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Skyjack SJ 6826RT, Service Manual

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Skyjack SJ 6826RT Service Manual Download Page 160

 

165

SJ6826RT, SJ6832RT

213560ABA  

Load Sensing System

 

Section 5 – Procedures

5.5-2  Machine Level Calibration 

Procedure

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. Always follow the instructions of the 
Calibration instrument.

1. 

Ensure aerial platform is parked on a firm and 
level surface.

2. 

Elevate the scissors high enough to lay a level 
across the base tubes. Ensure there is no debris 
on the base and the level sits flat. Do not elevate 
aerial platform higher than the high speed/tilt 
override limit switch.

3. 

Manually operate the outriggers and level the 
machine in 4 places: left side, right side, front 
and rear. All 4 outriggers must be firmly placed 
and all 4 tires are off the ground.

4. 

Double check that the aerial platform is level at 
all 4 points. 

5. 

Connect the EZcal tool to the P1 connector on 

the 

CONTROL MODULE

.

6. 

The display will show 

Help: Press Enter

.

Access Level Procedure

7. 

By using Left/Right buttons, select the 

Access 

Level (3 )

 from the menu and press the 

ENTER

 

button.

8. 

The display will show 

Access Level: Code 

(0000)

.

9. 

By using the Up/Down buttons, enter the 
Access Level Code (1 

1 

 2 

 2) followed by 

pressing the

 ENTER

 button. 

10. 

The display will show 

Access Level 2

. By using 

Left/Right buttons, select the 

Setups

 from the 

menu and press the

 ENTER

 button.

11. 

The display will show 

Setups: Change Defaults

. 

Select the 

Change Defaults

 from the menu and 

press the 

ENTER

 button.

12. 

The display will show 

Defaults, 0 = Custom

. 

By using Up/Down buttons, select the Defaults: 
Code Setting for your Model (For default code, 

refer to 

5 .5-9 Curved/Group codes chart ) 

from 

the menu.

13. 

Press 

ENTER

 and followed by

 ESCAPE

. 

Calibrate Level Procedure

14. 

The display will show 

Setups Change Defaults

. 

By using Left/Right buttons, select the 

Calibrate 

Level

 from the menu and press the 

ENTER

.

15. 

The display will show 

Calibrate Level: Yes: 

Enter, No: ESC

. Select the 

Yes

 from the menu 

by press the 

ENTER

 button.

16. 

The display will show 

Calibrate Level: Tilt 

0.0’ , 0.0’

. Select the 

ESCAPE

 from the menu 

once.

17. 

The display will show 

Setups Calibrate Level

 

Select the 

ESCAPE

 from the menu once again.

18. 

The Calibration procedure is complete, unplug 
and remove the EZcal. 

19. 

Close the hydraulic/electric cabinet.

To 

order 

go 

to 

Discount-Equipment.com

Summary of Contents for SJ 6826RT

Page 1: ...SERVICE MANUAL ROUGH TERRAIN SCISSORS 213560AA November 2019 ANSI CSA CE AS KC SJ6826RT SJ6832RT T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 2: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 3: ...RT A200 000 001 A200 999 999 Please refer to the website www skyjack com for contact information other serial numbers the most recent technical manuals and USB software Original instructions in English T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 4: ... 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 res...

Page 5: ...rd 16 1 4 Frequent Periodic Annual Pre Delivery Inspection Checklist 17 1 5 General inspections 18 1 5 1 Service Bulletins 18 1 5 2 Annual Inspection 18 1 5 3 Labels 18 1 5 4 Limit switches 18 1 6 Base Engine 19 1 7 Scissors inspection 24 1 8 Platform inspections 28 1 9 Function Tests 29 Section 2 Maintenance Tables and Diagrams 31 2 1 Standard Hose Numbering System 31 2 2 Torque Specifications fo...

Page 6: ...iring Diagram 65 3 19 Electrical Panel Diagram ANSI CSA CE AS 67 3 20 Electrical Panel Diagram KC 68 3 21 Electrical Panel Diagram Positive Air Shut Off 69 3 22 Electrical Panel Diagram Soft Stop 70 3 23 Hydraulic Schematic ANSI CSA 71 3 24 Hydraulic Schematic CE AS 72 3 25 Hydraulic Schematic KC 73 3 26 Electrical Schematic Kubota Dual Fuel WG752 ANSI CSA 74 3 27 Electrical Schematic Kubota Diese...

Page 7: ...Lift from Platform or Base Control Console with Outriggers Extended 106 4 2 25 Platform does not Lift from Platform or Base Control Console with Outriggers Extended or Retracted 108 4 2 26 Down Function Inoperative from Platform 108 4 2 27 Down Function Inoperative from Base 109 4 2 28 Hydraulic Generator Inoperative 111 4 2 29 Hydraulic Generator does not Shut Off from Generator Switch 112 4 2 30...

Page 8: ...ut Inspection and Torquing Procedure 133 5 2 5 Wheel Reinstallation and Torquing Procedure 133 5 2 6 Reconnecting the Platform Control Box for Use from the Ground 133 5 2 7 Tightening and Torque Recommendations for Hydraulic Couplings and Hoses 134 5 2 8 Torquing Using the Flats From Wrench Resistance Method 135 5 2 9 Checking the Holding Valve 136 5 2 10 System Pressure Setting 136 5 2 11 Lift Pr...

Page 9: ...S68 Replacement and Adjustment 162 5 4 9 Outrigger Mechanical Limit Switch Wiring Diagram 163 5 5 Load Sensing System 164 5 5 1 Calibrate Load Checking Load Procedure 164 5 5 2 Machine Level Calibration Procedure 165 5 5 3 Load Sense Module CM1 Pin Reference Table GP 102 166 5 5 4 Control Module Initial Set up Procedures 167 5 5 5 LED Error Codes Quick Reference Chart 170 5 5 6 LED Error Codes Cod...

Page 10: ... the first 2 years or 3000 hours whichever occurs first Any defective part will be replaced or repaired by your local Skyjack dealer at no charge for parts or labor In addition all products have a 5 year structural warranty Contact the Skyjack Service Department for warranty statement extensions or exclusions 1 1 5 Ownership of MEWP Notify Skyjack of MEWP ownership If you sell or transfer the owne...

Page 11: ...y must be immediately tagged and removed from service until proper repairs are completed 1 2 3 Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this MEWP All maintenance and service procedures should be performed in a well lighted and well ventilated area Anyone operating or servicing this MEWP must read and c...

Page 12: ...ence of metal particles also may indicate the possibility of imminent component failure A very small amount of fine particles is normal 5 All containers and funnels used in handling hydraulic oil must be absolutely clean Use a funnel when necessary for filling the hydraulic oil reservoir and fill the reservoir only through the filter opening The use of cloth to strain the oil should be avoided to ...

Page 13: ...the reason they are so often overlooked They are simply these 1 Change filters annually The filters will need to be changed more often depending on the operating conditions Dirty dusty high moisture environments may cause the hydraulic system to be contaminated more quickly 2 Maintain a sufficient quantity of clean hydraulic oil of the proper type and viscosity in the hydraulic reservoir 3 Keep al...

Page 14: ...guration MEWP parked on a flat and level surface Disconnect the batteries by disconnecting the main power connectors Repair any damaged or malfunction components before operating MEWP Keep records on all inspections Maintenance Instructions This manual consists of four schedules to be done for maintaining on an MEWP Inspection schedule frequency is shown below Task Frequency PDI Frequent B Perform...

Page 15: ...there is no inspection recorded in the last 13 months If you do not obey there is a risk of death or serious injury IMPORTANT The Owner s annual inspection record is located on the scissor assembly It must be filled out after an annual inspection has been completed Do not use the MEWP if an inspection has not been recorded in the last 13 months T o o r d e r g o t o D i s c o u n t E q u i p m e n...

Page 16: ...orrectly aligned B Wheel Tire Assembly Wheel nuts torqued as recommended C Axles Correctly attached no missing components Tight fittings and hoses no leaks B Axles Do a check and replace oil if necessary C Hydraulic Tank Pump Motor Lines Filler cap hoses and other hydraulic components are closed tightly no damage or leaks B Hydraulic Oil Level at or slightly above top mark B Hydraulic Oil Do a che...

Page 17: ... CAUTION Make sure that the MEWP is on a firm level surface before you do the visual and daily maintenance inspections If you do not obey there is a risk of machine damage 1 5 1 Service Bulletins B Go to www skyjack com and use your machine s serial number to find related open service bulletins 1 5 2 Annual Inspection B Do a check on the machine s service record to find information about previous ...

Page 18: ... on the air cleaner Replace the filter element if necessary 3 Engine Oil B Use the dipstick to check the oil level The oil level must be between the marks L low and H high Add oil if it is necessary 4 Radiator B C B Frequent periodic pre delivery Inspection Make sure that the radiator is correctly installed Make sure there are no loose or missing parts Make sure there is no visible damage C Annual...

Page 19: ...e sure all the battery connections are tight Clean the battery terminals and cable ends thoroughly with a terminal cleaning tool or wire brush If applicable do a check on the battery fluid levels If the plates do not have a minimum 13 mm 1 2 inch of solution above them add distilled or demineralized water Replace battery if damaged or incapable of holding a lasting charge WARNING Only use original...

Page 20: ...nd sidewalls for cuts cracks and unusual wear Do a check on each wheel for damage and cracked welds Make sure the wheels are correctly aligned vertically and horizontally Make sure there is no visible damage Do a check on wheel motor assembly for loose or missing parts and no visible damage WARNING Do not use tires other than the tires that Skyjack specifies for this MEWP Do not mix different type...

Page 21: ...de of the hydraulic oil tank The hydraulic oil level must be at or a small distance above the top mark of the gauge C Annual Inspection Do a check on the hydraulic oil for contamination Make sure the oil filter is in good condition Replace the hydraulic oil and filters if necessary 13 Electrical components B Do a check on these areas for chafed corroded and loose wires Base to platform cables and ...

Page 22: ...ed Make sure there is no visible damage AC power socket B Make sure there is no visible damage 18 Base Weldment B There are no cracks in the welds or structure There are no signs of deformation 19 Grease points B Make sure there is no visible damage Make sure there is no dirt or blockages Add grease if necessary 20 Ladder B Make sure there are no loose or missing parts Make sure there is no visibl...

Page 23: ...wear and or physical damage Make sure that the scissor bumpers are correctly attached and have no visible damage 3 Sliders Rollers B Make sure that the sliders and rollers on the left and right side of the MEWP are correctly attached Make sure there is no visible damage Make sure there is no dirt or blockages in the slider or roller paths 4 Lift Cylinder s B Make sure that the lift cylinders are c...

Page 24: ...n joint Cracks in welds of adjacent metals Dust or metal shaving from worn components Broken or missing pin retainer bolts Broken or missing pin retainers Rotated pin Elongated or enlarged pin hole 2 Remove damaged pins and bushings Do an inspection of the scissor bore after removing the applicable pins and bushings Look for signs of damage elongation and ovality of the hole 3 If there is no struc...

Page 25: ...ection Center Pin Outer Center Pin Middle Center Pin Inner Examples of damaged pin connections Broken retainer bolt Rust around the pin Rotated pin Rust around pin boss Stress cracks Broken pin boss Thrust washer 6 6 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 26: ...unts These signs can include Broken loose or missing retainers or bolts Bearing block degradation Cracks in welds or the surrounding metal or rust forming in the area Broken missing or loose retainers or bolts Cracks in weld or surrounding metal rust in the area Bearing block degradation Note weld intentionally not located at bolt area 7 7 Upper cylinder mount area Lower cylinder mount area Model ...

Page 27: ...rectly installed Make sure there is no visible damage 3 AC power socket B Make sure there is no visible damage 4 Platform control console B Make sure the control console is locked with lock pins Make sure the platform control cable is correctly locked and there is no visible damage Make sure all switches operate correctly 5 Manual storage box B Make sure that the operation manual and other importa...

Page 28: ...alified service technician must repair the MEWP If you do not obey there is a risk of death or serious injury After repairs are completed operator must do a pre operation inspection and a series of function tests again before putting MEWP into service Before you do the function tests read and understand the Start Operation section of the operating manual Before you do the function tests look for t...

Page 29: ... JIC SWIVEL FEMALE 37 JIC SWIVEL 100R13 H03 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R17 H04 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R13 H05 FEMALE 37 JIC SWIVEL LONG 90 FEMALE 37 JIC SWIVEL 100R17 H06 FEMALE 37 JIC SWIVEL SHORT 90 FEMALE 37 JIC SWIVEL 100R17 H07 LONG 90 FEMALE 37 JIC SWIVEL LONG 90 FEMALE 37 JIC SWIVEL 100R17 H08 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R4 H09 ...

Page 30: ...ONG 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R4 H40 SHORT 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R16 H43 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R16 H51 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H52 SHORT 45 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H53 MEDIUM 45 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H54 SHORT 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIV...

Page 31: ...ctite 1374AA Size Torque Type SAE2 SAE 5 SAE 8 Dry Lubed Dry Lubed Dry Lubed 9 16 12 ft lb 70 55 110 80 150 110 Nm 95 75 149 108 203 149 9 16 18 ft lb 80 60 120 90 170 130 Nm 108 81 163 122 230 176 5 8 11 ft lb 100 75 150 110 220 170 Nm 136 102 203 149 298 230 5 8 18 ft lb 110 85 180 130 240 180 Nm 149 115 244 176 325 244 3 4 10 ft lb 175 130 260 200 380 280 Nm 237 176 353 271 515 380 3 4 16 ft lb...

Page 32: ...106 201 150 6 8 5 1 M16 x 2 00 ft lb 161 121 230 172 68 51 Nm 218 164 312 233 7 7 5 8 M18 x 2 50 ft lb 222 167 318 238 12 9 Nm 301 226 431 323 16 12 M20 x 2 50 ft lb 314 235 449 337 14 10 Nm 426 319 609 457 19 14 M22 x 2 50 ft lb 428 321 613 460 25 18 Nm 580 435 831 624 34 24 M24 x 3 00 ft lb 543 407 776 582 25 20 Nm 736 552 1052 789 34 27 M27 x 3 00 ft lb 796 597 1139 854 45 35 Nm 1079 809 1544 1...

Page 33: ... lb Nm ft lb Nm Min Max Min Max Min Max Min Max 4 1 4 10 11 13 15 5 6 6 75 9 6 3 8 17 19 23 26 12 15 17 20 8 1 2 34 38 47 52 20 24 27 66 33 10 5 8 50 56 69 76 34 40 46 33 55 12 3 4 70 78 96 106 53 60 72 33 82 16 1 94 104 127 141 74 82 100 5 111 20 1 1 4 124 138 169 188 75 83 101 5 113 24 1 1 2 156 173 212 235 79 87 107 118 32 2 219 243 296 329 158 175 214 237 Hose End Torque Chart for Flat Face O ...

Page 34: ... Nm max 4 07 13 56 20 34 33 9 40 68 47 46 Bolts Type of Bolt Torque ft lb Torque Nm Directional valve mounting bolts 2 33 28 32 in lb 3 16 3 61 Wheel mounting bolts 90 122 Wheel motor castle nut front 350 474 54 Wheel motor castle nut back 350 474 54 Center drive sprocket mounting bolts 110 115 242 Loctite 149 156 Hydraulic drive motor mounting bolts 120 242 Loctite 162 Positive battery post cable...

Page 35: ...93 5 in 2510 mm 99 in Stowed Height Railings Down 1620 mm 63 5 in 1750 mm 69 in Drive Height Maximum 7 8 m 25 7 ft 9 6 m 31 6 ft Standard Operating Times Lift Time No Load 32 36 sec Lower Time No Load 46 50 sec 44 48 sec Lift Time Rated Load 34 38 sec 37 41 sec Lower Time Rated Load 34 38 sec Chassis Drive Speed Stowed 5 78 6 10 km h 3 59 3 79 mph Drive Speed Elevated 0 52 0 61 km h 0 32 0 38 mph ...

Page 36: ...niform Pressure is a measure of the average load the MEWP imparts on the whole surface directly underneath it The structure of the operating surface beams for example must be able to withstand more than the indicated values above 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 particul...

Page 37: ...tional information and models equipped with options 2 9 Environment Model SJ6826 RT SJ6832 RT Electromagnetic Compatibility EMC Meets requirements of ISO 13766 1 2018 and CAN CSA CISPR 12 10 Hazardous Location Rating MEWP not rated for hazardous locations with potentially flammable gases explosive gases or particles Sound Pressure Level ISO 3744 72 dB Guaranteed Maximum Sound Power Level ISO 4871 ...

Page 38: ...mmended Equivalent Oil Kubota D902 3 9 1 03 SAE 10W 30 10W30 API Service Designation CG 4 CF 4 CD SH Kubota D972 Kubota WG752 3 4 0 9 Engine Coolant Engine Type Capacity Liters Capacity US Gallons Coolant Type Kubota 3 1 0 82 Anti freeze 50 50 Premix Engine Fuel Engine Type Capacity Liters Capacity US Gallons Fuel Type Kubota D902 86 88 22 95 Diesel Kubota D972 Unleaded Gasoline Kubota WG752 1431A...

Page 39: ...41 SJ6826RT SJ6832RT 213560ABA Section 3 System Component Identification and Schematics T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 40: ...CUIT BREAKER VOLT METER CAPACITOR POTENTIOMETER SINGLE POLE DOUBLE THROW RELAY TRIPLE POLE DOUBLE THROW RELAY RELAY RELAY DOUBLE POLE DOUBLE THROW SINGLE POLE SINGLE THROWN TILT SWITCH CAM OPERATED LIMIT SWITCH LIMIT SWITCH ROTARY SWITCH PUSH BUTTON TOGGLE SWITCH FOOT SWITCH KEY SWITCH TEMPERATURE SWITCH LIMIT SWITCH LIMIT SWITCH CLOSED LIMIT SWITCH LIMIT SWITCH SILICON CONTROLLED RECTIFIER PROXIM...

Page 41: ...IC RELEASED BRAKE ADJUSTABLE FLOW CONTROL ENGINE FLOW DIVIDER COMBINER BRAKE CYLINDER CYLINDER CHECK VALVE FIXED DISPLACEMENT PUMP COUNTER BALANCE VALVE ROTARY ACTUATOR OIL COOLER VALVE COIL BI DIRECTIONAL HYDRAULIC MOTOR TWO POSITION TWO WAY NORMALLY CLOSED VALVE SERIES PARALLEL HYDRAULIC MOTOR TWO POSITION THREE WAY VALVE THREE POSITION FOUR WAY CLOSED CENTER OPEN PORT TWO POSITION THREE WAY VAL...

Page 42: ...HT 07 RED 28 GRN RED 60 BLK RED GRN 103 RED 3008 GRY 08 PUR WHT 29 BLU YEL 71 BLU RED 103B BLK 4002 RED 09 ORG RED 30 BRN 72 WHT BLK RED 103C WHT 7002 RED 10 BLU WHT 31 RED WHT 73 WHT RED GRN 104 RED 11 YEL BLK 32 GRN BLK 74 BLK RED GRN 105 GRN 12 BRN RED 33 75 WHT RED GRN 106 BLU 13 ORG 34 GRN WHITE 76 RED GRN 200 BLK WHT 14 BLK 35 RED BRN 77 GRN BLK WHT 203 ORG BLK 15 BLU 36 YEL 78 RED BLK WHT 2...

Page 43: ...LVE Pilot check CV7 104115 1 VALVE Pilot check CV8 104115 1 VALVE Pilot check CV9 104115 1 VALVE Pilot check CV10 104115 1 VALVE Pilot check F1 136408 1 FILTER ASSEMBLY FD1 169282 1 VALVE Flow divider HP2 110652 1 PUMP Brake hand 2H 13 107271 1 VALVE Control Lowering 2H 13 1 210298 1 VALVE Holding Lower cylinder 2H 13 2 125915 1 VALVE Holding Upper cylinder 2H 17A 114365 1 VALVE Control Large pump...

Page 44: ...1 137215 1 BLOCK Manifold Main MB2 MB3 130443 1 BLOCK Manifold Lower holding valve KC 210297 1 BLOCK Manifold Lower holding valve MB4 108778 1 BLOCK Manifold Upper holding valve MB5 140898 1 BLOCK Manifold Sandwich MB6 139450 1 BLOCK Manifold Splitter MB7 MB8 111970 1 BLOCK Manifold Outrigger MB9 146082 1 BLOCK Manifold Hydraulic generator MB10 194323 1 BLOCK Manifold Flow Control O1 105281 1 ORIF...

Page 45: ...t 40 Amp Reverse drive 16CR 127035 1 RELAY 12 Volt 40 Amp Forward drive 17CR 127035 1 RELAY 12 Volt 40 Amp Small pump 17DCR 127131 1 RELAY 12 Volt Outrigger lift disable 19CR 127035 1 RELAY 12 Volt 40 Amp Large pump 20CR 127035 1 RELAY 12 Volt 40 Amp Series Parallel drive 20ACR1 127035 1 RELAY 12 Volt 40 Amp Series Parallel 20ACR2 127035 1 RELAY 12 Volt 40 Amp Series Parallel 28ACR1 127035 1 RELAY...

Page 46: ...1 MODULE Overload sensing system ANSI AS CM1 139301 1 MODULE Overload sensing system CE CPS1 138224 1 SENSOR Crankshaft position CRD1 138225 1 CONTROL CABLE ASSEMBLY Control console CRD2 138226 1 CONTROL CABLE ASSEMBLY Scissor arm Model 6826RT 144387 1 CONTROL CABLE ASSEMBLY Scissor arm Model 6832RT CRD3 137354 1 CONTROL CABLE ASSEMBLY Electrical panel CS 31A 103007 1 SOLENOID Choke DXX 102921 AR ...

Page 47: ... contact Up down S3 1 SWITCH ASSEMBLY Lift Drive low Drive 137793 1 HEAD Switch selector 3 Way 137788 1 SWITCH ASSEMBLY Base 137783 3 BLOCK N C Contact 137782 4 BLOCK N O Contact 137781 1 LATCH S4 1 SWITCH ASSEMBLY Emergency stop 137795 1 SWITCH HEAD Emergency Stop Red 137790 1 SWITCH ASSEMBLY Base 137785 1 SWITCH LED block Red 137783 2 BLOCK N C Contact 137781 1 LATCH S6 137790 1 SWITCH BASE ASSE...

Page 48: ... S31 102692 1 SWITCH Engine glow plug S32 102692 1 SWITCH Engine start push button S33 115747 1 SWITCH Fuel select TPS1 113400 1 SWITCH Engine temperature TS1 146661 1 TILT SWITCH KC Only TT 195940 1 HOUR METER 2H 13 103613 1 COIL 12 Volt Lowering valve 2H 13 1 103613 1 COIL 12 Volt Lower lift cylinder holding valve 2H 13 2 103613 1 COIL 12 Volt Upper lift cylinder holding valve 2H 17A 106272 1 CO...

Page 49: ...H 72 128321 1 COIL 12 Volt Front right outrigger retract 4H 73 128321 1 COIL 12 Volt Rear right outrigger retract 4H 74 128321 1 COIL 12 Volt Rear left outrigger retract 4H 75 128321 1 COIL 12 Volt Front left outrigger extend 4H 76 128321 1 COIL 12 Volt Front right outrigger extend 4H 77 128321 1 COIL 12 Volt Rear right outrigger extend 4H 78 128321 1 COIL 12 Volt Rear left outrigger extend T o o ...

Page 50: ... CV1 CHECK VALVE CB1 MAIN COUNTERBALANCE VALVE CB2 PARALLEL COUNTERBALANCE VALVE S6 3H 30D BRAKE VALVE S3 2H 13B LOWERING VALVE S7 4H 20A SERIES PARALLEL VALVE O4 BRAKE ORIFICE S9 4H 15B PARALLEL REVERSE DRIVE VALVE S10 2H 20B HIGH SPEED VALVE S9 4H 16B PARALLEL FORWARD DRIVE VALVE TO STEER CYLINDER TO LIFT CYLINDER TO SMALL PUMP TO LARGE PUMP R2 LIFT RELIEF VALVE TO TANK TO DRAIN TO BRAKE S2 2H 1...

Page 51: ...REAR RETRACT 4H 73A OUTRIGGER RIGHT REAR RETRACT 4H 72A OUTRIGGER RIGHT FRONT RETRACT 4H 78A OUTRIGGER LEFT REAR EXTEND 4H 75A OUTRIGGER LEFT FRONT EXTEND 4H 77A OUTRIGGER RIGHT REAR EXTEND 4H 76A OUTRIGGER RIGHT FRONT EXTEND 2H 17C OUTRIGGER HOLDING VALVE M138045AB 3 7 Hydraulic Manifold Valve Assemblies and Port Outrigger Manifold MB8 Splitter Manifold MB6 T o o r d e r g o t o D i s c o u n t E...

Page 52: ...A B C D E F G H V Z Y X W 55 SJ6826RT SJ6832RT 213560ABA M208611AC 3 8 Control Box Wiring Diagram T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 53: ...A B C D E F G H V Z Y X W 56 SJ6826RT SJ6832RT 213560ABA M208044AB 3 9 Base to Platform Control Cable SJ6832 RT T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 54: ...A B C D E F G H V Z Y X W 57 SJ6826RT SJ6832RT 213560ABA M208020AB 3 10 Base to Platform Control Cable SJ6826 RT T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 55: ...A B C D E F G H V Z Y X W 58 SJ6826RT SJ6832RT 213560ABA M208726AA_SR 3 11 Beeper Wiring Assembly T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 56: ...LACK 16B WHITE RED 17A BLUE RED ANSI CSA 17B BLUE RED CE 18B RED BLACK ANSI CSA 18C RED BLACK CE 20A BLACK WHITE RED 23 BLACK WHITE 24 BLUE BLACK 30 BROWN 86D ORANGE BLACK WHITE 02 02 2 0 A 0 2 20B 02 02 86D PARALLEL FORWARD VALVE BLACK HIRSHMAN PIN 1 16B WHITE RED PIN 2 02 WHITE PARALLEL REVERSE VALVE GREY HIRSHMAN PIN 1 15B BLUE YELLOW PIN 2 02 WHITE INSERT ORIENTATION BOTTOM VIEW HYDRAULIC GENE...

Page 57: ...AL STRIP TO TERMINAL STRIP 02 17 17A 28A 28ACR2 02 18A 18B 28A 28ACR1 02 17A 17B 28E 28ECR2 02 18A 18B 28E 28ECR1 2A 37 3A 10 10CR1 DISCONNECT FROM 32CR1 ENGINE STARTER CONTACTOR TRACKUNIT RELAY TO TRACKUNIT RELAY WIRE 07 TO KEY LINE WIRE 07 TO TERMINAL STRIP J1 B 0 0 32C B 1 A 10 32AU 37 30 SPUMP SKEY 10E 07 17A B 18B C 18B C 17A B ANSI KC CE AS 32AD 32A 7 3 13 Elevate Telematics Harness T o o r ...

Page 58: ...A B C D E F G H V Z Y X W 61 SJ6826RT SJ6832RT 213560ABA M137528AC 3 14 Kubota Engine Harness Diesel T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 59: ...A B C D E F G H V Z Y X W 62 SJ6826RT SJ6832RT 213560ABA M198923AA 3 15 Kubota Engine Harness Dual Fuel T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 60: ...A B C D E F G H V Z Y X W 63 SJ6826RT SJ6832RT 213560ABA M129300AB_5 3 16 Outrigger Control Box T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 61: ...A B C D E F G H V Z Y X W 64 SJ6826RT SJ6832RT 213560ABA M129301AB_1 3 17 Outrigger Hydraulic Generator Control Box T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 62: ...A B C D E F G H V Z Y X W 65 SJ6826RT SJ6832RT 213560ABA M194265AB 3 18 Hydraulic Generator Electrical Panel Assembly T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 63: ... 2 100 TELEMATICS CONNECTIONS PART OF STANDARD ELECTRICAL PANEL TO TELEMATICS DEVICE 02 D10 37 37 KEY 02 KEY 37 103 1 0 3 03 MAIN DISCONNECT SWITCHS1 MAINBATTERY B1 TOENGINE D7 M171108AA 3 19 Telematic Harness Wiring Diagram T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 64: ...49 BLACK 00 WHITE 14GA 03 BLUE 14GA ENGINE HARNESS 49 02 PLATFORM CONTROL BOX HIGH SPEED LIMIT SW 10A 35 D18 18 4 7 1 6 9 3 BACK VIEW 2 5 8 10 12 11 LOAD SENSE CTRL MODULE OUTR CTRL MODULE 02 44 10A HOURMETER TT MAIN MANIFOLD HARNESS MAIN MANIFOLD HARNESS 02 WHITE 17B BLUE RED 13B ORANGE 18C RED BLACK 14A BLACK 20A BLACK WHITE RED 15A BLUE 23 BLACK WHITE 15B BLUE YELLOW 24 BLUE BLACK 16A WHITE BLA...

Page 65: ...EN 29 BLACK 82 RED TO HORN 02 WHITE 49 BLACK 00 WHITE 14GA MAIN DISCONNECT SWITCH S1 MAIN BATTERY B1 03 BLUE 14GA TO ENGINE 44 0 0 02 28C 05 10E 07 13 14E 29 10B 3A 29 10 32 22 05 2A 02 17 20 16B 16B 15B 32 32 15 15 16 16 20 19 19 37 37 34C 34C 32A 32A 02 02 02 02 02 02 02 02 02 02 02 02 02 02 02 05 32 32 32 29 28B 20A 20A 20A 21 33 44 18 18A 18A 17 17 44 16A 16A 15A 15A 10A 10A 10A 10A 17A 18B 28...

Page 66: ...TE FLAT PANEL LAYOUT MAIN BATTERY B1 D 0 9 35 35B A B B A B A A B 2 X2 X1 1 15B 20A 16B F1 FUSE 300 AMP TO LOAD SENSING CONTROL MODULE P2 PIN 1 N U PIN 2 10E BLUE WHITE PIN 3 14 BLACK PIN 4 13 ORANGE PIN 5 N U PIN 6 N U PIN 7 16 WHITE BLACK PIN 8 15 BLUE PIN 9 N U PIN 10 35B RED BLACK PIN 11 02 WHITE PIN 12 10A BLUE BLACK 103 1 0 3 03 MAIN DISCONNECT SWITCH S1 LS5 35 10A BACK VIEW TO OUTR CTRL MOD...

Page 67: ... 86D ORANGE BLACK WHITE 16B WHITE RED D17B D 1 8 C D08 D14A 1 D 1 0 E D 4 4 D14E 1 D 1 4 E 2 D16A 2 D 1 5 A 2 D15A 1 D 1 6 A 1 D24 D23 NOTE FLAT PANEL LAYOUT MAIN BATTERY B1 D 0 9 35 35B A B B A B A A B 2 X2 X1 1 15B 20A 16B F1 FUSE 300 AMP TO LOAD SENSING CONTROL MODULE P2 PIN 1 N U PIN 2 10E BLUE WHITE PIN 3 14 BLACK PIN 4 13 ORANGE PIN 5 10 RED PIN 6 N U PIN 7 16 WHITE BLACK PIN 8 15 BLUE PIN 9...

Page 68: ...6RT SJ6832RT 213560ABA V W Y Z L M N O F G H K X I J E D C B A U T S R M220059AA 3 24 Hydraulic Schematic ANSI CSA 3 24 Hydraulic Schematic ANSI CSA T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 69: ... Z L M N O F G H K X I J E D C B A U T S R 72 SJ6826RT SJ6832RT 213560ABA M137360AL 3 25 Hydraulic Schematic CE AS 3 25 Hydraulic Schematic CE AS T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 70: ...G VALVE 05 BRAKE ORIFICE Ø0 028 MB1 68XXRT MAIN MANIFOLD VALVE EXTEND OUTRIGGER LEFT FRONT 4H 75 VALVE EXTEND OUTRIGGER RIGHT FRONT 4H 76 VALVE EXTEND OUTRIGGER RIGHT REAR 4H 77 VALVE EXTEND OUTRIGGER LEFT REAR 4H 78 VALVE HOLDING OUTRIGGER 2H 17C VALVE RETRACT OUTRIGGER LEFT FRONT 4H 71 VALVE RETRACT OUTRIGGER RIGHT FRONT 4H 72 VALVE RETRACT OUTRIGGER RIGHT REAR 4H 73 VALVE RETRACT OUTRIGGER LEFT...

Page 71: ...AY SERIES PARELLEL RELAY SERIES PARELLEL RELAY BEEPER FLASHING LIGHT OPTION CONTROL MODULE SMALL PUMP RELAY D02 4 3H 14A HORN PRESSURE TRANSDUCER ANGLE TRANSDUCER AUX DOWN ENABLE RELAY SMALL PUMP DUMP AUX ENABLE RELAY LARGE PUMP DUMP ENABLE RELAY SMALL PUMP DUMP ENABLE RELAY LARGE PUMP DUMP AUX ENABLE RELAY H1 02 DOWN ENABLE RELAY MAIN LOWERING VALVE SOLENOID HOLDING VALVE SOLENOID HOLDING VALVE S...

Page 72: ...ESSURE TRANSDUCER ANGLE TRANSDUCER AUX DOWN ENABLE RELAY SMALL PUMP DUMP AUX ENABLE RELAY LARGE PUMP DUMP ENABLE RELAY SMALL PUMP DUMP ENABLE RELAY LARGE PUMP DUMP AUX ENABLE RELAY H1 02 DOWN ENABLE RELAY MAIN LOWERING VALVE SOLENOID HOLDING VALVE SOLENOID HOLDING VALVE SOLENOID THROTTLE RELAY START RELAY POWER ON DEMAND RELAY THROTTLE ENABLE RELAY MAIN POWER RELAY D02 3 D02 2 13B D02 1 2H 13B 1 2...

Page 73: ...H K X I J E D C B A U T S R 76 SJ6826RT SJ6832RT 213560ABA 3 29 Electrical Schematic Kubota Diesel D902 CE M220060AB 3 29 Electrical Schematic Kubota Diesel CE T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 74: ...NSDUCER AUX DOWN ENABLE RELAY SMALL PUMP DUMP AUX ENABLE RELAY LARGE PUMP DUMP ENABLE RELAY SMALL PUMP DUMP ENABLE RELAY LARGE PUMP DUMP AUX ENABLE RELAY H1 02 DOWN ENABLE RELAY MAIN LOWERING VALVE SOLENOID HOLDING VALVE SOLENOID HOLDING VALVE SOLENOID THROTTLE RELAY START RELAY POWER ON DEMAND RELAY THROTTLE ENABLE RELAY MAIN POWER RELAY D02 3 D02 2 13B D02 1 2H 13B 1 2H 13B 2H 13B 2 12V BATTERY ...

Page 75: ...8BLACK WHITE PIN4 73BLUE PIN5 77BLUE BLACK PIN6 74BLACK PIN7 71ORANGE PIN8 75ORANGE BLACK PIN9 72RED PIN10 76RED BLACK D36 1 TOLIMITSWITCHES PIN1 65GREEN BLACK PIN2 65AGREEN WHITE PIN3 66ABLUE WHITE PIN4 67ARED WHITE PIN5 68AWHITE PIN6 N U BACKVIEW BACKVIEW BACK VIEW 4 3 1 2 17C WHITE BLACK 02 WHITE 14 16 15 9 12 13 10 11 7 8 5 6 2 3 4 1 1 3 2 5 4 6 8 7 9 9 8 7 6 5 3 4 2 1 10 PIN1 73BLUE PIN2 02WH...

Page 76: ... E D C B A U T S R 79 SJ6826RT SJ6832RT 213560ABA 3 32 Outrigger Hydraulic Generator Electrical Assembly M194317AC 3 32 Outrigger Hydraulic Generator Electrical Assembly T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 77: ... that may occur If a specific trouble is not listed isolate the major component in which the trouble occurs 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 in the left hand column preceded by a number represents the probable cause The information in the r...

Page 78: ...efective circuit breaker CB1 Reset breaker Check for defective wiring Replace breaker if defective 9 Loose or broken wire 3A from circuit breaker CB1 to Power Relay 10CR1 Check continuity Replace if defective 10 Loose or broken wire 3A from Power Relay 10CR1 to Main Power Relay 10BCR Check continuity Replace if defective 11 Loose or broken wire 3A from Main Power Relay 10BCR to Anti Start Relay 32...

Page 79: ...ntinuity between wire 05 and wire 10 on switch Replace switch if no continuity between either one of the two contacts 4 2 3 All Functions Inoperative from The Base 1 Loose or broken wire 00 from Battery negative to circuit breaker CB3 Check continuity Replace if defective 2 Tripped or defective negative circuit breaker CB3 Reset breaker Check for defective wiring Replace breaker if defective 3 Loo...

Page 80: ... for 12 Volts at P3 6 If voltage present check for 12 Volts at wire 28E at 28ECR1 28ECR2 and 28ECR3 relays If voltage present check operation of relays If no voltage present check wire continuity Replace if defective 17 Defective Pressure Transducer PT1 or Angle Transducer AT1 or related wiring Check Transducer s functionality 18 Open diode D10B at base terminal block TB 1 Check diode Replace if d...

Page 81: ...1 Check continuity Replace if defective 6 Loose or broken wire 3A from Power Relay 10CR1 to Main Power Relay 10BCR Check continuity Replace if defective 7 Open or defective Platform Emergency Stop switch S4 Close switch Check continuity between wire 07 and wire 08 on switch Check continuity between wire 05 and wire 10 on switch Replace switch if no continuity between either one of the two contacts...

Page 82: ... Defective Pressure Transducer PT1 or Angle Transducer AT1 or related wiring Check Transducer s functionality 19 Open diode D10B at base terminal block TB 1 Check diode Replace if defective 20 Loose or broken wire 10 from Base terminal block TB 1 to Power Relay 10CR1 and Power Relay 10CR2 Check continuity Replace if defective 21 Defective Power Relay 10CR1 and or Power Relay 10CR2 Check Relays Rep...

Page 83: ...from Engine Start switch S15 to Engine Start switch S32 Platform only Check continuity Replace if defective 4 Open or defective Idle PLTF Base Key switch S10 Base only Select function with switch Check continuity between wire 05 and wire 07 on switch Platform selected Check continuity between wire 05 and wire 10E on switch Base selected Replace switch if no continuity during correct switch functio...

Page 84: ...nuity Replace if defective 16 Loose or broken wire 02 from Relay 10CR2 to Base terminal block TB 1 Check continuity Replace if defective 17 Open contact for ground not getting through N C set of contacts on Relay 10CR2 Check continuity between wire 02 and wire 41 on Relay Replace if defective 18 Loose or broken wire 3A from Relay 10BCR to Anti Start Relay 32CR1 Check continuity Replace if defectiv...

Page 85: ...ck diode Replace if defective 2 Loose or broken wire 37 from Engine Harness to Diesel Valve solenoid 2D37 Check continuity Replace if defective 3 Loose or broken wire 57 from Starter Contactor 32ACR to Diesel Valve solenoid 2D37 Check continuity Replace if defective 4 Loose or broken wire 00 from Diesel Valve solenoid 2D37 to battery negative Check continuity Replace if defective 5 Defective Diese...

Page 86: ...nd or Fuel Pump FP Check continuity Replace if defective 4 Loose or broken wire 00 from Gas Valve Solenoid 2G 11 and or Fuel Pump FP to battery negative Check continuity Replace if defective 5 Defective Gas Valve solenoid 2G 11 Check coil Replace if defective 6 Defective Fuel Pump FP Check pump Replace if defective 7 Loose or broken wire 50 from Fuel Select switch S33 to Propane Valve solenoids 2P...

Page 87: ...or broken wire 31 from Glow Plug Choke switch S13 to Engine Glow Plug Choke switch S31 Platform only Check continuity Replace if defective 4 Loose or broken wire 10B from Base terminal block TB 1 to Engine Glow Plug Choke switch S31 Base only Check continuity Replace if defective 5 Defective Engine Glow Plug Choke switch S31 Base only Operate switch Check continuity between wire 31 and wire 10B on...

Page 88: ...Replace if defective 5 Loose or broken wire 34D from Throttle Enable Relay 35ACR to Throttle Relay 34ACR Check continuity of wire 34D thru diode D34D to wire 34A in Base terminal Block TB 1 Check that diode D34D is not open or defective Replace if defective 6 Defective Throttle Relay 34ACR Check Relay Replace if defective 7 Loose or broken wire 42 from Throttle Relay 34ACR to Power Relay 10CR2 Che...

Page 89: ...gh Throttle solenoid HTS 34C to Base terminal block TB 1 Check continuity Replace if defective 22 Defective High Throttle Solenoid HTS 34C Check coil Replace if defective 4 2 10 Drive and Steer Inoperative Machines without outriggers option 1 Loose or broken wire 08 from Torque switch S16 to Joystick Controller S7 Vsupply P1 2 Check for 12 volts on wire 08 starting at Platform Emergency Stop switc...

Page 90: ...f defective 10 Loose or broken wire 15 from Lift Off Drive Select switch S3 to Reverse Relay 15CR Check continuity Replace if defective 11 Loose or broken wire 02 from Reverse Relay 15CR to Base terminal block TS 1 Check continuity Replace if defective 12 Defective Reverse Relay 15CR Check Relay Replace if defective 13 Loose or broken wire 15 from Reverse Relay 15CR to Control Module CM1 pin P2 8 ...

Page 91: ...e 25 Outriggers not fully retracted Fully retract outrigger cylinders 26 Loose or broken wire 10A from Base terminal block TB 1 to Outrigger Control Module OCM1 at pin P2 12 Check continuity Replace if defective 27 Left rear outrigger N O held closed limit switch LS64 is out of adjustment or defective Check continuity from wire 10A and wire 64 through switch when closed Adjust switch if out of adj...

Page 92: ...oose or broken wire 15A from Base terminal Block TB 1 to diode D15A 2 Check continuity Replace if defective 3 Defective or open diode D15A 2 Check diode Replace if defective 4 Loose or broken wire 30 from diode D15A 2 to Base terminal block TB 1 Check continuity Replace if defective 5 Loose or broken wire 16A from Forward Relay 16CR to Base terminal block TB 1 Check continuity Replace if defective...

Page 93: ...terminal block TB 1 to Steer Left Valve solenoid 4H 24 Check continuity Replace if defective 3 Defective Steer Left Valve solenoid 4H 24 Check coil Replace if defective 4 Loose or broken wire 02 from Steer Left Valve solenoid 4H 24 to Base terminal block TB 1 Check continuity Replace if defective 5 Open Diode D24 Check diode Replace if defective 4 2 14 Reverse Drive Inoperative 1 Lift Off Drive Se...

Page 94: ...alve solenoid 4H 15B in Parallel Drive High Torque mode Check continuity Replace if defective 13 Loose or broken wire 02 from Base terminal block TB 1 to Parallel Reverse Drive Valve Solenoid 4H 15B in Parallel Drive High Torque mode Check continuity Replace if defective 14 Defective Parallel Reverse Drive Valve solenoid 4H 15B in Parallel Drive High Torque Mode Check coil Replace if defective 15 ...

Page 95: ...ue mode Check continuity Replace if defective 13 Loose or broken wire 02 from Base terminal block TB 1 to Parallel Forward Drive Valve solenoid 4H 16B in Parallel Drive High Torque mode Check continuity Replace if defective 14 Defective Parallel Forward Drive Valve solenoid 4H 16B in Parallel Drive High Torque mode Check coil Replace if defective 15 Defective or open diodes D16A 1 and or D16A 2 Ch...

Page 96: ...13 Loose or broken wire 02 from Small Pump Dump Valve solenoid 2H 18C to Base terminal block TB 1 Check continuity Replace if defective 14 Defective Small Pump Dump Valve solenoid 2H 18C Check coil Replace if defective 4 2 17 Second Drive Speed Inoperative 1 Defective Joystick S7 Operate Joystick Check output to wire 19 Second Speed Out P1 7 Replace if defective 2 Loose or broken wire 19 from Joys...

Page 97: ...re 17 from Large Pump Relay 19CR to Small Pump Relay 17CR Check continuity Replace if defective 15 Loose or broken wire 02 from Small Pump Relay 17CR to Base terminal block TB 1 Check continuity Replace if defective 16 Defective Small Pump Relay 17CR Check relay Replace if defective 17 Loose or broken wire 17 from Small Pump Relay 17CR to Large Pump Dump Enable Relay 28ACR2 Check continuity Replac...

Page 98: ...re 08 and wire 20 on switch when High Torque selected Replace if defective 3 Loose or broken wire 20 from Torque switch S16 to Series Parallel Relay 20CR Check continuity Replace if defective 4 Loose or broken wire 02 from Series Parallel Relay 20CR to Base terminal block TB 1 Check continuity Replace if defective 5 Defective Series Parallel Relay 20CR Check relay Replace if defective 6 Loose or b...

Page 99: ...efective 17 Loose or broken wire 02 from High Speed Valve 2H 20B to Base terminal block TB 1 Check continuity Replace if defective 18 Defective High Speed Valve solenoid 2H 20B Check coil Replace if defective Reverse Inoperative 19 Loose or broken wire 20A from Series Parallel 20ACR1 Forward Relay to Series Parallel Reverse Relay 20ACR2 Check continuity Replace if defective 20 Loose or broken wire...

Page 100: ...Lift selected Replace if defective 5 Loose or broken wire 14 from Lift Off Drive Select switch S3 to Base terminal block TB 1 Check continuity Replace if defective 6 Loose or broken wire 14 from Base terminal block TB 1 to Control module CM1 pin P2 3 Check continuity Replace if defective 4 2 21 Up Circuit Inoperative from Base Control Console 1 Loose or broken wire 10E from Base terminal block TB ...

Page 101: ... Replace if defective 7 Defective diode D14A 1 Check diode Replace if defective 4 2 23 Platform does not Lift from Platform or Base Control Console with Outriggers Retracted Lift Operates Correctly with Outriggers Extended 1 Outriggers not fully retracted Fully retract outrigger cylinders 2 Loose or broken wire 10A from Base terminal block TB 1 to pin 4 on connector CN14 at the outrigger board Che...

Page 102: ...utrigger board to outrigger limit switch LS61 Check continuity Replace if defective 13 Left front outrigger N O held closed limit switch LS61 is out of adjustment or defective Check continuity from wire 62 and wire 36 through switch when closed Adjust switch if out of adjustment Replace if defective 14 Loose or broken wire 36 from outrigger limit switch LS61 to outrigger board Check continuity Rep...

Page 103: ...e if defective 10 Right Front outrigger N C held open limit switch LS66 is out of adjustment or defective Check continuity from wire 10A and wire 66A through switch when closed Adjust switch if out of adjustment Replace if defective 11 Loose or broken wire 66A from outrigger limit switch LS66 to outrigger control module pin P2 3 Check continuity Replace if defective 12 Loose or broken wire 10A fro...

Page 104: ...gger generator harness connector Check continuity Replace if defective 5 Loose or broken wire 14 from Base terminal block to Control Module CM1 at pin P2 3 Check continuity Replace if defective 6 Defective Up Relay 14CR Check Relay Replace if defective 7 Loose or broken wire 36A from Outrigger Lift Enable Relay 65CR to Up Relay 14CR Check continuity Replace if defective 8 Loose or broken wire 14A ...

Page 105: ... Replace if defective 13 Loose or broken wire 28E from Control module CM1 pin P3 6 to Aux Down Enable Relay 28ECR3 Check continuity Replace if defective 14 Loose or broken wire 02 from Aux Down Enable Relay 28ECR3 to Base terminal block TB 1 Check continuity Replace if defective 15 Defective Aux Down Enable Relay 28ECR3 Check Relay Replace if defective 16 Loose or broken wire 13B from Aux Down Ena...

Page 106: ...CR Check Relay Replace if defective 10 Loose or broken wire 13A from Down Enable Relay 28CR to Aux down Enable Relay 28ECR3 Check continuity Replace if defective 11 Loose or broken wire 28E from Control module CM1 pin P3 6 to Aux Down Enable Relay 28ECR3 Check continuity Replace if defective 12 Loose or broken wire 02 from Aux Down Enable Relay 28ECR3 to Base terminal block TB 1 Check continuity R...

Page 107: ...r broken wire 85 from Hydr Generator switch S12 to Hydr Generator Stop Relay 86ACR Check continuity Replace if defective 8 Loose or broken wire 86B from Hydr Generator Stop Relay 86ACR to Hydr Generator Latching Relay 86BCR Check continuity Replace if defective 9 Defective Hydr Generator Stop Relay 86ACR Check relay Replace if defective 10 Defective Hydr Generator Latching Relay 86BCR Check relay ...

Page 108: ...wire 17B from diode D86D to Base terminal block TB 1 Check continuity Replace if defective 4 2 29 Hydraulic Generator does not Shut Off from Generator Switch 1 Defective Hydr Generator switch S12 Operate switch Check continuity between wire 09 and wire 86 when switched to OFF Replace if defective 2 Loose or broken wire 86 from Hydr Generator switch S12 to diode D86 Check continuity Replace if defe...

Page 109: ... Check for continuity Replace if defective 4 Defective Outrigger Enable Relay 9CR2 and or Outrigger Proof Relay 9CR3 on outrigger board Check relays Replace if defective 5 Loose or broken wire 10A from Base Terminal block TB 1 to pin 4 on connector CN14 on outrigger board Main Power signal Check for power at connector Replace if defective 6 Defective Outrigger Lift Disable Relay 17DCR on outrigger...

Page 110: ...tinuity Replace if defective 4 2 32 All Outriggers Inoperative Base Controls only 1 Loose or broken wire 35C to Outrigger Control Module OCM1 pin P4 9 Outrigger Enable signal Check for power at module and check wire continuity 2 Defective outrigger enable switch S9B Check switch Replace if defective 4 2 33 All Outriggers Inoperative Auto Level only A LED Power Indicator Light at Outrigger Control ...

Page 111: ...at pin P4 9 of outrigger control module OCM1 7 1 1 Excessive vibration 2 Detective outrigger control module 1 Outrigger control module OCM1 cannot read tilt sensor 2 Replace 6 6 1 Outriggers are being manually controlled 1 Indicates function activated No repair necessary 7 8 1 Error occured while self diagnosing the hardware fail safe 1 Turn off power to reset the outrigger control module OCM1 2 T...

Page 112: ...heck continuity Replace if defective 5 Open diode D71 for UP function or D75 for DOWN function on outrigger board Check diodes Replace if defective 6 Loose or broken wire 71 for UP function at pin 7 on connector CN21 at outrigger board to Left Front Up Outrigger Valve solenoid 4H 71 Check continuity Replace if defective 7 Loose or broken wire 75 for DOWN function at pin 8 on connector CN21 at outr...

Page 113: ...20 at outrigger board Check continuity Replace if defective 5 Open diode D72 for UP function or D76 for DOWN function on outrigger board Check diodes Replace if defective 6 Loose or broken wire 72 for UP function at pin 9 on connector CN21 at outrigger board to Right Front Up Outrigger Valve solenoid 4H 72 Check continuity Replace if defective 7 Loose or broken wire 76 for DOWN function at pin 10 ...

Page 114: ...CN20 at outrigger board Check continuity Replace if defective 5 Open diode D73 for UP function or D77 for DOWN function on outrigger board Check diodes Replace if defective 6 Loose or broken wire 73 for UP function at pin 4 on connector CN21 at outrigger board to Right Rear Up Outrigger Valve solenoid 4H 73 Check continuity Replace if defective 7 Loose or broken wire 77 for DOWN function at pin 5 ...

Page 115: ...r CN20 at outrigger board Check continuity Replace if defective 5 Open diode D74 for UP function or D78 for DOWN function on outrigger board Check diodes Replace if defective 6 Loose or broken wire 74 for UP function at pin 6 on connector CN21 at outrigger board to Left Rear Up Outrigger Valve solenoid 4H 74 Check continuity Replace if defective 7 Loose or broken wire 78 for DOWN function at pin 3...

Page 116: ...and wire 70 on switch when Level selected Replace if defective 3 Loose or broken wire 70 from Auto Level Mode switch S24 to Outrigger Control Module OCM1 pin P2 5 Auto Level signal Check continuity Replace if defective 4 Loose or broken wire 10A from pin 4 on connector CN14 of outrigger board to Outrigger Control Module OCM1 pin P2 12 Power signal Check for power at P2 12 If no voltage present che...

Page 117: ...onnector CN14 of outrigger board to Outrigger Control Module OCM1 pin P2 12 Power signal Check for power at P2 12 If no voltage present check continuity of wire Replace if defective 5 Loose or broken wire 44 from pin 6 on connector CN14 of outrigger board to Outrigger Control Module OCM1 pin P2 10 Tilt Override High Drive Cutout signal Check for power at P2 10 If no voltage present check continuit...

Page 118: ...d Steer Orifice O4 Clean orifice Replace if defective 3 Steer Cylinder C7 damaged or bypassing internally Check cylinder Repair or replace if defective 4 3 3 Lift Steer and First Drive Speed Inoperative 1 Small Pump Dump Valve 2H 18C is stuck open Check valve Repair or replace if defective 2 Worn or defective Small Pump section of Pump P1 Check system pressures and Small Pump functionality Repair ...

Page 119: ...ylinder C8 bypassing internally Check cylinder Repair or replace if defective 4 3 6 Drive Sluggish 1 Stuck open or defective Check Valve CV3 CV4 CV5 and or CV6 Check Valves Replace if defective 2 Drive Relief Valve R5 set too low Refer to Section 5 of this manual for setup procedure 3 Defective Flow Divider FD1 Check valve Replace if defective 4 3 7 Reverse Drive Inoperative 1 Stuck or defective R...

Page 120: ...ective or not adjusted properly Adjust valve Replace if defective 3 Stuck or defective main Lowering Valve 2H 13B Check valve Repair or replace if defective 4 Stuck or defective manual Emergency Lowering Pull Valve V1 Check valve Repair or replace if defective 5 The manual overrides are open on Holding Valves 2H 13B 1 and or 2H 13B 2 Depress and turn manual overrides clockwise to close Replace if ...

Page 121: ...ft Front 1 Stuck or defective Left Front Up Outrigger Valve 4H 71 Retract Clean valve Replace if defective 2 Stuck or defective Left Front Down Outrigger Valve 4H 75 Extend Clean valve Replace if defective 3 Stuck or defective Check Valve CV7 Check valve Replace if defective 4 Fluid is bypassing Outrigger Cylinder C9 internally Check cylinder and repack if necessary Replace if defective Right Fron...

Page 122: ...p Outrigger Valve 4H 74 Retract Clean valve Replace if defective 14 Stuck or defective Left Rear Down Outrigger Valve 4H 78 Extend Clean valve Replace if defective 15 Stuck or defective Check Valve CV10 Check valve Replace if defective 16 Fluid bypassing Outrigger Cylinder C12 internally Check cylinder and repack if necessary Replace if defective 4 3 17 Outriggers Drift In 1 Defective Check valve ...

Page 123: ...s message is given if the elevation switch P2 10 is open at the start of calibration when the operator has confirmed the PLATFORM DOWN question If the platform is down check the elevation switch wiring 7 Flash Code F08 Check Elev This message is given if the elevation switch P2 10 is closed at the end of the DYNAMIC lift when the platform should be fully raised This message would occur if the UP s...

Page 124: ...opened before the platform was fully lowered If the platform is fully lowered check the elevation switch 15 Flash Code F16 Low Elev open This message is given if the elevation switch P2 10 opened during lift at a too low height below 5 If it opens below 5 the pressure is probably too unpredictable to allow reliable detection of an overloaded platform when initially raised Check CALIBRATIONS HEIGHT...

Page 125: ...d about 10 measurements for most vehicles The SETUPS HEIGHT SETUPS MIN LIFT time could be increased to force a longer time between static measurements but this should not be necessary 24 Flash Code F25 Check Elev This message indicates a problem with the elevation switch P2 10 during the STATIC phases The switch is either staying closed to a higher height or staying open to a lower height than tha...

Page 126: ...s show the loaded pressure first and the difference between loaded and empty pressure second 33 Flash Code F42 Low Pressure This message indicates that the pressure is too low 0 5 V or less when the elevation switch opens during the DYNAMIC lift This message would occur if the pressure sensor was disconnected or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure ...

Page 127: ...ntenance and Repair 5 2 Base 5 2 1 Winching and Towing Procedures and Parking Brake System This section provides the operator with procedures about towing and winching and on how to manually release the parking brake WARNING Ensure platform is fully lowered before winching or towing Sudden motion could cause the aerial platform to become unstable Death or serious injury could result WARNING In eme...

Page 128: ...isengaged for pushing towing or winching 1 Make sure that the aerial platform is on level ground Chock or block the wheels to keep aerial platform from rolling 2 Turn main power disconnect switch to off position 3 Locate brake hand pump and brake auto reset valve at main manifold in hydraulic fuel cabinet 4 Push in brake auto reset valve 2 5 Grasp the red hand pump 3 and rapidly depress until firm...

Page 129: ...olts to approximately 50 ft lb torque using the tightening sequence shown above 6 Tighten to 90 ft lb using the same sequence 7 Repeat the torque sequence to confirm that none have changed from 90 ft lb If any are found below 90 ft lb repeat complete sequence until there is no change in torque values If possible drive the machine prior to checking torques 8 Check torque values after 8 hours of ope...

Page 130: ...king and may lead to leaking or failure 3 When tightening hose couplings ensure the hose does not twist on the adapter Twisting will shorten hose life and scar the sealing surfaces of swivel type couplings JIC 45 etc which can create leaks 4 When tightening hose couplings use a torque wrench with crow s foot on the hose end hex swivel nut and a standard box wrench on the hose end stem hex to hold ...

Page 131: ...h torque wrench crow s foot tools or when a properly calibrated torque wrench is not available 1 Align the hose end or fitting to the mating component 2 Install the swivel hose end nut hand tight to the fitting to assure proper alignment Jiggle the hose while tightening to ensure the faces contact fully 3 Tighten the nut using a box wrench until minor resistance is felt 4 Mark the position of the ...

Page 132: ...em pressure for the unit 2 Connect a pressure gauge to the quick disconnect fitting located on the lift side of the main manifold in the tank side cabinet Pressure gauge attached to quick disconnect fitting System pressure relief valve 3 With the engine on use the control box joystick to steer fully left or right to produce pressure Read the pressure on the gauge 4 If the pressure shown on the gaug...

Page 133: ...rm s serial plate for the correct lift pressure for the unit 3 The lift manifold hose and port is located on the rear side of the main manifold in the tank side cabinet To access it release the latch beside the manifold then using the handle tip the manifold forward 4 With an oil pan and rag handy disconnect the hose capping off or plugging both the hose and the fitting on the manifold Release the...

Page 134: ...alve adjustment screw clockwise to raise the pressure or counterclockwise the to lower the pressure until it matches the value given on the serial plate 3 Psi should match serial plate or 1 2 10 Tighten the jam nut and apply a dab of torque seal where the jam nut and adjuster screw meet 11 Reconnect the lift hose to the main manifold lift port Refer to 5 2 7 Tightening and Torque Recommendations f...

Page 135: ...om the grease fitting 3 Connect a grease gun to the grease fitting and pump until a small amount of grease can be seen coming out around the joint or bearing 4 Disconnect the grease gun 5 Wipe off any excess grease from around the joint or bearing and from the grease fitting 6 Replace the grease fitting cap T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 136: ...r block wheels to keep the aerial platform from rolling forward or backward 4 Push in emergency stop buttons and turn main power disconnect switch off 5 Disconnect tilt switch from 4 pin connector 6 Remove old tilt switch from mount 7 Install the new switch in the same orientation as the old switch Connect switch plug to 4 pin connector NOTE The tilt switch circuit is only powered when controls ar...

Page 137: ...all emergency stop buttons 7 Verify switch is powered The red and green LED indicator lights should be flashing 8 On the back side of the switch press and hold the Set up button for 3 seconds M62332AA LED Indicator Lights Set up Button 9 Both LEDs turn off then begin flashing for a 5 second period 10 During this 5 second period press and release the Set up button 3 times 11 The red LED then flashe...

Page 138: ...m is moving in or out of tilt angle limits The time delay has not occurred yet Red LED on The red LED is on continuously when the tilt angle on one or more axes is off more than the allowable degrees from the zero position Green and Red LEDs on Both LEDs on continuously indicates a fault in the system is detected The switch does not function After a period of 5 seconds or on power up the switch at...

Page 139: ...resistance with an ohmmeter 3 If the resistance is not within the factory specifications replace it Resistance Factory Spec A B 1 87 to 2 53 Ω at 20 C A C 10 4 to 15 6 Ω at 20 C 1452AB A Terminal C High Tension Cord B Terminal B C A Resistance of Ignitor 1 Disconnect the connector 2 Measure the resistance with an ohmmeter 3 If the resistance is not within the factory specifications replace it A G ...

Page 140: ...tor adjustment bolt 2 Remove the old fan belt and install a new one 3 Replace the alternator pulley cover and tighten the adjustment bolt 4 Measure and adjust the fan belt deflection as described in the next section Adjustment bolt Pulley cover Test and Adjust the Deflection 1 Measure the fan belt deflection by depressing the belt halfway between the fan drive pulley and the alternator pulley at a...

Page 141: ...ach a small piece 2 When measuring the engine speed using a digital tachometer aim the tachometer at this reflective strip while the engine is running 3 On the platform control box set the low high throttle switch to low Start the engine and let it run until it reaches normal operating temperature High Throttle Check and Setting 1 Push the solenoid plunger in and hold it there Measure the rpm usin...

Page 142: ...link Use vice grips to hold the link stationary and a wrench to tighten the nut 1 Turn threaded link 2 Tighten nut Low Throttle Check and Setting 5 Measure the rpm using a digital tachometer as described in Step 2 6 If the tachometer reads 2050 50 rpm the low throttle is already properly set No further action is required If the tachometer reading is outside of the correct range proceed to the next...

Page 143: ...he correct range proceed to the next step to adjust it 6 Adjust the high throttle by first loosening the jam nuts on either end of the long coupling nut then turning the coupling nut and measuring the rpm until it reaches 3500 50 rpm Coupling nut Jam nuts 7 Once the correct rpm is reached apply a drop of Loctite 242 to the threads and tighten the jam nuts on each end Low Throttle Check and Setting...

Page 144: ...e a year More frequent changes may be needed in dusty environments IMPORTANT The air cleaner uses a dry element Never apply oil to it 1 Unlatch and remove the air cleaner cap Use a cloth to clean any dirt or dust from out of the cap 2 Remove the old air cleaner element by pulling it straight out 3 Install a new air cleaner element pushing firmly to seat it 4 Reinstall and latch the air cleaner cap...

Page 145: ...are free of dirt and dust 6 Bleed the fuel system of air refer to 5 2 7 Retaining Ring Filter Cup Filter Element Fuel Lever Open Closed 5 3 7 Bleeding the Fuel System of Air Kubota D902 Bleeding the fuel system of air is required after changing fuel hoses or filters or after the fuel tank has become empty 1 Allow the engine to cool if it has been running 2 Fill up the fuel tank with fuel 3 Open th...

Page 146: ... 9 Changing the Oil Kubota recommends changing the oil every 200 hours 1 With the aerial platform on a level surface start the engine and warm it up for approximately 5 minutes Shut off the engine 2 Place a container underneath the engine s oil pan drain plug 3 Remove the drain plug and allow the oil to drain completely 4 Screw the plug back into the oil pan tightening it to 24 27 ft lb 33 37 N m ...

Page 147: ...lacing coolant once a year WARNING Do not remove the radiator cap until the coolant had dropped below its boiling point 1 Place containers under the drain plugs to catch the coolant One drain plug is located on the underside of the radiator and the other on the body of the engine 2 Open both drain plugs and slowly open the radiator cap to relieve pressure Then open the radiator cap fully The coola...

Page 148: ...1CR 65 10A 10A 64 64 10A 62 63 63 61 62 10A 76 75 71 77 78 73 74 72 35C CN20 9CR2 17BCR 65CR D36 CN22 ENABLE FRONT LEFT FRONT RIGHT D74 D77 D78 D72 D71 D76 D75 D73 REAR RIGHT REAR LEFT D17B 1 D17B 2 CN21 72 74 73 78 77 71 75 76 17C 02 CN14 36A 02 28 02 09 10A 17B 28A 86A 44 61 36 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 149: ...switch contacts must be closed to produce in series signal P2 9 Not Used Not Used P2 10 44 Red 12V Input from 35CR Elevation Tilt Override High Speed Cutout Relay P2 11 02 White GND B 0V Reference Input from Base Terminal Strip P2 12 10A Black 12V B Input thru Main Power Relay 10BCR From Base Terminal Strip Outputs P4 1 78 Black White 12V Output for Outrigger Left Rear Down signal to 4H 78 Solenoi...

Page 150: ...s cleared the outrigger control module is reset and no longer detects the fault or idle timeout becomes active Since the outrigger control module 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 LED ERROR CODES EVERYTHING OK ON VEHICLE TILTED 1 1 OUTRIFFERS CANNOT BE MOVED 1 2 OUTRIGGERS NOT HO...

Page 151: ...ck that the battery voltage is not too low VEHICLE TILTED 1 1 This is not a true fault move the vehicle to level ground TESTING HWFS 7 8 STARTUP 7 7 These are not true faults unless they do not clear the start up tests should only occur for a short time OUTRIGGERS MANUALLY CONTROLLED 6 6 This is not a true fault the outriggers are being manually operated one or more outrigger legs on P4 pins 1 8 i...

Page 152: ...erial platform WARNING Read all instructions closely before attempting each phase of this procedure Outrigger Settings Model 6826RT 6832RT O R Settings 7 7 1438AB KEY FUNCTIONS SYMBOL ESC ENTER BUTTONS To move back and forth between menu and sub menu LEFT RIGHT BUTTONS Select menus and setting to be adjusted UP DOWN BUTTONS Adjust setting values T o o r d e r g o t o D i s c o u n t E q u i p m e ...

Page 153: ... and calibrations Adjustments Select This menu to see and adjust OCM1 settings NOTE this menu provides adjustments which may be needed for different work activities Setups Select this menu to carry out initial set up of the OCM1 NOTE This menu provides set ups needed to configure the OCM1 for a particular vehicle Help Menu Options help message A message displays current OCM1 status indicating if e...

Page 154: ...f left rear outrigger extend valve RRe P4 2 Displays state of right rear outrigger extend valve RFe P4 3 Displays state of right front outrigger extend valve LFe P4 4 Displays state of left front outrigger extend valve LRr P4 5 Displays state of left rear outrigger retract valve RRr P4 6 Displays state of right rear outrigger retract valve RFr P4 7 Displays state of right front outrigger retract v...

Page 155: ...ion of the GP106 tilt output P2 9 1 Output turns on to light lamp when tilted 2 Output turns off to cutout functions when tilted 3 Output turns off to cutout functions when tilted AND elevated TILT FILTER Displays the filter applied to the tilt measurements during the auto level function used to minimize the effect of vehicle vibrations on the tilt measurement Xlevel TARGET Displays the tilt in th...

Page 156: ...tch Replacement 1 Mount the new limit switch loosely on the bracket using the hardware removed previously 2 Starting from the top place the new limit switch cable in the split loom 3 Adjust the cable in the split loom as needed and close the split loom by wrapping electrical tape around it at regular intervals Tie wrap the split loom to the hoses 4 Cut off any unneeded length from the cable and st...

Page 157: ...rommet Retain the rubber grommet Discard the old limit switch and cable Limit Switch Replacement 1 Install a new limit switch to the mounting block using the hardware removed earlier 2 Feed the new cable through the rubber grommet and place the grommet in the hole in the outrigger weldment 3 Feed the cable up through the outrigger weldment until it comes out the top 4 Working from top to bottom ad...

Page 158: ...RETRACTED STATE RIGHT FRONT OUTRIGGER SECTION VIEW SHOWN IN THE RETRACTED STATE O R DOWN SWITCH NC BLACK BLACK WHITE O R DOWN SWITCH NC BLACK BLACK WHITE LEFT REAR OUTRIGGER SECTION VIEW SHOWN IN THE RETRACTED STATE RIGHT REAR OUTRIGGER SECTION VIEW SHOWN IN THE RETRACTED STATE SIXTEEN PIN CONNECTOR PLUG OUTRIGGER PCB ON ELECTRICAL PANEL TO CONTROL MODULE PIN 1 65 GREEN BLACK PIN 2 65A WHITE PIN 3...

Page 159: ...16 If the overload prevents lowering use the emergency lowering procedure as outlined in Operation manual to lower machine 10 Use base controls for all following movements Holding enable or key switch in platform mode while calibrator is in use will prevent it from returning to its main menu 11 If at any time it is not possible to perform the required operation go to Step 16 12 Select the Diagnost...

Page 160: ...the ENTER button 8 The display will show Access Level Code 0000 9 By using the Up Down buttons enter the Access Level Code 1 1 2 2 followed by pressing the ENTER button 10 The display will show Access Level 2 By using Left Right buttons select the Setups from the menu and press the ENTER button 11 The display will show Setups Change Defaults Select the Change Defaults from the menu and press the E...

Page 161: ...ch To Verify ON OFF Limits P2 11 02 White 0V GND Negative Reference From Base Terminal Strip P2 12 10A Blue Black 12V Main Power Input thru Main Power Relay 10BCR From Base Terminal Strip Outputs P3 1 22 Red 12V Output To FL 22 Flashing Light P3 2 29 Black 12V Output To BP 29 Beeper P3 3 60 Black White 12V Output To Overload Warning Lights On Base and Platform Emergency Stops P3 4 28 Green Black 1...

Page 162: ... Refer to 5 5 2 Machine Level Calibration Procedure 9 The display will show Access Level Code xxxx By using the Up Down buttons enter the Access Level Code xxxx followed by pressing the ENTER button 10 The display will show Access Level 2 By using Left Right buttons select the Setups from the menu and press the ENTER button 11 The display will show Machine Defaults Select the Machine Defaults from...

Page 163: ...eck that the platform is empty 25 By using the Up Down buttons enter the Yes followed by pressing the ENTER button The display will show Calibrate Load Please Lift Waiting for the lift switch to be activated 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 abor...

Page 164: ...ration The current date must be entered using the LEFT RIGHT and UP DOWN buttons 38 Press ENTER to complete date entry the information is stored 39 The display shows Calibrate Load option 40 Press the ESC button to exit the Calibrate Load option Remove the jumper wire and re connect the black wire 14 to the coil removed earlier 41 Close the hydraulic electric tray NOTE Continuing partially complet...

Page 165: ...et and no longer detects the fault or idle timeout becomes active The sequence is as follows 1 Quarter second flashes followed by quarter second pauses indicate the first digit 2 A 1 5 second pause 3 Quarter second flashes followed by quarter second pauses indicate the second digit 4 A 4 second pause Repeat Steps 1 4 Since the GP102 only reports one error only one code can be read from the LED per...

Page 166: ...son for the vehicle stop If the 21 or 22 flash code is triggered by a fault with the elevation switch it does not clear Check that the elevation switch correctly opens closes when the platform is raised lowered 21 Elevation Switch Shifted 22 Elevation Switch Stuck 43 P3 4 Short To 0 V Disconnect plug P3 If fault clears there is a wiring fault from P3 4 or P3 6 to the rest of the vehicle 45 P3 6 Sh...

Page 167: ...nd should vary as the platform position varies 78 Testing HWFS These are not true faults unless they do not clear the start up tests should only occur for a short time 77 Start Up 66 Overload Functions Disabled These are not true faults the GP102 has been configured to suppress overload functionality 67 Factory Override Always Off Idle Timeout Active Action a function to clear the idle timeout if ...

Page 168: ...e output A reading of 0V or 5V is probably due to a wiring problem Code F06 Check Elev This message is given if the elevation switch P2 10 is closed at the start of calibration when the operator has confirmed the PLATFORM DOWN question If the platform is down check the elevation switch wiring Code F08 Check Elev This message is given if the elevation switch P2 10 is closed at the end of calibratio...

Page 169: ...ded height where the switch opened Set up elevation switch to manufacturers specifications and calibrate load Code F18 Low Elev close This message is given if the elevation switch P2 10 closed during lower at a too low height below 5 Check CALIBRATIONS HEIGHT CALS the ElevDown value shows the recorded height where the switch opened Set up elevation switch to manufacturers specifications and calibr...

Page 170: ...than once during calibration lower Code F48 Bad Pressure This message indicates that the pressure transducer output P4 2 is out of range at the beginning of calibration Check DIAGNOSTICS SENSORS to read output Code F52 Too Few This message indicates that not enough measurements were recorded during calibration lifting or lowering Code F98 Out of Range This message indicates that the fine tune cali...

Page 171: ...ation Measuring This message is displayed when the platform is stopped during calibration when the GP102 takes a measurement There is 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 whe...

Page 172: ...ibrate date can be viewed in DIAGNOSTICS LOG Press LEFT and RIGHT to select the flashing digits Press UP and 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 5 5 9 Curved Group codes chart Model Number of Extension Decks Curve Code Group Code SJ6832 RT 1 Ma...

Page 173: ...2 Slide the limit switch cover back onto the pin Secure it with the gear clamp removed previously Limit Switch Electrical Connections 1 Route the new limit switch cable along the same path as the old one into the electrical panel cabinet Use tie wraps as needed to secure them at regular intervals 2 Strip the cable jacket back to separate the wires Cut the wires to length if needed and strip the en...

Page 174: ...ch that when the gate is opened halfway and released it will close fully and latch 2 To adjust the tension of the spring hinges first remove the safety locking screw located at the top or bottom of each hinge Retain the screws for reinstallation later 3 To increase the tension insert a 5 32 hex wrench in the screw socket and turn the wrench clockwise To release the tension depress the hex wrench i...

Page 175: ...rmed guardrail sections cracks or broken welds in railing sections damaged pin connections missing pins or broken pin lanyards missing railing hardware loose or missing parts additional holes in guardrail sections other than those approved by Skyjack Additionally the guardrails must be properly positioned and secured and the entry gate must be in good working order The strength of the guardrail sy...

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Page 177: ...T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

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