Professional Documents
Culture Documents
Service Manual
SJIII Conventional Series (CE)
Section 3 - Schematics
Table of Contents
Section 4 - Troubleshooting
Table of Contents
Section 5 - Procedures
Table of Contents
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.
IMPORTANT
IMPORTANT indicates a procedure essential for safe operation and which,
if not followed, may result in a malfunction or damage to the aerial platform.
Table of Contents
Operators Responsibility for Maintenance
Aerial Platform Definition...............................................................................................................................................7
Purpose of Equipment..................................................................................................................................................7
Use of Equipment.........................................................................................................................................................7
Manuals.........................................................................................................................................................................7
Service Policy and Warranty.........................................................................................................................................7
Optional Accessories....................................................................................................................................................7
Operator Safety Reminders..........................................................................................................................................8
Electrocution Hazard....................................................................................................................................................8
Safety Precautions........................................................................................................................................................9
Maintenance and Inspection Schedule......................................................................................................................12
Owners Annual Inspection Record............................................................................................................................12
Replacement Parts......................................................................................................................................................12
Maintenance and Service Safety Tips........................................................................................................................12
Hydraulic System & Component Maintenance and Repair.......................................................................................13
Maintenance Hints......................................................................................................................................................13
Scheduled Maintenance
1.1 Scheduled Maintenance Inspections...............................................................................................................18
1.2 Function Tests..................................................................................................................................................25
Tables
1.1 Owners Annual Inspection Record.................................................................................................................16
1.2 Maintenance and Inspection Checklist............................................................................................................17
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications and
dimensions are subject to change without notice.
Purpose of Equipment
The SKYJACK SJIII Compact and Conventional series aerial platforms are designed to transport and raise personnel,
tools and materials to overhead work areas.
Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level,
compacted surface.
Manuals
Operating
The operating manual is considered a fundamental part of the aerial platform. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the aerial platform at all times.
All information in this manual should be read and understood before any attempt is made to service the machine.
The updated copy of the manuals are found on the companys website: www.skyjack.com.
Optional Accessories
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under Standard
and Optional Features in Table2.1 of the Operating Manual. Operating instructions for these options (if equipped)
are located in section2 of the operating manual.
For options not listed under Standard and Optional Features, contact the SKYJACK Service Department at
( : 44-1691-676-235
7 : 44-1691-676-238
Include the model and serial number for each applicable aerial platform.
Equipment identified with CE meets the requirements for the European countries, i.e., Machinery Directive
2006/42/EC and Directive 2004/108/EC and the corresponding EN standards.
b. Operators are required to conform to national, state or territorial/provincial and local health and safety regulations
applicable to the operation of this aerial platform.
WARNING
Failure to comply with your required responsibilities in the use and operation of the aerial platform
could result in death or serious injury!
You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this aerial platform
is mandatory. The following pages of this manual should be read and understood completely before operating the
aerial platform.
Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety
devices to protect your eyes, ears, hands, feet and body.
Any modifications from the original design are strictly forbidden without written permission from SKYJACK.
Electrocution Hazard
This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from energized
power lines and parts as listed below. The operator must allow for the platform to sway, rock or sag. This aerial
platform does not provide protection from contact with or proximity to an electrically charged conductor.
DANGER
Avoid Power Lines
Adhere strictly to the governmental rulings and regulations applicable in your country.
Safety Precautions
Know and understand the safety precautions before going on to next section.
WARNING
Failure to heed the following safety DO NOT increase the lateral
precautions could result in tip over, surface area of the platform.
falling, crushing, or other hazards leading Increasing the area exposed
to death or serious injury. to the wind will decrease aerial
platform stability.
KNOW all national, state or territorial/provincial
and local rules which apply to your aerial platform
and jobsite. DO NOT drive or elevate the
aerial platform if it is not on a
TURN main power disconnect switch off firm level surface. Do not drive
when leaving the aerial platform unattended. Re- elevated near depressions
move the key to prevent unauthorized use of the or holes of any type, loading
aerial platform. docks, debris, drop-offs and
surfaces that may affect the
WEAR all the protective clothing and personal stability of the aerial platform.
safety devices issued to you or called for by job
conditions.
If operation in areas with
DO NOT wear loose clothing, holes or drop-offs is abso-
dangling neckties, scarves, lutely necessary, elevated
rings, wristwatches or other driving shall not be allowed.
jewelry while operating this Position the aerial platform
lift. horizontally only with the
DO NOT operate on surfaces not capable of DO NOT raise the aerial platform
holding the weight of the aerial platform including while the aerial platform is on a
the rated load, e.g. covers, drains, and trenches. truck, fork lift or other device or
vehicle.
DO NOT climb on scissor arm STUNT driving and horseplay are prohibited.
assembly. It is prohibited.
ENSURE ALL tires are in good condition and lug
nuts are properly tightened.
Hydraulic System & Component Oil change intervals will depend on the
Maintenance and Repair care used in keeping the oil clean, and the
The following points should be kept in mind when operating conditions. Dirt and/or moisture
working on the hydraulic system or any component: cotamination will dictate that the oil should
be changed more often. Under normal use
1. Any structure has limits of strength and durability. and operating conditions, the hydraulic oil
To prevent failure of structural parts of hydraulic should be changed every two years. Refer
components, relief valves which limit pressure to to Table 1.2 of this manual.
safe operating values are included in the hydraulic
circuits. 7. All hydraulic components must be dis-assembled
in spotlessly clean surroundings. During
2. Tolerance of working parts in the hydraulic system disassembly, pay particular attention to the
is very close. Even small amounts of dirt or foreign identification of parts to assure proper reassembly.
materials in the system can cause wear or damage Clean all metal parts in a clean mineral oil solvent.
to components, as well as general faulty operation Be sure to thoroughly clean all internal passages.
of the hydraulic system. Every precaution must After the parts have been dried thoroughly, lay
be taken to assure absolute cleanliness of the them on a clean, lint-free surface for inspection.
hydraulic oil.
8. Replace all O-rings and seals when overhauling
3. Whenever there is a hydraulic system failure any component. Lubricate all parts with clean
which gives reason to believe that there are metal hydraulic oil before reassembly. Use small
particles or foreign materials in the system, drain amounts of petroleum jelly to hold O-rings in place
and flush the entire system and replace the filter during assembly.
cartridges. A complete change of oil must be
made under these circumstances. 9. Be sure to replace any lost hydraulic oil when
completing the installation of the repaired
4. Whenever the hydraulic system is drained, check component, and bleed any air from the system
the magnets in the hydraulic reservoir for metal when required.
particles. If metal particles are present, flush the
entire system and add a new change of oil. The 10. All hydraulic connections must be kept tight. A
presence of metal particles also may indicate the loose connection in a pressure line will permit
possibility of imminent component failure. A very the oil to leak out or air to be drawn into the
small amount of fine particles is normal. system. Air in the system can cause damage
to the components and noisy or erratic system
5. All containers and funnels used in handling operation.
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic oil Maintenance Hints
reservoir, and fill the reservoir only through the Three simple maintenance procedures have the
filter opening. The use of cloth to strain the oil greatest effect on the hydraulic system performance,
should be avoided to prevent lint from getting into efficiency and life. Yet, the very simplicity of them may
the system. be the reason they are so often overlooked. What are
they? Simply these:
6. When removing any hydraulic component, be sure
to cap and tag all hydraulic lines involved. Also, 1. Change filters annually. The filters will need
plug the ports of the removed components. to be changed more often depending on
the operating conditions. Dirty, dusty, high
NOTE moisture environments may cause the
Samples of hydraulic oil should be drawn hydraulic system to be contaminated more
from the reservoir and tested annually. quickly.
These samples should be taken when the 2. Maintain a sufficient quantity of clean hydraulic
oil is warmed through normal operation of oil of the proper type and viscosity in the
the system. The sample should be analyzed hydraulic reservoir.
by a qualified lubrication specialist to 3. Keep all connections tight.
determine if it is suitable for continued use.
NOTE Legend
Preventive maintenance is the easiest and P = Pass
least expensive type of maintenance. F = Fail
R = Repaired
Unless otherwise specified, perform each
maintenance procedure with the aerial platform in
the following configuration:
Inspection
Date
Recording
Year
New 1 2 3 4 5 6 7 8 9
Owners Skyjack
Name Inc.
Inspected Skyjack
By Inc.
158AA
As described earlier in this section, this decal is located on the scissor assembly. It must be completed after an annual
inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 6
months.
Serial Number:
Model:
Hourmeter Reading: Name (Printed):
Date:
Time: Signature:
Each item shall be inspected using the the appropriate section of the Skyjack operating manual.
As each item is inspected, write the apropriate grade in the box.
INSPECTION FREQUENCY Inspection Schedule
DAILY Daily A
P - PASS FREQUENTLY Frequently* A+B
F - FAIL ANNUALLY Annually A+B+C
R - REPAIRED BI-ANNUALLY Bi-annually A+B+C+D
Schedule P F R Schedule P F R
Schedule Maintenance Inspections Platform Assembly
Labels A Lanyard Attachment Anchors A, B
Limit Switches A, B AC Outlet on Platform A, B
Entrance Side Platform Control Console A, B
Main Power Disconnect Switch A, B Manuals A, B
Base Control Switches A, B Powered Extension Control Console
A, B
Free-wheeling Valve Knob (If Equipped)
A, B
(Compacts - Front Side) Lift Mechanism
Brakes A, B, C Maintenance Support A, B
AC Outlet Receptacle A, B Scissor Assembly A, B
Ladder A, B Scissor Bumpers A, B
Battery Tray Side Rollers A, B
Pothole Protection Device A, B Lift Cylinder(s) A, B
Battery Tray A, B Function Tests
Battery Charger A, B Test Main Power Discconect Switch A, B
Battery A, B Base Control Console
Steer Cylinder Assembly A, B Test Base Emergency Stop A, B
Wheel/Tire Assembly A, B Test Off/Platform/Base A, B
Tie Rod (Conventionals) A, B Test Lower/Neutral/Raise Switch A, B
Greasing Points A, B, C Test Emergency Lowering A, B
Hydraulic/Electric Tray Side Test Free-wheeling A, B
Pothole Protection Device A, B Platform Control Console
Hydraulic Tank A, B, C Test Platform Emergency Stop A, B
Hydraulic Oil A, B, C Test Enable Trigger Switch A, B
Hydraulic Pump and Motor A, B Test Steering A, B
Electrical Panel A, B Test Driving A, B
Proportional and Main Manifolds A, B Test Brakes A, B
Load/Tilt Sensor A, B Test Platform Raising/Lowering A, B
Emergency Lowering Access Rod Test Lowering Warning A, B
A, B
(If Equipped) Test Horn A, B
Test Pothole Sensor A, B
Test Elevated Drive Speed A, B
1003AA
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every three months or 150 hrs. Refer to Section 1 of this manual.
C - Perform Scheduled Maintenance Inspection every year. Refer to Section 1 of this manual.
D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1 of this manual.
* Perform scheduled inspection every three months or 150 hours.
- Refer to Skyjack's website @ www.skyjack.com for latest service bulletins porior to performing quarterly or yearly inspection.
Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy.
High Speed
Limit Switch
High Speed
Limit Switch
Pothole Protection
Limit Switch
CONVENTIONALS COMPACTS
1.1 Scheduled Maintenance Inspections Hydraulic
Begin the scheduled maintenance inspections by Maintaining the hydraulic components is essential
checking each item in sequence for the conditions listed to good performance and service life of the aerial
in this section. platform.
Compact Conventional
220V Outlet (Back View)
Receptacle Free-wheeling
Valve
CAUTION
A 106515AC
Free-wheeling
Valve
Compact
(Back View)
Conventional Compact
Battery
Battery
Charger Battery
Charger
Hydraulic/Electric
Battery Tray Battery Fuse Box Tray Pothole Protection Device Battery Tray
Conventional
Steer Cylinder
Wheel/Tire
Battery Tray
Tie Rod
Electrical Panel
Load/Tilt
Sensor
Hydraulic/Electric
Tray
Main Manifold
Platform
Railing
Manual Storage
Box
Platform
Assembly
Maintenance
Support
Lift Cylinder
Scissor Bumper
Scissor Assembly
Roller
Conventional Compact
(Back View) (Back View)
Free-wheeling
Valve
Lower/ Lower/
Neutral/Raise Neutral/Raise
Switch Switch
CAUTION
A 106515AC
Conventional Compact
(Back View) (Back View)
Free-wheeling
Valve
Lower/ Lower/
Neutral/Raise Neutral/Raise
Switch Switch
CAUTION
A 106515AC
Conventional Compact
(Back View) (Back View)
Free-wheeling
Valve
Lower/ Lower/
Neutral/Raise Neutral/Raise
Switch Switch
CAUTION
A 106515AC
Platform Control Console with Toggle Switch Platform Control Console with Rotary Switch
1. Ensure base emergency stop button is 1. Pull out emergency stop button.
pulled out.
2. Without activating enable trigger
2. Select off/platform/base key switch to switch, attempt to activate any platform
platform position. function.
Result: All platform functions should not
3. Ensure main power disconnect switch is in operate.
on position.
Test Steering
4. Use the ladder of aerial platform to access For platform control console with rotary
platform. switch:
Select lift/inclined drive/level drive switch
5. Close the gate.
to either inclined drive (low speed/
6. On platform control console, pull out high torque) or level drive (high
emergency stop button. speed/low torque) position.
Platform Control Console with Toggle Switch Platform Control Console with Rotary Switch
Platform Control Console with Toggle Switch Platform Control Console with Rotary Switch
Test Horn
2. Activate and hold enable trigger
switch.
1. Push horn pushbutton.
Result: Horn should sound.
3. Push controller handle and raise the
platform to an approximate height of
0.5 meter.
Result: Platform should rise.
Compact
Pothole Protection
Device
WARNING WARNING
Ensure that you maintain three points Be aware of overhead obstructions
of contact to mount/dismount plat- or other possible hazards around the
form. aerial platform when lifting.
1. Use the ladder to dismount from platform 1. Ensure path of intended motion is clear.
and place a block, approximately 3.75 cm,
under the hydraulic/electric tray. 2. Raise the platform until approximately a
height of 2 meters is reached and attempt
2. Use the ladder of aerial platform to access to drive forward or reverse.
platform. Result: Aerial platform should move slower
than when it was in stowed position.
3. Close the gate.
Table of Contents
Tables
2.1 Specifications and Features...............................................................................................................................2
2.2 Floor Loading Pressure......................................................................................................................................4
2.3 Maximum Platform Capacities (Evenly Distributed)..........................................................................................6
2.4 Torque Specifications.........................................................................................................................................7
Height
Chassis
Hydraulic Oil
* Weight with standard 0.9m extension platform. Refer to serial nameplate for specific applications.
Note :
Emission sound pressure level does not exceed 70 dB(A).
Height
Chassis
Hydraulic Oil
* Weight with standard 1.2m extension platform. Refer to serial nameplate for specific
applications.
Note :
Emission sound pressure level does not exceed 70 dB(A).
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is
generally determined by the engineer or architect for that particular structure.
Width Width
Length
Length
WARNING
Intermixing tires of different types or using tires of types other than those originally supplied with
this equipment can adversely affect stability. Therefore, replace tires only with the exact original
Skyjack-approved type. Failure to operate with matched approved tires in good condition may
result in death or serious injury.
3220 408 kg 2 Persons 113 kg 1 Person 408 kg 2 Persons 113 kg 1 Person No Wind 1.5 x 3.5
4620 590 kg 3 Persons 136 kg 1 Person N/A 12.5 m/s 1.5 x 3.5
4626 454 kg 2 Persons 136 kg 1 Person N/A 12.5 m/s 1.5 x 3.5
132AB
NOTE: Overall Capacity - Occupants and materials not to exceed rated load.
3 3.4 5.4 12.5 19.4 11.5 17.75 8 12 Papers and thin branches move, flags wave
WARNING
This aerial platform is equipped with a load sensing system. Do not exceed the rated capacity of
the aerial platform. Failure to avoid this will prevent operation of all normal controls/functions of
the aerial platform. To resume normal operation remove the additional loads.
Table of Contents
Charts
3.1 Electrical Symbol Chart...................................................................................................................................3
3.2 Hydraulic Symbol Chart...................................................................................................................................4
3.3 Wire Number and Color Code.........................................................................................................................5
Parts List
3.4 Hydraulic Schematic Parts List........................................................................................................................6
3.5 Electrical Components Parts List.....................................................................................................................8
3
3.8a Platform Control Console with Toggle Switch - Powered Extension Platform Modification Diagram..........15
3.8b Platform Control Console with Rotary Switch - Powered Extension Platform Modification Diagram..........16
3.9 Powered Extension Platform Control Console and Harness........................................................................17
3.10 Base Control Console Diagram.....................................................................................................................18
3.11 Scissor Arm Control Cable Diagram.............................................................................................................19
3.12 Holding Valve & Horn Harnesses, and Limit Switch Diagrams.....................................................................20
3.13 Hydraulic Schematic (Models 322x).............................................................................................................21
3.14 Hydraulic Schematic (Models 46xx)..............................................................................................................22
3.15 Main Manifold Harness and Holding Valve Harness.....................................................................................23
3.16 Electrical Panel Diagram................................................................................................................................24
3.17 Control Module and Beeper Diagram...........................................................................................................25
3.18a Electrical Schematic (Models 322x - Equipped with all options)..................................................................26
3.18b Electrical Schematic (Models 322x - Equipped with all options)..................................................................27
3.19a Electrical Schematic (Models 46xx - Equipped with all options)..................................................................28
3.19b Electrical Schematic (Models 46xx - Equipped with all options)..................................................................29
LIMIT SWITCH
CIRCUITS LIGHT FOOT SWITCH
CONNECTED CLOSED
LIMIT SWITCH
HYDRAULIC
BATTERY TOGGLE SWITCH
VALVE COIL
SILICON
ELECTRIC CONTROLLED
FUSE ROTARY SWITCH
MOTOR RECTIFIER
CIRCUIT PROXIMITY
HORN LIMIT SWITCH
BREAKER SWITCH
SINGLE POLE
POTENTIOMETER LEVEL SENSOR SINGLE THROWN VACUUM
RELAY SWITCH
TRIPLE POLE
DOUBLE THROW DIODE RHEOSTAT TILT SWITCH
RELAY
VARIABLE
LINE CROSSING DISPLACEMENT SHUTTLE VALVE VELOCITY FUSE
PUMP
DOUBLE ACTING
HYDRAULIC PRESSURE
PRESSURE DOUBLE
FILTER WITH REDUCING
SWITCH RODDED
BYPASS VALVE
CYLINDER
FIXED
DISPLACEMENT COUNTER ROTARY
CHECK VALVE BALANCE VALVE ACTUATOR
PUMP
THREE POSITION
VARIABLE BI DIRECTIONAL
FOUR WAY
DISPLACEMENT HYDRAULIC
OIL COOLER VALVE COIL
PROPORTIONAL
HYDRAULIC MOTOR MOTOR
SERVO MOTOR/BRAKE
GRN/
05 PUR 28 GRN 51 BLK/GRN 74 99 BLK/GREY
GREY
06 29 GREY/ORG 52 GRN/BLU 75 GREY/PUR 103 BLK/PUR
This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire
numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red.
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Qty. Description
No. Part No.
2H-59B
Proportional Valve
(Internal Compensator Valve) To Main Manifold
To Main Manifold
To Pump 3H-14
Lift Valve
CB1
Counterbalance
Valve
02
Lowering Orifice R4
(Model 4620 & 4632 Only) Relief Valve
3H-17A
Brake Valve
R2
Lift Relief Valve
2H-13
R5 Lowering Valve
Relief Valve 4H-23
Right Steer Valve
4H-15
Reverse Drive Valve R1 Quick Disconnect
System Relief Valve (If equipped)
4H-24
Left Steer Valve
M138117AA_S3
3H-18A-1
07 Speed Valve A
Orifice
P2
Hand Pump
FD1
Flow Divier/Combiner
Valve
To M3
Wheel Motor
To M3
To M4 06 Wheel Motor
Wheel Motor Orifice From Main Manifold
(Forward Drive)
To Integral Brake
From Main Manifold
(Reverse Drive)
Model 46xx
2H-18A
If equipped
Differential Valve
3H-18A-2
Speed Valve B
FD1
Flow Divier/Combiner
Valve
V2 V3
Free-wheeling Valve Auto Reset Valve
Hydraulic
P2 Fittings
3H-18A-1 Hand Pump
Speed Valve A
15 16 12B
S8 - HORN
S27 - TORQUE
12B
B
18 A 8A
12B 08
08
49
13 14
S3 - LIFT/OFF/DRIVE
00
S4 - EMERGENCY STOP
RST1
8C 08
02
60/7A LED-1 02
X2
08 X1
07 7A
MALE
CTRL BOX
HARNESS
BACK VIEW
M156881AA
7B 15 A 08
12B 8A 08
D16
18 49
7B
S3 - LIFT/DRIVE SELECTOR
MIDDLE SECTION
S4 - EMERGENCY STOP
00
14 B
RST1
8C 08
16
16 B 02
60/7A LED-1 02
X2
X1
08 07 7A
MALE
CTRL BOX
PIN # - FUNCTION CTRL BOX HARNESS JOYSTICK HARNESS
HARNESS PIN 1 - LEFT 24 BLUE/BLACK WHITE/RED
PIN 2 - STEERING VS+ 12B BROWN/RED WHITE/GREEN BACK VIEW
PIN 3 - RIGHT 23 BLACK/WHITE WHITE
PIN 4 - FWD/UP B RED YELLOW
PIN 5 - JOYSTICK VS+ 08 BLUE WHITE/BLACK
JOYSTICK HARNESS
PIN 6 - REV/DOWN A PURPLE/WHITE GREY
XX
59 ORANGE/BLACK
PIN 8 - GND 02 WHITE BLACK CRD1
PIN 9 - ENABLE VS+ 8A BLUE WHITE/BLUE
118711-0
M146621AA
3.8a Platform Control Console with Toggle Switch - Powered Extension Platform Modification Diagram
Serial Breakdown
Reference Chart
Model Serial Number
SJ3 3220 60002138 & above
SJ3 3226 27006059 & above
SJ3 46XX 70006694 & above
S3 - LIFT/OFF/DRIVE
S8 - HORN
S27 - TORQUE
08
09
S4 - EMERGENCY STOP
08 02
LED-1
X2
X1
21B
D26 D27
MALE
21B
02 26 27 09 (7A) GREEN 8 16 RED WHITE (60/7A)
(49) GREEN WHITE 7 15 BLACK WHITE (23)
(8C) BLUE WHITE 6 14 BLUE BLACK (24)
(07) RED 5 13 GREEN BLACK (21B) (OPT)
(14) BLACK 4 12 ORANGE BLACK (59)
(13) ORANGE 3 11 RED BLACK (18)
(15) BLUE 2 10 WHITE BLACK (16)
(02) WHITE 1 9 (NOT USED)
BACK VIEW
TO PWR DECK
SOLENOID VALVES
1.BLACK (27)
2.WHITE (02)
3.GREEN (26)
TO PWR DECK
CONTROL BOX
1.BLACK (27)
2.WHITE (09)
3.GREEN (26)
4.(N/U)
M156955AA
3.8b Platform Control Console with Rotary Switch - Powered Extension Platform Modification Diagram
Serial Breakdown
Reference Chart
Model Serial Number
SJ3 3220 60002137 & below
SJ3 3226 27006058 & below
SJ3 46XX 70006693 & below
09 08
S3 - LIFT/DRIVE SELECTOR
MIDDLE SECTION
S4 - EMERGENCY STOP
08 02
LED-1
X2
X1
21B
D26 D27
MALE
21B
(7A) GREEN 8 16 RED WHITE (60/7A)
02 26 27 09 (49) GREEN WHITE 7 15 BLACK WHITE (23)
(8C) BLUE WHITE 6 14 BLUE BLACK (24)
(07) RED 5 13 GREEN BLACK (21B) (OPT)
(14) BLACK 4 12 ORANGE BLACK (59)
(13) ORANGE 3 11 RED BLACK (18)
(15) BLUE 2 10 WHITE BLACK (16)
(02) WHITE 1 9 (NOT USED)
M146620AB
BOX
WHITE BLACK
1 GREEN
1
2
2
3
26
02
02
M115592AI1_S3
TO ELECTRIC PANEL
PIN 1 - 07 (RED)
PIN 2 - 05 (ORANGE/BLACK)
PIN 3 - 13 (ORANGE)
PIN 4 - 14E (BLACK)
PIN 5 - 10E (WHITE/BLACK) (CE)
PIN 6 - 8C (BLUE)
PIN 7 - 7A (RED/BLACK)
PIN 8 - 02 (WHITE)
BACK VIEW
5 4
DEUTSCH
6 3
7 2
8 1
M149553AA_S3
M146650AB_S3
3.12 Holding Valve & Horn Harnesses, and Limit Switch Diagrams
1
13 - BLACK
13
PIN 1 - 13 BLACK
PIN 2 - 02 WHITE
2
02 - WHITE 02
1
13 - BLACK 13
HOLDING VALVE (UPPER)
02 - WHITE PIN 2 - 02 WHITE
PIN 1 - 13 BLACK
2
02
PIN 2 - 02 WHITE
2 1
HORN HARNESS
TO HORN 02
02 - WHITE
49 - BLACK 49 TO ELECTRIC PANEL
02 - WHITE
49 - BLACK
BROWN BLACK
19
NO NC
LS6
71
BLUE BLACK/WHITE
BROWN BLACK
18B 18A PIN 1 - 71 (BLACK/WHITE) PIN 5 - 7A (BLUE)
NO PIN 2 - 21 (BLACK) PIN 6 - 18B (BROWN)
LS1B
NC
1 8
DEUTSCH
BROWN BLACK
2 7
21 3 6
NO NC 4 5
LS1A
71
BLUE BLACK/WHITE
M129171AA2 M130560AC
M4
RIGHT DRIVE
C2
MOTOR/BRAKE 04
UPPER LIFT
CASE DRAIN EMERGENCY
CYLINDER
LOWERING
3226
MB4 ORIFICE V
REAR DRIVE .067
O6 2H-18A
DIFFERENTIAL DIFFERENTIAL MANIFOLD BLOCK
MB3
ORIFICE .040 VALVE
HOLDING VALVE
MANIFOLD BLOCK
R3 2H-13-2
FD1 PT1 RELIEF VALVE HOLDING VALVE PT1
3H-18A-2 PRESSURE PRESSURE
FLOW DIVIDER
SPEED VALVE B OVERLOAD OVERLOAD
COMBINER
P2 V3 TRANSDUCER TRANSDUCER
HAND PUMP AUTO RESET C2 OPTION C2
OPTION 04 04
VALVE LOWER LIFT LOWER LIFT
EMERGENCY EMERGENCY
C1 CYLINDER CYLINDER
LOWERING LOWERING
V2 CUSHION 3226 3220
ORIFICE ORIFICE
3H-18A-1 FREE-WHEELING CYLINDER .067 .067 W
O7 SPEED VALVE A VALVE
BRAKE ONE-WAY
ORIFICE .020 MB3 MB3
HOLDING VALVE HOLDING VALVE
C5 P.DECK
MANIFOLD BLOCK R3 2H-13-1 MANIFOLD BLOCK 2H-13-1
CYLINDER C3 STEERING
CASE DRAIN CYLINDER RELIEF VALVE HOLDING VALVE HOLDING VALVE
M3
LEFT DRIVE
4H-27 4H-26 PS1 OPTIONAL
EXTENSION DECK (SJ3D 3220)
MOTOR/BRAKE O3
RETRACT EXTEND PRESSURE
B
A
STEER ORIFICE
PLATFORM PLATFORM .040 SWITCH
OPTIONAL POWERED
VALVE VALVE
T
P
X
MB5 P. DECK
MANIFOLD BLOCK
MB9
PR0PORTIONAL 4H-15 4H-23
MANIFOLD REVERSE DRIVE RIGHT STEER
VALVE 3H-14 2H-13
BLOCK VALVE LIFT VALVE LOWERING VALVE
3H-17A P A
BRAKE VALVE
B P A
T
T B
4H-16 CRV1 CROSS-OVER
FORWARD DRIVE RELIEF VALVE OPTION
VALVE 4H-24 O2 R2 LIFT
R1 LOWERING ORIFICE RELIEF
CB1
LEFT STEER
SEE REFERENCE TABLE VALVE
Y
2H-59B SYSTEM RELIEF VALVE
PRESSURE- VALVE COUNTERBALANCE VALVE REFERENCE TABLE
COMPENSATED
PROPORTIONAL SJ3D ORIFICE
VALVE LOWERING LIFT
MB1 MODEL ORIFICE ORIFICE
MAIN MANIFOLD BLOCK MB2 V1 EMERGENCY
LOWERING LOWERING SJ3 3220 NONE
0.067
VALVE VALVE
DCM1 SJ3 3226 NONE
DC MOTOR BLOCK (MANUAL)
P1
M HYDRAULIC
F1
PUMP
RETURN
FILTER Z
RESERVOIR
M155905AA
M4
V3
RIGHT DRIVE C2
AUTO RESET 04
MOTOR/BRAKE UPPER LIFT
VALVE CASE DRAIN EMERGENCY
CYLINDER
LOWERING
P2 3226/4626/4632 V
MB4 ORIFICE
HAND PUMP REAR DRIVE .067
O6 2H-18A
DIFFERENTIAL DIFFERENTIAL MANIFOLD BLOCK 2H-13-2 (ANSI/CSA)
MB7 MB3 2H-13B-2 (CE)
ORIFICE .040 VALVE
BRAKE RELEASE HOLDING VALVE HOLDING VALVE
MANIFOLD BLOCK MANIFOLD BLOCK
O7 R3
BRAKE ONE-WAY FD1 PT1 RELIEF VALVE PT1
ORIFICE .020 FLOW DIVIDER PRESSURE PRESSURE
COMBINER OVERLOAD OVERLOAD
3H-18A-2 TRANSDUCER C2 TRANSDUCER C2
SPEED VALVE B OPTION LOWER LIFT 04 OPTION 04
LOWER LIFT
CYLINDER EMERGENCY CYLINDER EMERGENCY
C1 LOWERING LOWERING
V2 CUSHION 3226/4626/4632 3220/4620 W
ORIFICE ORIFICE
3H-18A-1 FREE-WHEELING CYLINDER .067 .067
SPEED VALVE A VALVE
C5 P.DECK C5 P.DECK MB3 MB3
CYLINDER CYLINDER HOLDING VALVE HOLDING VALVE
CASE DRAIN M3 MANIFOLD BLOCK R3 MANIFOLD BLOCK
2H-13-1 2H-13-1
LEFT DRIVE RELIEF VALVE HOLDING VALVE HOLDING VALVE
4H-27 4H-26
EXTENSION DECK (SJ3D 4626)
MOTOR/BRAKE C3 STEERING
RETRACT EXTEND
B
A
PRESSURE
VALVE VALVE
T
P
O3 SWITCH
STEER ORIFICE
.040 REFERENCE TABLE
MB5 P. DECK
X
MANIFOLD BLOCK SJ3D ORIFICE
MB9 LOWERING LIFT
4H-15 MODEL ORIFICE ORIFICE
PR0PORTIONAL 4H-23
REVERSE DRIVE 2H-13 (ANSI/CSA)
C5 P.DECK MANIFOLD RIGHT STEER SJ3 3220
VALVE 3H-14 2H-13B (CE) NONE
CYLINDER BLOCK VALVE LIFT VALVE LOWERING VALVE
3H-17A SJ3 3226 NONE
P A
EXTENSION DECK (SJ3D 3220/4620)
BRAKE VALVE
A
0.067
B P SJ3 4620 0.073" DIA
4H-27 4H-26 T
RETRACT EXTEND
B
A
T B
PLATFORM PLATFORM 4H-16 CRV1 CROSS-OVER SJ3 4626 NONE
OPTIONAL POWERED
RESERVOIR
M137018AD1
INSERT ORIENTATION
BOTTOM VIEW
FORWARD VALVE RIGHT STEER VALVE
REVERSE PIN 1 - 16 WHITE/BLACK PIN 1 - 23 BLACK/WHITE
15
02 PIN 2 - 02 WHITE PIN 2 - 02 WHITE
LEFT
24 CLE FORWARD REVERSE VALVE LEFT STEER VALVE
AR
16
02 PIN 1 - 15 BLUE PIN 1 - 24 BLUE/BLACK
02
PIN 2 - 02 WHITE PIN 2 - 02 WHITE
CLE
CLE
AR W
AR
RIGHT
23
02
CLE
AR
X
59
02 BRAKE VALVE
17A - BLUE/RED
17A 02 - WHITE
M146667AA1_S3
DEUTSCH
TO JOYSTICK BOX TO LOWER KEYSWITCH BOX 7 2 PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE)
6 3
PIN 3 - 13 (ORANGE) PIN 7 - 7A (GREEN)
TO TERMINAL BLOCK TO TILT SWITCH 5 4
PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE)
BLUE
TO ENGINE TO BATTERY
7A
TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH 71
TO REAR MANIFOLD TO POWER DECK YEL 8 1
PIN 1 - 71 (BLACK/WHITE) PIN 5 - 7A (GREEN)
DEUTSCH
TO OUTRIGGER 02 7 2 PIN 2 - 21 (ORANGE/BLACK) PIN 6 - 18B (RED/WHITE) (CE)
TO END OF STROKE 6 3
SOLENOID CABLES 02 02 02 5 4
PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE)
TO CONTROL MODULE TO HORN PIN 4 - 18A (RED/BLACK) PIN 8 - 71 (BLACK/WHITE)
03 00 W
ITEM F - 5 PLACES ITEM G - 2 PLACES
RELAY #1 - PIN 87 RELAY #5 - PIN 86
3A 02 RELAY #2 - PIN 86 RELAY #6 - PIN 86
RELAY #3 - PIN 86
19B
02
RELAY #3 - PIN 87
RELAY #4 - PIN 30
02
03
FROM MAIN DISCONNECT
19B
19
TO (+) AT MOTOR +
17B BRAKE/STEERING RELAY PROP. CTRL RELAY X
PIN 30 - 17B PIN 30 - 59A
30 30 PIN 85 - 17 BRAKE/ PIN 85 - 02 PROPORTIONAL
87a 87a 59A PIN 86 - 02
STEERING PIN 86 - 21A
CONTROL
D21B-1
D14E-1
PIN 87 - 17A PIN 87 - N/U
3A - BLACK 85 87 86 85 87 86 PIN 87a - 17C RELAY #1 PIN 87a - 59 RELAY #4
TO CHARGER #1 #4
05 - WHITE 8C 49 02 05 07 7A 10E 13 14 14E 18 18B 19 19B 60 72 21B 59 71 17 15 16 14 21 23 24
#2 #5 #3 #6
W W W
86 87 85 86 87 85 86 87 85 86 87 85
AUX. AUX.
D14E-2 D17C-1 D17C D21B-2 87a 87a 87a 87a DOWN DOWN TILT TILT
CONTROL CABLE OPTIONS
30 30 02 30 30 RELAY #3 RELAY #2 RELAY #6 RELAY #5
EUROPE N.A
WIRE COLOUR WIRE NUMBER WIRE NUMBER
GREEN/BLACK 21B 21B
RED/WHITE 60 7A
DOWN RELAY AUX. DOWN RELAY TILT RELAY AUX. TILT RELAY
PIN 30 - 13A PIN 30 - 13 PIN 30 - 19A PIN 30 - 19
PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02
BACK VIEW FRONT VIEW PIN 86 - 28 PIN 86 - 28E PIN 86 - 28 PIN 86 - 28E
PIN 87 - 13B PIN 87 - 13A PIN 87 - 19B PIN 87 - 19A
FEMALE PIN 87a - N/U PIN 87a - N/U PIN 87a - N/U PIN 87a - N/U
28E 28
CONTROL MODULE Z
28 - BLACK
28E - WHITE
60 - GREEN
M147918AA_S3
CM1
OVERLOAD SENSING MODULE
V
P4 P3 P2 P1 1-ST LEVEL INSIDE SCISSOR
BEEPER
29 - RED (+)
02 - BLUE (-)
N/U - BLACK (-)
W
CONNECT GROUND WIRES
TO CONTROL MODULE - P4
PIN 1 - N/U
PIN 2 - 60A GREEN TO PRESSURE TRANSDUCER
PIN 3 - 28B GREEN PIN 1 - 910A BLACK
PIN 4 - N/U PIN 2 - 60A GREEN
PIN 3 - 900 WHITE
PIN 5 - N/U TO ANGLE TRANSDUCER
PIN 6 - 910 BLACK PIN 1 - 910 BLACK
PIN 7 - 900 WHITE PIN 2 - 28B GREEN X
PIN 8 - 902 WHITE PIN 3 - 902 WHITE
CONTROL MODULE - P2
PIN 9 - 910A BLACK PIN 1 - N/U
BACK VIEW PIN 2 - 10E BLACK/WHITE
PIN 3 - 14 BLACK
3 2 1 PIN 4 - 13 ORANGE
6
9
5
8
4
7 PIN 5 - N/U
PIN 6 - N/U
12 11 10
M130612AE1
26
CHARGER
CUTOUT RELAY V
SJ3 3226 27006059 & above 4H-26 EXT
RET
9A 09
1 CHARGER
27
S11 S12
4H-27 B4 6V F1 B3 6V B2 6V B1 6V
2
RETRACT SOLENOID 21B 21B GREEN/BLACK 21B BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
D26 D27 00 BATTERY
3
PACK
S1 MAIN
S10 C1
DISCONNECT
S4 IDLE/PLTF/BASE MOTOR 4
EMERGENCY KEY SWITCH CONTACTOR DCM1
STOP (IN IDLE POSITION)
M 5 PUMP MOTOR
F2
08 8C 8C BLUE/WHITE 8C 8C 07 S28
6 INVERTER OPTION
NCHO EMERGENCY
STOP 50A FUSE
SWITCH
7
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 3A 03 00 02 10A CIRCUIT
8
BREAKER
10A CIRCUIT
NCHO BREAKER 85
7A GREEN 7A 7A 02 INVERTER OPTION
TIMER 9
TIMER
S8
HORN
SWITCH
10E
NO
7A
PRESSURE ANGLE
7A
LED-2
02 19B
10 POWER ON LED W
H1
08 49 49 GREEN/WHITE 49 TRANSDUCER TRANSDUCER POWER ON LIGHT HORN 49
11 HORN
PT1 AT1
02 02 60 60 RED/WHITE 60 00 02
12
LED-1 CM1
POWER ON/LSS CONTROL
LIGHT 13
MODULE
BP-29
29
P3-3 = 60
P2-12 = 7A
P4-2 = 60A
P4-7 = 900
P4-9 = 910A
P4-6 = 910
P4-3 = 28B
P4-8 = 902
P2-11 = 02
P3-2 = 29 14 BEEPER
P2-10 = 18B
P2-2 = 10E
P3-6 = 28E
P2-3 = 14
P2-8 = 15
P2-7 = 16
P2-4 = 13
P3-4 = 28
22 FLASHING LIGHT
P3-1 = 22 15
FL-22 OPTION
P3-5 = 02 16
02
S3
LIFT/ 14 BLACK 14 S2 14
DO2-3
3H-14
X
20 UP SOLENOID
OFF/ DO2-4
DRIVE 13
SWITCH 10E 28E 02
14E 21 AUX. DOWN RELAY
UP/DOWN 28ECR2
D14E-2 28 02
SWITCH 22 DOWN RELAY
CRD1 CRD2 CRD3
28CR2
09 19B 02
08 08 23 MOTOR CONTACTOR
POTHOLE PROTECTION 19BCR
LIMIT SWITCHES N.C.H.O. 24
LS4 LS5 DO2-5
D14
71 72 19 19 19A 19B
RST1 TT 25 HOURMETER
2.7K OHMS LS6
02 00 71 19 28E 02
26 AUX. TILT RELAY
DRIVE OVERRIDE D21
LIMIT SWITCH N.C. 28ECR1
28 02
27 TILT RELAY
D21B-2
02 02 WHITE 02 28CR1
28
HIGH SPEED
LIMIT SWITCHES
Y
3H-18A-1
LS1B 29 SPEED A SOLENOID
S27 DO2-6
TORQUE 2H-18A
7A 18B
SWITCH 30 DIFF. SOLENOID
N.O. DO2-7
12B 18 RED/BLACK 18 18 18A 3H-18A-2
31 SPEED B SOLENOID
N.C. 21ACR DO2-8
RST3
S7 71 21 21 21A 02 PROPORTIONAL
32
JOYSTICK N.C. RELAY
LOW VOLTAGE
PROTECTION RST2
59 59A
LS1A D14E-1 33
JOYSTICK PCB
D21B-1
08 PWM 59 59 ORANGE/BLACK 59 59 59 2H-59 PROPORTIONAL
OUTPUT 34
SOLENOID
D17C-1
02
35
13
A A D17-1 D17C
REV/DN 15 BLUE 15 4H-15
36 REVERSE SOLENOID
S7-1 15 DO2-9
D15 17CR
NUETRAL 17 17 02
37 TRANSFER RELAY
14
B B D16
FWD/UP 16 WHITE/BLACK 16 4H-16
38 FORWARD SOLENOID
Z
S7-6 16 DO2-10
D17
ENABLE 8A 8A 17B 17C
ENABLE 39
12B
23 23 BLACK/WHITE 23 4H-23
40 RIGHT SOLENOID
S7-2 D23 DO2-11
RIGHT 12B 17A 3H-17A
17B
41 BRAKE SOLENOID
S7-3 DO2-12
LEFT D24
24 24 BLUE/BLACK 24 4H-24
42 LEFT SOLENOID
DO2-13
M149743AB
P3-3 = 60
P2-12 = 7A
P4-2 = 60A
P4-7 = 900
P4-9 = 910A
P4-6 = 910
P4-3 = 28B
P4-8 = 902
P2-11 = 02
P2-10 = 18B
P2-2 = 10E
P3-6 = 28E
P2-3 = 14
P2-8 = 15
P2-7 = 16
P2-4 = 13
P3-4 = 28
22
P3-1 = 22 15 FLASHING
OPTION
LIGHT
FL-22
P3-5 = 02 16
S3
LIFT/DRV LOW/DRV HI 2H-13B-2 HOLDING VALVE
(IN LIFT POSITION) 17 TWO CYLINDERS
DO2-1
09 2H-13B-1 HOLDING VALVE
08 08 18 SINGLE CYLINDER
NOHC DO2-2
13 13 ORANGE 13 13 13 13A 13B 2H-13B
A 19 DOWN SOLENOID
NOHC
14 14 BLACK 14 S2 14
DO2-3
3H-14 X
B 20 UP SOLENOID
NOHC DO2-4
13
10E 28E 02
14E 21 AUX. DOWN RELAY
BCI UP/DOWN D14E-2 28ECR2 28 02
BATTERY CHARGE SWITCH 22 DOWN RELAY
INDICATOR CRD1 CRD2 CRD3
08 02 28CR2 19B 02
V 23 MOTOR CONTACTOR
02 POTHOLE PROTECTION 19BCR
LIMIT SWITCHES N.C.H.O. 24
LS4 LS5 DO2-5
D14
71 72 19 19 19A 19B
RST1 TT 25 HOURMETER
2.7K OHMS LS6
02 00 71 19 28E 02
26 AUX. TILT RELAY
DRIVE OVERRIDE D21
LIMIT SWITCH N.C. 28ECR1 28 02
27 TILT RELAY
D21B-2 28CR1
02 02 WHITE 02
28
HIGH SPEED
LIMIT SWITCHES
LS1B
3H-18A-1
DO2-6
29 SPEED A SOLENOID Y
7A 18B 2H-18A
30 DIFF. SOLENOID
N.O. DO2-7
7B 3H-18A-2
18 18 RED/BLACK 18 18 18A
NO 31 SPEED B SOLENOID
N.C. 21ACR DO2-8
71 21 21 RST3
S7 21A 02
JOYSTICK 32 PROPORTIONAL
RELAY
N.C. LOW VOLTAGE
PROTECTION 59 59A RST2
LS1A D14E-1 33
JOYSTICK PCB
D21B-1
08 PWM 59 59 ORANGE/BLACK 59 59 59 2H-59
OUTPUT 34 PROPORTIONAL
SOLENOID
D17C-1
02 35
D17-1 D17C
A A 15 15 BLUE 15 4H-15
REV/DN 36 REVERSE SOLENOID
S7-1 NCHO 17CR DO2-9
NUETRAL D15-1 D15
17 17 02 37 TRANSFER RELAY
D16-1 D16
B B 16 16 WHITE/BLACK 16 4H-16
FWD/UP 38 FORWARD SOLENOID
S7-6
ENABLE
NCHO
D17 DO2-10 Z
8A 8A 12B 17B 17C
ENABLE 39
NCHO
23 23 BLACK/WHITE 23 4H-23
40 RIGHT SOLENOID
S7-2 D23 DO2-11
RIGHT 12B 17B 17A 3H-17A
S7-3 41 BRAKE SOLENOID
D24 DO2-12
LEFT BLUE/BLACK 4H-24
24 24 24
42 LEFT SOLENOID
DO2-13
M149743AA
Reference Chart
LINE VOLTAGE
CONTROL BOX BASE
POWERED PLATFORM OPTION
Model Serial Number BC
EXTEND/ 24V CHARGER
EXTEND SOLENOID ENABLE
RETRACT
SJ3 46XX 70006694 & above SWITCH
SWITCH L1CR
V
CHARGER
26 CUTOUT RELAY
4H-26 EXT 9A 09
1 CHARGER
RET
27
S11 S12
4H-27 B4 6V F1 B3 6V B2 6V B1 6V
2
RETRACT SOLENOID 21B 21B GREEN/BLACK 21B BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
D26 D27 00 BATTERY
3
PACK
S1 MAIN
S10 C1
DISCONNECT 4
S4 IDLE/PLTF/BASE MOTOR
EMERGENCY KEY SWITCH CONTACTOR DCM1
STOP (IN IDLE POSITION)
M 5 PUMP MOTOR
F2
08 8C 8C BLUE/WHITE 8C 8C 07 S28
6 INVERTER OPTION
NCHO EMERGENCY
STOP 50A FUSE
SWITCH
7
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 3A 03 00 02 15A CIRCUIT
8
BREAKER
15A CIRCUIT
NCHO BREAKER 85
7A GREEN 7A 7A 02 INVERTER OPTION
TIMER 9
TIMER
S8
W
HORN 10E 7A 7A 02 19B
SWITCH 10 POWER ON LED
NO PRESSURE ANGLE LED-2 H1
08 49 49 GREEN/WHITE 49 TRANSDUCER TRANSDUCER POWER ON LIGHT HORN 49
11 HORN
PT1 AT1
02 02 60 60 RED/WHITE 60 00 02
12
LED-1 CM1
POWER ON/LSS CONTROL
LIGHT 13
MODULE
BP-29
29
P3-3 = 60
P2-12 = 7A
P4-2 = 60A
P4-7 = 900
P4-9 = 910A
P4-6 = 910
P4-3 = 28B
P4-8 = 902
P2-11 = 02
P3-2 = 29 14 BEEPER
P2-10 = 18B
P3-6 = 28E
P2-2 = 10E
BCI
P3-4 = 28
P2-8 = 15
P2-7 = 16
P2-4 = 13
P2-3 = 14
22 FLASHING LIGHT
BATTERY CHARGE P3-1 = 22 15
FL-22 OPTION
INDICATOR
08 02
V P3-5 = 02 16
UP/DOWN 28ECR2
D14E-2 28 02
SWITCH 22 DOWN RELAY
CRD1 CRD2 CRD3
28CR2
09 19B 02
08 08 23 MOTOR CONTACTOR
POTHOLE PROTECTION 19BCR
LIMIT SWITCHES N.C.H.O. 24
LS4 LS5 DO2-5
D14
71 72 19 19 19A 19B
TT 25 HOURMETER
LS6
71 19 28E 02
26 AUX. TILT RELAY
DRIVE OVERRIDE D21
LIMIT SWITCH N.C. 28ECR1
28 02
27 TILT RELAY
D21B-2
02 02 WHITE 02 28CR1
28
HIGH SPEED
LIMIT SWITCHES
Y
3H-18A-1
LS1B 29 SPEED A SOLENOID
S27 DO2-6
TORQUE 2H-18A
7A 18B
SWITCH 30 DIFF. SOLENOID
N.O. DO2-7
12B 18 RED/BLACK 18 18 18A 3H-18A-2
31 SPEED B SOLENOID
N.C. 21ACR DO2-8
RST3
S7 71 21 21 21A 02 PROPORTIONAL
32
JOYSTICK N.C. RELAY
LOW VOLTAGE
PROTECTION RST2
59 59A
LS1A D14E-1 33
JOYSTICK PCB
D21B-1
08 PWM 59 59 ORANGE/BLACK 59 59 59 2H-59 PROPORTIONAL
OUTPUT 34
SOLENOID
D17C-1
02
35
13
A A D17-1 D17C
REV/DN 15 BLUE 15 4H-15
36 REVERSE SOLENOID
S7-1 15 DO2-9
D15 17CR
NUETRAL 17 17 02
37 TRANSFER RELAY
14
B B D16
FWD/UP 16 WHITE/BLACK 16 4H-16
38 FORWARD SOLENOID
Z
S7-6 16 DO2-10
D17
ENABLE 8A 8A 17B 17C
ENABLE 39
12B
23 23 BLACK/WHITE 23 4H-23
40 RIGHT SOLENOID
S7-2 D23 DO2-11
RIGHT 12B 17A 3H-17A
17B
41 BRAKE SOLENOID
S7-3 DO2-12
LEFT D24
24 24 BLUE/BLACK 24 4H-24
42 LEFT SOLENOID
DO2-13
M147346AE
V
CHARGER
26 CUTOUT RELAY
4H-26 EXT 9A 09
1 CHARGER
RET
27
S11 S12
4H-27 B4 6V F1 B3 6V B2 6V B1 6V
2
RETRACT SOLENOID 21B 21B GREEN/BLACK 21B BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
D26 D27 00 BATTERY
3
PACK
S1 MAIN
S10 C1
DISCONNECT 4
S4 IDLE/PLTF/BASE MOTOR
EMERGENCY KEY SWITCH CONTACTOR DCM1
STOP (IN IDLE POSITION)
M 5 PUMP MOTOR
F2
08 8C 8C BLUE/WHITE 8C 8C 07 S28
6 INVERTER OPTION
NCHO EMERGENCY
STOP 50A FUSE
SWITCH
7
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 3A 03 00 02 15A CIRCUIT
8
BREAKER
15A CIRCUIT
NCHO BREAKER 85
7A GREEN 7A 7A 02 INVERTER OPTION
TIMER 9
TIMER
S8
W
HORN 10E 7A 7A 02 19B
SWITCH 10 POWER ON LED
NO PRESSURE ANGLE LED-2 H1
08 49 49 GREEN/WHITE 49 TRANSDUCER TRANSDUCER POWER ON LIGHT HORN 49
11 HORN
PT1 AT1
02 02 60 60 RED/WHITE 60 00 02
12
LED-1 CM1
POWER ON/LSS CONTROL
LIGHT 13
MODULE
BP-29
29
P3-3 = 60
P2-12 = 7A
P4-2 = 60A
P4-7 = 900
P4-9 = 910A
P4-6 = 910
P4-3 = 28B
P4-8 = 902
P2-11 = 02
P3-2 = 29 14 BEEPER
P2-10 = 18B
P3-6 = 28E
P2-2 = 10E
P3-4 = 28
P2-8 = 15
P2-7 = 16
P2-4 = 13
P2-3 = 14
22 FLASHING LIGHT
P3-1 = 22 15
FL-22 OPTION
P3-5 = 02 16
S3
LIFT/DRV LOW/DRV HI 2H-13B-2 HOLDING VALVE
(IN LIFT POSITION) 17
TWO CYLINDERS
DO2-1
09 2H-13B-1 HOLDING VALVE
08 08 18
SINGLE CYLINDER
DO2-2
NOHC
13 13 ORANGE 13 13 13 13A 13B 2H-13B
A 19 DOWN SOLENOID
NOHC
14 14 BLACK 14 S2 14
DO2-3
3H-14 X
B 20 UP SOLENOID
DO2-4
NOHC 13
10E 28E 02
14E 21 AUX. DOWN RELAY
M147346AD
Table of Contents
Introduction...................................................................................................................................................................3
Electrical System
4.1-1 All Controls Inoperative....................................................................................................................................4
4.1-2 All Controls Inoperative From Base Control Console.....................................................................................5
4.1-3 All Controls Inoperative From Platform Control Console................................................................................5
4.1-4 No Drive or Up Function from Platform Controls ...........................................................................................5
4.1-5 No Down or Reverse Function from Platform Controls...................................................................................6
4.1-6 No Up or Forward Only Function from Platform Control Console..................................................................6
4.1-7 No Up Function from Platform or Base Control Console................................................................................6
4.1-8 No Up Function from Base Control Console...................................................................................................7
4.1-9 No Down Function from Platform or Base Control Console ..........................................................................7
4.1-10 No Down Function from Base Control Console..............................................................................................7
4.1-11 Steer Only Inoperative.....................................................................................................................................7
4.1-12 Drive Only Inoperative.....................................................................................................................................8
4.1-13 No Drive or Steer when Platform Fully Lowered.............................................................................................8
4.1-14 No Drive or Steer when Platform Elevated......................................................................................................8
4.1-15 Elevated Drive Speed Does Not Activate........................................................................................................8
4.1-16 Platform Drives in Slow Speed Only................................................................................................................9
4.1-17 Forward Drive Function Inoperative................................................................................................................9
4
4.1-18 Reverse Drive Function Inoperative.................................................................................................................9
4.1-19 Brake will not Release...................................................................................................................................10
4.1-20 High/Low Torque Inoperative.........................................................................................................................10
4.1-21 Right Steer Inoperative .................................................................................................................................11
4.1-22 Left Steer Inoperative ....................................................................................................................................11
4.1-23 Power Extension Platform will not Extend or Retract....................................................................................11
4.1-24 Power Extension Platform will not Extend.....................................................................................................12
4.1-25 Power Extension Platform will not Retract.....................................................................................................12
4.1-26 Two or more Functions at one time...............................................................................................................12
Hydraulic System
4.2-1 All Function Inoperative.................................................................................................................................13
4.2-2 All System sluggish.......................................................................................................................................13
4.2-3 Platform Drifts Down......................................................................................................................................13
4.2-4 Platform Lifts Slowly.......................................................................................................................................13
4.2-5 Platform does not Lift.....................................................................................................................................13
4.2-6 Platform will not Lower...................................................................................................................................13
4.2-7 Platform Drives Slow......................................................................................................................................14
4.2-8 Platform will not Drive in Forward or Reverse...............................................................................................14
4.2-9 Brake(s) will not Release...............................................................................................................................14
4.2-10 Aerial Platform will not hold on a Grade .......................................................................................................14
4.2-11 Platform does not Steer.................................................................................................................................14
4.2-12 Power Extension Platform will not Extend or Retract....................................................................................14
4.2-13 High/Low Torque Inoperative.........................................................................................................................15
Introduction
The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble
which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information
will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and
deficiencies that may occur. If a specific trouble is not listed, isolate the major component in which the trouble oc-
curs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem.
The content of this section is separated into probable cause and remedy. The information preceded by a num-
ber represents the probable cause. The following line, noted by a dash represents the remedy to the probable
cause directly above it. See example below for clarification.
1. Probable Cause
-- Remedy
Electrical System
24. Loose or broken wire #7A from base terminal block to CM1 control module pin P2-12.
-- Check continuity. Replace if defective.
25. Loose or broken wire #02 from base terminal block to CM1 control module pin P2-11.
-- Check continuity. Replace if defective.
26. Loose or broken wire #28 from CM1 control module pin P3-4 to tilt relay 28CR1 and down relay
28CR2.
-- Check continuity. Replace if defective.
27. Loose or broken wire #28E from CM1 control module pin P3-6 to Aux. tilt relay 28ECR1 and Aux. down
relay 28ECR2.
-- Check continuity. Replace if defective.
7. Loose or broken wire #19B from tilt relay 28CR1 to hour meter.
-- Check continuity. Replace if defective.
8. Loose or broken wire #19B from hour meter to motor contactor C1.
-- Check continuity. Replace if defective.
9. Loose or broken wire #59 from proportional controller S7 to base terminal block.
-- Check continuity. Replace if defective.
10. Loose or broken wire #59 from base terminal block to proportional coil 2H-59.
-- Check continuity. Replace if defective.
11. Loose or broken wire #02 from base terminal block to proportional coil 2H-59.
-- Check continuity. Replace if defective.
12. Defective proportional coil 2H-59.
-- Check continuity through coil. Replace if defective.
NOTE
Down function is not proportionally controlled.
1. Loose or broken wire #13 from base terminal block to CM1 control module pin P2-4.
-- Check continuity. Replace if defective.
2. Defective down relay 28CR2 or Aux. down relay 28ECR2.
-- Check relay. Replace if defective.
3. Loose or broken wire #02 from base terminal block to down relay 28CR2 or Aux. down relay
28ECR2.
-- Check continuity. Replace if defective.
4. Loose or broken wire #13 from base terminal block to Aux. down relay 28ECR2.
-- Check continuity. Replace if defective.
5. Loose or broken wire #13A from Aux. down relay 28ECR2 to down relay 28CR2.
-- Check continuity. Replace if defective.
6. Loose or broken wire # 13B from down relay 28CR2 to down valve 2H-13B or holding valve 2H-13B-1
and 2H-13B-2 (if equipped).
-- Check continuity. Replace if defective.
7. Defective down valve coil 2H-13B.
-- Check continuity through coil. Replace if defective.
8. Defective lift cylinder holding valve coil 2H-13B-1 or 2H-13B-2 (if equipped).
-- Check continuity through coil. Replace if defective.
9. Loose or broken wire #02 from holding valve coil 2H-13B-1 or 2H-13B-2 (if equipped) or down valve
coil 2H-13B to base terminal block.
-- Check continuity. Replace if defective.
10. See 4.1-5 platform controls or 4.1-10 base controls of this section for more troubleshooting
information.
3. Loose or broken wire #17B from 17CR steer relay to base terminal block TB1.
-- Check continuity. Replace if defective.
4. Loose or broken wire #17C from 17CR steer relay to diodes D17C and D17C-1.
-- Check continuity. Replace if defective.
5. Open or defective diode D17C or diode D17C-1.
-- Check diode. Replace if defective.
6. No output to wire #17 (while operating a reverse drive function) from diode module DM1 at base terminal
block TB1.
-- Check for 24 volts at #17 at terminal block. Replace diode module if no voltage found or is
defective.
Hydraulic System
NOTE
Down function is not proportionally controlled.
Table of Contents
Platform
5.1-1 OEM Controller Electronics Information............................................................................................................3
5.1-2 OEM Controller Troubleshooting.......................................................................................................................4
5.1-3 OEM Controller switch wiring.............................................................................................................................5
Base
5.2-1 System Relief Pressure Adjustment...................................................................................................................6
5.2-2 Lift Pressure Adjustment....................................................................................................................................6
WIRE CHART
COLOR FROM TO
WHT/RED STEER LEFT PIN #1
WHT/GRN STEER COMMON PIN #2
WHT STEER RIGHT PIN #3
YEL FORWARD/UP PIN #4
WHT/BLK +24V INPUT PIN #5
GRY REVERSE/DOWN PIN #6
BLU PWM OUT (A) PIN #7
BLK GROUND (-) PIN #8
WHT/BLU ENABLE OUT PIN #9
DOUBLE DOT
(STEER RIGHT)
15589 PCB
H1
YEL FORWARD/UP H9
GRY REVERSE/DOWN H8
H6 S1
H5
RED NO
BLK
CONNECTOR
PIN WIRE #
PLUG WIRE FUNCTION
# AND COLOUR
P1 The Calibration Connection
P2 1 Not Used Not Used
P2 2 10E Black/White Input Power From Base Terminal Strip To Confirm Lower Control Is Selected
P2 3 14 Black Raise Platform Input
P2 4 13 Orange Lower Platform Input
P2 5 Not Used Not Used
P2 6 Not Used Not Used
P2 7 16 White/Black Forward Direction Input
P2 8 15 Blue Reverse Direction Input
P2 9 Not Used Not Used
P2 10 18B Red/Black Input From LS1 High Speed Limit Switch To Verify ON/OFF Limits
P2 11 02 White Negative Input From Base Terminal Strip
P2 12 7A Red Main Power Input From Base Terminal Strip
P3 1 22 Red Output To FL-22 Flashing Light
P3 2 29 Black Output To BP-29 Beeper
P3 3 60 Black/White Output To Overload Warning Light On Control Box
P3 4 28 Green/Black Output To 28CR1 Tilt Relay And 28CR2 Down Relay
P3 5 02 White Negative for Flashing Light and Beeper
P3 6 28E Green/White Output To 28ECR1 Aux. Tilt Relay And 28ECR2 Aux. Down Relay
P4 1 Not Used Not Used
P4 2 60A Green Varied Input From Transducer
P4 3 28B Green Varied Input From Angle Transducer
P4 4 Not Used Not Used
P4 5 Not Used Not Used
P4 6 910 Black Positive Signal To Angle Transducer
P4 7 900 White Negative Signal To Pressure Transducer
P4 8 902 White Negative Signal To Angle Transducer
P4 9 910A Black Positive Signal To Pressure Transducer
60303AH
3. Quarter second flashes followed by quarter second pauses indicate the second digit
Since the GP102 only reports one error, only one code can be read from the LED per instance. If the error is cleared
and another error is present, it will then be presented.
Armguard Active! 23
Elevation Switch Shifted? 21
Elevation Switch Stuck? 22
If the 23 flash code is triggered by armguard, it will occur once then clean. This is not a true fault but just an indica-
tion of the reason for the vehicle stop. If the 21 or 22 flash code is triggered by a fault with the elevation switch, it
will not clear. Check that the elevation switch correctly opens/closes when the platform is raised/lowered.
Vehicle Tilted 11
Vehicle Overloaded 12
Too High - Drive Prevented 14
Too High - Lift Up Prevented 15
These are not true faults but an indication that vehicle movement is prevented. Remove excessive load from the
platform. Lower the platform if close to maximum height. Move the vehicle to level ground.
Testing HWFS 78
Start Up! 77
These are not true faults unless they do not clear.
WARNING
Only trained and authorized personnel shall be permitted to service and aerial platform.
WARNING
Read all instructions closely before attempting each phase or the calibration procedure.
LEFT/RIGHT Buttons
Select menus and setting to be adjusted
UP/DOWN BUTTONS
Adjust setting values
This message would occur if the DOWN switch was accidentally opened before the platform was fully
lowered.
-- If the platform is fully lowered, check the elevation switch.
The platform must return to the same height each time it is fully lowered.
-- Check DIAGNOSTICS / SYSTEM to check the height.
The height sensor output must be between 1.0V and 4.0V at all times.
-- Check DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring
problem.
This is probably due to a faulty transducer or faulty/open holding valve(s)/ emergency lowering valve.
Platform Empty?
This message is prompting for confirmation that the platform is completely empty. Press ENTER to confirm if
the platform is empty.
Platform Loaded?
This message is prompting for confirmation that the platform is loaded to rated load Press ENTER to confirm
if the platform is loaded.
Please Lift
This message is prompting for the platform to be raised. The UP switch should be closed.
Please Lower
This message is prompting for the platform to be lowered. The DOWN switch should be closed.
Lift Empty
This message is displayed while the platform is being raised to the next measurement height, when an EMPTY
platform is being calibrated.
Lift Loaded
This message is displayed while the platform is being raised to the next measurement height, when a LOADED
platform is being calibrated.
Lifting
This message is displayed while the platform is being raised, during HEIGHT-only calibration.
Measuring #
This message is displayed when the platform is stopped during calibration, when the GP102 takes a measurement.
There will be a short delay while the machine is allowed to stabilize after movement is stopped.
Must Go Down!
This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be lowered.
Must Go Up!
This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be raised.
Please Wait
This message indicates that the GP102 is busy; the delay will be short (no more than 5 s).
Lower Empty
This message is displayed while the platform is being lowered to the next measurement height, when an EMPTY
platform is being calibrated.
Lower Loaded
This message is displayed while the platform is being lowered to the next measurement height, when an EMPTY
platform is being calibrated.
Lowering
This message is displayed while the platform is being lowered, during HEIGHT-only calibration.
Total Data:
This message is displayed at the end of each phase, to confirm the number of measurements recorded by the
GP102.
Caldate
This message is prompting for the date to be entered; it is stored to identify when the machine was
calibrated.
The last calibrate date can be viewed in DIAGNOSTICS / LOG. Press LEFT & RIGHT to select the flashing digits.
Press UP & DOWN to change the flashing digits. Press ENTER when the entry is complete. IMPORTANT: The
date 00/00/00 is not allowed!
Finished
This message confirms that calibration is complete and successful.
1. Move the aerial platform to a test area where the platform can be elevated to its maximum working height and
reach.
IMPORTANT
Each phase must be completed before the next phase can be carried out.
All phases must be completed before the aerial platform can be operated.
IMPORTANT
Always follow the instructions of the Calibration instrument.
IMPORTANT
Make sure the aerial platform is on BASE mode.
NOTE
To ensure a good and clear contact, clean the wire terminals before attaching the jumper clip.
6. The jumper connection must be connected between the contractor (wire #19B) and the lift coil (instead of the
black wire #14)
JUMPER, Insulated
Alligator Clip
Coil Black wire #14 Wire #19B
Lift Valve
13. The display will show X=GROUP CODE. (Refer to 5.3-7 for group code)
By using the Up/Down buttons, enter the Group Code (?) then by using Left/Right buttons, select the Curve
from the menu.
14. The display will show X=CURVE. (Refer to 5.3-7 for curve code)
By using the Up/Down buttons, enter the Curve Code (?) followed by pressing the ESCAPE button.
17. The display will show Calibrate Level: Yes: Enter, No: ESC.
Select the Yes from the menu by press the ENTER button.
18. The display will show Calibrate Level: Tilt 0.0 , 0.0.
Select the ESCAPE from the menu once.
26. Hold the lift switch and keep holding it until the platform is fully elevated.
IMPORTANT
If the lift switch is released earlier than full-height position, the
calibration will have to be aborted and repeated from the beginning!
27. When the system detects the lift switch closed, the display will show Calibrate Load: Lift Empty.
28. After a delay, the system will stop the platform lifting and will take height & pressure measurements; the display
will show MEASURING # xx When the measurements have been taken, the platform will resume lifting.
NOTE
The Lifting......stopping.......measuring....lifting process will continue until the platform reaches full height.
29. When the platform reaches full height release the lift switch.
30. The display will briefly show TOTAL DATA: 04 to indicate the number of measurements taken.
IMPORTANT
If the lower switch is released earlier than full-lower position, the
calibration will have to be aborted and repeated from the beginning!
32. Hold the lower switch and keep holding it until the platform is fully lowered.
33. When the system detects the lower switch closed, the display will show Calibrate Load: Lower Empty
34. After a delay, the system will stop the platform lowering and will take height & pressure measurements; the.
display will show MEASURING #xx. When the measurements have been taken, the platform will resume
lowering.
NOTE
The lowering......stopping.......measuring....lowering process will
continue until the platform is fully lowered.
35. When the platform is fully lowered, release the lower switch.
36. The display will show briefly TOTAL DATA: 04 to indicate the number of measurements taken.
38. Press ENTER to complete date entry (the system will store it). Display will show FINISHED.
39. Remove the jumper wire and re-connect the black wire #14 to the coil removed earlier.
NOTE
Continuing partially complete load calibration.
If the phase does not need to be repeated, just press ENTER to move on.
If the phase does need to be repeated, press UP or DOWN to change NO to YES then press ENTER.
Number of
Model Curve Code Group Code
Extension Platforms
3220 1 Manual Extension Platform 3 3
3220 1 Powered Extension Platform 4 3
3226 1 Manual Extension Platform 5 3
4620 1 Manual Extension Platform 8 3
4620 1 Powered Extension Platform 9 3
4626 1 Manual Extension Platform 12 3
4626 1 Powered Extension Platform 13 3
4632 1 Manual Extension Platform 14 3
60404AE_SJ3D
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