to Port T (SJ1256 THS)
CV4 X
Check Valve on Brake Pedal
CV12
(SJ1256 THS)
Check Valve
Port LS to Port X
CV3 on Hydraulic Pump
Check Valve (SJ1256 THS)
Port DR1 to Port T

CV7 Port J4 to Port 4 on Brake Pedal
Check Valve on Joystick (SJ10XX TH/THS)
CV2
OR1 Check Valve
Y
CV6
Check Valve
DRAIN to
CV1 Hydraulic Tank
Port STLS to Port LS Port BR3 to Port LS to Port X
Check Valve
on Steering Control Rear Axle on Hydraulic Pump
Unit (SJ10XX TH/THS)
CV1
CV8 Check Valve
Port STLS to Port LS Check Valve
CV9 (SJ1256 THS)
on optional Reserve
Port BR2 Check Valve
Brake Manifold
to Front Axle CV5
Check Valve Z
OR7
Port DR3 to Port T
on optional Reserve
Brake Manifold RV2 PS1
Relief Valve Pressure Switch
M191300AG-S2-12k
63
A B C D E F G H
RV1 Port STT to Port T

4H-47-1 Relief Valve on Steering Control
V2 Carriage Down Unit 3H-26
Carriage Pilot Solenoid Valve Park Brake Disable
Operated
Solenoid Valve V
Valve
2H-14A
Boom Up Enable
Solenoid Valve
Port SB to Port A1
on optional Reserve
4H-47 Port SB to Port P Brake Manifold 4H-223
Carriage Up on Brake Pedal Frame Level Left
Solenoid Valve Solenoid Valve
V3 W
Telescopic Pilot
Operated
Valve
X
GP2 4H-217 & 4H-218
Steer Function
Solenoid Valve
V1
Boom Function
Pilot Operated
Valve
V4
Frame Tilt Pilot
Operated Valve
4H-223-1
Frame Level Right Z
Solenoid Valve
M169032AF-S3
64
3.17 Enclosed Cab Harness & Wiring Diagram
A B C D E F G H
FRONT WIPER GROUND

ON CHASSIS
WASHER MOTOR FOR

FRONT & TOP WIPER
V
FAN
TO CONSOLE W
HARNESS
TOP WIPER
CONNECTOR
J44 DEUTSCH DT
4-WAY SOCKET
8 1
05N PE 208 DK PE
X
DEUTSCH
05L PE 208A DK PE
05L PE 260 TN/WH
259A LT YW/PE 259 LT YW/PE
5 4
LIGHT
GND ON WASHER MOTOR FOR

FRONT WIPER CHASSIS FRONT & TOP WIPER
4 3 2 1
00-10 WH
260-16 TN/WH
259A-16 LT YW/PE
259-16 LT YW/PE
00-16 WH
00-16 WH
05L-16 PE
FAN
05N-16 PE
00-16 WH
Y
TO CONSOLE
HARNESS
TOP WIPER
208-16 DK PE
1
208A-16 DK PE 208A-16 DK PE
1
260-16 TN/WH 05L-16 PE
2
3
208-16 DK PE
3
259-16 LT YW/PE 00-16 WH
4
259A-16 LT YW/PE
5
05L-16 PE
6
05L-16 PE
7
05N-16 PE SPL 05N
8
SPL 00
05N-16 PE
00-16 WH
Z
2 1
LIGHT
M191472AC-S
65
3.18 Glow Plug Harness & Wiring Diagram
A B C D E F G H
J5
V
CONNECTOR J5 11
PIN 1 - 11C BLACK
PIN 2 - 11A BLACK
RELAY CONNECTION DETAIL
PIN 3 - 11 RED 11C TERM 30 - 11B (RED)
PIN 4 - PLUGGED
11B
TERM 85 - 11A (BLACK)
TERM 86 - 11 (BLACK)
11A
TERM 87 - 11C (RED) W
100
03 03 11B
J5
CONNECTOR P1
SOCKET 1 - 11C RED (10GA)
P1
4
SOCKET 2 - 11C RED (10GA) Y
11-18 BK 11-18 BK
TO 86
3
11A-18 BK 11A-18 BK
TO 85
2
1 11C-18 RD
P1
11C-10 RD
2
(+) 11C-10 RD 11C-8 RD

TO 87
1
Z
11B-8 RD 11B-8 RD
TO 30
M191468AB-S1
66
3.19 Road Lights Harness & Wiring Diagram
A B C D E F G H
RIGHT RIGHT
FRONT RIGHT TURN SIGNAL/ BACKUP
FRONT LEFT BRAKE LIGHT
HEAD LIGHT & HEAD LIGHT &
TURN SIGNAL V
TURN SIGNAL
PS2
BRAKE PRESSURE
SWITCH
GND FRAME REAR
LEFT
12 1
TURN SIGNAL/ W
261 BN/YW BRAKE
250 LT BL/BK
DEUTSCH
251 PK/BL
271A BE/YW 253 RD/GY
271 BE/YW 251B PK/BL
15 BL 250B LT BL/BK
7 6
LEFT
BACKUP
LIGHT
TO CONSOLE
HARNESS
X
RIGHT RIGHT
TURN SIGNAL/ BACKUP
BRAKE LIGHT
PS2
FRONT LEFT FRONT RIGHT
HEAD LIGHT & HEAD LIGHT & BRAKE PRESSURE
TURN SIGNAL TURN SIGNAL SWITCH GND NEAR FRAME
ON MAIN MANIFOLD COUNTER WEIGHT
1 2 3 4 5 6 1 2 3 4 5 6 A B
BLACK
WHITE
WHITE
00-12 WH
RED
RED
253-16 RD/GY
00-16 WH
250-16 LT BL/BK
271A-16 BE/YW
271A-16 BE/YW
271-16 BE/YW
271-16 BE/YW
251-16 PK/BL
00-16 WH
00-16 WH
SPL SPL SPL SPL SPL
261-16 BN/YW
251B-16 PK/BL
00-16 WH
00-16 WH
15-16 BL
LEFT
TURN SIGNAL/
SPL 00 BRAKE
00-16 WH SPL WHITE

261-16 BN/YW 261-16 BN/YW SPL BLACK
1
SPL 261 250B-16 LT BL/BK SPL RED
250-16 LT BL/BK SPL 250
D250
2
SPL 251
251-16 PK/BL
D251
TO CONSOLE 4
253-16 RD/GY
SPL
00-16 WH WHITE
HARNESS 5 251B-16 PK/BL
SPL 250B
SPL 251B
6 250B-16 LT BL/BK
7
8
15-16 BL
271-16 BE/YW SPL 271 SPL15
15-16 BL SPL RED Z
9 271A-16 BE/YW
10 SPL 271A
11
12 LEFT
BACKUP
LIGHT
M190595AA-S
67
3.20 Work Lights Harness & Wiring Diagram
A B C D E F G H
RIGHT FRONT LEFT FRONT

WORKLIGHT WORKLIGHT
ON CAB V
ON FRAME
SPL00
FRONT GND.
W
TO CONSOLE
HARNESS
P41 SPL246 LEFT REAR

SPL247
WORKLIGHT
ON CAB
REAR GND.
RIGHT FRONT X
WORKLIGHT LEFT FRONT
ON WORKLIGHT
FRAME ON CAB
1 2 1 2
00-14 WH
00-14 WH
246-14 LT GN/PK
RIGHT REAR
246-14 LT GN/PK
WORKLIGHT
ON FRAME TO CONSOLE
HARNESS
00-12 WH
FRONT GND.
SPL00
P41
A
246-14 LT GN/PK
SPL246 Y
247-14 LT GN/WT 247-14 LT GN/WT LEFT REAR

B 1
SPL247 00-14 WH
WORKLIGHT
C 2 ON CAB
00-14 WH
REAR GND.
247-14 LT GN/WT
00-14 WH
1 2 Z
RIGHT REAR
WORKLIGHT
ON FRAME
M190231AB-S
68
3.21 Boom Lights Harness & Wiring Diagram
A B C D E F G H
V
GROUND.
P26
TO CHASSIS W
BOOM LIGHTS HARNESS
00-14 WH
B
256-14 TN/BK
A Y
BOOM LIGHTS
00-14 WH SPL00
00-12 WH
B GND.
256-14 TN/BK 256-14 TN/BK TO CHASSIS
A
256-14 TN/BK HARNESS
Z
P26
M190288AC-S
69
3.22 Beacon Light Harness & Wiring Diagram
A B C D E F G H
GROUND
V
P37
BEACON BEACON
OPTION LIGHT
X
GND ON
CHASSIS
Y
00-16 WH
00-16 WH
P37 2
5D-16 PE 5D-16 PE 1
BEACON Z
(OPT)
M191613AB-S
70
3.23 RAS System Schematic and Wiring
A B C D E F G H
V
1 2 3 4
P118
221-16 DK GN/TN
65-16 YW/PK
00-16 WH
TO CHASSIS HARNESS
W
SPL221
SPL00
J116 J117
RAS UNLOCK RAS UNLOCK

SPL65
221-1 -16 DK GN/TN
221-2 -16 DK GN/TN
221-3 -16 DK GN/TN

65-1 -16 YW/PK
RAS RESTRICT RAS RESTRICT
65-16 YW/PK
00-16 WH
00-16 WH
00-16 WH
00-16 WH
00-16 WH
J114 J115 J75
RAS UNLOCK 1 2 1 2 1 2 1 2 1 2 Z
J114 J75 J115 J116 J117
RAS RESTRICT RAS RESTRICT RAS UNLOCK RAS UNLOCK RAS UNLOCK
M199375AB-S1
71
3.24 Elevate Telematics Harness
A B C D E F G H
03-GRN/PUR-16-TEW 60C-WHT/BLU-16-TEW
1
00-WH-16-TEW 60B-WHT/BLU-16-TEW
2
J77 J1
60C-WHT/BLU-16-TEW 03-GRN/PUR-16-TEW
FRONT VIEW BACK VIEW
3
PIN 1 - 60C-WHITE/BLUE 60B-WHT/BLU-16-TEW 00-WH-16-TEW
4
PIN 1 - 03-GREEN/PURPLE PIN 2 - 60B-WHITE/BLUE
PIN 2 - 00-WHITE PIN 3 - 03-GREEN/PURPLE
J77
5
PIN 3 - 60C-WHITE/BLUE 5 4 7 6 PIN 4 - 00-WHITE
6
PIN 4 - 60B-WHITE/BLUE 6 3 8 5 PIN 5 - PLUGGED W
PIN 5 - PLUGGED 7 2 9 4 PIN 6 - PLUGGED
CANH-YEL/BLU-16-TEW CANH-YEL/BLU-16-TEW J1
7
PIN 6 - PLUGGED 8 1 10 3 PIN 7 - CANH-YELLOW/BLUE CANL-GRN-16-TEW CANL-GRN-16-TEW
8
PIN 7 - CANH-YELLOW/BLUE 11 2 PIN 8 - CANL-GREEN
PIN 8 - CANL-GREEN 12 1 57D-BRN/GRN-16-TEW
PIN 9 - 57D-BROWN/GREEN
9
PIN 10 - PLUGGED 85 57D-BRN/GRN-16-TEW
10
PIN 11 - 221-DARK GREEN/TAN 57-BRN/GRN-16-TEW 87
221-DK GRN/TAN-16-TEW
11
PIN 12 - 26B-BLUE/YELLOW 30
57E-BRN/GRN-16-TEW D57B
26B-BLU/YEL-16-TEW
12
86
03B-GRN/PUR-16-TEW
J77 J1
221
03B
03B-GRN/PUR-16-TEW
HARNESS X
26B
26B SCHEMATIC
26B S26B
221 S221
221
57D 03B
26B-BLU/YEL-16-TEW
26B-BLU/YEL-16-TEW
S03B
03B
57DCR 57
Y
57E
M221451AC-S1
72
3.25 A/C Harness
A B C D E F G H
V
PRESS. SW.
TO HARNESS, A/C
HEATER & AC COMPRESSOR
269-16 DBE/RD
268-16 DBE/OE
Y
TO ENCL. CAB 268-16 DBE/OE 269-16 DBE/RD A/C

HARNESS COMPRESSOR
Z
M191598AB - S1
73
3.26 Transmission Electrical Connections
A B C D E F G H
P9
Reverse
P10
Forward
Y
P11
1st Gear
P12
2nd Gear
3.26 Transmission Electrical Connections
74
3.27 Console Harness and Layout 74 HP
A B C D E F G H I J K L M N O
R
402-16 GN 2
00-16 WH 9 7
26C-16 BL/YW
00-16 WH 3
26-16 BL/YW 1
OPTIONAL OPTIONAL OPTIONAL OPTIONAL 05-16 PE 57-16 BN/GN

2 5
FUEL GAUGE
POSITIVE SHUTOFF ROAD LIGHT WORKLIGHTS BOOM LIGHTS
J55
26C-16 BL/YW 3 6
57A-16 BN/GN
J55 J110 J52 J54
FUSE BLOCK
87 30
1 4 1 4
J53 I
S
05A-16 PE
55-16 YW/PE
86 271A-16 BE/YW 261-16 BN/YW 251-16 PK/BL 251A-16 PK/BL 00-16 WH
1 4
1 4 G
85 05H-16 PE 2 5
05H-16 PE 249-16 LT PE 05J-16 PE
2 2 5 2 5 2 5
258-16 LT YW/PK 2 5
J48 271-16 BE/YW 3 6
261-16 BN/YW
05L-16 PE
4
05L-16 PE
250-16 LT BL/BK 3 6
250A-16 LT BL/BK
10A
10A
10A
10A
F1 F4 3 3 6 3 3 6
260-16 TN/WH
2 5
258-16 LT YW/BE
POWER
J110 J51
3 6
RELAY
J57
15A
10A
10A
5A
F5 F8 S
J22
246-14 LT GN/PK 1 4
247-14 LT GN/WT
05G-14 PE 2 5
05G-14 PE 255-16 LT YW/BE
246-14 LT GN/PK 05F-16 PE
4
05F-16 PE
225-16 LT BE/WH 12 1 00-16 WH
DEUTSCH
3 1
10A
2 5
5A
F9 F12 ENCL. CAB REAR WASHER/ 238-16 LT GR/OR 255-16 LT YW/BE

05S-16 PE 2 60-16 WH/BE
J52
3 6
PARK BRAKE 226-16 LT GN 3
WASHER/WIPER WIPER STEER SEL.
J53 J57 J88 J58 J88
F13 F16 9
1
7
4 4 1
5K-16 PE 5K-16 PE
J82 CANH-18 YW/BE
CANL-18 GN
2 5
218-16 DK BL/GN 1
7 6
256-16 TN/BK 3 6
256-16 TN/BK TURN SWITCH
2 5 2 5 2 5 2 05A-16 PE 2
J54
217-16 DK BL/GY
J51
J65
10A
3
F17 F20 3 6 3 6 3 6 3
J58 227-16 LT GN/BE
6
1
8 1 05S-16 PE 2
3
228-16 LT GN/BK
26-16 BL/YW 16-16 WH/BK 3
DEUTSCH
SWITCH J49 219-16 DK BL/PK 05A-16 PE 74-16 GN/GY 203-16 BK
IGN.
9 7 9 7 15-16 BL 216-16 DK BL/GY
57B-16 BN/GN 215-16 DK BL/PE
GLOW PLUG/
220-16 DK GN/WE
10 8
00-16 WH 28C-16 GN
10 8
00-16 WH
57A-16 BN/GN
5 4
J83
DISPLAY
+VE SHUTOFF/
RESERVE BRAKE
J61
FRAME LEVEL
STOP
J96
TRANS TEMP/
RAS LOCK
J59
J59 J96 HAZARD SWITCH OUTRIGGER RIGHT
J83
OUTRIGGER LEFT
J82
MODULE
J22
J87 1 2
POWER PORT 9 7 9 7 9 7 GEAR SHIFTER & FNR
B+
HOUR METER J65 249-16 LT PE 05J-16 PE

HORN
J61
2 5
252-16 PK/RED 252A-16 PK/RED 1 1 8 7
3 6
PR
+
IGN
-
ST
2 5 2 2
00-16 WH 9 7
403A-16 RD
J87 3 6 3 3
AC
C
10 8 10 8 10 8
U
GR
211-16 DK PE/WH 8
00-16 WH
10
"+" "-"
03B-16 GN/PE OPT.
J49 BAT 57-16 BN/GN J102 GUAGE

LIGHT J50
STRTR 3 4
J69 P66 PIN # - WIRE NO. & COLOR J122
IGN
257-16 LT YW/GN 00-16 WH 249-16 LT PE

PR
FLASHER
1
05F-16 PE DEUTSCH
257A-16 LT YW/GN E D
C A 60-16 WH/BE F N/U J50 OPT. 05J-16 PE 249-16 LT PE 6 7
60-16 WH/BE P66
IGN
ACC
2 1 ENGINE F A B F 105-16 GN/BN CANL-18 YW/BE

D A B 00-16 WH J122 6 7
2
60-16 WH/BE CANH-18 GN

DIAGNOSTIC G 104-16 GN/OE 5 8
1-16 WH/BK 16-47 PE/OE PLUG C CANH-16 YE/BE 00-18 WH 4 9 57D-18 BN/GN
J H N/U
2-15 BL 17-05A PE D CANL-16 GN 03-18 GN/PE 3 10
8 1 G H
3-14A BK 18-19 OR/GN J/N/U 60-18 WH/BE 2 11 221-18 DK GR/TN
E N/U
4-216 DK BL/GY 19-49 GN/RD 05N-16 PE 208-16 DK PE 60B-18 WH/BE 1 12 26B-18 BL/YW V
DEUTSCH
31 20
30 21
20-05D PE J77
403A-16 RD
8 5-215 DK BL/PE 60-16 WH/BE 00-16 WH 05L-16 PE 208A-16 DK PE
402-16 GN
19 9
18 10 21-220 DK GN/WE ELEVATE 1 12
29 7
2
3 22 6-233 DK PE/OR 05L-16 PE 260-16 TN/WH
17 11
7-00 WH 22-213 DK GN/RD 259A-16 LT YW/PE 259-16 LT YW/PE
P66 TELEMATICS
J48
8
1
1
28 6 4 23 86 85 TELEMATICS
16 5 12 8-234 DK PE/RD 23-221 DK GN/TN
J44 03-16 GN/PE

15 13
9-219 DK BL/PK 24-05R PE 5 4 P66 PIN # - WIRE NO. & COLOR
DEUTSCH
27 14 24 D
26 25
25-212 DK GN/OE C E 00-16 WH
10-211 DK PE/WH P66 A 60-16 WH/BE F N/U J77
11-217 DK BL/GY 26-256 TN/BK ENGINE B A F 60B-16 WH/BE
12-218 DK BL/GN 27-256 TN/BK DIAGNOSTIC B 00-16 WH G 105-16 GN/BN MOREY
03
J G 60-16 WH/BE
13-26A BL/YW 28-28R GN PLUG C N/U H 104-16 GN/OE
J31
MC-3
00
14-223 DK GR H
29-28L GN ENCL. D N/U J N/U TELEMATICS
60B
REAR WIPER
FUEL LEVEL
5
CAB
4
15-57 BN/GR 30-28B RD/WE E N/U
31-28A GN J102 OPT. ENCL. ENCL.
POSITIVE OUTRIGGER WORK ROAD BEACON
CAB SHUTOFF OPTION. LIGHTS LIGHTS OPT.
TO BATTERY "B+" J47 CAB OPT.
OPT. OPT. OPT OPT.
J44 J45 J69 J81 J41 J42 J37
J81 28R CR
J120 FRAME
85
FLK
FLK
H
WASHER MOTOR 85
RIGHTJ99 87 W
12 1 226-16 LT GN 227-16 LT GN/BE 00-16 WH ENABLE 30
J31 FOR REAR WIPER 261-16 BN/YW
J42
DEUTSCH
225-16 LT BL/WH 228-16 LT GN/BK 213-16 DK GN/RD 87 87A 86
250-16 LT BL/BK 213A-16 DK GN/RD 85
TO CHASSIS
65-16 YW/PK 30 85 220CR
HARNESS 251-16 PK/BL 28L CR 87 87a J119 RAS
87
E
223A-16 DK GR 86 FRAME 30
271A-16 BE/YW 253-16 RD/GY DRIVE/BRAKE
LEFT J98 30
271-16 BE/YW 251B-16 PK/BL ENABLE 86
86
15-16 BE 250B-16 LT BL/BK J43 J32 85 85
212CR 87 87 223ACR
J113 00-16 WH 85 00-16 WH 85 87a 87a J120 RAS RESTRICT
7 6 BOOM J80
30 30
03A-16 GN/PE 87A 03B-16 GN/PE 259-16 LT YW/PE 87 259A-16 LT YW/PE ANGLE
TO CHASSIS 86 86
HARNESS 30 05L-16 PE 30
85 85 258CR
J41 403A-16 RD 86 258-16 LT YW/PK 86 28CR
BOOMJ104 87 87 87a J32 FRONT
WIPER
RAISE
65-16 YW/PK
3 4
C A
J99 J39 J100 DISABLE
86
30 30
86
DEUTSCH
28-16 GN 28C-16 GN 85 85
2 1 J95 00-16 WH 85
00-16 WH 85 00-16 WH 85 255CR
87 87
258ACR X
TO ENGINE 65A-16 YW/PK 87
87
REAR J28 87a 87a
J100 TOP
HARNESS 05B-16 PE 208-16 DK PE 87 87A 208A-16 DK PE WIPER 30 30 WIPER
CHASSIS GROUND J46 28B-16 GN 30
J68
J113 TO ENGINE
J1
JOYSTICK THROTTLE 28R-16 GN 86
47-16 PE/OE
224-16 DK GN/PK
30 05L-16 PE
258-16 LT YW/PK
30 86
85
86
85
86 86
247-14 LT GN/WT
246-14 LT GN/PK
HARNESS 87 251ACR
87a 87 87a
2 1 J46 J68 J98 J38 J108
403ACR
POSITIVE J43 30 30
J108 RIGHT
TURN
1 12 85 SHUTOFF 86 86
8 1 00-16 WH 85 85
6 1 00-16 WH 00-16 WH 85 85
CANH-18 YW/BE 104-16 GN/OE
74-16 GN/GY
222-16 DK BE/YW 05C-16 PE 65A-16 YW/PK 87 250ACR

DEUTSCH
DEUTSCH
05B-16 PE 87 254-16 TN 87A 251B-16 PK/BL 224CR

224-16 DK GN/PK 05C-16 PE 87 87 87a
J107 LEFT
DEUTSCH
CANL-18 GN 105-16 GN/BN 30

203-16 BK
28A-16 GN 223-16 DK GR 30 CARRIAGE J39

234-16 DK PE/RD 05B-16 PE 99-16 BK/GY 30 30 30 TURN
77-16 BN/GY 90-16 RD/GY 206-16 LT GN/YW 28L-16 GN 86 LEVEL
233-16 DK PE/OR 05B-16 PE 222-16 DK BE/YW 86 251A-16 PK/BL 86 86
60-16 WH/BE 54-16 PE/RD 86
85 85
99-16 BK/GY 57B-16 BN/GN 5 4 4 3 222CR 5JCR
J80 J36 FRAME J38 87 87
J106 BRAKE
90-16 RD/GY 206-16 LT GN/YW
00-16 WH 85 00-16 WH 85
J107 LEVEL 30 30 LAMP
86 86
J95 6 7 05R-16 PE 87 213-16 DK GN/RD 05A-16 PE 87 00-16 WH 85
85 85
Y
221-16 DK GN/TN 30 14-16 BK 30 254-16 TN 87A 250B-16 LT BL/BK 19CR 77CR
F4 F8 F12 F16 F20 BOOM 87 87
J36 J33
J1 04-10 RD/YW 212-16 DK GN/OE 86 19-16 OR/GN 86
250A-16 LT BL/BK
30 E.O.S 30 30
ENGINE
RUNNING
265-12 DK GN/BK 86 86 86
04-10 RD/YW
05E-14 PE 2x 05H-16 PE 266-16 BN/YW
J104 J97 05CR
85 85 65CR
05B-16 PE 04-10 RD/YW 77-16 BN/GY 85 J106 PARK J97
BRAKE
87a 87
30
87
30
J56 FRAME
LEVEL
00-16 WH 85 87 DISABLE
2x 05D-16 PE 2x 05G-14 PE 2x 05L-16 PE 05T-16 PE 26-16 BL/YW 26B-16 BL/YW 85 RELEASE
253-16 RD/GY 86 86
2x 05A-16 PE 14-16 BK 87 26A-16 BL/YW 30
05J-16 PE 87 85
14A-16 BK 30 05-16 PE
04-10 RD/YW 05C-16 PE 05S-16 PE 2x 05K-16 PE 05P-10 PE 86 254-16 TN 30 57DCR 87a 87
2x 05-16 PE 04-10 RD/YW 04-10 RD/YW
28-16 GN 86 STARTER J121 30
05J-16 PE 86 INTERRUPT
2x 05R-16 PE 86
03-10 GN/PE
03-16 GN/PE
2x 05F-16 PE 2x 05J-16 PE 05N-16 PE
J28 J119 J33
03A-16 GN/PE
00-16 WH 85 85
00-16 WH 85
F1 F5 F9 F13 F17 257-16 LT YW/GN 87 87A 257A-16 LT YW/GN 223A-16 DK GR 87 87A 223-16 DK GR
77-16 BN/GY
60-16 WH/BE 87
J121 Z
30
05F-16 PE 220-16 DK GN/WE 30
J56
F1 TO F20 255-16 LT YW/BE 86 220-16 DK GN/WE 86
60B-16 WH/BE
60-16 WH/BE
30
86 00-16 WH 85 57D-18 BN/GR 85
57E-16 BN/GR 87 87A D57B
05T-16 PE 87
57-16 BN/GR 30
65A-16 YW/PK 30
60-16 WH/BE 86
65-16 YW/PK 86
M216785AF-S2 3.27 Console Harness and Layout 74 HP
75
3.28 Console Harness Wiring Diagram 74HP
60ACR R
SW4
SW12 SW23 POWER
TURN SW. (OPT)
RESERVE BRAKE TRANS. REAR STEER MODE SW2 SW11 SW19
HAZ SW. (OPT)
SW24 SW14 RELAY
PREHEAT FRAME LEVEL SELECT SW. SW9
D05J
POSITIVE LOW HIGH AXLE SW10 OUTRIGGER WASHER/WIPER 2 (OPT) REAR WASHER/WIPER
PARK BRAKE SW. WORK LIGHTS ROAD LIGHTS
GLOW PLUG STOP SHUTOFF PRESSURE TEMP. LOCK. 05A-16 PE POSITIVE SHUTOFF BOOM LIGHTS SW. (OPTION) SW. (OPTION)
SW21 SW'S (OPTION) SW22
SW6 J110 J51 FLASHER SW1
J96 J61 J59 J58 (OPTION) SW (OPT)
J87 L.H. R.H. SPL05L SPL05F
(OPTION) SPL05S IGN. SW.
YW HORN J55 J53
RD RD RD RD RD J52 5 2
05J-16 PE
05J-16 PE
2 5 2
SWITCH J54 POWER PORT J50 J82 J83 J57 J88 J49
3 1 2 5 9 2 5 2 5 5 2 2 5 2 5
9 7 10 8 9 7 10 8 9 7 10 8 1 3 6 4 3 1 6 4 3 1 2 2 GR PR ST ACC IGN IGN B+
49
00
2 3
6 7 6 4 3 1 3 1 3 1
3 1 6 4
3 1 6 4 3 1 6 4 3 1 6 4
SPL05J
252A-16 PK/RED
211-16 DK PE/WH
213A-16 DK GN/RD
218-16 DK BL/GN
217-16 DK BL/GY
252-16 PK/RED
250A-16 LT BL/BK
87
219-16 DK BL/PK
74-16 GN/GY
250-16 LT BL/BK
SPL261
249-16 LT PE
249-16 LT PE
249-16 LT PE
249-16 LT PE
28C-16 GN
49-16 GN/RD
251A-16 PK/BL
203-16 BK
246-14 LT GN/PK
246-14 LT GN/PK
05E-14 PE
00-16 WH
251-16 PK/BL
00-14 WH
403A-16 RD
05J-16 PE
00-16 WH
00-16 WH
57A-16 BN/GN
30
247-14 LT GN/WT
225-16 LT BE/WH
03B-16 GN/PE
402-16 GN
228-16 LT GN/BK
227-16 LT GN/BE
03-10 GN/PE
57E-16 BN/GN
26C-16 BL/YW
00-18 WH
26C-16 BL/YW
03-10 GN/PE
04-10 RD/YW
04-10 RD/YW
256-16 TN/BK
256-16 TN/BK
60-16 WH/BE
60-16 WH/BE
00-16 WH
00-16 WH
00-16 WH
26-16 BL/YW
60-16 WH/BE
05A-16 PE
57-16 BN/GN
271A-16 BE/YW
226-16 LT GN
261-16 BN/YW
271-16 BE/YW
85
05G-14 PE
05H-16 PE
05H-16 PE
05G-14 PE
5K-16 PE
5K-16 PE
00-16 WH
05-16 PE
86
05S-16 PE
00
238-16 LT GR/OR
258-16 LT YW/PK
258-16 LT YW/BE
255-16 LT YW/BE
255-16 LT YW/BE
60
260-16 TN/WH
05F-16 PE
05L-16 PE
05L-16 PE
05F-16 PE
GAUGE
D00
LIGHT OPT. D252A-1 D252A-2
SPL246 SPL251A
246-14 LT GN/PK D00-1
D26B SPL258 SPL255
SPL250A
SPL57
1000 Ω
RESISTOR
00-16 WH
60-16 WH/BE
26B-16 BL/YW
26B-16 BL/YW
D252-1 D252
SPL251 S
SPL250
SPL00
03-10 GN/PE
SPL03
03A-16 GN/PE
10A F1
05-16 PE
10A F2
05-16 PE
SPL05A 05A-16 PE 10A F3
05A-16 PE
T
05B-16 PE 10A F4
05R-16 PE
10A F5
05R-16 PE
05C-16 PE 5A F6
04-10 RD/YW
05D-16 PE 10A F7
05D-16 PE
04-10 RD/YW
05E-14 PE 15A F8
05F-16 PE
05F-16 PE 5A F9
05S-16 PE 10A F10
04-10 RD/YW
05G-14 PE
05G-14 PE F11
04-10 RD/YW
05H-16 PE
05H-16 PE F12
05J-16 PE
F13
05J-16 PE
05K-16 PE
F14
05K-16 PE
05L-16 PE
F15
05L-16 PE
F16
05N-16 PE F17
04-10 RD/YW
05P-10 PE F18 U
05T-16 PE 10A F19
05A-16 PE
I
SPL05A 266-16 BN/YW
FUEL 55-16 YW/PE F20
S
GAUGE
00-16 WH
G
265-12 DK GN/BK
55-16 YW/PE
FUEL 55
LEVEL 00
00-16 WH
SPL00
J65 3 215-16 DK BL/PE

216-16 DK BL/GY
V
2
5 57A-16 BN/GN
6 57B-16 BN/GN
F-N-R 8
26-16 BL/YW SPL26
15-16 BL SPL15 SPL15
7
16-16 WH/BK SPL16
1
D15A
4
SPL16A
D16
-ve 77-16 BN/GY

-
HOUR
METER TT SPL00
+ve 54-16 PE/RD
+
P66
00-16 WH
B
60-16 WH/BE
A
ENGINE
DIAGNOSTIC
CONN.
CAP
G
H
105-16 GN/BN
104-16 GN/OE W
P66A
C CANH-18 WY/BE
SPL00
D CANL-18 GN
00-16 WH SPL00
B
DIAGNOSTIC CAP 60-16 WH/BE SPL60 SPL60
D60-1
105-16 GN/BN SPL105

F
104-16 GN/OE SPL104
ENGINE G
CONN. 105-16 GN/BN

120 Ω
RESISTOR 104-16 GN/OE
J68 6 J46
SPL05C 05C-16 PE
2
1
05C-16 PE 2
1 SPL05B 05B-16 PE
THROTTLE 206-16 LT GN/YW 3
3 05B-16 PE
99-16 BK/GY 4
5 233-16 DK PE/OR JOYSTICK
90-16 RD/GY 5
4 234-16 DK PE/RD
6
224-16 DK GN/PK
26B-16 BL/YW 7
12 222-16 DK BE/YW
221-16 DK GR/TN 8
11
10
57D-16 GN
9
J122
TELEMATICS
8
7
CANL-18 GN
CANH-18 YW/BE
SPLCANL
SPLCANH X
6 SPL403A
5
00-16 WH
4
3
03-16 GN/PE
60-16 WH/BE SPL65
2
60B-16 WH/BE
1
03-16 GN/PE SPL03

1
00-16 WH SPL00
2
J77 SPL60B
60B-16 WH/BE
3
TELEMATICS SPL60 SPL223
4
60-16 WH/BE
5 SPL77
6
7
8
DIODE
D60
TO MOREY MC-3
SPL 254
60B-16 WH/BE
60B SPLD60
257A-16 LT YW/GN
257A-16 LT YW/GN
05P-10 PE
00-16 WH
257-16 LT YW/GN
257-16 LT YW/GN
255-16 LT YW/BE
00
SPL 05J
238-16 LT GR/OR
03-16 GN/PE
03
SPL05L
00-16 WH
05F-16 PE
05F-16 PE
00-16 WH
00-16 WH
J47 J45
12 A B
11
10 CANH-18 YW/BE J28
9 120 Ω
6 RESISTOR CANL-18 GN
Y
J22 5
86 85 J102 ENCL.
4 87A CAB ENCL. CAB
3 30 1 2 3 4
(OPT) BLOWER SWITCH
DISPLAY CANL-18 GN SPLcanL SPLcanL 87
7 WASHER (OPT)
MODULE SPLcanH
8 CANH-18 YW/BE SPL65A RELAY REAR WIPER MOTOR REAR WIPER
60-16 WH/BE SPLcanH FOR
SPL220
3-10 GN/PE
3-10 GN/PE
2 255CR REAR
57E-16 BN/GR
00-16 WH
57D-16 BN/GR
WIPER
60-16 WH/BE
57-16 BN/GR
1
258-16 LT YW/PK
259A-16 LT YW/PE
258-16 LT YW/PK
259-16 LT YW/PE
259A-16 LT YW/PE
208A-16 DK PE
259-16 LT YW/PE
221-16 DK GN/TN
221-16 DK GN/TN
208-16 DK PE
222-16 DK BE/YW
225-16 LT BL/WH
208A-16 DK PE
224-16 DK GN/PK
228-16 LT GN/BK
227-16 LT GN/BE
260-16 TN/WH
220-16 DK GN/WE
SPL3A
208-16 DK PE
220-16 DK GN/WE
213A-16 DK GN/RD
247-14 LT GN/WT
SPL3
00-16 WH
246-14 LT GN/PK
65A-16 YW/PK
05L-16 PE
05L-16 PE
213-16 DK GN/RD
226-16 LT GN
00-16 WH
213-16 DK GN/RD
223-16 DK GR
212-16 DK GN/OE
47-16 PE/OE
253-16 RD/GY
223A-16 DK GR
65-16 YW/PK
19-16 OR/GN
03B-16 GN/PE
250B-16 LT BL/BK
65A-16 YW/PK
03A-16 GN/PE
65A-16 YW/PK
223A-16 DK GR
250A-16 LT BL/BK
223-16 DK GR
250-16 LT BL/BK
05L-16 PE
05L-16 PE
05N-16 PE
250B-16 LT BL/BK
00-16 WH
65-16 YW/PK
00-16 WH
00-16 WH
251B-16 PK/BL
403A-16 RD
254-16 TN
5D-16 PE
271A-16 BE/YW
261-16 BN/YW
05B-16 PE
05B-16 PE
271-16 BE/YW
05J-16 PE
05J-16 PE
05T-16 PE
00-16 WH
00-16 WH
28A-16 GN
253-16 RD/GY
05A-16 PE
14A-16 BK
00-16 WH
28B-16 GN
251A-16 PK/BL
28R-16 GN
251-16 PK/BL
00-16 WH
28L-16 GN
00-16 WH
00-16 WH
251B-16 PK/BL
233-16 DK PE/OR
28-16 GN
211-16 DK PE/WH
234-16 DK PE/RD
D57B
218-16 DK BL/GN
220-16 DK GN/WE
05R-16 PE
00-16 WH
00-16 WH
14-16 BK
14-16 BK
216-16 DK BL/GY
217-16 DK BL/GY
215-16 DK BL/PE
219-16 DK BL/PK
254-16 TN
221-16 DK GN/TN
212-16 DK GN/OE
00-16 WH
254-16 TN
15-16 BL
00-16 WH
60-16 WH/BE
2.0 FLK
2.0 FLK
26B-16 BL/YW
60B-16 WH/BE
57-16 BN/GR
60-16 WH/BE
26A-16 BL/YW
26A-16 BL/YW
206-16 LT GN/YW
49-16 GN/RD
223-16 DK GR
28B-16 RD/WE
CANH-18 YW/BE
77-16 BN/GY
26-16 BL/YW
77-16 BN/GY
19-16 OR/GN
47-16 PE/OE
05D-16 PE
16A-16 WH/BK
16-16 WH/BK
256-16 TN/BK
256-16 TN/BK
J100
65-16 YW/PK
05A-16 PE
104-16 GN/OE
105-16 GN/BN
403A-16 RD
00-16 WH
60-16 WH/BE
74-16 GN/GY
402-16 GN
77-16 BN/GY
90-16 RD/GY
28R-16 GN
57B-16 BN/GN
28A-16 GN
99-16 BK/GY
54-16 PE/RD
05-16 PE
14A-16 BK
28L-16 GN
CANL-18 GN
J121 J32
28C-16 GN
28-16 GN
J56
05R-16 PE
15-16 BL
J98 J99 J43 J106 J107 J108 J81

203-16 BK
J119 J120 J104 J36 J38 J39

J37 J41 J42 86 85 86 85 86 85 J44
87 30
J80 B C E F G
86 85 86 85 B+ B+ 86 85 86 85 86 85 86 85 86 85 86 85 86 85 A B C 86 85 86 85
1 2 3 4 5 6 7 8 87A 87A 87A
65-16 YW/PK 86 85 86 85 9 10 11 12 30 30 30
J33 J97 87 87 87 1 2 3 4 5 6 7 8
JUMPER WIRE
00-10 WH
87A 87A 87A 87A 87A 87A 87A 87A 87A 87A 87A
A B C D 1 2 3 4 30 30 30 30 30 30 30 30 30 30 30 87A 87A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 87 87 87 87 87 87 87 87 87 87 87
86 85 86 85 87 30 87 30 STARTER RELAY FRONT RELAY TOP
1 2 3 4 5 6 7 8 9 10 11 12 1 2 J69 INTERRUPT OUTRIGGERS WIPER WIPER
J113 J31 BEACON
(OPT) 258A CR
87A 87A 86 85 WORKLIGHTS 57DCR 258CR
87
30
87
30 BOOM ANGLE RAS DRIVE/BRAKE BOOM RAISE BOOM E.O.S FRAME LEFT FRAME RIGHT FRAME LEVEL (OPT) FRAME LEVEL CARRIAGE LEVEL POSITIVE SHUTOFF BRAKE LAMP LEFT TURN RIGHT ROAD
J1 J95 TO CHASSIS HARNESS ENABLE RELAY HARN
RELAY RELAY 87A DISABLE RELAY ENABLE RELAY ENABLE RELAY ENABLE ENABLE ENABLE RELAY SIGNAL TURN SIGNAL LIGHTS ENCL. CAB OPTION
TO ENGINE HARNESS TO ENGINE HARNESS 30 (OPT)
POSITIVE 87 GND ON RELAY RELAY RELAY (OPT)
ENGINE PARK BRAKE 212CR 220CR 28 CR 19CR 28L CR 28R CR 65CR
CHASSIS
RUNNING RELEASE SHUTOFF (OPT) 222CR 224CR 403ACR 5JCR 250ACR 251ACR
RAS RESTRICT MODE
77CR 05CR ENABLE RELAY
223ACR
M216785AF-S1 3.28 Console Harness Wiring Diagram 74HP
76
3.29 Console Harness and Layout 107 HP - THS Models
ENCL. CAB OPT. J47

OPTIONAL OPTIONAL OPTIONAL OPTIONAL
402-16 GN 2
00-16 WH 9 7
26C-16 BL/YW
STANDSTILL 05A-16 PE R
00-16 WH 26-16 BL/YW 1 I
POSITIVE SHUTOFF ROAD LIGHT WORKLIGHTS BOOM LIGHTS 3
05-16 PE 57-16 BN/GN
START/STOP
55-16 YW/PE
J55 J110 J52 J54 26C-16 BL/YW
2 5
57A-16 BN/GN J89 S
3 6
J55
00-16 WH
87 G
30
FUSE BLOCK
85
86
1 4 1 4 J53 251-16 PK/BL 1 4
251A-16 PK/BL
FUEL GAUGE
2 2 5 2 5 2 5 249-16 LT PE 2 5
05J-16 PE 2
J48 271A-16 BE/YW 1 4
261-16 BN/YW 250-16 LT BL/BK 3 6
250A-16 LT BL/BK
10A
10A
10A
10A
F1 F4 3 3 6 3 3 6 05H-16 PE 2 5
05H-16 PE 4
258-16 LT YW/PK 3
POWER
J51
271-16 BE/YW 3 6
261-16 BN/YW 05L-16 PE 2 5
05L-16 PE
RELAY 260-16 TN/WH 3 6
258-16 LT YW/BE
J110 J57 J22

15A
10A
10A
5A
F5 F8
12 1 00-16 WH
DEUTSCH
60-16 WH/BE
225-16 LT BE/WH
246-14 LT GN/PK 247-14 LT GN/WT 1
S
10A
1 4
255-16 LT YW/BE
5A
F9 F12 ENCL. CAB REAR WASHER/ 05G-14 PE 2 5

05G-14 PE 4 05S-16 PE 2
05F-16 PE 05F-16 PE 226-16 LT GN
PARK BRAKE 246-14 LT GN/PK 2 5 3
CANH-18 YW/BE
WASHER/WIPER WIPER STEER SEL. 3
238-16 LT GR/OR 3 6
255-16 LT YW/BE
J53 J57 J88 J58
F13 F16 9 7 J52 J88 J82
CANL-18 GN
7 6
1 4 4 1
2 5 2 5 2 5 2 TURN SWITCH
5K-16 PE 5K-16 PE 218-16 DK BL/GN 1
2 5
J65 J51
10A
05A-16 PE
F17 F20 3 6 3 6 3 6 3 256-16 TN/BK 3 6
256-16 TN/BK 2
217-16 DK BL/GY 3
J54 J58
227-16 LT GN/BE
6
1
8 1 05S-16 PE 2
228-16 LT GN/BK
3
30A
15A
26-16 BL/YW
5A
5A
F21 F24 16-16 WH/BK 3
DEUTSCH
SWITCH J49 15-16 BL 216-16 DK BL/GY
IGN.
74-16 GN/GY 203-16 BK 57B-16 BN/GN 215-16 DK BL/PE
J83
9 7
219-16 DK BL/PK 05A-16 PE
9 7
57A-16 BN/GN
T
GLOW PLUG/ 5 4
28C-16 GN 00-16 WH
+VE SHUTOFF/ FRAME LEVEL TRANS TEMP/ 220-16 DK GN/WE 8
00-16 WH 10 8 DISPLAY
10
HAZARD SWITCH OUTRIGGER RIGHT OUTRIGGER LEFT MODULE
RESERVE BRAKE
J61
STOP
J96
RAS LOCK
J59
J59 J96 GEAR SHIFTER & FNR
J87 J83 J82
1 2
J22
POWER PORT 9 7 9 7 9 7
B+
J65 249-16 LT PE 05J-16 PE

HOUR METER
J61
2 5
HORN 252-16 PK/RED 252A-16 PK/RED 8 7
3 6 1 1
PR
+
IGN
-
ST
2 5 2 2
00-16 WH 9 7
403A-16 RD
J87 3 6 3 3
AC
C
10 8 10 8 10 8
GR
211-16 DK PE/WH 8
00-16 WH
10
"+" "-"
U
1-16 WH/BK 16-47 PE/OE J92
2-15 BL 17-05A PE
J90 85 OPT.
3-14A BK 18-19 OR/GN 240 CR A04-18 BK 85 GUAGE
30
31
8
20
21
4-216 DK BL/GY
5-215 DK BL/PE
19-49 GN/RD
20-05D PE
SCR J90
CONTROL
87
30
242A-16 BK 87 LIGHT J50
18
19 9
10 21-220 DK GN/WE 00-16 WH 30
29 7
2
3 22 6-233 DK PE/OR A41-18 BK 85 86 P66 PIN # - WIRE NO. & COLOR
22-213 DK GN/RD 242-18 BK 249-16 LT PE
28
17
16
6
1
5
4
11
12
23 7-00 WH
8-234 DK PE/RD 23-221 DK GN/TN
232-14 LT BL 87 85 86
P66
E D
C A 60-16 WH/BE F N/U J50 FLASHER
OPT. 05J-16 PE 249-16 LT PE
J122 J85
15 13 232A-14 LT BL 30 241 CR 87
9-219 DK BL/PK 24-05R PE F A B F 105-16 GN/BN
27
26
14
25
24
10-211 DK PE/WH 25-212 DK GN/OE 240-18 BK 86

SUCTION J91
LINE
30 J93 ENGINE
DIAGNOSTIC
B 00-16 WH
C CANH-16 YE/BE G 104-16 GN/OE
6 7 00-18 WH 85
11-217 DK BL/GY 26-256 TN/BK 86 PLUG 6 7 CANL-18 YW/BE 03S-14 GN/PE 87
12-218 DK BL/GN A04-18 BK 85 J
D CANL-16 GN H N/U J122 CANH-18 GN
27-256 TN/BK 85 G H 5 8 04A-14 RD/YW 30
13-26A BL/YW 28-28R GN 242 CR J/N/U 00-18 WH 57D-18 BN/GN
J31 87 243A-16 BK 87 E N/U 4 9

14-223 DK GR 29-28L GN BACK J92 03-18 GN/PE 04-16 RD/YW 86
00-16 WH 30 3 10
15-57 BN/GR 30-28B RD/WE FLOW 30 60-18 WH/BE 2 221-18 DK GR/TN
11
243-18 BK
J91
31-28A GN 86 86 60B-18 WH/BE 26B-18 BL/YW
85
1 12
V
ELEVATE 1 12
03B-16 GN/PE
85
243 CR
PRESSURE J93
87
30
J94 J77 TELEMATICS
J49
A04-18 BK
LINE
BAT 57-16 BN/GN
241A-16 BK 87 86 A04-18 BK 85
P66 J86
8
1
STRTR 00-16 WH 30 85 244A-16 BK
IGN
87 TELEMATICS 85
03-16 GN/PE 00-18 WH
PR
DEUTSCH
241-18 BK 244 CR 87 00-16 WH 30 P66 PIN # - WIRE NO. & COLOR
1
86 D
SUPPLY J94 P66 C E 00-16 WH 235-16 LT BE/RD 87
60-16 WH/BE 30 244-18 BK
IGN
ACC
MODULE 86 ENGINE A 60-16 WH/BE F N/U J77 60B-16 WH/BE 30

86 B A F 236-16 LT BE/GY
2
60-16 WH/BE DIAGNOSTIC B 00-16 WH G 105-16 GN/BN 60-16 WH/BE 26C-16 BL/YW
J31 PLUG J G
C N/U H 104-16 GN/OE
86
H
TO CHASSIS D N/U J N/U
5
4
8 1 MOREY
03
HARNESS E N/U
MC-3
00
60-16 WH/BE 00-16 WH 05N-16 PE 208-16 DK PE TELEMATICS
DEUTSCH
60B
05L-16 PE 208A-16 DK PE
J48 86 85 J102 05L-16 PE

259A-16 LT YW/PE
260-16 TN/WH
259-16 LT YW/PE 87
85
87a
J119 RAS
220CR
3 4 30 DRIVE/BRAKE W
J44
257-16 LT YW/GN 00-16 WH
05F-16 PE DEUTSCH
257A-16 LT YW/GN
5 4 J81 J120
28R CR
FRAME
85 86
FUEL LEVEL J41 RIGHTJ99 87
H
2 1 85
85 ENABLE 30 04CR
226-16 LT GN 227-16 LT GN/BE 00-16 WH 87 87a
ENCL. 86 SWITCHED
CAB C A 225-16 LT BL/WH 228-16 LT GN/BK 213-16 DK GN/RD 87 87A 213A-16 DK GN/RD J85 POWER
12 1 261-16 BN/YW 30
OPT. ENCL. POSITIVE OUTRIGGER WORK ROAD BEACON 85
J42
DEUTSCH
REAR WIPER ENCL. LIGHTS LIGHTS OPT. 65-16 YW/PK 30 28L CR
CAB SHUTOFF OPTION. 87 86
TO ENGINE J47 CAB OPT. 250-16 LT BL/BK FRAME
J102 OPT. OPT. 223A-16 DK GR 86 85
E
TO BATTERY "B+" HARNESS OPT. OPT LEFT J98 30 235CR
251-16 PK/BL
J29
J44 J45 J69 J81 J41 J42 J37
271A-16 BE/YW 253-16 RD/GY
J43 ENABLE 86
87
J86 POWER TO
SCR
B+
271-16 BE/YW 251B-16 PK/BL 00-16 WH 85 J32 85
30
86
J113 B- 212CR
247-14 LT GN/WT
87
246-14 LT GN/PK
87A 87a
15-16 BE 250B-16 LT BL/BK 03A-16 GN/PE 03B-16 GN/PE 85
FLK
BOOM J80
FLK
00-16 WH 85
30 ANGLE 30 223ACR
3 4 259-16 LT YW/PE 87 259A-16 LT YW/PE 87 J120 RAS RESTRICT
65-16 YW/PK
28-16 GN DEUTSCH
28C-16 GN J29 WASHER MOTOR
FOR REAR WIPER
7 6 403A-16 RD 86 05L-16 PE
258-16 LT YW/PK
30
86 28CR
86
85
30
86
2 1
242A-16 BK
3 4
243A-16 BK J99 J39
BOOMJ104
RAISE
87
30
85 258CR
241A-16 BK DEUTSCH
232A-14 LT BL DISABLE 87 87a J32 FRONT X
2 1 00-16 WH 85
00-16 WH 85 J100 86
85
30
WIPER
65A-16 YW/PK 87
05B-16 PE 87 85 255CR 86
00-16 WH 87
J113 J69 28B-16 GN
28R-16 GN
30
47-16 PE/OE 30
208-16 DK PE 87 87A 208A-16 DK PE
REAR J28
WIPER
87a
30
85
258ACR
86 87 87a
TO CHASSIS 8 1
224-16 DK GN/PK 86 05L-16 PE 30 86 J100 TOP
D A 30 WIPER
HARNESS 85
232A-14 LT BE 235-16 LT BE/RD
J98 J38
258-16 LT YW/PK 86
DEUTSCH
231-18 TN/PK 236-16 LT BE/GY JOYSTICK 86

J68 403ACR
87a 87
85
229-16 DK GN/YW 239-18 LT GN/TN
CHASSIS GROUND J46 6 1

00-16 WH 85
00-16 WH 85 J108 POSITIVE J43
SHUTOFF 86
30
87 87a
J108 RIGHT
251ACR
5 4 65A-16 YW/PK 87
J46 05B-16 PE 87 85 30 TURN
85
403A-16 RD
30 00-16 WH
DEUTSCH
28A-16 GN
402-16 GN
8 1 223-16 DK GR 30 86
J2 J78 222-16 DK BE/YW 05C-16 PE
J68
THROTTLE
99-16 BK/GY
90-16 RD/GY 206-16 LT GN/YW 28L-16 GN 86 222-16 DK BE/YW 86
254-16 TN 87A 251B-16 PK/BL 224CR
CARRIAGE J39
87
85
DEUTSCH
TO ENGINE 30 30 250ACR
224-16 DK GN/PK 05C-16 PE LEVEL 87 87a
HARNESS 234-16 DK PE/RD 05B-16 PE 251A-16 PK/BL 86 86 J107 LEFT
4 3 TURN
12 1 240-18 BK
J78 233-16 DK PE/OR 05B-16 PE J80 J36 222CR
85
30
86
TO ENGINE 87
DEUTSCH
85 85 FRAME J38
A41-18 BK HARNESS 5 4
00-16 WH 00-16 WH
J107 LEVEL 30
85
5JCR Y
05R-16 PE 87 213-16 DK GN/RD 05A-16 PE 87 87
244A-16 BK 00-18 WH
30 30
86 J106 BRAKE
F4 F8 F12 F16 F20 F24 221-16 DK GN/TN 14-16 BK 00-16 WH 85 30 LAMP
244-18 BK 230-18 TN/BL 85
J1 04-10 RD/YW 212-16 DK GN/OE 86 19-16 OR/GN 86 254-16 TN 87A 250B-16 LT BL/BK 19CR 86
A04-18 BK 241-18 BK BOOM 87
TO ENGINE 04-10 RD/YW
265-12 DK GN/BK 04A-14 RD/YW 30 E.O.S
J36 30 85
242-18 BK
243-18 BK HARNESS 05E-14 PE 2x 05H-16 PE 266-16 BN/YW 230-18 TN/BL
J104 J97 250A-16 LT BL/BK 86 86
87
J33
77CR
ENGINE
05B-16 PE 04-10 RD/YW 30 RUNNING
7 6 77-16 BN/GY 85 85
2x 05D-16 PE 86
1 12 2x 05G-14 PE 2x 05L-16 PE 05T-16 PE 231-18 TN/PK 05CR
2x 05A-16 PE 04-16 RD/YW
00-16 WH
87
85
26-16 BL/YW 87 26B-16 BL/YW J106 PARK J97
BRAKE
87a 87
30 85 65CR
J2 CANH-18 YW/BE 104-16 GN/OE 14-16 BK 26A-16 BL/YW 30 FRAME
DEUTSCH
04-10 RD/YW 05C-16 PE 05S-16 PE 2x 05K-16 PE 05P-10 PE 229-16 DK GN/YW 85 RELEASE 87 J56
CANL-18 GN 105-16 GN/BN 14A-16 BK 30 253-16 RD/GY 86 LEVEL
04-10 RD/YW 04-10 RD/YW
05-16 PE 86 30
2x 05-16 PE
05J-16 PE 87 85 DISABLE
77-16 BN/GY 2x 05R-16 PE
28-16 GN 86 57DCR 86
03-10 GN/PE 2x 05F-16 PE 2x 05J-16 PE 05N-16 PE 232-14 LT BL 30
254-16 TN STARTER J121 87a 87
60-16 WH/BE 54-16 PE/RD 03-16 GN/PE
99-16 BK/GY 57B-16 BN/GN

03A-16 GN/PE
03S-14 GN/PE
03S-10 GN/PE J28 J119 05J-16 PE 86 INTERRUPT
86
30
90-16 RD/GY 206-16 LT GN/YW 85

00-16 WH 85
F1 F5 F9 F13 F17 F21
257-16 LT YW/GN 87 87A 257A-16 LT YW/GN
00-16 WH
223A-16 DK GR 87 87A 223-16 DK GR
J33 J56 J121 Z
6 7 30 85
05F-16 PE 30 85 85
J1
F1 TO F24 255-16 LT YW/BE 86
220-16 DK GN/WE
220-16 DK GN/WE 86
77-16 BN/GY
60-16 WH/BE 87
00-16 WH
05T-16 PE 87
57D-18 BN/GR
57E-16 BN/GR 87
30
87A D57B
60B-16 WH/BE 30 65A-16 YW/PK 30 57-16 BN/GR
60-16 WH/BE 65-16 YW/PK 86 60-16 WH/BE 86
86
M216786AF-S2 3.29 Console Harness and Layout 107 HP - THS Models
77
3.30 Console Harness Wiring Diagram 107 HP - THS Models
60ACR
SW4
SW12 SW23 POWER
TURN SW. (OPT)
RESERVE BRAKE TRANS. REAR STEER MODE SW2 SW11 SW19
HAZ SW. (OPT)
SW24 SW14
SW25 TO ENGINE HARNESS TO ENGINE HARNESS
RELAY
SELECT SW. SW9
D05J
PREHEAT FRAME LEVEL POSITIVE LOW HIGH AXLE SW10 OUTRIGGER
PARK BRAKE SW. WORK LIGHTS ROAD LIGHTS WASHER/WIPER 2 (OPT) REAR WASHER/WIPER START/STOP
GLOW PLUG STOP SHUTOFF PRESSURE TEMP. LOCK. 05A-16 PE POSITIVE SHUTOFF BOOM LIGHTS SW21 SW'S (OPTION) SW22
SW. (OPTION) SW. (OPTION) SWITCH
J58 SW6 (OPTION) SW (OPT) J110 J51 FLASHER SPL05L SPL05F J89 SW1
J96 J61 J59 J87 L.H. R.H.
(OPTION) SPL05S IGN. SW.
YW HORN J55 J53
RD RD RD RD RD J52 5 2
05J-16 PE
05J-16 PE
2 5 2
SWITCH J54 POWER PORT J50 J82 J83 J57 J88 2 5 J29 J2 J49
2 5 5 2 2 5 2 5 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12
7 10 8 7 10 8 8 1 3 1 2 5 9 2 5
6 4 3 1 6 4 3 1 2 2 GR
9 9 9 7 10 3 PR ST ACC IGN IGN B+
49
00
2
S
3
6 7 6 4 3 1 3 1 3 1 3 6
3 1 6 4
3 1 6 4 3 1 6 4 3 1 6 4
SPL05J
252A-16 PK/RED
244A-16 BK
213A-16 DK GN/RD
211-16 DK PE/WH
244-18 BK
A04-18 BK
218-16 DK BL/GN
217-16 DK BL/GY
252-16 PK/RED
242-18 BK
243-18 BK
230-18 TN/BL
250A-16 LT BL/BK
87
219-16 DK BL/PK
74-16 GN/GY
54-16 PE/RD
250-16 LT BL/BK
SPL261
249-16 LT PE
249-16 LT PE
249-16 LT PE
240-18 BK
A41-18 BK
249-16 LT PE
241-18 BK
28C-16 GN
49-16 GN/RD
00-18 WH
03B-16 GN/PE
251A-16 PK/BL
246-14 LT GN/PK
246-14 LT GN/PK
05E-14 PE
232A-14 LT BL
251-16 PK/BL
00-16 WH
00-14 WH
403A-16 RD
05J-16 PE
00-16 WH
00-16 WH
243A-16 BK
57A-16 BN/GN
242A-16 BK
30
241A-16 BK
247-14 LT GN/WT
225-16 LT BE/WH
239-18 LT GN/TN
402-16 GN
228-16 LT GN/BK
227-16 LT GN/BE
03-10 GN/PE
57E-16 BN/GN
26C-16 BL/YW
00-18 WH
26C-16 BL/YW
03-10 GN/PE
04-10 RD/YW
04-10 RD/YW
256-16 TN/BK
256-16 TN/BK
60-16 WH/BE
60-16 WH/BE
60-16 WH/BE
00-16 WH
00-16 WH
00-16 WH
26-16 BL/YW
05A-16 PE
57-16 BN/GN
271A-16 BE/YW
236-16 LT BE/GY
226-16 LT GN
261-16 BN/YW
271-16 BE/YW
85
05G-14 PE
05H-16 PE
05H-16 PE
05G-14 PE
5K-16 PE
5K-16 PE
00-16 WH
05-16 PE
86
05S-16 PE
00
238-16 LT GR/OR
258-16 LT YW/PK
258-16 LT YW/BE
255-16 LT YW/BE
255-16 LT YW/BE
60
260-16 TN/WH
05F-16 PE
05L-16 PE
05L-16 PE
05F-16 PE
GAUGE
26B-16 BL/YW
D00
LIGHT OPT. D252A-1 D252A-2
SPL246 SPL251A
246-14 LT GN/PK
D26B SPL258 SPL255
D00-1
SPL250A
SPL57
1000 Ω
RESISTOR
26B-16 BL/YW
26C-16 BL/YW
D252-1 D252
00-16 WH
60-16 WH/BE
SPL251
SPL250
SPL00
T
03-10 GN/PE
SPL03
03A-16 GN/PE
10A F1
05-16 PE
10A F2
05-16 PE
SPL05A 05A-16 PE 10A F3
05A-16 PE
05B-16 PE 10A F4
05R-16 PE
10A F5
05R-16 PE
05C-16 PE 5A F6
04-10 RD/YW
05D-16 PE 10A F7
05D-16 PE
04-10 RD/YW
05E-14 PE 15A F8
05F-16 PE
05F-16 PE 5A F9
05S-16 PE 10A F10
04-10 RD/YW
05G-14 PE
05G-14 PE F11
04-10 RD/YW
05H-16 PE
05H-16 PE F12
05J-16 PE
F13
05J-16 PE
05K-16 PE
05K-16 PE
05L-16 PE
F14
F15
U
05L-16 PE
F16
05N-16 PE F17
04-10 RD/YW
05P-10 PE F18
05T-16 PE 10A F19

05A-16 PE
I
SPL05A 266-16 BN/YW
FUEL 55-16 YW/PE F20
S
GAUGE
00-16 WH
G
265-12 DK GN/BK
55-16 YW/PE
55
FUEL
LEVEL 00-16 WH
00
SPL00
55
00
SPL00
04-16 RD/YW
V
J65 3 215-16 DK BL/PE
2 216-16 DK BL/GY
5 57A-16 BN/GN 03S-14 GN/PE
6 57B-16 BN/GN
F-N-R 8
26-16 BL/YW SPL26
SPL15 SPL15 232-14 LT BL 30A F21
15-16 BL B+
7 03S-10 GN/PE
16-16 WH/BK SPL16
1
229-16 DK GN/YW 15A F22
D15A
4
SPL16A
D16
231-18 TN/PK 5A F23
230-18 TN/BL 5A F24 04A-14 RD/YW
04A-14 RD/YW
-ve 77-16 BN/GY

-
HOUR
METER TT SPL00
+ve 54-16 PE/RD SPL54
+
P66
00-16 WH
B
60-16 WH/BE
A
ENGINE
DIAGNOSTIC CAP
G 105-16 GN/BN
CONN.
104-16 GN/OE
H
P66A
CANH-18 WY/BE
W
C
SPL00
D CANL-18 GN
00-16 WH SPL00
B
DIAGNOSTIC CAP 60-16 WH/BE SPL60 SPL60
D60-1
105-16 GN/BN SPL105

F
104-16 GN/OE SPL104
G
105-16 GN/BN
120 Ω
RESISTOR 104-16 GN/OE
J68 6 J46
SPL05C 05C-16 PE
2 1
05C-16 PE 2
1
THROTTLE 206-16 LT GN/YW SPL05B 05B-16 PE
3 3
99-16 BK/GY 05B-16 PE
5 4
233-16 DK PE/OR JOYSTICK
90-16 RD/GY 5
4
234-16 DK PE/RD
6
26B-16 BL/YW 224-16 DK GN/PK
12 7
221-16 DK GR/TN 222-16 DK BE/YW
11 8
10
57D-16 GN
9
CANL-18 GN SPLCANL
J122 8
SPLCANH
7
CANH-18 YW/BE
TELEMATICS 6
5 SPL403A SPL A04
00-16 WH
4
3
03-16 GN/PE
60-16 WH/BE SPL65
2
60B-16 WH/BE
1
J77
1
03-16 GN/PE SPL03A
SPL00
SPL236
X
00-16 WH
2
60B-16 WH/BE SPL60B
3
TELEMATICS SPL223
60-16 WH/BE SPL60 SPL232A
4
SPL77
5 SPL00S
6
7
8
229-16 DK GN/YW
236-16 LT BE/GY
236-16 LT BE/GY
235-16 LT BE/RD
235-16 LT BE/RD
239-18 LT GN/TN
DIODE
26C-16 BL/YW
04A-14 RD/YW
03S-14 GN/PE
232A-14 LT BL
231-18 TN/PK
04-16 RD/YW
232A-14 LT BE
D60
232-14 LT BL
TO MOREY MC-3
A41-18 BK
244A-16 BK
241A-16 BK
242A-16 BK
243A-16 BK
00-14 WH
00-16 WH
00-16 WH
00-16 WH
00-16 WH
00-18 WH
00-18 WH
A04-18 BK
A04-18 BK
A04-18 BK
A04-18 BK
240-18 BK
241-18 BK
242-18 BK
243-18 BK
244-18 BK
SPL 254
60B-16 WH/BE
60B SPLD60
257A-16 LT YW/GN
257A-16 LT YW/GN
05P-10 PE
00-16 WH
257-16 LT YW/GN
257-16 LT YW/GN
255-16 LT YW/BE
TELEMATICS 00
SPL 05J
238-16 LT GR/OR
03-16 GN/PE
03
J86 J78 J90 J91 J92 J93 J94
SPL05L J85
00-16 WH
05F-16 PE
05F-16 PE
00-16 WH
1 2 3 4 5 6 7 8
85 86 85 86 85 86 85 86 85 86 85 86 85 86 J47 J45
12 A B
11 87A
30 30 30 30 30 30
10 CANH-18 YW/BE J28 87
30 87 87 87 87 87 87
9 120 Ω
6 RESISTOR CANL-18 GN
J22 86 85 J102 TO ENGINE RELAY SUCTION RELAY BACK RELAY PRESSURE RELAY SUPPLY ENCL.
5 POWER TO SCR SWITCHED POWER RELAY SCR B-VE
4 HARNESS FOR E.A.T LINE FLOW LINE LINE MODULE CAB ENCL. CAB
87A
S/Ws CONTROL
3 30 1 2 3 4 (OPT) BLOWER SWITCH
DISPLAY CANL-18 GN SPLcanL SPLcanL 87 241CR 242CR 243CR 244CR
7 235CR 04CR 240CR (OPT)
MODULE WASHER
CANH-18 YW/BE
SPLcanH SPLcanH
8 SPL65A RELAY REAR WIPER MOTOR REAR WIPER
60-16 WH/BE FOR
3-10 GN/PE
3-10 GN/PE
2 SPL220 255CR REAR

00-16 WH WIPER
1
57E-16 BN/GR
258-16 LT YW/PK
57D-16 BN/GR
60-16 WH/BE
259A-16 LT YW/PE
258-16 LT YW/PK
259-16 LT YW/PE
57-16 BN/GR
259A-16 LT YW/PE
208A-16 DK PE
221-16 DK GN/TN
221-16 DK GN/TN
259-16 LT YW/PE
208-16 DK PE
222-16 DK BE/YW
225-16 LT BL/WH
208A-16 DK PE
224-16 DK GN/PK
228-16 LT GN/BK
227-16 LT GN/BE
260-16 TN/WH
SPL3A
208-16 DK PE
247-14 LT GN/WT
SPL3
00-16 WH
246-14 LT GN/PK
65A-16 YW/PK
05L-16 PE
220-16 DK GN/WE
05L-16 PE
213-16 DK GN/RD
226-16 LT GN
00-16 WH
223-16 DK GR
212-16 DK GN/OE
47-16 PE/OE
253-16 RD/GY
220-16 DK GN/WE
213A-16 DK GN/RD
65-16 YW/PK
19-16 OR/GN
03B-16 GN/PE
250B-16 LT BL/BK
65A-16 YW/PK
03A-16 GN/PE
65A-16 YW/PK
250A-16 LT BL/BK
250-16 LT BL/BK
05L-16 PE
05L-16 PE
05N-16 PE
213-16 DK GN/RD
250B-16 LT BL/BK
223A-16 DK GR
00-16 WH
00-16 WH
00-16 WH
251B-16 PK/BL
403A-16 RD
254-16 TN
5D-16 PE
261-16 BN/YW
271A-16 BE/YW
05B-16 PE
223A-16 DK GR
05B-16 PE
271-16 BE/YW
05J-16 PE
223-16 DK GR
05J-16 PE
05T-16 PE
00-16 WH
00-16 WH
28A-16 GN
253-16 RD/GY
05A-16 PE
14A-16 BK
00-16 WH
28B-16 GN
251A-16 PK/BL
28R-16 GN
251-16 PK/BL
28L-16 GN
00-16 WH
00-16 WH
251B-16 PK/BL
65-16 YW/PK
233-16 DK PE/OR
28-16 GN
211-16 DK PE/WH
234-16 DK PE/RD
218-16 DK BL/GN
220-16 DK GN/WE
05R-16 PE
00-16 WH
14-16 BK
14-16 BK
216-16 DK BL/GY
217-16 DK BL/GY
215-16 DK BL/PE
219-16 DK BL/PK
254-16 TN
221-16 DK GN/TN
00-16 WH
57A-16 BN/GR
212-16 DK GN/OE
00-16 WH
254-16 TN
15-16 BL
00-16 WH
60-16 WH/BE
2.0 FLK
2.0 FLK
60B-16 WH/BE
26B-16 BL/YW
60-16 WH/BE
26A-16 BL/YW
26A-16 BL/YW
00-16 WH
206-16 LT GN/YW
49-16 GN/RD
223-16 DK GR
28B-16 RD/WE
CANH-18 YW/BE
77-16 BN/GY
26-16 BL/YW
77-16 BN/GY
19-16 OR/GN
47-16 PE/OE
16A-16 WH/BK
05D-16 PE
16-16 WH/BK
256-16 TN/BK
256-16 TN/BK
J100
D57B
65-16 YW/PK
05A-16 PE
104-16 GN/OE
105-16 GN/BN
403A-16 RD
00-16 WH
60-16 WH/BE
74-16 GN/GY
402-16 GN
90-16 RD/GY
77-16 BN/GY
28R-16 GN
57B-16 BN/GN
28A-16 GN
99-16 BK/GY
54-16 PE/RD
05-16 PE
14A-16 BK
28L-16 GN
CANL-18 GN
J32
28C-16 GN
28-16 GN
J56
05R-16 PE
15-16 BL
J80 J104 J36 J98 J99 J43 J106 J107 J108

J38 J39 J41 J121
J119 J120 J37 J42 J81 86 85 86 85 J44
J33 J97
86 85
86 85
87 30
B+ 86 85 86 85 86 85 86 85 86 85 86 85 86 85 A B C 86 85 86 85
86 85 86 85 1 2 3 4 5 6 7 8 9 10 11 12 86 85
B C E F G
87
87A
30 87
87A
30
1 2 3 4 5 6 7 8 Y
00-10 WH
87A 65-16 YW/PK 87A 87A 87A 87A 87A 87A

87A 87A 87A 87A
A B C D 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 87
30
87A JUMPER WIRE 87
30
87
30
87
30
87
30
87
30
87
30
87
30
87
30
87
30 87A 87A
87
30
RELAY TOP
86 85 86 85 30 87 30 87 30 RELAY FRONT
1 2 3 4 5 6 7 8 9 10 11 12
J69 87 OUTRIGGERS WIPER WIPER
J113 J31 BEACON
(OPT) 258A CR
87A 87A WORKLIGHTS STARTER 258CR
30 30 BOOM ANGLE BOOM RAISE BOOM E.O.S FRAME LEFT FRAME RIGHT FRAME LEVEL (OPT) FRAME LEVEL CARRIAGE LEVEL POSITIVE SHUTOFF BRAKE LAMP LEFT TURN RIGHT ROAD
J1 87 87 TO CHASSIS HARNESS 86 85 DISABLE RELAY HARN INTERRUPT
RELAY DISABLE RELAY ENABLE RELAY ENABLE RELAY ENABLE ENABLE ENABLE RELAY SIGNAL TURN SIGNAL LIGHTS ENCL. CAB OPTION
RAS DRIVE/BRAKE (OPT) 57DCR
TO ENGINE HARNESS RELAY RELAY RELAY (OPT)
ENGINE PARK BRAKE POSITIVE 212CR RELAY 87A 28 CR 19CR 28L CR 28R CR 65CR
30
RUNNING RELEASE SHUTOFF (OPT) 87
222CR 224CR 403ACR 5JCR 250ACR 251ACR
220CR
77CR 05CR
RAS RESTRICT MODE
ENABLE RELAY
223ACR
M216786AF-S1 3.30 Console Harness Wiring Diagram 107 HP - THS Models
78
3.31 Engine Harness 74 HP
X17.1 PIN # - WIRE NO. & COLOR

1- A38-18 BK 32 - A07-18 BK R
2- K28-18 BK 33 -
3- K37-18 BK 34 -
4- 35 - A16-16 WH
X17.1 5- 36 -
6- 37 - A18-16 WH
7- 38 - A32-16 BK
B+
8- 39 -
P1 TEMP.
9- A53-18 RD 40 - A46-16 BK
B+
10 - 41 - A03-16 WH
P6 TRANS. 11 - 42 - A48-16 BK S
00
7 1
(30A) 12 - 43 -
219
206 BK CNAH BK
P7 13 - A52-18 BK 44 -
00
57A BK CANL BK 1" 14 - A37-18 WH 45 - P4 P4 PIN # - WIRE NO. & COLOR
54 BK (20A)
1- 203 BK
10
77 WH 60 BK 15 - A39-18 BK 46 - K85-18 BK
105 WH 99 WH 16 - 47 - A19-16 BK 2- 202 WH
104 BK 90 BK 3- 204 RD
17 - K61-18 BK 48 - A20-16 WH
10
6 4-
12 18 - 49 -
19 - A04-16 WH 50 - K44-18 BK P3
1 2
TO CONSOLE 20 - A05-16 BK 51 - K82-18 BK
21 - A54-18 BK 52 - 200 BK 201 WH T
HARNESS
P1 22 - A24-18 BK 53 -
23 - A43-18 BK 54 -
60D
24 - A28-18 BK 55 - P3
25 - A26-18 BK 56 -
26 - A44-18 BK 57 -
47 Ω
10
CHASSIS 27 - A29-18 BK 58 -
00 28 - A40-18 BK 59 -
GROUND
D60
29 - A27-18 BK 60 -
TO CONSOLE 30 - 61 - A02-16 WH FUEL PUMP
P95 HARNESS
31 - A25-18 BK 62 - A33-16 BK
U
2 P95 00
48 WH SPLCANH SPL54
203 BK DEUTSCH SPLCANL SPL203
10
56B
1
SPL51
TO CHASSIS
HARNESS
10
POSI-"CAN" 10
FUEL PUMP
SPL02
10
RELAY V
P109
P8
120
SP
TO PRE-HEAT
SPLH
10
LL
P13
Ω
P13 P109 54 BK 85 30 BA+ RD P5
D15
2 1
SPLK01
56B BK 56A WH 3 4
SPL00
8 1 CANH BK CANL BK
87 86
A45 BK
DEUTSCH
16 WH A35 BK A23 BK
DEUTSCH
51 BL/GN P5 2 1
219 DK BL/PK 216 DK BL/GRY
15 BL 215 DK BL/PRL
W
5 4 TRANSMISSION SOLS.
10
D2.2 D2.1
X
D2.2 PIN # - WIRE NO. & COLOR
1- K01-14 RD 21 - 41 - 61 - K61-18 BK 81 - D2.1 PIN # - WIRE NO. & COLOR
2- 00-14 WH 22 - 42 - 62 - 90-18 BK 82 - K82-18 BK 1- 21- 41-
2 - A02-16 WH 22- 42-
3- K01-14 RD 23 - 43 - 63 - 206-18 BK 83 -
3 - A03-16 WH 23- A23-18 BK 43- A43-18 BK
4- 00-14 WH 24 - 44 - K44-18 BK 64 - 200-18 BK 84 -
4 - A04-16 WH 24- A24-18 BK 44- A44- 18 BK
5- K01-14 RD 25 - 45 - 65 - 85 - K85-18 BK
5 - A05-16 BK 25- A25-18 BK 45- A45-18 BK
6- 00-14 WH 26 - 56A-18 WH 46 - 99-18 WH 66 - 86 - 6- 26- A26-18 BK 46- A46-16 BK
7- 27 - 47 - 67 - 87 - 202-18 WH 7 - A04-18 BK 27- A27-18 BK 47-
8- 28 - K28-18 BK 48 - 48-18 WH 68 - 103-18 BK 88 - 60-16 BK 8- 28- A28-18 BK 48- A48-16 BK REV
9- 29 - 203-18 BK 49 - 69 - 89 - 9- 29- A29-18 BK 49- FWD P10 1ST P11 2ND P12
10 - 30 - 50 - 70 - 90 - 54-18 BK 10- 30 50-
(TOP) P9 Y
11- 31- 51-
11 -
12 -
31 -
32 -
51 -
52 -
71 -
72 -
77-18 WH 91 -
92 - 12- 32- A32-16 BK 52- A52-18 BK P9 P10 P11 P12
13 - 204-18 WH 33 - 53 - 105-18 WH 73 - K61-18 BK 93 - 13- 33- A33-16 BK 53- A53-18 RD
14 - 34 - 54 - CANH-18 BK 74 - 94 - 14- 34- 54- A54-18 BK
2 1 2 1
15- 35- A35-18 BK 55- 2 1 2 1 00 WH 215 DK BL/PRL
15 - 103-18 BK 35 - 57A-16 BK 55 - 75 - 104-18 BK 51 BL/GN 15A BL 00 WH 216 DK BL/GRY
16- A16-16 WH 36- 56- 51 BL/GN 16 WH/BK
16 - 36 - 56 - 76 - CANL-18 WH
17- 37- A37-18 WH 57-
17 - 37 - 57 - 201-18 WH 77 - 18- A18-16 WH 38- A38-18 RD 58-
18 - 38 - 58 - 78 - 19- A19-16 BK 39- A39-18 WH 59-
19 - 39 - 59 - 79 - 20- A20-16 WH 40- A40-18 BK 60
20 - 40 - 60 - 80 -
Z
M232310AB - S1 3.31 Engine Harness 74 HP
79
3.32 Engine Harness 74 HP Wiring Diagram
D2.2 - 94 PIN 1 3 5 2 4 6 26 54 76 90 88 46 62 63 35 71 53 75 48 57 64 68 15 28 73 61 85 44 82 13 87 29 7 8 9 10 11 12 14 16 17 18 20 21 22 23 24 25 27 30 31 32 33 34 36 37 38 39 40 41 42 43 45 47 49 50 51 52 19 55 56 58 59 60 65 66 67 69 70 72 74 77 78 79 80 81 83 84 86 89 91 92 93 94
R
TO ECU
202-WH-18-TXL
48-WH-18-TXL
77-WH-18-TXL
204-RD-18-TXL
CANL-WH-18-TXL
201-WH-18-TXL
CANH-BK-18-TXL
K28-BK-18-TXL
K73-BK-18-TXL
K44-BK-18-TXL
K61-BK-18-TXL
K82-BK-18-TXL
105-WH-18-TXL
99-WH-18-TXL
103-BK-18-TXL
103-BK-18-TXL
56A-WH-18-TXL
K85-BK-18-TXL
200-BK-18-TXL
203-BK-18-TXL
00-WH-14-TXL
00-WH-14-TXL
57A-BK-16-TXL
00-WH-14-TXL
104-BK-18-TXL
54-BK-18-TXL
K01-RD-14-TXL
90-BK-18-TXL
K01-RD-14-TXL
60-BK-16-TXL
K01-RD-14-TXL
206 -BK-18-TXL
P4
SPLH
SPL203 203-BK-18-TXL
1
SPLK01 SPL00 202-WH-18-TXL
SPLL
2 TO COOLANT
120 Ω
204-RD-18-TXL
3 SENSOR
K01-RD-12-TXL
00-WH-12-TXL
4
SPL60
60D-BK-16-TXL 47 Ω
TO ALTERNATOR D60-2
51 52 53 54 55 56 57 58 59 60
60
59
58
57
56
51 55
K82-BK-18-TXL
K44-BK-18-TXL
50
50
T
49
49
K85-BK-18-TXL
46
47
A45-BK-18-TXL
45
45
A44-BK-18-TXL A44-BK-18-TXL
26
44
43
23
41 42
44
43
40
28
39
36
A35-BK-18-TXL
35
36
31 34
34
U
33
30
30
29
27
28
24
29
27
X17.1 - 62 PIN
26
31 25
25
D2.1 - 60 PIN A24-BK-18-TXL A24-BK-18-TXL TO ENGINE
22
24
A23-BK-18-TXL
TO ECU
23
18
K61-BK-18-TXL
21 22
17
16
A20-WH-16-TXL A20-WH-16-TXL
20
48
A19-BK-16-TXL A19-BK-16-TXL V
19
47
17
11 12
15
10
14
13
8
11 12
7
6
10
5
4
9
K73-BK-18-TXL
8
3
32
7
K28-BK-18-TXL
W
6
2
A54-BK-18-STP A54-BK-18-STP
21
54
A39-WH-18-STP A39-WH-18-STP
39
15
A38-RD-18-TXL A38-RD-18-TXL
38
1
A53-RD-18-TXL A53-RD-18-TXL
53
9
A52-BK-18-STP A52-BK-18-STP
52
13
A37-WH-18-STP A37-WH-18-STP
37
14
48
42
37
18
33
62
35
16
20
5
A04-WH-16-TXL A04-WH-16-TXL X
19
4
46
41 40
3
32
61 38
2
P6
1
B
30A
P7
B
A
20A
SPL54
D15
A
SPL51 SPL02 Y
215-DK BU/PU-16-TEW
BA+-RD-12-TXL
216-DK BU/GY-16-TEW
219-DK BU/PK-16-TEW
215-DK BU/PU-16-TEW
56A-WH-18-TXL
216-DK BU/GY-16-TEW
A54-BK-18-TXL
56B-BK-12-TXL
219-DK BU/PK-16-TEW
16-WH/BK-16-TEW
51-BK/GN-16-TEW
51-BK/GN-16-TEW
51-BK/GN-16-TEW
16-WH/BK-16-TEW
00-WH-16-TEW
15A-BU-16-TEW
00-WH-16-TEW
201-WH-18-TXL
105-WH-18-TXL
15-BU-16-TEW
200-BK-18-TXL
00-WH-16-TEW
57A-BK-16-TXL
48-WH-18-TXL
104-BK-18-TXL
99-WH-18-TXL
77-WH-18-TXL
B+-RD-12-TXL
B+-RD-12-TXL
203-BK-18-TXL
56B-RD-12-TXL
00-WH-12-TXL
00-WH-12-TXL
00-WH-12-TXL
60-BK-16-TXL
90-BK-18-TXL
54-BK-18-TXL
CANH-BK-18-TXL
CANH-BK-18-TXL
CANL-BK-18-TXL
CANL-BK-18-TXL
A23-BK-18-TXL
A35-BK-18-TXL
A45-BK-18-TXL
206-BK-18-TXL
P8
85 86
87A
87 30
2 1 2 1 1 2 3 4 2 1 2 1 2 1 2 1
1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8
56ACR (+) (-) B- B+
P10 P9 P11 P12 CHASSIS TRANS.

P109 P1 P95 P3 P5 P13 FWD
(TOP)
1ST 2ND
GROUND TEMP.
FUEL PUMP RELAY TO FUEL PUMP TO BATTERY TO POSI TO CONSOLE HARNESS TO CONSOLE TO WATER TO PRE-HEAT TO CHASSIS HARNESS REV Z
CAN HARNESS SENSOR TRANSMISSION
M209178AA-S2 3.32 Engine Harness 74 HP Wiring Diagram
80
3.33 Engine Harness Diagram 107 HP - THS Models
FUEL PUMP
B65 PIN # - WIRE NO. & COLOR
R
56B
1- A47 BK
00
2- A26 BK
UREA DOSING VALVE
Y24
P3
1 2 B65 PIN # - WIRE NO. & COLOR
1- A27 BK
B+
200 BK 201 WH 2- A09 BK
B65 P6
B+
00
EXST GAS TEMP.
BEFORE
OXY CAT
(30A)
B90 PIN # - WIRE NO. & COLOR P3 P7
00
10
B54 PIN # - WIRE NO. & COLOR (20A)
1- 230 BK S
1- A77 BK
2- A98 BK 2- A98 BK
10
D60 47 Ω 60D
3- A77 BK 3- 00 WH
4- 229 BK B78
4- 00 WH P11
B54
UREA QUALITY, P4 2 1 NOx SENSOR
PRIOR SCR CAT
A15-18 BK A27-18 BK
P1
LEVEL & TEMP 00 WH 216 DK BL/GRY
B78 7 1
UNDERNEATH
P4 PIN # - WIRE NO. & COLOR MIXING PIPE 206 BK CNAH BK
2ND
EXST GAS TEMP.
BEFORE P78 57A BK CANL BK
P79 PIN # - WIRE NO. & COLOR 1- 203 BK 1ST P11 SCR
54 BK 74 WH
8
1
(BOTTOM)
B90 1- A10 BK
2- 202 WH
TRANSM. P12 235-16 BK 232A-14 RD 77 WH 60 BK
DEUTSCH
3- 204 RD P12 2 1 99 WH
2- A50 WH SOLS.
237-18 WH 231-18 BK 105 WH
B65 PIN # - WIRE NO. & COLOR
4- 00 WH 215 DK BL/PRL 104 BK 90 BK T
1- A27 BK 00 239-18 WH 229-16 BK
AMBIENT AIR INLET 2- A09 BK 12 6
TEMP. SENSOR
5
4
TO
P79 B56 CONSOLE
UREA TANK NOx SENSOR
AFTER SCR CAT
P78 HARNESS
HEATING VALVE REV TO P1
CONSOLE
Y31 P9 P13 HARNESS
FWD (TOP)
Y31 PIN # - WIRE NO. & COLOR P10 10
P13
10
1- A92 WH 8 1
2- P10 P9 16 WH
DEUTSCH
3- 2 1 2 1 51 BL/GN
219 DK BL/PK 216 DK BL/GRY 00
4- 232A BK 51 BL/GN 16 WH/BK 51 BL/GN 51A BL 15 BL 215 DK BL/PRL
NOx & AIR U
5 4 INTAKE B-
SPLCANH
SPLCANL
SPLA03
X45 UREA PUMP
10
P8 10
10
SPLA75
A82-18 BK 244A-16 WH
A05-18 BK 232A-16 BK 54 BK 85 30 BA+ RD P109
A59-18 BK A70-18 BK P8 POSI-"CAN"
A03-16 BK A-57-18 BK 56B BK 56A WH
A89-18 BK A19-18 BK
87 86 FUEL V
120 LH
S Ω
P109
PLL
SP
PUMP
P5
R=120 Ω
RELAY
P2
TO PRE-HEAT TO
219
SPLK01
2 1 CONSOLE
SPL00
3 4 HARNESS
A45 BK CANH BK CANL BK
DEUTSCH
A35 BK A23 BK
SPLA98 SPLA77
1 12
2 1
DEUTSCH
A03 BK
X17.1 PIN # - WIRE NO. & COLOR P5 B88 A41 BK
1- X1-18 BK 22- A21-18 BK 43- PRESSURE DS DPF
D2.2 D2.1 00 WH 244A WH
2- A95-18 BK 23- A73-18 BK 44- P4 PIN # - WIRE NO. & COLOR D2.1 PIN # - WIRE NO. & COLOR 230 BK A62 BK
3- A94-18 BK 24- A13-18 BK 45- 1- K18 BK D2.2 PIN # - WIRE NO. & COLOR 1- 31- 61- A61-18 BK 91- A80 BK A04 BK W
1- K01-14 RD 31- K31-18 BK 61- 91- 235-16 BK 92- A92-18 BK A37 BK A61 BK
4- A98-18 BK 25- A78-18 BK 46- A55-18 BK 2- K31 BK 2- A02-16 BK 32- 62- A62-18 BK
3- K13 BK 2- 00-14 WH 32- 239-18 WH 62- 204-18 BK 92- 3- A03-16 BK 33- 63- A63-18 BK 93-
5- A77-18 BK 26- A72-18 BK 47- A02-16 BK 6 7
4- 3- K01-14 RD 33- 63- 93- 94- A94-18 BK
6- A51-18 BK 27- A35-18 BK 48- A67-16 WH 4- A04-18 BK 34- 64- A64-16 BK
7- A08-18 BK 28- A74-18 BK 49- A38-18 BK
4- 00-14 WH 34- 64- 57A-18 BK 94- 5- A05-18 BK 35- A35-18 BK 65- 95- A95-18 BK P2
5- K01-14 RD 35- 65- 95- 6- 36- A36-18 BK 66- A66-16 WH 96-
8- 29- A11-18 BK 50- A18-18 BK
6- 00-14 WH 36- 66- 96- 7- A07-18 BK 37- A37-18 BK 67- A67-16 WH 97-
9- X9-18 BK 30- 51- A76-18 BK
7- 37- 74-18 WH 67- 60-16 BK 97- 8- A08-18 BK 38- A38-18 BK 68- 98- A98-18 BK
10- X10-18 BK 31- A36-18 BK 52- A07-18 BK
8- 38- 77-18 WH 68- 98- 9- A09-18 BK 39- 69- 99- A99-18 BK
11- X11-18 BK 32- A17-18 BK 53-
9- 39- 69- 99- 10- 40- 70- A70-18 BK 100- A100-18 WH X
12- 33- 54- X17.1
10- A10-18 BK 40- 70- 200-18 WH 100- 11- A11-18 BK 41- A41-18 BK 71- 101- A101-18 WH
13- A99-18 BK 34- 55-
11- 41- 71- 101- 12- 42- 72- A72-18 BK 102- A102-18 WH
14- A100-18 WH 35- A64-16 WH 56-
12- 42- 72- 102- 13- A13-18 BK 43- 73- A73-18 BK 103-
15- A102-18 WH 36- 57-
13- K13-18 BK 43- 237-18 WH 73- 103- 14- 44- A44-16 BK 74- A74-18 BK 104-
16- 37- A66-16 WH 58-
14- 44- 74- 56D-18 BK 104- 15- A15-18 BK 45- A45-16 BK 75- A75-18 BK 105-
17- A54-18 BK 38- A44-16 BK 59- 231-18 BK
15- 45- 75- 105- 16- 46- A46-16 WH 76- A76-18 BK
18- 39- 60- 00-18 WH 16- 46- 76-
19- A46-16 WH 40- A45-16 BK 61- A23-16 WH 17- A17-18 BK 47- A47-18 BK 77- A77-18 BK
17- 47- 77- 18- A18-18 BK 48- A48-18 BK 78- A78-18 BK
20- A25-16 BK 41- A24-16 WH 62- A85-16 BK 18- K18-18 BK 48- 78-
19- A19-18 BK 49- 79- Y
21- A101-18 BK 42- A87-16 BK 19- 49- 79-
20- 50- 80- A80-18 BK
20- 99-18 WH 50- A50-18 WH 80-
21- A21-18 BK 51- A51-18 BK 81-
21- 51- 81- 103A-18 WH
22- 52- 82- A82-18 BK
22- 52- 82- 104-18 BK
23- A23-16 BK 53- 83-
23- 56A-18 WH 53- 83- 105-18 WH
24- A24-16 WH 54- A54-18 BK 84-
24- 54- 84- 90-18 BK
25- A25-16 BK 55- A55-18 BK 85- A85-16 BK
25- 55- 85- CANH-18BK
26- A26-18 BK 56- 86-
26- 201-18 BK 56- 86- CANL-18WH
27- A27-18 BK 57- A57-18 BK 87- A87-16 BK
27- 57- 54-18 BK 87-
28- 58- A58-18 BK 88- A88-18 BK
28- 58- 88- Z
29- 59- A59-18 BK 89- A89-18 BK
29- 206-18 BK 59- 89-
30- 60- 90-
30- 60- 90-
M232311AB - S1 3.33 Engine Harness Diagram 107 HP - THS Models
81
3.34 Engine Harness Wiring Diagram 107 HP
A62-BK-18-TXL R
62
A80-BK-18-TXL
80
A04-BK-18-TXL
04
A37-BK-18-TXL
37
A61-BK-18-TXL
61 89
A89-BK-18-TXL
A59-BK-18-TXL
59
A03-BK-16-TXL
03
A41-BK-18-TXL
41
A09-BK-18-TXL
09 27
FUEL PUMP RELAY TO FUEL PUMP TO BATTERY
A27-BK-18-TXL
A15-BK-18-TXL
15
56ACR (+) (-) B+ B+ B- A48-BK-18-TXL
48
87 30
87A
A19-BK-18-TXL
19
56B-RD-12-TXL
B+-RD-12-TXL
B+-RD-10-TXL
00-WH-12-TXL
85 86
A57-BK-18-TXL
57
P8 A70-BK-18-TXL
00-WH-12-TXL
00-WH-10-TXL
70
A26-BK-18-TXL
26
S
56A-WH-18-TXL
56B-RD-12-TXL
56-RD-12-TXL
56D-BK-18-TXL
A47-BK-18-TXL
47 82
A82-BK-18-TXL
A05-BK-18-TXL
05
A92-WH-18-TXL
92
A98-BK-18-TXL
98 77
A77-BK-18-TXL
A23-WH-16-TXL
23
A44-BK-16-TXL
44
A24-WH-16-TXL
24
A
A45-BK-16-TXL
45
20A
A46-WH-16-TXL
46
A25-BK-16-TXL
B
25
P7 A64-WH-16-TXL
64
A85-BK-16-TXL
A
85
A66-WH-16-TXL
30A
66
K01-RD-10-TXL
A87-BK-16-TXL
87 100 99
B
A100-WH-18-STP
P6
A99-BK-18-STP
A75-BK-18-TXL T
75
SPLA75
102 101 17
A102-WH-18-STP
A101-BK-18-STP
A17-BK-18-TXL
A18-BK-18-TXL D2.1 - 105 PIN
18
A55-BK-18-TXL
55
TO ECU
A76-BK-18-TXL
76
A02-BK-16-TXL
02 67
A67-WH-16-TXL
A58-BK-18-TXL
58
A21-BK-18-TXL
21
A36-BK-18-TXL
36
A78-BK-18-TXL
78
A11-BK-18-TXL
11
A13-BK-18-TXL
13
A35-BK-18-TXL
35
A63-BK-18-TXL
63
A74-BK-18-TXL
U
74
A73-BK-18-TXL
73
A72-BK-18-TXL
72 88
A88-BK-18-TXL
A54-BK-18-TXL
54 95 94
A95-BK-18-TXL
A94-BK-18-TXL
A51-BK-18-TXL
51 08 07 38
A08-BK-18-TXL
A07-BK-18-TXL
A38-BK-18-TXL
K01-RD-14-TXL
1
K01-10 RD K01-RD-14-TXL
3
SPLK01
K01-RD-14-TXL
5
00-WH-14-TXL
2
00-10 WH 00-WH-14-TXL
4
SPL00
00-WH-14-TXL
6
56A-WH-18-TXL
V
23 74
56D-BK-18-TXL
201-BK-18-TXL 201-BK-18-TXL
P3
26 70
2
TO WATER SENSOR 200-WH-18-TXL 200-WH-18-TXL

1
P109 CANL-GN-18-TXL 120 Ω

1
TO POSI CAN CANH-YL/BU-18-TXL

2
CANH-YL/BU-18-TXL CANH-YL/BU-18-TXL
85 86
1
SPLH
CANL-GN-18-TXL CANL-GN-18-TXL
2
SPLL
74-WH-18-TXL 74-WH-18-TXL
37
3
60-BK-16-TXL SPL60 60-BK-16-TXL
67
4
20 84
5
P1 90-BK-18-TXL 90-BK-18-TXL
6
TO CONSOLE HARNESS D2.2 - 91 PIN

206-BK-18-TXL 206-BK-18-TXL
29 64 57
TO ECU
7
57A-BK-18-TXL 57A-BK-18-TXL
8
54-BK-18-TXL SPL54 54-BK-18-TXL

9
10
38 83 82 62
105-WH-18-TXL 105-WH-18-TXL
W
11 12
104-BK-18-TXL 104-BK-18-TXL
204-BK-18-TXL
103A-WH-18-TXL
81
235-BK-16-TXL 235-BK-16-TXL
91 43
1
237-WH-18-TXL 237-WH-18-TXL
2 3 4
239-WH-18-TXL 239-WH-18-TXL
32
K18-BK-18-TXL
18
P78 K31-BK-18-TXL
31 13
TO CONSOLE HARNESS K13-BK-18-TXL
229-BK-16-TXL SPL229 A10-BK-18-TXL
10 50
5 6 7
231-BK-18-TXL A50-WH-18-TXL
232A-RD-14-TXL SPL232A
8
A03-BK-16-TXL SPLA03
X
1 2
A41-BK-18-TXL
00-WH-18-TXL
3
230-BK-18-TXL
4
D15
P2 A80-BK-18-TXL
5
SPL51 SPL00
TO CONSOLE HARNESS A37-BK-18-TXL
6
A61-BK-18-TXL
7
A04-BK-18-TXL
8
A62-BK-18-TXL
9
244A-WH-16-TXL
10 11 12
216-DK BU/GYY-16-TEW
215-DK BU/PU-16-TEW
216-DK BU/GY-16-TEW
219-DK BU/PK-16-TEW
215-DK BU/PU-16-TEW
219-DK BU/PK-16-TEW
16-WH/BK-16-TEW
51-BK/GN-16-TEW
51-BK/GN-16-TEW
51-BK/GN-16-TEW
16-WH/BK-16-TEW
15A-BU-16-TEW
00-WH-16-TEW
00-WH-16-TEW
15-BU-16-TEW
00-WH-16-TEW
120 Ω 120 Ω
47 Ω
2 1 2 1 2 1 2 1
1 2 3 4 5 6 7 8
P10 P9 P11 P12
CHASSIS
GROUND
TRANS.
TEMP.
Y
D60-2
TO CHASSIS HARNESS (TOP)
FWD 1ST 2ND
REV
SPLA77-1
P13 TRANSMISSION
SPLA77-2 SPLA77
SPLA98-2 SPLA98-1
SPLA98
00-WH-18-TXL
00-WH-18-TXL
00-WH-18-TXL
232A-BK-16-TXL
103A-WH-18-TXL
A102-WH-18-STP
A101-BK-18-STP
A100-WH-18-STP
K13-BK-18-TXL
204-RD-18-TXL
K18-BK-18-TXL
K31-BK-18-TXL
A50-WH-18-TXL
230-BK-18-TXL
54-BK-18-TXL
A10-BK-18-TXL
A03-BK-16-TXL
231-BK-18-TXL
229-BK-18-TXL
229-BK-18-TXL
244A-WH-16-TXL
A89-BK-18-TXL
A76-BK-18-TXL
A59-BK-18-TXL
A09-BK-18-TXL
A27-BK-18-TXL
A15-BK-18-TXL
A19-BK-18-TXL
A57-BK-18-TXL
A70-BK-18-TXL
A05-BK-18-TXL
A82-BK-18-TXL
A26-BK-18-TXL
A47-BK-18-TXL
232A-BK-16-TXL
A98-BK-18-TXL
A98-BK-18-TXL
A98-BK-18-TXL
X10-BK-18-TXL
X11-BK-18-TXL
A98-BK-18-TXL
A48-BK-18-TXL
A77-BK-18-TXL
A77-BK-18-TXL
A77-BK-18-TXL
A77-BK-18-TXL
A23-WH-16-TXL
A44-BK-16-TXL
A24-WH-16-TXL
A45-BK-16-TXL
A46-WH-16-TXL
A25-BK-16-TXL
A64-WH-16-TXL
A85-BK-16-TXL
A66-WH-16-TXL
A87-BK-16-TXL
A99-BK-18-STP
X9-BK-18-TXL
X1-BK-18-TXL
A95-BK-18-TXL
A13-BK-18-TXL
A54-BK-18-TXL
A36-BK-18-TXL
A78-BK-18-TXL
A74-BK-18-TXL
A11-BK-18-TXL
A21-BK-18-TXL
A73-BK-18-TXL
A72-BK-18-TXL
A35-BK-18-TXL
A18-BK-18-TXL
A55-BK-18-TXL
A02-BK-16-TXL
A67-WH-16-TXL
A51-BK-18-TXL
A08-BK-18-TXL
A07-BK-18-TXL
A38-BK-18-TXL
00-WH-18-TXL
A58-BK-18-TXL
A63-BK-18-TXL
A88-BK-18-TXL
A17-BK-18-TXL
A92-WH-18-TXL
A94-BK-18-TXL
60D-BK-16-TXL
00-WH-18-TXL
00-WH-18-TXL
00-WH-18-TXL
123 4 2 1 2 1 1 2 1 2 3 4 4 3 2 1 4 3 2 1 4 3 2 1 10 11 4 5 61 38 41 40 19 20 35 62 37 42 14 13 9 1 15 21 2 3 24 17 32 31 25 28 29 22 23 26 27 50 46 51 47 48 6 7 52 49 59 60 1 2 3 4 4 3 2 1 1 2
1 2 3 4 5 6 7 8 9 10 11 12
UREA EXST EXST UREA PRESSURE NOx & AIR NOx SENSOR NOx SENSOR UREA TO AMBIENT AIR
X45 TANK GAS GAS DOSING DS DPF INTAKE B- AFTER SCR PRIOR SCR QUALITY, X17.1-62 PIN TO PRE-HEAT TO COOLANT TEMPERATURE TO ALTERNATOR
TEMP. TEMP. CAT CAT SENSOR
TO UREA PUMP HEATG VALVE B88 LEVEL & AIR INLET SENSOR
BEFORE BEFORE
VALVE
OXY SCR Y24 B56 B54 TEMP P5 P4 P79
Y31
CAT B90
B65 B78
M232311AB - S2 3.34 Engine Harness Wiring Diagram 107 HP
82
3.35 Chassis Harness
J27 J103
1 1
233 DK PE/OR 234 DK PE/RD
00 WH 00 WH J34
1
2 2 57 BN/GR
FRAME 00 WH
P113
J14 LEVEL SOLS (BOTTOM) (TOP) 2
2 1 1 J15
1 AUX.
28-16 GN 28C-16 GN AUX.
223 DK GR 223 DK GR RESERVE BRAKE SOL
65-16 YW/PK HORN 00 WH 00 WH RETRACT
3 4
EXTEND
2 2 J26
1
J27 J103
256 TN/BK S
TO CONSOLE WITH DUMMY
256 TN/BK
HARNESS J14 J15 J34 2 BOOM

LIGHTS
(OPT.)
J26
P113 WITH DUMMY
J13
(BOTTOM) (TOP)
J16 CARRIAGE T
CRAB 4W 1
1
J17
8 1 47 PE/OE TILT SOLS
16 WH/BK
STEER STEER 00 WH
47 PE/OE
00 WH
DEUTSCH
15 BL/GN
2
219 DK BL/PK 216 DK BL/GRY 2
15 BL 215 DK BL/PRL J19 J19 J20 J20 J16 J17
5 4 217-16 DK BL/GY
1 2
00-16 WH 1 2
218-16 DK BL/GN 00-16 WH
TO ENGINE HARNESS
J13 BOOM UP
ENABLE
U
J25
J25 J24
1 1
14A BK 15 BL
00 WH 00 WH
P31 2 2
20 31
21 8 30
9 19
10 2 18
22 3 7 29
11 1 17 D221
B/U
23 4 6 28
12 5 16
13 15
24 14 27
25 26
P31 ALARM
J24 V
P31 PIN # - WIRE NO. & COLOR BOOM 40°
R.A.S.
1-16 WH/BK 17-5A PE
FRAME ANGLE SENSOR J105 SENSOR
2-15 BL 18-19 OR/GN
3-14A BK
4-216 DK BL/GY
19-49 GN/RD J118
20-5D PE J71
5-215 DK BL/PE
21-220 DK GN/WE
6-233 DK PE/OR
22-16 WH/BK
05R PE
7-00 WH 4 1
23-221 DK GN/TN
DEUTSCH
8-234 DK PE/RD
24-05R PE
FRAME LEVEL 65 YW/PK
9-219 DK BL/PK
25-212 DK GN/OE J105 J76 SPEED 00 WH 3 221 DK GN/TN
10-211 DK PE/WH 2 J71
26-256 TN/BK BROWN
11-217 DK BL/GY 8 1
12-218 DK BL/GN 27-256 TN/BK 1
13-26A BL/YW 28-28R GN 28C GN 3 4
DEUTSCH
14-223 DK GR 29-28L GN 28R GN 05R DK GN/PE J76 BLUE BLACK

W
15-57 BN/GR 30-28B RD/WE 28L GN 00 WH 1 PRESSURE
212 DK GN/OE
16-47 PE/OE 31-28A RD/BE 28 GN 221 DK GN/TN P18
221 DK GN/TN SWITCH PS1
00 WH
GND ON 00 WH
5 4
CHASSIS 2 P18
1
51 BL/GN
00 WH
2
J23
BOOM E.O.S.
SENSOR
211 DK PE/WH
5D PE
X
5A PE
J21 J23
BROWN
1
P35
3 4 WITH DUMMY
BLUE BLACK
1
PRESSURE
P112
00 WH
SWITCH PS3
19 OR/GN
PRESSURE P35
PARK BRAKE
DISABLE P112 SWITCH RB.
3 213A DK GN/RD
213 DK GN/RD Y
J74 J73 2
1
J74 1
00-16 WH 1
220 DK GN/WE
28A GN J73 28B GN

00 WH
DEUTSCH
26A-16 BL/YW
00 WH FRAME
2 1
2 LEFT FRAME J21
ENABLE RIGHT
ENABLE
M199477AA-S1 3.35 Chassis Harness
83
3.36 Chassis Harness Wiring Diagram
TO CONSOLE HARNESS
P113 P31
R
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
220-16 DK GN/WE
212-16 DK GN/OE
221-16 DK GN/TN
65-16 YW/PK
223-16 DK GR
26A-16 BL/YW
57-16 BN/GR
49-16 GN/RD
47-16 PE/OE
211-16 DK PE/WH
218-16 DK BL/GN
217-16 DK BL/GY
233-16 DK PE/OR
234-16 DK PE/RD
216-16 DK BL/GY
219-16 DK BL/PK
215-16 DK BL/PE
05R-16 PE
28B-16 RD/WE
28-16 GN
28C-16 GN
5D-16 PE
28A-16 RD/BE
16A-16 WH/BK
256-16 TN/BK
256-16 TN/BK
16-16 WH/BK
19-16 OR/GN
28R-16 GN
28L-16 GN
00-16 WH
14A-16 BK
5A-16 PE
15-16 BL
S
J105
8 7
28R-16 GN
28L-16 GN
6 5
28-16 GN
FRAME
ANGLE SENSOR 221-16 DK GN/TN
4
00-16 WH
3
05R-16 DK GN/PE
2 1
28C-16 GN
SPL05R
SENSOR CABLE J71

00-16 WH BLUE 3
212-16 DK GN/OE BLACK 4 BOOM 40°
05R-16 PE BROWN 1
SENSOR
J103 T
234-16 DK PE/RD 1
00-16 WH TOP
2
AUX. EXTEND
J27
233-16 DK PE/OR
1 BOTTOM
SPL00 00-16 WH
2 AUX. RETRACT
P112
220-16 DK GN/WE N.C.
3
PS3
PRESSURE SWITCH 16A-16 WH/BK CO
2
1
SENSOR CABLE J23

00-16 WH BLUE 3
19-16 OR/GN BLACK 4 BOOM E.O.S U
5A-16 PE BROWN 1
SENSOR
SPL221
SPL65 221-16 DK GN/TN
D221
P35
5D-16 PE
1
RESERVE BRAKE
PRESSURE SWITCH 211-16 DK PE/WH
2
J26
BOOM 256-16 TN/BK V
LIGHTS 256-16 TN/BK
(OPT)
49-16 GN/RD
HORN 5D-16 PE
SPL5D
J25
14A-16 BK
1
BOOM
UP ENABLE 00-16 WH
2
J24 SPL00
1
15-16 BL
BACKUP SPL15 SPL00
ALARM 00-16 WH
2
SPL00
SPL223 SPL00 SPL47 SPL00

Y
221-16 DK GN/TN
221-16 DK GN/TN
26A-16 BL/YW
223-16 DK GR
223-16 DK GR
57-16 BN/GR
65-16 YW/PK
47-16 PE/OE
47-16 PE/OE
218-16 DK BL/GN
217-16 DK BL/GY
216-16 DK BL/GRY
215-16 DK BL/PRL
219-16 DK BL/PK
00-16 WH
00-16 WH
00-16 WH
16-16 WH/BK
51-16 BL/GN
51-16 BL/GN
00-16 WH
00-12 WH
00-16 WH
00-16 WH
00-16 WH
00-16 WH
00-16 WH
00-16 WH
00-16 WH
28A-16 GN
00-16 WH
00-16 WH
28B-16 GN
15-16 BL
1 2 3 4 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 2 1 2 1 1 2
1 2 3 4 5 6 7 8
J14 J15 J16 J17 J13 P18 J19 J20 J21 Z
J118 J76 J73 J74 J34 CARRIAGE PS1 GND ON CRAB
FRAME LEVEL TO ENGINE HARNESS 4W PARK BRAKE
R.A.S. FRAME LEVEL FRAME FRAME SOLS. SOLS. PRESSURE CHASSIS STEER STEER
RESERVE BRAKE DISABLE
SPEED RIGHT LEFT SWITCH
SOL.
ENABLE ENABLE
M199477AA-S2 3.36 Chassis Harness Wiring Diagram
84
M190121AP-S1
B1
03 03 B+ 00 1 BATTERY
403B
D
2
A
SW26 3
DISCONNECT
SWITCH 4
03 BA+ B+ 00 5
TO ENGINE TO TO TO ENGINE
R2 STARTER POST FUEL PUMP ECU GROUND 6
120 Ω M N K L 7
ENGINE DETAIL HERE
8
CANH DISPLAY MODULE
1
8 CANH CAN
9
7 CANL CANL
ENGINE DISPLAY
2 3
10
60 60 60 4
UNIT 2 IGNITION
11
00
1
12
B
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS
P68 J68 13
99 99 THROTTLE POWER
5
THROTTLE VREF +5 V 5 5
14
90 90 THROTTLE GROUND
6
THROTTLE THROTTLE GROUND 4 4

PEDAL 15
206 206
7
THROTTLE SIGNAL 3 3 THROTTLE SIGNAL

16
57B START
8
P66 17
00
B
9
60 18
60 77
ENGINE DIAGNOSTIC A
10
CONNECTION 19
105 105
G
11
DIAGNOSTIC CAN
20
104 104
12
H
R3 21
203
1
PREHEAT LAMP
120 Ω PL1 - YW R4 22
RELAY CHART 1000 Ω
C
74
2
23
+
-
RELAY FUNCTION
NO. PREHEAT
24
60ACR POWER RELAY 25

11CR GLOW PLUG 26
56ACR FUEL PUMP 27
403ACR POSITIVE SHUTOFF 28
19CR BOOM UP 29
3.37 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH
222CR FRAME LEVEL ENABLE 30
224CR CARRIAGE ENABLE 31
5JCR BRAKE LAMP 32

D
33
77CR ENGINE RUNNING
34
212CR BOOM ANGLE
35
65CR FRAME LEVEL ENABLE 77CR TELEMATICS OPTION
60C WHITE
ENGINE RUNNING 36
03 RED
28CR BOOM RAISE DISABLE 60B 77
BLACK 37
28LCR FRAME LEFT ENABLE 60B M6 TELEMATICS OPTION
60C 60C 3 2
03 60B 38
03 1 4
28RCR FRAME RIGHT ENABLE 60
TO SHEET 2 39
D60
DIODE
03 M8H
05CR PARK BRAKE RELEASE RELAY 403A 1 2
E 60B 4 40
3
M CANH 11 12 CANL N
255CR REAR WIPER 403ACR RELAY REVERSE CAMERA OPTION 41 POSITIVE SHUTOFF
POSITIVE SHUTOFF RELAY
00 00 00 00
258CR FRONT WIPER 42
REV. MONITOR CAM1
1 1 ME501-4 REVERSE CAMERA
258ACR TOP WIPER 03 43
E
03 04 2 4 REVERSE 3 OPTION
GND
60A 4 3 CAMERA
7 CANH TRACK UNIT
60C 1
DC12V 5 2 44
250ACR LEFT TURN SIGNAL D60-1 7 6 TELEMATICS OPTION
SW1 - IGNITION SWITCH DIODE CAM1 UNIT 8 CANL
60B 2 TRACK
TRIGG REVERSE SENSOR OPTION TELE. 00
RIGHT TURN SIGNAL 57D 9 4 45 REVERSE SENSOR OPTION
251ACR F1 REV. DETECTOR 2 8
OFF 221 11 12 26B
10 A CANH 1 1 REVERSE 7 IGNITION SWITCH
46
223ACR R.A.S. RESTRICT MODE ENABLE ON CANL 2 3 SENSOR 6
START PWR 5 4 5 POWER RELAY
47
220CR R.A.S. DRIVE/BRAKE INPUT RELAY GND 6 JMPR1
03A SW2 - PARK
60A 00 BRAKE SW. NOTE A PARKING BRAKE
48 SWITCH
57DCR STARTER INTERRUPT PL2 - RD
03B B+ IGN 60A 15
26B 26B 26B 49 PARKING BRAKE
3
- 04 05 2 APPLY
- 60ACR D26B
POWER 1 DIODE
ACC F2 26 26 26A 50 PARKING BRAKE
- - RELAY 10 A RELEASE
3H-26
51
60A
5 6 57A PARK BRAKE RELEASE
ST 57E 57 52 RELAY
4
05 77
FUSE AMPERE 53
F
CIRCUIT 05CR
NO. RATING
PARK BRAKE RELEASE 54 RESERVE BRAKE JUMPER
IGNITION/POWER RELAY C
F1 10A F-N-R J47
TO SHEET 2 55
F2 10A TRANS/B-U ALARM/PARK BRAKE 8 26
3RD REMOVE RELAY TO ADD JUMPER WIRE
F3 2ND
56 F - N - R SHIFTER
10A STEER SELECT/GAUGE/TRANS TEMP 60A FOR RESERVE BRAKE (OPTION)
57D 1ST 2ND
F4 10A FRAME/CARRIAGE ENABLE D57D 3 215 215 57
2ND GEAR SOL.
DIODE
F5 10A REAR AXLE LOCK 57DCR 58
STARTER
F6 INTERRUPT 1ST
5A AUXILLARY HYDRAULICS 216 216 59
2 1ST GEAR SOL.
F7 10A HORN/BEACON OPT. 60
F8 15A POWER PORT 5 57A 61
F9 5A REAR WIPER
N 15 62
F10 10A F
OUTRIGGERS 6 57B
63 SERVICE BRAKE
F11 D15 TRANSMISSTION
G
10A WORK LIGHTS

DIODE DISCONNECT
51 64
7 15 15 15A
F12 15A ROAD LIGHTS REVERSE SOL.
1 16 REVERSE 65
F13 5A TURN/HAZ./BRAKE LIGHTS
PS1
15 66 BACKUP ALARM
F14 10A BOOM LIGHTS
OPTIONS D16 D15A WHITE NOISE
DIODE BACKUP ALARM 67 BACKUP ALARM
F15 10A WIPER, FRONT & TOP DIODE
FORWARD SOL.
F16 - - 16 68
ENCLOSED
CAB FORWARD WHITE NOISE
F17 5A FAN/INT. LIGHT 16A 69
OPTION BACKUP ALARM
F18 30A BLOWER 70
SW4 - STEER 4H-217
F20 10A HEATER VALVE, A/C MODE SW. CRAB STEER 71 STEERING MODE SWITCH
3 217 CRAB STEER SOL.
F19 5A FRAME LEVEL INTERLOCK 04 05A 2
FRONT 72
F3 1
F21 - - 10 A 218 73 4 WHEEL STEER SOL.
F22 - -
H
4H-218
4W STEER 74
F23 - - PL3 - YW
75
F24 - -
TRANS. TEMP. TRANSMISSION TEMP.
76
F25 30A ECM TPSW1 SWITCH TPS1
219
77
F26 20A FUEL PUMP
F27 100A GLOW PLUG 78

FUEL GAUGE
+ 79
55 FUEL LEVEL FUEL GAUGE
S
80 FUEL LEVEL SENDER
-
81
82
BOOM UP
E.O.S
CLOSED BELOW 70° BOOM UP
NOTE A - REMOVE WITH TRACK UNIT TELEMATICS 83 E.O.S SWITCH
I
19CR
BOOM E.O.S 84
19 BOOM UP E.O.S
85 RELAY
2H-14A
05A 14 BOOM UP
14A 86
ENABLE VALVE
87
FRAME ANGLE
28 BOOM RAISE
SENSOR
88 DISABLE RELAY
28 CR
±4 DEGREES
BOOM RAISE
DISABLE
89
5 28
PL4 - RD 90 FRAME LEVEL
1 28C
INTERLOCK LAMP
+
05R 05R 2 -
91
3 00 FRAME ANGLE SENSOR
221 4
28L CR
92
65CR 6 28L
FRAME LEVEL FRAME LEFT
ENABLE 7 28R ENABLE RELAY 93
FRAME LEVEL ENABLE
65 28L
J
94
2H-28A
28A 95 FRAME LEFT ENABLE
04 05T 65A 65A
F19 96
5A 28R CR
FRAME RIGHT 97
ENABLE RELAY
28R 98
2H-28B
99 FRAME RIGHT ENABLE
65A 28B
BOOM 40° ANGLE 100
SENSOR
Closed Below 40° BOOM ANGLE SENSOR
101
212CR RELAY
BOOM ANGLE 102
05R
BOOM ANGLE RELAY
F5 103
10 A
104
K
PL5 - YW 105
213A 106 R.A.S LOCK INDICATOR
213
65 2H-65-1 107 R.A.S. RESTRICT MODE
D221
DIODE
221 65 2H-65 108 R.A.S. RESTRICT MODE
2H-221-3 109 R.A.S UNLOCK
2H-221-2 110 R.A.S. UNLOCK
221 2H-221-1 111 R.A.S. UNLOCK
221 FRAME LEVEL SPEED

2H-221 112
113
220 CR 114
R.A.S. DRIVE/BRAKE
L
N.C. (SERVICE BRAKE RELEASED)

220 INPUT RELAY PS3 SERVICE BRAKE
115 PRESSURE SWITCH
PS3
116
FRONT SWITCH ON JOYSTICK
220 223A 117 FRAME LEVEL ENABLE
SW5 - FRAME LEVEL 222CR 223
223ACR 118
PUSH BUTTON FRAME LEVEL ENABLE R.A.S. RESTRICT MODE
RELAY ENABLE RELAY
04 05B 222 FRAME LEVEL
119 ENABLE RELAY
F4
4H-223 120
10 A 223 223 FRAME LEVEL
ENABLE LEFT
121
REAR SWITCH ON JOYSTICK 4H-223-1
FRAME LEVEL
SW7 - CARRIAGE TILT 224CR
223 122 ENABLE RIGHT
PUSH BUTTON CARRIAGE ENABLE
RELAY 123
224
CARRIAGE TILT
124 ENABLE RELAY
4H-47
M
47 47 125
CARRIAGE
ENABLE TILT UP
4H-47-1 126
HORN SW6 - HORN SW. 47 CARRIAGE ENABLE
127 TILT DOWN
04 05D 49
HORN
F7 128 HORN SWITCH
10 A
J
129
TO SHEET 2
130
04 05E POWER PORT
F8 131
15 A SW 14
WASHER/WIPER 1 WINDSHIELD
WASHER
SWITCH 132 WASHER SWITCH
05F 3 238 WINDSHIELD WASHER

04 2 M1 133
F9
1
255CR RELAY
5A REAR WIPER 134
6 257A PARKING FEED
05F 5
N
4 255 00 135
NOMINAL SPEED
257 REAR WIPER 136
05F REAR WIPER
M2
05F 137 PARKING AUX. FEED
138
SW15
AUX. EXTEND 139
PUSH BUTTON 4H-233
04 05C 233 140 AUX. EXTEND
F6 SW16
5A 141
AUX. RETRACT
PUSH BUTTON 4H-234
142
04 234 AUX. RETRACT
143
A TOP SWITCHES ON JOYSTICK 00
B 144
TO SHEET 2
O
TO SHEET 2
Z
T
Y
X
S
R
230790ABA
85
M190121AP-S2
A
FROM SHEET 1 FROM SHEET 1

A B
04 00 1
SW21 OUTRIGGER SW. 2

RELAY CHART LEFT 4H-225
1 225 3 LEFT OUTRIGGER SW.
04 05S 2
3 OUTRIGGER - R2
RELAY FUNCTION F10 4H-226 RETRACT LEFT
4
NO. 10 A 226
SW22
OUTRIGGER SW. OUTRIGGER - E2
60CR 5 EXTEND LEFT
POWER RELAY RIGHT 4H-227
1 227 6
11CR GLOW PLUG 2 RIGHT OUTRIGGER SW.
3
OUTRIGGER - R1
4H-228
7 RETRACT RIGHT
228
B
56ACR FUEL PUMP
OUTRIGGER - E1
8 EXTEND RIGHT
403ACR POSITIVE SHUTOFF
9
19CR BOOM UP
10
222CR FRAME ENABLE DL6 - RD
403A 403A 11
E VALVE HOLD
224CR CARRIAGE ENABLE RED LIGHT
12
5JCR BRAKE LAMP CANL
L
401
1
13
VALVE ENGAGE
77CR ENGINE RUNNING R3
CANH CANL 14
2
K CANL
212CR BOOM ANGLE 50 Ω
403A 403A 15
3
VALVE HOLD
C
65CR FRAME LEVEL DISABLE 402 16

4
MANUAL SHUTOFF
5
28CR BOOM RAISE DISABLE 17

403B 403 403 AUTO-RESET
6
D
28LCR FRAME LEFT ENABLE 18 BREAKER
B1 02
7
20 A GROUND
28RCR FRAME RIGHT ENABLE 408 19
8
VALVE GROUND
05CR PARK BRAKE RELEASE RELAY SHUT OFF-SOL. 20
CANH
9 10
CANH
SW 9 21
255CR REAR WIPER
POS. SHUTOFF.
FROM SHEET 1
1 22
258CR FRONT WIPER 2 MANUAL SHUTOFF.
3 SWITCH
TOP WIPER 23
258ACR
24
D
LEFT TURN SIGNAL 2H-57

250ACR
C
57 25 RESERVE BRAKE
251ACR RIGHT TURN SIGNAL SOL.
26
223ACR R.A.S. RESTRICT MODE ENABLE PL7 - RD
PS.RB
27
05D 211 RESERVE BRAKE P/S &
J
220CR R.A.S. DRIVE/BRAKE INPUT RELAY LIGHT
28
57DCR STARTER INTERRUPT BEACON
29
- - BEACON LIGHT
30
- - 31
SW11 - WORK
LIGHTS SW. 32
LEFT FRONT WORKLIGHT
E
WORKLIGHT SWITCH
3 246 246 33
FUSE AMPERE 04 05G 2 LEFT FRONT WORKLIGHT
CIRCUIT 1
NO. RATING F11
10 A FUEL GAUGE LAMP 34 FUEL GAUGE LAMP
F1 10A IGNITION/POWER RELAY 246
35
F2 10A TRANS/B-U ALARM/PARK BRAKE RIGHT FRONT WORKLIGHT
246 246 36
F3 10A STEER SELECT/GAUGE/TRANS TEMP RIGHT FRONT WORKLIGHT
37
F4 10A FRAME/CARRIAGE ENABLE LEFT REAR WORKLIGHT
6
5 LEFT REAR WORKLIGHT
4 247 247 38
F5 10A REAR AXLE LOCK
F6 5A RIGHT REAR WORKLIGHT

39
AUXILLARY HYDRAULICS
247 RIGHT REAR WORKLIGHT
F7 10A HORN/BEACON OPT. 247 40
F
F8 15A POWER PORT 41
F9 5A REAR WIPER 42
F10 10A OUTRIGGERS 43
F11 10A WORK LIGHTS
44
F12 15A ROAD LIGHTS HEAD LIGHTS HEAD LIGHTS
HIGH BEAM
45 HIGH BEAM
F13 5A TURN/HAZ./BRAKE LIGHTS 271 RIGHT
46
F14 10A BOOM LIGHTS SW19 - ROAD LIGHT
OPTIONS 3 271 LEFT 47
F15 2
10A WIPER, FRONT & TOP HEAD LIGHTS
1
LOW BEAM 48 LOW BEAM
F16 - - ENCLOSED 271A RIGHT
CAB 49
F17 5A FAN/INT. LIGHT
G
OPTION
271A LEFT 50
F18 30A BLOWER
F20 10A HEATER VALVE, A/C 51
F19 5A FRAME LEVEL INTERLOCK TAIL LIGHTS 52

6 TAIL LIGHTS
04 05H 5 261
F21 - - 4 53
F12
15 A
F22 - - 261 54
F23 - -
55
F24 - - SW 23 - HAZ.
56
F25 30A ECM 1
249 2
3 252 57 HAZARD SWITCH
F26 20A FUEL PUMP 4
05J 5 252A
H
6 58
F27 100A GLOW PLUG
59
FL1 SW12 - TURN SIGNAL D252A-1 D252A-2 D252 D252-1
FRONT LEFT TURN FLASHER
FLASHER 60
3 LEFT 250 250 FRONT LEFT TURN
04 05J X L 249 2
1 RIGHT LEFT TURN SIGNAL
F13 D250
61
5A 251 251 RIGHT TURN SIGNAL
62 FRONT RIGHT TURN
D251 FRONT RIGHT TURN

250ACR 63
D05J LEFT SIGNAL
05J 6 250A 250A
5 64
4 251ACR
RIGHT SIGNAL
251A 251A 65
5JCR 66
I
BRAKE LAMP RELAY

PS2
05J 253 BRAKE LAMP RELAY
67
BRAKE PRESSURE SWITCH
LEFT TURN/BRAKE LIGHT
250B 250A 68 LEFT TURN/BRAKE LIGHT
05J 254 254 254
69
251B RIGHT TURN/BRAKE LIGHT
254 254 251A
70
RIGHT TURN/BRAKE LIGHT
71
SW10
BOOM LIGHTS
SW.
72
1 BOOM LIGHT BOOM LIGHTs
04 05K 2 73
3 256 BOOM LIGHTS SWITCH
F14
10A 74
4 BOOM LIGHT
J
05K 5 75
6 256
76
77
SW24
WASHER/WIPER
78
SW. WASHER WINDSHIELD WASHER SWITCH
79
3 260 WINDSHIELD WASHER
04 05L 2 M3
1 80
F15
258CR RELAY
10 A
6 FRONT WIPER 259A
05L 5 81
4 258 00
FRONT WIPER
82
05L 259 FRONT WIPER
83
K
M4
05L 84
85
258A CR RELAY 86
TOP WIPER
208A
87
00
88 TOP WIPER
TOP WIPER
05L 208
M5 89
05L
90
91
L
92
93
SW 8 FAN
94 FAN
04 05N
F17
M6 95
5A
96
SW 13 97
INT. LIGHT
INTERIOR LIGHT
98
99
100
M
101
SW17
BLOWER 102
SW. BLOWER
262 262
H 103 BLOWER MOTOR
M 263 263
05P B+ L
M7 104
04 264 264
F18
30 A 0 105
C
SW18
A/C SW. TPSW2 PS3 106
A/C TEMP. SW. A/C PRESS. SW.
A/C COMPRESSOR A/C PRESSURE SWITCH
265 266 + 107
OUT 267 268 269 269 A/C COMPRESSOR SOL
F20
10 A 108
N
GN 109
110
111
HEATER POT.
266 MOTORIZED
112
HEATER VALVE
HEATER POT.
270 270 D
113
266 266 A C
M8 MOTORIZED
114 HEATER VALVE
115
O

Z
T
Y
X
S
R
230790ABA
86
M190121AP-S3
A
TO BATTERY TO BATTERY TO BATTERY

B+ POST B- POST B+ POST
B+
B
B+-12 RD
BA+-12 RD
00-12 WH
00-12 WH
F26 F25
20A 30A
56
A02-16 WH
2
A32-16 BK
32
A03-16 WH
3
A46-16 BK
46
(-) 00-12 WH
A04-16 WH
4
C
FUEL
PUMP FP A05-16 BK
5
(+) 56B-12 BK
A16-16 WH
16
56C (220149AA) A33-16 BK

33
A18-16 WH
18
A48-16 BK
48
A37-18 WH
37
A52-18 BK
52
A53-18 RD
53
D2.1 - 60 PIN
56 56B-12 BK A38-18 RD
38
A39-18 WH
TO ECU
D
39
54-18 BK 56A-18 WH A54-18 BK

54
56ACR A28-18 BK
FUEL PUMP RELAY A07-18 BK
28 7
A25-18 BK
A26-18 BK
A40-18 BK
A27-18 BK
A24-18 BK
25 26 40 27 24
A43-18 BK
43
A44-18 BK
A29-18 BK
E
A19-16 BK
44 29 19
A20-16 WH
A23-18 BK
A35-18 BK
A45-18 BK
20 23 35 45
K01-14 RD
1
K01-12 RD K01-14 RD
3
F
K01-14 RD
5
00-14 WH
SPLK01
2
00-12 WH 00-14 WH
4
00-14 WH
6
SPL00
56A-18 WH
CANH-18 BK CANH-18 BK
1
CANL-18 WH CANL-18 WH
2
26 54 76
R1
3
120 Ω
60-16 BK 60-16 BK
4
88
99-18 WH 99-18 WH
5
G
SEE 90-18 BK 90-18 BK
6
46 62
SHEET 1 206 -18 BK 206 -18 BK
7
63
57B-16 BK 57B-16 BK
8
54-18 BK 54-18 BK
9
35 90
77-18 WH 77-18 WH
10
105-18 WH 105-18 WH
104-18 BK 104-18 BK
11 12
71 53 75
D2.2 - 94 PIN
103-18 BK
WATER IN 103-18 BK
TO ECU
L L1
68 15
FUEL SWITCH
201-18 WH 201-18 WH
H
200-18 BK 200-18 BK
57 64
K28-18 BK
K73-18 BK
K61-18 BK
K44-18 BK
K85-18 BK
28 73 61 44 85
K82-18 BK
204-18 RD
202-18 WH
203-18 BK SPL 203 203-18 BK
1
82 13 87 29
SEE
2
48-18 WH 48-18 WH
48
SHEET 1
I
J
K
K82-18 BK
203-18 BK
204-18 RD
A24-18 BK
A32-16 BK
A46-16 BK
A05-16 BK
A33-16 BK
A48-16 BK
A52-18 BK
A54-18 BK
K28-18 BK
A28-18 BK
A25-18 BK
A40-18 BK
A27-18 BK
K61-18 BK
A26-18 BK
A43-18 BK
A44-18 BK
A29-18 BK
K44-18 BK
K85-18 BK
A19-16 BK
A53-18 RD
A38-18 RD
A07-18 BK
K73-18 BK
202-18 WH
A02-16 WH
A03-16 WH
A04-16 WH
A16-16 WH
A18-16 WH
A37-18 WH
A39-18 WH
A20-16 WH
A23-18 BK
A35-18 BK
A45-18 BK
X17.1-62 PIN 61 38 41 40 19 20 35 62 37 42 14 13 9 1 15 21 2 3 24 17 32 31 25 28 29 22 23 26 27 50 46 51 47 48 1 2 3 4 4 3 2 1
L
AT ENGINE
L L2 COOLANT
LEVEL
11 11A SENSOR
11CR
2 1 1 2 3 4 3 1 2 1 2 3 4 1 2 3 4 5 4 3 2 1 11B 11C GP1

U U U U U U U
n n n P P p&t° P M
FUEL FUEL ACTUATOR FUEL FUEL F27
100A 11C GP2
INJ. INJ. MPROP INJ. INJ. ENGINE ENGINE COOLING FUEL LOW FUEL BOOST OIL
CYL.3 CYL.2 CYL.1 CYL.4 SPEED SPEED TEMPERATURE PRESSURE RAIL PRESSURE & PRESSURE 03
EXHAUST GAS
SENSOR SENSOR SENSOR SENSOR PRESS. TEMPERATURE SENSOR
RECIRCULATION
CAMSHAFT CRANKSHAFT SENSOR SENSOR 11C GP3
VALVE (EGR)
M
11C GP4
STARTER
RELAY
STARTER
SOLENOID
TO BATTERY TO BATTERY
03 00
B+ POST B- POST
STARTER
M
ALTERNATOR
D56C
N
B+ G
3
DIODE
STYLE A 56C (220149AA)
47 Ω
STYLE B 60D-16 BK
47 Ω
D60D
DIODE
O

Z
T
Y
X
S
R
230790ABA
87
RELAY CHART
RELAY FUNCTION
NO. B1
M213409AG-S1
03 03 B+ 00 1 BATTERY
60ACR POWER RELAY 403B
D
2
11CR GLOW PLUG
A
SW26 3
56ACR FUEL PUMP DISCONNECT
SWITCH 4
03 BA+ B+ 00 5
19CR BOOM UP TO ENGINE TO TO TO ENGINE
R2 STARTER POST FUEL PUMP ECU GROUND 6
222CR FRAME LEVEL ENABLE
120 Ω M N K L 7
ENGINE DETAIL HERE
224CR NOT USED
8
CANH DISPLAY MODULE
1
5JCR BRAKE LAMP 8 CANH CAN
9
7 CANL CANL
77CR ENGINE RUNNING ENGINE DISPLAY 2 3 10
60 60 60
4
UNIT 2 IGNITION
212CR BOOM ANGLE 11
00
1
B
28CR BOOM RAISE DISABLE P68 J68 13
99 99 THROTTLE POWER
5
THROTTLE VREF +5 V 5 5
28LCR FRAME LEFT ENABLE 14
90 90 THROTTLE GROUND
6
THROTTLE THROTTLE GROUND 4 4

PEDAL 15
28RCR FRAME RIGHT ENABLE 206 206
7
THROTTLE SIGNAL 3 3 THROTTLE SIGNAL

16
05CR PARK BRAKE RELEASE RELAY 57B START
8
P66 17
255CR REAR WIPER 00
B
9
60 18
258CR FRONT WIPER 60 77
ENGINE DIAGNOSTIC A
10
CONNECTION 19
258ACR TOP WIPER 105 105
G
11
DIAGNOSTIC CAN
20
104 104
12
250ACR LEFT TURN SIGNAL H

R3 21
203
1
RIGHT TURN SIGNAL PREHEAT LAMP

251ACR PL1 - YW
120 Ω R4 22
1000 Ω
C
R.A.S. RESTRICT MODE ENABLE 74

2
223ACR 23
+
-
220CR R.A.S. DRIVE/BRAKE INPUT RELAY PREHEAT
24
57DCR STARTER INTERRUPT 25
- - 26
- - 27
28
AMPERE 29
FUSE
CIRCUIT
NO. RATING
30
F1 10A IGNITION/POWER RELAY
31
F2 10A TRANS/B-U ALARM/PARK BRAKE
32
F3 10A STEER SELECT/GAUGE/TRANS TEMP
D
33
F4 10A FRAME/CARRIAGE ENABLE REV. DETECTOR
CANH 1 REVERSE REVERSE WARNING
SENSOR
34 SENSOR OPTION
F5 10A REAR AXLE LOCK CANL 2
1 8
2 7 35
F6 5A NOT USED TELEMATICS OPTION
3 6 77CR 60C WHITE
DISP PWR 5 4 5 ENGINE RUNNING 36
F7 10A HORN/BEACON OPT. 03 RED
DISP GND 6 60B 77
F8 15A POWER PORT BLACK 37
60B M6 TELEMATICS OPTION
60C 60C 3 2
F9 5A REAR WIPER 03 60B 38
03 1 4
F10
60
10A OUTRIGGERS TO SHEET 2 39
D60
3.38 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH
DIODE
03 M8H
F11 10A WORK LIGHTS 403A 1 2
E 60B 4 40
3
F12 M CANH 11 12 CANL N
15A ROAD LIGHTS 403ACR RELAY 41 POSITIVE SHUTOFF
POSITIVE SHUTOFF RELAY
F13 5A TURN/HAZ./BRAKE LIGHTS 00 00 00 00 00
42
REV. MONITOR CAM1
F14 10A BOOM LIGHTS
E
1 ME501-4 TRACK UNIT

OPTIONS 03 04 2
03 43 TELEMATICS OPTION
GND 3
F15 10A WIPER, FRONT & TOP 60A 4
7 CANH REVERSE CAMERA
REVERSE
60C 1
DC12V 5 44
D60-1 SHLD CAMERA OPTION
F16 10A PREMIUM JOYSTICK ENCLOSED SW1 - IGNITION SWITCH DIODE CAM1 REVERSE UNIT 8 CANL
60B 2 TRACK
TRIGG SENSOR 1
CAB 57D 9 TELE. 4 00 45
F17 5A FAN/INT. LIGHT F1 1 8 2
OPTION OFF
CANH 3 221 11 12 26B
10 A 2 7 IGNITION SWITCH
15 4 46
F18 30A BLOWER ON CANL 3 6 5
START DISP PWR 4 5 6 POWER RELAY
F20 10A HEATER VALVE, A/C SHLD 47
DISP GND JMPR1
03A SW2 - PARK
60A 00 BRAKE SW. NOTE A PARKING BRAKE
F19 5A FRAME LEVEL INTERLOCK 48 SWITCH
PL2 - RD
03B B+ IGN 60A
F21 - - 26B 26B 26B 49 PARKING BRAKE
3
04 05 2 APPLY
60ACR D26B
F22 - - POWER 1 DIODE
ACC F2 26 26 26A 50 PARKING BRAKE
RELAY 10 A RELEASE
F23 - - 3H-26
51
60A
F24 - - 5 6 57A PARK BRAKE RELEASE
ST 57E 57 52 RELAY
4
05 77
F
F25 30A ECM

53
05CR
F26 20A FUEL PUMP
PARK BRAKE RELEASE 54 RESERVE BRAKE JUMPER
C F-N-R
F27 100A GLOW PLUG J47
TO SHEET 2 55
8 26
3RD REMOVE RELAY TO ADD JUMPER WIRE
2ND
56 F - N - R SHIFTER
60A FOR RESERVE BRAKE (OPTION)
57D 1ST 2ND
D57D 3 215 215 57
2ND GEAR SOL.
DIODE
NOTE A - REMOVE WITH TRACK UNIT TELEMATICS 57DCR 58
STARTER
INTERRUPT 1ST
216 216 59
2 1ST GEAR SOL.
60
5 57A 61
N 15 62
F
6
G
57B
63 SERVICE BRAKE
D15 TRANSMISSTION
DIODE DISCONNECT
51 64
7 15 15 15A
REVERSE SOL.
1 16 REVERSE 65
PS1
15 66 BACKUP ALARM
WHITE NOISE
BACKUP ALARM 67 BACKUP ALARM
FORWARD SOL.
16 68
FORWARD WHITE NOISE 69
BACKUP ALARM
70
SW4 - STEER 4H-217
MODE SW. CRAB STEER 71 STEERING MODE SWITCH
3 217 CRAB STEER SOL.
04 05A 2
FRONT 72
F3 1
H
10 A 218 73 4 WHEEL STEER SOL.
4H-218
4W STEER 74
PL3 - YW
75
TRANS. TEMP. TRANSMISSION TEMP.
76
TPSW1 SWITCH TPS1
219
77
78
FUEL GAUGE
+ 79
55 FUEL LEVEL FUEL GAUGE
S
80 FUEL LEVEL SENDER
-
81
82
BOOM UP
I
E.O.S
CLOSED BELOW 70° BOOM UP
83 E.O.S SWITCH
19CR
BOOM E.O.S 84
19 BOOM UP E.O.S
85 RELAY
2H-14A
05A 14
14A 86 BOOM UP
ENABLE VALVE
87
FRAME ANGLE
28 BOOM RAISE
SENSOR
88 DISABLE RELAY
28 CR
±4 DEGREES
BOOM RAISE
DISABLE
89
5 28
PL4 - RD 90 FRAME LEVEL
1 28C
INTERLOCK LAMP
+
05R 05R 2 -
91
3 00 FRAME ANGLE SENSOR
221 4
28L CR
92
65CR 6 28L
J
FRAME LEVEL FRAME LEFT

ENABLE 7 28R ENABLE RELAY 93
FRAME LEVEL ENABLE
65 28L
94
2H-28A
28A 95 FRAME LEFT ENABLE
04 05T 65A 65A
F19 96
5A 28R CR
FRAME RIGHT 97
ENABLE RELAY
28R 98
2H-28B
99 FRAME RIGHT ENABLE
65A 28B
BOOM 40° ANGLE 100
SENSOR
Closed Below 40° BOOM ANGLE SENSOR
101
212CR RELAY
BOOM ANGLE 102
05R
BOOM ANGLE RELAY
K
F5 103
10 A
JUMPER TH 643/843 MODELS ONLY 104
105
106
213
107
D221
DIODE
221 65 108
224CR
NOT USED
109
00
110
05B 221 111
221 FRAME LEVEL SPEED

2H-221 112
L
113
114
PS3 SERVICE BRAKE
115 PRESSURE SWITCH
116
117 FRAME LEVEL ENABLE

222CR
FRAME LEVEL ENABLE 118
RELAY
222 FRAME LEVEL
119 ENABLE RELAY
CONTROL 4H-223 120

HANDLE 223 223 FRAME LEVEL
04 05B 05B ENABLE LEFT
121
4.3V 4.3V F4 4H-223-1
CARRIAGE DUMP AUX (-)
FRAME LEVEL
10 A 223 122 ENABLE RIGHT
2.5V 2.5V
M
HORN SW6 - HORN SW.

0.7V CARRIAGE TILT (UP) 0.7V AUX (+)
123
04 05M
SGL
04 05D 49
SGL
-
HORN
+
F16 124
10 A F7 HORN SWITCH
JOYSTICK 10 A
J46A J 125
A - SIGNAL
5 TO SHEET 2
02
126
3 05E POWER PORT
04
08 127
4 F8
15 A SW 14
C - SIGNAL WASHER/WIPER 1 128 WINDSHIELD
WASHER
2 SWITCH WASHER SWITCH
08 05F 3 238 129 WINDSHIELD WASHER
1 04 2 M1
F9
1
222 255CR RELAY
6 5A 130
FRAME LEVEL
6 REAR WIPER 257A PARKING FEED
SWITCH 05M 5
7
05F 255
4 00 131
NOMINAL SPEED
132
257 REAR WIPER
05F REAR WIPER
N
M2
04 133 PARKING AUX. FEED
05F
FRAME LVL/ F6
AUX HYD. 5A 134
CONTROLLER TOC-2 J91
05M 135
12VDC POWER IN 1
3H-41
41 41 136 CARRIAGE TILT UP
CARRIAGE TILT UP RETURN 2
3H-40
40 40 CARRIAGE TILT DOWN
CARRIAGE DUMP RETURN 3 137 (DUMP)
10A 10A
CARRIAGE TILT/DUMP POWER 4 138
08
+5 VDC SENSOR POWER 7 139
C - SIGNAL
CARRIAGE TILT/DUMP SIGNAL 8
140
00
GROUND 9
G Y/R 4H-233 141
233 233
AUX (-) RETURN 10 AUX. EXTEND
POWER STATUS 4H-234 142
ON LED LED 234 234 AUX. RETRACT
O
AUX (+) RETURN 11
10B 10B
143
AUX (+/-) POWER 12 00
02 B 144
INPUT SENSOR GROUND 15 04 A
A - SIGNAL
AUX (+/-) SIGNAL 16 TO SHEET 2
3.38 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH
TO SHEET 2
Z
T
Y
X
S
R
230790ABA
88
M213409AG-S2
A
RELAY CHART FROM SHEET 1 FROM SHEET 1

RELAY FUNCTION A B
NO.
04 00 1
60CR POWER RELAY
2
11CR GLOW PLUG
3
56ACR FUEL PUMP
4
5
19CR BOOM UP
6
B
222CR FRAME LEVEL ENABLE
7
224CR NOT USED 8
5JCR BRAKE LAMP 9
77CR ENGINE RUNNING 10

DL6 - RD
212CR BOOM ANGLE 403A 403A 11
E VALVE HOLD
RED LIGHT
CANL
L
401
1
28CR BOOM RAISE DISABLE 13

VALVE ENGAGE
CANH R3 CANL 14
2
28LCR FRAME LEFT ENABLE K CANL

50 Ω
403A 403A 15
3
C
28RCR FRAME RIGHT ENABLE VALVE HOLD
402 16
4
05CR PARK BRAKE RELEASE RELAY MANUAL SHUTOFF

5
17
403B 403 403 AUTO-RESET
6
255CR REAR WIPER D

18 BREAKER
B1 02
7
258CR FRONT WIPER 20 A GROUND
408 19
8
258ACR TOP WIPER VALVE GROUND

SHUT OFF-SOL. 20
CANH
9 10
CANH
250ACR LEFT TURN SIGNAL
SW 9 21
POS. SHUTOFF.
FROM SHEET 1
251ACR RIGHT TURN SIGNAL 1
2
22
MANUAL SHUTOFF.
3 SWITCH
223ACR R.A.S. RESTRICT MODE ENABLE

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SERVICE

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

Skyjack Service Center Parts & Service (Europe)

Parts (North America) Skyjack Brasil

BECOME ALERT! YOUR SAFETY IS INVOLVED.

The Safety Alert Symbol identifies important safety

Section 1 – Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Section 2 – Maintenance Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 41

Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1.2 Maintenance and 1.2-3 Maintenance and Service Safety

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

1.4 About this Section 1.4-3 Maintenance Instructions

Table 1.1 MAINTENANCE AND INSPECTION CHECKLIST

Change Oil Filters A,C

1.5 Scheduled Maintenance 1.5-2 Electrical

Rear Axle Frame Level

Front & Rear

1.5-5 Cylinders - A ▪ Air-filled Tires - A

▪ Engine Intake Air Filter - A WARNING

▪ Ensure fuel filler cap is secure. ▪ Ensure tank cap is secure.

▪ Hydraulic Oil - A, D ▪ Engine Coolant -A

WARNING ▪ Ensure belts are in good working condition

▪ Drain water by opening water drain plug at ▪ Boom Angle Switches - A

Daily & Weekly

1.5-11 Grease Fittings - B

Shifter Storage Box

▪ Operator’s Cab Controls - A

Use the steps of telehandler to access operator’s cab.

1.6 Function Tests

Table 2.1 Standard and Optional Equipment

Ultra Low Sulfur Diesel (EN 590, ASTM D975)

* Refer to engine manufacturer’s manual 1348AE

CVT Case: Dropcase:

* Refer to manufacturer’s manual. 1233AE

Model SJ1256 THS

SJ1044 TH/THS - SJ1056 TH/THS - SJ1256 THS

FITTING LENGTH IN FRACTIONS

Using the number above as an example,

Fitting Arrangement Schedule

Hose End Torque Chart Hose End Torque Chart

R-134a Temperature/Pressure Chart

Interpreting Pressure Readings

Min* 12837 28300 4173 9200 290 42 1050 215

Min* 15150 33400 4037 8900 276 40 1240 254

Min* 16738 36900 4808 10600 331 48 1372 281

Wheel is the weight that can be experienced on one wheel.

Foot Print Area

Table 3.1 Electrical Symbol Chart

CIRCUITS CROSSING LIMIT SWITCH

PROPORTIONAL LIMIT SWITCH

EMERGENCY CAM OPERATED PNP

CAPACITOR RESISTOR NPN

SINGLE POLE DOUBLE POLE DOUBLE POLE TEMPERATURE

Table 3.2 Hydraulic Symbol Chart

ACCUMULATOR, SINGLE ACTING

HYDRAULIC CUSHION DOUBLE ACTING

ELECTRIC MOTION SPRING APPLIED