OPERATING MAINTENANCE & PARTS MANUAL · 2018. 10. 3. · ANSI/SIA (United States) You are required by ANSI/SIA A92.5 -1992 to read and understand YOUR RESPONSIBILITIES in the Manual

OPERATINGMAINTENANCE &PARTS MANUAL

BO

OM

Serial Numbers 90876 and Below.

SKSKSKSKSKYJACK CORPYJACK CORPYJACK CORPYJACK CORPYJACK CORP. (USA). (USA). (USA). (USA). (USA)3451 Swenson Ave,. St. Charles, IL. 60174 TTTTTelelelelel:1-800 275-95221-800 275-95221-800 275-95221-800 275-95221-800 275-9522 FFFFFax: (630) 262-0006ax: (630) 262-0006ax: (630) 262-0006ax: (630) 262-0006ax: (630) 262-0006

SKSKSKSKSKYJACK INC.YJACK INC.YJACK INC.YJACK INC.YJACK INC.55 Campbell Rd., Guelph, Ontario, Canada N1H1B9 TTTTTel:el:el:el:el: (519) 837-0888 (519) 837-0888 (519) 837-0888 (519) 837-0888 (519) 837-0888 F F F F Fax: (519) 837-3102ax: (519) 837-3102ax: (519) 837-3102ax: (519) 837-3102ax: (519) 837-3102

SJKB

-33N

700424-2 Printed in Canada Complete Revision 5/1/97

CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the state ofCalifornia to cause cancer, birth defects, and other reproductive harm.

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TABLE OF CONTENTS

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Page iSJKB33N

SECTION 1 INTRODUCTIONPURPOSE OF EQUIPMENT ................................................................................................ Page 1USE OF EQUIPMENT .......................................................................................................... Page 1WARNINGS .......................................................................................................................... Page 1DESCRIPTION ..................................................................................................................... Page 1Figure 1-1A. Front Panel Labels............................................................................................. Page 2Figure 1-1B. Front Panel labels .............................................................................................. Page 3Table 1-1. Specifications and Features .................................................................................. Page 4WORK PLATFORM MAJOR COMPONENTS IDENTIFICATION Figure 1-2. SKYJACK SJKB Boom Work Platform (Model SJKB-33C Shown) ................... Page 5

SECTION 2 OPERATIONOPERATOR QUALIFICATIONS ............................................................................................. Page 1OPERATING CONTROL IDENTIFICATION Base Controls - Electrical .................................................................................................. Page 3 Base Controls - Mechanical ............................................................................................... Page 4 Base Controls - Hydraulic .................................................................................................. Page 4 Platform Controls - Electrical ............................................................................................. Page 6OPERATING PROCEDURES Prestart Checks ................................................................................................................ Page 8 Start and Operation ........................................................................................................... Page 8 Shutdown Procedure .......................................................................................................... Page 9 Loading and Tie Down Procedure ....................................................................................... Page 9BATTERY SERVICE AND CHARGING PROCEDURES Battery Service ................................................................................................................ Page 10 Battery Charging Procedures ........................................................................................... Page 10BATTERY CHARGING OPERATIONS ................................................................................ Page 11Table 2-1 - Maintenance and Inspection Schedule ............................................................... Page 12Table 2-2 - Owners Annual Inspection Record ..................................................................... Page 13Table 2-3 - Tire Specifications ............................................................................................. Page 13Table 2-4 - Maximum Platform Capacities ........................................................................... Page 13RECOMMENDED HYDRAULIC OILS.................................................................................. Page 13Table 2-5 - General Specifications ....................................................................................... Page 14

SECTION 3 SYSTEMS COMPONENT IDENTIFICATION AND SCHEMATICSTABLE OF CONTENTS ........................................................................................................ Page 1

SECTION 4 TROUBLESHOOTING INFORMATIONELECTRICAL TROUBLESHOOTING .................................................................................... Page 1HYDRAULIC TROUBLESHOOTING .................................................................................... Page 17

SECTION 5 MAINTENANCE AND SERVICETABLE OF CONTENTS ........................................................................................................ Page 3

SECTION 6 PARTS LISTLIST OF ILLUSTRATIONS .................................................................................................... Page 3

SJKB33NPage ii

WARNING

ANSI/SIA (United States)You are required by ANSI/SIA A92.5 -1992 to read and understand YOUR RESPONSIBILITIES in the Manual OfResponsibilities before you use or operate this work platform.

CSA (Canada) and CE (Europe)You are required to conform to national health and safety regulations applicable to the operation of this work platform.

FAILURE TO COMPLY with your REQUIRED RESPONSIBILITIES in the use and operation of the work platformcould result in death or serious injury.

OPERATOR SAFETY REMINDERSThe National Safety Council reminds us that most accidents are caused by the failure of some individuals to followsimple and fundamental safety rules and precautions. Common sense dictates the use of protective clothing whenworking on or near machinery. Use appropriate safety devices to protect your eyes, ears, hands, feet and body.

You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this work platformis mandatory. The following pages of this manual should be read and understood completely before operating thework platform. Any modifications from the original design are strictly forbidden without written permission fromSKYJACK, Inc.

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

THIS MACHINE IS NOT INSULATED.

MAINTAIN SAFE CLEARANCES FROM

ELECTRICAL POWER LINES AND

APPARATUS. YOU MUST ALLOW FOR

PLATFORM SWAY, ROCK OR SAG. THIS

WORK PLATFORM DOES NOT PROVIDE

PROTECTION FROM CONTACT WITH OR

PROXIMITY TO AN ELECTRICALLY

CHARGED CON-DUCTOR.

ELECTROCUTION HAZARD

DANGER VOLTAGE RANGE MINIMUM SAFE APPROACH DISTANCE

(PHASE TO PHASE) (FEET) (METERS)

AVOID CONTACT

10

(0 TO 300V)

(Over 300V to 50KV)

(Over 50KV to 200KV)





15

20

25

35

45

3.05

4.60

6.10

7.62

10.67

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SJKB33N Page iii

SERVICE POLICY AND WARRANTYSKYJACK, Inc. warrants each new work platform to be free of defective parts and workmanship during the first 12months. Refer to Warranty Statement on Page iv for details.

NOTESKYJACK, Inc. is continuously improving and expanding product features on it’s equipment; therefore,specifications and dimensions are subject to change without notice.

This Safety Alert Symbol Means Attention!

Become Alert! Your Safety Is Involved.

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

SCOPE OF THIS MANUALThis manual applies to the ANSI/SIA, CSA and CE versions of the SJKB-33, -40 work platform. Equipment identifiedwith “ANSI/CSA” meets the ANSI/SIA-A92.5 -1992 standards. Equipment identified with “CSA” meets the CAN3-B354.2&.3 M82 standards. Equipment identified with “CE” meets the requirements for the European countries, i.e.Machinery Directive 89/392/EEC and EMC Directive 89/336/EEC and the corresponding EN standards.

DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERAUTHORIZATION AND TRAINING. DEATH OR SERIOUSINJURY COULD RESULT FROM IMPROPER USE OF THISEQUIPMENT!

SJKB33NPage iv

SKYJACK, Inc. warrants each new work platform to befree of defective parts and workmanship. During thefirst full year, labor and defective parts will be providedby the local authorized Skyjack dealer without charge.For the following 48 months, structural components foundto be defective will be replaced or repaired at no charge.

A warranty registration card is supplied with each workplatform. The warranty is only effective when the warrantycard has been completed and returned to Skyjack within15 days from the time of billing. When work platformsare put into stock, the warranty period does not startuntil the work platform has been shipped to the dealerscustomer. If a unit is put into service and no warrantycard has been mailed to Skyjack, Inc., the warranty periodwill commence 15 days from the date the dealer wasinvoiced for the work platform.

All warranty claims are subject to approval by Skyjack’sService Department. Skyjack, Inc. reserves the right tolimit or adjust claims with regard to defective parts, laboror travel time based on usual and customary guidelines.Parts purchased from sources other than Skyjack willnot be covered under this warranty. Misuse or improperoperation, lack of normal maintenance and inspectionsas outlined in this manual, alterations to original designand/or components or accidents will void all warranty.Batteries are not covered by this warranty.

The above mentioned warranty statement is exclusiveand no other warranty whether written, oral or impliedshall apply. Skyjack excludes any implied warranty ofmerchantability and fitness and accepted no liability forconsequential damages or for other negligence.

WARRANTY PROCEDURES

The selling distributor or authorized dealer shall beresponsible for the complete handling of customer claimsunder this warranty. Here’s what to do:

1. When a customer files a claim under this warranty,contact Skyjack’s Service Department to verifywarranty coverage. NOTE: The complete serial numberof the work platform is required to verify the claim.

2. When Skyjack’s Service Department verifies warrantycoverage, they will also issue an RA (ReturnAuthorization) number for the return of any defectivecomponent(s). All items over $25.00 in value mustbe returned to Skyjack, Inc.

WARRANTY STATEMENT3. Fill out a Warranty Claim Form from dealer’s supply of

claim forms. Then notify Skyjack’s ServiceDepartment of the warranty claim number on the formused.

4. The distributor/dealer should then file a warranty claimwith Skyjack, Inc. describing the nature of the defect,probable cause, work performed, travel hours, andlabor hours listed separately. Warranty labor will bepaid at a rate of $42.00 per hour. The travel allowancewill be paid at the same hourly rate within the dealersspecified territory, limited to a maximum of four (4)hours. If a part has serviceable components,PLEASE replace the bad component. For instance,if you have a bad switch on a controller, please replacethe switch. Hydraulic cylinders should be repacked,unless they are damaged beyond repair. Enginefailures should be directed to your local enginedistributor and covered by the manufacturers warranty.Skyjack will accommodate you and your labor. Laborrates and travel allowances are subject to changewithout notice.

5. Warranty claims must be received by Skyjack within15 working days from the date of the repair. Warrantyclaims received with insufficient information will bereturned for correction or completion.

6. Materials returned for warranty inspection must havethe following procedures:

A. Carefully packaged to prevent additional damageduring shipping.

B. Drained of all contents and all open ports cappedor plugged.

C. Shipped in a container tagged or marked with theRA number.

D. Shipped PREPAID. Any item(s) returned forwarranty by any other means may be refused andreturned unless prior approval from Skyjack isobtained.

E. Items shipped to the dealer will be sent freightprepaid and added to the invoice.

Failure to comply with the above procedures may delayapproval and processing of the warranty claim and couldresult in the denial of a warranty claim. Skyjack’s dealer’saccounts must be kept current in order to approve andissue warranty credits. Skyjack reserves the right towithhold issuance of warranty credits to a dealer if theiraccount is not in good standing. This is subject to changewithout prior notice.

SECTION 1, Page 1SJKB-33N

SECTION 1INTRODUCTION

PURPOSE OF EQUIPMENTThe SKYJACK SJKB-33N Boom Work Platform isdesigned to transport and raise personnel and tools tooverhead work areas.

USE OF EQUIPMENTThe work platform (Figure 1-2.) is a compact, highlymaneuverable work station. Driving and lifting MUSTbe on a flat, level, firm, slab surface.

WARNINGSThe operator MUST read and completely understandthe front panel labels (Figures 1-1A and 1-1B) and ALLother warnings in this manual and on the work platform.Compare the labels on the work platform with the labelsfound throughout Sections 1 and 2 of this manual. Ifany labels are damaged or missing, replace themimmediately.

DESCRIPTIONThe work platform consists of four major assemblies,the platform, boom assembly, turret and drive chassis.An operator’s control console is located on the platform.A foot switch on the platform enables and disables theplatform controls. Auxiliary and emergency controls arelocated in the hydraulic/electric cabinet on the rotatingturret.

PLATFORM - The platform is constructed of a skid-resistant see-thru deck surface and a 42" high tubularsteel railing system with midrails and 6" toe boards. Theplatform can be entered through a sliding midrail bar atthe center of the railing system or optional hinged gate.The platform can be rotated 90 degrees from center ineither direction. A 110 VAC GFI outlet is also locatedon the platform.

BOOM ASSEMBLY - The boom is mounted on the turretand consists of a 4 foot hydraulic boom jib, telescopingboom assembly and riser arm. This mechanism usesdouble-acting hydraulic cylinders with holding valves tocontrol vertical movement. Manual lowering valves atthe base of the riser, boom and jib cylinders allow themechanism to lower in the event of an emergency orelectrical system failure.

TURRET - The turret rotates 355 degreesnoncontinuous. Within the turret are two cabinets. Onecabinet contains the hydraulic tank and boom functionpump/motor assembly. The other cabinet containshydraulic and electric components and the base controlpanel.

DRIVE CHASSIS - This weldment supports two batterycompartments each holding four six volt, deep-cyclebatteries. The 48 volt, 25 amp battery charger is locatedat the front of the chassis. An electric motor coupledwith a drive locking differential is used for driving thework platform. Dynamic braking as well as spring-applied hydraulically-released parking brakes arelocated on the drive axle. The front axle has two non-driven wheels steerable by double-acting steer cylinders.

PLATFORM CONTROL CONSOLE - Located on theplatform, this removable control station contains controlsfor work platform motion and emergency stopping.

OPTIONAL ACCESSORIES - The SKYJACK SJKB-33N Boom Work Platform is designed to accept a varietyof optional accessories. These are listed in Table 1-1.Specifications and Features found later in this section.Operating instructions for these options (if required) canbe found in Section 2 of this manual.

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SECTION 1, Page 2 SJKB-33N

Figure 1-1A. Front Panel Labels

FAILURE TO AVOID THESE HAZARDS WILLRESULT IN SERIOUS INJURY OR DEATH.


Figure 1-1B. Front Panel Labels


TABLE 1-1. SPECIFICATIONS AND FEATURES

Specifications

WEIGHT ........................................................................................................... 14,500# (6577kg)WORK HEIGHT ........................................................................................................ 39' (11.89m)RAISED PLATFORM HEIGHT(nominal) ..................................................................33' (10.06m)STOWED HEIGHT ..................................................................................................... 6' 7" (2.0m)OVERALL WIDTH ...................................................................................................... 48" (1.22m)STOWED LENGTH ................................................................................................ 14' 4" (4.36m)PLATFORM CAPACITY (Unrestricted) ................................................................... 500# (227kg)PLATFORM SIZE ........................................................................ 30.00" x 48.00" (.76m x 1.22m)ELECTRICAL SYSTEM ............................................................................................. 48 Volts DCGRADABILITY .......................................................................................................................30%TURRET ROTATION .................................................................................. 355° (Noncontinuous)TIRE SIZE ........................................................................................... 28" x 7" x 15" Foam Filled

Features

STANDARD EQUIPMENT4 Foot Hydraulically Controlled Boom JibVariable Speed Drive and Function ControlsIn-Line Elevating AssemblyContinuous Drive and Steer Directional SensingElectrical Dynamic Braking SystemTwo Spring-Applied Hydraulically-Released Parking BrakesANSI and CSA Standards Compliance

OPTIONAL EQUIPMENTOperator HornAll Function Motion AlarmDescent AlarmTravel AlarmFlashing Amber LightSpring-Loaded Half GateSpring Loaded Full GateOn-Board 110VAC GeneratorLifting LugsNon Marking TiresAdditional Battery BoxesOverload Sensing (France)8 Meter Drive Cutout (Europe)


WORK PLATFORM MAJOR COMPONENT IDENTIFICATION

Figure 1-2. SKYJACK SJKB-33N Boom Work Platform

OPERATOR’S TELESCOPINGCONTROL BOOM ASSEMBLYCONSOLE

BOOMJIB

RISERARM

TURRET

BATTERYCHARGER

DRIVECHASSIS

BASECONTROLPANEL

PLATFORM


NOTES


SECTION 2OPERATOR CONTROLS/INSPECTIONS

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

OPERATOR’S RESPONSIBILITY FOR MAINTENANCEDeath or injury can result if the work platform is not kept in good working order. Inspection and maintenance should beperformed by competent personnel who are familiar with mechanical procedures.The operator should be assured that the work platform has been properly maintained and inspected before using it.Even if the operator is not directly responsible for the maintenance of this work platform, the operator should performALL the daily inspections found in Table 2-1. Maintenance and Inspection Schedule.

NOTEReplace all worn or damaged parts or labels discovered during this inspection.

MAINTENANCE AND INSPECTION SCHEDULEThe actual operating environment of the work platform governs the use of the maintenance schedule. The inspectionpoints covered in Table 2-1. Maintenance and Inspection Schedule indicates the areas of the work platform to bemaintained or inspected and at what intervals the maintenance and inspections are to be performed.

OWNER’S ANNUAL INSPECTION RECORD

It is the responsibility of the owner to arrange daily, weekly, monthly and annual inspections of the work platform. Table2-2. Owner’s Annual Inspection Record is to be used for recording the date of inspection, owners’ name and the personresponsible for the inspection of this work platform.

GENERAL MAINTENANCE HINTS

• Before attempting any repair work, disconnect the batteries by separating the 350A connectors.

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

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

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NOTEDepressing the Emergency Stop Button instantlyengages parking brakes.

9. EMERGENCY STOP BUTTON - When struck, thisred push-button switch disconnects power to the controlcircuit. In the event of an emergency or at work platformshut down, push button in. To restore power, simply pullbutton out.

8. JIB UP/DOWN TOGGLE SWITCH - This switchcontrols the up/down movement of the jib. To move thejib upward, push and hold this toggle switch to the “ Ý“ (up) position. Release switch to stop. To move thejib downward, push and hold this toggle switch to the “ ß “ (down) position. Release switch to stop.

1. OFF/PLATFORM/BASE SELECT KEY SWITCH2. RISER UP/DOWN TOGGLE SWITCH3. BOOM UP/DOWN TOGGLE SWITCH4. TURRET ROTATION TOGGLE SWITCH5. PLATFORM LEVELING TOGGLE SWITCH6. BOOM RETRACT/EXTEND TOGGLE SWITCH7. PLATFORM ROTATION TOGGLE SWITCH8. JIB UP/DOWN TOGGLE SWITCH9. EMERGENCY STOP BUTTON10. CIRCUIT BREAKERS11. BEEPER ALARM (option)

BASE CONTROL PANEL - This control station is locatedon the rotating turret in the hydraulic/electric cabinetcover. It contains the following controls:

1. OFF/PLATFORM/BASE SELECT KEY SWITCH -Turning the key to the “ ” (off) position disconnectspower from the control circuit. When the “ ” (platform)position is selected, power is directed to the controlstation on the platform. When the switch is held in the“ ” (base) position power is directed to the controlstation on the base.

3. BOOM UP/DOWN TOGGLE SWITCH - This switchcontrols the up/down movement of the boom section. Toraise the boom section, push and hold this toggle switchto the “ Ý “ (up) position. Release switch to stop. Tolower the boom section, push and hold this toggle switchto the “ ß “ (down) position. Release switch to stop.

2. RISER UP/DOWN TOGGLE SWITCH - This switchcontrols the up/down movement of the riser section. Toraise the riser section, push and hold this toggle switchto the “ Ý “ (up) position. Release switch to stop. Tolower the riser section, push and hold this toggle switchto the “ ß “ (down) position. Release switch to stop.

4. TURRET ROTATION TOGGLE SWITCH - This switchcontrols clockwise and counterclockwise turret rotation.To rotate the turret clockwise, push and hold this toggleswitch to the “ Ü “ (cw) position. Release switch tostop. To rotate the turret counterclockwise, push andhold this toggle switch to the “ Þ “ (ccw) position. Releaseswitch to stop.

6. BOOM RETRACT/EXTEND TOGGLE SWITCH - Thisswitch controls the retraction and extension of thetelescoping boom arm. To retract the boom arm, pushand hold this toggle switch to the “ Ý “ (retract) position.Release switch to stop. To extend the boom arm, pushand hold this toggle switch to the “ß “ (extend) position.Release switch to stop.

5. PLATFORM LEVELING TOGGLE SWITCH - Thisswitch controls the leveling of the platform if adjustmentis necessary. If the platform is tilted away from the jib,push and hold this toggle switch to the “ Ý “ (up) position.Release switch when level. If the platform is tilted towardthe jib, push and hold this toggle switch to the“ß“ (down) position. Release switch when level.

7. PLATFORM LEFT/RIGHT ROTATION TOGGLESWITCH - This switch controls left and right rotation ofthe platform. To rotate the platform to the left, push andhold this toggle switch to the “ Ü “ (left) position. Releaseswitch to stop. To rotate the platform to the right, pushand hold this toggle switch to the “ Þ “ (right) position.

Base Controls - ElectricalBase Control Panel

Figure 2-1. Base Control Panel and Label

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1. TURRET ROTATION SPEED CONTROL VALVE

Base Controls - HydraulicTurret Rotation Speed Control Valve

Figure 2-5. Turret Rotation Speed Control Valve

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1. EMERGENCY TURRET ROTATING MECHANISM -This mechanism is located on the rotation gear underthe turret. Using a 7/8" 6-point socket with ratchet torotate the turret back to center. NOTE: On Europeanmodels a 7/8" 6-point ratcheting wrench (SKYJACK#701517) is located inside the hydraulic/electric cabinet.

Base Controls - MechanicalEmergency Turret Rotating Mechanism

Figure 2-4. Emergency Turret Rotating Mechanism

1. EMERGENCY TURRET ROTATING MECHANISM

11. BEEPER ALARM - This optional audible pulse devicecan be setup as a motion alarm, or as an all functionalarm.

350 Amp Battery Connectors

Figure 2-2. 350 Amp Battery Connectors

1. 350 AMP BATTERY CONNECTORS

1. 350 AMP BATTERY CONNECTOR - These connectors,located adjacent to the battery charger(on earlier modelsthis connection will be located inside the turret),disconnects the batteries and all power to both controlstations in the event of an emergency and for workplatform shut down. This connection MUST be made tooperate any control on either control station. The batterycharger works independently of this connection and thebatteries may still be charged while these connectorsare separated.

Control Circuit Disconnect Switch

Figure 2-3. Control Circuit Disconnect Switch(Machines with Serial Number 90306 and below.)

1. CONTROL CIRCUIT DISCONNECT SWITCH

1. CONTROL CIRCUIT DISCONNECT SWITCH - Thisswitch, located at the rear of the base behind the batterycharger, disconnects power to both control stations inthe event of an emergency and for work platformshutdown. This switch MUST be turned to ‘’ON’‘ positionto operate any control on either of these control stations.

NOTETo disconnect the batteries, separate the two 350Amp battery connectors.

NOTEMachines with Serial Number 90307 and above haveonly two circuit breakers.

10. CIRCUIT BREAKERS - In the event of a poweroverload or positive circuit grounding, the circuit breakerwill pop out. Make the necessary corrections, thendepress the push-button to reset.

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DO NOT release the brakes on an incline without thewheels chocked.

1. PARKING BRAKE RELEASE PLUNGER -Locatedon the brake manifold in the hydraulic/electriccabinet, when this red plunger on the brake valve isdepressed, the brake valve opens allowingaccumulator pressure to immediately disengage theparking brakes.

DANGER

Figure 2-7. Parking Brake Release Plunger(Machines with Serial Number 90307 and above.)

1. PARKING BRAKE RELEASE PLUNGER

NOTE:On European models, the manual lowering valveknobs are located inside the hydraulic/electriccabinet on the turret.

Parking Brake Release Plunger

1. EMERGENCY LOWERING VALVE ON RISER2. EMERGENCY LOWERING VALVE ON BOOM3. EMERGENCY LOWERING VALVE ON JIB

1. EMERGENCY LOWERING VALVE ON RISER -Located at the base on the riser cylinder, this valve allowsriser lowering in the event of an emergency or an electricalsystem failure. Turning the valve knob counterclockwiseallows the riser to gradually lower. Valve MUST be fullyclosed (clockwise) to restore normal operation.

2. EMERGENCY LOWERING VALVE ON BOOM -Located at the base on the boom cylinder, this valveallows boom lowering in the event of an emergency oran electrical system failure. Turning the valve knobcounterclockwise allows the boom to gradually lower.Valve MUST be fully closed (clockwise) to restore normaloperation.

Figure 2-6. Emergency Lowering Valves and ProcedureLabel

3. EMERGENCY LOWERING VALVE ON JIB - Locatedat the base on the jib cylinder, this valve allows jiblowering in the event of an emergency or an electricalsystem failure. Turning the valve knob counterclockwiseallows the jib to gradually lower. Valve MUST be fullyclosed (clockwise) to restore normal operation.

1. TURRET ROTATION SPEED CONTROL VALVE -Located on the lower left side of the main manifold in thehydraulic/electric cabinet, this rotary valve when rotatedto a fully closed position (clockwise) allows maximumturret rotation speed. By opening the valve(counterclockwise) the turret rotation speed can bereduced.

Emergency Lowering Valves

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Step 1. Disconnect the batteries by separating the 350Amp Battery Connectors.

Step 2. Firmly depress the red plunger knob on the brakemanifold. The brakes are now released.

NOTEThe brake will automatically return to normaloperation when a drive function is selected.


Brake override Valve and Parking Brake ReleaseHand Pump

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Figure 2-8. Brake Override Valve and Parking BrakeRelease Hand Pump

(Machines with Serial Number 90306 and below.)

1. BRAKE OVERRIDE VALVE PLUNGER2. PARKING BRAKE RELEASE HAND PUMP

DANGER

DO NOT release the brakes on an incline without thewheels chocked.

1. BRAKE OVERRIDE VALVE PLUNGER - Located onthe brake manifold and accessed thru a hole in the drivechassis, when this black plunger on top of the brakevalve is depressed, the brake valve closes allowing useof the parking brake hand pump.

2. PARKING BRAKE RELEASE HAND PUMP - Locatedon the brake manifold and accessed through an openingin the drive chassis, the hand pump MUST be used todisengage the parking brakes. To release the parkingbrakes, the procedure below MUST be followed:

Step 1. Turn the Control Circuit Disconnect Switch to the‘’OFF’‘ position.

Step 2. Depress the black plunger on the Brake Valveuntil the knob stays in.

Step 3. Grasp the hand pump plunger and pump rapidlyuntil firm resistance is felt. The brakes are nowreleased.

NOTEThe brake will automatically return to normaloperation when a drive function is selected.

Platform Controls - ElectricalFoot Switch

Figure 2-9. Foot Switch

1. FOOT SWITCH

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

IMPORTANT NOTE

The foot switch MUST be depressed and held to useany control on the operator’s control console.

WARNING

Before releasing the foot switch, the controllers shouldbe returned to the neutral position. Work platformmotion will stop when the foot switch is released.When driving and foot switch is released, parkingbrake engages instantly.


12. HORN PUSH-BUTTON (Optional) - The horn canbe sounded by depressing this red push-button on thecontroller handle.

Operator’s Control Console

Figure 2-10. Operator’s Control Console and Label

1. JIB UP/DOWN SELECTOR PUSH-BUTTON2. RISER UP/DOWN SELECTOR PUSH-BUTTON3. BOOM UP/DOWN SELECTOR PUSH-BUTTON4. TURRET ROTATION SELECTOR PUSH-

BUTTON5. PLATFORM LEVELING/ROTATION SELECTOR

PUSH-BUTTON6. BOOM RETRACT/EXTEND SELECTOR PUSH-

BUTTON7. BOOM FUNCTION CONTROLLER8. DRIVE/STEER CONTROLLER9. EMERGENCY STOP BUTTON10. TILT SENSOR INDICATOR LIGHT11. POWER ON INDICATOR LIGHT12. HORN PUSH-BUTTON (Optional)

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OPERATOR’S CONTROL CONSOLE - This metalcontrol station is located at the front of the platform. Itcan be disconnected and removed to safeguard againstunauthorized use. It contains the following controls:

IMPORTANT NOTE

The foot switch MUST be depressed and held to useany control on the operator’s control console. Referto Operating Procedures for detailed instructions onoperating these controls.

NOTEOn earlier models, a trigger switch on the controllergrip sounded the optional horn.

1. JIB UP/DOWN SELECTOR PUSH-BUTTON - Thisswitch enables the operator to move the jib up or down.

2. RISER UP/DOWN SELECTOR PUSH-BUTTON - Thisswitch enables the operator to move the riser up or down.

3. BOOM UP/DOWN SELECTOR PUSH-BUTTON - Thisswitch enables the operator to move the boom up ordown.

4. TURRET ROTATION SELECTOR PUSH-BUTTON -This switch enables the operator to rotate the turret.The turret can be rotated 355 degrees noncontinuous.

5. PLATFORM LEVELING/ROTATION SELECTORPUSH-BUTTON - This switch enables the operator tolevel the platform (if adjustment is necessary) and torotate the platform up to 87 degrees to the left or right.Platform leveling is not available on European models.

6. BOOM RETRACT/EXTEND SELECTOR PUSH-BUTTON - This push-button enables the operator toretract and extend the boom arm.

7. BOOM FUNCTION CONTROLLER - This lever-typecontrol allows the operator to choose the direction andvary the speed for each selected function.

8. DRIVE/STEER CONTROLLER - This lever-typecontrol allows the operator to drive in forward or reverseand by using the rocker on top of the controller to steerleft and right.

9. EMERGENCY STOP BUTTON - This red mushroom-shaped button is designed to cut power to the platformcontrols when struck in the event of an emergency or atwork platform shutdown. To restore power, simply pullbutton out.

NOTEDepressing the Emergency Stop Button instantlyengages parking brakes.

10. TILT SENSOR INDICATOR LIGHT - This red lightindicates that the work platform is on a slope whichexceeds the limits for safe operation. A horn will alsosound.

11. POWER ON INDICATOR LIGHT - This red lightindicates that the foot switch has been depressed andpower is available to operate the controls on the operator’scontrol console.


12. TO MOVE THE JIB DOWN: Depress and holdthe Jib Up/Down Selector Push-button, thenslowly move the Function Controller to the“ ß “ (down) position. Release the controller tostop.

OPERATORS CHECK LISTINSPECT AND/OR TEST THE FOLLOWINGDAILY OR AT THE BEGINNING OF EACH SHIFT 1. OPERATING AND EMERGENCY CONTROLS. 2. SAFETY DEVICES. 3. PERSONAL PROTECTIVE DEVICES. 4. TIRES AND WHEELS. 5. OUTRIGGERS (IF EQUIPPED) AND OTHER STRUCTURES. 6. AIR, HYDRAULIC AND FUEL SYSTEM FOR LEAKS. 7. LOOSE OR MISSING PARTS OR HARDWARE. 8. CABLES OR WIRING HARNESS. 9. PLACARDS, WARNINGS, CONTROL MARKINGS AND OPERATING MANUAL(S).10. GUARDRAIL SYSTEM.11. ENGINE OIL SYSTEM (IF SO EQUIPPED).12. BATTERY FLUID LEVEL.13. HYDRAULIC AND BRAKE FLUID RESERVOIR LEVEL.14. COOLANT LEVEL (IF SO EQUIPPED).

OPERATING PROCEDURESBefore operating any control, read and completelyunderstand ALL Dangers, Warnings and Cautions onthe work platform and in this operator’s manual.

SJ108891

Pre-start Checks

1. Check for obstacles around the work platformand in the path of travel such as holes, dropoff’s, debris, ditches and soft fill.

2. Check overhead clearances.

3. Make sure that the batteries are fully charged.Disconnect battery charger from external powersource.

4. Make sure emergency lowering valves at thebase of the riser, boom and jib cylinders are fullyclosed.

Start and Operation

1a. Make sure that the 350 Amp Battery Connectorsare not separated.

1b. Turn the Control Circuit Disconnect Switch tothe “ON” position. (Serial Number 90306 andbelow.)

2. Pull out the Emergency Stop Button on the BaseControl Panel.

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

4. Enter the platform by sliding the entry bar at thecenter of the platform upward. Make sure theentry midrail returns to midrail position.

WARNING

DO NOT operate any control on the operator’s controlconsole without your safety belt fastened and properlysecuring the safety belt lanyard to the platform lanyardrings. Failure to avoid this hazard could result indeath or serious injury!

5. Attach the safety belt lanyards of each occupantto the platform lanyard rings.

6. Pull out the Emergency Stop Button.

7. Depress and hold the Foot Switch.

REMEMBER: The controls on the Operator’s ControlConsole WILL NOT operate unless the Foot Switch isdepressed and held.

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

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

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

NOTE: For European models only, drive circuit willcut out when the platform is elevated to 8 meters orabove.10. TO STEER: Depress the rocker on the Drive/

Steer Controller handle in the direction you wishto steer.

NOTE: On early machines the Function SelectionButton must be held the entire time a function isbeing performed. Later machines require that theFunction Selection Button be pushed only to begin afunction and then can be released until the controlleris returned to a neutral position.

11. TO MOVE THE JIB UP: Depress and hold theJib Up/Down Selector Push-button , then slowlymove the Function Controller to the “Ý“ (up)position. Release the controller to stop.


Loading and Tie Down Procedure

13. TO MOVE THE RISER UPWARD: Depress andthe Riser Up/Down Selector Push-button, thenslowly move the Function Controller to the “ Ý “(up) position. Release the controller to stop.

14. TO MOVE THE RISER DOWNWARD: Depressand hold the Riser Up/Down Selector Push-button, then slowly move the Function Controllerto the “ß “ (down) position. Release the controllerto stop.

15. TO MOVE THE BOOM UPWARD: Depress andhold the Boom Up/Down Selector Push-button,then slowly move the Function Controller to the“Ý “ (up) position. Release the controller to stop.

16. TO MOVE THE BOOM DOWNWARD: Depressand hold the Boom Up/Down Selector Push-button, then slowly move the Function Controllerto the “ ß“ (down) position. Release the controllerto stop.

17. TO ROTATE THE TURRET CLOCKWISE:Depress and hold the Turret Rotation SelectorPush-button, then slowly move the FunctionController to the “ Þ“ (cw) position. Release thecontroller to stop.

18. TO ROTATE THE TURRETCOUNTERCLOCKWISE: Depress and hold theTurret Rotation Selector Push-button, then slowlymove the Function Controller to the “Ü“ (ccw)position. Release the controller to stop.

19. TO LEVEL THE PLATFORM (Platform is tiltedaway from the jib): Depress and hold thePlatform Leveling/Rotation Selector Push-button,then slowly move the Function Controller to the“ Ý “ (up) position. Release the controller to stop.

20. TO LEVEL THE PLATFORM (Platform is tiltedtoward the jib): Depress and hold the PlatformLeveling/Rotation Selector Push-button, thenslowly move the Function Controller to the “ ß “(down) position. Release the controller to stop.

NOTE:Platform leveling from platform control console isnot available on European models.

21. TO ROTATE THE PLATFORM TO THE LEFT:Depress and hold the Platform Leveling/RotationSelector Push-button, then slowly move theFunction Controller to the “ Ü “ (left) position.Release the controller to stop.

22. TO ROTATE THE PLATFORM TO THE RIGHT:Depress and hold this push-button, then slowlymove the Function Controller to the “ Þ “ (right)position. Release the controller to stop.

23. TO RETRACT THE BOOM ARM: Depress andhold the Boom Retract/Extend Selector Push-button, then slowly move the Function Controllerto the “ Ý “ (retract) position. Release thecontroller to stop

24. TO EXTEND THE BOOM ARM: Depress andhold the Boom Retract/Extend Selector Push-button, then slowly move the Function Controllerto the “ ß “ (extend) position. Release thecontroller to stop.

25. TO SOUND THE HORN: Depress the triggeron the Drive/Steer Controller (early models), orpress button on top left of Drive/Steer controller(later models).

Shutdown Procedure1. Fully lower the platform.2. Push in the Emergency Stop Buttons.3. Rotate the Off/Platform/Base Key Switch to

the ” “(off) position. Remove the key.4. Rotate the Control Circuit Disconnect Switch to

the “OFF” position.

1. With the telescopic boom fully retracted andtrailer on firm level ground. Align the tires of theboom with the back end of the trailer.

2. Slightly raise the jib for ground clearance whileloading. Slowly and carefully drive the machineon to the trailer.

NOTEFor loading and unloading using a winch line, seethe brake release procedures in this section.

3. With machine loaded on trailer, tie down asrecommended. (Refer to Figure 2-11.)

Figure 2-11. Recommended Tie Down LocationsMa40-212


BATTERY SERVICE AND CHARGINGPROCEDURESBattery Service

WARNINGEXPLOSION HAZARD

Keep flames and sparks away. DO NOT smoke nearbatteries.

CAUTION

Contact with electrolytic acid can cause skin irritationand damage clothing. Wear a protective apron, glovesand goggles when working with batteries.

FIRST AID

Immediately flush eyes with cold water if electrolyticacid is splattered into them. Seek medical attentionif discomfort continues.

1. Disconnect the batteries by separating the350 Amp battery connectors.


DO NOT service the batteries without first separatingthe 350 Amp battery connectors. Vapors emitted bybatteries can be ignited by a spark or arc.

2. Check battery fluid level in each battery. If platesare not covered, add distilled or demineralizedwater.

3. Check each battery case for damage.

4. Clean battery terminals and cable endsthoroughly with a terminal cleaning tool or wirebrush.

5. Make sure all battery connections are tight.

6. Replace any battery that is damaged orincapable of holding a lasting charge.

7. Reconnect the 350 Amp battery connectors.

Battery Charging Procedures


Chargers can ignite flammable materials and vapors. DONOT use near fuels, grain dust, solvents, or otherflammables.

WARNINGSHOCK HAZARD

To reduce the risk of electrical shock, connect chargeronly to a properly grounded single phase outlet. DONOT use a extension cord longer than 25 feet.

1. Select “ ” (off) or “ ” (platform) positionwith the Off/Platform/Base Key Select Switch.

NOTEThe battery charger WILL NOT operate if the Off/Platform/Base Key Select Switch is in the “ ”(base) position.

NOTEFor machines with Serial Number 90695 and above.When the battery charger is operating all machinefunctions are disabled.For machines with Serial Number 90694 and below.The battery charger cuts out when the foot switch isdepressed.

2. Connect charger AC plug to proper voltagesource. Refer to charger nameplate for voltagerequirements.

3. Charge batteries. DO NOT leave chargerunattended for more than two consecutive days.Severe overcharging and battery damage willresult if charger fails to turn off.

4. Disconnect charger from external power source.


BATTERY CHARGER OPERATION

BATTERY STATUS

1. GREEN LED ................ CHARGE COMPLETE

2. YELLOW LED ...........................80% CHARGE

3. RED LED .................................. INCOMPLETE

CHARGER STATUS

4. YELLOW LED .......................... CHARGER ON

5. RED LED ........................ ABNORMAL CYCLE

6. CHARGER STOP SWITCH

7. FUSE HOLDER

OPERATION OF THE COMPLETELY AUTOMATICBATTERY CHARGER

This charger is equipped with an electronic circuit thatwill completely recharge the batteries and automaticallyturn off after the charge cycle is complete.The function of the LED indicators is as follows:When the AC power is connected to the charger, theLED’s will flash several times then flash independentlyto check the light circuits. After the flashing sequenceis complete the “INCOMPLETE” light will come on. Fiveseconds later, the “CHARGER ON” light will come onand at the same time, the ammeter will indicate howmuch current is going to the batteries.As the charge cycle continues, which can last between1-1/2 hours and 16 hours for a complete cycle, dependingon the state of charge of the batteries, the “80%CHARGE” light will come on and the “INCOMPLETE”light will go off. When voltage of the batteries reachesapproximately 60 volts, the “80% CHARGE” light will gooff and the “CHARGE COMPLETE” light will come on.This light will remain on even after the charger is turnedoff by the electronic control. After the charger turns off,the “CHARGE COMPLETE” light will indicate to theoperator that the batteries are healthy and are fullycharged.If the “80% CHARGE” light continues to stay on after thecharge cycle is complete, this indicates to the operatorthat the batteries are not capable of attaining a full charge.If the “INCOMPLETE” light remains on after the chargecycle is complete, this indicates to the operator that thebatteries are not capable of attaining even an 80% charge.If either the “80% CHARGE” or “INCOMPLETE” lightremain on after the charge cycle is complete, the batteriesshould be inspected for problems.Your standard good watering procedures should be usedat all times.

Figure 2-12. Automatic Battery Charger

76

54

3 2 1


NOTES


Table 2-1. Maintenance and Inspection ScheduleDaily Weekly Monthly 3 Months 6 Months *Yearly

MECHANICAL

Struct. damage/welds (1) á á

Parking brakes (2) á á

Tires and wheels (1)(2)(3) á á

Guides and slides (1)(2) á á

Railings and gates (2)(3) á á

Bolts and fasteners (3) á á

Rust (1) á á

Wheel bearings (2) and king pins (1)(6) á á

Turret gear (1)(2)(3)(6) á á

Turret gear box (1)(2)(3) á á

Pivot pins (1) á á

Steer cylinder ends (6) á á

Axle gear oil (12) á

ELECTRICAL

Battery fluid level (1) á á

Control switches (1)(2)(3) á á

Cords and wiring (1) á á

Battery trays (11) á á

Battery terminals (1)(3)(11) á á

Terminals and plugs (1)(3)(11) á á

Generator and recepticals (2) á á

Limit switches (2) á á

Tilt sensor (2) á á

Directional sensing (2) á á

HYDRAULIC

Hydraulic fluid level (1) á á

Hydraulic leaks/hoses (1)(3) á á

Lift/lowering time (8) á á

Hydraulic cylinders (1)(2)(3) á á

Emergency lowering (2) á á

Lift capacity (5) á á

Hydraulic oil filter (7) á á

MISCELLANEOUS

Labels (1)(9) Manuals (10) á á

NOTES:(1) Visuallly inspect (2) Check operation(3) Check tightness (4) Check oil level(5) Check releif valve setting. Refer to Serial Number Nameplate.(6) Lubricate (7) Replace

(8) See Table 2-5. General Specifications.(9) Replace if missing or illegible.(10) Proper Operation Manual MUST be in manualenclosure. (11) Clean(12) Change oil. *Record inspection date.

Mt40-500


Proper operation of the parking brakes should be checked daily or at the beginning of each shift. Locate the machinein an appropriate area for testing the brakes. IMPORTANT NOTE: The area for testing the machine MUST be completelylevel and free of obstructions. DO NOT drive on an incline unless the parking brakes are working properly. With themachine fully stowed and the throttle switch in the high position (if engine powered). Drive the machine forward at fullspeed and remove foot from foot switch. Repeat this step driving in reverse.

WARNING

Parking brakes will instantly engage causing the machine to stop immediately.The machine should come to an instant and abrupt stop. If the machine does not stop instantly or if the machine pullsto one side while stopping, the brake adjustment MUST be checked before putting the machine into service.

MODEL NUMBER__________________________ SERIAL NUMBER______________

RECORDINGDATE

RECORDINGYEAR # 1 2 3 4 5 6 7 8

OWNERSNAME

INSPECTEDBY

Table 2-3. Tire Specifications

Table 2-4. Maximum Platform Capacities

Model Platform Capacity (unrestricted)

ALL MODELS 500# (227kg) 2 occupants

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

Model

Tire

Fill SpecificationSize Rating

SJKB-33N 28 x 7.00 x 15 14 Ply Solid Urethane†

NON-MARKING(Option) 28 x 7.00 x 15 Solid

† - Solid urethane used for filling MUST be 55 durometer installed at 105 psi.

RECOMMENDED HYDRAULIC OILSDO NOT use synthetic or fire resistant oil in this work platform. Use ATF Dexron III (ESSO) or equivalent hydraulic oil.For conditions causing oil temperatures below -31°F (-35° C) and above 122°F (50° C) consult Skyjack, Inc.

Table 2-2. Owner’s Annual Inspection Record


Table 2-5. General Specifications - SJKB-33N

ELECTRICAL SYSTEM 48 Volts DC

BATTERIES (8) 6 Volt, 375AH

TIRES Refer to Table2-3.

INSIDE TURNING RADIUS 66" (1.68m)

OUTSIDE TURNING RADIUS 122" (3.09m)

UNDERCLEARANCE 4" (0.10m)

FLOOR LOAD RATING 64.7psi (4.55kg/cm²)

PIVOTAL HEIGHT 15' - 0" (4.6m)

TAILSWING AT PIVOTAL HEIGHT ZERO

TURRET ROTATION (non-continuous) 355 degrees

LIFT TIME (minimum) (entry height to maximum platform height) 95 Seconds

LOWERING TIME (mimimum) (maximum platform height to entry height) 80 Seconds

SYSTEM RELIEF PRESSURE (R1) 2900 psi

PUMP (boom function)PUMP (brake)

.194 ci./rev

.065 ci./rev

TRAVEL SPEED (maximum at stowed height) 3.4mph (5.5kph)

TRAVEL SPEED (maximum at elevated height) 0.8mph (1.3kph)

RETURN FILTER 10 micron

HYDRAULIC SYSTEM CAPACITY 9.2 gallons (34.8 liters)

HYDRAULIC TANK CAPACITY 5.5 gallons (20.8 liters)

BRAKE SYSTEM CAPACITY (Use Dextron II only) 1.5 pints (.71 liters)

AMBIENT NOISE LEVEL 56db

Mt33N-205

SJKB-33N SECTION 3, Page 1

SECTION 3SYSTEM COMPONENT IDENTIFICATION

AND SCHEMATICS

TABLE OF CONTENTS

ELECTRICAL SYSTEMFIGURE 3-1. BATTERY CHARGER DIAGRAM AND PARTS LIST. ............................................................. Page 3

FIGURE 3-2. OPERATOR’S CONTROL CONSOLE DIAGRAM PARTS LIST - S/N 90242 and Above ............. Page 4

FIGURE 3-2. OPERATOR’S CONTROL CONSOLE DIAGRAM - Serial Number 90242 and Above .................. Page 5

FIGURE 3-3. OPERATOR’S CONTROL CONSOLE DIAGRAM - Serial Number 90241 and Below .................. Page 6

FIGURE 3-3. OPERATOR’S CONTROL CONSOLE DIAGRAM PARTS LIST - S/N 90241 and Below .............. Page 7

FIGURE 3-4. LOAD SENSING OPTION DIAGRAM PARTS LIST (France) ...................................................... Page 8

FIGURE 3-4. LOAD SENSING OPTION DIAGRAM (France) .......................................................................... Page 9

FIGURE 3-5. BASE CONTROL/ELECTRICAL PANEL DIAGRAM - Serial Number 90307 and Above .............Page 10

FIGURE 3-5. BASE CONTROL/ELECTRICAL PANEL DIAGRAM PARTS LIST - S/N 90307 and Above ........Page 11

FIGURE 3-6. BASE CONTROL/ELECTRICAL PANEL DIAGRAM PARTS LIST - S/N 90306 and Below ........Page 12

FIGURE 3-6. BASE CONTROL/ELECTRICAL PANEL DIAGRAM - Serial Number 90306 and Below .............Page 13

FIGURE 3-7. FIGURE 3-8. ELECTRICAL SCHEMATIC PARTS LIST North American ...................................Page 14

FIGURE 3-7. ELECTRICAL SCHEMATIC North American - S/N 90307 and Above ........................................Page 15

FIGURE 3-8. ELECTRICAL SCHEMATIC North American - S/N 90306 and Below.........................................Page 16

FIGURE 3-9. ELECTRICAL SCHEMATIC Europe - Serial Number 90307 and Above ..................................... Page 17

FIGURE 3-10. ELECTRICAL SCHEMATIC Europe - Serial Number 90306 and Below ....................................Page 18

FIGURE 3-9. FIGURE 3-10. ELECTRICAL SCHEMATIC PARTS LIST Europe ............................................... Page 19

HYDRAULIC SYSTEM

FIGURE 3-11. HYDRAULIC SCHEMATIC PARTS LIST - Serial Number 90307 and Above ............................ Page 20

FIGURE 3-11. HYDRAULIC SCHEMATIC - Serial Number 90307 and Above ................................................. Page 21

FIGURE 3-12. HYDRAULIC SCHEMATIC PARTS LIST - Serial Number 90306 and Below .............................Page 22

FIGURE 3-12. HYDRAULIC SCHEMATIC - Serial Number 90306 and Below ..................................................Page 23

FIGURE 3-13. MAIN MANIFOLD COMPONENT AND PORT IDENTIFICATION - S/N 90299 and Above .......Page 24

FIGURE 3-14. BRAKE MANIFOLD COMPONENT AND PORT IDENTIFICATION - S/N 90307 and Above ....Page 24

FIGURE 3-15. MAIN MANIFOLD COMPONENT AND PORT IDENTIFICATION - S/N 90298 and Below ........Page 25

FIGURE 3-16. BRAKE MANIFOLD COMPONENT AND PORT IDENTIFICATION - S/N 90306 and Below .....Page 25

�

SJKB-33NSECTION 3, Page 2

NOTES


FIGURE 3-1. BATTERY CHARGER DIAGRAM AND PARTS LIST

1

2

3

4

56

78

9

10

11

12

13

700302 BATTERY CHARGER ASSEMBLY (MAC #BA821) -1 108554 AMMETER, 0-30 12 700685 CAPACITOR 13 108556 DIODE, 70 Amp 24 111905 FUSE, 45 Amp NON 15 700688 FUSE, 25 Amp AC 16 700689 RECTIFIER ASSEMBLY 17 108562 TRIAC 18 700691 TRANSFORMER, Main 19 108564 TRANSFORMER, Control circuit 110 700692 VARISTOR 111 700701 CONTROL CIRCUIT, 48VDC/120VAC 112 110857 SWITCH, Charger stop 113 701236 RELAY, Charger interlock 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 3-2. OPERATOR’S CONTROL CONSOLE DIAGRAM PARTS LIST(Machines with Serial Number 90242 and above.)

1 (Ref.) CONTROLLER, Drive/steer 1 (For components, refer to Figure 6-6 and 6-7.)

2 700775 CONTROLLER, Boom function 1 (For components, refer to Figure 6-8.)

3 (Ref.) SWITCH ASSEMBLY, Emergency stop 1 (For components, refer to Figure 6-3.)

4 (Ref.) SWITCH ASSEMBLY, Boom up/down selector 1push-button (For components, refer to Figure 6-3.)

5 (Ref.) SWITCH ASSEMBLY, Turret rotation selector 1push-button (For components, refer to Figure 6-3.)

6 (Ref.) SWITCH ASSEMBLY, Platform levelling/rotation 1selector push-button (For components, refer to Figure 6-3.)

7 (Ref.) SWITCH ASSEMBLY, Riser up/down selector 1push-button (For components, refer to Figure 6-3.)

8 (Ref.) INDICATOR LIGHT, Tilt sensor 1 (For components, refer to Figure 6-3.)

9 (Ref.) INDICATOR LIGHT, Power on 1 (For components, refer to Figure 6-3.)

10 (Ref.) SWITCH ASSEMBLY, Jib up/down selector 1push-button (For components, refer to Figure 6-3.)

11 (Ref.) SWITCH ASSEMBLY, Boom retract/extend 1selector push-button (For components, refer to Figure 6-3.)

12 103057 BEEPER, 24 Volt 113 108589 RELAY, 40 Amp sealed 114 103012 STRIP, Terminal block 0.515 103036 STRAIN RELIEF, Cord 116 (Ref.) CONNECTOR, 32 Pole male (recessed) 1

(For components, refer to Figure 6-5.)17 (Ref.) CONNECTOR, 5 Pole female 1

(For components, refer to Figure 6-5.)18 103256 CABLE, 18/2 x 34” lg. 119 700187 SWITCH, Foot 120 (Ref.) CONNECTOR, 5 Pole male 1

(Refer to Figure 6-4.)21 700182 CONTROLLER BOARD, Boom function 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 3-2. OPERATOR’S CONTROL CONSOLE DIAGRAM(Serial Number 90242 and above.)

21

20

19

181716 15

1413

12

11

10

9

8

7

6

54

3

2

1

TB4

Typical Maintained On Switch Module Installation


FIGURE 3-3. OPERATOR’S CONTROL CONSOLE DIAGRAM(Serial Number 90241 and below.)

16

15

1413

12

1110

9

8

7

6

5

4

3

2

1

22

21

20

19

18

17

TB4


1 (Ref.) CONTROLLER, Drive/steer 1 (For components, refer to Figure 6-6 and 6-7.)

2 700181 CONTROLLER, Boom function 1 (For components, refer to Figure 6-8.)

3 (Ref.) SWITCH ASSEMBLY, Emergency stop 1 (For components, refer to Figure 6-2.)

4 (Ref.) SWITCH ASSEMBLY, Boom up/down selector 1push-button (For components, refer to Figure 6-2.)

5 (Ref.) SWITCH ASSEMBLY, Turret rotation selector 1push-button (For components, refer to Figure 6-2.)

6 (Ref.) SWITCH ASSEMBLY, Platform levelling/rotation 1selector push-button (For components, refer to Figure 6-2.)

7 (Ref.) SWITCH ASSEMBLY, Riser up/down selector 1push-button (For components, refer to Figure 6-2.)

8 (Ref.) INDICATOR LIGHT, Tilt sensor 1 (For components, refer to Figure 6-2.)

9 (Ref.) INDICATOR LIGHT, Power on 1 (For components, refer to Figure 6-2.)

10 (Ref.) SWITCH ASSEMBLY, Jib up/down selector 1push-button (For components, refer to Figure 6-2.)

11 (Ref.) SWITCH ASSEMBLY, Boom retract/extend 1selector push-button (For components, refer to Figure 6-2.)

12 103057 BEEPER, 24 Volt 113 108589 RELAY, 40 Amp sealed 114 103012 STRIP, Terminal block 2.315 103036 STRAIN RELIEF, Cord 116 (Ref.) CONNECTOR, 32 Pole male (recessed)(See Note A) 117 (Ref.) CONNECTOR, 5 Pole female (See Note A) 1

(Ref.) CONNECTOR, 4 Pole female (See Note B) 118 103256 CABLE, 18/2 x 30” lg. 119 700187 SWITCH, Foot 120 (Ref.) CONNECTOR, 5 Pole male (See Note A) 1

(Ref.) CONNECTOR, 4 Pole male (See Note B) 121 (Ref.) CABLE ASSEMBLY, Control box (See Note B ) 1

(Ref.) • CONNECTOR, 28 Pole male 1(Ref.) • STRAIN RELIEF, Cord 1/2” 1

22 700182 CONTROLLER BOARD, Boom function 1

Note A - Machines with serial number 90015 andabove. For components, refer to Figure 6-5.Note B - Machines with serial number 90014 andbelow. For components, refer to Figure 6-4.

FIGURE 3-3. OPERATOR’S CONTROL CONSOLE DIAGRAM PARTS LIST(Machines with Serial Number 90241 and below.)

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 3-4. LOAD SENSE OPTION DIAGRAM PARTS LIST (France)

702338 OPTION, Platform load sensing -

1 702305 PROCESSOR KIT, Load sense option 12 702306 ENCLOSURE, Load sense processor (not shown) 13 103260 CABLE, 18/5 64"4 103568 HOUSING, 5 Pole connector female 1

103570 INSERT, 5 Pole connector female 15 103567 HOUSING, 5 Pole connector male 1

103569 INSERT, 5 Pole connector male 16 103036 STRAIN RELIEF, Straight 17 108589 RELAY, 40 Amp sealed 18 102921 DIODE, 6 Amp/1000PIV 29 702337 LABEL, Overload indicator

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 3-4. LOAD SENSE OPTION DIAGRAM (France)(Refer to European Electrical Schematic)

8

7

6

5 43

1

TB4


FIGURE 3-5. BASE CONTROL/ELECTRICAL DIAGRAM(Serial Number 90307 and above.)

25

24

25

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

8 Meter Drive Cut Out Option (Europe)

TB1 TB2 TB3


FIGURE 3-5. BASE CONTROL/ELECTRICAL PANEL DIAGRAM PARTS LIST(Machines with Serial Number 90307 and above.)

1 102853 SWITCH, Toggle 72 700158 CIRCUIT BREAKER, 10 Amp 23 108589 RELAY, 40 Amp sealed 24 (Ref.) SWITCH ASSEMBLY, Emergency stop 1

(For components, refer to Figure 6-28.)5 103011 STRIP, Terminal block 3.26 (Ref.) SWITCH ASSEMBLY, Key select 1

(For components, refer to Figure 6-28.)7 702434 LIMIT SWITCH, Riser lift 18 111356 SWITCH, Turret 19 700160 LIMIT SWITCH, Boom telescope 1

10 700190 CABLE ASSEMBLY, Base to operator’s controlconsole 1 (Refer to Figure 6-12.)

700162 • CORD, 18/30 x 576” lg. 1700163 • CONNECTOR, 32 Pole female 1

11 (Ref.) CABLE ASSEMBLY, Tachometer 1700165 • CABLE, Shielded 22/2 x 98” lg. 1

12 (Ref.) CABLE ASSEMBLY, Tilt switch 1103255 • CABLE, 18/4 x 72” lg. 1

13 (Ref.) CABLE ASSEMBLY, Brake 1103255 • CABLE, 18/4 x 46” lg. 1

14 102921 DIODE, 6 Amp/1000PIV 2715 701868 HARNESS, Main manifold wiring 116 103057 BEEPER, 24 Volt (optional) 117 108589 RELAY, 40 Amp sealed (horn option) 118 102860 HORN, 24 Volt (horn option) 119 103267 FLASHER, 24 Volt (flashing light option) 120 106756 FLASHING LIGHT, 24 Volt (flashing light option) 121 108589 RELAY, 40 Amp sealed (flashing light option) 122 700552 SWITCH, Tilt 123 108589 LEVELING INTERLOCK RELAY, 40 Amp sealed 124 108589 RELAY, 40 Amp sealed (8m drive cutout)25 703054 SWITCH, Proximity (8m drive cutout)

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


1 700156 CONTACTOR, Brake pump/motor 12 102853 SWITCH, Toggle 73 700157 CIRCUIT BREAKER, 50 Amp 14 700158 CIRCUIT BREAKER, 10 Amp 25 108589 RELAY, 40 Amp sealed 26 (Ref.) SWITCH ASSEMBLY, Emergency stop 1

(For components, refer to Figure 6-28.)7 103011 STRIP, Terminal block 3.28 (Ref.) SWITCH ASSEMBLY, Key select 1

(For components, refer to Figure 6-28.)9 111356 LIMIT SWITCH, Riser lift 110 111356 SWITCH, Turret 111 700160 LIMIT SWITCH, Boom telescope 112 700190 CABLE ASSEMBLY, Base-operator’s control console 1

(Machines with Serial Number 900015 and above.)700162 • CORD, 18/30 x 576”” lg. 1700163 • CONNECTOR, 32 Pole female 1

13 (Ref.) CABLE ASSEMBLY, Tachometer 1700165 • CABLE, Shielded 22/2 x 98”” lg. 1

14 (Ref.) CABLE ASSEMBLY, Tilt switch 1103255 • CABLE, 18/4 x 72”” lg. 1

15 (Ref.) CABLE ASSEMBLY, Brake 1103257 • CABLE, 18/3 x 133”” lg. 1

16 102921 DIODE, 6 Amp/1000PIV 1817 700396 HARNESS, Main manifold wiring 118 (Ref.) CABLE ASSEMBLY, Base control/electric panel 1

(Machines with Serial Number 90014 and below.)(Ref.) • CONNECTOR, 28 Pole female 1

(Refer to Figure 6-4.)19 (Ref.) CABLE ASSEMBLY, Base-operator’s control console 1

(Models with Serial Numbers 900014 and below.)700162 • CORD, 18/30 x 496”” lg. 1(Ref.) • CONNECTOR, 28 Pole male 1

(Refer to Figure 6-4.)(Ref.) • CONNECTOR, 28 Pole female 1

(Refer to Figure 6-4.)20 103057 BEEPER, 24 Volt (optional) 121 108589 RELAY, 40 Amp sealed (horn option) 122 102860 HORN, 24 Volt (horn option) 123 103267 FLASHER, 24 Volt (flashing light option) 124 106756 FLASHING LIGHT, 24 Volt (flashing light option) 125 108589 RELAY, 40 Amp sealed (flashing light option) 126 108589 RELAY, 40 Amp sealed (leveling interlock) 127 700552 SWITCH, Tilt 1

FIGURE 3-6. BASE CONTROL/ELECTRICAL PANEL DIAGRAM PARTS LIST(Machines with Serial Number 90306 and below.)

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 3-6. BASE CONTROL/ELECTRICAL PANEL DIAGRAM(Machines with Serial Number 90306 and below.)

2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

1819

20

2122

23

24

25

26

27

TB1 TB2 TB3


B1 - B8 700193 BATTERY, 6 Volt 375 AH 8BC 700302 BATTERY CHARGER, 48 Volt (MAC#821) 1

BCB1 700182 CONTROLLER BOARD, Boom function 1BP-27 103057 BEEPER, 24 Volt 1BP-29 103057 BEEPER, 24 Volt 1CB1 700158 CIRCUIT BREAKER, 10 Amp 1CB2 700157 CIRCUIT BREAKER, 50 Amp (S/N 90306 and below.) 1CB3 700158 CIRCUIT BREAKER, 10 Amp 1

CRD1 700190 CABLE ASSEMBLY, Base to operator’s control console 1 (Machines with serial number 90015 and above, refer to Figure 6-12.)

(Ref.) CABLE ASSEMBLY, Base to operator’s control console 1 (Machines with serial number 90014 and below, refer to Figure 6-12.)

D02-1thru 700166 DIODE, Flyback 1Amp/400PIV 17

D02-18D7B-1thru 102921 DIODE, 6Amp/1000PIV ARD41

DCB1 700834 CONTROLLER BOARD, Drive/steer 1DCM1 701007 DC MOTOR, Drive 20hp (9”) 1DCM2 700675 DC MOTOR, Brake (S/N 90306 and below.) 1DCM3 700668 DC MOTOR, Boom control 1

F1 110855 FUSE, 10 Amp 1F2 110855 FUSE, 10 Amp 1F3 700228 FUSE, 300 Amp 1F4 102756 FUSE, 200 Amp 1F5 700777 FUSE, 20 Amp 1F6 700776 FUSE, 6.3 Amp 1F7 114866 FUSE, 1 Amp 1

FL-22A 103267 FLASHER, 24 Volt (optional) 1FL-22 104535 FLASHING LIGHT, 24 Volt (optional) 1

H1 102860 HORN, 24 Volt (optional) 1IL1 102671 INDICATOR LIGHT CONTACT BLOCK, Power on 1IL2 102671 INDICATOR LIGHT CONTACT BLOCK, Tilt sensor 1

LB1 thru LB8 102771 LIGHT BULB, 24 Volt (indicator lights and push-buttons) 8LS1 111356 LIMIT SWITCH, Riser lift 1LS2 700160 LIMIT SWITCH, Boom telescope 1R1B 701081 RESISTOR, Line 1K 1

R19B 700800 RESISTOR, 2.2k 1S1 102600 SWITCH, Control circuit disconnect (S/N 90306 and below.) 1S2 103225 CONTACT BLOCK, N.C. (key switch) 2

103141 CONTACT BLOCK, N.O. (key switch) 2S3 103225 CONTACT BLOCK, N.C. (emergency stop switch) (platform) 1S4 103225 CONTACT BLOCK, N.C. (emergency stop switch (base) 1S5 700187 FOOT SWITCH 1S6 700181 CONTROLLER, Boom function 1S7 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1

103141 CONTACT BLOCK, N.O. (boom up/down selector push-button switch) 1S8 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1

103141 CONTACT BLOCK, N.O. (riser up/down selector push-button switch) 1S9 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1

103141 CONTACT BLOCK, N.O. (Boom retract/extend selector push-button switch) 1

S10 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1103141 CONTACT BLOCK, N.O. (jib up/down selector push-button switch) 1

S11 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1103141 CONTACT BLOCK, N.O. (platform levelling/rotation selector push-button switch) 1

S13 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1103141 CONTACT BLOCK, N.O (turret rotation selector push-button switch). 1

S14 102853 SWITCH, Toggle (boom up/down) 1S15 102853 SWITCH, Toggle (riser up/down) 1S16 102853 SWITCH, Toggle (boom retract/extend) 1S17 102853 SWITCH, Toggle (jib up/down) 1S18 102853 SWITCH, Toggle (platform rotation) 1S19 102853 SWITCH, Toggle (platform levelling) 1S20 102853 SWITCH, Toggle (turret rotation) 1S21 (Ref.) CONTROLLER, Drive/steer (Refer to Figure 6-7.) 1

S21-1 105733 • SWITCH, Right steer 1S21-2 105733 • SWITCH, Left steer 1S21-3 105733 • SWITCH, Trigger 1S21-4 701240 • SWITCH, Horn button (optional) 1S22 111356 SWITCH, Turret 1S26 700542 SWITCH, Brake pressure (S/N 90306 and below.) 1

701194 SWITCH, Brake pressure (S/N 90307 and above.) 1SM7-SM13 701525 SWITCH MODULE, Maintained on 7

SV1 700990 SEVCONTROL, Drive 1SV2 700214 SEVCONTROL, Pump 1TC1 700217 TACHOMETER CARD 1TG1 700227 TACHOMETER GENERATOR 1TS1 700552 TILT SWITCH 1

2H-21 702754 COIL, 24 Volt (dump valve) (S/N 90299 and above.) 1700684 COIL, 24 Volt (dump valve) (S/N 90298 and below.) 1

3H-25 103605 COIL, 24 Volt (brake valve) (S/N 90306 and below.) 1701298 COIL, 24 Volt (brake valve) (S/N 90307 and above.) 1

4H-13thru 702755 COIL, 24 Volt (directional valves)

4H-41 (Machines with Serial Number 90299 and above.) 164H13thru 107439 COIL, 24 Volt (directional valves)

4H41 (Machines with Serial Number 90298 and below.) 1610ACR1 700219 CONTACTOR, Pump (boom control) 110ACR2 108589 RELAY, 40 Amp (sevcontrol) 110CR3 701078 CONTACTOR, Line 110CR4 701236 RELAY, Charger interlock 115ACR 700218 CONTACTOR, Drive pump/motor 116ACR 700218 CONTACTOR, Drive pump/motor 117ACR1 108589 RELAY, 40 Amp (steer) 117ACR2 108589 RELAY, 40 Amp (steer) 130ACR 108589 RELAY, 40 Amp (leveling interlock) 121CR 108589 RELAY, 40 Amp (flashing light) (optional) 126CR 700156 CONTACTOR, Brake pump/motor (S/N 90306 and below.) 127CR 108589 RELAY, 40 Amp (tilt) 149CR 108589 RELAY, 40 Amp (horn) (optional) 1

FIGURE 3-7./FIGURE 3-8. ELECTRICAL SCHEMATIC PARTS LIST(North American) FIGURE 3-7./FIGURE 3-8. ELECTRICAL SCHEMATIC PARTS LIST( North American)

1 2 3 4 5 6 7

Ref.No.

SkyjackPart No.

Description Unitsper

Assy 1 2 3 4 5 6 7

Ref.No.

SkyjackPart No.


Assy


FIGURE 3-6. ELECTRICAL SCHEMATIC (North American - S/N 90307 and Above)

702390-c


FIGURE 3-7. ELECTRICAL SCHEMATIC (North American - See notes for Serial Number break)

NOTE: Use this schematic section for machineswith Serial Number 90241 and below.

NOTE: Use this schematic section for machineswith Serial Number 90242 through 90306.

702389


FIGURE 3-8. ELECTRICAL SCHEMATIC (Europe - Serial Number 90307 and Above)

702393-d


FIGURE 3-9. ELECTRICAL SCHEMATIC (Europe - See notes for Serial Number break)

NOTE: Use this schematic section for machineswith Serial Number 90241 and below.

NOTE: Use this schematic section for machineswith Serial Number 90242 through 90306.

702391


B1 - B8 700193 BATTERY, 6 Volt 375 AH 8BC 700302 BATTERY CHARGER, 48 Volt (MAC#821) 1

BCB1 700182 CONTROLLER BOARD, Boom function 1BP-27 103057 BEEPER, 24 Volt 1BP-29 103057 BEEPER, 24 Volt 1CB1 700158 CIRCUIT BREAKER, 10 Amp 1CB2 700157 CIRCUIT BREAKER, 50 Amp (S/N 90306 and below.) 1CB3 700158 CIRCUIT BREAKER, 10 Amp 1

CRD1 700190 CABLE ASSEMBLY, Base to operator’s control console 1 (Machines with serial number 90015 and above, refer to Figure 6-12.)

(Ref.) CABLE ASSEMBLY, Base to operator’s control console 1 (Machines with serial number 90014 and below, refer to Figure 6-12.)

D02-1thru 700166 DIODE, Flyback 1Amp/400PIV 17

D02-18D7B-1thru 102921 DIODE, 6Amp/1000PIV ARD41

D81A 102921 DIODE, 6Amp/1000PIV 1DCB1 700834 CONTROLLER BOARD, Drive/steer 1DCM1 701007 DC MOTOR, Drive 20hp (9”) 1DCM2 700675 DC MOTOR, Brake (S/N 90306 and below.) 1DCM3 700668 DC MOTOR, Boom control 1

F1 110855 FUSE, 10 Amp 1F2 110855 FUSE, 10 Amp 1F3 700228 FUSE, 300 Amp 1F4 102756 FUSE, 200 Amp 1F5 700777 FUSE, 20 Amp 1F6 700776 FUSE, 6.3 Amp 1F7 114866 FUSE, 1 Amp 1

FL-22A 103267 FLASHER, 24 Volt (optional) 1FL-22 104535 FLASHING LIGHT, 24 Volt (optional) 1

H1 102860 HORN, 24 Volt (optional) 1IL1 102671 INDICATOR LIGHT CONTACT BLOCK, Power on 1IL2 102671 INDICATOR LIGHT CONTACT BLOCK, Tilt senso 1

LB1 thru LB8 102771 LIGHT BULB, 24 Volt (indicator lights and push-buttons) 8LS1 111356 LIMIT SWITCH, Riser lift 1LS2 700160 LIMIT SWITCH, Boom telescope 1

OWPI 702305 OVERLOAD WARNING PROCESSOR 1PS2-3 703054 SWITCH, Proximity (8m drive cutout) 2R1B 701081 RESISTOR, Line 1K 1

R19B 700800 RESISTOR, 2.2k 1S1 102600 SWITCH, Control circuit disconnect (S/N 90306 and below.) 1S2 103225 CONTACT BLOCK, N.C. (key switch) 2

103141 CONTACT BLOCK, N.O. (key switch) 2S3 103225 CONTACT BLOCK, N.C. (emergency stop switch) (platform) 1S4 103225 CONTACT BLOCK, N.C. (emergency stop switch) (base) 1S5 700187 FOOT SWITCH 1S6 700181 CONTROLLER, Boom function 1S7 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1

103141 CONTACT BLOCK, N.O. (boom up/down selector push-button switch) 1S8 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1

103141 CONTACT BLOCK, N.O. (riser up/down selector push-button switch) 1

S9 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1103141 CONTACT BLOCK, N.O. (Boom retract/extend selector push-button switch) 1

S10 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1103141 CONTACT BLOCK, N.O. (jib up/down selector push-button switch) 1

S11 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button (platform rotation selector push-button switch) 1

S13 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1103141 CONTACT BLOCK, N.O. (turret rotation selector push-button switch) 1

S14 102853 SWITCH, Toggle (boom up/down) 1S15 102853 SWITCH, Toggle (riser up/down) 1S16 102853 SWITCH, Toggle (boom retract/extend) 1S17 102853 SWITCH, Toggle (jib up/down) 1S18 102853 SWITCH, Toggle (platform rotation) 1S19 102853 SWITCH, Toggle (platform levelling) 1S20 102853 SWITCH, Toggle (turret rotation) 1S21 (Ref.) CONTROLLER, Drive/steer (Refer to Figure 6-7.) 1

S21-1 105733 • SWITCH, Right steer 1S21-2 105733 • SWITCH, Left steer 1S21-3 105733 • SWITCH, Trigger 1S21-4 701240 • SWITCH, Horn button (optional) 1S22 111356 SWITCH, Turret 1S26 700542 SWITCH, Brake pressure (S/N 90306 and below.) 1

701194 SWITCH, Brake pressure (S/N 90307 and above.) 1SM7-SM13 701525 SWITCH MODULE, Maintained on 7

SV1 700990 SEVCONTROL, Drive 1SV2 700214 SEVCONTROL, Pump 1TC1 700217 TACHOMETER CARD 1TG1 700227 TACHOMETER GENERATOR 1TS1 700552 TILT SWITCH 1

2H-21 702754 COIL, 24 Volt (dump valve) (S/N 90299 and above.) 1700684 COIL, 24 Volt (dump valve) (S/N 90298 and below.) 1

3H-25 103605 COIL, 24 Volt (brake valve) (S/N 90306 and below.) 1701298 COIL, 24 Volt (brake valve) (S/N 90307 and above.) 1

4H-13thru 702755 COIL, 24 Volt (directional valves) 16

4H-41 (Machines with Serial Number 90299 and above.)4H13thru 107439 COIL, 24 Volt (directional valves) 16

4H41 (Machines with Serial Number 90298 and below.)10ACR1 700219 CONTACTOR, Pump (boom control) 110ACR2 108589 RELAY, 40 Amp (sevcontrol) 110CR1 108589 RELAY, 40 Amp seal (8m drive cutout) 110CR3 701078 CONTACTOR, Line 110CR4 701236 RELAY, Charger interlock 115ACR 700218 CONTACTOR, Drive pump/motor 116ACR 700218 CONTACTOR, Drive pump/motor 117ACR1 108589 RELAY, 40 Amp (steer) 117ACR2 108589 RELAY, 40 Amp (steer) 130ACR 108589 RELAY, 40 Amp (leveling interlock) 121CR 108589 RELAY, 40 Amp (flashing light) (optional) 126CR 700156 CONTACTOR, Brake pump/motor (S/N 90306 and below.) 127CR 108589 RELAY, 40 Amp (tilt) 149CR 108589 RELAY, 40 Amp (horn) (optional) 181CR 108589 RELAY, 40 Amp seal (overload sensing) 1

FIGURE 3-9./FIGURE 3-10. ELECTRICAL SCHEMATIC PARTS LIST(Europe) FIGURE 3-9./FIGURE 3-10. ELECTRICAL SCHEMATIC PARTS LIST(Europe )

1 2 3 4 5 6 7

Ref.No.

SkyjackPart No.


Assy 1 2 3 4 5 6 7

Ref.No.

SkyjackPart No.


Assy


AC1 700903 PRESSURE ACCUMULATOR, Brake (450 PSI) 1C1 700328 CYLINDER ASSEMBLY, Riser lift 1

700452 • KIT, Seal repair ARC2 700332 CYLINDER ASSEMBLY, Boom lift 1

700452 • KIT, Seal repair ARC3 700350 CYLINDER ASSEMBLY, Boom telescoping 1

700455 • KIT, Seal repair ARC4 700241 CYLINDER ASSEMBLY, Jib lift 1

700456 • KIT, Seal repair ARC5 700333 CYLINDER ASSEMBLY, Platform levelling master 1

700454 • KIT, Seal repair ARC6 700388 CYLINDER ASSEMBLY, Platform levelling slave 1

700454 • KIT, Seal repair ARC7 700299 CYLINDER ASSEMBLY, Steer LH 1

700299 CYLINDER ASSEMBLY, Steer RH 1700451 • KIT, Seal repair AR

CB1-CB9 700568 COUNTERBALANCE VALVE (3000 PSI) 9CB10 700670 COUNTERBALANCE VALVE (1800 PSI) 1CB11 700670 COUNTERBALANCE VALVE (1800 PSI) 1

F1 704488 FILTER ASSEMBLY, Return 1104254 • ELEMENT, Filter AR

2H-21 700677 VALVE, Dump 13H-25 701298 VALVE, Brake 14H-13 701860 VALVE, Riser down (includes 4H-14) 14H-14 701860 VALVE, Riser up (includes 4H-13) 1

4H-23A 701861 VALVE, Right steer (includes 4H-24A) 14H-24A 701861 VALVE, Left steer (includes 4H-23A) 14H-30 701860 VALVE, Boom down (includes 4H-31) 14H-31 701860 VALVE, Boom up (includes 4H-30) 14H-32 701860 VALVE, Turret rotation clockwise (includes 4H-33) 14H-33 701860 VALVE, Turret rotation c-clockwise (includes 4H-32) 14H-34 701860 VALVE, Jib down (includes 4H-35) 14H-35 701860 VALVE, Jib up (includes 4H-34) 14H-36 701860 VALVE, Platform rotation left (includes 4H-37) 14H-37 701860 VALVE, Platform rotation right (includes 4H-36) 14H-38 701860 VALVE, Boom retract (includes 4H-39) 14H-39 701860 VALVE, Boom extend (includes 4H-38) 14H-40 701860 VALVE, Platform levelling down (includes 4H-41) 14H-41 701860 VALVE, Platform levelling up (includes 4H-40) 1

M1 700316 MOTOR, Turret rotation 1704237 • KIT, Seal Repair AR

O1 700679 ORIFICE, 0.100 diameter 1O2 700680 ORIFICE, 0.060 diameter 1O3 700682 ORIFICE, 0.025 diameter 1O4 700682 ORIFICE, 0.025 diameter 1P1 700669 PUMP, Hydraulic .194 ci/rev 1

PM1 700224 PUMP/MOTOR ASSEMBLY, Boom function 1PR1 701296 PRESSURE REDUCING VALVE, Brake (650 PSI) 1PS1 701194 PRESSURE SWITCH (off at 750 PSI) 1RA1 700448 ROTARY ACTUATOR 1

701875 • KIT, Seal repair AR

FIGURE 3-11. HYDRAULIC SCHEMATIC PARTS LIST(Serial Number 90307 and Above) FIGURE 3-11. HYDRAULIC SCHEMATIC PARTS LIST(Serial Number 90307 and Above)

RV1 700673 RELIEF VALVE, System (2600 PSI) 1RV2 700672 RELIEF VALVE, Turret rotation (900 PSI) 1RV3 700672 RELIEF VALVE, Turret rotation (900 PSI) 1V1 103136 VALVE, Riser cylinder emergency lowering 1V2 103136 VALVE, Boom cylinder emergency lowering 1V3 103136 VALVE, Emergency turret rotation 1V4 701297 VALVE, Brake override 1V5 103136 VALVE, Jib cylinder emergency lowering 1

1 2 3 4 5 6 7

Ref.No.

SkyjackPart No.


Assy 1 2 3 4 5 6 7

Ref.No.

SkyjackPart No.


Assy


FIGURE 3-11. HYDRAULIC SCHEMATIC(Machines with Serial Number 90307 and above.)

702860-0


FIGURE 3-12. HYDRAULIC SCHEMATIC PARTS LIST(Serial Number 90306 and Below) FIGURE 3-12. HYDRAULIC SCHEMATIC PARTS LIST(Serial Nu mber 90306 and Below)

C1 700328 CYLINDER ASSEMBLY, Riser lift 1700452 • KIT, Seal repair AR

C2 700332 CYLINDER ASSEMBLY, Boom lift 1700452 • KIT, Seal repair AR

C3 700350 CYLINDER ASSEMBLY, Boom telescoping 1700455 • KIT, Seal repair AR

C4 700241 CYLINDER ASSEMBLY, Jib lift 1700456 • KIT, Seal repair AR

C5 700333 CYLINDER ASSEMBLY, Platform levelling master 1700454 • KIT, Seal repair AR

C6 700388 CYLINDER ASSEMBLY, Platform levelling slave 1700454 • KIT, Seal repair AR

C7 700299 CYLINDER ASSEMBLY, Steer LH 1700299 CYLINDER ASSEMBLY, Steer RH 1700451 • KIT, Seal repair AR

CB1-CB9 700568 COUNTERBALANCE VALVE (650 PSI) 9CB10 700670 COUNTERBALANCE VALVE (1800 PSI) 1CB11 700670 COUNTERBALANCE VALVE (1800 PSI) 1

F1 109568 FILTER ASSEMBLY, Return 1104254 • ELEMENT, Filter AR

2H-21 700677 VALVE, Dump 13H-25 700676 VALVE, Brake 14H-13 701860 VALVE, Riser down 1

(Machines with Serial Number 90299 and above.)700526 VALVE, Riser down (includes 4H-14) 1

(Machines with Serial Number 90298 and below.)4H-14 701860 VALVE, Riser down 1

(Machines with Serial Number 90299 and above.)700526 VALVE, Riser up (includes 4H-13) 1

(Machines with Serial Number 90298 and below.)4H-23A 701861 VALVE, Left steer 1

(Machines with Serial Number 90299 and avove.)103614 VALVE, Right steer (includes 4H-24A) 1

(Machines with Serial Number 90298 and below.)4H-24A 701861 VALVE, Left steer 1

(Machines with Serial Number 90299 and avove.)103614 VALVE, Left steer (includes 4H-23A) 1

(Machines with Serial Number 90298 and below.)4H-30thru 701860 VALVE, Directional 6

4H-41 (Machines with Serial Number 90299 and above.)4H-30thru 700526 VALVE, Directional 6

4H-41 (Machines with Serial Number 90298 and below.)

HP1 110652 HAND PUMP, Brake release 1M1 700316 MOTOR, Turret rotation 1O1 700679 ORIFICE, 0.100 diameter 1O2 700680 ORIFICE, 0.060 diameter 1O3 700682 ORIFICE, 0.025 diameter 1O4 700682 ORIFICE, 0.025 diameter 1

P1 700669 PUMP, Hydraulic .194 ci/rev 1P2 700674 PUMP, Hydraulic .065 ci/rev 1

PM1 700224 PUMP/MOTOR ASSEMBLY, Boom function 1PM2 700225 PUMP/MOTOR ASSEMBLY, Brake 1PS1 700542 PRESSURE SWITCH (off at 350 PSI) 1RA1 700448 ROTARY ACTUATOR 1

701875 • KIT, Seal repair ARRV1 700673 RELIEF VALVE, System (2600 PSI) 1RV2 700672 RELIEF VALVE, Turret rotation (900 PSI) 1RV3 700672 RELIEF VALVE, Turret rotation (900 PSI) 1RV6 700683 RELIEF VALVE, Drive (425 PSI) 1RV7 700484 RELIEF VALVE, Brake (425 PSI) 1V1 103136 VALVE, Riser cylinder emergency lowering 1V2 103136 VALVE, Boom cylinder emergency lowering 1V3 103136 VALVE, Emergency turret rotation 1V4 113752 VALVE, Brake override 1V5 103136 VALVE, Jib cylinder emergency lowering 1

1 2 3 4 5 6 7

Ref.No.

SkyjackPart No.


Assy 1 2 3 4 5 6 7

Ref.No.

SkyjackPart No.


Assy


FIGURE 3-12. HYDRAULIC SCHEMATIC(Machines with Serial Number 90306 and below.)

700064-1


4H-40PLATFORM LEVELINGDOWN VALVE

4H-30BOOM DOWNVALVE

TO (C5) PLATFORM LEVELING MASTER CYLINDER (up)

TO (C5) PLATFORM LEVELING MASTER CYLINDER (down)

TO (C1) RISER LIFT CYLINDER (up)

TO (C3) BOOM TELESCOPING CYLINDER (retract)

TO (C1) RISER LIFT CYLINDER (down)

TO (C3) BOOM TELESCOPING CYLINDER (extend)

TO (RA1) ROTARY ACTUATOR (right)

TO (RA1) ROTARY ACTUATOR (left)

TO (C4) JIB LIFT CYLINDER (down)

TO (C4) JIB LIFT CYLINDER (up)

TO (C2) BOOM LIFT CYLINDER (down)

TO (C2) BOOM LIFT CYLINDER (up)

TO (C7/C8) STEER CYLINDERS (turn right)

TO (C7/C8) STEER CYLINDER (turn left)

TO (M1) TURRET ROTATION MOTOR (ccw)

4H-41PLATFORM LEVELINGUP VALVE

4H-13RISER DOWNVALVE

4H-14RISER UPVALVE

4H-38BOOM TELESCOPERETRACT VALVE

4H-36PLATFORM ROTATIONLEFT VALVE

4H-35JIB UPVALVE

4H-31BOOM UPVALVE

4H-24ALEFT STEERVALVE

RV2RELIEFVALVE

4H-32TURRET ROTATIONCLOCKWISE VALVE

V3EMERGENCYTURRETROTATIONVALVE

RETURNTO TANK

TO PUMPPRESSURE

RV3RELIEFVALVE

2H-21DUMP VALVE

4H-33TURRET ROTATIONC-CLOCKWISE VALVE

4H-23ARIGHT STEERVALVE

4H-34JIB DOWNVALVE

4H-39BOOM TELESCOPEEXTEND VALVE

4H-37PLATFORM ROTATIONRIGHT VALVE

CB-11COUNTERBALANCE VALVE


RV1SYSTEM RELIEF VALVE

TO (M1) TURRET ROTATION MOTOR (cw)

O1ORIFICE(0.100)

O2ORIFICE(0.060)

O3ORIFICE(0.025)

O4ORIFICE(0.025)

FIGURE 3-13. MAIN MANIFOLD COMPONENT AND PORT IDENTIFICATION(Machines with Serial Number 90299 and above.)

FIGURE 3-14. BRAKE MANIFOLD COMPONENT AND PORT IDENTIFICATION(Machines with Serial Number 90307 and above.)

CAUTION - Brake system under pressure. Bleed pressure before servicing.

3H-25BRAKEVALVE

SYSTEMPRESSURE

BRAKESYSTEMPRESSURE

PR1PRESSUREREDUCINGVALVE

PS1PRESSUREVALVE

V4BRAKEOVERRIDEVALVE

RETURNTO TANK

TO BRAKES

TO PUMPPRESSURE

TO AC1ACCUMULATOR

2H-?BRAKEVALVE


TO (C5) PLATFORM LEVELING MASTER CYLINDER (up)

TO (C5) PLATFORM LEVELING MASTER CYLINDER (down)

TO (C1) RISER LIFT CYLINDER (up)

TO (C3) BOOM TELESCOPING CYLINDER (retract)

TO (C1) RISER LIFT CYLINDER (down)

TO (C3) BOOM TELESCOPING CYLINDER (extend)

TO (RA1) ROTARY ACTUATOR (right)

TO (RA1) ROTARY ACTUATOR (left)

TO (C4) JIB LIFT CYLINDER (down)

TO (C4) JIB LIFT CYLINDER (up)

TO (C2) BOOM LIFT CYLINDER (down)

TO (C2) BOOM LIFT CYLINDER (up)

TO (C7/C8) STEER CYLINDERS (turn right)

TO (C7/C8) STEER CYLINDER (turn left)

TO (M1) TURRET ROTATION MOTOR (ccw)


O1ORIFICE(0.100)

4H-40PLATFORM LEVELINGDOWN VALVE

4H-30BOOM DOWNVALVE

4H-41PLATFORM LEVELINGUP VALVE

4H-13RISER DOWNVALVE

4H-14RISER UPVALVE

4H-38BOOM TELESCOPERETRACT VALVE

4H-36PLATFORM ROTATIONLEFT VALVE

4H-35JIB UPVALVE

4H-31BOOM UPVALVE

4H-24ALEFT STEERVALVE

RV2RELIEFVALVE

4H-32TURRET ROTATIONCLOCKWISE VALVE

V3EMERGENCYTURRETROTATIONVALVE

RETURNTO TANK

TO PUMPPRESSURE

RV3RELIEFVALVE

2H-21DUMP VALVE

4H-33TURRET ROTATIONC-CLOCKWISE VALVE

4H-23ARIGHT STEERVALVE

4H-34JIB DOWNVALVE

4H-39BOOM TELESCOPEEXTEND VALVE

4H-37PLATFORM ROTATIONRIGHT VALVE


RV1SYSTEM RELIEF VALVE

TO (M1) TURRET ROTATION MOTOR (cw)

O2ORIFICE(0.060)

O3 ORIFICE(0.025) IN VALVEPRESSURE PORT

O4ORIFICE(0.025)

FIGURE 3-15. MAIN MANIFOLD COMPONENT AND PORT IDENTIFICATION(Machines with Serial Number 90298 and below.)

FIGURE 3-16. BRAKE MANIFOLD AND BRAKE PUMP/MOTOR COMPONENT AND PORTIDENTIFICATION

(Machines with Serial Number 90306 and below.)

PS1PRESSURESWITCH

3H-25BRAKEVALVE

P2PUMP

TO BRAKEMANIFOLD

RV6RELIEFVALVE

DC MOTOR

TO BRAKEFLUID TANK

TO LEFTBRAKE

HP1BRAKE RELEASEHAND PUMP

TO PRESSURE SWITCH

V4BRAKEOVERRIDEVALVE

TO RIGHTBRAKE

RV7RELIEFVALVE

VENT


NOTES


TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

SECTION 4TROUBLESHOOTING

The following pages contain a Table of Troubleshooting information for locating and correcting most service troublewhich can develope. Careful and accurate analysis of the system listed in the Table of Troubleshooting Information willlocalize the trouble more quickly than any other method. This manual can not cover all possible troubles and deficienciesthat may occur. If a specific trouble is not listed, isolate the major component in which the trouble occurs, and thenisolate and correct the specific problem.

All ControlsInoperative

1A. Batteries disconnected.

1B. Batteries not fully charged.

1C. Dirty or loose battery terminals orconnector pins.

2. Broken or loose wire #1 on main

3. 24V Disconnect Switch (S1) openor defective(S/N 90306 and below).

4. Broken or loose wire #3 to (CB1).

5. Circuit Breakers (CB1) or (CB3)tripped or defective.

6. Broken or loose wire #5 to (CB1)from (S3).

7. Base Emergency Stop Switch (S3)open or defective.

8. Broken or loose wire #7 from (S3)to (S2).

9. Base Platform Select Switch (S2)defective.

10. Defective relay (10CR2).

11. Defective Sevcon.

12. Line contactor (10CR3) open ordefective.

1A. Connect batteries.

1B. Check each cell with hydrometer;reading should be 1.275 (fullycharged). Recharge if low reading.Replace if reading differencebetween cells is 0.050.

1C. Clean and/or tighten.

2. Check continuity. Replace ifdefective.

3. Close switch or replace if no continuityreading.


5. Reset switch or replace if defective.


7. Check continuity thru switch, replaceif defective.


9. Check continuity thru switch, replaceif defective.

10. Replace if defective.

11. See Sevcon Troubleshooting.


�


TROUBLESHOOTING (Cont.)


13. No power to wire #10 on linecontactor (10CR3).

1. Broken or loose #7 wire in boomcontrol cable.

2. Broken or loose #7A pin in plug.

3. Foot Switch (S5) open or defective.

4. Broken or loose wire #7C from (S5)to (S4) Emergency Stop.

5. Open Emergency Stop Button (S4).

6. Broken or loose wire #8 from (S4) toplatform controls.

7. Broken or loose #8 wire in boomcontrol cable.

8. Broken or loose #8 pin in plug.

9. Diode (D8) open or defective.

All Controls Inoperative (cont.)

13. Check wire #10 on line contactor(10CR3) for 24V with foot switchdepressed or base controlsselected. Repair as necessary.

ControlsInoperativefrom Platform

1. Check continuity. Replace if open.

2. Replace pin if defective.

3. Check continuity thru switch,replace if defective.


5. Check continuity thru switch,replace if defective.



8. Replace pin if defective.


1. Key Selector Switch (S2) open ordefective.

2. Loose or broken wire #7B from (S2)to function switches, or to pin #11 onPump Sevcon (SV2).

3. Open or defective Diode (D7B-1).

4. Broken or loose #19A wire, from pin#14 on Pump Sevcon to Key Switch(S2).

5. Broken or loose #19A wire to pin #7on tach board.

6. Defective (R19A) 2.2K resistor.





5. Check resistance. Should read2200 ohms.


ELECTRICAL SYSTEM (Cont.)

Base ControlsInoperative




Base ControlsInoperative (cont.)

7. Broken or loose #00 wire to batteryplug.


Up CircuitInoperative(Riser Only)

1. Broken or loose 9B wire to switch (S8).

2. Defective switch (S8).

3. Defective Switch Module (SM8).

4. Loose pin or broken wire #14 in boomcontrol cable.

5. Defective coil (4H-14).

6. Diode (D02-4) or (D-14) shorted.


8. Diode (D02-1) shorted.


2. Check switch. If defective replace.




6. Replace Diode.


8. Replace Diode.

Down CircuitInoperative(Riser Only)

1. Broken or loose 9A wire to switch (S8).



4. Loose pin or broken wire #13 inboom control cable.










6. Replace Diode.


8. Replace Diode.






Up CircuitInoperative(Boom Only)

1. Broken or loose 9B wire to switch (S7)













6. Replace Diode.


8. Replace Diode.

Down CircuitInoperative(Boom Only)

1. Broken or loose 9A wire to switch(S7).



4. Loose pin or broken wire #30 in boomcable.










6. Replace Diode.


8. Replace Diode.

Telescope OutInoperative

1. Broken or loose 9A wire to switch(S9).










Telescope OutInoperative(cont.)








6. Replace Diode.


8. Replace Diode.

Telescope InInoperative

1. Broken or loose 9E wire to switch (S9).








1. Check continuity. Replace if defective.

2. Check switch. Replace if defective.




6. Replace Diode.


8. Replace Diode.

Jib UpInoperative

1. Broken or loose 9B wire to switch(S10).






1. Check continuity. Replace if defective.





6. Replace Diode.





Jib UpInoperative(cont.)




8. Replace Diode.

Jib DownInoperative














6. Replace Diode.


8. Replace Diode.

Platform RotateLeft or RightInoperative

1. Broken or loose wires #11 or #11A.


3. Defective Switch Module (SM-11-1).

4. Loose pin or broken wire #36 [L] or#37 [R] in boom cable.

5. Defective coil (4H-36) [L] or (4H-37)[R].

6. Diode (D02-10) [R] or (D02-11) [L]shorted.

7. Diode (D36) [L] or (D37) [R] shorted.








6. Replace Diode.

7. Replace Diode.


9. Replace Diode.





PlatformLevel UpInoperative

1. Broken or loose 9B wire to switch (S11).













6. Replace Diode.


8. Replace Diode.

PlatformLevel DownInoperative









1. Broken or loose wires #11 or #11A.








6. Replace Diode.


8. Replace Diode.

Turret RotateCW or CCWInoperative








4. Loose pin or broken wire #32 [CW] or#33 [CCW] in boom cable.

5. Defective coil (4H-32) [CW] or (4H-33) [CCW].

6. Diode (D02-14) [CCW], (D02-15)[CW], (D-32) [CW] or (D-33) [CCW]shorted.



Turret RotateCW or CCWInoperative(cont.)



6. Replace Diode.


8. Replace Diode.

SteeringLeft or RightInoperative

NOTE:Steering shouldalways remain leftor right relative toboom position. Seesteering does notchange directionwith boom position.

1. Broken or loose wire #8 fromEmergency Stop Switch (S4) to rightswitch (S21-3) or left switch (S21-2).

2. Steer switch (S21-3) [R] or (S21-2)[L] defective.

3. Loose pin or broken wire #23 [R] or#24 [L] from (S21-3) [R] or (S21-2)[L] to (17ACR2) [R] or (17ACR1)[L]relay.

4. Open N.C. contacts on (17ACR1)[L]or (17ACR2) relay.

5. Broken or loose wire #23A [R] or#24A [L] from relay (17ACR2) [R] or(17ACR1) [L] to coil (4H-23A) [R] orcoil (4H-24A) [L].

6. Defective coil (4H-23A) or (4H-24A).

7. Diodes (D02-16) [R] or (D02-17) [L]shorted.

8. Diode (D23A) [R] or (D24A) [L] open.

9. Broken or loose wire 20A from diodes(D23A) [R] or (D24A)[L] to pumpSevcon terminal 8.

10. Diode (D20A) open.





4. Check relay. If defective replace.



7. Replace Diode.

8. Replace Diode.


10. Replace Diode.






12. Diode (D02-1) shorted. 12. Replace Diode.SteeringLeft or RightInoperative(cont.)

Steering DoesNot ChangeDirection WithBoom Position.

1. Broken or loose wire #10 from D8diode to turret Switch (S22).

2. Defective Turret Switch (S22).

3. Broken or loose wire #17A fromTurret Switch (S22) to (17ACR1) or(17ACR2).

4. Broken or loose wire #2 from(17ACR1) or (17ACR2) to terminalstrip on base.





Forward - ReverseDrive Inoperative

1. Defective Drive/Steer Controller(S21).

2. Broken or loose #6 wire from (S21)to drive Sevcon pin #14.

3. Loose pin or broken wire #15 [R] or#16 [F] from terminal block (TB2) onbase.

4. Broken or loose wire #15 [R] or #16[F] from terminal block (TB2) to driveSevcon pin #11 [R] or #8 [F].

5. Sevcon inoperative.

6. Broken or loose wire #15 [R] or#16A [F] from Sevcon pin #15 [R] or#17 [F] to contactor (15ACR) or(16ACR).

7. Defective coil (15ACR) [R] or(16ACR) [F].

8. Broken or loose wire #10 from coil(15ACR) [R] or (16ACR) [F] to driveSevcon pin #5.

9. Defective fuse (F3).

1. Check output. If no output replace.




5. Refer to Sevcon troubleshooting.Check 10 amp (F2) Fuse.









Forward - ReverseDrive Inoperative(cont.)

10. Broken or loose cable #1E from (F3)to contactor (15ACR) [R] or (16ACR)[F].

11. Bad contacts in contactor (15ACR)[R] or (16ACR) {F}.

12. Defective drive motor (DCM1).

13. Defective Tach Generator (TG1).

14. Defective tach card.

15. Defective drive Sevcon.

16. Brake not releasing.

17. Defective (F5) or (F6) fuse on tachcards.


11. Replace contactor.

12. Check motor. Replace if defective.

13. See Sevcon troubleshooting.


15. Refer to Sevcon troubleshooting.

16. See brake troubleshooting.


Forward - ReverseSlow Speed Only

1. Broken or loose #10 wire fromterminal block (TB1) on base to liftLimit Switch (LS1).

2. Lift Limit Switch (LS1) defective.

3. Broken or loose #18A wire from LimitSwitch (LS1) to Limit Switch (LS2).

4. Telescope Limit Switch (LS2)defective.

5. Broken or loose #18 wire from (LS2)to drive Sevcon pin #13.

6. Defective Tilt Switch (TS1). No powerto tach board wire #28.

7. Blown 1 Amp Fuse (F7) on TiltSwitch.


2. Replace Limit Switch.


4. Replace Limit Switch.


6. Replace Tilt Switch.

7. Replace Fuse.

Brake NotReleasing(Serial # 90307and above)

1. Broken or loose wire #25 from driveSevcon pin #1 to relay (26CR).

2. Defective relay (26CR).


4. Broken or loose wire #3 [24v] toCircuit Breaker (CB2).


2. Replace relay.







Brake NotReleasing(Serial # 90307and above)(cont.)

5. Defective circuit breaker (CB2).

6. Broken or loose wire #3A from(CB2) to relay (26CR).

7. Broken or loose wire #3B from(26CR) to motor (DCM2).

8. Motor (DCM2) defective.

9. Broken or loose wire #1B frommotor (DCM2) to Battery Plug(BP1).

5. Replace circuit breaker.



8. Replace Motor.


Brake NotReleasing(Serial # 90306and below)

1. Broken or loose wire #25 from driveSevcon pin #1 to relay (26CR).

2. Defective relay (26CR).

3. Broken or loose wire #26 topressure switch (S26).

4. Defective pressure switch (S26).

5. Broken or loose wire #10 frompressure switch (S26) to pin $5 ondrive Sevcon.


7. Broken or loose wire #3 [24v] toCircuit Breaker (CB2).

8. Defective circuit breaker (CB2).

9. Broken or loose wire #3A from(CB2) to relay (26CR).

10. Broken or loose wire #3B from(26CR) to motor (DCM2).

11. Motor (DCM2) defective.

12. Broken or loose wire #1B frommotor (DCM2) to Battery Plug(BP1).


2. Replace relay.


4. Replace switch.




8. Replace circuit breaker.



11. Check motor. Replace if defective






No BoomFunctions

1. Loose or broken wire #10A fromterminal B of Tachometer Card (TC1)to pin #5 on Sevcon (SV2).

2. Loose or broken wire #10A fromterminal B of Tachometer Card (TC1)to Motor Contactor (10CR1).

3. Loose or broken wire from pin 1 on(SV2) to (10CR1).

4. Fuse (F1) open or defective.

5. Pump Motor (DCM3) defective.

6. Loose connection at terminal #20 on(TB2).

7. Loose or broken wire 20 from TB3 toTB2.

8. Open or defective Diode (D20-1).

9. Loose or broken wire #21 from (TB2)to Dump Solenoid (2H-21).

10. Open or defective Dump Solenoid(2H-21).

11. Defective Pump Sevcon (SV2).

1. Check continuity, repair if defective.





6. Repair if defective.






No Boom FunctionsFrom Platform(Boom Operatesfrom Base Controls)

1. Loose or broken wire #8 from platformterminal block to Boom FunctionController (S6).

2. Loose or broken wire #2 from platformterminal block to Boom FunctionController (S6).

3. Loose or broken wire #19A from BoomFunction Controller (S6) to platformterminal strip.

4. Broken or loose #19 pin in plug.

5. Boom Function Controller (S6)defective.

6. Loose or broken wire #19 in BoomControl Cable.

7. Stuck contact block at 19A and 19Bon Key Switch (S2).









DRIVE SEVCON (SV1) TROUBLESHOOTING

FLASH CODE TROUBLE PROBABLE CAUSE REMEDY

SEVCON ELECTRICAL SYSTEM

NOTE: A SteadyLight on DriveSevcon MeansSystem is Readyto Operate

2 Flash Fault(ProcedureFault)

1. Selecting function beforepower is on.

2. Broken #2 wire at drive/steercontroller.

1. Turn power on and operate footswitch before selecting function.

2. Check continuity. If defectivereplace.

3 Flash Fault 1. Sevcon shorted.

2. Drive motor (DCM1) shorted.

1. Replace Sevcon.

2. Replace Motor.

4 Flash Fault 1. Contactor welded. 1. Replace contactor.

5 Flash Fault 1. Contactor not shifting.


1. Clean contactor. Replace ifdefective.

2. Replace Sevcon.

6 Flash Fault No Drive 1. Broken #6 wire from drive/steer controller (S21) to pin 14on Drive Sevcon (SV1).

2. Defective Drive Sevcon (SV1).

3. Defective drive/steer controller(S21).


2. Disconnect wire #6 from terminalstrip in upper control box. Checkvoltage on wire #6 from DriveSevcon (SV1). With foot switchdepressed voltage should beapproximately 8 volts. If no voltagepresent replace defective Sevcon(SV1). If voltage present see step 3.

3A. Remove brown wire from terminalstrip in upper control box where wire#6 is located. Depress foot switchand check voltage on brown wire. Itshould read 3.8 to 4.2 volts DC. Ifvoltage present replace defectiveSevcon. If no voltage present moveto step 3B.

3B. Locate white/red wire on drive/steercontroller board. Measure voltage atwhite/red wire with foot switchdepressed. It should read 6.1 to 6.2volts DC. If no voltage presentreplace defective board. If voltagepresent move to step 3C.


DRIVE SEVCON (SV1) TROUBLESHOOTING (cont.)


SEVCON ELECTRICAL SYSTEM (cont.)

6 Flash Fault(cont.)

No Drive(cont.)

3. Defective drive/steer control-ler.(cont.)

3C. Locate white/black wire on drive/steercontroller board. Measure voltage atwhite/black wire with foot switchdepressed. It should read 2 volt DC.If no voltage present replacedefective Potentiometer. If voltagepresent replace defective Sevcon.(Refer to Section 5 page 15)

7 Flash Fault 1. Low battery voltage. 1. Charge battery.

8 Flash Fault 1. Sevcon overheating. 1. Let unit cool down.

10 Flash Fault 1. Tachometer fault broken wire atterminal #2 or #12 on DriveSevcon.

2. Broken or loose T1 or T2 wiresfrom Tach Generator (TG1) onMotor to Terminal Block (TB1).



11 Flash Fault 1. Tachometer Gen. defective.

2. Tachometer Gen. wiresreversed.

3. Defective Tachometer Card.(TC1)

1. Check output - 2.5 volts per 100RPM.

2. Switch wires at Tachometer Gen.



PUMP SEVCON (SV2) TROUBLESHOOTING INFORMATION


SEVCON ELECTRICAL SYSTEM

NOTE: A SteadyLight on PumpSevcon MeansSystem isReady toOperate.

2 Flash Fault( P r o c e d u r eFault)

1. Selecting function beforepower is on.

2. Broken #2 wire.

1. Turn power on and operate footswitch before selecting function.

2. Check continuity. If defectivereplace.

3 Flash Fault 1. Pump motor (DCM3) shorted.

2. Sevcon shorted.

1. Replace motor.

2. Replace Sevcon.

4 Flash Fault 1. Contactor welded. 1. Replace contactor.

5 Flash Fault 1. Contactor not shifting.


1. Replace contactor.

2. Replace Sevcon.

6 Flash Fault 1. Broken wire 19 from BoomFunction Controller (S6) to pin#14 on Pump Sevcon (SV2).

2. Defective Pump Sevcon(SV2).

3. Defective Boom FunctionController.

No BoomFunctionsFromPlatform

1. Check continuity. If defective replace.

2. Disconnect wire #19 from theterminal strip in upper control box.Check voltage on wire 19 fromPump Sevcon (SV2) with foot switchdepressed. Voltage should be ap-proximately 8 volts DC. If no voltagepresent, replace defective Sevcon. Ifvoltage present see step 3.

3A. Remove brown wire from theterminal strip in the upper controlbox where the #19 wire is located.Depress foot switch and checkvoltage on brown wire. It should be3.8 to 4.2 volts DC. If voltage ispresent, replace defective PumpSevcon (SV2). If no voltage presentmove to step 3B.

3B. Locate the "+" and "-" terminals onthe Boom Controller Board.Measure voltage at "+" and "-" withfoot switch depressed. It should be5 volts. If no voltage present, replacedefective board. If voltage present,move to step 3C.


PUMP SEVCON (SV2) TROUBLESHOOTING INFORMATION (cont.)


SEVCON ELECTRICAL SYSTEM (cont.)

6 Flash Fault(cont.)

No BoomFunctionsFromPlatform(cont.)

3. Defective Boom FunctionController.(cont.)

3C. Locate "Y" sig. terminal on BoomController Board. Measure voltagebetween "-" terminal and "Y" sig.terminal on Boom Controller Boardwith foot switch depressed. It shouldread 2.2 to 2.5 DC volts. If no voltagepresent replace defective Joy Stick.If voltage present, move to step 3D.

3D. Locate "X" sig. terminal on BoomController Board. Measure voltagebetween "-" terminal and "X"terminal on Boom Controller Boardwith Foot Switch depressed. Itshould read 2.2 to 2.5 volts DC. Ifno voltage present, replacedefective Joy Stick. If voltagepresent, replace defective PumpSevcon (SV2).(Refer to Section 5 page 16)

6 Flash Fault No BoomFunctionFrom BaseControlsOnly

1. Loose or broken #19 wire fromkey switch to terminal block(TB2) in base controls.

2. Loose or broken #19 wirefrom key switch to pin #14 onPump Sevcon (S2).

3. Defective R19A resistor onTachometer Board Con-nector.



3. Check resistor 19A with Ohm-Meter. Replace if defective.

7 Flash Fault 1. Low battery voltage. 1. Charge battery.

8 Flash Fault 1. Sevcon overheating. 1. Let unit cool down.


TROUBLESHOOTING INFORMATION


HYDRAULIC SYSTEM

No BoomFunctions

1. Dump Valve (2H-21) stuck open.

2. System Relief Valve (RV1) defectiveor set low.

3. Pump (P1) defective.

1. Inspect valve, replace if defective.

2. Inspect valve, replace if defective.

3. Replace pump.

Up CircuitInoperative(Riser Only)

1. Riser Up Valve (4H-14) not shiftingproperly or contaminated.

2. Emergency lowering valve (V1)open.

1. Clean valve and reinstall. Replaceif defective.

2. Close valve.

Down CircuitInoperative(Riser Only)

1. Riser Down Valve (4H-13) notshifting properly or contaminated.

2. Counter Balance Valve (CB1) notshifting.

1. Clean valve and reinstall. Replace ifdefective.


Riser DriftsDown

1. Emergency Lowering Valve (V1)open or contaminated.

2. Counter Balance Valve (CB1) openor defective.

3. Bad cylinder packing Riser Cylinder(C1).

1. Close or clean valve.


3. Replace defective packing.

Up CircuitInoperative(Boom Only)

1. Boom Up Valve (4H-31) not shiftingproperly or contaminated.



2. Close valve.

Down CircuitInoperative(Boom Only)

1. Boom Down Valve (4H-30) notshifting properly or contaminated.




Boom DriftsDown


2. Counter Balance Valve (CB2) openor defective.

3. Bad cylinder packing (C2) BoomCylinder.





TROUBLESHOOTING INFORMATION (Cont.)


HYDRAULIC SYSTEM (Cont.)

Boom ExtendInoperative

1. Boom Extend Valve (4H-39) notshifting properly or contaminated.




Boom RetractInoperative

1. Boom Retract Valve (4H-38) notshifting properly or contaminated.




Jib UpInoperative

1. Jib Valve (4H-35) open or defective.


3. Orifice (O1) plugged.




3. Clean orifice.

4. Close valve.

Jib DownInoperative

1. Jib Down Valve (4H-34) open ordefective.





3. Clean orifice.

Jib DriftsDown


2. Counter Balance Valve (C5) open ordefective.

3. Bad cylinder packing (C4) Jib LiftCylinder.




PlatformRotate LeftInoperative

1. Platform Rotate Left Valve (4H-36)not shifting or contaminated.




PlatformRotate RightInoperative

1. Platform Rotate Right Valve (4H-37)not shifting or contaminated.








No PlatformRotate EitherDirection

1. Orifice (O4) plugged. 1. Clean orifice.

PlatformLevel UpInoperative

1. Level Up Valve (4H-41) not shiftingor contaminated.


3. Platform Master Leveling Cylinder(C5) or (C6) by passing.

4. Counter Balance Valve (CB11) notshifting or set to high.


2. Clean orifice.

3. Reseal cylinder.

4. Adjust valve. Replace if defective.

PlatformLevel DownInoperative

1. Level Down Valve (4H-40) notshifting or contaminated.

2. Platform Master Leveling Cylinder(C5) or (C6) by passing.

3. Counter Balance Valve (CB10) notshifting or set to high.


2. Reseal cylinder.


No ManualPlatform Level

1. Plugged Orifice (O3). 1. Clean Orifice.

TurretRotate Left(Clockwise)

1. Turret Rotate Left [CW] Valve (4H-32) not shifting or contaminated.

2. Relief Valve (RV3) set to low.


2. Adjust relief valve. Replace ifdefective.

TurretRotate Right(Counter Clockwise)

1. Turret Rotate Left [CCW] Valve (4H-32) not shifting or contaminated.

2. Relief Valve (RV2) set to low.



No TurretRotationEither Direction

1. Emergency Turret Rotation Valve(V3) open to much.

2. By passing or defective rotateHydraulic Motor (M1).

1. Close valve.

2. Reseal motor. Rebuild or replace ifdefective.

No Steering 1. Steer Valve (4H-24A) or (4H-23A)not shifting or contaminated.

2. By passing Steer Cylinder (C7) or(C8)


2. Reseal cylinder.





BrakesWon't Release(Serial # 90307and above)

1. Brake Valve (3H-25) not shifting.

2. By passing brake assembly.

3. Defective Accumulator (AC1).

4. Pressure Reducing Valve (PR1) setto low or defective.

5. Brake over ride valve (V4) stuck orleaking.


2. Reseal brake assembly.


4. Adjust to proper setting. Replace ifdefective.

5. Replace if defective.(Refer to Section 5 page 19)

BrakesWon't Release(Serial # 90306and below)

1. Relief Valve (RV6) set to low ordefective.

2. Brake Valve (3H-25) not shifting.

3. Relief Valve (RV7) set to low orcontaminated.

4. By passing brake assembly.

5. Defective Pump (P2).




4. Reseal brake assembly.

5. Replace Pump.(Refer to Section 5 page 21)


MAINTENANCE AND SERVICE SAFETYTIPS • Maintenance and repair should only be

performed by personnel who are trained andqualified to service this machine.

• All maintenance and service procedures shouldbe performed in a well lighted and well ventilatedarea.

• Anyone operating or servicing this machine mustread and completely understand all operatinginstructions and safety hazards in this manual.

• All tools, supports and lifting equipment to beused must be of proper rated load and in goodworking order before any service work begins.Work area should be kept clean and free of debristo avoid contaminating components whileservicing.

• All service personnel must be familiar withemployer and governmental regulations thatapply to servicing this type of equipment.

• Keep sparks and flames away from allflammable or combustible materials.

• Properly dispose of all waste material, i.e. usedoil, old parts etc.

SECTION 5MAINTENANCE AND SERVICE

5

GENERAL MAINTENANCE HINTS

• Before attempting any repair work, disconnectthe batteries by separating the 350A connectors.

• Preventive maintenance is the easiest and leastexpensive type of maintenance.

REPLACEMENT PARTS

Use only original replacement parts. Parts such asbatteries, chargers, wheels, railings, etc. with weight anddimensions different from original parts will affect stabilityof the work platform and must not be used withoutmanufacturer’s consent.Use only original filled tires for models which must be soequipped. Consult manufacturer.

Any machine that is damaged or notoperating properly MUST be immediatelytagged and removed from service untilproper repairs are completed.


SECTION 5MAINTENANCE AND SERVICE

TABLE OF CONTENTS

GENERAL MAINTENANCE HINTS ................................................................................................................ Page 1

REPLACEMENT PARTS................................................................................................................................. Page 1

MAINTENANCE AND SERVICE SAFETY TIPS ............................................................................................. Page 1

HYDRAULIC SYSTEM AND COMPONENT MAINTENANCE AND REPAIR ................................................... Page 3

TABLE 5-1. TORQUE SPECIFICATIONS ........................................................................................................ Page 4

TABLE 5-2. SPECIAL TOOLS ......................................................................................................................... Page 4

SEVCON CALIBRATION TOOL....................................................................................................................... Page 5

TRACTION SEVCON CONTROLLER PIN REFERENCE ................................................................................ Page 9

TACHOMETER BOARD TERMINAL REFERENCE ........................................................................................Page 11

TACHOMETER GENERATOR TESTING PROCEDURE .................................................................................Page 12

BOOM FUNCTION SEVCON CONTROLLER PIN REFERENCE ...................................................................Page 13

DRIVE JOYSTICK CIRCUIT BOARD DIAGNOSTICS ....................................................................................Page 14

SJKB BOOM JOYSTICK DIAGNOSTICS ......................................................................................................Page 15

BRAKE ADJUSTMENT PROCEDURES ........................................................................................................Page 16

STANDARD HOSE NUMBERING SYSTEM ...................................................................................................Page 20


HYDRAULIC SYSTEM AND COMPONENTMAINTENANCE AND REPAIR

The following points should be kept in mind when workingon the hydraulic system or any component:

1. Any structure has limits of strength and durability.To prevent failure of structural parts of hydrauliccomponents, relief valves which limit pressureto safe operating values are included in thehydraulic circuits.

2. Tolerance of working parts in the hydraulicsystem is very close. Even small amounts ofdirt or foreign materials in the system can causewear or damage to components, as well asgeneral faulty operation of the hydraulic system.Every precaution must be taken to assureabsolute cleanliness of the hydraulic oil.

3. Samples of hydraulic oil should be drawn fromthe reservoir every six months. These samplesshould be about two quarts and should be takenwhile the oil is warmed through normal operationof the system. If possible, the sample shouldbe analyzed by a qualified lubrication specialistto determine whether it is suitable for furtheruse. The intervals between oil changes dependon operating conditions and on the care used inkeeping the oil clean.

4. Whenever there is a hydraulic system failurewhich gives reason to believe that there are metalparticles of foreign materials in the system, drainand flush the entire system and replace the filtercartridges. A complete change of oil must bemade under these circumstances.

5. Whenever the hydraulic system is drained,check the magnets in the hydraulic reservoir formetal particles. If metal particles are present,flush the entire system and add a new changeof oil. The presence of metal particles also mayindicate the possibility of imminent componentfailure. A very small amount of fine particles isnormal.

6. DO NOT use synthetic or fire resistant oil in thiswork platform. Use ATF Dexron III (ESSO) orequivalent hydraulic oil. For conditions causingoil temperatures below -31°F (-35° C) and above122°F (50° C) consult Skyjack, Inc.

7. All containers and funnels used in handlinghydraulic oil must be absolutely clean. Use afunnel when necessary for filling the hydraulicoil reservoir, and fill the reservoir only throughthe filter opening. The use of cloth to strain theoil should be avoided to prevent lint from gettinginto the system.

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

9. All hydraulic components must be disassembledin spotlessly clean surroundings. Duringdisassembly, pay particular attention to theidentification of parts to assure properreassembly. Clean all metal parts in a cleanmineral oil solvent. Be sure to thoroughly cleanall internal passages. After the parts have beendried thoroughly, lay them on a clean, lint-freesurface for inspection.

10. Replace all o-rings and seals when overhaulingany component. Lubricate all parts with cleanhydraulic oil before reassembly. Use smallamounts of petroleum jelly to hold o-rings inplace during assembly.

11. Be sure to replace any lost hydraulic oil whencompleting the installation of the repairedcomponent, and bleed any air from the systemwhen required.

12. All hydraulic connections must be kept tight. Aloose connection in a pressure line will permitthe oil to leak out or air to be drawn into thesystem. Air in the system can cause damage tothe components and noisy or erratic systemoperation.

MAINTENANCE. Three simple maintenance procedureshave the greatest effect on the hydraulic systemperformance, efficiency and life. Yet, the very simplicityof them may be the reason they are so often overlooked.What are they? Simply these:

1. Change filters regularly.

2. Maintain a sufficient quantity of clean hydraulicoil of the proper type and viscosity in thehydraulic reservoir.

3. Keep all connections tight.


Table 5-2. Special Tools

ROTACIDNILAID 295007TRAPKCAJYKS

HCNERWNELLAmm71 YLLACOLESAHCRUP

ROTARBILACNOCVES 150107TRAPKCAJYKS

isp0005-0EGUAGERUSSERP YLLACOLESAHCRUP

isp0001-0EGUAGERUSSERP YLLACOLESAHCRUP

HCTIWSTRATSETOMER YLLACOLESAHCRUP

retemaiDedisnI"½3-LOOTYLBMESSAREDNILYC 278307TRAPKCAJYKS

retemaiDedisnI"½4-LOOTYLBMESSAREDNILYC 378307TRAPKCAJYKS

Table 5-1. Torque Specifications

DIRECTIONAL VALVE MOUNTING SCREWS 28-32 in. lbs.

TURRET ROTATE GEAR MOUNTING BOLTS 375 ft. lbs.

WHEEL MOUNTING BOLTS 290 ft. lbs.

COUNTERWEIGHT BOLTS 240 ft. lbs.

TURRET ROTATE GEAR BOX 200 ft. lbs.

AXLE MOUNTING BOLTS 205 ft. lbs.

CARTRIDGE VALVES

SIZE 08 38 58 10 12 16

ft. lbs. (max) 20 20 20 25 35 50

in. lbs. (max) 240 240 240 300 420 600

COILS

SIZE 4 to 5

ft. lbs. (max) 48 to 60

in. lbs. (max)

SAE PLUGS

SIZE 2 4 5 6 8 10 12 16

ft. lbs.(max)

3 10 15 15 25 25 30 35

in. lbs.(max)

36 120 180 180 300 300 360 400

MTWB-505

SECTION 5, Page 5SJKB33N

SEVCONTROLLER ADJUSTMENT AND DIAGNOSTICSSevcon Calibration Tool

All machine functions remain operational while calibrator is plugged in.

ADJUSTMENT PROCEDURE:

The following procedure is relevant for both the drive and pump controllers, except where otherwise noted. Bothcontrollers are preset to factory specifications but may be readjusted.

A hand-held calibrator (Figure 5-1, Skyjack part #701051) can be plugged into the controller adjustment socket andused to digitally view or reset the parameters. The current value of these parameters will be shown on an LCD display.Additionally, the calibrator can perform certain measurements that can be useful for diagnostic purposes.

The calibrator has a bar display, operated by the SELECT button, showing the parameters/ measurement selected andan LCD display showing values that, provided they are parameters, may be adjusted using the +/- buttons.This unit can also be used to perform certain tests on the control wiring and controller (joystick).

1. Remove electrical panel cover, located inside door on right side of machine.

2. Locate controller adjustment socket, as shown in Figure 5-2, and connect hand-held calibrator.Power up the boom by selecting base or platform controls (foot switch must be engaged for platform controlsto be active) using key switch at electrical panel.

3. No LED segments on the bar display will be lit and the minutes/seconds count is displayed. The hourscount is displayed by pressing the (-) button and the 1000’s of hours count is displayed by pressing the(+) button as described later in this section. Pressing the select button reverts the calibrator to its normaloperation and the IMax LED will be lit.

4. When the desired parameters has been selected, on the left side of the calibrator, it may be adjusted bypressing the + or - button on the right side of the calibrator. See Table 5-8. for adjustable parameters andranges.

5. When the calibrator is unplugged the Sevcontrol will ‘memorize’ the new parameters settings.Figure 5-1.

WARNING

Front Back

SECTION 5, Page 6 SJKB33N

Drive Controller

Parameter Min. Max. Units Default

IMAXMaximum Controller CurrentACCEL.Acceleration DelayDECEL.Deceleration DelayCREEPDrive Creep SpeedMAXMax Allowed SpeedELEVA.Elevated Cutback SpeedTILTTilted Cutback Speed

50

1.0

0.5

0

5

5

5

600

3.0

3.0

10

100

25

60

Amps

Seconds

Seconds

% of Max Speed

% of Max Possible Speed

% of Max Speed

% of Max Speed

600 Amps

1.0 Sec.

0.5 Sec.

2%

100%

25%

50%

Pump Controller

Parameter Min. Max Units Default

I.MAXMaximum Controller CurrentS.DELAYPump Soft Start/Stop DelayCREEPPump Creep SpeedSTEERSteer Speed Base

50

0.5

0

0

270

5.0

30

100

Amps

Seconds

% of Max Speed

% of Max Possible Speed

270 Amps

3.0 Sec.

0%

80%

Figure 5-2.

Table 5-8. Sevcontrol Adjustable Parameters

Diagnostic LED

ControllerAdjustmentSocket


Sevcon Calibration Tool Cont.

HOURS COUNTER:The hours counter records pulsing hours, and is displayed when the calibrator is first plugged in. Once the SELECTbutton is pressed, the calibrator reverts to normal operation.

Initially a minute/seconds count is displayed. By pressing the (-) button, hours are displayedand by pressing the (+) button 1000’s of hours are displayed.

Releasing the buttons reverts back to the minute/seconds display. The decimal point blinks every second during drive.The counter will record up to 65,500 hours before rolling back to 0.

DIAGNOSTIC PROCEDURE: WARNING

All machine functions remain operational while calibrator is plugged in.

The last five segments on the bar display are as follows.

BATT Displays the current battery voltage. Pressing the (+) button displays the highest voltage,for the machine, that the Sevcontrol has recorded.

MOTOR V. Displays the motor voltage as the machine is being driven.

MOTOR AMP Displays the motor current as the machine is being driven.

TEMP Displays the temperature of the MOSFET heat sink in °C. Pressing the (+) button displaysthe highest temperature recorded and pressing the (-) button displays the lowesttemperature recorded.

TEST This invokes the diagnostic test routines to check machine switches, joystick,control wiring etc.

With the calibrator connected and the boom powered up, as described in the adjustment procedure. Use the SELECTbutton to select the test segment. If the SELECT button is pressed at any time during the test, the test will beterminated and the minute/seconds count will be displayed.

The first test displayed, for both drive and pump Sevcontrol, is the joystick input. This displays the input as 0-100% asjoystick is moved from min. to max.

Pressing the (+) and (-) buttons step through the tests as shown in Table 4-8. After the final test, the sequence will loopback to the joystick input test, then test 1.


Table 5-9. Sevcontrol Test Sequence

Drive Controller Test Sequence

Sequence No. Test Display

-

1

2

3

4

5

6

7

8

9

10

Controller (Joystick) Input

Forward Switch

Reverse Switch

Tachometer Input

Turret Position Limit Switch

Tilt Switch

Boom Lift Function Selected

Actual Direction, Tachometer Output

Boom Lift Limit Switches

Not Used

Not Used

0 to 100%

CL/OP

CL/OP

0 to 100%

CL = Normal OP = Rotated

CL = Level OP = Tilt

CL/OP

CL = Reverse OP = Forward

CL = Lowered OP = Raised

Pump Controller Test Sequence

Sequence No. Test Display

-

1

2

3

4

5

6

7

8

9

10

Controller (Joystick) Input

Steer Function

Base Controls

Not Used

Not Used

Not Used

Boom Lift Function Selected

Drive Function Selected

Not Used

Not Used

Not Used

0 to 100%

CL/OP

OP=Base ControlsCL=Platform Controls

CL/OP

CL = Reverse OP = Forward


SEVCONTROLLER ADJUSTMENT AND DIAGNOSTICS Cont.Pin Voltage Readings

TRACTION SEVCON CONTROLLER PIN REFERENCE

Figure 5-3. Traction Controller

Pin 1 - Brake contactor control. Brings B- through wire 25 to 26CR brake motor contactor in drive only.Test between pin 1 and 10 wire (B+).

Pin 2 - From pin 4 of tachometer board. Determines direction.0 volts = forward15 volts = reverseTest between pin 2 and 02 wire (B-).

Pin 3 - Not used

Pin 4 - Turret position. Determines where platform is in relation to base. Changes sequencing of 15ACR and 16ACRcontactors.24 volts = platform over drive axle0 volts = platform over steer axleTest between pin 4 and 02 wire (B-).

Pin 5 - 24 volt input from wire 10A.Test between pin 5 and 02 wire (B-).

Pin 6 - 48 volt signal from relay 10ACR248 volt = OK0 volts = blown F2 fuse, bad 10ACR2 relay or broken 10 wire.Test between pin 6 and 02 wire (B-).

Pin 7 - Tiltswitch input.0 volts = 50% full speed. (0% speed if off a limit switch)24 volts = 100% full speed available,Test between pin 7 and 02 wire (B-).

Pin 8 - Forward direction input from drive joystick (wire 16).24 volts = forward selectedTest between pin 8 and 02 wire (B-)..

Pin 9 - Not used

Pin 10 - Not used

Pin 11 - Reverse direction input from drive joystick (wire 15).24 volts = reverse selectedTest between pin 11 and 02 wire (B-).

Pins are identified from left to rightPin #1 thru Pin #17


Pin 12 - Signal from Pin 2 of tachometer board. Tachometer generator signal to Traction Controller. Varies with speed ofmachine.Will see 7.5 volts when foot switch is depressed and joystick is in neutral position (center position).7.5 volts to 15 volts = reverse7.5 volts to 0 volts = forwardTest between pin 12 and 02 wire (B-).

Pin 13 - From boom and telescope limit switches.24 volts = full speed0 volts = creep speed (one or more limit switches open)Test between pin 13 and 02 wire (B-).

Pin 14 Accelerator input. Wire #6 from drive controller.Foot switch depressed = 3.8 to 4.2 voltsJoystick threshold = 3.5 volts = slowest speedJoystick at full travel = 0 volts = full speedTest between pin 14 and 02 wire (B-).

Pin 15 - Forward contactor output.Completes B- to 16ACR motor contactorIf platform is over steer axle operates 15ACRTest between pin 15 and 10 wire (B+).

Pin 16 - Drive function cutout signal.0 volts = drive available24 volts = drive is cutout when operating a lift functionTest between pin 16 and 02 wire (B-).

Pin 17 - Reverse contactor output.Completes B- to 15ACR motor contactorIf platform is over steer axle operates 16ACRTest between 17 and 10 wire (B+).

2 Flash 3 Flash 4 Flash 5 Flash 6 Flash 7 Flash 8 Flash 9 Flash 10 Flash

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

Pin 6 X

Pin 7

Pin 8 X X

Pin 9

Pin 10

Pin 11 X X

Pin 12 X X

Pin 13

Pin 14 X

Pin 15 X X

Pin 16 X X

Pin 17 X X

Table 5-10. Traction Controller Flash Fault Pin References


Pin Voltage Readings Cont.TACHOMETER BOARD TERMINAL REFERENCE

Figure 5-4. Tachometer Board.

Term A -48 volt input from 10ACR2Test between term A and 02 wire (B-).

Term B -24 volt output to boom pump motor, forward and reverse contactors, Pin 5 of traction and boomSevcon’s. From Term C through 20 Amp fuse on tachometer board. Wire 10A.Test between term B and 02 wire (B-).

Term C -24 volt input from wire 10.Test between term C and 02 wire (B-).

Term D -24 volt output to Pin 7 of traction Sevcon.0 volts = 50% full drive speed. (0% if off telescope or boom limit switch)24 volts = 100% full drive speed available.Test between term D and 02 wire (B-).

Term E -24 volt input from tilt switch. Wire 28.0 volts = 50% full drive speed. (0% if off telescope or boom limit switch)24 volts = 100% full drive speed available.Test between term E and 02 wire (B-).

Pin 1 - Battery negative. Wire 02.Pin 2 - Speed signal to Pin 12 of traction Sevcon.

7.5 volts with foot switch depressed and drive joystick is in center position.7.5 volts to 15 volts = reverse7.5 volts to 0 volts = forwardTest between pin 2 and 02 wire (B-).

Pin 3 - Wire T1 from tachometer generator.Pin 4 - To Pin 2 of traction Sevcon. Determines direction.

0 volts = forward15 volts = reverseTest between pin 4 and 02 wire (B-).

Pin 5 - Wire T2 from tachometer generator.Pin 6 - Speed reducing resistor. Also attach to Pin 1.

Controls speed of boom functions when using base controls2.2k ohm resistor

Pin 7 - Speed reducing resistor. From wire 19A.Controls speed of boom functions when using base controls2.2k ohm resistor

Pin 8 through Pin 16 - Spike suppression for pump and directional contactors.

Pins are identified from right to left


TACHOMETER GENERATOR TESTING PROCEDURE

1. Jack up and support the steer axle end of the machine.

CAUTION

The supports used must have a capacity of at least 5300 lbs.

2. Locate tachometer generator on back of drive motor. Remove rubber boot from the rear of the tachometergenerator.

3. Mark the location of the wires attached to the generator and remove wires. NOTE: Wires must be reattachedto the same terminals as they were removed from or the Sevcon controller will not function when reassembled.

4. Remove the four 5/16-18 x 1-1/2" bolts securing the tachometer generator mounting plate to the rear of themotor.NOTE: Do not attempt to remove the tachometer generator from mounting plate until it has been determined tobe defective.

5. Remove the coupler half from the tachometer generator and attach generator to a drill with a 1000 RPM rating.

6. Attach a voltmeter to the terminals on the rear of the tachometer generator and set the meter for D.C. voltage.

7. Energize drill and read voltage on meter. At 1000 RPM you should read at least 20.8 volts. If reading is lowerthan 20.8 volts, the tachometer generator is defective.

1. DRIVE AXLE2. DRIVE MOTOR3. COUPLER HALF4. TACHOMETER GENERATOR MOUNTING PLATE5. COUPLER HALF6. TACHOMETER GENERATOR 6

5

4

3

2

1

Figure 5-5. Axle Assembly.


SEVCONTROLLER ADJUSTMENT AND DIAGNOSTICS Cont.Pin Voltage ReadingsBOOM FUNCTION SEVCON CONTROLLER PIN REFERENCE

Figure 5-6. Boom Controller.Pin 1 - Pump motor contactor control.

Brings B - to pump contactor 10ACR1Test between pin 1 and 10A wire.

Pin 2 - Boom function cut out signal0 volts = Boom functions available24 volts = Boom functions cut out while drive.Test between pin 2 and 02 wire (B-).

Pin 3 - Not usedPin 4 - Not usedPin 5 - 24 volt input from wire 10A.

Test between pin 5 and 02 wire (B-).Pin 6 - 48 volt input from relay 10ACR2

48 volts = O.K.0 volts = blown F1 fuse, defective 10ACR2 relay or broken 10A wire.Test between pin 6 and 02 wire (B-).

Pin 7 - Not usedPin 8 - Steer select. Overrides 24 volt signal on pin 2 to allow steering while driving.

0 volts = steer not selected24 volts = steer selectedTest between pin 8 and 02 wire (B-).

Pin 9 - Not usedPin 10 - Not usedPin 11 - 24 volt input from key switch when base selected.

Signals pump Sevcon key switch is in base positionSends 24 volt signal to pin 16 of drive Sevcon to cut out driveTest between pin 11 and 02 wire (B-).

Pin 12 - Not usedPin 13 - Not usedPin 14 - Accelerator input. Wire 19 from boom function controller.

Foot switch depressed = 3.8-4.2 volts (joystick in neutral).Joystick threshold = 3.5 volts = slowest speedJoystick at full stroke = 0 volts = full speedTest between pin 14 and 02 wire (B-).

Pin 15 - Not usedPin 16 - 24 volt signal from boom functions, wire 20.

Signal to activate boom Sevcon when boom function is selectedSends 24 volt signal to Pin 16 of drive Sevcon to cut out drive.Test between pin 16 and 02 wire (B-).

Pin 17 - Not used

Pins are identified from left to rightPin #1 thru Pin #17


BLACK GROUND TO WIRE #2

BROWN SPEED SIGNAL TO WIRE #6

BLUE 24 VOLT SUPPLY FROM WIRE #8

ORANGE REVERSE TO WIRE #15

WHITE/ORANGE FORWARD TO WIRE #16

WHITE 24 VOLT TO STEER SWITCH TO WIRE #8

YELLOW RIGHT STEER TO WIRE #23

GREEN LEFT STEER TO WIRE #24

RED 24 VOLT TO TRIGGER AND HORN BUTTON FROM WIRE #8

ORANGE HORN TO WIRE #49

VIOLET NOT USED

WHITE/VIOLET NOT USED

6.2 volts4.2 volts

2.0 volts

24 volts when right steer is activated

24 volts when left steer is activated

24 volt supply to steer switch

24 volts when horn button is activated

Not used

Not used

24 volt supply to trigger and horn button

3.8 - 4.2 volts when foot switch is depressed

20 - 23 volts when joystick is in reverse

20 - 23 volts when joystick is in forward

24 volt supply to drive circuit board

Ground (wire 2) to drive circuit board

DRIVE JOYSTICK CIRCUIT BOARD DIAGNOSTICS

All tests performed with foot switch depressed and voltages read between function and terminal on strip with wire 2.


SJKB BOOM JOYSTICK DIAGNOSTICS

All tests performed with foot switch depressed and joystick in neutral position.

WHITE/RED 5 Volt + Supply to Joystick

WHITE/BLACK 5 Volt - Supply to Joystick

ORANGE X output - Side to Side

BROWN Y output - Front to Back

5 volts

2.2 to 2.5 Volts

2.2 to 2.5 VoltsWire 9

Wire 11A Wire 11

Wire 9A

NOTE: Voltage readings with controller fully stroked.


BRAKE ADJUSTMENT PROCEDURESMechanical

Checking the adjustment of each brake on the rear axle requires the following procedure:

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

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

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

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

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

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

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

7. Remove the Dial Indicator. Pull out the Brake Override Valve Plunger to engage the brakes. With a M19socket and wrench, adjust the Actuator Shaft (Item #3) by tightening (clockwise) the Actuator Shaft Nut (Item#4) to reach a lower setting or loosening (counterclockwise) the Actuator Shaft Nut (Item #4) to reach a highersetting.

8. Repeat steps 3, 4, 5 and 6.

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

Skyjack PartNo. 700592

4

3

2

1

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

Figure 5-8. Cross Section of Brake Assembly


Figure 5-8. Brake Manifold MB2

BRAKE PRESSURE SWITCHPS1

PRESSURE REDUCING VALVEPR1

BRAKE VALVE3H-25

BRAKE OVERRIDE VALVEV4

SYSTEM PRESSURETEST PORT

STEP 12PRESSURE TEST PORTFOR ACCUMULATORPRESSURE (1000PSI)

BRAKE VALVE2H-?

BRAKE ADJUSTMENT PROCEDURES Cont.Hydraulic (Serial Number 90307 and Above)

Make sure unit is on level ground with front wheels chocked.

1. Bleed all brake pressure off by pumping the brake override valve 10 times, until system has no pressure.(Fig. 5-9)

2. Install pressure gauge at the tee in the main brake line on the drive axle. (Fig. 5-10)3. Lift drive axle off the ground so the drive wheels don’t move the machine.4. Engage drive slowly and check pressure gauge. It should read 650 psi.5. If the pressure is low repeat step #1.6. Remove the cap plug from pressure reducing valve using a 5/16 allen wrench. (Fig. 5-9)7. Using an 3/8 allen wrench turn pressure reducing valve in a 1/4 of a turn. (Fig. 5-9)8. Repeat steps #4, 5 & 7 until pressure reaches 650 psi.9. Replace pressure reducing valve plug cap.10. Repeat step #1.11. Remove pressure gauge and connect brake lines.12. Install pressure gauge at the test port between the brake manifold and the pressure switch. (Fig. 5-9)13. Engage drive slowly and check pressure gauge. It should read 750 psi.14. If the pressure is low repeat step #1.15. Turn pressure switch body a 1/4 of a turn clockwise. (Fig. 5-9)16. Repeat steps #13-15 until pressure reaches 750 psi.17. Repeat step #1.18. Remove pressure gauge.19. Pressure adjustment

complete, lower machineand test drive.

WARNING

SECTION 5, Page 18 SJKB33NFigure 5-10. Brake pressure system

PRESSURE GAUGE

ADJUST PRESSURE REDUCING VALVEUNTIL THIS GAUGE READS 650PSI

TEE INTO THE MAIN BRAKE LINE

STEP 2

PRESSURE GAUGE

ADJUST PRESSURESWITCH UNTIL GAUGEREADS 750 PSI

A QUICK CONNECTIONPORT IS PROVIDED BETWEEN THEMANIFOLD AND THEPRESSURE SWITCH

STEP 12


BRAKE ADJUSTMENT PROCEDURES Cont.Hydraulic (Serial Number 90306 and Below)

Special Tools Required: 0-1000 PSI Gauge, Remote Starter Button.

NOTE

The brake pump/motor should not run continuously while driving. The brake pressure switch (PS1) should signal thepump/motor to run when the hydraulic pressure drops to about 250 PSI. It should shut off at 350 PSI. Both reliefvalves (RV6 & RV7) should be set at 425 PSI. Before the pressure switch can be adjusted, both valves must be setcorrectly.

Brake relief valve and pressure switch adjusting procedure:

1. Tee a 0-1000 PSI pressure gauge into either one of the brake lines going to the axle.

2. Push down on the brake override valve (black knob) located on the brake manifold.

3. Using the hand pump (red knob) on the brake manifold, pump up the brakes and adjust the relief valve (RV7)to 425 PSI.

4. Connect one lead of the remote starter switch to wire #25 on the brake motor contactor located behind thelower control panel on the turret. Connect the other lead to wire #2 on the circuit breaker (CB3).

5. Select base control with the off/platform/base select key switch.

6. Turn the black knurled knob on the pressure switch (PS1) clockwise 1 full turn.

7. Push and hold the remote starter switch button. The pump/motor should run. Adjust the relief valve (RV6)located on the pump to 425 PSI.

8. While cycling the remote starter switch on and off, turn the knurled knob on the pressure switch (PS1) counterclockwise until pump/motor shuts off at 350 PSI.

9. Remove gauge from brake line and test brakes for proper operation.

Figure 5-11. Brake Assembly

13

2

1

8

7

6 3


H1104 0081 2-0

FITTINGARRANGEMENT(See ScheduleBelow)

HOSE SIZE(See ChartBelow)

LENGTH OF HOSEIN WHOLE INCHES

LENGTH INFRACTIONS (1/4”INCREMENTS) I.E.1=1/4”2=1/2”3=3/4”

REVISION LEVEL

HOSE SIZE CHART

FITTING ARRANGEMENT SCHEDULE

Using the number above as an example (H1104 0081 2 0). This hose requires a 37° JIC, female swivel fitting on oneend. A medium length 90° JIC, female swivel fitting for the other end. The Hose must meet or exceed S.A.E. 100R13hose specification, and be a total of 81-1/2” long. NOTE: Hose ends and hose must be from same manufacturer perS.A.E. J1273 Nov. ‘91, Sections 3.10 and 4.2. Hose ends and hose must be of the same size i.e. #4 size fittings mustbe used with #4 size hose.

STANDARD HOSE NUMBERING SYSTEM

SIZE 03 04 06 08 10 12 16 20 24 32 40 48 56 64

I.D. 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"

HOSE PREFIX HOSE END FITTING HOSE END FITTINGS.A.E. HOSESPECIFICATION

H1 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R1


H3 FEMALE, 37° JIC, SWIVEL 45°, FEMALE, 37° JIC, SWIVEL 100R1


H5 FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R1

H6 FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R1

H7 LONG 90°, FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R1



H10 FEMALE, 37° JIC, SWIVEL MALE PIPE THREAD FITTING 100R1

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 100R1

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


H21 FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R2AT

H22 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R2AT

H23 FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R2AT




SECTION 6PARTS LIST

GENERALThe information contained in this section is designed toaid the user in locating and identifying replacement parts.Component parts of various assemblies andsubassemblies comprising the work platform are illustratedand accompanied by a descriptive parts list. Explodeddrawings are used to show relative location of componentparts in disassembly order. If a part cannot be found inthis section, order by work platform model number andserial number, giving a complete description of the part.

PARTS ORDERING INFORMATIONWhen ordering replacement parts, the complete partnumber and description should be used to ensure properidentification and delivery of the desired item. Thiscomplete identification should also be used when requestingequipment information.

METHOD OF LISTINGParts are listed in order according to the reference numbershown in the illustration, followed by a full descriptionbased upon the “NOUN FIRST” method. That is, the nounname of the part is listed first, then the modifyingdescription information which serves to specifically identifythe item. For example: PIN, Clevis. Assemblies or groupsare shown at the beginning of a parts list and are identifiedwith the letter references A, B, C, etc. Individual parts inthese lists have corresponding letters after their descriptionto identify which assembly or group it is used in. Individualparts without identifying letters areused in all the assemblies or group shown at the beginning

CUSTOMER___________________________________________________________________

DEALER______________________________________________________________________

MODEL NUMBER ______________________________________________________________

SERIAL NUMBER ______________________________________________________________

DATE PURCHASED ____________________________________________________________ 6

of the parts list. Descriptions preceded with an (•)indicates a serviceable component or attaching hardwarefor the higher level assembly.

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

HARDWAREStandard screws, washers, nuts, etc. are not identifiedby a reference number. These parts are known asCOMMON HARDWARE items and appear indentedunder the major items with which they are used. Theyshould be ordered separately as listed, since they arenot component parts of the pieces they attach to.

HOW TO ORDER REPAIR PARTS1. Address all orders to your local SKYJACK dealer.2. Specify model and serial number of the work platform (found on the serial number plate).3. List the quantity needed.4. List the length needed (if bulk item).5. List the part number and description as shown in this manual for each item.6. Show billing and shipping address and name of individual if possible.7. Suggest best routing.

USE ONLY SKYJACK AUTHORIZED REPLACEMENT PARTS!


LIST OF ILLUSTRATIONS

Description Page

FIGURE 6-1. PLATFORM ASSEMBLY .................................................................................................................... 4FIGURE 6-2. OPERATOR’S CONTROL CONSOLE ASSEMBLY

(Machines with Serial Number 90242 and above) ................................................................................ 8FIGURE 6-3. OPERATOR’S CONTROL CONSOLE ASSEMBLY

(Machines with Serial Number 90241 and below) ............................................................................... 12FIGURE 6-4. CABLE PLUG AND SOCKET COMPONENTS (Weidmuller)

(Machines with Serial Number 90015 and Above) .............................................................................. 17FIGURE 6-5. CABLE PLUG AND SOCKET COMPONENTS

(Machines with Serial Number 90014 and below) ............................................................................... 18FIGURE 6-6. DRIVE/STEER CONTROLLER ASSEMBLY

(All machines with Serial Number 90149 and below, and machines with Serial Number 90150 andabove without horn option.) ............................................................................................................... 19

FIGURE 6-7. DRIVE/STEER CONTROLLER ASSEMBLY(Machines with Serial Number 90151 and above with factory installed horn option.) .......................... 19

FIGURE 6-8. BOOM FUNCTION CONTROLLER ASSEMBLY............................................................................... 21FIGURE 6-9. BOOM ASSEMBLY (Jib Section) ..................................................................................................... 22FIGURE 6-10. JIB LIFT CYLINDER ASSEMBLY .................................................................................................. 24FIGURE 6-11. PLATFORM LEVELING SLAVE CYLINDER ASSEMBLY ............................................................... 27FIGURE 6-12. BOOM ASSEMBLY (Main and Telescopic Section) ........................................................................ 28FIGURE 6-13. BOOM TELESCOPING CYLINDER ASSEMBLY............................................................................ 32

FIGURE 6-14. BOOM ASSEMBLY (Riser Section) ................................................................................................ 34FIGURE 6-15. RISER LIFT CYLINDER ASSEMBLY ............................................................................................. 36FIGURE 6-16. BOOM LIFT CYLINDER ASSEMBLY ............................................................................................. 38FIGURE 6-17. PLATFORM LEVELING MASTER CYLINDER ASSEMBLY ........................................................... 41FIGURE 6-18. HYDRAULIC HOSE CONNECTIONS - Boom Assembly ................................................................ 42FIGURE 6-19. TURRET ASSEMBLY

(Machines with Serial Number 90307 and above.) ............................................................................. 44FIGURE 6-20. TURRET ASSEMBLY

(Machines with Serial Number 90306 and below.) .............................................................................. 48FIGURE 6-21. MAIN MANIFOLD ASSEMBLY

(Machines with Serial Number 90299 and above.) ............................................................................. 52FIGURE 6-22. MAIN MANIFOLD ASSEMBLY

(Machines with Serial Number 90298 and below.) .............................................................................. 54FIGURE 6-23. HYDRAULIC TANK ASSEMBLY

(Machines with Serial Number 90307 and above.) ............................................................................. 56FIGURE 6-24. HYDRAULIC TANK ASSEMBLY

(Machines with Serial Number 90306 and below.) .............................................................................. 57FIGURE 6-25. HYDRAULIC BRAKE MANIFOLD ASSEMBLY

(Machines with Serial Number 90307 and above.) ............................................................................. 58FIGURE 6-26. SEVCON PANEL ASSEMBLY ........................................................................................................ 59FIGURE 6-27. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY

(Machines with Serial Number 90307 and above.) ............................................................................. 60


LIST OF ILLUSTRATIONS

Description Page

FIGURE 6-28. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY(Machines with Serial Number 90306 and below.) .............................................................................. 62

FIGURE 6-29. BASE, AXLES AND WHEELS ........................................................................................................ 64FIGURE 6-30. HYDRAULIC BRAKE ASSEMBLY

(Machines with Serial Number 90306 and below.) .............................................................................. 69FIGURE 6-31. HYDRAULIC HOSE CONNECTIONS - Brake

(Machines with Serial Number 90306 and below. ............................................................................... 70FIGURE 6-32. STEERING CYLINDER ASSEMBLY .............................................................................................. 72FIGURE 6-33. BATTERY TRAY ASSEMBLY ......................................................................................................... 73FIGURE 6-34. BATTERY CHARGER ASSEMBLY ................................................................................................. 74FIGURE 6-35. HYDRAULIC HOSE CONNECTIONS - Turret/Base

(Machines with Serial Number 90307 and above) .............................................................................. 76FIGURE 6-36. HYDRAULIC HOSE CONNECTIONS - Turret/Base

(Machines with Serial Number 90306 and below) ............................................................................... 78FIGURE 6-37. DRIVE AXLE ASSEMBLY.............................................................................................................. 80FIGURE 6-38. DRIVE AXLE (Haessler)(Machines with Serial Number 90409 and above) ....................................... 82FIGURE 6-39. DRIVE AXLE (Sige) (Serial Number 90408 and below) .................................................................... 84FIGURE 6-40. PLANETARY REDUCTION GEAR ASSEMBLY (Brevini)

A Brevini gear assembly WILL have a Model Number Plate riveted to the side of the output housing. 86FIGURE 6-41. PLANETARY REDUCTION GEAR ASSEMBLY (Benevelli)

A Benevelli gear assembly will NOT have a Model Number Plate. ..................................................... 87FIGURE 6-42. LABELS AND NAMEPLATES ........................................................................................................ 89


FIGURE 6-1. PLATFORM ASSEMBLY

MA-SJB-01

11

10

9876

5

4

3

2

1

12

13

14

2120

19

18

17

15

16

1819


FIGURE 6-1. PLATFORM ASSEMBLY.

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

A 701287 PLATFORM ASSEMBLY, (standard) -B 701306 PLATFORM ASSEMBLY, (with half gate option) -C 703752 PLATFORM ASSEMBLY, (with full gate option) -D 701557 PLATFORM ASSEMBLY, Europe (standard) -E 701558 PLATFORM ASSEMBLY, Europe (with half gate -

option)F (Ref.) PLATFORM ASSEMBLY, Europe (with full gate -

option)1 700399 • WELDMENT, Platform, A 1

701050 • WELDMENT, Platform, B 1703751 • WELDMENT, Platform, C 1701464 • WELDMENT, Platform, D 1701548 • WELDMENT, Platform, E 1

• WELDMENT, Platform, F 1103910 • • BOLT, Hex-hd ½-13 x 1-1/4” lg. 6107964 • • WASHER, Lock 1/2” 6102972 • • CLAMP, Hose G-8 Double 1103632 • • BOLT, Self tap. 1/4-14 x 3/4” lg. 1

2 706856 • PLATE, Info/ warning 1103632 • • BOLT, Self tap. 1/4-14 x 3/4” lg. 4103995 • • WASHER, Flat 1/4” 4104000 • • WASHER, Lock 1/4” 4

3 700395 • CAP, Tube end (Early machines) 44 708028 • RAILING ASSEMBLY, Entry, A , D (S/N 90762 and above.) 1

708027 • • WELDMENT, Entry rail 1103872 • • BOLT, HHCS 3/8-16 x 2-1/4 lg. 2104606 • • NUT, Lock 3/8-16 2

• ENTRY RAIL ASSEMBLY, A,D 1 (S/N 90761 and below. Replace entire assembly with P/N 708028.)

700427 • • RAILING, Entry 1200463 • • GUIDE, Railing 2101149 • • PIN, Roll 1/4” x 1-1/4” lg. 2

5 (Ref.) • OPERATOR’S CONTROL CONSOLE ASSEMBLY 1 (For components, refer to Figure 6-3.)

6 109700 • RECEPTACLE 110V GFCI BOX 1112707 • • SCREW, Self tapping #10-24 x 5/8” lg. 4103035 • • STRAIN RELIEF, Metal 90° 1105269 • • CORD, 14/3 48 ft.

7 109698 • RECEPTACLE 110V GFCI, A, B, C 18 109699 • RECEPTACLE 110V, Cover plate, A, B, C 19 703737 • COVER 110V., Outlet Blank, D, E 110 700520 • SWITCH ASSEMBLY, Foot 1

700187 • • SWITCH, Foot 1(Ref.) • • CONNECTOR ASSEMBLY, 5 Pole male 1

(Machines with Serial Number 90015 and above, refer to Figure 6-4.)(Ref.) • • CONNECTOR ASSEMBLY, 4 Pole male 1

(Machines with Serial Number 90014 and below, refer to Figure 6-5.)Parts list continued on Page 7.


FIGURE 6-1. PLATFORM ASSEMBLY

MA-SJB-01

11

10

9876

5

4

3

2

1

12

13

14

2120

19

18

17

15

16

1819


FIGURE 6-1. PLATFORM ASSEMBLY.

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

Parts list continued from 5.11 700188 • COVER, Foot switch 1

103857 • • BOLT, Hex-hd 1/4-20 x 1” lg. 2103980 • • NUT, Hex 1/4-20 2700598 • • WASHER, Fender 9/32” x 1-1/4" x 1/16" thk. 2104000 • • WASHER, Lock 1/4” 2

12 105807 • LANYARD 6” lg. 1112707 • • SCREW, Self tap. #10-32 x 5/8” lg. 1

13 100509 • PIN, Quick release 3/8” diameter x 2” lg. 114 706142 • KICK PLATE, A 1

706603 • • BOLT, BHCS 1/4-20 x 1/2” lg. SS 4700583 • • NUT, Lock 1/4-20 4

15 117293 • MANUAL, Enclosure 1706857 • • BOLT, Machine RD HD 1/4-20 x 3/4” lg. 4700583 • • NUT, Lock 1/4-20 4700438 • MANUAL, ANSI A-92.5 (Not shown) 1

16 706802 • WELDMENT, Half gate, B, E 117 706803 • WELDMENT, Full gate, C, F 118 701027 • BUMPER RUBBER AR19 117277 • HINGE SPRING 220 700426 • CENTER BOLT, Rotary actuator 121 700570 • NUT, Hex 1”-14 2


17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

MA-SJB-02

FIGURE 6-2. OPERATOR’S CONTROL CONSOLE ASSEMBLY(Machines with Serial Number 90242 and above)



A 701871 OPERATOR’S CONTROL CONSOLE ASSEMBLY - (Machines without horn option.)

B 701872 OPERATOR’S CONTROL CONSOLE ASSEMBLY - (Machines with factory installed horn option.)

C 701873 OPERATOR’S CONTROL CONSOLE ASSEMBLY - (European machine.)

1 700548 • WELDMENT, Control box 12 701038 • WELDMENT, Control box lid 1

700185 • WELDMENT, Control box lid, A (For machines with S/N 90410 and below)

700481 • • SCREW, Machine 1/4-20 x 1/2” lg. 4103983 • • NUT, Lock 1/4-20 4700479 • • SCREW, Machine #10-24 x 3/4” lg. 2700480 • • NUT, Clip #10-24 2

3 700066 • SUPPORT, Wrist 1103962 • • SCREW, Machine #10-32 x 1/2” lg. 2104003 • • NUT, #10-32 2

4 702406 • CONTROLLER ASSEMBLY, Drive/steer, A (For machines with S/N 90411 and above)

700180 • CONTROLLER ASSEMBLY, Drive/ steer, A 1 (For machines with S/N 90410 and below) (For components, refer to Figure 6-6.)

701044 • CONTROLLER ASSEMBLY, Drive/ steer, B, C 1 (For components, refer to Figure 6-7.)

5 700775 • CONTROLLER, Boom function 1 (For components, refer to Figure 6-8.)

104698 • • SCREW, Machine #10-32 x 3/4” lg. 4104003 • • NUT, #10-32 4

6 700182 • CONTROLLER BOARD, Boom function 1103955 • • SCREW, Machine #6-32 x 3/4” lg. 4103985 • • NUT, #6-32 4

7 (Ref.) • SWITCH ASSEMBLY, Lighted push-button 6700926 • • BASE W/LIGHT SOCKET, Indicator 6103141 • • SWITCH, N.O. Contact, A, B 6103141 • • SWITCH, N.O. Contact, C 6701525 • • SWITCH MODULE, Maintained on A, B 7701525 • • SWITCH MODULE, Maintained on C 6701799 • • • BOLT, Soc-hd M3 x 0.5 x 30mm AR700184 • • HEAD, Sealed push-button 6102771 • • BULB, 24 Volt 6

8 (Ref.) • LIGHT ASSEMBLY, Indicator 2102671 • • BASE, Lighted 2103202 • • HEAD, Light 2102771 • • BULB, 24 Volt 2

Parts list continued on Page 11.

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

MA-SJB-02




IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

Parts list continued from Page 9.9 (Ref.) • SWITCH ASSEMBLY, Emergency stop 1

103100 • • BASE, Contact 1103225 • • BLOCK, N.C. Contact 1102769 • • HEAD, Emergency stop switch 1

10 103057 • BEEPER, 24 Volt 111 103012 • BLOCK, Terminal 1/2

700818 • • SCREW, Machine #8-32x3/4”lg. 5103986 • • NUT, #8-32 5

12 700093 • LABEL, Control console, A, B 1701472 • LABEL, Control console, C 1

13 108589 • RELAY, Sealed 40 Amp 1103962 • • SCREW, Machine #10-32 x 1/2” lg. 1104694 • • WASHER, Flat #10 1104185 • • WASHER, Lock #10 1104003 • • NUT, #10-32 1

14 102956 • PLUG, Snap-in 7/8” dia. 115 (Ref.) • CABLE ASSEMBLY, Foot switch 1

103256 • • CORD, Foot switch 18/2 30”103036 • • RELIEF, Strain 1(Ref.) • • CONNECTOR ASSEMBLY, 5 Pole female 1

(For components, refer to Figure 6-4.)(Ref.) • • CONNECTOR ASSEMBLY, 4 Pole female 1

(Machines with Serial Number 90014 and below only. For components, refer to Figure 6-5.)

16 (Ref.) • CONNECTOR ASSEMBLY, 32 Pole male 1 (For components, refer to Figure 6-4.)

17 102929 • CLAMP, Hose G-8 Single 2


MA-SJB-02

FIGURE 6-3. OPERATOR’S CONTROL CONSOLE ASSEMBLY(Machines with Serial Number 90241 and below)

18

1716

15

14

13

12

1110

9

8

7

6

5

4

3

2

1



A 700150 OPERATOR’S CONTROL CONSOLE ASSEMBLY - (Machines with Serial Number 90149 and below. Machines with Serial Number 90150 and above without horn option.)

B 701013 OPERATOR’S CONTROL CONSOLE ASSEMBLY - (Machines with Serial Number 90150 and above with factory installed horn option.) -

C 701502 OPERATOR’S CONTROL CONSOLE ASSEMBLY - (European machine.)

1 700548 • WELDMENT, Control box 1700186 • WELDMENT, Control box

(Machines with Serial Number 90014 and below only)2 700185 • WELDMENT, Control box lid, A 1

701038 • WELDMENT, Control box lid, B, C700481 • • SCREW, Machine 1/4-20 x 1/2” lg. 4103983 • • NUT, Lock 1/4-20 4700479 • • SCREW, Machine #10-24 x 3/4” lg. 2700480 • • NUT, Clip #10-24 2

3 700066 • SUPPORT, Wrist 1103962 • • SCREW, Machine #10-32 x 1/2” lg. 2104003 • • NUT, #10-32 2

4 700180 • CONTROLLER ASSEMBLY, Drive/ steer, A 1 (For components, refer to Figure 6-6.)

701044 • CONTROLLER ASSEMBLY, Drive/ steer, B, C 1 (For components, refer to Figure 6-7.)

5 700775 • CONTROLLER, Boom function 1 (For components, refer to Figure 6-8.)

104698 • • SCREW, Machine #10-32 x 3/4” lg. 4104003 • • NUT, #10-32 4

6 700182 • CONTROLLER BOARD, Boom function 1103955 • • SCREW, Machine #6-32 x 3/4” lg. 4103985 • • NUT, #6-32 4

7 (Ref.) • SWITCH ASSEMBLY, Lighted push-button 6700926 • • BASE W/LIGHT SOCKET, Indicator 6103141 • • SWITCH, N.O. Contact, A, B 20103141 • • SWITCH, N.O. Contact, C 18700184 • • HEAD, Sealed push-button 6102771 • • BULB, 24 Volt 6

8 (Ref.) • LIGHT ASSEMBLY, Indicator 2102671 • • BASE, Lighted 2103202 • • HEAD, Light 2102771 • • BULB, 24 Volt 2

9 (Ref.) • SWITCH ASSEMBLY, Emergency stop 1103100 • • BASE, Contact 1103225 • • BLOCK, N.C. Contact 1102769 • • HEAD, Emergency stop switch 1


IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


MA-SJB-02


18

1716

15

14

13

12

1110

9

8

7

6

5

4

3

2

1



IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

Parts list continued from Page 13.10 103057 • BEEPER, 24 Volt 111 103012 • BLOCK, Terminal 2 1/2

700818 • • SCREW, Machine #8-32x3/4”lg. 5103986 • • NUT, #8-32 5

12 700093 • LABEL, Control console, A, B 1701472 • LABEL, Control console, C 1

13 108589 • RELAY, Sealed 40 Amp 1103962 • • SCREW, Machine #10-32 x 1/2” lg. 1104694 • • WASHER, Flat #10 1104185 • • WASHER, Lock #10 1104003 • • NUT, #10-32 1

14 102956 • PLUG, Snap-in 7/8” dia. 115 (Ref.) • CABLE ASSEMBLY, Foot switch 1

103256 • • CORD, Foot switch 18/2 30”103036 • • RELIEF, Strain 1(Ref.) • • CONNECTOR ASSEMBLY, 5 Pole female 1

(For components, refer to Figure 6-5.)(Ref.) • • CONNECTOR ASSEMBLY, 4 Pole female 1


16 (Ref.) • CONNECTOR ASSEMBLY, 32 Pole male 1 (For components, refer to Figure 6-4.)

17 700189 • CABLE ASSEMBLY, Control 1700162 • • CABLE, Control 18/30 30”103365 • • RELIEF, Strain 1(Ref.) • • CONNECTOR, 28 Pole male 1


18 102929 • CLAMP, Hose G-8 Single 2


NOTES


FIGURE 6-4. CABLE PLUG AND SOCKET COMPONENTS (Weidmuller)(Machines with Serial Number 90015 and Above)

MA-SJB-03

(Ref.) PLUG ASSEMBLY, 32 Pole male -1 700560 • HOUSING W/GASKET 12 700558 • INSERT, #1-#16 Male 13 700559 • INSERT, #17-#32 Male 1

(Ref.) SOCKET ASSEMBLY, 32 Pole female -4 700557 • HOUSING 15 700555 • INSERT, #1-#16 Female 16 700556 • INSERT, #17-#32 Female 1

(Ref.) PLUG ASSEMBLY, 5 Pole male -7 103567 • HOUSING 18 103569 • INSERT, Male 1

(Ref.) SOCKET ASSEMBLY, 5 Pole female -9 103568 • HOUSING 110 103570 • INSERT, Female 1

10

9

87

6

5

4

3

2

1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-5. CABLE PLUG AND SOCKET COMPONENTS(Machines with Serial Number 90014 and below)

MA-BOE-11

43

21

1 (Ref.) PLUG ASSEMBLY, 4 Pole male -2 (Ref.) SOCKET ASSEMBLY, 4 Pole female -

For replacement of item 1 or 2, order the following.103567 HOUSING, 5 Pole male 1103569 INSERT, 5 Pole male 1103568 HOUSING, 5 Pole female 1103570 INSERT, 5 Pole female 1

3 (Ref.) PLUG ASSEMBLY, 28 Pole male -4 (Ref.) SOCKET ASSEMBLY, 28 Pole female -

For replacement of item 3 or 4, order the following.114465 HOUSING, 32 pole 1114467 INSERT, #1-#16 Female 1114468 INSERT, #17-#32 Female 1114466 HOUSING, 32 Pole, with clip 1114469 INSERT, #1-#16 Male 1114470 INSERT, #16-#32 Male 1700162 CABLE, 18/30 60”

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-6. DRIVE/STEER CONTROLLER ASSEMBLY(All machines with Serial Number 90149 and below, and machines with Serial Number 90150 and above

without horn option.)

702406 CONTROLLER ASSEMBLY, Drive/steer(Machines with Serial Number 90411 and above) -

700180 CONTROLLER ASSEMBLY, Drive/steer(Machines with Serial Number 90410 and below) -

1 700833 • GRIP ASSEMBLY, Controller 12 105733 • • SWITCH, Steer 23 105733 • • SWITCH, Trigger 14 105734 • • ACTUATOR, Rocker 15 700958 • • PIN, Rocker actuator 16 105735 • • CAP, Elastic 17 700953 • • GRIP HALF, Threaded 18 700954 • • GRIP HALF 19 700955 • • TRIGGER ASSEMBLY 1

700956 • • • SPRING, Trigger 110 $ • BASE ASSEMBLY, Controller 1

(Order Controller Assembly.) 111 700957 • BOOT, Controller handle 112 701241 • GASKET, Controller mounting

(Machines with Serial Number 90411 and above) 1700959 • GASKET, Controller mounting

(Machines with Serial Number 90410 and below) 113 700834 • CONTROLLER BOARD, Drive/steer 114 700835 • POTENTIOMETER ASSEMBLY 1

700836 • KIT, Assembly hardware 1

MA-SJB-04a

87

6

5

4

3

2

1

14

13

1211

10

9

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-7. DRIVE/STEER CONTROLLER ASSEMBLY(Machines with Serial Number 90151 and above with factory installed horn option.)

701044 CONTROLLER ASSEMBLY, Drive/steer -

1 701791 • GRIP ASSEMBLY, Controller 12 105733 • • SWITCH, Steer 23 105733 • • SWITCH, Trigger, not used 14 701240 • • SWITCH, Horn button 15 105734 • • ACTUATOR, Rocker 16 700958 • • PIN, Rocker actuator 17 105735 • • CAP, Elastic 18 701239 • • GRIP HALF, Threaded 19 700954 • • GRIP HALF 1

10 700955 • • TRIGGER ASSEMBLY 1700956 • • • SPRING, Trigger 1

11 $ • BASE ASSEMBLY, Controller 1 (Order Controller Assembly.) 1

12 700957 • BOOT, Controller handle 113 701241 • GASKET, Controller mounting 114 700834 • CONTROLLER BOARD, Drive/steer 115 700835 • POTENTIOMETER ASSEMBLY 1

700836 • KIT, Assembly hardware 1

15

14

1312

11

10

9

8

7

6

5

4

32

1

MA-SJB-04b

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-8. BOOM FUNCTION CONTROLLER ASSEMBLY

MA-SJB-05

700775 CONTROLLER ASSEMBLY, Boom function -1 $ • BASE ASSEMBLY, Controller 1

(Not serviced separately, order Controller Assembly, 700775.)

2 700976 • GASKET, Controller base 13 700977 • KNOB, Controller handle 14 700978 • BOOT, Control handle 15 700979 • SPRING, Torsion 16 700980 • GUIDE, Spring 1

6

5

4

3

2

1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-9. BOOM ASSEMBLY (Jib Section)

MA-SJB-06

14

13

12

11

10

11

8

7

6

5

4

3

2

1

9


FIGURE 6-9. BOOM ASSEMBLY (Jib Section)

1 (Ref.) ACTUATOR ASSEMBLY, Rotary 1700450 • ACTUATOR, Rotary 1701875 • • SEAL KIT, Rotary actuator AR700390 • MANIFOLD, Rotary actuator 1700568 • VALVE, Counterbalance 2103024 • CLAMP, Hose G-8 Single 2103632 • BOLT, Self tap. 1/4-14 x 3/4” lg. 2

2 700388 CYLINDER ASSEMBLY, Platform leveling slave 1 (For components, refer to Figure 6-11.)

3 700432 PIN, Slave cylinder bottom 1103884 • BOLT, Hex-hd 5/16-18 x 2-1/2” lg. 1103984 • NUT, Lock 5/16-18 1

4 700375 WELDMENT, Actuator bracket 15 700386 PIN, Actuator bracket 4

103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 4103404 • WASHER, Lock 5/16-18 4

6 700434 SPACER, Actuator pin 17 700969 PARALLEL ASSEMBLY, Jib upper 1

700371 • WELDMENT, Jib upper parallel 18 700611 • COVER, Cable track 30” lg. (See Note) 2

700613 • • RIVET, Pop 1/8 dia. x 3/8” lg. 69 100309 • BUSHING, 1” x 1-1/8" x 1" lg. 610 700970 PARALLEL ASSEMBLY, Jib lower 1

700371 • WELDMENT, Jib lower parallel 1700611 • COVER, Cable track 30” lg. (See Note) 1

11 700521 • COVER, Cable track 8” lg. (See Note) 1700613 • • RIVET, Pop 1/8” dia. x 3/8" lg. 5

12 100309 • BUSHING, 1” x 1-1/8" x 1" lg. 613 700241 CYLINDER ASSEMBLY, Jib lift 1

(For components, refer to Figure 6-10.)14 700376 WASHER, Bronze 1” x 1-1/8" x 1" thk. 1

NOTE: Make from 104127 (72” lg.)

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-10. JIB LIFT CYLINDER ASSEMBLY

MA-SJB-07

19

18

17

16

15

14

13

11

10

9

8

7

6

5

4

3

2

1

14

12


FIGURE 6-10. JIB LIFT CYLINDER ASSEMBLY

700241 CYLINDER ASSEMBLY, Jib lift -1 700245 • WELDMENT, Cylinder barrel 12 700244 • WELDMENT, Cylinder rod 13 700243 • GLAND, Cylinder 14 700242 • PISTON, Cylinder 1*5 700576 • SEAL, Rod 1*6 700585 • SEAL, Piston 1*7 700578 • WIPER, Rod 18 700575 • NUT, Lock 3/4-10 1*9 701965 • O-RING, Gland 1*10 701634 • O-RING, Piston 111 700449 • SPACER, Cylinder 1-1/8” x 2" x 1-5/16" lg. 112 100695 • BUSHING, 1” x 1-1/8" x 1-1/2" lg. 213 100309 • BUSHING, 1” x 1-1/8" x 1" lg. 214 100249 • BUSHING, 1” x 1-1/8" x 3/4" lg. 215 701029 VALVE BLOCK, Jib cylinder 1

108429 • BOLT, Soc-hd 5/16-18 x 2” lg. 4103404 • WASHER, Lock 5/16 4

16 700568 VALVE, Counterbalance 217 103069 FITTING, Connector #6orb-#6 218 700569 O-RING, Valve block 219 103136 VALVE, Manual lowering (Serial Number 90277 and above) 1

700997 VALVE, Manual lowering (Serial Number 90276 and below) 1700456 KIT, Seal repair AR

* Part of Seal Repair Kit.

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


NOTES


FIGURE 6-11. PLATFORM LEVELING SLAVE CYLINDER ASSEMBLY

MA-SJB-08

700388 CYLINDER ASSEMBLY, Platform leveling slave -1 700389 • WELDMENT, Cylinder barrel 12 700600 • WELDMENT, Cylinder rod 13 700340 • GLAND, Cylinder 14 700341 • PISTON, Cylinder 1*5 107935 • SEAL, Piston 1*6 108798 • SEAL, Gland 1*7 106449 • WIPER, Rod 1*8 701964 • O-RING, Gland 1*9 701633 • O-RING, Piston 110 103830 • NUT, Lock 5/8-11 111 100309 • BUSHING, 1” x 1-1/8" x 1" lg. 412 103073 FITTING, Elbow 90° #6orb-#6 213 700040 VALVE BLOCK, Slave cylinder 1

103933 • BOLT, Soc-hd 5/16-18 x 1-3/4 lg. 4103404 • WASHER, Lock 5/16” 4

14 700568 VALVE, Counterbalance 115 700569 O-RING, Valve block 2

700454 KIT, Seal repair AR* Part of Seal Repair Kit.

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

11

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-12. BOOM ASSEMBLY (Main and Telescopic Section)

MA-SJB-09

23

22

21

20

19

18

17

1413

1211

10

9

8

7

6

54

3

2

1

24

16

15



1 700384 PIN, Jib parallel 2103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 2103404 • WASHER, Lock 5/16” 2

2 700207 WELDMENT, Telescopic boom 13 700350 CYLINDER ASSEMBLY, Boom telescopic 1

(For components, refer to Figure 6-13)4 700368 PIN, Telescopic cylinder 1

103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 1103404 • WASHER, Lock 5/16” 1

5 700370 SPACER, Telescopic pin 26 700077 PAD, Sliding 167 700097 SHIM, Sliding pad (.059 thk.) AR8 700580 SHIM, Sliding pad (.023 thk.) AR9 700098 BRACKET, Sliding pad 16

101632 • BOLT, Hex-hd 3/8-16 x 3/4” lg. 12700264 • BOLT, Hex-hd 3/8-16 x 1/2” lg. 12103473 • BOLT, Hex-hd 3/8-16 x 1” lg. 8103472 • WASHER, Flat 3/8” 16103999 • WASHER, Lock 3/8” 32700579 • PIN, Roll 1/4 dia. x 5/8” lg. 16

10 700258 SUPPORT ASSEMBLY, Telescopic cylinder 1700260 • WEAR PAD, Telescopic cylinder support 2700259 • BRACKET, Telescopic cylinder support 1700581 • BOLT, Soc-hd 1/4-20 x 1-1/2” lg. 2700582 • BOLT, Flat-hd 1/4-20 x 3/4” lg. 4

11 700367 PIN, Telescopic cylinder 1103884 • BOLT, Hex-hd 5/16-18 x 2-1/2” lg. 1103984 • NUT, Lock 5/16-18 1

12 700929 WELDMENT, Main boom (NOTE C) 1700196 WELDMENT, Main boom (NOTE D) 1

13 700362 PIN, Main lift cylinder upper 1103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 1103404 • WASHER, Lock 5/16” 1

14 700366 PIN, Platform leveling master cylinder (upper) 1103884 • BOLT, Hex-hd 5/16-18 x 2-1/2” lg. 1103984 • NUT, Lock 5/16-18 1

15 700088 COVER, Boom hose 2170583 • NUT, Lock 1/4-20 4

16 701979 SUPPORT, Boom hose(S/N 90277 and above) 1700089 SUPPORT, Boom hose(S/N 90276 and below) 1700583 • NUT, Lock 1/4-20 3

17 701980 WELDMENT, Hose carrier support (Serial Number 90277 and above) 1

700461 WELDMENT, Hose carrier support (Serial Number 90276 and below) 1

103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 4103984 • NUT, Lock 5/16-18 4


IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.



MA-SJB-09

23

22

21

20

19

18

17

1413

1211

10

9

8

7

6

54

3

2

1

24

16

15



Parts list continued from Page 29.

19 700092 SUPPORT, Hose carrier 1700583 • NUT, Lock 1/4-20 3

20 700633 CARRIER ASSEMBLY, Hose 1700609 • CARRIER, Hose (43-5/8” lg.) 1700588 • • LINK, Carrier repair AR700610 • MOUNT BRACKET, Hose carrier 1700584 • • BOLT, Button hd 1/4-20 x 1/2” lg. 4104000 • • WASHER, Lock 1/4” 4103983 • • NUT, Hex 1/4-20 4

21 700190 CABLE ASSEMBLY, Control (NOTE A) 1700162 • CABLE, 18/30 Control 46 ft.(Ref.) • CONNECTOR ASSEMBLY, Female 32 Pole 1

(For components refer to Figure 6-5.)(Ref.) CABLE ASSEMBLY, Control (NOTE B) 1

700162 • CABLE, 18/30 Control 46 ft.(Ref.) • CONNECTOR ASSEMBLY, 28 Pole 1

(For components refer to Figure 6-5.)22 105269 CORD, 14/3 (110v Service) 48 ft.23 700160 SWITCH, Sealed limit 1

700549 • BOLT, Rnd-hd #10-32 x 3/4” lg. 2104694 • WASHER, Flat #10 2104185 • WASHER, Lock #10 2

24 700831 LIGHT KIT, Flashing (option) 1106756 • LIGHT ASSEMBLY, Flashing 1104416 • • LENS, Amber 1103111 • • BULB, 24 Volt 1700808 • ADAPTOR PLATE, Flashing light 1103267 • FLASHER, 24 Volt 1103256 • CORD, 18/2 23 ft.102921 • DIODE, 6 Amp 1000 PIV 1108589 • RELAY, 24 Volt 1

NOTE A - Machines with Serial Numbers 90015 and above.NOTE B - Machines with Serial Numbers 90014 and below.NOTE C - Machines with Serial Numbers 90166 and above.NOTE D - Machines with Serial Numbers 90165 and below.

18 701983 WELDMENT, Hose carrier bracket (Serial Number 90277 and above) 1

700462 WELDMENT, Hose carrier bracket (Serial Number 90276 and below) 1

700781 • BOLT, Button hd 5/16-18 x 3/8” lg. 4103404 • WASHER, Lock 5/16” 4

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-13. BOOM TELESCOPING CYLINDER ASSEMBLY

MA-SJB-10

2

1

18

15

14

13

12

11

10

9

8

7

6

5

4

3

14

13

1716

17


FIGURE 6-13. BOOM TELESCOPING CYLINDER ASSEMBLY

700350 CYLINDER ASSEMBLY, Boom telescopic -1 700351 • WELDMENT, Cylinder barrel 12 700356 • WELDMENT, Cylinder rod 13 700359 • GLAND, Cylinder 14 700360 • PISTON, Cylinder 1*5 700576 • SEAL, Rod 1*6 700577 • SEAL, Piston 1*7 700578 • WIPER, Rod 1*8 110949 • WEAR RING, Piston 19 700575 • NUT, Lock 3/4-10 1

*10 701964 • O-RING, Gland 1*11 701634 • O-RING, Piston 112 703981 • SPACER, Cylinder 1-1/4” x 1-1/2" x 2-3/8" lg. 113 100309 • BUSHING, 1” x 1-1/8" x 1" lg. 414 100695 • BUSHING, 1” x 1-1/8" x 1-1/2" lg. 215 700041 VALVE BLOCK, Telescopic cylinder 1

108429 • BOLT, Soc-hd 5/16-18 x 2” lg. 4103404 • WASHER, Lock 5/16” 4

16 700568 VALVE, Counterbalance 217 103073 FITTING, Connector #6orb-#6 218 700569 O-RING, Valve block 2

700455 KIT, Seal repair AR


IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-14. BOOM ASSEMBLY (Riser Section)

MA-SJB-11

4

16

4

15

14

13

12

11

10

9

8

7

6

5

3

2 1

16

1817


FIGURE 6-14. BOOM ASSEMBLY (Riser Section)

1 700364 PIN, Upper knuckle 1103868 • BOLT, Hex-hd 5/16-18 x 3-1/2” lg. 1103984 • NUT, Lock 5/16-18 1

2 700430 PIN, Platform leveling master cylinder (lower) 1103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 1103404 • WASHER, Lock 5/16” 1

3 700348 PIN, Lift cylinder (lower) 1103868 • BOLT, Hex-hd 5/16-18 x 3-1/2” lg. 1103984 • NUT, Lock 5/16-18 1

4 700425 WASHER, Stop 6103900 • BOLT, Hex-hd 1/2-13 x 1-1/4” lg. 6103470 • WASHER, Lock 1/2” 6

5 700966 KNUCKLE ASSEMBLY 1700266 • WELDMENT, Knuckle 1100904 • BUSHING, 1-1/2” x 1-11/16" x 1" lg. 2

6 700332 CYLINDER ASSEMBLY, Boom lift 1 (For components, refer to Figure 6-16.)

7 700333 CYLINDER ASSEMBLY, Platform leveling master 1 (For components, refer to Figure 6-17.)

8 700343 PIN, Riser parallel (upper) 2103868 • BOLT, Hex-hd 5/16-18 x 3-1/2” lg. 2103984 • NUT, Lock 5/16-18 2

9 700965 PARALLEL ASSEMBLY, Riser upper700253 • WELDMENT, Riser upper parallel 1103216 • BUSHING, 1-1/2” x 1-11/16" x 1-1/2" lg. 2100904 • BUSHING, 1-1/2” x 1-11/16" x 1" lg. 2

10 700964 PARALLEL ASSEMBLY, Riser lower700250 • WELDMENT, Riser lower parallel 1103216 • BUSHING, 1-1/2” x 1-11/16" x 1-1/2" lg. 2100904 • BUSHING, 1-1/2” x 1-11/16" x 1" lg. 2

11 700344 PIN, Riser parallel (lower) 4103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 4103404 • WASHER, Lock 5/16” 4

12 700327 HOSE STRAP, Riser 1100397 • NUT, 5/16-18 2103404 • WASHER, Lock 5/16 2

13 700238 HOSE COVER, Riser 1103984 • NUT, Lock 5/16-18 6103996 • WASHER, Flat 5/16” 6

14 700347 PIN, Riser lift cylinder (upper) 1103868 • BOLT, Hex-hd 5/16-18 x 3-1/2” lg. 1103984 • NUT, Lock 5/16-18 1

15 700328 CYLINDER ASSEMBLY, Riser lift 1 (For components, refer to Figure 6-15.)

16 700342 WASHER, Bronze 1-1/2” x 2-1/2" x 1/8" thk. 417 703054 SWITCH, Proximity (European Model) 118 703059 BRACKET, Proximity Switch (European Model) 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-15. RISER LIFT CYLINDER ASSEMBLY

MA-SJB-12

13

1817

1615

14

13

12

11

109

8

7

6

5

4

3

2

1


FIGURE 6-15. RISER LIFT CYLINDER ASSEMBLY

700328 CYLINDER ASSEMBLY, Riser lift -1 700135 • WELDMENT, Cylinder barrel 12 700145 • WELDMENT, Cylinder rod 13 700329 • GLAND, Cylinder 14 700330 • PISTON, Cylinder 1*5 700571 • SEAL, Rod 1*6 106225 • SEAL, Piston 1*7 700573 • WIPER, Rod 1*8 700574 • WEAR RING, Gland 1*9 106220 • WEAR RING, Piston 110 106230 • NUT, Lock 1-1/4-12 1*11 701966 • O-RING, Gland 1*12 701639 • O-RING, Piston 113 103216 • BUSHING, 1-1/2” x 1-11/16" x 1-1/2" lg. 614 700044 VALVE BLOCK, Riser lift cylinder 1


15 103136 VALVE, Manual lowering 116 700568 VALVE, Counterbalance 117 103069 FITTING, Connector #6orb-#6 218 700569 O-RING, Valve block 2

700452 KIT, Seal repair AR703872 TOOL, Cylinder assembly -


IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


MA-SJB-13

FIGURE 6-16. BOOM LIFT CYLINDER ASSEMBLY

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

14


FIGURE 6-16. BOOM LIFT CYLINDER ASSEMBLY

700332 CYLINDER ASSEMBLY, Boom lift -1 700141 • WELDMENT, Cylinder barrel 12 700147 • WELDMENT, Cylinder rod 13 700329 • GLAND, Cylinder (NOTE A) 1

700995 • GLAND, Cylinder (NOTE B) 14 700330 • PISTON, Cylinder 1*5 700571 • SEAL, Rod 1*6 106225 • SEAL, Piston 1*7 700573 • WIPER, Rod 1*8 700574 • WEAR RING, Gland 1*9 106220 • WEAR RING, Piston 1*10 701966 • O-RING, Gland 1*11 701639 • O-RING, Piston 112 106230 • NUT, Lock 1-1/4-12 113 700458 • SPACER, Cylinder 3” dia. x 1-1/2" lg. (NOTE A) 1

701070 • SPACER, Cylinder 3” dia. x 1-3/32" lg. (NOTE B) 114 103216 • BUSHING, 1-1/2” x 1-11/16" x 1-1/2" lg. 615 700043 VALVE BLOCK, Boom lift cylinder 1


16 103136 VALVE, Manual lowering 117 700568 VALVE, Counterbalance 118 107742 FITTING, Elbow 45° #6orb-#6 219 700569 O-RING, Valve block 2

700452 KIT, Seal repair AR703872 TOOL, Cylinder assembly -


NOTE A - Machines with Serial Number 90127and below.NOTE B - Machines with Serial Number 90128and above.

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


NOTES


FIGURE 6-17. PLATFORM LEVELING MASTER CYLINDER ASSEMBLY

700333 CYLINDER ASSEMBLY, Platform leveling master -1 700334 • WELDMENT, Cylinder barrel 12 700337 • WELDMENT, Cylinder rod 13 700340 • GLAND, Cylinder 14 700341 • PISTON, Cylinder 1*5 107935 • SEAL, Piston 1*6 108798 • SEAL, Gland 1*7 106449 • WIPER, Rod 1*8 701964 • O-RING, Gland 1*9 701633 • O-RING, Piston 110 103830 • NUT, Lock 5/8-11 111 100309 • BUSHING, 1” x 1-1/4" x 1" lg. 412 114109 FITTING, Tee #6swv-#6-#6 213 103069 FITTING, Connector #6orb-#6 2

700454 KIT, Seal repair AR

* Part of Seal Repair.

13

12

11

10

9

8

7

6

54

3

2

1

11

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

MA-SJB-14


MA-SJB-15

FIGURE 6-18. HYDRAULIC HOSE CONNECTIONS - Boom Assembly

19

18

17

16

15

14

13

1211

10

9

87

6

5

4

3

2

1

6

5

14


FIGURE 6-18. HYDRAULIC HOSE CONNECTIONS - Boom Assembly

1 (Ref.) MANIFOLD ASSEMBLY, Main 1 (Refer to Figure 6-21.)

2 700392 HOSE ASSEMBLY, Manifold to master cylinder 23 700391 HOSE ASSEMBLY, Manifold to lift cylinder 24 700398 HOSE ASSEMBLY, Master cylinder to slave cylinder 25 700393 HOSE ASSEMBLY, Manifold to telescopic cylinder, 4

and union to jib cylinder.6 700394 HOSE ASSEMBLY, Manifold to union 47 700397 HOSE ASSEMBLY, Union to rotary actuator 28 700450 ACTUATOR, Rotary 19 700333 CYLINDER ASSEMBLY, Platform leveling master 1

(For components, refer to Figure 6-17.)10 700332 CYLINDER ASSEMBLY, Boom lift 1

(For components, refer to Figure 6-16.)11 700350 CYLINDER ASSEMBLY, Telescopic 1

(For components, refer to Figure 6-13.)12 700241 CYLINDER ASSEMBLY, Jib lift 1

(For components, refer to Figure 6-10.)13 700388 CYLINDER ASSEMBLY, Platform leveling slave 1

(For components, refer to Figure 6-11.)14 103069 FITTING, Connector #6orb-#6 1815 114109 FITTING, Tee #6 female #6-#6 216 700318 FITTING, Union #6-#6 417 103073 FITTING, Elbow 90° #6orb-#6 218 113348 FITTING, Elbow 90° #4orb-#6 219 107742 FITTING, Elbow 45° #6orb-#6 2

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-19. TURRET ASSEMBLY(Machines with Serial Number 90307 and above.)

MA-SJB-16a

30

31

14

4

18

19

21

22

16

17

20

24

23

13

12

252627

15

23

129

6

828

9

10

75

11

32



1 702622 WELDMENT, Turret 1701762 • BOLT, Hex-hd 5/8-11 x 4-1/2” lg. 23700782 • WASHER, Flat-hard 5/8” 23

2 700482 BUSHING, 1-1/2” x 1-11/16" x 1/2" lg. 43 700483 BUSHING, 1-1/2” x 1-11/16" x 1-1/4" lg. 44 700167 WELDMENT, Counterweight 1

700501 • BOLT, Hex-hd 1.00-8 x 3-3/4” lg. 3107948 • WASHER, Lock 1” 3700435 • WASHER, Flat 1” 3

5 102780 LATCH, Door R.H. 1111534 • KNOB, Latch 1103855 • BOLT, Hex-hd 1/4-20 x 1/2” lg. 1103864 • BOLT, Hex-hd 5/16-18 x 1” lg. 3103996 • WASHER, Flat 5/16” 3103404 • WASHER, Lock 5/16” 3

6 102781 LATCH, Door L.H. 1111534 • KNOB, Latch 1103855 • BOLT, Hex-hd 1/4-20 x 1/2” lg. 1103864 • BOLT, Hex-hd 5/16-18 x 1” lg. 3103996 • WASHER, Flat 5/16” 3103404 • WASHER, Lock 5/16” 3

7 700271 WELDMENT, Door latch bracket R.H. 1103887 • BOLT, Hex-hd 3/8-16 x 3/4” lg. 2103996 • WASHER, Flat 5/16” 2103404 • WASHER, Lock 5/16” 2

8 700126 WELDMENT, Door latch bracket L.H. 1103887 • BOLT, Hex-hd 3/8-16 x 3/4” lg. 2103996 • WASHER, Flat 5/16” 2103404 • WASHER, Lock 5/16” 2

9 700275 WELDMENT, L.H. Door 110 700276 WELDMENT, R.H. Door 111 700087 LINK, Door stop 2

103473 • BOLT, Hex-hd 3/8-16 x 1” lg. 2101297 • BOLT, Hex-hd 3/8-16 x 1-1/4” lg. 2103472 • WASHER, Flat 3/8” 2104606 • NUT, Hex 3/8” 2

12 700814 GUIDE, Main boom 213 700813 REST PAD, Main boom 2


14 111135 PAD, Riser rest 2103606 • NUT, Hex 3/8-16 2103999 • WASHER, Lock 3/8” 2103472 • WASHER, Flat 3/8” 2

15 700224 PUMP/MOTOR ASSEMBLY, Boom function 1700669 • PUMP, Hydraulic 1103073 • • FITTING, Elbow 90° #6orb-#6 1700524 • • FITTING, Hose barb 90° #12orb-#8 1103032 • • HOSE, 3/4” suction 4”106052 • COUPLING 1700668 • MOTOR, 48 Volt 1109174 • • BRUSH SET 1109175 • • SPRING, Brush 8


IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.



MA-SJB-16a

30

31

14

4

18

19

21

22

16

17

20

24

23

13

12

252627

15

23

129

6

828

9

10

75

11

32



IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

Parts list continued from page 45.103887 • • BOLT, Hex-hd 5/16-18 x 3/4” lg. 4103996 • • WASHER, Flat 5/16” 8103404 • • WASHER, Lock 5/16” 4700523 • • BUSHING, Rubber 4102972 • • CLAMP, Hose G-8 1103632 • • SCREW, Self tap. 1/4-14 x 3/4” lg. 1

16 (Ref.) MANIFOLD ASSEMBLY, Main 1 (For components, refer to Figure 6-21.)

103871 • BOLT, Hex-hd 3/8-16 x 1-3/4” lg. 4103999 • WASHER, Lock 3/8” 4103472 • WASHER, Flat 3/8” 4

17 702107 TANK ASSEMBLY, Hydraulic 1 (For components, refer to Figure 6-23.)

104606 • NUT, Hex 3/8-16 3103999 • WASHER, Lock 3/8” 3103472 • WASHER, Flat 3/8” 3

18 (Ref.) PANEL ASSEMBLY, Electrical 1 (For components, refer to Figure 6-27.)

103980 • NUT, Hex 1/4-20 8104000 • WASHER, Lock 1/4” 4

19 (Ref.) PANEL ASSEMBLY, Sevcon 1 (For components, refer to Figure 6-26.)


20 700552 SWITCH, Tilt 1114866 • FUSE, 250 Volt, 1 amp 1103855 • BOLT, Hex-hd 1/4-20 x 1/2” lg. 4104000 • WASHER, Lock 1/4” 4

21 700445 WELDMENT, Electrical panel cover bracket 122 700475 PANEL COVER, Electrical 1

700624 • NUT, Wing 1/4-20 2103995 • WASHER, Flat 1/4” 2

23 700605 PROTECTOR, Cable 12” lg. 124 708604 SWITCH, Sealed limit (riser) 1

103256 • CABTRIE CABLE, 18/2 114”700549 • BOLT, Soc-hd #10-32 x 3/4” lg. 2104694 • WASHER, Flat #10 2104185 • WASHER, Lock #10 2

25 102860 HORN, 24 Volt (OPTION) 126 701248 CABLE ASSEMBLY, Pump motor (pos) 127 701249 CABLE ASSEMBLY, Pump motor (neg) 128 706911 MANIFOLD ASSEMBLY, Brake 1

(For components, refer to Figure 6-25.)103882 • BOLT, HHCS 5/16-18 x 4” lg. 2103404 • WASHER, Lock 5/16” 2

29 700903 ACCUMULATOR, Brake pressure 1700904 ACCUMULATOR CLAMP 1103993 • BOLT, Hex-hd 5/16-18 x 1-3/4” lg. 2103404 • WASHER, Lock 5/16” 2100397 • NUT, Lock 5/16-18 2

30 703054 SWITCH, Proximity (European Model) 131 703060 BRACKET, Proximity switch (European Model) 132 700346 Pin, Riser cylinder lower 1


FIGURE 6-20. TURRET ASSEMBLY(Machines with Serial Number 90306 and below.)

MA-SJB-16

2426

25

23

27

22

21

20

19

18

17

16

15

14

1312

11

10

9

8

7

6

5

4

3

2

1


1 700928 WELDMENT, Turret 1 (Machines with Serial Number 90166 and above.)

700127 WELDMENT, Turret 1 (Machines with Serial Number 90165 and below.)

701762 • BOLT, Hex-hd 5/8-11 x 4-1/2”lg. 23700782 • WASHER, Flat-hard 5/8” 23

2 700482 BUSHING, 1-1/2” x 1-11/16" x 1/2" lg. 43 700483 BUSHING, 1-1/2” x 1-11/16" x 1-1/4" lg. 44 700167 WELDMENT, Counterweight 1

700501 • BOLT, Hex-hd 1.00-8 x 3-3/4” lg. 3107948 • WASHER, Lock 1” 3700435 • WASHER, Flat 1” 3

5 102780 LATCH, Door R.H. 1111534 • KNOB, Latch 1103855 • BOLT, Hex-hd 1/4-20 x 1/2” lg. 1103864 • BOLT, Hex-hd 5/16-18 x 1” lg. 3103996 • WASHER, Flat 5/16” 3103404 • WASHER, Lock 5/16” 3

6 102781 LATCH, Door L.H. 1111534 • KNOB, Latch 1103855 • BOLT, Hex-hd 1/4-20 x 1/2” lg. 1103864 • BOLT, Hex-hd 5/16-18 x 1” lg. 3103996 • WASHER, Flat 5/16” 3103404 • WASHER, Lock 5/16” 3

7 700126 WELDMENT, Door latch bracket R.H. 1103887 • BOLT, Hex-hd 3/8-16 x 3/4” lg.” 2103996 • WASHER, Flat 5/16” 2103404 • WASHER, Lock 5/16” 2

8 700271 WELDMENT, Door latch bracket L.H. 1103887 • BOLT, Hex-hd 3/8-16 x 3/4” lg. 2103996 • WASHER, Flat 5/16” 2103404 • WASHER, Lock 5/16” 2

9 700275 WELDMENT, L.H. Door 110 700276 WELDMENT, R.H. Door 1

701468 WELDMENT, R.H. Door, Europe 111 700087 LINK, Door stop 2

103473 • BOLT, Hex-hd 3/8-16 x 1” lg. 2101297 • BOLT, Hex-hd 3/8-16 x 1-1/4” lg. 2103472 • WASHER, Flat 3/8” 2104606 • NUT, Hex 3/8” 2

12 700814 GUIDE, Main boom 213 700813 REST PAD, Main boom 2


NOTE: Items 12 and 13 are for machines withSerial Numbers 90046 and above. For machineswith Serial Numbers 90045 and below order PartNumber 700263, one per side.Parts list continued on Page 51.


IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.



MA-SJB-16

2426

25

23

27

22

21

20

19

18

17

16

15

14

1312

11

10

9

8

7

6

5

4

3

2

1



Parts list continued from page49.14 111135 PAD, Riser rest 2


15 700224 PUMP/MOTOR ASSEMBLY, Boom function 1700669 • PUMP, Hydraulic 1103073 • • FITTING, Elbow 90° #6orb-#6 1700524 • • FITTING, Hose barb 90° #12orb-#8 1103032 • • HOSE, 3/4” suction 4106052 • COUPLING 1700668 • MOTOR, 48 Volt 1109174 • BRUSH SET 1109175 • • SPRING, Brush 8103887 • • BOLT, Hex-hd 5/16-18 x 3/4” lg. 4103996 • • WASHER, Flat 5/16” 8103404 • • WASHER, Lock 5/16” 4700523 • • BUSHING, Rubber 4102972 • • CLAMP, Hose G-8 1103632 • • SCREW, Self tap. 1/4-14 x 3/4” lg. 1

16 (Ref.) MANIFOLD ASSEMBLY, Main 1 (For components, refer to Figure 6-22.)

103871 • BOLT, Hex-hd 3/8-16 x 1-3/4” lg. 4103999 • WASHER, Lock 3/8” 4103472 • WASHER, Flat 3/8” 4

17 700325 TANK ASSEMBLY, Hydraulic 1 (For components, refer to Figure 6-24.)


18 700149 PANEL ASSEMBLY, Electrical 1 (For components, refer to Figure 6-28.)


19 700213 PANEL ASSEMBLY, Sevcon 1 (For components, refer to Figure 6-28.)


20 700532 SWITCH, Tilt 1114866 • FUSE, 250 Volt, 1 amp 1103855 • BOLT, Hex-hd 1/4-20 x 1/2” lg. 4104000 • WASHER, Lock 1/4” 4

21 700445 WELDMENT, Electrical panel cover bracket 122 700475 PANEL COVER, Electrical 1

700624 • NUT, Wing 1/4-20 2103995 • WASHER, Flat 1/4” 2

23 700605 PROTECTOR, Cable 12” lg. 124 700160 SWITCH, Sealed limit (riser)” 1

700549 • BOLT, Soc-hd #10-32 x 3/4” lg. 2104694 • WASHER, Flat #10 2104185 • WASHER, Lock #10 2

25 102860 HORN, 24 Volt (OPTION) 126 701248 CABLE ASSEMBLY, Pump motor (pos) 127 701249 CABLE ASSEMBLY, Pump motor (neg) 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


2

1

3

4

5

6

7

8

9

10

11

12

14

15

17

8

16

16

17

4

8

MA-SJB-17a

FIGURE 6-21. MAIN MANIFOLD ASSEMBLY(Machines with Serial Number 90299 and above.)

13


FIGURE 6-21. MAIN MANIFOLD ASSEMBLY(Machines with Serial Number 90299 and above.)

701867 MANIFOLD ASSEMBLY, Main (MCD 5379) (Consists of items 1-14)

1 702753 • BLOCK, Main manifold 12 700677 • VALVE, Dump 13 702754 • COIL, 24 Volt 14 700672 • VALVE, Relief (turret rotate) 25 700763 • VALVE, Needle (emergency turret rotate) 16 700670 • VALVE, Counterbalance (platform tilt) 27 700682 • ORIFICE, .025 dia. (platform tilt) 18 700764 • PLUG, Soc-hd #2orb AR9 700765 • PLUG, Soc-hd #4orb AR10 700679 • ORIFICE, .100 dia. (jib lift) 111 104437 • PLUG, Soc-hd #6orb 312 700673 • VALVE, Relief (dump) 113 700680 • ORIFICE, .060 dia. (jib lift) 114 700682 • ORIFICE, .025 dia (platform rotate) 115 701861 VALVE ASSEMBLY, 24 Volt spool (steering) 1

702755 • COIL, 24 Volt with Internal Diode 2103918 • BOLT, Soc-hd #10-24 x 1-1/4” lg. 4

16 701860 VALVE ASSEMBLY, 24 Volt spool (lift functions) 7702755 • COIL, 24 Volt with Internal Diode 14103918 • BOLT, Soc-hd #10-24 x 1-1/4” lg. 28

17 103069 FITTING, Connector #6orb-#6 18

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

8

16

16

17

4

818 19

FIGURE 6-22. MAIN MANIFOLD ASSEMBLY(Machines with Serial Number 90298 and below.)

MA-SJB-17


FIGURE 6-22. MAIN MANIFOLD ASSEMBLY(Machines with Serial Number 90298 and below.)

A 700525 MANIFOLD ASSEMBLY, Main (MCD 4933)(Machines with Serial Number 90019 and above.)

B 700832 MANIFOLD ASSEMBLY, Main (MCD 4721)(Machines with Serial Number 90018 and below.)(Consists of items 1-14)

1 700671 • BLOCK, Main manifold, A 1700850 • BLOCK, Main manifold, B 1

2 700677 • VALVE, Dump, A 1700851 • VALVE, Dump, B 1

3 700684 • COIL, 24 Volt 14 700672 • VALVE, Relief (turret rotate), A 2

700852 • VALVE, Relief (turret rotate), B 15 700763 • VALVE, Needle (emergency turret rotate), A 1

700853 • VALVE, Needle (emergency turret rotate), B 16 700670 • VALVE, Counterbalance (platform tilt) 27 700682 • ORIFICE, .025 dia. (platform tilt) 1

(Located in the pressure port of the valve, accessible by removing valve.)

8 700764 • PLUG, Soc-hd #2orb AR9 700765 • PLUG, Soc-hd #4orb, A AR

700855 • PLUG, Soc-hd #5orb, B AR10 700679 • ORIFICE, .100 dia. (jib lift), A 111 104437 • PLUG, Soc-hd #6orb 312 700673 • VALVE, Relief (dump), A 113 700680 • ORIFICE, .060 dia. (jib lift), A 1

700856 • ORIFICE, .030 dia. (platform tilt, jib lift), B 214 700682 • ORIFICE, .025 dia (platform rotate) 115 103614 VALVE ASSEMBLY, 24 Volt spool (steering) 1

107439 • COIL, 24 Volt 2104409 • CONNECTOR, Black 1104345 • CONNECTOR, Gray 1103918 • BOLT, Soc-hd #10-24 x 1-1/4” lg. 4700866 VALVE, Crossover relief (not shown), B 1

16 700526 VALVE ASSEMBLY, 24 Volt spool (lift functions) 7107439 • COIL, 24 Volt 14107409 • CONNECTOR, Black 7107435 • CONNECTOR, Gray 7103918 • BOLT, Soc-hd #10-24 x 1-1/4” lg. 28

17 103069 FITTING, Connector #6orb-#6 1818 103272 FITTING, Elbow 90° #6orb-1/4 NPT 119 103246 FITTING, Quick coupler 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-23. HYDRAULIC TANK ASSEMBLY(Machines with Serial Number 90307 and above.)

2

1

3

4

5

6

7 8

9

702107 TANK ASSEMBLY, Hydraulic -1 702106 • WELDMENT, Hydraulic tank 12 702398 • WELDMENT, Hydraulic tank lid 1

103962 • • SCREW, Machine-hd #10-32 x 1/2” lg. 83 704488 • FILTER ASSEMBLY, Return 1

104254 • • ELEMENT, Filter 1103864 • • BOLT, Hex-hd 5/16-18 x 1” lg. 2103404 • • WASHER, Lock 5/16” 2100397 • • NUT, Hex 5/16-18 2

4 103339 • PLUG, Magnetic 3/4 NPT 15 103236 • GAUGE, Oil level temp 16 102693 • CAP W/ GASKET, Filler/breather 1

103962 • • SCREW, Mach-hd #10-32 x 1/2” lg. 37 102918 • HOSE, Tank 1” x 6" lg. 18 103320 • CLAMP, #16 Gear 19 102961 • LABEL, Use hydraulic oil 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

MA-SJB-18a


FIGURE 6-24. HYDRAULIC TANK ASSEMBLY(Machines with Serial Number 90306 and below.)

700325 TANK ASSEMBLY, Hydraulic -1 700326 • WELDMENT, Hydraulic tank 12 700457 • WELDMENT, Hydraulic tank lid 1

103962 • • SCREW, Machine-hd #10-32 x 1/2” lg. 143 704488 • FILTER ASSEMBLY, Return 1

104254 • • ELEMENT, Filter 1103864 • • BOLT, Hex-hd 5/16-18 x 1” lg. 2103404 • • WASHER, Lock 5/16” 2100397 • • NUT, Hex 5/16-18 2

4 103339 • PLUG, Magnetic 3/4 NPT 15 103236 • GAUGE, Oil level temp 16 102693 • CAP W/ GASKET, Filler/breather 1

103962 • • SCREW, Mach-hd #10-32 x 1/2” lg. 37 102918 • HOSE, Tank 1” x 6" lg. 18 103320 • CLAMP, #16 Gear 19 102961 • LABEL, Use hydraulic oil 1

2

1

3

4

5

6

7 8

9

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

MA-SJB-18


FIGURE 6-25. HYDRAULIC BRAKE MANIFOLD ASSEMBLY(Machines with Serial Number 90307 and above.)

706911 BRAKE MANIFOLD ASSEMBLY -1 ? • BLOCK, Brake manifold 12 701295 • VALVE, Check 13 701296 • VALVE, Pressure reducing 14 701297 • HAND VALVE, Brake release 15 701298 • SOLENOID VALVE, Brake 1

? • • COIL 16 700764 • PLUG, #2 SAE 107 700765 • PLUG, #4 SAE 58 701194 • PRESSURE SWITCH, Brake 19 103322 • FITTING, Connector #4orb-#6 3

10 103069 • FITTING, Connector #6orb-#6 111 704064 • FITTING, Street tee 1/4NPT 112 701458 • FITTING, Pipe nipple 1/4NPT 113 114520 • FITTING, Hydraulic disconnect 2

114521 • DUST CAP 214 701986 • COVER, Brake release 115 702005 • LABEL, Danger 116 703071 • FITTING, Adaptor #4 - 1/4 NPT 217 ? • SOLENOID VALVE, Brake 1

? • • COIL 1

CAUTION - Brake system under pressure. Bleed pressure before servicing.MA-WB-15

17

16

1514

13

12

11

10

9

8

7 6

5

4

3

21

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-26. SEVCON PANEL ASSEMBLY

700837 PANEL ASSEMBLY, Sevcon -1 700216 • PLATE, Base 12 700214 • CONTROLLER, Pump 1

701082 • • RESISTOR ASSEMBLY, 2.2k - 3w 13 700990 • CONTROLLER, Drive 14 102756 • FUSE, 200 Amp pump 15 700228 • FUSE, 300 Amp drive 16 700219 • CONTACTOR, Pump (boom control) 17 700218 • CONTACTOR, Directional 28 700222 • FUSE HOLDER, Double 1

110855 • • FUSE, AGC 10 29 108589 • RELAY, Sealed 40 Amp 110 700217 • TACHOMETER BOARD 1

701080 • • RESISTOR, 2.2 K 1700776 • • FUSE, 250 Volt, 6.3 Amp 1700777 • • FUSE, 250 Volt, 20 Amp 1

11 700991 • MOUNT PLATE, Tachometer board 112 701078 • LINE CONTACTOR 1

701081 • • RESISTOR ASSEMBLY, 1k - 5w 1701291 • BRAIDED CABLE, 10” lg. 1700220 • BRAIDED CABLE, 7” lg. 3700229 • BRAIDED CABLE, 5”” lg. 2701083 • CABLE ASSEMBLY, Line contactor to fuse 1

13 700963 CABLE/CONNECTOR ASSEMBLY 114 700925 HANDLE, Disconnect 1

10

11

12

13

2 1

34

5

6

7

8

9

MA-SJB-19

14

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


10

11

12

13

14

15

17

18

19

20

2122

23

24

2

1

3

4

5

6

7

8

9

FIGURE 6-27. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY(Machines with Serial Number 90307 and above.)

MA-SJB-20a

2516

26


FIGURE 6-27. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY(Machines with Serial Number 90307 and above.)

1 700106 PANEL, Base control/electrical 12 102853 SWITCH, Toggle 73 701445 PLUG, Hole 3/8” dia. 14 700158 BREAKER, 10 Amp circuit 25 108589 RELAY, 40 Amp sealed 2

103962 • BOLT, Mach-hd #10-32 x 1/2” lg. 2104694 • WASHER, Flat #10 2104185 • WASHER, Lock #10 2104003 • NUT, Lock #10-32 2

6 (Ref.) SWITCH ASSEMBLY, Emergency stop 1102769 • HEAD, Stop switch 1103225 • BLOCK, N.C. Contact 1103100 • BASE, Contact 1

7 (Ref.) SWITCH ASSEMBLY, Key select 1702395 • HEAD, 3-Position key select 1104466 • • KEY, #455 AR103100 • BASE, Contact 1103225 • BLOCK, N.C. Contact 1103141 • BLOCK, N.O. Contact 2

8 700159 PLUG, Hole 1-1/4” dia. (Machines without beeper) 19 103011 STRIP, Terminal block 3.2

103956 • BOLT, Mach-hd #6-32 x 1” lg. 7103985 • NUT, Hex #6-32 7

10 102921 DIODE, 6 Amp 1000 PIV 2411 700165 CABLE, 22Ga. Shielded x 98” lg. (tachometer) 112 103255 CORD, 18/4 x 72” lg. (tilt switch) 6 ft.13 103255 CORD, 18/4 x 48” lg. (brake) 4 ft.14 701868 WIRING HARNESS, Main manifold 1

700831 LIGHT KIT, Flashing (option) 1104535 • LIGHT, Flashing (Refer to Figure 6-12.)

15 108589 • RELAY, 40 Amp sealed 116 103267 • FLASHER, 24 Volt 117 103256 • CORD, 18/2 21 ft.18 102921 • DIODE, 6 Amp 1000 PIV 1

700496 HORN ASSEMBLY, 24 Volt (option) 119 108589 • RELAY, 40 Amp sealed 120 103256 • CORD, 18/2 8 ft.

102860 • HORN, 24 Volt 1700497 ALARM ASSEMBLY, Travel (option) 1

21 103057 • BEEPER, 24 Volt 222 102921 • DIODE, 6 Amp 1000 PIV 223 700190 CABLE ASSEMBLY, Control (Refer to Figure 6-12.) 124 108589 RELAY, 40 Amp sealed (leveling interlock) 125 108589 RELAY, 40 Amp sealed (8 meter drive cutout)26 700094 LABEL, Turret panel 1

708570 LABEL, Turret panel (European machine.) 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-28. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY(Machines with Serial Number 90306 and below.)

10

11

12

13

14

15

16

17

18

19

20

21

22

23

26

25

24

2

1

3

4

5

6

7

8

9

MA-SJB-20


FIGURE 6-28. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY(Machines with Serial Number 90306 and below.)

1 700106 PANEL, Base control/electrical 12 700156 CONTACTOR, Brake pump/motor 1


3 102853 SWITCH, Toggle 74 700157 BREAKER, 50 Amp Circuit 15 700158 BREAKER, 10 Amp Circuit 26 108589 RELAY, 40 Amp sealed 2


7 (Ref.) SWITCH ASSEMBLY, Emergency stop 1102769 • HEAD, Stop switch 1103225 • BLOCK, N.C. Contact 1103100 • BASE, Contact 1

8 (Ref.) SWITCH ASSEMBLY, Key select 1102753 • HEAD, 3-Position key select 1104466 • • KEY, #455 AR103100 • BASE, Contact 1103225 • BLOCK, N.C. Contact 1103141 • BLOCK, N.O. Contact 2

9 700159 PLUG, Hole 1-1/4”dia. (Machines without beeper) 110 103011 STRIP, Terminal block 3.2

103956 • BOLT, Mach-hd #6-32 x 1” lg. 7103985 • NUT, Hex #6-32 7

11 102921 DIODE, 6 Amp 1000 PIV 2312 700165 CABLE, 22Ga. Shielded x 98” lg. (tachometer) 113 103255 CORD, 18/4 x 72” lg. (tilt switch) 6 ft.14 103257 CORD, 18/3 x 133” lg. (brake) 11 ft.15 700396 WIRING HARNESS, Main manifold 116 700166 • DIODE, 1 Amp 400 PIV 17

700831 LIGHT KIT, Flashing (option) 1104535 • LIGHT, Flashing (Refer to Figure 6-12.)

17 108589 • RELAY, 40 Amp sealed 118 103267 • FLASHER, 24 Volt 119 103256 • CORD, 18/2 21 ft.20 102921 • DIODE, 6 Amp 1000 PIV 1

700496 HORN ASSEMBLY, 24 Volt (option) 121 108589 • RELAY, 40 Amp sealed 122 103256 • CORD, 18/2. 8 ft.

102860 • HORN, 24 Volt 1700497 ALARM ASSEMBLY, Travel (option) 1

23 103057 • BEEPER, 24 Volt 224 102921 • DIODE, 6 Amp 1000 PIV 125 700190 CABLE ASSEMBLY, Control (Refer to Figure 6-12.) 126 108589 RELAY, 40 Amp sealed (leveling interlock) 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


10

11 12

13

14

15

16

17

18

19

20

2122

23

30

29

28

27

26

25

24

2

1

3

4

5

6

7

8

9

31

32

FIGURE 6-29. BASE, AXLES AND WHEELS

MA-SJB-21

33



1 700000 WELDMENT, Base 12 103216 BUSHING, 1-1/2” x 1-11/16" x 1-1/2" lg. AR

100904 BUSHING, 1-1/2” x 1-11/16" x 1" lg. (Not shown) 4 (Machines with Serial Number 90065 and below)

3 700049 PLATE, 110V outlet 1103855 • BOLT, Hex-hd 1/4-20 x 1/2” lg. 4104000 • WASHER, Lock 1/4” 4

4 700047 PLATE, Brake cover 1700474 • SCREW, Thumb 3/8-16 x 3/4” lg. 4

5 700285 BRAKE ASSEMBLY, Hydraulic 1 (Machines with Serial Number 90306 and below.) (For components, refer to Figure 6-30.)

103887 • BOLT, Hex-hd 5/16-18 x 1” lg. 2103404 • WASHER, Lock 5/16” 2

6 700985 SPINDLE ASSEMBLY, R.H. 1700056 • WELDMENT, Front spindle R.H. 1100309 • BUSHING, 1” x 1-1/4" x 1" lg. 1

7 700986 SPINDLE ASSEMBLY, L.H. 1700057 • WELDMENT, Front spindle L.H. 1100309 • BUSHING, 1” x 1-1/4" x 1" lg. 1

8 700463 HUB ASSEMBLY, Front 2700464 • HUB, Front 2700471 • BEARING, Inner 2700469 • BEARING, Outer 2700466 • SEAL, Grease 2700467 • CAP, Dust 2102646 • WASHER, Flat 2104351 • NUT, Castle 1” 2700508 • PIN, Cotter 3/16 x 2” lg. 2

9 700291 PIN, Spindle king 2103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 2103404 • WASHER, Lock 5/16” 2

10 700262 BEARING, Thrust 211 700293 WELDMENT, Tie bar 112 700297 PIN, Tie bar 2

103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 2103404 • WASHER, Lock 5/16” 2

13 700299 CYLINDER ASSEMBLY, Steering 2 (For components, refer to Figure 6-32.)

14 700312 PIN, Steering cylinder outer 2103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 2103404 • WASHER, Lock 5/16” 2

15 700409 PIN, Steering cylinder inner 2103887 • BOLT, Hex-hd 5/16-18 x 3/4” lg. 2103404 • WASHER, Lock 5/16” 2

16 700314 SPACER, Steering cylinder pin 817 700315 AXLE ASSEMBLY, Rear drive 1

(For components, refer to Figure 6-37.)Parts list continued on page 67.

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


10

11 12

13

14

15

16

17

18

19

20

2122

23

30

29

28

27

26

25

24

2

1

3

4

5

6

7

8

9

31

32

33


MA-SJB-21



IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

Parts list continued from page 65.18 700144 PLATE, Axle mounting 2

704844 • BOLT, HHCS 3/4-10 x 8” lg. 8700575 • NUT, Lock 3/4-10 8

19 WHEEL/ TIRE ASSEMBLY 4706863 (27 x 7.50 x 15 Foam Filled) (Machines with S/N 90631 and Above)700465 (28 x 7.00 x 15 Foam Filled) (Machines with S/N 90630 and Below)703660 (27 x 7.50 x 15 Solid Non-marking) (Late machines)701787 (28 x 7.00 x 15 Solid Non-marking) (Early machines)

20 700316 MOTOR, Turret rotate 1103307 • FITTING, Adaptor #10 orb-#6 2103907 • BOLT, Hex-hd 1/2-13 x 1-1/2” lg. 2107964 • WASHER, Lock 1/2” 2

21 700317 GEAR ASSEMBLY, Turret rotate 1700500 • BOLT, Soc-hd, 5/8-11 x 4-1/2” lg. 20100352 • WASHER, Flat 5/8” 40

22 (Ref.) BATTERY CHARGER ASSEMBLY 1 (For components, refer to Figure 6-34.)


23 700237 COVER, Battery charger 1103983 • NUT, Hex 1/4-20 4103995 • WASHER, Flat 1/4” 4104000 • WASHER, Lock 1/4” 4

24 (Ref.) TRAY ASSEMBLY, Battery - (For components, refer to Figure 6-33.)

700517 • PIN, Linch 5/16 425 105271 PLUG, 110V Recessed 1

700519 • SCREW, #6 Self-tapping 2113227 • PROTECTOR BOOT, Rubber 1

26 700521 PROTECTOR, Cable 8” lg. (Cut length of 104127.) 127 700604 PROTECTOR, Cable 2” lg. (Cut length of 104127.) 128 102600 SWITCH, Circuit disconnect (S/N 90306 and below) 129 108714 LEVER KIT, Locking (S/N 90306 and below) 1

103964 • SCREW, Mach-hd #10-32 x 1/4” lg. 2104185 • WASHER, Lock #10 2

30 700160 SWITCH, Sealed limit (turret) 1700549 • BOLT, Soc-hd #10-32 x 3/4” lg. 2104694 • WASHER, Flat #10 2104185 • WASHER, Lock #10 2

31 700468 BOLT, Wheel 5/8-18x1-1/2” lg. 12100352 • WASHER, Flat 5/8” (hardened) 12

32 700498 NUT, Wheel 18MM-1.5 1233 (Ref.) ASSEMBLY, Grease zerk 1

703099 • FITTING, Pipe 1/8 NPT x 3 1/2” lg. 1703100 • FITTING, Coupling 1/8 NPT 1703101 • FITTING, Grease zerk 1/8 NPT 45° 1


NOTES


FIGURE 6-30. HYDRAULIC BRAKE ASSEMBLY(Machines with Serial Number 90306 and below.)

700285 BRAKE ASSEMBLY, Hydraulic -1 700037 • BRACKET, Brake mounting 1

700225 • PUMP/MOTOR ASSEMBLY 12 700675 • • MOTOR, Brake 1

103473 • • • BOLT, 3/8-16 x 1” lg. 2103999 • • • WASHER, Lock 3/8” 2

3 700674 • • PUMP, Brake hydraulic 14 700542 • • SWITCH, Hydraulic pressure 15 700676 • • VALVE, Brake 16 103605 • • COIL, 24 Volt 17 700683 • • VALVE, Relief 18 700286 • WELDMENT, Brake reservoir 19 700507 • FITTING, Adaptor #8-#6 110 700506 • PLUG, Breather 111 700113 • MANIFOLD BLOCK, Brake 1

103857 • • BOLT, 1/4-20 x 1” lg. 2104000 • • WASHER, Lock 1/4” 2

12 113752 • PLUNGER, Brake override 113 110652 • HAND PUMP, Brake release 114 700484 • VALVE, Adjustable relief 115 103069 • FITTING, Connector #6orb-#6 216 103073 • FITTING, Elbow 90° #6orb-#6 317 104660 • FITTING, Tee #6orb-#6-#6 118 107232 • FITTING, Reducer #6-#4 1

18

17

16

15

14

13

12

11

109

8

7

6 5

4

3

2

1

16

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

MA-SJB-22


FIGURE 6-31. HYDRAULIC HOSE CONNECTIONS - Brake(Machines with Serial Number 90306 and below.

13

12

11

10

9

8

7

6

5

4

3

2

1

MA-SJB-23


FIGURE 6-31. HYDRAULIC HOSE CONNECTIONS - Brake(Machines with Serial Number 90306 and below.

1 700286 WELDMENT, Brake reservoir 1 (Refer to Figure 6-25.)

2 700674 PUMP, Brake hydraulic 1 (Refer to Figure 6-25.)

3 700542 SWITCH, Hydraulic pressure 1 (Refer to Figure 6-25.)

4 700287 HOSE ASSEMBLY, Brake reservoir to manifold 15 700289 HOSE ASSEMBLY, Brake pump to manifold 16 700113 MANIFOLD BLOCK, Brake 1

(Refer to Figure 6-25.)7 700290 HOSE ASSEMBLY, Brake manifold to L.H. brake 18 700288 HOSE ASSEMBLY, Brake manifold to R.H. brake 19 107232 FITTING, Reducer #6-#4 110 104660 FITTING, Tee #6orb-#6-#6 111 103073 FITTING, Elbow 90° #6orb-#6 312 103069 FITTING, Connector #6orb-#6 213 700507 FITTING, Adaptor #8-#6 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


MA-SJB-24

700299 CYLINDER ASSEMBLY, Steering -1 700300 • WELDMENT, Cylinder barrel 12 700305 • WELDMENT, Cylinder rod 13 700308 • GLAND, Cylinder 14 700309 • PISTON, Cylinder 15 700310 • SPACER, Cylinder 1*6 106449 • WIPER, Rod 1*7 701963 • O-RING, Gland 1*8 701634 • O-RING, Piston 1*9 108798 • SEAL, Gland 1*10 104661 • SEAL, Piston 111 103830 • NUT, Lock 5/8-11 Grade C 1

700451 KIT, Seal repair AR12 102025 BEARING, Sherical 213 104114 RING, Retaining 414 700510 NIPPLE, Grease 1/8NPT - 90° 2


14

13

12

11

10

9

8

7

6

5

4

3

2

1

FIGURE 6-32. STEERING CYLINDER ASSEMBLY

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-33. BATTERY TRAY ASSEMBLY

1 700083 WELDMENT, Battery tray 22 700460 WELDMENT, Battery tray lid 2

700474 • SCREW, Thumb 3/8-16 x 3/4” lg. 43 700246 TRAY LINER, Battery (plywood) 24 700076 LID LINER, Battery tray (styrene) 25 700193 BATTERY, 6 Volt 350AH 86 700753 CABLE ASSEMBLY, Battery jumper 67 700754 CABLE ASSEMBLY, Battery tray crossover 18 700755 CABLE ASSEMBLY, Battery charger 1

103364 • CONNECTOR, Charger 50 Amp 19 703831 CABLE/CONNECTOR ASSEMBLY 1

(Machines with Serial Number 90100 and above.)700540 • HOUSING, Connector 1701008 • CONTACT TIP, 2/0 2701001 • CABLE, 2/0 AR(Ref.) CABLE/CONNECTOR ASSEMBLY 1

(Machines with Serial Number 90099 and below. To700541 replace entire assembly order Part Number 701727.) 2700476 • CONTACT TIP, 2 Ga. wire 2104533 • BUSHING, 2 Ga. wire AR

• CABLE, 2 Ga.

98

7 6 5

4

3

2

1

MA-SJB-25

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-34. BATTERY CHARGER ASSEMBLY

MA-SJB-26

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7 6

5

4

32

1


FIGURE 6-34. BATTERY CHARGER ASSEMBLY

A 700302 CHARGER ASSEMBLY, Battery (BA821)(North - American) 48VDC, 25A, 120VAC, 60 Hz

B 700870 CHARGER ASSEMBLY, Battery (BA842)(Europe) 48VDC, 25A, 220VAC, 50/60 Hz

1 108554 • AMMETER, 0-30 12 700685 • CAPACITOR, A 1

700877 • CAPACITOR, B 13 700686 • CORD, D.C. 1

103364 • • PLUG, 50 Amp 14 108556 • DIODE, 70 Amp 25 108558 • HOLDER, Fuse 16 700687 • HOLDER ASSEMBLY, Fuse 17 111905 • FUSE, 45 Amp NON 18 700688 • FUSE, A.C. 25 Amp 19 700689 • RECTIFIER ASSEMBLY, A 1

700878 • RECTIFIER ASSEMBLY, B 110 700690 • STRAIN RELIEF 111 108562 • TRIAC 112 700691 • TRANSFORMER, A 1

700879 • TRANSFORMER, B 113 108564 • TRANSFORMER, Control 114 700692 • VARISTOR, A 1

700880 • VARISTOR, B 115 700701 • CONTROL CIRCUIT, 48VDC/120VAC 116 $ • BASE, Charger 117 $ • COVER, Charger 118 $ • FOOT, Charger 219 110857 • STOP SWITCH, Charger stop 120 700530 CABLE ASSEMBLY, Charger A.C., A 1

700635 • PLUG, 15A Male 1700597 • RECEPTACLE, 20 Amp Female 1105269 • CABLE, 14/3 8”105807 • LANYARD, 6” lg 1

21 701236 RELAY, Charger interlock 1700913 CABLE ASSEMBLY, Charger A.C., B (not shown) 1700914 • PLUG, Male 1108561 • STRAIN RELIEF 1700915 SWITCH, 50/60 Hz, B (not shown) 1

$ Consult factory.

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-35. HYDRAULIC HOSE CONNECTIONS - Turret/Base(Machines with Serial Number 90307 and above)

MA-SJB-27a

10

11

12

13

14

15

16

17

18

19

20

21

2223

29

28

27

26

25

24

2

1

3

4

5

6

7

8

9

14

14

14

16

12

17


1 (Ref.) TANK COVER, Hydraulic 1 (Refer to Figure 6-23.)

2 102854 CLAMP, Gear #12 23 103032 HOSE, Suction 4”4 700322 HOSE ASSEMBLY, Manifold to tank (return) 15 700524 FITTING, Adaptor #12-3/4” hose barb 16 700321 HOSE ASSEMBLY, Manifold to hydraulic pump 17 700320 HOSE ASSEMBLY, Manifold to turret rotate motor 28 700669 PUMP, Hydraulic 19 700316 MOTOR, Turret rotate 110 103307 FITTING, Reducer #10orb-#6 211 (Ref.) MANIFOLD ASSEMBLY, Main 1

(For components refer to Figure 6-22)12 103069 FITTING, Connector #6orb-#6 1113 700324 HOSE ASSEMBLY, Manifold to steering cylinders 214 700311 HOSE ASSEMBLY 515 700299 CYLINDER ASSEMBLY, Steering 2

(For components refer to Figure 6-32)16 103073 FITTING, Elbow 90° #6orb-#6 417 103072 FITTING, Tee #6orb-#6-#6 318 700328 CYLINDER ASSEMBLY, Riser 1

(For components refer to Figure 6-14)19 700323 HOSE ASSEMBLY, Manifold to riser cylinder 220 109052 FITTING, Connector #12orb-#6 121 (Ref.) MANIFOLD ASSEMBLY, Brake 1

(For components, refer to Figure 6-25.)22 702383 HOSE ASSEMBLY, Brake manifold to tank 123 702381 HOSE ASSEMBLY, Brake manifold to axle 124 700903 ACCUMULATOR, Brake pressure 125 103322 FITTING, Connector #4orb - #6 326 702382 FITTING, Tee #6 female - #6 127 700817 FITTING, Connector #14orb - #6 228 702761 FITTING, Elbow 90° #6 female - #6 129 103070 FITTING, Connector #8 - #6 1

FIGURE 6-35. HYDRAULIC HOSE CONNECTIONS - Turret/Base(Machines with Serial Number 90307 and above)

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-36. HYDRAULIC HOSE CONNECTIONS - Turret/Base(Machines with Serial Number 90306 and below)

MA-SJB-27

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

32

1

16


FIGURE 6-36. HYDRAULIC HOSE CONNECTIONS - Turret/Base(Machines with Serial Number 90306 and below)

1 (Ref.) TANK COVER, Hydraulic 1 (Refer to Figure 6-24.)

2 102854 CLAMP, Gear #12 23 103032 HOSE, Suction 4”4 700322 HOSE ASSEMBLY, Manifold to tank (return) 15 700524 FITTING, Adaptor #12-3/4”” hose barb 16 700321 HOSE ASSEMBLY, Manifold to hydraulic pump 17 700320 HOSE ASSEMBLY, Manifold to turret rotate motor 28 700669 PUMP, Hydraulic 19 700316 MOTOR, Turret rotate 110 103307 FITTING, Reducer #10orb-#6 211 (Ref.) MANIFOLD ASSEMBLY, Main 1

(For components refer to Figure 6-22)12 103069 FITTING, Connector #6orb-#6 1013 700324 HOSE ASSEMBLY, Manifold to steering cylinders 214 700311 HOSE ASSEMBLY, Steering cylinder cross over 215 700299 CYLINDER ASSEMBLY, Steering 2

(For components refer to Figure 6-32)16 103073 FITTING, Elbow 90° #6orb-#6 317 103072 FITTING, Tee #6orb-#6-#6 218 700328 CYLINDER ASSEMBLY, Riser 1

(For components refer to Figure 6-14)19 700323 HOSE ASSEMBLY, Manifold to riser cylinder 220 109052 FITTING, Connector #12orb-#6 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-37. DRIVE AXLE ASSEMBLY

MA-SJB-29

7

6

54

3

2

1


FIGURE 6-37. DRIVE AXLE

700315 AXLE ASSEMBLY, Drive -1 703846 • DRIVE AXLE (Haessler) 1

(For components, refer to Figure 6-38.)701052 • DRIVE AXLE (Sige) 1

(For components, refer to Figure 6-39.)2 701046 • PLANITARY ASSEMBLY 1

(For components, refer to Figure 6-40 and 6-41.)701054 • • BOLT, Hex-hd 8mm-1.25 x 40mm lg. 8701055 • • NUT, Hex 8mm-1.25 8701056 • • WASHER, Lock 8mm 8

3 701007 • MOTOR, Traction, 9”-20 HP 1103899 • • BOLT, Hex-hd 5/8-11 x 1-3/4” lg. 4103998 • • WASHER, Lock 5/8” 4

4 700069 • ADAPTOR PLATE, Tachometer 1103886 • • BOLT, Hex-hd 5/16-18 x 1-1/2” lg. 4103404 • • WASHER, Lock 5/16” 4

5 700487 • COUPLER, Tachometer (rubber) 16 700081 • COUPLER, Tachometer (steel) 17 700227 • GENERATOR, Tachometer 1

700515 • • SCREW, Machine #2-56 x 3/8” lg. 3700516 • • WASHER, Lock #2 3701244 CABLE ASSEMBLY, 46”” A1 terminal 1701245 CABLE ASSEMBLY, 40”” S1 terminal 1701246 CABLE ASSEMBLY, 44”” S2 terminal 1701247 CABLE ASSEMBLY, 52”” A2 terminal 1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-38. DRIVE AXLE (Haessler)(Machines with Serial Number 90409 and above, except for 90415 and 90416)

15 14

13

12

11

10

98

7

65

43

2

1

24

25

23

22

21

20

19

18

17

16

30

31

32

2928

26

27

333435

36

37

26

27

2627

61

65

63

62

60

64

59

58

5756

55

54

53

5251

5049

48

47

46

45

444342

41

40

39

38

82

67 68

69

66

70

71

72

73

74

8180

79

78

7776

75

45

MA-SJB-31


704439 AXLE, Drive (Haessler) -1 900002 SEAL, Radial 12 900001 HOUSING, Sun wheel 13 900016 BOLT, Soc-hd 64 900003 CIRCLIP 15 900004 BEARING, Sealed ball 16 900005 CIRCLIP 17 900006 WHEEL, Sun 18 900009 CIRCLIP 29 900010 WASHER, Thrust 4

10 900007 WHEEL, Planetary 211 900011 ROLLERS, Needle 5612 900014 DISK, Planetary 113 900015 CIRCLIP 114 900013 BOLT, Planetary 215 900018 NUT, Lock 116 900076 WASHER, Lock 117 900019 BEARING, Taper roller 118 900012 SEAL, O-ring 219 900008 GEAR, Ring 120 900017 HOUSING, Pinion 121 900025 BOLT, Soc-hd 622 900024 SEAL, O-ring 123 900022 BEARING, Taper roller 124 900020 GEAR, Pinion 124 900021 GEAR, Ring 125 900023 SHIM 426 900071 PLUG, Hex socket 427 900072 RING, Sealing 428 900077 VENT, Breather 129 900026 HOUSING, Differential 130 900029 SHIM SET 131 900028 BEARING, Taper roller 232 900030 BOLT, Soc-hd 1233 900027 DIFFERENTIAL 134 900031 COVER, Differential 235 900033 HOUSING, Brake 236 900051 BOLT, Soc-hd 2237 900154 SHIM 238 900054 SEAL, Radial 239 900052 BEARING, Sealed ball 240 900063 SHIM SET 141 900155 STUD, Wheel 1242 900057 FLANGE 243 900053 BEARING, Sealed ball 244 900056 BUSHING, Spacer 2

45 Ref. PLANETARY ASSEMBLY, Torque hub900059 • FLANGE, Ring gear 2900064 • WHEEL, Sun 2900065 • WHEEL, Planetary 6900066 • GEAR, Ring 2

46 900067 CIRCLIP 247 900058 BOLT, Soc-hd 1648 900062 CAP, Housing 249 900156 NUT, Wheel 1250 900070 BOLT, Flat-hd 651 900219 PLUG, Frost 252 900036 ACTUATOR, Brake 453 900034 DISK, Brake friction 854 900035 DISK, Brake stator 455 900161 CIRCLIP, Brake bolt 456 900158 BOLT, Brake link 457 900157 LINK, Brake 458 900040 PULLROD, Brake 259 900044 NUT, Lock 260 900038 WASHER 261 900037 PIN, Clevis 262 900039 PIN, Cotter 263 900074 PIN, Torque 664 900041 SPRING, Disk 3265 900042 PISTON, Spring 266 900043 WASHER SET, Spherical 267 900045 PISTON, Brake 268 900046 SEAL, Brake piston 269 900047 CAP, Brake housing 270 900048 BOLT, Soc-hd 871 900032 SHAFT, Axle 272 900061 CIRCLIP 273 900159 SPRING, Brake 474 900049 SEAL, O-ring 275 900078 CIRCLIP 676 900079 SHAFT, Planetary 677 900069 WASHER, Thrust 1278 900068 ROLLERS, Needle 10279 900060 SEAL, O-ring 280 900162 BALL, Precision 681 900160 AXLE TUBE 282 900055 BEARING, Sealed ball 2

FIGURE 6-38. DRIVE AXLE (Haessler)(Machines with Serial Number 90409 and above, except for 90415 and 90416)

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-39. DRIVE AXLE Machines with Serial Number 90408 and below)

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

21

7

7

MA-SJB-30


FIGURE 6-39. DRIVE AXLE (Sige) (Serial Number 90408 and below)

1 701836 RETAINING NUT, Pinion lock 12 701837 OIL SEAL, Pinion shaft 13 701838 OIL SEAL SPACER, Pinion shaft 14 701839 O-RING, Pinion shaft 15 701848 O-RING, Pinion flange 16 701851 O-RING, Breather plug 17 701843 WASHER, Oil plug gasket 58 701844 WASHER, Brake plug gasket 29 701852 O-RING, Fail safe brake 210 701890 O-RING, Fail safe brake housing AR11 701853 BELLOWS, Brake 212 701845 ACTUATOR, Brake 213 701846 BRAKE DISK, Intermediate 414 701847 BRAKE DISK 815 701840 AXLE SHAFT 216 701808 OIL SEAL, Wheel flange 217 701889 DUST COVER, Wheel flange 218 701888 WEAR RING, Oil seal 219 701809 O-RING, Wheel flange 220 702003 COVER, Torque hub 221 703045 COVER, Brake housing 2

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-40. PLANETARY REDUCTION GEAR ASSEMBLY (Brevini)A Brevini gear assembly WILL have a Model Number Plate riveted to the side of the output housing.

MA-WB-18a

1 701841 LIP SEAL, Output housing 12 $ HOUSING, Output 13 701849 O-RING SEAL 24 $ RING GEAR 15 $ HOUSING, Input 16 701942 O-RING SEAL, Input adapter 17 701842 LIP SEAL, Input adapter 18 701030 HOUSING, Input adapter 1

$ Consult factory

8

7

6

5

4

3

2

1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


FIGURE 6-41. PLANETARY REDUCTION GEAR ASSEMBLY (Benevelli)A Benevelli gear assembly will NOT have a Model Number Plate.

MA-WB-18b

1 701960 LIP SEAL, Output housing 12 $ HOUSING, Output 13 701961 O-RING SEAL 34 $ RING GEAR 15 $ HOUSING, Input 16 701962 LIP SEAL, Input adapter 17 $ HOUSING, Input adapter 1

$ Consult factory

7

6

5

4

3

2

1

IndexNo.

SkyjackPart No.

Description

1 2 3 4 5 6 7

Unitsper

Assy.


700816 707991 707646 707409 708589 707993 707420 708675 708742 KIT, Service labels and nameplates - (Consists of items 1-26.)

1 700026 707429 707495 702973 708042 707561 700026 708109 708176 • LABEL, Danger 12 700028 708569 708567 708566 708575 708568 707734 708576 708577 • LABEL, Design standards 13 700032 707433 707499 702983 708046 707565 700032 708113 708180 • LABEL, Attached safety belt (large) 14 700035 707435 707501 702978 708048 707567 700035 708115 708182 • LABEL, Annual inspection 15 700473 707439 707505 702981 708052 707571 700473 708119 708186 • LABEL, Check battery level daily (on battery tray lid) 26 700107 707437 707503 702964 708050 707569 700107 708117 708184 • LABEL, Attach safety belt (small) 27 700108 707438 707504 702980 708051 707570 700108 708118 708185 • LABEL, Do not lift here 28 700551 707440 707506 702984 708053 707572 700551 708120 708187 • LABEL, Warning hazards 29 110333 707427 707493 702965 708040 707559 110333 708107 708174 • LABEL, AC supply (on plate below outlet) 1

10 108666 707426 707492 702975 708039 707558 108666 708039 708173 • LABEL, Use original parts 111 106691 707424 707490 702977 708037 707556 106691 708104 708171 • LABEL, Operators checklist 112 700029 707431 707497 702976 708044 707563 700029 708111 708178 • LABEL, Tie down 213 106705 707425 707491 702963 708038 707557 106705 708105 708172 • LABEL, Do not alter 314 701086 707443 707509 702962 708056 707575 701086 708123 708190 • LABEL, Jib emergency lowering 115 701114 707445 707511 702961 708058 707577 701114 708125 708192 • LABEL, Manual rotate valve (on turret vertical plate near manual rotate valve.) 116 701111 707444 707510 702967 708057 707576 701111 708124 708191 • LABEL, Manual brake release (S/N 90307 and above)(on turret vertical plate near brake release) 1

113846 • LABEL, Manual brake release (S/N 90306 and below)(on turret vertical plate near brake release) 117 700033 707434 707500 702966 708047 707566 700033 708114 708181 • LABEL, Lead warning 118 701085 707442 707508 702974 708055 707574 701085 708122 708189 • LABEL, Charger 119 700031 707432 707498 702979 708045 707564 700031 708112 708179 • LABEL, Capacity 500 lbs. 220 700096 707446 707512 706726 708059 707578 701469 708126 708193 • LABEL, Emergency lowering 221 117294 707428 707494 706860 708041 707560 117294 708108 708175 • LABEL, Manual enclosed (Manual Enclosure) 122 702005 707451 707517 702969 708064 707583 702005 708131 708198 • LABEL, Danger brake release (on turret vertical plate near brake release) 123 703727 707472 707538 706257 708084 707604 703727 708151 708218 • LABEL, ATF only (on hydraulic tank) 124 701814 707450 707516 702968 708063 707582 701814 708130 708197 • LABEL, Main disconnect (S/N 90307 and above) 1

700027 • LABEL, Main disconnect (on plate above switch)(S/N 90306 and below.) 125 707447 707513 702972 708060 707579 701470 708127 708194 • LABEL, Knob location Europe (on turret vertical plate near knob) 126 117023 117023 117023 117023 117023 117023 117023 117023 • LABEL, CE Approval 327 700025 700025 700025 700025 700025 700025 700025 700025 700025 LABEL, Skyman 228 102631 102631 102631 102631 102631 102631 102631 102631 102631 LABEL, Skyjack 429 708016 708016 708016 708016 708016 708016 708016 708016 708016 LABEL, Made in USA 230 103125 103125 103125 103125 103125 103125 103125 103125 103125 LABEL, Blue/white striping 389”31 700034 700034 700034 700034 700034 700034 700034 700034 700034 LABEL, SJKB-33N 232 700030 700030 700030 700030 700030 700030 700030 700030 700030 LABEL, Serial number nameplate (Consult factory) 133 700093 701472 701472 701472 701472 701472 701472 701472 701472 LABEL, Control box 134 700094 708570 708570 708570 708570 708570 708570 708570 708570 LABEL, Electrical panel 135 708838 708836 708835 708839 708837 707736 708840 708841 LABEL, European load 1

FIGURE 6-42. LABELS AND NAMEPLATES

IndexNo.

EnglishLabels

Description

1 2 3 4 5 6 7

Unitsper

Assy.

DutchLabels

FrenchLabels

GermanLabels

PortugueseLabels

SpanishLabels

EnglandLabels

DanishLabels

SwedishLabels


FIGURE 6-42. LABELS AND NAMEPLATES

15

25

12

14

20

13

31

27

17

1912

1110

9

26 28

30

18

8

7

633

5

4

3

2

13

1

27

32

24

26

19

28

30

317

263413

208

16

MA-SJB-28

23

22

21

29

27

29

35


NOTES

Documents

OPERATING MAINTENANCE & PARTS MANUAL · 2018. 10. 3. · ANSI/SIA (United States) You are required by ANSI/SIA A92.5 -1992 to read and understand YOUR RESPONSIBILITIES in the Manual