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Skyjack SJKB-40-D, Operating Maintenance Instructions & Part List

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SJKB-40-D, SJKB-40-D/F

SECTION 3, Page 18

JUN. 1999

FIGURE 3-8/ FIGURE 3-9./FIGURE 3-10./FIGURE 3-11./ FIGURE 3-12. ELECTRICAL SCHEMATIC PARTS LIST

1   2   3   4   5   6   7

Ref.

No.

Skyjack

Part No.

Description

Units

per

Assy

1   2   3   4   5   6   7

Ref.

No.

Skyjack

Part No.

Description

Units

per

Assy

01CR

THRU

701943

RELAY, 12 Volt sealed

AR

74CR

108CR

300242

CONTACTOR, Emergency pump

1

114CR

701943

RELAY, 12 Volt sealed

1

2G-56

111626

LOCKOFF, Gasoline

1

2H-12

707825

FLOW CONTROL VALVE, Proportional

1

2H-21A

707820

VALVE COIL, Dump

1

2H-59

708331

VALVE COIL, High speed drive

1

2P-50

111618

LOCKOFF, Propane

1

3H-26B

703803

VALVE COIL, Brake

1

2H-28B

703803

VALVE COIL, 5° Tilt brake

1

4H-13A

707821

VALVE COIL, Riser down

1

4H-14A

707821

VALVE COIL, Riser up

1

4H-15

$

REVERSE DRIVE VALVE

1

4H-16

$

FORWARD DRIVE VALVE

1

4H-23A

707821

VALVE COIL, Right steer

1

4H-24A

707821

VAVLE COIL, Left steer

1

4H-30A

THRU

707821

VALVE COIL , Directional

12

4H-41

B1

103295

BATTERY, 12 Volt 675CCA

1

BCB1

707678

Governor control (Kubota engine)

1

701643

Governor control (Ford engine)

1

BFC

704332

CONTROL BOARD, Boom function

1

BP20A

707912

ALARM, Boom motion (option)

1

BP27

103057

BEEPER, Tilt alarm

1

BP46

707912

ALARM, All motion (option)

1

BP58A

707912

ALARM, Boom descent (option)

1

BP-26A

707912

ALARM, Travel (option)

1

CB1

702402

CIRCUIT BREAKER

1

D08

THRU

102921

DIODE, 6 Amp/ 1000 PIV

AR

D114

DS1

102600

DISCONNECT SWITCH, Battery

1

EDA1

701547

CONTROLLER BOARD

1

F1

114866

FUSE, 250 Volt/1 amp

1

FG1

706282

GUAGE, Fuel level

1

FG1-1

706172

SENDING UNIT, Fuel guage

1

FL-20A

703323

LIGHT ASSEMBLY, Flashing (option)

1

FP1

115304

FUEL PUMP, Electric (Kubota engine)

1

115387

FUEL PUMP, Electric (Ford engine)

1

H1

703322

HORN, (Option)

1

LA1

707675

THROTTLE ACTUATOR, Linear (diesel)

1

707677

THROTTLE ACTUATOR, Linear (gas and dual fuel)

1

CS1

707676

CHOKE ACTUATOR, Linear (gas and dual fuel only)(Kubota engine)

1

LB1-LB3

(Ref.)

LIGHT ASSEMBLY, Indicator

3

103202

•   LIGHT HEAD

1

102671

•   LIGHT BASE

1

703185

• •   BULB

1

LB4

703720

INDICATOR LIGHT, Amber (diesel only)

1

LS1

702434

LIMIT SWITCH, Riser lift

1

LS2

700160

LIMIT SWITCH, Boom telescope

1

MDSD1

701546

DUAL SOLENOID DRIVER BOARD

1

OPS1

112838

PRESSURE SENSOR, Oil (Kubota engine)

1

R1

707177

SPEED CONTROL SWITCH, Boom function

1

S1-S2

(Ref.)

SWITCH ASSEMBLY, Emergency stop

2

102769

•   SWITCH HEAD, Emergency stop

1

103281

•   CONTACT BASE, NC switch

1

S3

(Ref.)

SWITCH ASSEMBLY, Key

1

102753

•   HEAD, Key switch

1

104466

•   Key, #455

1

103279

•   BASE, Contact 2 N.C.

1

103141

•   CONTACT, N.O.

1

S4-S5

701929

TOGGLE SWITCH, 2 Position momentary SPDT

2

S6-S7

701931

IGNITION SWITCH

2

S8-S9

701929

TOGGLE SWITCH, 2 Position momentary SPDT

2

S10

701930

TOGGLE SWITCH, 2 Position maintained SPDT

1

S11

700187

FOOT SWITCH

1

S12

704330

CONTROLLER, Drive/steer (without horn)

1

707658

CONTROLLER, Drive/steer (with horn)

1

S14-S18

702662

TOGGLE SWITCH, 3 Position momentary DPDT

3

S19-S27

102853

TOGGLE SWITCH, 3 Position momentary SPDT

11

S28

706294

LIMIT SWITCH, Turret directional sensing (booted)

1

S29

701930

TOGGLE SWITCH, 2 Position maintained SPDT

1

TP1

707824

TACHOMETER SENSOR (Kubota engine)

1

115389

TACHOMETER SENSOR (Ford engine)

1

TPS1

113400

TEMPERATURE SENSOR (Kubota engine)

1

TS1

700552

TILT SWITCH

1

TT1

701925

HOUR METER

1

VM1

704732

VOLT METER

1

VS1

111623

VACUUM SWITCH (Kubota dual fuel)

1

TD1

704616

RELAY, Time delay (Ford engine)

1

708685

CABLE ASSEMBLY, Starter to disconnect

1

708686

CABE ASSEMBLY, E-Pump to disconnect

1

707230

CABE ASSEMBLY, Battery to chassis

1

706524

CABE ASSEMBLY, Battery to disconnect

1

707230

CABE ASSEMBLY, Engine block to chassis

1

706096

CABE ASSEMBLY, E-Pump relay to E-pump

1

709554

CABE ASSEMBLY, Starter to alternator

1

DEC. 1999

Summary of Contents for SJKB-40-D

Page 1: ......

Page 2: ...Charles IL 60174 FAX 630 262 0006 For Parts in North America and Asia please call 800 965 4626 Skyjack Inc Parts Center 990 Vernon Rd Wathena KS 66090 FAX 888 782 4825 For Parts Service in Canada please call 800 265 2738 Skyjack Inc 55 Campbell Rd Guelph Ontario Canada N1H 1B9 FAX 519 837 3883 For Parts Service in Europe please call 31 297 255 526 Skyjack Europe Communicatieweg 29 3641 SG Mijdrech...

Page 3: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm JUN 1999 ...

Page 4: ...m Controls Electrical Page 5 OPERATING PROCEDURES Prestart Checks Page 7 Start and Operation Page 7 Shutdown Procedure Page 9 Loading and Tie Down Procedure Page 9 Table 2 1 Maintenance and Inspection Schedule Page 10 Table 2 2 Owners Annual Inspection Record Page 11 Table 2 3 Tire Specifications Page 11 Table 2 4 Maximum Platform Capacities Page 11 RECOMMENDED HYDRAULIC OILS Page 11 RECOMMENDED A...

Page 5: ...ty devices to protect your eyes ears hands feet and body You as a careful operator are the best insurance against an accident Therefore proper usage of this work platform is mandatory The following pages of this manual should be read and understood completely before operating the work platform Any modifications from the original design are strictly forbidden without written permission from SKYJACK...

Page 6: ...ines safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message SCOPE OF THIS MANUAL This manual applies to the ANSI SIA CSA and CE versions of the SJKB 40 engine poweredwork platform Equipment identified with ANSI CSA meets the ANSI SIA A92 5 1992 standards Equipment identified with CSA meets ...

Page 7: ...fies warranty coverage they will also issue an RA Return Authorization number for the return of any defective component s All items over 25 00 in value must be returned to Skyjack Inc WARRANTY STATEMENT DEC 1999 3 Fill out a Warranty Claim Form from dealer s supply of claim forms Then notify Skyjack s Service Department of the warranty claim number on the form used 4 The distributor dealer should ...

Page 8: ...embly and riser arm This mechanism uses double acting hydraulic cylinders with holding valves to control vertical movement Manual lowering valves at the base of the main boom and jib cylinders allow the mechanism to lower in the event of an emergency or electrical system failure TURRET The turret rotates 360 degrees continuously On each side of the turret is an enclosure One with hinged doors that...

Page 9: ...cal lines Also be aware of poorly lit areas that might hide overhead obstacles DO NOT elevate the work platform if the unit is not on firm level surfaces Avoid pot holes loading docks debris drop offs and surfaces that my affect the stability of your work platform DO NOT climb or descend a grade steeper than 30 while in travel mode Boom elevated driving must be done only on firm surfaces Ref Table...

Page 10: ...ROTATION Continuous TIRE SIZE 10x16 5 Air Filled Features STANDARD EQUIPMENT 4 Foot Hydraulically Controlled Boom Jib Variable Speed Drive and Function Controls In Line Elevating Assembly Continuous Drive and Steer Directional Sensing Spring Applied Hyd Released Parking Brakes ANSI and CSA Standards Compliance Kubota Gas Engine OPTIONAL EQUIPMENT Kubota Diesel Engine Dual Fuel Gas Propane Operator...

Page 11: ...B 40 D SJKB 40 D F JUN 1999 Figure 1 2 SKYJACK SJKB Boom Work Platform Model SJKB 40 D Shown OPERATOR S CONTROL CONSOLE BOOM JIB PLATFORM RISER ARM BASE CONTROL PANEL TURRET TELESCOPING BOOM ASSEMBLY DRIVE CHASSIS DEC 1999 ...

Page 12: ... to arrange daily weekly monthly and annual inspections of the work platform Refer to Table 2 2 in this manual GENERAL MAINTENANCE HINTS Before attempting any repair work disconnect the battery by turning the Battery Disconnect Switch to the OFF position Preventative maintenance is the easiest and least expensive type of maintenance OPERATING CONTROL IDENTIFICATION The following descriptions are f...

Page 13: ...ch to the ñ up position Release switch to stop To lower the boom section push and hold this toggle switch to the ò down position Release switch to stop 4 TURRET ROTATION TOGGLE SWITCH This switch controls clockwise and counterclockwise turret rotation To rotate the turret clockwise push and hold this toggle switch to the ï left position Release switch to stop To rotate the turret counterclockwise ...

Page 14: ...e 12 volt emergency pump and allows all functions to be operated To resume normal operation move the switch to the down position by closing the switch cover 14 FUEL GUAGE Electronic fuel level guage 15 VOLT METER This meter displays battery voltage 16 HOUR METER Activated by the ignition system this guage measures engine running time 17 110 VOLT RECEPTACLE Power to platform This 110 volt receptiac...

Page 15: ...he base on the jib cylinder this valve allows boom lowering in the event of an emergency or an electrical system failure Turning the valve knob counterclockwise allows the jib to gradually lower Valve MUST be fully closed clockwise to restore normal operation NOTE For European models only the manual lowering valve knobs are located inside engine cabinet bi fold door on turret Drive Relief Valve Ov...

Page 16: ...nd pump rapidly until firm resistance is felt and the brake pressure gauge reaches 700 psi The brakes are now release Although the gauge reading may decrease the brakes will remain released until pressure drops below 300 psi NOTE To return brakes to normal operation depress red plunger or operate any hydraulic function Base Controls Hydraulic Turret Rotation Speed Control Valve Ma40 213 Figure 2 8...

Page 17: ...eft position kills the engine enables the 12 volt emergency pump and allows all functions to be operated To resume normal operation move the switch to the right position by closing the switch cover 4 FUEL SELECT TOGGLE SWITCH Dual Fuel This switch allows the operator to select the fuel source to be used 5 ENGINE SPEED SELECT TOGGLE SWITCH This switch allows the operator to select from low or high ...

Page 18: ... oil pressure is low or the engine is overheating the engine will shut off automatically 18 TILT SENSOR INDICATOR LIGHT This red indicator light warns the operator that the work platform is on a slope which exceeds the limits for safe operation A warning buzzer will also sound 19 FUNCTION ENABLE LIGHT This red indicator lighttells the operator that the foot switch has been depressed and power is a...

Page 19: ...ive Steer Controller handle to the ò reverse position Release controller handle to stop 13 TO STEER Depress the rocker on the Drive Steer Controller handle in the direction you wish to steer 14 TO ADJUST BOOM FUNCTION SPEED Turn the Boom Speed Control Knob counter clockwise to decrease function speed or clockwise to increase funtion speed The Boom Speed Control will affect all lifting lowering and...

Page 20: ...o lower the work platform for repairs to be made This function is not intended to be used for an extended period of time Shutdown Procedure 1 Fully lower the platform 2 Push in the Emergency Stop Buttons 3 Rotate the Off Platform Base Key Switch to the off position Remove the key 4 Rotate the Battery Disconnect Switch to the OFF position Loading and Tie Down Procedure 1 With the telescopic boom fu...

Page 21: ...SECTION 2 Page 10 SJKB 40 D SJKB 40 D F JUN 1999 Table 2 1 Maintenance and Inspection Schedule Mt40c 200 Daily Weekly Monthly 3 Months 6 Months Yearly Engine 11 Fuel leaks 1 ...

Page 22: ...OT drive on an incline unless the parking brakes are working properly With the machine fully stowed and the throttle switch in the high position if engine powered Drive the machine forward at full speed and remove foot from foot switch Repeat this step driving in reverse WARNING Parking brakes will instantly engage causing the machine to stop immediately The machine should come to an instant and a...

Page 23: ...idle 2200 3350 1400 idle 1800 3000 ELECTRICAL SYSTEM engine 12 VDC BATTERY engine 12 Volt 850 CCA LIFT TIME minimum entry height to maximum platform height 124 Seconds LOWERING TIME minimum maximum platform height to entry height 92 Seconds SYSTEM RELIEF PRESSURE R1 2600 psi TRAVEL SPEED maximum at stowed height 3 0 mph 4 8kph TRAVEL SPEED maximum at elevated height 0 8mph 1 3kph HYD RESERVOIR CAP...

Page 24: ...ual fuel Page 12 FIGURE 3 5 ENGINE WIRING DIAGRAM Kubota gas and dual fuel Page 13 FIGURE 3 6 ENGINE WIRING DIAGRAM Diesel Page 14 FIGURE 3 6 ENGINE WIRING DIAGRAM PARTS LIST Diesel Page 15 FIGURE 3 7 ENGINE WIRING DIAGRAM PARTS LIST Ford dual fuel Page 16 FIGURE 3 7 ENGINE WIRING DIAGRAM Ford dual fuel Page 17 FIGURES 3 8 3 9 3 10 3 11 3 12 ELECTRICAL SCHEMATIC PARTS LIST Page 18 FIGURE 3 8 ELECT...

Page 25: ...FOOT SWITCH TOGGLE SWITCH BUSH BUTTON SWITCH ROTARY SWITCH LIMIT SWITCH N O LIMIT SWITCH N O HELD CLOSED LIMIT SWITCH N C LIMIT SWITCH N C HELD OPEN CAM OPERATED LIMIT SWITCH TILT SWITCH LEVEL SENSOR PRESSURE VACUUM SWITCH TEMPERATURE SWITCH RELAY SINGLE POLE SINGLE THROW RELAY SINGLE POLE DOUBLE THROW RELAY DOUBLE POLE SINGLE THROW RELAY DOUBLE POLE DOUBLE THROW RELAY TRIPLE POLE DOUBLE THROW DIO...

Page 26: ...ROL ASSEMBLY FLOW DIVIDER COMBINER COUNTER BALANCE VALVE ELECTRICAL VALVE COIL VELOCITY FUSE SINGLE ACTING CYLINDER DOUBLE ACTING CYLINDER DOUBLE ACTING DOUBLE RODDED CYLINDER SPRING APPLIED HYDRAULICALLY RELEASED BRAKE ROTARYACTUATOR FIXED DISPLACEMENT HYDRAULIC MOTOR BIDIRECTIONAL VARIABLE DISPLACEMENT HYDRAULIC MOTOR BIDIRECTIONAL SERIES PARELLEL HYDRAULIC MOTOR TWO POSITION TWO WAY NORMALLY OP...

Page 27: ... Boom Control Relay 20A 02 10 10A Base Panel All 20CR Function Select Relay 20 02 20A 09 Base Panel All 21CR1 Dump Valve Relay 21 02 21A 09 Base Panel All 21CR2 Emergency Pump Relay 21 02 01A 108 Base Panel All 26ACR Brake Relay 02 09 26A 26B Base Panel All 28ACR Tilted Braking Relay 02 09 28A 28B Base Panel All 28CR Tilted Function Dissable Relay 28 02 08 99 Platform Console All 30ACR Level Circu...

Page 28: ...28 GRN 51 BLK GRN 79 BRN PUR 107 BLK BLU 10 BLU WHT 29 GREY ORG 53 BRN RED 80 GREY WHT 108 YEL BRN 11 WHT ORG 30 RED GRN 54 PUR RED 81 GREY BLK 109 GRN YEL 12 GREY ORG 31 RED WHT 55 YEL PUR 82 BRN WHT 110A BLU 13 ORG 32 GRN BLK 56 YEL BLK 83 BLU GREY 110B BRN 14 BLK 33 GRN WHT 57 BRN GRN 84 WHT BLK PUR 111 GREY GRN 15 BLU 34 ORG BLK 59 YEL BLU 85 GREY BLU 114 YEL RED 16 WHT BLK 35 ORG WHT 60 WHT B...

Page 29: ...rn 1 707658 CONTROLLER ASSEMBLY Drive with horn 1 11 704332 CONTROL BOARD Boom function 1 12 701943 RELAY 12 Volt sealed 3 13 103057 BEEPER 4 28 Volt alarm 1 14 103036 STRAIN RELIEF Plastic 1 15 702186 WIRE DUCT 1 1 2 20 707187 COVER Wire duct 20 16 707143 TERMINAL BLOCK Through 16 17 707144 TERMINAL BLOCK Ground 2 18 707146 END PLATE Terminal block 1 19 707147 END STOP Terminal block 2 20 707148 ...

Page 30: ...CONSOLE DIAGRAM S N 95088 AND ABOVE MA40 306 13 1 23 24 3 PLATFORM LEVELING FROM PLATFORM CONTROL CONSOLE IS NOT AVAILABLE ON EUROPEAN MACHINES H G F E D C B A 7 6 5 4 3 2 1 W V U T S R Q P O N M L K J I 14 13 12 11 10 9 8 6 8 2 5 4 6 9 10 6 7 12 18 21 22 16 25 17 20 15 19 14 11 ...

Page 31: ...CONSOLE DIAGRAM S N 95087 AND BELOW MA40 300 PLATFORM LEVELING FROM PLATFORM CONTROL CONSOLE IS NOT AVAILABLE ON EUROPEAN MACHINES H G F E D C B A 7 6 5 4 3 2 1 W V U T S R Q P O N M L K J I 14 13 12 11 10 9 8 1 8 3 4 2 6 9 5 6 10 6 7 13 19 15 20 17 25 16 18 21 22 24 12 11 14 23 ...

Page 32: ... 95088 AND ABOVE MA40 307 31 32 19 18 8 7 6 5 4 3 2 1 33 29 28 25 23 27 24 30 MAIN CONTROL CABLE GOVERNOR WIRE HARNESS ENGINE WIRE HARNESS NOT USED MAIN FUNCTION MANIFOLD LEGEND 17 16 15 14 13 12 34 26 11 10 9 21 22 11 8 21 12 20 H G F E D C B A 7 6 5 4 3 2 1 W V U T S R Q P O N M L K J I 14 13 12 11 10 9 8 ...

Page 33: ...N 95087 AND BELOW MAIN CONTROL CABLE GOVERNOR WIRE HARNESS ENGINE WIRE HARNESS NOT USED MAIN FUNCTION MANIFOLD LEGEND 31 32 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 33 29 28 26 25 23 27 24 30 20 21 22 8 11 12 21 MA40 301 34 H G F E D C B A 7 6 5 4 3 2 1 W V U T S R Q P O N M L K J I 14 13 12 11 10 9 8 ...

Page 34: ...Emergency stop switch 1 103281 BASE N C Contact 1 14 Ref SWITCHASSEMBLY Key 1 102753 HEAD Key switch 1 104466 Key 455 1 103279 BASE Contact 2 N C 1 103141 CONTACT N O AR 15 701931 SWITCH Ignition 1 16 706282 GAUGE Fuel 1 17 704732 VOLTMETER 1 18 701925 METER Hour 1 19 105271 PLUG Recessed male 110 volt 1 113227 BOOT Rubber 1 20 702402 BREAKER 15 Amp circuit 2 21 102921 DIODE 6 Amp 1000PIV 5 22 706...

Page 35: ...1 6 111623 DIAPHRAM SWITCH Vaccum 1 7 103011 TERMINAL BLOCK Large 1 8 102921 DIODE 6 Amp 1000 PIV 1 9 701943 RELAY 12 Volt sealed 4 10 707824 TACHOMETER SENSOR 1 11 104345 CONNECTOR Directional valve 2 12 707677 THROTTLEACTUATOR Linear 1 13 115329 ALTERNATOR 1 14 707676 CHOKEACTUATOR Linear 1 15 COIL Ignition 1 16 115309 STARTER 1 FIGURE 3 5 ENGINE WIRING DIAGRAM PARTS LIST Kubota Gas and Dual Fue...

Page 36: ...SJKB 40 D SJKB 40 D F SECTION 3 Page 13 JUN 1999 FIGURE 3 5 ENGINE WIRING DIAGRAM Kubota gas and Dual Fuel 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 MA40 302 ...

Page 37: ...SJKB 40 D SJKB 40 D F SECTION 3 Page 14 JUN 1999 FIGURE 3 6 ENGINE WIRING DIAGRAM Diesel 13 12 11 10 9 8 7 6 5 4 3 2 1 MA40 303 ...

Page 38: ...20 Ga shielded 180 2 708332 VALVE High torque 1 708331 COIL 12 Volt 1 3 300242 CONTACTOR Emergency pump 1 4 102838 PRESSURE SENSOR Oil 1 5 TEMPERATURE SENSOR Coolant 1 6 103011 TERMINAL BLOCK Large 1 7 102921 DIODE 6 Amp 1000 PIV 1 8 701943 RELAY 12 Volt sealed 3 9 707824 TACHOMETER SENSOR 1 10 104345 CONNECTOR Directional valve 2 11 707675 THROTTLEACTUATOR Linear 1 12 115329 ALTERNATOR 1 13 11545...

Page 39: ...1643 THROTTLE CONTROL Engine 1 2 707709 HARNESS Governor 1 700165 SHIELDED CABLE 20 Ga 60 3 707708 HARNESS Engine wiring 1 700165 SHIELDED CABLE 20 Ga 156 4 FORD TERMINAL STRIP 2 5 115389 SENSOR Magnetic tachometer 1 6 704616 RELAY 12 Volt time delay 1 7 FORD SWITCH 6 PSI Oil pressure 1 8 701943 RELAY 12 Volt sealed 3 9 707677 THROTTLE ACTUATOR Linear 1 10 103256 CABLE 18 2 76 ...

Page 40: ...SJKB 40 D SJKB 40 D F SECTION 3 Page 17 JUN 1999 FIGURE 3 7 ENGINE WIRING DIAGRAM Ford Dual Fuel 9 8 7 6 5 4 3 2 1 MA40 305 10 ...

Page 41: ...OR Linear diesel 1 707677 THROTTLEACTUATOR Linear gas and dual fuel 1 CS1 707676 CHOKE ACTUATOR Linear gas and dual fuel only Kubota engine 1 LB1 LB3 Ref LIGHT ASSEMBLY Indicator 3 103202 LIGHT HEAD 1 102671 LIGHT BASE 1 703185 BULB 1 LB4 703720 INDICATOR LIGHT Amber diesel only 1 LS1 702434 LIMIT SWITCH Riser lift 1 LS2 700160 LIMIT SWITCH Boom telescope 1 MDSD1 701546 DUAL SOLENOID DRIVER BOARD ...

Page 42: ...SJKB 40 D F SECTION 3 Page 19 FIGURE 3 8 ELECTRICAL SCHEMATIC Kubota Gas and Dual Fuel S N 95088 and above 704372AF AUG 1999 M L G K I H F J E D C B A 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 N 20 19 18 17 16 23 22 21 ...

Page 43: ...Page 20 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 3 9 ELECTRICAL SCHEMATIC Kubota Gas and Dual Fuel S N 95087 and below 704372AA M L G K I H F J E D C B A 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 N 20 19 18 17 16 23 22 21 ...

Page 44: ...KB 40 D SJKB 40 D F SECTION 3 Page 21 FIGURE 3 10 ELECTRICAL SCHEMATIC Diesel S N 95088 and above 706969AF AUG 1999 M L G K I H F J E D C B A 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 N 20 19 18 17 16 23 22 21 ...

Page 45: ...CTION 3 Page 22 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 3 11 ELECTRICAL SCHEMATIC Diesel S N 95087 and below 706969AA M L G K I H F J E D C B A 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 N 20 19 18 17 16 23 22 21 ...

Page 46: ...SJKB 40 D SJKB 40 D F SECTION 3 Page 23 JUN 1999 FIGURE 3 12 ELECTRICAL SCHEMATIC Ford Dual Fuel 708852 M L G K I H F J E D C B A 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 N 20 19 18 17 16 23 22 21 ...

Page 47: ...SECTION 3 Page 24 SJKB 40 D SJKB 40 D F FIGURE 3 13 HYDRAULIC SCHEMATIC 704667AA MAR 2000 H G F E D C B A 7 6 5 4 3 2 1 W V U T S R Q P O N M L K J I 14 13 12 11 10 9 8 ...

Page 48: ... C5 700333 CYLINDER ASSEMBLY Platform leveling master 1 700454 KIT Seal repair AR C6 700388 CYLINDER ASSEMBLY Platform leveling slave 1 700454 KIT Seal repair AR C7 700783 CYLINDER ASSEMBLY Steering 1 701076 KIT Seal repair AR CB01 09 700568 VALVE Counter balance 9 CB10 11 706384 VALVE Counter balance 2 CB12 13 700670 VALVE Counter balance 2 CV1 706833 VALVE Check 1 DCM1 706921 PUMP MOTOR ASSEMBLY...

Page 49: ...OUNTER BALANCE VALVE TO C2 BOOM LIFT CYLINDER down TO C2 BOOM LIFT CYLINDER up TO C7 C8 STEER CYLINDERS turn left TO C7 C8 STEER CYLINDERS turn right RV1 SYSTEM RELIEF VALVE TO M1 TURRET ROTATION MOTOR cw TO M1 TURRET ROTATION MOTOR ccw 4H 30 BOOM DOWN VALVE 4H 23A RIGHT STEER VALVE 4H 33 TURRET ROTATION C CLOCKWISE VALVE TO PUMP PRESSURE 4H 32 TURRET ROTATION CLOCKWISE VALVE RV3 RELIEF VALVE 2H 2...

Page 50: ...TO IN LINE CHECK VALVE B TO HYDRAULIC TANK Mb DRIVE PUMP TO SHUTTLE VALVE AT ENGINE G fa CHARGE PUMP TO LOW PRESSURE FILTER Ps DRIVE PUMP TO LOW SPEED LOW TORQUE VALVE Ma DRIVE PUMP TO SHUTTLE VALVE AT ENGINE RV7 DRIVE PRESSURE RELIEF VALVE T2 FROM SYSTEM MANIFOLD PORT P T LOW SPEED TORQUE TO PROPORTIONAL FLOW CONTROL PORT 1 2 DRIVE PUMP S TO HYDRAULIC TANK RV5 CHARGE PUMP RELIEF VALVE 4H 16 FORWA...

Page 51: ...SJKB 40 D SJKB 40 D F SECTION 3 Page 28 JUNE 1999 NOTES ...

Page 52: ...l block TB3 7 Loose or broken wire 03 from base terminal block TB3 to circuit breaker CB1 8 Tripped or defective circuit breaker CB1 9 Loose or broken wire 05 from circuit breaker CB1 to base emergency stop switch S1 10 Open or defective emergency stop switch S1 11 Loose or broken wire 07 from emergency stop switch S1 to key select switch S3 12 Loose or broken wire 07 from base emergency stop swit...

Page 53: ... 5 Loose or broken wire 57 from platform terminal blockTB1 to relay 08CR1 6 Defective relay 08CR1 7 Loose or broken wire 57A from relay 08CR1 to platform terminal block TB2 8 Loose or broken wire 57A from platform terminal blockTB2 to base terminal block TB3 1 Remove foot from footswitch 2 Check Continuity Replace if defective 3 Check Switch Replace if defective 4 Check Continuity Replace if defec...

Page 54: ...R 6 Loose or broken wire 54 from relay 01CR to base terminal block TB3 7 Loose or broken wire 54 from base terminal blockTB3 to engine terminal block TB4 8 Loose or broken wire 54 from engine terminal block TB4 to oil pressure switch OPS1 9 Defective oil pressure switch OPS1 10 Loose or broken wire 54B from oil pressure switch OPS1 to temperature switch TPS1 11 Defective temperature switch TPS1 12...

Page 55: ...TFORM 1 Defective platform ignition switch S6 2 Loose or broken wire 60 from platform ignition switch S6 to platform terminal block TB1 3 Open diode D60 1 at platform terminal block TB1 4 Loose or broken wire 60A from platform terminal block TB2 5 Loose or broken wire 60A from platform terminal block TB2 to base terminal block TB3 1 Check Switch Replace if defective 2 Check Continuity Replace if d...

Page 56: ...e or broken wire 12 from base terminal block TB3 to proportional valve coil 2H 12 15 Defective proportional valve coil 2H 12 16 Loose or broken wire 02 from proportional valve coil 2H 12 to base terminal block TB3 1 Check Continuity Replace if defective 2 Check Relay Replace if defective 3 Check Continuity Replace if defective 4 Check Continuity Replace if defective 5 Check Continuity Replace if d...

Page 57: ...D PLATFORM LEVELING DOWNFUNCTIONSONLY INOPERATIVE 1 Open diode D58 1 Check diode Replace if defective MAIN BOOM UP RISER BOOM UP TELESCOPE EXTEND JIB BOOM UP ANDPLATFORMLEVEL ING UP FUNCTIONS ONLY INOPERATIVE 1 Machine not level 2 Looseorbrokenwire 09frombase terminal block TB3 to tilt switch fuse F1 3 Blown tilt switch fuse F1 4 Looseorbrokenwire 02frombase terminal block TB3 to tilt switch TS1 5...

Page 58: ...B3 8 Open diode D13 1 Check Continuity Replace if defective 2 Check Continuity Replace if defective 3 Check Relay Replace if defective 4 Check Continuity Replace if defective 5 Check Continuity Replace if defective 6 Check Continuity through coil Replace if defective 7 Check Continuity Replace if defective 8 Check Diode Replace if defective NO RISER BOOM UP FROM PLATFORM OR BASE 1 Loose or broken ...

Page 59: ...OR BASECONTROLS 1 Looseorbrokenwire 30frombase terminal block TB3 to relay 30CR 2 Looseor broken wire 02fromrelay 30CR to base terminal block TB3 3 Defective relay 30CR 4 Looseorbrokenwire 09frombase terminal block TB3 to relay 30CR 5 Loose or broken wire 30A from relay 30CR to main boom down valve coil 4H 30A 6 Defective main boom down coil 4H 30A 7 Looseorbrokenwire 02frommain boom down valve co...

Page 60: ...n switch S14 2 Defective main boom up down switch S14 3 Loose or broken wire 30 from main boom up down switch to platform terminal block TB1 4 Loose or broken wire 30 from platform terminal block TB2 to base terminal block TB3 1 Check Continuity Replace if defective 2 Check Switch Replace if defective 3 Check Continuity Replace if defective 4 Check Continuity Replace if defective NO TURRET ROTATE ...

Page 61: ... if defective 7 Check Continuity Replace if defective 8 Check Diode Replace if defective NO TURRET ROTATE RIGHT OR LEFT FROM PLATFORMCONTROLS 1 Loose or broken wire 08 from platform terminal block TB1 to turret rotate switch S20 2 Defective turret rotate switch S20 1 Check Continuity Replace if defective 2 Check Switch Replace if defective NO TURRET ROTATE LEFT FROM PLATFORM CONTROLS 1 Defective t...

Page 62: ...om base terminal block TB3 to relay 39CR 2 Loose or broken wire 02 from relay 39CR to base terminal block TB3 3 Defective relay 39CR 4 Loose or broken wire 09 from base terminal block TB3 to relay 39CR 5 Loose or broken wire 39A from relay 39CR to telescope retract valve coil 4H 39A 6 Defective telescope retract valve coil 4H 39A 7 Loose or broken wire 02 from telescope retract valve coil 4H 39A t...

Page 63: ...n wire 02 from jib down valve 4H 34A to base terminal block TB3 8 Open diode D34 1 Check Continuity Replace if defective 2 Check Continuity Replace if defective 3 Check Relay Replace if defective 4 Check Continuity Replace if defective 5 Check Continuity Replace if defective 6 Check Continuity through coil Replace if defective 7 Check Continuity Replace if defective 8 Check Diode Replace if defect...

Page 64: ...ck TB2 3 Loose or broken wire 35 from platform terminal block TB2 to base terminal block TB3 1 Check Switch Replace if defective 2 Check Continuity Replace if defective 3 Check Continuity Replace if defective NO PLATFORM ROTATE LEFT FROM PLATFORM OR BASE CONTROLS 1 Loose or broken wire 36 from base terminal block TB3 to relay 36CR 2 Loose or broken wire 02 from relay 36CR to base terminal block TB...

Page 65: ...f defective 7 Check Continuity Replace if defective 8 Check Diode Replace if defective NOPLATFORMROTATE LEFT OR RIGHT FROM PLATFORMCONTROLS 1 Loose or broken wire 08 from platform terminal block TB1 to platform rotate switch S19 2 Defective platform rotate switch S19 1 Check Continuity Replace if defective 2 Check Switch Replace if defective NOPLATFORMROTATE LEFT FROM PLATFORM CONTROLS 1 Defective...

Page 66: ...M WILL NOT LEVEL UP FROM PLAT FORM AND BASE CON TROLS 1 Loose or broken wire 41 from base terminal block TB3 to relay 41CR 2 Loose or broken wire 02 from relay 41CR to base terminal block TB3 3 Defective relay 401R 4 Loose or broken wire 09 from base terminal block TB3 to relay 41CR 5 Loose or broken wire 41A from relay 41CR to platform level up valve coil 4H 40A 6 Defective level up valve coil 4H...

Page 67: ...se or broken wire 08 from platform terminal block TB1 to relay 08CR2 2 Loose or broken wire 02 from relay 08CR2 to platform terminal block TB1 3 Defective relay 08CR2 4 Looseorbrokenwire 62fromEDA board EDA1 to relay 51CR 5 Loose or broken wire 51 from base terminal block TB3 to relay 51CR 6 Loose or broken wire 02 from relay 51CR to base terminal block TB3 7 Defective relay 51CR 8 Loose or broken...

Page 68: ...rm terminal block TB2 24 Loose or broken wire 64 from platform terminal block TB2 to base terminal block TB3 25 Loose or broken wire 64 from base terminal blockTB3 to terminal 10 on MDSD board MDSD1 26 Defective drive potentiometer R2 27 Loose or broken wire 09 from base terminal block TB3 to EDA board EDA1 28 Blown EDA board fuse F2 29 Loose or broken wire 02 from base terminal block TB3 to EDA b...

Page 69: ...use Check for shorted wiring 39 Refer to section 5 MDSD board troubleshooting NO DRIVE REVERSE 1 Loose or broken wire 15 from terminal 5 on MDSD board MDSD1 to base terminal block TB3 2 Loose or broken wire 15 from base terminal block TB3 to drive reverse valve coil 4H 15 3 Defective drive reverse valve coil 4H 15 4 Loose or broken wire 02 from drive reverse valve coil 4H 15 to the drive pump case...

Page 70: ...e 4 Check Continuity Replace if defective 5 Check Switch Replace if defective 6 Check Continuity Replace if defective 7 Check Continuity Replace if defective 8 Check Continuity Replace if defective 9 Check Continuity through coil Replace if defective 10 Check Continuity Replace if defective NO DRIVE ELEVATED OR TELESCOPED OUT 1 EDA board out of adjustment 2 MDSD board MDSD1 out of adjustment 1 Ref...

Page 71: ...ontinuity Replace if defective 8 Check Continuity through coil Replace if defective 9 Check Continuity Replace if defective 10 Check Diode Replace if defective NO STEER RIGHT 1 Defective right steer switch S12 2 2 Loose or broken wire 23 from drive steer controller S12 to platform terminal block TB2 3 Loose or broken wire 23 from Platform terminal block TB2 to base terminal block TB3 4 Looseorbrok...

Page 72: ...OT RE LEASE 1 Defective switch S12 4 in drive steer controller S12 2 Loose or broken wire 26 from drive steer controller S12 to platform terminal block TB2 3 Loose or broken wire 26 from platform terminal block TB2 to base terminal block TB3 4 Loose or broken wire 26 from base terminal block TB3 to relay 51CR2 5 Defective relay 51CR2 6 Loose or broken wire 26A from relay 51CR2 to relay 26ACR 7 Loo...

Page 73: ...inuity Replace if defective 3 Check Continuity Replace if defective 4 Check Continuity Replace if defective 5 Check Continuity Replace if defective 6 Check Continuity Replace if defective 7 Check Relay Replace if defective 8 Check Continuity Replace if defective 9 Check Diode Replace if defective ENGINE WILL NOT STARTFROMBASECON TROLS 1 Defective base ignition switch S7 2 Open diode D60 2 at base ...

Page 74: ...atform rotate switch S25 2 Loose or broken wire 36 left0 or 37 right from platform rotate switch S25 to base terminal block TB3 1 Check Switch Replace if defective 2 Check Continuity Replace if defective PLATFORM LEVELING INOPERATIVE FROM BASECONTROLS 1 Looseorbrokenwire 10fromriser up down switch S22 to relay 30ACR 2 Defective relay 30ACR 3 Loose or broken wire 47 from relay 30ACR to platform lev...

Page 75: ...nwire 78frombase terminal block TB3 to barber colman controller BCB1 2 Defective barber colman controller BCB1 1 Check Continuity Replace if defective 2 Refer to section 5 barber colman troubleshooting ENGINE STAYS AT IDLE 950 rpm FROM PLAT FORMCONTROLS 1 Loose or broken wire 08 from platform terminal block TB1 to base terminal block TB3 2 Open diode D08 1 Check Continuity Replace if defective 2 C...

Page 76: ...e or broken wire 56 from fuel relay to 2G 56 gasoline valve or FG 1 fuel pump 9 Defective gasoline valve 2G 56 10 Defective fuel pump FP 1 1 Check Continuity Replace if defective 2 Check Switch Replace if defective 3 Check Continuity Replace if defective 4 Check Continuity Replace if defective 5 Check Continuity Replace if defective 6 Check Continuity Replace if defective 7 Check Relay Replace if ...

Page 77: ...ERGENCY PUMP IN OPERATIVEFROMPLAT FORM AND BASE CON TROLS 1 Looseorbrokenwire 09frombase terminal block to relay 01CR 2 Looseorbrokenwire 02fromrelay 01CR to base terminal block TB3 3 Defective relay 01CR 4 Loose or broken wire 01A from relay 01CR to relay 01CR to relay 21CR2 5 Looseorbrokenwire 21frombase terminal blockTB3 to relay 21CR2 6 Looseorbrokenwire 02fromrelay 21CR2 to base terminal bloc...

Page 78: ...al block TB1 to emergency pump switch S5 2 Defective emergency pump switch S5 3 Loose or broken wire 01 from emergency pump switch S5 to platform terminal block TB2 4 Loose or broken wire 01 from platform terminal block TB2 to base terminal block TB3 1 Check Continuity Replace if defective 2 Check Switch Replace if defective 3 Check Continuity Replace if defective 4 Check Continuity Replace if def...

Page 79: ...eplace if defective 2 Clean Valve Replace if defective 3 Clean Valve Replace if defective 4 Check Motor Replace if defective 5 Clean Valve Replace if defective 6 Refer to section 2 page 5 NO TURRET RIGHT 1 Stuck or defective turret rotate right valve 4H 33A 2 Stuck or defective relief valve RV2 3 Stuck or defective relief valve RV3 4 Defective turret rotation motor M2 5 Stuck or defective counter ...

Page 80: ... Rebuild Cylinder Replace if damaged NO JIB BOOM DOWN 1 Stuck or defective jib boom down valve 4H 34A 2 Plugged orifice 02 3 Stuck or defective counter balance valve CB8 4 Plugged orifice 01 1 Clean Valve Replace if defective 2 Clean Orifice 3 Clean Valve Replace if defective 4 Clean Orifice NO JIB BOOM UP 1 Stuck or defective jib boom up valve 4H 35A 2 Plugged orifice 01 3 Stuck or defective coun...

Page 81: ...efective 2 Clean Valve Replace if defective TELESCOPE CYLINDER DRIFTS IN 1 Leaking or defective counter balance valve CB4 2 Telescope cylinder C3 by passing internally 1 Check Valve Replace if defective 2 Rebuild Cylinder Replace if damaged NO RISER BOOM DOWN 1 Stuck or defective riser boom down valve 4H 13A 2 Stuck counter balance valve CB2 1 Clean Valve Replace if defective 2 Clean Valve Replace...

Page 82: ...2 Defective or misadjusted pressure reducing valve PR1 3 Defective relief valve RV8 4 Stuck shuttle valve SV1 1 Check Valve Replace if defective 2 Check Valve Replace if defective 3 Check Valve Replace if defective 4 Check Valve Replace if defective BRAKES WILL NOT EN GAGE 1 Stuck or defective brake valve 3H 26A 2 Brakes out of adjustment 3 Brake apply control valve FC2 closed 1 Check Valve Replac...

Page 83: ...EVERSE 1 Defective relief valve RV6 1 Check Valve Replace if defective NO HIGH DRIVE 1 Stuck or defective high speed drive valve 2H 59 2 Relief valve RV5 set to low 1 Check Valve Replace if defective 2 Refer to section 5 drive pump test procedure If pressure is lower than 300 PSI replace relief valve RV5 NO ELEVATED DRIVE 1 Defective or misadjusted hi low drive relief valve RV4 1 Check Valve Repla...

Page 84: ...damaged or not operating properly MUST be immediately tagged and removed from service until proper repairs are completed MAINTENANCE AND SERVICE SAFETY TIPS Maintenance and repair should only be performed by personnel who are trained and qualified to service this machine All maintenance and service procedures should be performed in a well lighted and well ventilated area Anyone operating or servic...

Page 85: ...SECTION 5 Page 2 SJKB 40 D SJKB 40 D F JUN 1999 NOTES ...

Page 86: ...OOM FUNCTION BOARD DIAGNOSTICS Page 12 BOOM FUNCTION BOARD ADJUSTMENT PROCEDURE Page 13 GOVERNOR DIAGNOSTICS Kubota Engines Page 14 GOVERNOR ADJUSTING PROCEDURE Kubota Engines Page 16 GOVERNOR DIAGNOSTICS Ford Engines Page 18 GOVERNORADJUSTING PROCEDURE Ford Engines Page 20 MAGNETIC PICK UP TEST PROCEDURE Page 21 MAGNETIC PICKUP REPLACEMENT INSTRUCTIONS Page 22 HYDRAULIC SYSTEM DIAGNOSTICS AND ADJ...

Page 87: ...sistant oil in this work platform Use ATF Dexron III ESSO or equivalent hydraulic oil For conditions causing oil temperatures below 31 F 35 C and above 122 F 50 C consult Skyjack Inc 7 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 o...

Page 88: ... 240 240 300 420 600 COILS SIZE ft lbs max 4 to 5 in lbs max 48 to 60 SAE PLUGS SIZE 2 4 5 6 8 10 12 16 ft lbs max 3 10 15 15 25 25 30 35 in lbs max 36 120 180 180 300 300 360 400 BRAKE ADJUSTMENT TOOL SKYJACK PART 707704 17mm ALLEN WRENCH PURCHASE LOCALLY PRESSURE GAUGE 0 5000 psi PURCHASE LOCALLY PRESSURE GAUGE 0 1000 psi PURCHASE LOCALLY CYLINDER ASSEMBLY TOOL 2 Inside Diameter SKYJACK PART 706...

Page 89: ...er set to RX100 scale measure resistance across the two wires removed in Step 6 Reading should be between 135 to 165 ohms If reading is outside this range replace magnetic pickup 8 Reconnect wires to terminals 9 and 10 9 Restart the engine from the platform control console Depress and hold foot switch 10 Select HIGH RPM s with engine speed switch at the platform control console 11 Measure the volt...

Page 90: ...e In forward the voltage on terminal 10 will increase In reverse it will decrease In both cases the increase or decrease should be smooth If reading is erratic in either direction replace drive joystick potentiometer 12 Locate and remove wire 16 from terminal 4 on MDSD board 13 Using a Volt Ohm meter set on ohms scale check continuity between wire 16 and terminal 3 on MDSD board If continuity pres...

Page 91: ...e 5 2 Dual Solenoid Driver MDSD Card MDSD 2X 2 MA 66 502 12 VOLT INPUT GROUND WIRE 16 DRIVE FORWARD NOTUSED WIRE 15 DRIVE REVERSE NOTUSED NOTUSED NOTUSED NOTUSED WIRE 64 POTENTIOMETER WIPER SIGNAL WIRE 63 POTENTIOMETER CENTER SIGNAL NOTUSED FUSE OCT 1999 ...

Page 92: ...racted and the main boom is below horizontal 15 Select LOW RPM s with engine speed switch Lower position 16 Adjust P3 on EDA board to 3 79 volts 17 Select HIGH RPM s with engine speed switch Upper position 18 Adjust P4 on EDA board to 5 9 volts NOTE Dip switch sequence 1 4 on SW2 may have to be changed in order to obtain 5 9 volts NOTE Adjusting P4 will affect adjustment of P3 Repeat steps 16 thro...

Page 93: ... wire 16 and terminal 3 Reattach wire 16 to terminal 3 41 Remove wire 15 from terminal 5 of MDSD board 42 Attach milliammeter between wire 15 and terminal 5 43 Fully retract and lower the boom 44 Move drive joystick fully to the reverse position 45 Adjust P4 on MDSD board to 847 milliamps 847A 46 Remove meter from wire 15 and terminal 5 Reattach wire 15 to terminal 5 47 Reengage drive pump relief ...

Page 94: ... the pot click CCW until you hear the pot click CW until you hear the pot click CCW until you hear the pot click CW until you hear the pot click WIRE 59 STRAIGHTENED PAPER CLIP PUSH SWITCH HERE TO SET SWITCH OFF PUSH SWITCH HERE TO SET SWITCH ON Ma40 504 SET DIP SWITCHES ACCORDING TO CHART BELOW Figure 5 4 Base EDA Board Settings ...

Page 95: ...rol Board Refer to Figue 5 5 for location 8 Attach the Meter leads to the terminals labeled and SIG 9 Slowly operate the Speed Knob several times from the fully counterclockwise left to the clockwise right position while observing the meter The reading should vary SMOOTHLY between 3 volts fully counterclockwise to 4 8 volts fully clockwise If no voltage present or reading skips replace the Speed C...

Page 96: ...h 7 Rotate the Boom Speed Control knob fully counterclockwise left to the slow position 8 Locate and adjust the Potentiometer labeled LOW until the meter reads 550 mA 55A Refer to figure 5 6 for location 9 Rotate the Boom Speed Control knob fully clockwise right to the fast position 10 Locate and adjust the Potentiometer labeled HI A until the meter reads 1500mA 1 5A NOTE Making adjustments to eit...

Page 97: ...s range replace Actuator If reading is within range go to Step 5 5 Reconnect spade connectors 6 Start the Engine from the Platform Controls 7 Select LOW with the Engine Speed switch Depress and hold Foot Switch 8 In the Lower Control Box locate wire 78 in Terminal Block TB3 Refer to section 3 page 8 9 Measure voltage on wire 78 It should read 12 volts 2 volts If no voltage present refer to Engine ...

Page 98: ... 98 WHITE 98A SHIELD 02 SHIELDED WIRE Mt40 507 COLOR CONVERSION CHART BARBER COLMAN COLOR SKYJACK COLOR FUNCTION Red Brown Gray 77 12 Volts Black White 02 Ground Purple Purple Blue 86 Actuator Purple Purple Blue 87 Actuator Black White Brown Purple 79 High RPM Signal White Red Blue 78 Mid RPM Signal SHIELDED WIRES Bare Shield White 02 Black Black 98 White White 98A ...

Page 99: ...itch Depress and hold the Foot switch 10 Locate and adjust the MID Potentiometer on the Governor Control Box to LOW RPM s See Figure 5 9 for location 11 Select HI RPM s with the Engine Speed switch Depress and hold the Foot switch 12 Locate and adjust the HI Potentiometer on the Governor Control Box to HIGH RPM s See Figure 5 9 for location 13 Continue to hold Foot Switch depressed with the Engine...

Page 100: ...SECTION 5 Page 17 SJKB 40 D SJKB 40 D F JUN 1999 NOTES ...

Page 101: ...een terminal 7 on the governor control box and a good chassis ground Reading should be 12 volt 2 volts If no voltage present repair wiring between speed select switch and control box 8 With speed select switch in the high position and the foot switch held down repeat step 7 between terminal 8 on the governor control box and a good chassis ground Reading should be 12 volt 2 volts If no voltage pres...

Page 102: ... Page 19 SJKB 40 D SJKB 40 D F JUN 1999 TO SPEED SWITCH A TO SPEED SWITCH B TO D I S MODULES ACTUATOR CONNECTOR 12 VOLTS GOVERNOR ACTUATOR 2 0 OHMS Figure 5 10 Barber Colman Governor Control Diagnostics Ma40 507 ...

Page 103: ...600 RPM s 5 85 Khz by jumping terminal 9 to 10 to increase RPM s or terminal 9 to terminal 11 to decrease RPM s 11 Recheck engine idle low and high settings Readjust if necessary 12 Select Base with the key select switch 13 Locate the GAIN Potentiometer on the Governor Control Box and turn it clockwise until the engine surges Turn the GAIN potentiometer counter clockwise until the engine stablizes...

Page 104: ...2 Mark location of leads from the magnetic pickup and remove from terminal strip 3 Using a volt ohm meter set on the RX100 scale measure the resistance across the leads Refer to Figure 5 12 It should read between 135 165 ohms If reading is outside of this range the pick up is defective S o l d e r Splice Ma40 506 Figure 5 12 Magnetic Tachometer Pickup Terminal Block TB 3 Located in Lower Control P...

Page 105: ...up bore 7 Gently turn the replacement pickup clockwise until it just bottoms out on the flywheel tooth 8 Turn the magnetic pickup counter clockwise 1 2 turn NOTE Do not exceed 1 2 turn or pickup will not sense the flywheel properly 9 Tighten lock nut against bellhousing 10 Connect pickup wires to the wires in the engine wiring loom solder and shrink wrap the connection 11 Start engine from the pla...

Page 106: ...ator Refer to Figure 5 14 for location 2 Attach a Calibrated 5000 PSI gauge to the Coupler 3 Start the Engine from Base Controls 4 Engage and hold the Riser Boom Down Toggle switch 5 Observe reading on Gauge 6 Adjust RV1 to 2600 PSI Refer to Figure 5 14 for location 7 Shut Engine off remove Gauge Figure 5 14 Boom Pump Pressure Settings RV1 QUICK COUPLING Ma40 500 HYDRAULIC ACCUMULATOR ...

Page 107: ... 6 If no pressure present or below 390 PSI replace relief valve RV5 7 If no pressure present or below 390 PSI after replacing relief valve RV5 replace the pressure over ride valve POR1 8 If no pressure present or below 390 PSI replace drive pump 9 Locate and disconnect the forward drive hose from the top of the rotary manifold 10 Cap port in rotary manifold to prevent contaminating hydraulic syste...

Page 108: ...0 9 7 6 5 3 2 1 Figure 5 15 Drive Pump Test Ports Figure 5 16 Rotary Manifold REVERSE PRESSURE GAUGE PORT RV3 CHARGE PRESSURE RELIEF VALVE FORWARD PRESSURE GAUGE PORT CAP REVERSE DRIVE HOSE DRIVE MOTOR CASE DRAIN FORWARD DRIVE HOSE FRONT Ma40 512 Ma40 513 ...

Page 109: ...d It should read 390 PSI 4 Extend telescope 3 feet Adjust Hi Low relief valve to 250 PSI Refer to Figure 5 18 5 Remove gauge and test drive With boom fully lowered and retracted high drive will be available With the boom above horizontal or extended only low drive will be available TEE A 1000 PSI GAUGE INTO HOSE AT Ps PORT Ps PORT PILOT PRESSURE HOSE TO TURRET MANIFOLD Figure 5 17 Drive Pump Ma40 ...

Page 110: ... 6 Pump brake release hand pump See Figure 5 19 Adjust releif valve to 700 PSI on gauge 7 Push brake release override valve in 8 Start engine from platform controls and extend boom slightly to achive low speed drive 9 Drive machine forward or reverse and observe pressure gauge should read 600 650 PSI 10 Stop machine and adjust pressure reducing valve 1 4 turn at a time until 600 650 pressure readi...

Page 111: ... Dial Indicator setting The proper setting range is 1 8mm 0 080 to 2 2mm 0 085 If the setting is within this range pull out the Brake Override Valve Plunger to engage the brakes then perform the same adjusting check on the right brake Remove the Dial Indicator and reinstall Center Plug NOTE If setting on either brake is not within the specified range proceed to step 7 7 Remove the Dial Indicator P...

Page 112: ...CTION 5 Page 29 SJKB 40 D SJKB 40 D F JUN 1999 Boom Wear Pad Clearances 1 Main Boom wear pads 0 010 Clearance 2 Telescopic Boom wear pads 0 0 010 Clearance 2 1 Ma40 523 Figure 5 21 Boom Wear Pad Locations ...

Page 113: ... 37 JIC SWIVEL 100R1 H4 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R13 H5 FEMALE 37 JIC SWIVEL LONG 90 FEMALE 37 JIC SWIVEL 100R1 H6 FEMALE 37 JIC SWIVEL SHORT 90 FEMALE 37 JIC SWIVEL 100R1 H7 LONG 90 FEMALE 37 JIC SWIVEL LONG 90 FEMALE 37 JIC SWIVEL 100R1 H8 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R4 H9 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R4 H10 FEMALE 37 JIC SWIVEL MALE PIP...

Page 114: ...erences A B C etc Individual parts in these lists have corresponding letters after their description to identify which assembly or group it is used in Individual parts without identifying letters are used in all the assemblies or group shown at the beginning of the parts list Descriptions preceded with an indicates a serviceable component or attaching hardware for the higher level assembly The sym...

Page 115: ...EIGHTS 6 38 FIGURE 6 19 FUELTANK ASSEMBLY 6 40 FIGURE 6 20 HYDRAULIC TANK ASSEMBLY 6 41 FIGURE 6 21 ROTARY MANIFOLD ASSEMBLY 6 42 FIGURE 6 22 SYSTEM MANIFOLD ASSEMBLY 6 44 FIGURE 6 23 BRAKE MANIFOLD ASSEMBLY 6 46 FIGURE 6 24 SPEED REDUCER ASSEMBLY 6 47 FIGURE 6 25 BASE CONTROL ELECTRICAL PANEL ASSEMBLY 6 48 6 50 FIGURE 6 26 ENGINE AND RELATED PARTS Kabota Gas and Dual Fuel 6 52 6 54 FIGURE 6 27 DU...

Page 116: ...IGURE 6 46 BRAKE ASSEMBLY 6 87 FIGURE 6 47 LABELS AND NAMEPLATES 6 89 FIGURE 6 48 TRAVELALARM OPTION 6 90 FIGURE 6 49 ALL MOTION ALARM OPTION 6 90 FIGURE 6 50 DESCENT ALARM OPTION 6 91 FIGURE 6 51 FLASHING LIGHT OPTION 6 92 FIGURE 6 52 HORN OPTION 6 93 FIGURE 6 53 PLATFORM WORK LIGHTS OPTION 6 94 FIGURE 6 54 AIRLINE TO PLATFORM OPTION 6 97 FIGURE 6 55 HYDRAULICTOOLOPTION 6 98 FIGURE 6 56 PLATFORMT...

Page 117: ...SECTION 6 Page 4 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 1 PLATFORM ASSEMBLY 30 x 66 Ma40 600 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 15 18 19 20 ...

Page 118: ...7 FOOT SWITCH 1 103567 CONNECTOR Housing 4 pin male 1 103569 CONNECTOR Insert 4 pin male 1 5 700188 SWITCH COVER Foot 1 103857 BOLT HHCS 1 4 20x1 lg 2 103980 NUT 1 4 20 2 700598 WASHER Fender 1 1 4 0 D 9 32 I D 2 104000 WASHER Lock 1 4 2 6 109700 RECEPTACLE 110V GFCI BOX 1 112707 SCREW Self tapping 10 24x5 8 lg 4 103035 STRAIN RELIEF Metal 90 1 7 109698 RECEPTACLE 110V GFCI A B C 1 8 109699 RECEPT...

Page 119: ... SJKB 40 D F JUN 1999 FIGURE 6 2 OPERATOR S CONTROL CONSOLE ASSEMBLY Ma40 602 30 31 32 29 24 28 26 25 23 27 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 33 35 36 6 7 7 7 7 7 7 7 7 7 9 14 14 14 14 15 37 11 34 MAR 2000 ...

Page 120: ...OL BOX LID WELDMENT 1 2 704374 CONTROL BOX WELDMENT 1 700481 BOLT Mach RD HD 1 4 20x1 2 lg 4 700583 NUT Lock 1 4 20 4 700480 NUT CLIP 10 24 2 104698 BOLT Mach HD 10 32x3 4 2 711094 SEAL Closed cell weather 1 8x1 1 711095 SEAL Closed cell weather 1 710266 STRAIN RELIEF 1 2 NPT 1 703077 STRAIN RELIEF 3 4 1 3 707655 LABEL Control box 1 4 700066 SUPPORT Wrist 1 103962 BOLT Mach HD 10 32x1 2 2 104185 W...

Page 121: ... SJKB 40 D F JUN 1999 FIGURE 6 2 OPERATOR S CONTROL CONSOLE ASSEMBLY Ma40 602 30 31 32 29 24 28 26 25 23 27 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 33 35 36 6 7 7 7 7 7 7 7 7 7 9 14 14 14 14 15 37 11 34 MAR 2000 ...

Page 122: ... BEEPER 4 28VDC 1 26 710143 WIRE DUCT 1x2 1 710142 WIRE DUCT 1 710446 WIRE DUCT 1 27 710144 WIRE DUCT COVER 1 710145 WIRE DUCT COVER 1 710447 WIRE DUCT COVER 1 28 707143 TERMINAL BLOCK Through 16 703031 BOLT Threadsert 10 32 2 103962 BOLT Mach HD 10 32 x 1 2 2 104185 WASHER Lock 10 2 104694 WASHER Flat SAE 10 2 29 707144 TERMINAL BLOCK Ground 2 30 707146 TERMINAL BLOCK End plate 1 31 707147 TERMIN...

Page 123: ... 2 708995 MOUNTING PLATE 1 3 700953 LEFT GRIP 1 4 700954 RIGHT GRIP 1 5 105734 SWITCH Actuator 1 6 700955 TRIGGER 1 7 105735 CAP 1 8 105733 SWITCH Rocker 2 9 105733 SWITCH Trigger 1 10 708996 POTENTIOMETER Mounting plate and switch 1 11 709385 POTENTIOMETER 1 12 708998 PINION GEAR 1 13 709386 SWITCH w Roller Actuator Not Shown 1 14 709387 CAM for Neutral Switch Not Shown 1 709000 GRIP ASSEMBLY No ...

Page 124: ...PLATE 1 3 701239 LEFT GRIP 1 4 709391 RIGHT GRIP 1 5 105734 SWITCH Actuator 1 6 700955 TRIGGER 1 7 105735 CAP 1 8 105733 SWITCH Rocker 2 9 105733 SWITCH Trigger 1 10 701240 SWITCH Horn button 1 11 708996 POTENTIOMETER Mounting plate and switch 1 12 709385 POTENTIOMETER 1 13 708998 PINION GEAR 1 14 709386 SWITCH w Roller Actuator Not Shown 1 15 709387 CAM for Neutral Switch Not Shown 1 709390 GRIP ...

Page 125: ...SECTION 6 Page 12 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 5 BOOM ASSEMBLY Ma40 601 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 ...

Page 126: ... lg 2 700425 WASHER Stop 2 1 4 DIA x 3 16 2 12 700366 PIN Master cylinder top 1 103873 BOLT HHCS 3 8 16 x 2 1 2 lg 1 104606 NUT Lock 3 8 16 1 13 700430 PIN Master cylinder bottom 1 103887 BOLT HHCS 5 16 18 x 3 4 lg 1 103404 WASHER Lock 5 16 1 14 706000 CYLINDER ASSEMBLY Lift For components refer to Figure 6 8 1 15 711316 PIN Lift cylinder bottom 1 706872 BOLT HHCS 1 2 13 x 1 1 4 lg 1 700425 WASHER...

Page 127: ...SECTION 6 Page 14 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 6 JIB LIFT CYLINDER ASSEMBLY Ma40 604 20 19 18 17 16 15 14 13 11 10 9 8 7 6 5 4 3 2 1 15 12 ...

Page 128: ... 1 9 701965 O RING Gland 1 10 701634 O RING Piston 1 11 700449 SPACER Cylinder 1 1 8 x 1 3 4 x 1 5 16 lg 1 12 708650 SPACER Cylinder 1 1 4 x 1 3 4 x 2 3 4 lg 1 13 100695 BUSHING 1 x 1 1 8 x 1 1 2 lg 2 14 100309 BUSHING 1 x 1 1 8 x 1 lg 2 15 100249 BUSHING 1 x 1 1 8 x 3 4 lg 2 16 701029 VALVE BLOCK Jib cylinder 1 103884 BOLT HHCS 5 16 18 x 2 1 2 lg 4 103404 WASHER Lock 5 16 4 17 700568 VALVE Counte...

Page 129: ...SECTION 6 Page 16 SJKB 40 D SJKB 40 D F JUN 1999 NOTES ...

Page 130: ... 1 4 700341 PISTON Cylinder 1 5 107935 SEAL Piston 1 6 108798 SEAL Gland 1 7 106449 WIPER Rod 1 8 701964 O RING Gland 1 9 701633 O RING Piston 1 10 103830 NUT Lock 5 8 11 1 11 100309 BUSHING 1 x 1 1 4 x 1 lg 4 12 103069 FITTING Connector 6orb 6 2 13 703223 FITTING Tee 6swv 4 4 2 700454 KIT Seal repair AR 706522 TOOL Cylinder assembly 2 Part of Seal Repair Index No Skyjack Part No Description 1 2 3...

Page 131: ...SECTION 6 Page 18 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 8 BOOM LIFT CYLINDER ASSEMBLY Ma40 606 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 13 ...

Page 132: ...NG Gland 1 11 701639 O RING Piston 1 12 106230 NUT Lock 1 1 4 12 1 13 103216 BUSHING 1 1 2 x 1 11 16 x 1 1 2 lg 6 14 700043 VALVE BLOCK Boom lift cylinder 1 103865 BOLT HHCS 5 16 18 x 2 lg 4 103404 WASHER Lock 5 16 4 15 103136 VALVE Manual lowering 1 16 700568 VALVE Counterbalance 1 17 707234 FITTING Elbow 45 6orb 4 2 18 701635 O RING Valve block 2 700452 KIT Seal repair AR 703872 TOOL Cylinder as...

Page 133: ...SECTION 6 Page 20 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 9 RISER LIFT CYLINDER ASSEMBLY Ma40 607 18 17 16 15 14 13 12 11 10 9 8 6 5 4 3 2 1 7 13 ...

Page 134: ... Lock 1 1 4 12 1 11 701966 O RING Gland 1 12 701639 O RING Piston 1 13 103216 BUSHING 1 1 2 x 1 11 16 x 1 1 2 lg 6 14 700043 VALVE BLOCK Riser lift cylinder 1 103865 BOLT HHCS 5 16 18 x 2 lg 4 103404 WASHER Lock 5 16 4 15 707694 PLUG Cavity C10 2 1 16 700568 VALVE Counterbalance 1 17 707234 FITTING Elbow 45 6orb 4 2 18 701635 O RING Valve block 2 700452 KIT Seal repair AR 703872 TOOL Cylinder asse...

Page 135: ...SECTION 6 Page 22 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 10 ROTARYACTUATOR ASSEMBLY Ma40 608 12 11 10 9 2 8 7 6 5 4 3 1 5 6 2 ...

Page 136: ...Actuator 1 709835 BOLT HHCS 1 4 20x1 5 8 lg 3 4 701487 SEAL O Ring 2 012 2 5 701850 FITTING 4orb 4 2 6 700568 VALVE Counterbalance 2 7 700432 PIN Slave cylinder 1 103873 Bolt HHCS 3 8 16x2 1 2 lg 1 104606 NUT Lock 3 8 16 1 8 700376 WASHER Bronze 1 3 4 OD x 1 ID 1 9 700434 SPACER Actuator pin 1 10 700375 WELDMENT Actuator bracket 1 704101 HOSE CLAMP 7 8 1 104000 WASHER Lock 1 4 1 103632 SCREW Self ...

Page 137: ...SECTION 6 Page 24 SJKB 40 D SJKB 40 D F JUN 1999 NOTES ...

Page 138: ...0341 PISTON Cylinder 1 5 107935 SEAL Piston 1 6 108798 SEAL Gland 1 7 106449 WIPER Rod 1 8 701964 O RING Gland 1 9 701633 O RING Piston 1 10 103830 NUT Lock 5 8 11 1 11 100309 BUSHING 1 x 1 1 8 x 1 lg 4 12 701999 FITTING Elbow 90 6orb 4 2 13 700040 VALVE BLOCK Slave cylinder 1 103885 BOLT HHCS 5 16 18 x 1 75 lg 4 103404 WASHER Lock 5 16 4 14 700568 VALVE Counterbalance 1 15 701635 O RING Valve blo...

Page 139: ...SECTION 6 Page 26 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 12 BOOM ASSEMBLY Main and Telescopic Section Ma40 610 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ...

Page 140: ...3404 WASHER Lock 5 16 4 700583 NUT Lock 1 4 20 3 7 704738 BOOM TRACK BRACKET WELDMENT Outer 1 700583 NUT Lock 1 4 20 3 700584 BOLT BHCS 1 4 20 x 1 2 lg 4 103980 NUT HEX 1 4 20 4 8 704263 HOSE GUIDE Lower 1 9 706162 HOSE COVER Main boom 2 700583 NUT Lock 1 4 20 2 10 704431 BOOM TRAY COVER Outer 1 700583 NUT Lock 1 4 20 2 11 700935 BOOM WELDMENT Telescopic 1 12 706192 CABLE CARRIER E CHAIN ASSEMBLY ...

Page 141: ...SECTION 6 Page 28 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 13 BOOM TELESCOPING CYLINDER ASSEMBLY Ma40 613 15 20 22 17 16 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 14 13 19 21 24 22 23 21 22 ...

Page 142: ...ASSEMBLY Telescopic cylinder 1 700260 PAD Telescopic cylinder support 2 700259 BRACKET Telescopic cylinder support 1 700581 BOLT Soc hd 1 4 20 x 1 1 2 lg 2 700582 BOLT Flat hd 1 4 20 x 3 4 lg 4 NOTE Items 16 thru 22 are for machines with S N 95210 and above 16 709824 VALVE BLOCK Telescopic cylinder 1 707809 BOLT HHCS 5 16 18 x 3 lg 4 103404 WASHER Lock 5 16 4 17 700568 VALVE Counterbalance 1 18 71...

Page 143: ...EAR PAD 8 700579 PIN Roll 1 4x1 2 lg 1 2 700098 BRACKET Wear Pad 8 101632 BOLT HHCS 3 8 16x3 4 lg 2 103472 WASHER Flat SAE 3 8 2 103999 WASHER Lock 3 8 2 3 700097 SHIM Wear pad 059 thk AR 4 700580 SHIM Wear pad 023 thk AR 4 3 4 3 1 2 1 2 1 2 Index No Skyjack Part No Description 1 2 3 4 5 6 7 Units per Assy ...

Page 144: ...k AR 700580 SHIM Wear pad 023 thk AR 101632 BOLT HHCS 3 8 16x3 4 lg 2 103472 WASHER Flat SAE 3 8 2 103999 WASHER Lock 3 8 2 3 701072 WEAR PAD 2 700579 PIN Roll 1 4x1 2 lg 1 4 701071 BRACKET Wear Pad 2 702196 SHIM Wear pad 024 thk AR 103473 BOLT HHCS 3 8 16x1 lg 2 103472 WASHER Flat SAE 3 8 2 103999 WASHER Lock 3 8 2 4 3 2 1 1 2 Index No Skyjack Part No Description 1 2 3 4 5 6 7 Units per Assy ...

Page 145: ...SECTION 6 Page 32 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 16 HYDRAULIC HOSE CONNECTIONS Boom Assembly Ma40 614 23 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 20 21 22 17 17 17 19 22 ...

Page 146: ...SE ASSEMBLY Manifold to riser cylinder H104 0024 00 0 2 10 701498 ACTUATOR Rotary 1 11 700328 CYLINDER ASSEMBLY Riser lift 1 For components refer to Figure 6 9 12 700333 CYLINDER ASSEMBLY Platform leveling master 1 For components refer to Figure 6 7 13 700989 CYLINDER ASSEMBLY Boom lift 1 For components refer to Figure 6 8 14 700871 CYLINDER ASSEMBLY Telescopic 1 For components refer to Figure 6 1...

Page 147: ...SECTION 6 Page 34 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 17 TURRET ASSEMBLY MA40 603 34 31 32 33 30 21 20 18 17 25 27 26 24 23 22 29 28 14 13 11 9 8 7 6 3 2 16 15 4 1 10 5 12 19 35 ...

Page 148: ...LY Rotary Manifold For components refer to Figure 6 21 1 101632 BOLT HHCS 3 8 16 x 3 4 lg 3 103472 WASHER Flat 3 8 SAE 3 103999 WASHER Lock 3 8 3 702195 BOLT HHCS 3 8 16 x 1 1 2 lg 2 702929 NUT Hex jam 3 8 16 2 12 708861 SWITCH Tilt 1 103855 BOLT HHCS 1 4 20 x 1 2 lg 4 104000 WASHER Lock 1 4 4 13 704269 ASSEMBLY System manifold For components refer to Figure 6 22 1 101632 BOLT HHCS 3 8 16 x 3 4 lg...

Page 149: ...SECTION 6 Page 36 SJKB 40 D SJKB 40 D F JUN 1999 34 31 32 33 30 21 20 18 17 25 27 26 24 23 22 29 28 14 13 11 9 8 7 6 3 2 16 15 4 1 10 5 12 19 35 FIGURE 6 17 TURRET ASSEMBLY MA40 603 ...

Page 150: ...HER Lock 3 8 2 24 Ref PANELASSEMBLY Turret control For components refer to Figure 6 25 1 101632 BOLT HHCS 3 8 16 x 3 4 lg 4 103472 WASHER Flat 3 8 SAE 4 103999 WASHER Lock 3 8 4 25 706833 CHECK VALVE In line 1 707809 BOLT HHCS 5 16 18 x 3 lg 1 103984 NUT Lock 5 16 18 1 702116 FITTING Connector 8orb 8 1 707995 FITTING Branch tee 8orb 8 1 26 703658 PIN Hitch 3 8 SJKB 40 D 40 D F Kabota engine only 1...

Page 151: ...SECTION 6 Page 38 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 18 TURRET COVERS DOORS AND COUNTERWEIGHTS MA40 634 12 11 10 9 8 7 6 5 4 3 2 1 ...

Page 152: ...nly 1 103856 HHCS 1 4 20 3 4 lg 4 103995 WASHER Flat 1 4 SAE 4 104000 WASHER Lock 1 4 4 103980 NUT Hex 1 4 20 4 707863 ANGLE Bi fold door 1 104698 BOLT Machine head 10 32 x 3 4 lg 2 701695 NUT Lock 10 32 2 7 706216 WELDMENT Engine side door 1 103855 BOLT HHCS 1 4 20 x 1 2 lg 6 104000 WASHER Lock 1 4 6 710188 BUMPER Rubber 6 8 701129 DOOR LATCH Eingine side 2 104698 BOLT Machine head 10 32 x 3 4 8 ...

Page 153: ...TING KIT Fuel level sender S N 95036 and Below 1 3 703937 FILLER CAP Fuel tank 1 4 700506 PLUG Breather vent 1 5 701862 PLUG 3 8 NPT Gas and Dual Fuel 1 703593 FITTING Elbow 90 brass barb Diesel 1 6 701458 FITTING Connector 4 4 1 7 702313 FITTING Pipe 1 4 full coupling 1 8 702308 FITTING Needle valve 1 9 103339 PLUG 3 4 magnetic zinc plated 1 9 8 7 6 5 4 3 2 1 Ma40 616 Index No Skyjack Part No Des...

Page 154: ...Connector 6NPT 6 1 7 707117 FITTING Elbow 45 12NPT 16 1 8 707116 FITTING Elbow 45 12NPT 12 1 9 706137 FITTING Elbow 45 12NPT 8 1 10 706188 GASKET Hydraulic tank cover plate 1 11 706076 WELDMENT Hydraulic tank cover plate 1 103856 BOLT HHCS 1 4 20 x 3 4 lg grade 5 16 103995 WASHER Flat 1 4 16 104000 WASHER Lock 1 4 16 12 700506 PLUG Breather vent 1 13 702290 STRAINER Hydraulic tank filler cap 1 14 ...

Page 155: ...SECTION 6 Page 42 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 21 ROTARY MANIFOLD ASSEMBLY MA40 618 14 13 12 11 10 9 8 7 6 5 4 3 2 1 17 16 15 5 9 12 12 ...

Page 156: ...witch mounting 1 105621 BOLT Machine head 10 32 x 1 lg 2 104694 WASHER Flat 10 2 104185 WASHER Lock 10 2 104003 NUT Hex 10 32 2 5 702118 FITTING Connector 12orb 12 3 6 702119 FITTING Elbow 90 female 12 12 3 7 701956 FITTING Connector 6orb 4 2 8 103069 FITTING Connector 6orb 6 1 9 104437 FITTING Plug 6 2 10 103073 FITTING Elbow 90 6orb 6 1 11 701999 FITTING Elbow 90 6orb 4 2 12 702117 FITTING Elbow...

Page 157: ...SECTION 6 Page 44 SJKB 40 D SJKB 40 D F FIGURE 6 22 SYSTEM MANIFOLD ASSEMBLY 704269 AUG 1999 14 13 12 11 10 9 8 7 6 5 4 3 2 1 19 18 17 16 15 14 4 11 ...

Page 158: ...ia platform tilt 1 8 710507 PLUG Hollow HEX hd 2orb 21 9 700765 PLUG Hollow HEX hd 4orb 11 10 700679 ORIFICE 100 dia jib lift 1 11 710508 PLUG Hollow HEX hd 6orb 4 12 700680 ORIFICE 060 dia jib lift 1 13 700682 ORIFICE 025 dia platform rotate 1 14 704822 VALVE ASSEMBLY 12 Volt spool lift functions 7 710511 VALVE Directional 1 707821 COIL 12 Volt 2 103918 BOLT Socket head 10 24 x 1 1 4 lg 4 15 7048...

Page 159: ...rake 1 4 703188 BLOCK Manifold 1 5 703189 VALVE Brake 1 703803 COIL 12 Volt 1 6 703190 VALVE Tilt braking 1 703803 COIL 12 Volt 1 7 703191 VALVE Pressure reducing 1 8 703192 VALVE Brake release override 1 9 703193 VALVE Brake release hand pump 1 10 703194 VALVE Adjustable relief 1 11 706026 VALVE Needle 1 12 703197 VALVE Shuttle 2 700764 PLUG SAE 2 21 700765 PLUG SAE 4 3 104437 PLUG SAE 6 5 13 103...

Page 160: ...3 707996 FITTING Connector 10orb 4 2 4 701850 FITTING Elbow 90 4orb 4 1 5 701954 FITTING Connector 4orb 4 1 6 703030 VALVE Shuttle cartridge 1 710868 ASSEMBLY Speed reducer Hydraulic motor 1 7 702989 SPEED REDUCER 1 704222 GASKET 1 704230 KIT Seal 1 8 703973 MOTOR Hydraulic 1 103909 BOLT HHCS 1 2 13 x 1 1 4 lg 2 103470 WASHER Lock 1 2 2 704237 KIT Seal 1 9 704504 ASSEMBLY Hose H1204 0009 00 0 Not ...

Page 161: ...8 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 25 BASE CONTROL ELECTRICAL PANEL ASSEMBLY MA40 628 14 13 12 10 8 7 6 5 3 2 1 33 34 35 20 19 18 17 16 15 32 36 37 24 25 30 27 38 8 30 23 22 21 26 31 29 28 15 9 4 11 11 39 40 41 ...

Page 162: ...ine head 10 32 x 1 2 lg AR 104185 WASHER Lock 10 AR 104000 NUT Hex 10 32 AR 12 701547 CARD Multi purpose controller EDA 1 103985 NUT Hex 6 32 AR 13 701546 CARD Dual solenoid driver MDSD 1 103985 NUT Hex 6 32 AR 14 102853 SWITCH Toggle 3 position momentary 7 15 701929 SWITCH Toggle 2 position momentary AR 16 Ref SWITCH ASSEMBLY Emergency stop 1 102769 HEAD Emergency stop switch 1 103281 BASE N C Co...

Page 163: ...0 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 25 BASE CONTROL ELECTRICAL PANEL ASSEMBLY MA40 628 14 13 12 10 8 7 6 5 3 2 1 33 34 35 20 19 18 17 16 15 32 36 37 24 25 30 27 38 8 30 23 22 21 26 31 29 28 15 9 4 11 11 39 40 41 ...

Page 164: ...elf adhesive 1 30 102921 DIODE 6 Amp 1000PIV 5 31 706074 SNAP ON FERRITE CORE 1 32 703077 STRAIN RELIEF 3 4 1 33 103041 STRAIN RELIEF 5 8 2 34 103036 STRAIN RELIEF Strait plastic 7 35 707722 WIRE HARNESS Main manifold 1 36 707709 WIRE HARNESS Governor All Kubota Engines 1 708958 WIRE HARNESS Governor All Ford Engines 1 37 707708 WIRE HARNESS Engine control 1 38 703720 LIGHT Indicator amber diesel ...

Page 165: ...e 52 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 26 ENGINE AND RELATED PARTS Kubota Gas and Dual Fuel MA40 640 14 13 12 11 10 9 8 7 6 5 4 3 2 1 33 34 35 20 19 18 17 16 15 24 26 25 23 22 21 30 31 32 29 28 27 38 39 36 37 ...

Page 166: ...4 20 x 1 lg grade 5 3 104000 WASHER Lock 1 4 3 103980 NUT Hex 1 4 20 3 11 707027 EXHAUST PIPE 1 707747 CLAMP Exhaust 1 12 707070 MOUNTING PLATE 1 13 707110 MOUNTING PLATE Choke solenoid 1 14 707676 CHOKE SOLENOID 1 103856 BOLT HHCS 1 4 20 x 3 4 lg 2 104000 WASHER Lock 1 4 2 103980 NUT Hex 1 4 20 2 15 707886 ASSEMBLY Clevis yoke bead chain 1 708033 BOLT HHCS 4M 0 70 x 10MM lg 1 16 707299 BRACKET Th...

Page 167: ...e 54 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 26 ENGINE AND RELATED PARTS Kubota Gas and Dual Fuel MA40 640 14 13 12 11 10 9 8 7 6 5 4 3 2 1 33 34 35 20 19 18 17 16 15 24 26 25 23 22 21 30 31 32 29 28 27 38 39 36 37 ...

Page 168: ...2 701879 FITTING Connector 16 12 2 28 708591 MOUNTING BRACKET Overflow reservoir 1 BOTTLE Overflow 1 710196 CLAMP Hose 1 102893 ZIP TIE 2 29 707285 BOTTOM PLATE Engine baffle 1 103857 BOLT HHCS 1 4 20 x 1 lg grade 5 4 103995 WASHER Flat 1 4 SAE 4 700583 NUT Lock 1 4 20 4 30 707286 BRACKET Oil filter 1 101632 BOLT HHCS 3 8 16 x 3 4 lg grade 5 4 103472 WASHER Flat 3 8 4 104606 NUT Lock 3 8 16 4 31 7...

Page 169: ...SECTION 6 Page 56 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 27 DUAL FUEL SYSTEM Kubota MA40 645 13 12 11 10 9 8 7 6 5 4 3 2 1 7 15 14 ...

Page 170: ...ilter 1 4 HOSE LP Vapor 1 5 702253 TANK 43 5 lb Propane 2 6 103006 COUPLING Quick connect LP 2 7 704546 HOSE ASSEMBLY Propane 2 8 702239 FITTING Brass swivel 90 6 4 1 9 702821 FITTING Adaptor 12 6 1 10 702820 FITTING Adaptor 12 4 1 11 702499 FITTING Pipe nipple 1 4 NPT x 2 lg 1 12 702500 FITTING Brass elbow 90 4 4 1 13 707707 HOSE ASSEMBLY 32 Propane 1 14 710320 PIPE NIPPLE 1 4 Close 1 15 702237 F...

Page 171: ...SECTION 6 Page 58 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 28 ENGINE AND RELATED PARTS Ford Gas and Dual Fuel MA40 647 14 13 12 11 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 21 22 23 ...

Page 172: ... 3 8 16 x 1 lg Grade 5 2 103999 WASHER Lock 3 8 2 702119 FITTING Elbow 90 swivel 12 12 1 704582 FITTING Connector 10orb 12 1 703533 FITTING Elbow 90 10orb 8 1 6 703693 PUMP Hydraulic drive 1 103907 BOLT HHCS 1 2 13 x 1 1 2 lg grade 5 2 103468 WASHER Flat 1 2 SAE 2 103470 WASHER Lock 1 2 2 704582 FITTING Connector 10orb 12 1 702119 FITTING Elbow 90 swivel 12 12 2 707036 FITTING Split flange 12 12 2...

Page 173: ...SECTION 6 Page 60 SJKB 40 D SJKB 40 D F JUN 1999 MA40 647 14 13 12 11 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 21 22 23 FIGURE 6 28 ENGINE AND RELATED PARTS Ford Gas and Dual Fuel ...

Page 174: ... BOLT HHCS 3 8 16 x 3 4 lg grade 5 4 103999 WASHER Lock 3 8 4 109052 FITTING Connector 12orb 6 2 13 707774 LANYARD 8 1 14 707775 SPLIT RING 1 1 15 706448 WELDMENT Latch bolt 1 16 702672 MOUNT Motor 4 103908 BOLT HHCS 1 2 20 x 1 1 2 lg grade 5 1 103468 WASHER Flat 1 2 SAE 1 103470 WASHER Lock 1 2 1 103857 BOLT HHCS 1 4 20 x 1 lg grade 5 2 103995 WASHER Flat 1 4 SAE 2 17 708814 WELDMENT Engine tray ...

Page 175: ...SECTION 6 Page 62 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 29 DUAL FUEL SYSTEM Ford MA40 645 13 12 11 10 9 8 7 6 5 4 3 2 1 7 15 14 ...

Page 176: ...OSE LP Vapor 1 5 702253 TANK 43 5 lb Propane 2 6 103006 COUPLING Quick connect LP 2 7 704546 HOSE ASSEMBLY Propane 2 8 702239 FITTING Brass swivel 90 6 4 1 9 702821 FITTING Adaptor 12 6 1 10 702820 FITTING Adaptor 12 4 1 11 702499 FITTING Pipe nipple 1 4 NPT x 2 lg 1 12 702500 FITTING Brass elbow 90 4 4 1 13 708856 HOSE ASSEMBLY 36 Propane 1 14 710320 PIPE NIPPLE 1 4 Close 1 15 702237 FITTING Bras...

Page 177: ...SECTION 6 Page 64 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 30 ENGINE AND RELATED PARTS Diesel Option MA40 641 14 13 12 11 10 9 8 7 6 5 4 3 2 1 33 20 19 18 17 16 15 24 26 25 23 22 21 30 31 32 29 28 27 ...

Page 178: ...m 3 8 16 2 FIGURE 6 30 ENGINE AND RELATED PARTS Diesel Option Index No Skyjack Part No Description 1 2 3 4 5 6 7 Units per Assy Index No Skyjack Part No Description 1 2 3 4 5 6 7 Units per Assy 1 706185 ENGINE ASSEMBLY Kubota 1 711459 FILTER Oil 1 711458 FILTER Fuel 1 119184 ASSEMBLY Glow plug 1 708250 ASSEMBLY Fuel line 1 2 708334 ASSEMBLY Air cleaner 1 708335 ELEMENT Air filter 1 702557 CLAMP 40...

Page 179: ...41 78 24 28 26 25 23 27 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 33 34 35 36 37 67 68 69 66 76 65 63 62 60 64 59 58 57 56 55 54 53 52 51 50 78 48 47 46 45 44 43 42 41 40 39 38 70 71 72 73 74 75 1 2 3 5 27 41 26 35 47 29 32 23 24 28 61 26 60 31 79 49 77 81 80 83 82 85 84 48 41 30 86 45 ...

Page 180: ...2orb 6 2 49 707234 FITTING Elbow 45 6orb 4 1 50 707996 FITTING Connector 10orb 4 2 51 701998 FITTING Elbow 90 8orb 8 1 52 707829 HOSE ASSEMBLY H108 0047 00 0 1 53 708322 HOSE ASSEMBLY H612 0046 00 0 1 54 708327 HOSE ASSEMBLY H2516 0040 00 0 1 55 707831 HOSE ASSEMBLY H112 0089 00 0 1 708348 HOSE ASSEMBLY H112 0103 00 0 Ford Engine Only 1 56 706577 HOSE ASSEMBLY H612 0031 00 0 1 57 707828 HOSE ASSEM...

Page 181: ...SJKB 40 D SJKB 40 D F SECTION 6 Page 68 JUN 1999 FIGURE 6 32 BASE AXLES AND WHEELS Standard 4x2 Ma40 615 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 3 8 13 13 12 13 9 16 ...

Page 182: ...03887 BOLT HHCS 5 16 18 x 3 4 lg 2 103404 WASHER Lock 5 16 2 103216 BUSHING 1 1 2 x 1 11 16 x 1 1 2 lg 2 9 700262 THRUST BEARING 2 10 704146 STEERING ASSEMBLY Left 1 For components refer to Figure 6 37 11 700693 TIE BAR WELDMENT 1 12 700297 PIN Tie bar 2 703016 BOLT HHCS 5 16 18 x 5 8 lg 2 103404 WASHER Lock 5 16 2 13 103216 BUSHING 1 1 2 x 1 11 16 x 1 1 2 lg 4 14 700783 STEER CYLINDER ASSEMBLY 1 ...

Page 183: ...SECTION 6 Page 70 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 33 BASE AXLES AND WHEELS Optional 4x4 Ma40 620 11 10 9 7 6 5 4 3 2 1 3 8 12 6 ...

Page 184: ...ASSEMBLY 1 For components refer to Figure 6 42 700498 WHEEL NUT 18 x 1 5MM 12 701956 FITTING Connector 6orb 4 2 702875 FITTING 90 4orb 4 2 8 706304 PLATE Axle mounting 1 708959 BOLT HHCS 3 4 10 x 8 1 2 lg Grade 8 4 700575 NUT 3 4 10 Grade C Top Lock 4 9 706960 DRIVE SHAFT 1 702956 BOLT HHCS 7 16 20 UNF x 1 1 4 lg Grade 8 8 702991 WASHER Lock 7 16 heavy split 8 702960 NUT HEX 7 16 20 UNF Grade 8 8 ...

Page 185: ...s refer to Figure 6 36 7 702117 FITTING 90 12 12 3 8 701999 FITTING 90 6orb 4 5 9 703877 HOSE ASSEMBLY H104 0050 00 0 2 10 707816 HOSE ASSEMBLY H112 0028 00 0 1 11 707817 HOSE ASSEMBLY H212 0042 00 0 2 12 704554 HOSE ASSEMBLY H606 0024 00 0 1 13 704530 HOSE ASSEMBLY H606 0050 00 0 1 14 704958 DRIVE MOTOR 1 NOTE Refer to Standard Hose Numbering System SECTION 5 Page 30 for explanation of hose numbe...

Page 186: ...117 FITTING 90 12 12 3 8 701999 FITTING 90 6orb 4 3 9 702991 FITTING Union Tee 6 6 6 1 10 701956 FITTING Connector 6orb 4 2 11 702875 FITTING 90 Swivel nut 4 4 2 12 703877 HOSE ASSEMBLY H104 0050 00 0 2 13 707816 HOSE ASSEMBLY H112 0028 00 0 1 14 707817 HOSE ASSEMBLY H212 0042 00 0 2 15 704554 HOSE ASSEMBLY H606 0024 00 0 3 16 707819 HOSE ASSEMBLY H106 0020 00 0 1 17 707818 HOSE ASSEMBLY H606 0034...

Page 187: ...linder 1 4 700787 PISTON Cylinder 1 5 700788 SPACER Cylinder 1 6 106449 WIPER Rod 1 7 701965 O RING Gland 1 8 701634 O RING Piston 1 9 108798 SEAL Gland 1 10 700585 SEAL Piston 1 11 700575 NUT Lock 3 4 10 Grade C 1 12 102025 BEARING Spherical 2 13 104114 RING Retaining 4 14 700510 NIPPLE Grease 1 8NPT 90 2 15 103073 FITTING 90 6orb 4 2 701076 KIT Seal repair AR Part of Seal Repair Kit 15 Index No ...

Page 188: ...63 HUB ASSEMBLY 1 3 700471 BEARING Inner 1 700472 BEARING CUP Inner 1 4 700469 BEARING Outer 1 700470 BEARING CUP Outer 1 5 700467 DUST CAP 1 6 700464 HUB 1 7 102646 WASHER Flat 1 8 104351 NUT Castle 1 1 9 700508 PIN Cotter 3 16 x 2 lg 1 10 700466 SEAL Grease 1 11 700468 WHEEL BOLT 5 8 18x1 1 2 gr 5 6 12 700782 WASHER Flat SAE 5 8 hard 6 12 11 10 9 8 7 6 5 4 3 2 1 Index No Skyjack Part No Descript...

Page 189: ...SECTION 6 Page 76 SJKB 40 D SJKB 40 D F JUN 1999 NOTES ...

Page 190: ...2 4 704829 WASHER Flat 9 16 4 702192 WASHER Lock 9 16 4 702899 NUT HEX 9 16 12 4 2 700498 WHEEL NUT 18x1 5MM 12 3 701047 PLANETARY For components refer to Figure 6 39 40 1 701054 BOLT HHCS 8MM 1 25 x 40MM lg 8 701056 WASHER Lock 8MM 8 701055 NUT Hex 8MM 1 25 8 4 701053 DRIVE AXLE For components refer to Figure 6 41 1 5 702438 FITTING 90 8orb 12 1 6 707622 FITTING 45 16orb 12 2 7 700817 FITTING Con...

Page 191: ...0 1 701841 LIP SEAL Output housing 1 2 HOUSING Output 1 3 701849 O RING SEAL 2 4 RING GEAR 1 5 HOUSING Input 1 6 701942 O RING SEAL Input adapter 1 7 701842 LIP SEAL Input adapter 1 8 701030 HOUSING Input adapter 1 Consult factory 8 7 6 5 4 3 2 1 Index No Skyjack Part No Description 1 2 3 4 5 6 7 Units per Assy ...

Page 192: ...1 2 3 4 5 6 7 Units per Assy FIGURE 6 40 PLANETARY REDUCTION GEAR ASSEMBLY Sige Ma40 631 1 701960 LIP SEAL Output housing 1 2 HOUSING Output 1 3 701961 O RING SEAL 3 4 RING GEAR 1 5 HOUSING Input 1 6 701962 LIP SEAL Input adapter 1 7 HOUSING Input adapter 1 Consult factory 7 6 5 4 3 2 1 ...

Page 193: ...SECTION 6 Page 80 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 41 DRIVE AXLE Standard 4x2 Ma40 633 6 5 4 3 2 1 8 7 7 13 12 11 10 9 7 14 15 ...

Page 194: ... 701838 OIL SEAL SPACER Pinion shaft 1 4 701839 O RING Pinion shaft 1 5 701848 O RING Pinion flange 1 6 701851 O RING Breather plug 1 7 701843 WASHER Oil plug gasket 5 8 701845 ACTUATOR Brake 2 9 701846 BRAKE DISK Intermediate 4 10 701847 BRAKE DISK 8 11 701808 OIL SEAL Wheel flange 2 12 701889 DUST COVER Wheel flange 2 13 701809 O RING Wheel flange 2 14 702003 COVER Torque hub 2 15 Ref BRAKE ASSE...

Page 195: ...SECTION 6 Page 82 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 42 STEER AXLE ASSEMBLY Optional 4x4 Ma40 77 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 4 4 11 18 ...

Page 196: ...inion 1 3 SEAL O ring 1 4 WASHER Oil plug 5 5 COVER Dust 2 6 ACTUATOR Brake 2 7 BRAKE DISK Intermediate 6 8 BRAKE DISK Friction 10 9 SHAFT ASSEMBLY Axle 2 JOINT Universal 4 10 SEAL O ring 2 11 SEAL Oil 4 12 SEAL Shaft 2 13 SEAL Shaft 2 14 708441 CYLINDER ASSEMBLY Steer 1 708408 KIT Seal repair AR 15 JOINT Axial 2 16 TIE ROD END 2 17 NUT Steer arm 2 18 Ref BRAKE ASSEMBLY For components refer to Fig...

Page 197: ...tional 4x4 1 704958 DRIVE MOTOR 1 702191 BOLT HHCS M14x2 0x45MM gr 8 8 4 702192 WASHER Lock 9 16 4 2 700498 WHEEL NUT 18x1 5MM 16 3 706296 DRIVE AXLE For components refer to Figure 6 45 1 4 Ref TRANSFER CASE For components refer to Figure 6 44 1 5 702438 FITTING 90 8orb 12 1 6 707622 FITTING 45 16orb 12 2 7 700817 FITTING Connector 14orb 6 2 8 702382 FITTING Swivel nut tee 6 6 1 4 8 7 6 5 3 2 1 6 ...

Page 198: ...9 Index No Skyjack Part No Description 1 2 3 4 5 6 7 Units per Assy FIGURE 6 44 TRANSFER CASE ASSEMBLY Optional 4x4 Ma40 82 1 706540 SEAL O ring 1 2 706541 SEAL Oil 1 3 701843 WASHER Oil seal 2 4 706542 SEAL Oil 1 5 706543 SEAL O ring 1 5 4 3 2 1 3 ...

Page 199: ...ve with transfer case 1 NUT Pinion retaining 1 2 OIL SEAL Pinion 1 3 SEAL O ring 1 4 SEAL O ring 1 5 WASHER Oil plug 5 6 COVER Dust 2 7 ACTUATOR Brake 2 8 BRAKE DISK Intermediate 6 9 BRAKE DISK Friction 10 10 SHAFT Axle 2 11 SEAL Hub oil 2 12 SEAL O ring 2 13 FLANGE ASSEMBLY 1 14 Ref BRAKE ASSEMBLY For components refer to Figure 6 46 1 Consult factory 14 13 12 11 10 9 8 7 6 4 3 2 1 5 5 5 5 ...

Page 200: ...2 4 704219 SEAL O ring piston 1 5 701853 SEAL Spring 1 6 703045 COVER Brake 1 7 706544 PISTON Brake 1 8 706545 FLANGE 1 9 708982 PLUG 1 10 708983 NUT Tristop M 12 1 11 119101 BALL 2 12 710197 BRAKE KIT Piston spring 1 13 710198 SPRING Outer 1 14 710199 SPRING Inner 1 15 710200 STEM 1 16 710201 COVER 1 17 708986 SPRING 1 18 708987 BRAKE FORK 1 19 708988 SNAP RING 1 20 708989 THRUST WASHER 1 21 7089...

Page 201: ...LABEL Manual enclosed Manual Enclosure 1 25 117023 117023 117023 117023 117023 117023 117023 117023 LABEL CE Approval 3 26 708838 708836 708835 708839 708837 707736 708840 708841 LABEL European load 2 27 710497 710617 710620 710609 710619 710618 710497 710616 710621 LABEL Pinch point 2 28 707097 710731 710729 710730 710732 710733 707097 710728 710734 MANUAL Operator Not shown 1 29 706229 706229 70...

Page 202: ...SJKB 40 D F SECTION 6 Page 89 FIGURE 6 47 LABELS AND NAMEPLATES 707335cad 30 31 32 29 24 26 25 40 27 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 33 34 35 36 37 23 39 38 1 19 40 15 25 16 38 APRIL 2000 ...

Page 203: ...yellow 72 Terminal Block at Lower Control Panel 3 2 1 Turret Index No Skyjack Part No Description 1 2 3 4 5 6 7 Units per Assy FIGURE 6 49 ALL MOTION ALARM OPTION Ma40 637 707913 ALL MOTION ALARM OPTION 1 703321 ALARM 1 109210 TERMINAL 16 ga x5 16 ring 1 102955 TERMINAL 16 ga x 10 ring 2 104185 WASHER Lock 10 4 104003 NUT Hex 10 32 4 103962 BOLT Mach Hd 10 32 x 1 2 lg 4 2 704307 WIRE LOOM 60 3 702...

Page 204: ...N 1 703321 ALARM For location refer to Figure 6 48 1 109210 TERMINAL 16 ga x5 16 ring 1 102955 TERMINAL 16 ga x 10 ring 1 104185 WASHER Lock 10 4 104003 NUT Hex 10 32 4 103692 BOLT Mach Hd 10 32 4 2 704307 WIRE LOOM 60 3 702353 WIRE 16 ga yellow red 82 4 701943 RELAY 12VDC Sealed 1 702000 TERMINAL 16 ga x1 4 SPD F 4 702478 WIRE 16 ga yellow 5 702465 WIRE 16 ga white 5 2 4 3 TO ALARM ...

Page 205: ...710138 FLASHING LIGHT OPTION New Style 707915 FLASHING LIGHT OPTION Old Style 1 710139 FLASHING LIGHT 12VDC New Style 1 703323 FLASHING LIGHT 12VDC Old Style 1 2 103256 CABLE 18 2 Cabtire AR 3 710136 HOSE COVER Flashing light option New Style 1 709026 HOSE COVER Flashing light option Old Style 1 NOTE Seal wire entry holes with silicone sealant 2 1 3 AUG 1999 ...

Page 206: ...404 WASHER Lock 5 16 1 100397 NUT 5 16 18 1 109210 TERMINAL 16 ga x 5 16 ring 1 702000 TERMINAL 16 ga x 1 4 SPD F 2 2 701943 RELAY 12V 1 702485 WIRE 16 GA red 57 702479 WIRE 16 GA green red 36 702465 WIRE 16 GA white 17 702000 TERMINAL 16 ga x 1 4 SPD F 4 1 2 07A RED TO N C ON KEYSWITCH 02 WHT TO GROUND 02 TERMINAL BLOCK 49 GRN RED TO 49 TERMINAL BLOCK 49A GRN RED FROM ENGINE HARNESS 02 WHT FROM G...

Page 207: ...SECTION 6 Page 94 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 53 PLATFORM WORK LIGHTS OPTION Ma40 662 4 4 3 2 1 Terminal Block at Lower Control Panel 02 WHT 02 WHT 02 WHT 02 WHT 02 WHT AUG 1999 ...

Page 208: ...ch contol box 1 710527 ENCLOSURE Toggle 1 701930 TOGGLE SPDT 2 position maintained 1 701927 TOGGLE GUARD RED BOTTOM 1 103036 STRAIN RELIEF Plastic 3 710530 CABTIRE 18 2 660 1 710532 CABTIRE 18 2 41 1 710531 CABTIRE 18 2 79 1 709844 LABEL Lights 1 102955 TERMINAL 16 ga 6 ring 3 109210 TERMINAL 16 ga 5 16 ring 2 703298 HEATSHRINK 1 4 4 703926 HEATSHRINK 3 16 24 103855 BOLT HHCS 1 4 20 x 1 2 lg 2 104...

Page 209: ...SECTION 6 Page 96 SJKB 40 D SJKB 40 D F JUN 1999 NOTES ...

Page 210: ...702125 FITTING Tube union 8 1 5 709116 BRACKET Air line platform 1 6 706970 BRACKET Air line turret 1 7 703683 FITTING Pipe 1 2 NPT plug zinc 2 8 703681 FITTING Bulk head connector LN8 female 2 9 703671 LABEL Air line 2 NOTE Refer to Standard Hose Numbering System SECTION 5 Page 30 for explanation of hose numbering Index No Skyjack Part No Description 1 2 3 4 5 6 7 Units per Assy 9 8 7 1 6 5 4 3 2...

Page 211: ...SECTION 6 Page 98 SJKB 40 D SJKB 40 D F JUN 1999 FIGURE 6 55 HYDRAULIC TOOLOPTION Ma40 664 24 23 22 21 20 19 18 17 16 15 13 12 11 10 9 8 7 6 5 4 3 2 1 13 11 10 JUL 1999 ...

Page 212: ... 4 SPD F 2 707143 TERMINAL BLOCK THRU 1 707145 TERMINAL BLOCK DIODE 1 103570 CONNECTOR INSERT 4 Pin female 1 103568 CONNECTOR HOUSING 4 Pin female 1 103569 CONNECTOR INSERT 4 Pin male 1 103567 CONNECTOR HOUSING 4 Pin male 1 15 703681 FITTING Female bulkhead connector 8 2 16 703683 FITTING Pipe plug 1 2 NPT 2 17 703672 LABEL Hydraulic line 1 18 709625 ASSEMBLY Cable carrier e chain 1 19 702125 FITT...

Page 213: ...525 TOOL TRAY WELDMENT 1 700583 NUT lock nylon insert 1 4 20 4 703273 BOLT BHCS 1 4 20x1 00 SS 4 2 710061 TOOLTRAY SUPPORT 1 710427 CONTROLCOVER OPTION 3 710479 CONTROL COVER WELDMENT 1 700583 NUT lock nylon insert 1 4 20 6 103995 WASHER Flat 1 4 12 103860 BOLT HHCS 1 4 20x1 3 4 6 Index No Skyjack Part No Description 1 2 3 4 5 6 7 Units per Assy AUG 1999 2 1 3 ...

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