Skyjack SJ-7027 Operating, Maintenance And Parts Manual

OPERATING
MAINTENANCE &
PARTS MANUAL

SJ-600

TM

Series

Engine Powered

For Service please call ..................................................................... 800 275-9522

Skyjack Inc. Service Center, 3451 Swenson Ave., St. Charles, IL. 60174 ....FAX [phone]

For Parts in North America and Asia please call .....................................

Skyjack Inc. Parts Center, 3451 Swenson Ave., St. Charles, IL. 60174.............. FAX [phone]

For Parts & Service in Europe please call....................................................

Skyjack Europe Communicatieweg 29, 3641 SG Mijdrecht Netherlands ............. FAX [phone]

112715AI Printed in Canada Sep, 2005

800 965-4626

31 297 255 526

California Proposition 65

WARNING:

Some Materials and Fuels Used On This Equipment Are Known To The State Of

California To Cause Cancer, Birth Defects and Other Reproductive Harm.

Engine Exhaust and Some Of Its Constituents Are Known To The State Of
California To Cause Cancer, Birth Defects, and Other Reproductive Harm.

SERIAL NUMBER BREAKDOWN

MODELS

7027

MANUAL

PART #112715

All Serial Numbers Not Used Not Used

MANUAL

PART #122891

MANUAL

PART #122894

71XX

Not Used 340000-340002 340003 & ABOVE

Table Of Contents

Section - Paragraph Page No.

Section 1 - Introduction

Purpose Of Equipment ................................................................................................................... 1

Use Of Equipment ........................................................................................................................... 1

Warnings .......................................................................................................................................... 1

Description....................................................................................................................................... 1

Operator Warnings .......................................................................................................................... 2

Specifications And Features ........................................................................................................... 3

Standard Features And Optional Equipment ................................................................................ 4

Work Platform Major Component Identification ............................................................................ 5

Section 2 - Operation

Operating Controls Identification ............................................................................................ 1

Base Controls .................................................................................................................................. 1

Platform Controls ............................................................................................................................ 3

Identification And Operation Of Safety Devices ............................................................................. 5

Operating Procedures .............................................................................................................. 6

Set-Up Procedure ............................................................................................................................ 6

Prestart Checks ............................................................................................................................... 7

Operator Qualifications ................................................................................................................... 8

Start and Operation......................................................................................................................... 8

Shutdown Procedure ...................................................................................................................... 9

Emergency Lowering System ......................................................................................................10

Hydraulic Generator (Option)....................................................................................................... 11

Electrical Inverter (Option) ............................................................................................................ 11

Winching and Towing Procedures ............................................................................................... 11

1

S

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2

T

I

3

O

N

Section 3 - Systems Component Identification And Schematics

Table of Contents .............................................................................................................................A

Section 4 - Troubleshooting Information

Troubleshooting Information .......................................................................................................... 1

Section 5 - Maintenance And Service

Table of contents ............................................................................................................................. 1

Section 6 - Parts Lists

List Of Illustrations ........................................................................................................................... 2

List Of Tables

Table 1-1. Specifications And Features .......................................................... Section 1, Page 3

Table 1-2. Standard Features And Optional Equipment ............................... Section 1, Page 4

Table 2-1. Owner’s Annual Inspection Record ............................................... Section 2, Page 13

Table 2-2. Tire Specifications .......................................................................... Section 2, Page 13

Table 2-3. Maximum Platform Capacities ....................................................... Section 2, Page 13

Table 2-4. Maintenance And Inspection Schedule ........................................ Section 2, Page 14

Table 5-1. General Specifications ................................................................... Section 5, Page 4

Table 5-2. Tire Specifications .......................................................................... Section 5, Page 5

Table 5-3. Torque Specifications ..................................................................... Section 5, Page 5

I

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X

4

5

6

SJ600 Series Engine Powered

June 2001

Page i

WARNING

ANSI/SIA (United States)

You are required by the current ANSI/SIA A92.6 standards to read and understand YOUR
RESPONSIBILITIES in the Manual Of Responsibilities before you use or operate this work platform.

CSA (Canada) and CE (Europe)

You are required to conform to national health and safety regulations applicable to the operation of this
elevating work platform.

FAILURE TO COMPLY with your REQUIRED RESPONSIBILITIES in the use and operation of the
work platform could result in DEATH OR SERIOUS INJURY!

OPERATOR SAFETY REMINDERS

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

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, Inc.

DANGER

ELECTROCUTION HAZARD

THIS MACHINE IS NOT INSULATED. MAINTAIN SAFE CLEARANCES FROM ELECTRICAL
POWER LINES AND APPARATUS. YOU MUST ALLOW FOR PLATFORM SWAY, ROCK OR SAG.
THIS WORK PLATFORM DOES NOT PROVIDE PROTECTION FROM CONTACT WITH OR
PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR.

Minimum Safe Approach Distance

ANSI/SIA A92.6-1999 &

CSA CAN3-B354.2&.3-M82 Requirements

Voltage Range

(Phase to Phase) Feet Meters

0 To 300V Avoid Contact

Over 300V to 50KV 10 3.05

Over 50KV to 200KV 15 4.60
Over 200KV to 350KV 20 6.10
Over 350KV to 500KV 25 7.62
Over 500KV to 750KV 35 10.67

Over 750KV to 1000KV 45 13.72

Minimum Safe Approach Distance

“Avoidance of danger from Overhead Lines”

These machines should not operate within 15M
of overhead lines suspended from steel towers.

These machines should not operate within 9M of

overhead lines suspended from wooden poles.

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

CE Guidance Note

Page ii

SJ600 Series Engine Powered

June 2001

DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPER

AUTHORIZATION AND TRAINING. DEATH OR SERIOUS

INJURY COULD RESULT FROM IMPROPER USE OF THIS

EQUIPMENT!

SERVICE POLICY AND WARRANTY

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

NOTE

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

This Safety Alert Symbol Means Attention!

Become Alert! Your Safety Is Involved.

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

SCOPE OF THIS MANUAL

This manual applies to the ANSI/SIA, CSA and CE versions of the SJ-600 Series work platform models listed in
Table 1-1. Equipment identified with “ANSI/SIA” meet the ANSI/SIA-A92.6 -1990 or ANSI/SIA-A92.6 -1999 standards.
Equipment identified with “CSA” meets the CAN3-B354.2 & .3-M82 standards. Equipment identified with “CE”
meets the requirements for the European countries, i.e. Machinery Directive 89/392/EEC and EMC Directive 89/
336/EEC and the corresponding EN standards.

SJ600 Series Engine Powered

June 2001

Page iii

WARRANTY STATEMENT

SKYJACK, Inc. warrants each new work platform to
be free of defective parts and workmanship. During
the first full year, labor and replacement parts will be
provided by the local authorized Skyjack dealer
without charge. For the following 48 months,
structural components found to be defective will be
replaced or repaired at no charge.

A warranty registration card is supplied with each
work platform. The warranty is only effective when
the warranty card has been completed and returned
to Skyjack within 15 days from the time of billing.
When work platforms are put into stock, the warranty
period does not start until the personnel lift has been
shipped to the dealers customer. If a unit is put into
service and no warranty card has been mailed to
Skyjack, Inc., the warranty period will commence 15
days from the date the dealer was invoiced for the
work platform.

All warranty claims are subject to approval by
Skyjack’s Service Department. Skyjack, Inc. reserves
the right to limit or adjust claims with regard to
defective parts, labor or travel time based on usual
and customary guidelines. Parts purchased from
sources other than Skyjack will not be covered under
this warranty. Misuse or improper operation, lack of
normal maintenance and inspections as outlined in
this Operating/Maintenance and Parts Manual,
alterations to original design and/or components or
accidents will void all warranty. Batteries are not

covered by this warranty.

The above mentioned warranty statement is exclusive
and no other warranty whether written, oral or implied
shall apply. Skyjack excludes any implied warranty
of merchantability and fitness and accepts no liability
for consequential damages or for other negligence.

WARRANTY PROCEDURES

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 then file a warranty
claim with Skyjack, Inc. describing the nature of
the defect, probable cause, work performed, travel
hours, and labor hours listed separately. Warranty
labor will be paid at a rate of $42.00 per hour. The
travel allowance will be paid at the same hourly
rate within the dealers specified territory, limited to
a maximum of four (4) hours. If a part has
serviceable components, PLEASE replace the bad
component. For instance, if you have a bad switch
on a controller, please replace the switch. Hydraulic
cylinders should be resealed, unless they are
damaged beyond repair. Engine failures should be
directed to your local engine distributor and covered
by the manufacturers warranty. Skyjack will
accommodate you and your labor. Labor rates and
travel allowances are subject to change without
notice.

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

6. Materials returned for warranty inspection must have
the following procedures:

A. Carefully packaged to prevent additional damage
during shipping.

B. Drained of all contents and all open ports capped
or plugged.

C. Shipped in a container tagged or marked with
the RA number.

The selling distributor or authorized dealer shall be
responsible for the complete handling of customer
claims under this warranty. Here’s what to do:

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

2. When Skyjack’s Service Department verifies
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.

Page iv

June 2001

D. Shipped PREPAID. Any item(s) returned for
warranty by any other means may be refused and
returned unless prior approval from Skyjack is
obtained.

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

Failure to comply with the above procedures may de­lay approval and processing of the warranty claim and
could result in the denial of a warranty claim. Skyjack’s
dealer’s accounts must be kept current in order to
approve and issue warranty credits. Skyjack reserves
the right to withhold issuance of warranty credits to a
dealer if their account is not in good standing. This is
subject to change without prior notice.

SJ600 Series Engine Powered

SECTION 1

654

32toc

INTRODUCTION

Purpose Of Equipment

The SKYJACK SJ-600 Series Work Platform is designed
to transport and raise personnel, tools and materials to
overhead work areas.

Use Of Equipment

The work platform (Table 1-1) is a highly
maneuverable, mobile work station. Lifting and
elevated driving MUST be on a flat, level, compacted
surface. The work platform can be driven over uneven
terrain only when the platform is fully lowered.

Warnings

The operator MUST read and completely understand
the safety panel labels and ALL other warnings in this
manual and on the work platform. Compare the labels
on the work platform with the labels found throughout
this manual. If any labels are damaged or missing,
replace them immediately.

Description

The work platform consists of three major assemblies,
the platform, lifting mechanism and the base. An
operator’s control box is mounted on the platform
railing. Auxiliary and emergency controls are located at
the base.

Platform - The platform is constructed of a tubular

support frame, a skid-resistant “diamond plate” deck
surface, and 43-1/2" (1.10m) hinged railings with 6"
(15.24cm) toe boards and mid-rails. The platform can
be entered from the rear through a spring returned
gate. The 600 Series can be equipped with a front
extension platform.

Lifting Mechanism - The lifting mechanism is

constructed of formed steel sections making up a
scissor-type assembly. The scissor-type assembly is
raised and lowered by single-acting hydraulic lift
cylinders with holding valves. A two-section pump,
driven by an engine provides hydraulic power to the lift
cylinders. A safety bar located inside the lifting
mechanism (when properly positioned) prevents the
scissor-type assembly from being lowered while
maintenance or repairs are being performed within the
lifting mechanism.

Base - The base is a rigid one piece weldment which

supports two component side cabinets. One cabinet
contains the hydraulic components, up/down controls,
electrical components and starter battery. The other
cabinet contains the fuel tank and hydraulic tank. The
LP tank (if equipped) is located at the rear of the
platform behind the entrance ladder. The front axle
has two wheels, steerable by a hydraulic cylinder and
is either non-driven (2WD models) or drive shaft/gear
box driven (4WD models). The rear axle is drive shaft/
gear box driven and has a spring-applied hydraulically­released disc parking brake. A slide-out drawer at the
front of the base, supports an engine coupled with a
two-section hydraulic pump providing power to the
hydraulic system. An engine control panel is also
located at the front of the base.

Operator’s Control Box - A removable control

box, mounted at the right front of the platform, contains
controls for engine operation, work platform motion
and emergency stopping.

Serial Number Nameplate - The serial number

nameplate, located on the rear of the machine, lists the
model number, serial number, machine weight, drive
height, capacities, platform height, voltage, system
and lift pressures, and date manufactured. Use this
information for proper operation and maintenance and
when ordering service parts.

Optional Accessories - The SKYJACK Work

Platform is designed to accept a variety of optional
accessories. These are listed in Table 1-2. Standard

Features and Optional Equipment. Operating

instructions for these options (if required) are located in
Section 2 of this manual.

1

SJ-600 Series Engine Powered

June 2001

SECTION 1, Page 1

Operator Warnings

Warning

DO NOT exert excessive side forces on platform

while elevated.

DO NOT overload. The lift relief valve does not

protect against overloading when the
platform is elevated.

DO NOT climb or descend a grade steeper than

35%. Elevated driving must only be done
on firm level surfaces. (Ref. Table 1-1)

BE AWARE of overhead obstacles, and poorly lit

areas in case of overhead obstacles.

ENSURE that there is no person(s) in the path of

travel.

Warning

DO NOT alter or disable limit switches or other

safety devices.

DO NOT exceed the rated capacity of your

scissorlift and make sure the load is
evenly distributed on the platform.

DO NOT raise your platform in windy or gusty

conditions.

Warning

Jobsite Hazards

DO NOT operate on surfaces not capable of

holding weight of the work platform
including the rated load, e.g. covers,
drains, and trenches.

DO NOT elevate the work platform if it is not on

firm level surfaces. Avoid pot holes,
loading docks, debris, drop offs and
surfaces that may affect the stability of
your work platform.

Work Platform Conditions

An Operator Should Not Use Any Work Platform That:

• Has ladders, scaffolding or other devices mounted
on it to increase its size or work height.

• Does not have a clean, uncluttered work area.

• Does not appear to be working properly.

• Has been damaged or appears to have worn or
missing parts.

• Has alterations or modifications not approved by
the manufacturer.

• Has safety devices which have been altered or

disabled.

SECTION 1, Page 2

June 2001

SJ-600 Series Engine Powered

Table 1-1 Specifications And Features

7027

Height

Tires

Weight*

Width

Length

Platform Size

Working

Platform

Lowered

Drive

Normal

Drive

8,600 lbs.
(3450 kg)

70.0”

(1.78 m)

119.0”

(3.02 m)

65” x 112.5”
(1.65 x 86m)

33.0’

(10.1m)

27.0’

(8.23m)

60.0”

(1.52m)

Full

Refer To Table 2-2.

3.0 mph

(4.8 km/h)

.6 mph

39 sec.

33 sec.

Not Applicable

900 (Low)/

2800 (High)

1500 (Low)/

3900 (High)

35%

Speed

Engine (RPM)

Elevated Low Drive

Raise (Rated Load)

Lower (Rated Load)

Ford Gasoline

Kubota Diesel

Kubota Gasoline

Gradability

* Weights are approximate, refer to serial nameplate for specific weight. Values shown are for standard 2WD machines

with a manual extension platform.

CE Kubota Diesel Models

Sound Pressure & Power Levels

NET INSTALLED POWER: 17.1kW
SOUND PRESSURE @ OPERATOR STATION: 79 dB
G

UARANTEED SOUND POWER LEVEL: 103 dB

SJ-600 Series Engine Powered

June 2001

SECTION 1, Page 3

Table 1-2. Standard Features and Optional Equipment

Optional Equipment (ANSI & CE)

• Kubota Diesel Water-Cooled Engine (ANSI only)

• Movement Alarm

• Front Mounted 5 Ft. (1.5m) Powered Extension Platform

• 3500 Watt Hydraulic AC Generator

• 1500W AC Inverter

• 4-Wheel Drive Package

• Rotating Amber Beacon

• Type #6F Foam Filled Tires

• Type #7F Foam Filled Tires

• Type #8F Foam Filled Tires

• Type #7 Air Filled Tires

• Type #8 Air Filled Tires

• Scissor Guards (ANSI Only)

• 5 Ft. (1.5m) Slide Out Extension Platform

Standard Features (ANSI & CE)

• Operator Horn

• Joystick Control

• Diamond Pattern, All Steel Platform Deck Construction

• Flashing Light and Descent Alarm

• Hourmeter

• Lockable Cabinets With Swing-Out Door

• Color-Coded, Numbered Wiring System

• Tie Down Points

• Hinged Railing System With 6” (15.24cm) Toe Boards

• 23 Hp Kubota Dual Fuel- Gasoline/Propane (ANSI)

• Dual Fuel - Gasoline/Propane (ANSI)

• Kubota Diesel Water-Cooled Engine (CE only)

• Dual Range (torque/speed) Selector

• Engine Mounted on Slide-Out Tray

• Type #6 Air Filled Tires

• AC Outlet on Platform

• Scissor Guards (CE Only)

• Disc Brake System on Rear Axle

• Tilt Alarm with Lift/Drive Cut Out

• Base Key Switch Box (CE only)

• D-Rings (Lanyard Attachment Points)

SECTION 1, Page 4

June 2001

SJ-600 Series Engine Powered

POWERED
EXTENSION
PLATFORM
(OPTIONAL)

MAIN
PLATFORM

Work Platform Major Component Identification

OPERATOR’S
CONTROL BOX

ENTRY
GATE

SAFETY
BAR

LIFTING
MECHANISM

ENGINE
TRAY

HYDRAULIC/
ELECTRIC
SIDE
CABINET

HYDRAULIC/
FUEL TANK
SIDE
CABINET

Figure 1-1. SKYJACK SJ-600 Series Work Platform

(Model 7027 with powered extension platform option shown)

SJ-600 Series Engine Powered

June 2001

SECTION 1, Page 5

SECTION 2

65431

toc

OPERATION

Operating Controls Identification

The following descriptions are for identification,
explanation and locating purposes only. A qualified
operator MUST read and completely understand
these descriptions before operating this work
platform. Procedures for operating this work platform
are detailed in the “OPERATING PROCEDURES”
section. Both standard and optional controls are
identified in this section. Therefore, some controls
may be included that are not furnished on your work
platform.

Base Controls

Electrical Panel

3

1

Emergency Battery Disconnect Switch

1

Figure 2-2. Emergency Battery Disconnect Switch

1. Emergency Battery Disconnect Switch Located
at the front of the Hydraulic/Electric Side Cabinet, this
switch when in the “OFF” position, disconnects power
to all circuits. Switch MUST be in “ON” position to
operate any circuit.

Base Control Box (CE)

2

2

4

Figure 2-1. Electrical Panel

Electrical Panel - This control station is located in the
Hydraulic/Electric Side Cabinet. It contains the
following controls:

1. Up Push-Button Switch - This push-button switch
will raise the platform to desired height.

2. Down Push-Button Switch - This push-button
switch will lower the platform to desired height.

3. Hour meter - This gauge records engine running
time.

4. 20 Amp Circuit Breaker Resets - In the event of
a power overload or positive circuit grounding, circuit
breaker will pop out.

2

3

Figure 2-3. Base Control Box and Labels

(Located at rear of hydraulic/electric side cabinet)

Base Control Box - This metal control station is
mounted on the rear of the base . It contains the
following controls:

1. Platform/Base Select Key Switch - Key to
“PLATFORM” position directs power to the operator’s
control box on the platform. Key to “BASE” position
directs power to the base control box.

2. Platform Up/Down Selector Switch - This toggle
switch raises or lowers the platform to a desired
height.

1

SJ-600 Series Engine Powered

3. Emergency Stop Button - This red “mushroom-

head” shaped button switch is designed to disengage
power to the platform controls.

June 2001

SECTION 2, Page 1

Engine Control Panel (Dual Fuel)

Engine Control Panel (Diesel)

1

2

3

4

Figure 2-4A. Engine Control Panel -

Ford Gasoline Engine

(Shown with Dual Fuel)

Engine Control Panel - This control station is
attached to the Engine Roll-out at the front of the base.
It contains the following controls:

1. Engine Off/On Switch - This plunger-type switch,
when pulled out, energizes the engine circuit and the
operator’s control box. To stop engine, push plunger
in.

1

4

3

2

Figure 2-4B. Engine Control Panel -

Kubota Diesel Engine

Engine Control Panel - This control station is
attached to the Engine Roll-out at the front of the base.
It contains the following controls:

1. Engine Off/On Switch - This plunger-type switch,
when pulled out, energizes the engine circuit and the
operator’s control box. To stop engine, push plunger
in.

2. Fuel Select Switch (Machines with Dual Fuel) ­Used to switch from LP GAS to gasoline

3. Engine Start Push-Button - This push-button
switch energizes the engine starter motor.

4. Engine Choke Push-Button - This push-button
switch sets the choke for starting a cold gasoline/
propane engine.

2. Engine Start Push-Button - This push-button
switch energizes the engine starter motor.

3. Engine Glow Plug Push-Button - This push­button switch energizes the glow plug to aid in starting
a cold diesel engine.

4. Glow Plug Indicator Light - This red lamp
illuminates until the glow plugs have completed their
timed heating cycle. When the lamp goes out, the
engine is ready to be started.

SECTION 2, Page 2

June 2001

SJ-600 Series Engine Powered

Platform Controls

Operator’s Control Box

5. Enable Push-Button - When depressed and

held, this push-button switch brings power to the lift
or outrigger circuits. On some models, This button
must also be held depressed to energize the drive or
steer functions.

13

1

2

3

4

5

6

Figure 2-5. Operator’s Control Box

Operator’s Control Box - This metal control station is
mounted at the right front of the platform. It contains
the following controls:

1. Torque Toggle Switch - This toggle switch, when
in the “ ” position, cuts out High Range and 3rd
speed to provide maximum torque when climbing
grades and in rough terrain. When in the “ ”
position, all three speeds are available.

2. Operator Horn Push-Button - Located on the
side of the Operator’s Control Box, this push-button
switch, when depressed, sounds an automotive-type
horn.

3. Engine Choke Push-Button (Dual fuel engines) ­Located on the side of the control box, this push­button sets choke for starting a cold gasoline engine.

Glow Plug Push-Button (Diesel Engines) ­Located on the side of the control box, this push­button powers the glow plug for starting cold diesel
engines.

12

11

10

9

8

7

6. Emergency Stop Button - When struck, this red
push-button switch disconnects power to the control
circuit.

7. Off/Lift/Drive Select Key Switch - Key to “OFF”
position disconnects power to the control box. Key
to “LIFT” position brings power to the Lift Enable
Push-button. Key to “DRIVE” position brings power
to the Drive/Steer Controller.

8. Up/Down Selector Switch - This rotating selector
switch raises or lowers the platform to the desired
height.

9. Platform Power Indicator Light - Light will glow
when key switch is in “LIFT” or “DRIVE” position.
Light will not glow when key switch is in “OFF”
position.

10. Low/High Throttle Select Switch - This rotary
switch allows selection between high and low engine
throttle speeds.

11. Low/High Range Select Switch - This rotary
switch selects “LOW” range (high torque) or “HIGH”
range (high speed).

12. Drive/Steer Controller - A one-hand toggle type
lever to control steer and three-speed drive motion. It
is a “deadman” control which returns to neutral when
released.

13.Drive Enable Switch - On later models, this
momentary “Trigger” style switch energizes the drive/
steer controller. It must be held depressed
continuously while engaging either the drive or steer
functions.

4. Engine Start Push-Button - Located on the side
of the control box, this push-button energizes the
engine starter motor.

SJ-600 Series Engine Powered

June 2001

SECTION 2, Page 3

Hydraulic Generator Control (Option)

Powered Extension Platform
Control Box (Option)

1

Figure 2-6. Hydraulic Generator Control

Hydraulic Generator Control - Located on the side of
the Operator’s Control Box, this push-button switch
starts the hydraulic generator on the base.

1. Hydraulic generator Off/On Push-Button Switch
This illuminated push-button switch starts the base
mounted generator. It illuminates when the
generator is activated.

1500W AC Inverter (Option)

2

3

1

Figure 2-8. Powered Extension Platform Control Box

Powered Platform Control Box - This metal control
station is mounted at the right front of the extension
platform. It contains the following controls:

1. Enable Switch - This switch, when activated
brings power to the Platform Extend/Retract Switch.

2. Platform Extend/Retract Switch - This switch,
when activated extends/retracts the powered exten­sion platform.

2

1

Figure 2-7. 1500W AC Inverter

Inverter - The inverter is located on the base of the
machine, it has the following controls.

1. ON/OFF Switch - This slide switch will activate or
terminates inverter function.

2. Status LEDs - These LEDs indicate the operating
or fault status of the inverter .

3. 15 Amp Circuit Breaker - In the event of a power
overload or circuit grounding, this circuit breaker will
pop out.

4. GFCI Outlet - During inverter operation, this
outlet provides AC power.

4

SECTION 2, Page 4

June 2001

SJ-600 Series Engine Powered

Identification And Operation of
Safety Devices

Fold-Down Guardrail System

1

Base Controls - Manual Safety Bar

1

Figure 2-11. Safety Bar

1. Safety Bar - Designed to support the scissors
assembly (when properly positioned), the safety bar
MUST be used for inspection and performing
maintenance or repairs within the scissors assembly.
To lower safety bar, push lock lever rearward and the
safety bar will drop. Follow procedure on safety bar
decal to properly position safety bar.

1

Figure 2-9. Fold-Down Guardrail System

Fold-Down Guardrail System - This system when
folded down, reduces the shut height of the work
platform for transporting and traveling through
doorways.

1. Guardrail Locking Pin W/Lanyard - To fold the
guardrail system down, remove the locking pin at
each pivot point and lower each guardrail. To raise
the guardrail system, swing up each guardrail and
lock in place with the locking pins ensuring that the
detent ball of each pin is clear of the side of the pivot
brackets. (Figure 2-10.)

Warning

The guardrail system MUST be upright and locked in
place before resuming normal operation. Check the

guardrail system for loose or missing locking pins
before operating this equipment!

Warning

Crushing Hazard

DO NOT reach through scissor assembly without the

safety bar properly positioned. Failure to avoid this

hazard will result in death or serious injury!

DETENT BALL
CLEAR OF SIDE
OF PIVOT
BRACKET

Figure 2-10. Correct Position of Locking Pin

SJ-600 Series Engine Powered

June 2001

SECTION 2, Page 5

Operating Procedures

Warning

The following descriptions are for Operating
Procedures. A qualified operator MUST read and
completely understand these descriptions before

operating this work platform.

Set-Up Procedure

1. Remove all packing materials and inspect for
damage incurred during transport. This is
normally required for equipment being put into
service for the first time, after the equipment has
been unloaded.

Note

Report any damage to delivery carrier immediately.

2. Inspect work platform thoroughly and remove
any foreign objects.

3. Raise the side, extension platform (if so
equipped), and gate railings to their upright
position and lock in place with locking pins.
Lock side railings to front railings with locking
pins.

Explosion Hazard

Keep flames and sparks away. DO NOT smoke near
batteries.

First Aid

Immediately flush eyes with cold water if electrolytic
acid is splattered into them. Seek medical attention.

10. Move the work platform to a level, firm test area
where the work platform can be vertically
extended to its maximum working height. If the
work platform is to be pushed, towed or winched,
ensure that the parking brake has been
disengaged. When pushing, towing or

winching, DO NOT exceed 2 mph (3.2 kph).

Using the Base Controls:

11. Turn the Emergency Power Disconnect Switch
to “ON” position.

Using the Platform Controls:

12. Pull out the Emergency Stop Button.

4. Remove the operator’s control box from its
shipping container and secure it to the railing at
the right front of the platform. Attach the control
cable and power deck extension cable (if so
equipped) to the scissor’s control cable.

5. Open the fuel tank side cabinet door. Fill the
fuel tank to “F” level on fuel gauge with the
proper fuel. (Refer to decal on fuel tank)

6. Close the fuel tank side cabinet door.

7. Machines with Dual Fuel:
Make sure propane hose coupler is properly
secured at propane cylinder and valve on
propane cylinder is opened all the way.

8. Open the hydraulic tank side cabinet door.
Check the hydraulic oil level (scissors must be
fully lowered) in the tank. Level should be at or
slightly above the top mark on the sight glass. If
required, add a quality grade hydraulic oil such
as ATF Dexron III (ESSO).

9. Check the battery fluid level. If fluid level is not
at FULL mark on battery, add distilled or
demineralized water only.

Note

Engine will not start unless this button is in the
“ON” position.

13. Insert key into Off/Lift/Drive Select Key Switch
and turn to “LIFT” position.

Note

Start engine in low throttle position.

Using the Engine Controls on the Engine:

14. Pull Engine Off/On Switch plunger out.

15. Select desired fuel source with Fuel Select
Switch. (Gasoline engines with dual fuel)

Note

Refer to label on inside of engine front guard for
fuel switch sequence.

16. Depress and hold the Choke Push-Button.
(Gasoline engines) Depress and hold Glow Plug
Push-Button for 15 to 20 seconds. (Diesel
engines)

SECTION 2, Page 6

June 2001

SJ-600 Series Engine Powered

17. Depress and hold the Engine Start Push-Button
until the engine starts, then release. DO NOT
over crank the starter. Release the Engine Choke
Push-button.

Using the Base Controls:

18. Raise the platform with the “Up” Selector Switch
on the Base Control Box until the open height
between scissors center pins is approximately
18” (45.72cm).

19. Unlatch and carefully swing down the safety bar.
Follow procedure on safety bar decal to properly
position safety bar.

Warning

Operating Procedures

Prestart Checks

1. Carefully read and completely understand ALL
of Section 2, OPERATION in this manual and
ALL warnings and instruction decals on the work
platform.

2. Check for any obstacles around the work
platform and in the path of travel such as holes,
drop offs, debris, ditches and soft fill.

3. Check overhead clearances.

4. Make sure all guardrails are in place and locked
in position.

Crushing Hazard

DO NOT reach through scissor assembly without the

safety bar properly positioned. Failure to avoid this
hazard will result in death or serious injury!

20. Slowly lower the platform with “Down” Selector
Switch on the Base Control Box until the scissors
assembly is firmly resting on the safety bar.

21. Inspect all hoses, fittings, wires, valves, etc. for
leaks, loose or missing parts, hidden damage,
and foreign material.

22. Raise the platform with the Up Switch until the
open height between scissors center pins is
approximately 18” (45.72cm).

23. Carefully swing up safety bar and lock in
position.

24. Again, raise the platform with the Up Switch until
the platform has reached maximum working
height.

Note

Refer to Table 1-1. Specifications and Features for
proper lift and lowering times.

25. Use the Down Switch to lower the platform to
it’s fully lowered position.

OPERATOR’S CHECKLIST

INSPECT AND/OR TEST THE FOLLOWING DAILY

OR AT BEGINNING OF EACH SHIFT

1. OPERATING AND EMERGENCY CONTROLS.

2. SAFETY DEVICES AND LIMIT SWITCHES.

3. PERSONAL PROTECTIVE DEVICES.

4. TIRES AND WHEELS.

5. OUTRIGGERS (IF EQUIPPED) AND OTHER STRUCTURES.

6. AIR, HYDRAULIC AND FUEL SYSTEM(S) FOR LEAKS.

7. LOOSE OR MISSING PARTS.

8. CABLES AND WIRING HARNESSES.

9. PLACARDS, WARNINGS, CONTROL MARKINGS AND
OPERATING MANUALS.

10. GUARDRAIL SYSTEM, INCLUDING LOCKING PINS.

11. ENGINE OIL LEVEL (IF SO EQUIPPED).

12. BATTERY FLUID LEVEL.

13. HYDRAULIC RESERVOIR LEVEL.

14. COOLANT LEVEL (IF SO EQUIPPED).

Warning

DO NOT OPERATE THIS EQUIPMENT

WITHOUT PROPER AUTHORIZATION AND
TRAINING. DEATH OR SERIOUS INJURY
COULD RESULT FROM IMPROPER USE
OF THIS EQUIPMENT!

26. Your SKYJACK Model is now ready for use by
an authorized, qualified operator who has read
and completely understands ALL of Section 2,
OPERATION in this manual.

SJ-600 Series Engine Powered

June 2001

SECTION 2, Page 7

Operator Qualifications

Only trained and authorized persons should use this
work platform. Safe use of this work platform requires
the operator to understand the limitations and
warnings, operating procedures and operator’s
responsibility for maintenance. Accordingly, the
operator MUST understand and be familiar with this
operating manual, its warnings and instructions and

ALL warnings and instructions on the work platform.

The operator also MUST be familiar with employer’s
work rules, related government regulations and be
able to demonstrate his/her ability to understand and
operate THIS make and model work platform in the
presence of a qualified person.

Start and Operation

Using the Base Controls:

7. If the engine is cold, depress and hold the Engine
Choke Push-button (Gasoline engines) or
depress and hold the Glow Plug Push-button
for 15 to 20 seconds) (Diesel engines) and
release.

8. Depress and hold the Engine Start Push-Button
until engine starts, then release. DO NOT over
crank the starter.

9. Select “HIGH” position with the Low/High Throttle
Select Switch.

10. To Raise the Platform: Ensure the emergency
stop button is pulled out. Select “LIFT” position
with Off/Lift/Drive Select Key Switch. Depress
and hold the Enable Push-button, then select

××

“

×” (up) position with Up/Down Selector Switch.

××

Release switch to stop.

1. Turn Emergency Power Disconnect Switch to
“ON” position. CE units - make sure base control
box emergency stop button is in the “ON”
position.

Using the Engine Controls on the Engine:

2. Pull Engine Off/On Switch plunger out.

3. Select desired fuel source with Fuel Select
Switch. (Gasoline engines with Dual Fuel)

Note

Refer to label on inside of engine front guard for fuel
switch sequence.

4. Use the ladder of the work platform to access
the work platform deck. Close and latch the gate.

Using the Platform Controls:

Warning

TO PROTECT AGAINST UNINTENDED
MOVEMENT OF THE WORK PLATFORM, PUSH
IN THE EMERGENCY STOP BUTTON AFTER YOU
HAVE ARRIVED AT YOUR DESIRED LOCATION
OR ELEVATION.

5. Pull out the Emergency Stop Button.

6. Insert key into the Off/Lift/Drive Select Key Switch,
then select “LIFT” or “DRIVE”.
Select “LOW” position with HI/LOW Throttle
Select Switch.

SECTION 2, Page 8

June 2001

11. To Lower the Platform: Ensure the emergency
stop button is pulled out. Select “LIFT” position
with Off/Lift/Drive Select Key Switch. Depress
and hold the Enable Push-button, then select

ØØ

“

Ø ” (down) position with Up/Down Selector

ØØ

Switch. Release switch to stop. A warning alarm
will sound while lowering.

12. If High Torque is Desired: Select “LOW” position
with the Low/High Range Select Switch. Select
“LOW” range when climbing grades, traveling
in rough terrain and when loading or unloading
the work platform.
If High Speed is Desired: Select “HIGH”
position with the Low/High Range Select Switch.
Select “HIGH” range when traveling on a hard
level surface with the platform fully lowered.

13. To Drive Forward or in Reverse:

1- Ensure the emergency stop button is pulled

out. Select “DRIVE” position with the Lift/
Off/Drive Key Switch.

2- Earlier models: Depress and hold the

Enable push-button (if equipped), then lift
the controller lock ring.
Later models: Activate and hold the Enable
trigger switch (by squeezing it towards the
joystick)

3- Push or pull the controller handle forward or

backward to the desired speed and direction
of platform travel.

4- Return the joystick to the neutral center

position to stop. Release the Enable switch
(If equipped).

SJ-600 Series Engine Powered

14. To Steer: Select “DRIVE” position with Off/Lift/
Drive Select Key Switch. If equipped, activate
and hold the Enable switch (by squeezing the
trigger towards the joystick or pressing the
control box side mounted push button), then
press the rocker switch on top of the Drive/Steer
Controller handle in the direction you wish to
steer.

Shutdown Procedure

1. Completely lower the platform.

2. Turn key to “OFF” position and remove key from
Off/Lift/Drive Select Key Switch in control box.

3. Push Emergency Stop Button(s) in.

15. To Climb a Grade: Select “ ” position with
the Torque Toggle Switch.

Warning

MACHINE MUST BE IN FULLY RETRACTED
POSITION

16. To extend/retract a manual extension platform:
To extend the platform remove the retaining
locking pins and push/pull the extension platform
using the push bar until the desired extension is
reached. Reinsert the locking pins to prevent
accidental movement of the extension deck
during travel or transport.

17. To extend/retract a hydraulic powered
extension platform: To extend the platform,
turn key to “LIFT” position with Off/Lift/Drive
Select Key Switch, activate the Enable Switch,
then push the extension/retraction toggle switch
to the “
reached. Release switch to stop. To retract the
platform, turn key to “LIFT” position with Off/
Lift/Drive Select Key Switch, activate the Enable
Switch, then push the extension/retraction toggle
switch to the “
retraction is reached. Release switch to stop.

××

×” position until desired extension is

××

ØØ

Ø” (retract) position until desired

ØØ

4. Turn Emergency Power Disconnect Switch to
“OFF” position. CE units - remove key then
push in Emergency Stop Button on the base
control box.

18. To switch from LP GAS to gasoline: Move fuel
selector switch on engine control panel to the
“GASOLINE” position. To shut off fuel, move
switch to “OFF” position.
To switch from gasoline to LP GAS: With the
engine running, move switch to “OFF” position
and let engine run until gasoline is exhausted
from carburetor. When engine stops, move
switch to “LP GAS” position and restart engine.
Make sure LP GAS valve is ON when switching
from gasoline to LP GAS and valve is OFF when
switching from LP GAS to gasoline.

SJ-600 Series Engine Powered

June 2001

SECTION 2, Page 9

Emergency Lowering System

2

2. Emergency Lowering Valve - Pull out and hold
the Emergency Lowering Valve plunger, and the
platform will gradually lower. Located at the rear of the
hydraulic/electric side cabinet, this pull-type valve
when used in conjunction with the holding valve
manual overrides, allows platform lowering in the
event of an emergency or electrical system failure.
Activate all holding valve manual override knobs, then
pull and hold the plunger out to lower platform.
Release to stop.

Warning

1

Figure 2-12. Emergency Lowering System

Emergency Lowering System - This system allows
platform lowering in the event of an emergency or an
electrical system failure.

1. Holding Valve Manual Override Knob - Located

on the holding valve at the bottom of each lift cylinder,
these red knurled knobs when depressed and turned
counter-clockwise allow hydraulic oil to bypass each
holding valve. The red knurled knobs on each
holding valve MUST be depressed and turned
clockwise to restore normal operation. An access

rod for reaching the elevated manual override
knob shall be provided for CE units only.

Crushing Hazard

Keep clear of scissors mechanism when using
emergency lowering valve! After emergency

lowering is completed, the red knurled knobs on each
holding valve MUST be depressed and turned
clockwise to restore normal operation.

SECTION 2, Page 10

June 2001

SJ-600 Series Engine Powered

Hydraulic Generator (Option)

Winching And Towing Procedures

1. To start the hydraulic generator, Ensure the
engine is on high throttle by selecting “HIGH”
on the “Low/High Throttle Select” switch. Select
the “LIFT” position with the “Off/Lift/Drive” key
switch, then depress hydraulic generator push­button on the side of the operator’s control box.
The push-button will illuminate and generator
on base will start. To restore normal operation,
depress push-button again. The light in push­button will go out and the generator will turn off.

Note

While hydraulic generator push-button switch light is
illuminated, the lift and drive circuits in the Operator’s
Control Box are cut out.

Electrical Inverter (Option)

1. Turn the main disconnect switch to the “ON”
Position.

2. Turn the “ON/OFF” switch located on the front
face of the inverter to the “ON” Position.

3. Start the machine and turn the throttle switch to
the high idle setting.

4. Inverter activation is indicated by a glowing green
LED on the front face of the inverter.

Warning

When Towing, DO NOT drive onto a downward slope
or brake the towing vehicle rapidly.

Parking Brake System

2

1

3

Figure 2-13. Disc Parking Brake

1 - 3. Parking Brake Disc -This device disengages
the brake disc(1) when driving forward or in reverse. A

hydraulic brake cylinder(2), linked to a disc
caliper(3), engages and disengages a brake disc on

the rear axle drive shaft yoke. The brake MUST be
manually disengaged for pushing, towing or winching.

DO NOT push or tow the work platform onto a

downward slope or pull the platform down an incline
towards the winch. The special procedure for

manually disengaging the parking brake is as follows:

5. To turn off the inverter, shut down the platform
engine and/or slide the “ON/OFF” switch on the
inverter to the “OFF” position.

Note

The inverter will only supply power to the platform
when the engine is running and the throttle switch is
set to the HIGH idle position. Deselecting the high idle
throttle setting or stopping the engine will turn the
inverter off.

Warning

DO NOT manually disengage the parking brakes if

the work platform is on a slope.

SJ-600 Series Engine Powered

June 2001

SECTION 2, Page 11

Later Models:

Earlier Models:

7

4

Figure 2-14A. Parking Brake Release Hand Pump and

Brake Valve Plunger (Machines With Serial Number

30167 and Above)

4 - 5. Parking Brake Release Hand Pump(4) and
Brake Valve Plunger(5) - Located on the brake

manifold in the hydraulic electric side cabinet, this
hand operated pump MUST be used when pushing,
towing or winching the work platform. To release the
parking brake:

1. Make sure that the work platform is on level
ground. Chock or block the wheels to keep
work platform from rolling.

2. Turn Emergency Power Disconnect Switch to
“OFF” position.

3. Depress the black plunger on the Brake Valve
until the plunger stays in.

4. Grasp the red hand pump plunger and rapidly
depress 60 to 80 times until firm resistance is
felt. The brake is now released.

5. Remove the wheel chocks or blocks, then push,
tow or winch the work platform to the desired
location. When pushing, towing or winching,

DO NOT exceed 2 mph (3.2 km/h). DO NOT push

or tow the platform onto a downward slope or
pull the platform down an incline towards the
winch.

6. Position machine on a firm and level surface.
Chock or block the wheels to prevent the
platform from rolling or re-engage the parking
brake by momentarily activating the drive
function.

5

Note

The parking brake will reset automatically when the
work platform is put back into service.

6

Figure 2-14B. Parking Brake Release Hand Pump

and Quick Brake Valve (Machines With Serial

Number 30166 and Below)

6 - 7. Parking Brake Release Hand Pump (6) and
Brake Valve Knob (7) - Located on the brake manifold

in the hydraulic electric side cabinet, this hand operated
pump MUST be used when pushing or winching the
work platform. To release the parking brake:

1. 1. Make sure that the work platform is on level
ground. Chock or block the wheels to keep
work platform from rolling.

2. Turn Emergency Power Disconnect Switch to
“OFF” position.

3. Depress and turn the red knurled knob on the
quick brake valve counterclockwise to a fully
closed position.

4. Grasp the red hand pump plunger and rapidly
depress 60 to 80 times until firm resistance is
felt. The brake is now released.

5. Remove the wheel chocks or blocks, then push,
tow or winch the work platform to the desired
location. When pushing, towing or winching,

DO NOT exceed 2 mph (3.2 km/h). DO NOT

push or tow the platform onto a downward
slope or pull the platform down an incline
towards the winch.

6. Position machine on a firm and level surface.
Chock or block the wheels to prevent the platform
from rolling. Re-engage the parking brake. Open
the quick brake valve by depressing, then turning
the red knurled knob on the brake valve
clockwise to a fully open position.

Warning

The quick brake valve MUST be open to restore
normal operation. Failure to follow the procedure

discussed above could result in death or serious
injury!

SECTION 2, Page 12

June 2001

SJ-600 Series Engine Powered

Table 2-1. Owner’s Annual Inspection Record

MODEL NUMBER________________________________ SERIAL NUMBER________________________

RECORDING

DATE

RECORDING

BY

YEAR #

OWNER’S

NAME

INSPECTED

1 2 3 4 5 6 7 8

Table 2-2. Tire Specifications

WARNING

Air Pressure Can Affect Stability. Temperature Changes Can Affect Air Pressure. It Is Important To

Check Tire Pressures Prior To Use On A Daily Basis In The Operating Conditions Experienced By End

User. If The Measured PSI Reading Is Less Than The Specification And Tolerance, Re-inflate To The

Proper Specification Within The Tolerance Range Specified. Tires Shall Also Not Be Subject To Over-

Inflation Above The Recommended Specification And Tolerance Range.

Tire* Fill Specification

Pressure

Size Fill Type Ply Rating

Factory

#6 30-10-16.5 NHS 8 50 (344.7)* 65 (448.2)
#6 32.3-10-16.5 HD Stabilizer 10 70 (482.6)* 75 (517.1)
#6 30-10-16.5 OTR Outrigger 10 70 (482.6)* 75 (517.1)

Air
#7 31-15.5-15 NHS 8 50 (344.7)* Not Available
#8 31-13.5-15 NHS
#6F 30-10-16.5 NHS 8 **
#7F 31-15.5-15 NHS 8 **
#8F 31-13.5-15 NHS

*

Factory preset @ 20°C, Check pressures regularly as tires can lose pressure over time and over different
ambient temperatures even under normal conditions.

**

Urethane used for filling #6F and #7F tires MUST be 50-55 durometer.

Solid

Urethane

Consult Skyjack Inc.

Consult Skyjack Inc.

Psi (kPa)

Listed Sidewall

Maximum

Table 2-3. Maximum Platform Capacities (600 Series)(Evenly Distributed)

Main

Platform

MODEL

No extension

Platform

One Extension

7027

Platform

NOTE: Occupants AND materials are not to exceed rated load.

Capacities listed are for standard machines equipped with #6 pneumatic tires.
Refer to capacity label at sides of platform for additional information.

Capacity

1500 lbs.

(680 kg)

1000 lbs.

(454 kg)

Number Of
Occupants

5 - - - -

3

Capacity

500 lbs.

(227 kg)

SJ-600 Series Engine Powered

First

Extension

June 2001

Number Of
Occupants

2 - -

Extension

Capacity

Second

Number Of
Occupants

Total
Platform
Capacity

1500 lbs.

(680 kg)

1500 lbs.

(680 kg)

SECTION 2, Page 13

Table 2-4. Maintenance And Inspection Schedule

A

A

A

Daily Weekly Monthly 3 Months 6 Months 12 Months*

Engine

Fuel leaks A
Engine oils H & I
Engine RPM
Fuel filter
Belts/Hoses
Muffler
Air cleaner
Fuel tank cap B & C
Coolant level A & L

A & C

A I

G

F F

B, C & J

Mechanical

Structural damage/welds A A
Locking Pins/Retainers A & B C A, B & C
Parking brake B B
Tires/wheels & fasteners A, B, C & R O A, B, C & O
Guides/ rollers & slider pads A, B & N A, B & N
Railings/Entry chains/gates A, B & C A, B & C
Bolts and fasteners A C A & C
Safety Bar B B
Gear Oil** A & H A, H & F
Rust A A
Wheel Bearings & King pins A B & E A, B & E
Steering cylinder & tie rod A B & E A, B & E

Electrical

Battery fluid level A
Control switches/Indicator Lights A & B
Cords & wiring A
Battery terminals
Generator/receptacle
Terminals & plugs
Limit Switches
Tilt Switch

B

B

& B B

A & C

C

B

Hydraulic

Hydraulic oil H
Hydraulic hoses/fittings A & P
Lift/lowering speeds
Cylinders
Emergency lowering
Lift capacity
Hydraulic oil & oil filter

F

C

G

A & B

B

D

Miscellaneous

Labels and manual A, K & M
Lanyard Attachments A & C

Notes

A. Visually Inspect.
B. Check operation.
C. Check tightness.
D. Check relief valve setting. Refer to serial number

nameplate
E. Lubricate.
F. Replace.
G. Refer to Table 1-1 specifications and features.
H. Check oil level.
I. Refer to engine manual.
J. Check noise level.

K. Replace if missing or illegible.

L. Check only when cooled.
M. Proper manual must be in box
N. Ensure there is no metal to metal contact with slider, slider

side or running surface. Check for free movement of surface.
Also check for free movement of the slider pin through the

slider and pad.
O. Ensure proper torquing procedure and sequence is followed.
P. Check for leaks.
Q. Have oil sample tested.
R. Check tire pressure prior to use. (Refer To Table 2-2.)
* Record inspection date and signature
** Gear Oil Requirements: Axle: ESSO GX 85W-140
Center Drive: ESSO GX 85W-140

A

H & I

G

& C

B, C & J

A & I

B & C

A & L

A

A & B

A
A & C
A & B

C

A & B

H & Q

A, C & P

G
A & B

B

D

F

A, K & M

A & C

SECTION 2, Page 14

June 2001

SJ-600 Series Engine Powered

SECTION 3

SYSTEM COMPONENT IDENTIFICATION

AND SCHEMATICS

TABLE OF CONTENTS

SYMBOLS & CHARTS

FIGURE 3.1-1. RELAY TERMINAL FUNCTION IDENTIFICATION ...................................................................... 2

FIGURE 3.1-2. ELECTRICAL SYMBOL CHART.................................................................................................. 3

FIGURE 3.1-3. HYDRAULIC SYMBOL CHART ................................................................................................... 4

HYDRAULIC SYSTEM

FIGURE 3.2-1. HYDRAULIC SCHEMATIC Powered Extension Platform ........................................................... 5

FIGURE 3.2-2. HYDRAULIC SCHEMATIC .......................................................................................................... 6

FIGURE 3.2-3. HYDRAULIC MANIFOLD Component and Port Identification ................................................... 8

ELECTRICAL DIAGRAMS

FIGURE 3.4-1. ELECTRICAL PARTS LIST ........................................................................................................ 27

CONTROL BOXES

CONTROL BOX REFERENCE TABLE

Serial Range Diagram Location

From To

Below 32097

32098 33047

33048 33188

33189 Above

ELECTRICAL PANEL DIAGRAMS

Serial Range Diagram Location

From To
Below 30985 Figure 3.4-2.
30986 32097 Figure 3.4-3.
32098 Above
Below 30985 Figure 3.4-5.
30986 32097 Figure 3.4-6.
32098 Above

Current Production ANSI, CSA & CE Both

LARGE PULL-OUT ELECTRICAL SCHEMATICS

ELECTRICAL SCHEMATIC REFERENCE TABLE

Serial Range Model Engine Options Schematic Location

31801 & Below Figure 3.5-1.
31802 to 33047 Figure 3.5-2.
33048 to 33467 Figure 3.5-5.

33468 & Above
33047 & Below Figure 3.5-3.

33048 to 33467 Figure 3.5-6.

33468 & Above

SJ-600 Series Engine Powered 112715

Model Engine Options

No Options Figure 3.3-1A. 10

All Options Figure 3.3-2A. 18

No Options Figure 3.3-1B. 12

ANSI/SIA & CSA W/Ford Dual Fuel

And CE W/Kubota Diesel

PANEL DIAGRAM REFERENCE TABLE

Model Engine Options

ANSI & CSA Kubota Dual Fuel

CE Kubota Diesel

ANSI/SIA & CSA Kubota Dual Fuel

CE Kubota Diesel

June 2001

All Options Figure 3.3-2B. 20

No Options Figure 3.3-1C. 14

All Options Figure 3.3-2C. 22

No Options Figure 3.3-1D. 16

All Options Figure 3.3-2D. 24

All Options

Electrical

Inverter

All Options

Figure Page

Figure

Figure 3.4-4.

Figure 3.4-7.
Figure 3.4-8.

Figure 3.5-7.

Figure 3.5-8.

SECTION 3, Page 1

Page

3

31
32
33
34
35
36

37

FIGURE 3.1-1. RELAY TERMINAL AND FUNCTION CHART

COMMON

COIL

CONTROL

(B+)

NORMALLY

CLOSED

CONTACT

RELAY NO. RELAY FUNCTION

GROUND (B-)

CONTROL

NORMALLY

CONTACT

10BCR1 Engine On (DPDT)
10BCR2 Engine Protection (DPDT)

13CR Down (SPDT)
14CR Up (SPDT)
15CR Reverse Drive (DPDT)
16CR Forward Drive (DPDT)
17CR 2nd Speed (SPDT)

17ACR Small Pump

18CR 3rd Speed (SPDT)

COIL

(B-)

OPEN

COMMON

COIL

CONTROL

(B+)

NORMALLY

CLOSED

CONTACT

NORMALLY

OPEN

CONTACT

RELAY NO. RELAY FUNCTION

20CR Series/Parallel Drive (SPDT)
23CR Right Steer (SPDT)
24CR Left Steer (SPDT)
28CR Tilt Switch (DPDT)
30CR Brake (SPDT)
31CR Choke/Glow Plug (SPDT)
32CR Engine Start (DPDT)

32BCR Low/High Throttle (SPDT)

35CR Tilt Override (DPDT)
49CR Horn (SPDT)

COIL

CONTROL

(B-)

NORMALLY

CLOSED

CONTACT

SECTION 3, Page 2

June 2001

SJ-600 Series Engine Powered 112715

FIGURE 3.1-2. ELECTRICAL SYMBOL CHART

WIRE CROSSING HOURMETER

WIRES JOINED LIGHT

HYDRAULIC VALVE

BATTERY

GROUND

FUSE

COIL

PROPORTIONAL
HYDRAULIC VALVE
COIL

ELECTRIC MOTOR

KEY SWITCH

FOOT SWITCH

TOGGLE SWITCH

PUSH BUTTON

ROTARY SWITCH

CIRCUIT BREAKER

BATTERY CHARGE
INDICATOR

CAPACITOR RESISTOR

POTENTIOMETER

SINGLE POLE
DOUBLE THROW
RELAY

HORN

EMERGENCY
STOP BUTTON

LEVEL SENSOR

DOUBLE POLE
SINGLE THROW
RELAY

LIMIT SWITCH

CAM OPERATED
LIMIT SWITCH

TILT SWITCH

SINGLE POLE
SINGLE THROWN
RELAY

DOUBLE POLE
DOUBLE THROW
RELAY

TRIPLE POLE
DOUBLE THROW
RELAY

SJ-600 Series Engine Powered 112715

DIODE

June 2001

TRANSISTOR

SECTION 3, Page 3

FIGURE 3.1-3. HYDRAULIC SYMBOL CHART

LINE CROSSING

HYDRAULIC TANK

HYDRAULIC
FILTER WITH
BYPASS

ELECTRIC
MOTOR

VARIABLE
DISPLACEMENT
PUMP

HAND PUMPLINE JOINED

RELIEF VALVE

PRESSURE
REDUCING VALVE

FIXED ORIFICE

SHUTTLE VALVE

ACCUMULATOR,
GAS CHARGED

CUSHION
CYLINDER

PRESSURE
SWITCH

MOTION
CONTROL VALVE

VELOCITY FUSE

SINGLE ACTING
CYLINDER

DOUBLE ACTING
CYLINDER

DOUBLE ACTING
DOUBLE RODDED

SPRING APPLIED
HYDRAULIC
RELEASED
BRAKE

ENGINE

FIXED
DISPLACEMENT
PUMP

THREE POSITION
FOUR WAY
PROPORTIONAL

SERIES
PARALLEL
HYDRAULIC
MOTOR

TWO POSITION
TWO WAY
NORMALLY OPEN

ADJUSTABLE
FLOW CONTROL

CHECK VALVE

OIL COOLER

TWO POSITION
TWO WAY
NORMALLY
CLOSED

TWO POSITION
THREE WAY

FLOW DIVIDER
COMBINER

COUNTER
BALANCE VALVE

VALVE COIL

TWO POSITION
THREE WAY

THREE POSITION
FOUR WAY
CLOSED CENTER
CLOSED PORT

BRAKE CYLINDER

ROTARY
ACTUATOR

BI DIRECTIONAL
HYDRAULIC
MOTOR

THREE POSITION
FOUR WAY
CLOSED CENTER
OPEN PORT

THREE POSITION
FOUR WAY
PROPORTIONAL

SECTION 3, Page 4

June 2001

SJ-600 Series Engine Powered 112715

NOTES

FIGURE 3.2-1. HYDRAULIC SCHEMATIC - Powered Extension Platform

50017AA

Index

No.

Skyjack
Part No.

Description

Units

per

Assy.

C3 (Ref.) CYLINDER ASSEMBLY, Powered extension platform 1

(Refer to Figure 6-5.)

107396 • KIT, Seal repair AR

4H-26 103397 VALVE, “Vickers” Platform extend (Earlier models - replace with Hytos) 1

128797 VALVE, Platform extend (Later models - replacement for Vickers) 1

4H-27 103397 VALVE, Platform retract (Earlier models - replace with Hytos) 1

128797 VALVE, Platform retract (Later models - replacement for Vickers) 1

MB5 111290 MANIFOLD BLOCK, Powered extension platform 1

P2 113173 PUMP, Hydraulic 1.2gpm powered extension platform 1

R5 113289 RELIEF VALVE, Powered extension platform (500 psi) 1

SJ-600 Series Engine Powered 112715 SECTION 3, Page 5

June 2001

FIGURE 3.2-2. HYDRAULIC SCHEMATIC

Parts List

A

B

C

D

EF

GH

V

W

X

Y

Z

SECTION 3, Page 6

50016AA

SJ-600 Series Engine Powered 112715

June 2001

FIGURE 3.2-2. HYDRAULIC SCHEMATIC PARTS LIST FIGURE 3.2-2. HYDRAULIC SCHEMATIC PARTS LIST

Index

No.

Skyjack
Part No.

Description

C1 121091 CYLINDER ASSEMBLY, Lift 1

Use Part # 110530 for Machines with Serial # 32328 and below.

C2 121091 CYLINDER ASSEMBLY, Lift 1

Use Part # 110530 for Machines with Serial # 32328 and below.

121095 • KIT, Seal repair AR

Use Part # 105888 for Machines with Serial # 32328 and below.

C5 112448 CYLINDER ASSEMBLY, Disc brake 1

112274 • KIT, Seal repair AR

C7 121086 CYLINDER ASSEMBLY, Steer (2WD/4WD) -

Use Part # 113356 for Machines with Serial # 32328 and below.

(Replaces 105325 for 2WD and 105335 for 4WD)
121108 • KIT, Seal repair (For cylinder, 121086) AR
113443 • KIT, Seal repair (For cylinder, 113356) AR
103762 • KIT, Seal repair (For cylinders, 105325 or 105335) AR

C8 107752 CYLINDER, Cushion 1
CV1 104624 CHECK VALVE, Small pump 1
CV2 104624 CHECK VALVE, Large pump 1
CV3 104624 CHECK VALVE, Lift 1

F1 109568 FILTER ASSEMBLY, Return 1

104254 • ELEMENT, Filter AR

HP2 110652 HAND PUMP, Brake release 1

M1 109311 MOTOR, Center drive hydraulic 1
M2 113875 MOTOR/PUMP with flow control 1

(hydraulic generator option)

MB1 114178 MANIFOLD BLOCK, Main 1

(Machines with serial number 30208 and above)

108009 MANIFOLD BLOCK, Main 1

(Machines with serial number 30207 and below)
MB2 103137 MANIFOLD BLOCK, Emergency lowering 1
MB3 106688 MANIFOLD BLOCK, Holding valve 1
MB4 106688 MANIFOLD BLOCK, Holding block 1
MB6 110666 MANIFOLD BLOCK, Lift 1
MB7 111943 MANIFOLD BLOCK, Auto reset brake 1

(Machines with serial number 30167 and above)

MB7A 110643 MANIFOLD BLOCK, Quick brake 1

(Machines with serial number 30166 and below)
MB9 103137 MANIFOLD BLOCK, Hydraulic generator valve (option) 1
MC1 110434 MOTION CONTROL ASSEMBLY 1

O1 104630 ORIFICE, Main lowering .096 diameter 1
O2 105501 ORIFICE, Lift cylinder .094 diameter 2
O3 113343 ORIFICE, Free-wheeling valve .104 diameter 1
O4 104435 ORIFICE, Manual lowering .067 diameter 1

OC1 114284 OIL COOLER ASSEMBLY (hyd. generator option) 1

Units

per

Assy.

Index

No.

Skyjack

Part No.

Description

Units

per

Assy.

P1 110460 PUMP, Dual inlet hydraulic .488/.854 1

(Machines with Kubota diesel engine)

114201 PUMP, Dual inlet hydraulic .366/.671 1

(Machines with Kubota gas engine)
NOTE: For service replacement of single inlet pump,

order dual inlet and conversion kit)
R1 104534 RELIEF VALVE, System 1
R2 104534 RELIEF VALVE, Lift 1
R3 106557 RELIEF VALVE, Lift cylinder 1
R4 106557 RELIEF VALVE, Lift cylinder 1

V1 107271 VALVE, Manual lowering 1
V6 113752 VALVE, Auto reset brake 1

(Machines with serial number 30167 and above)

2H-10A 104132 VALVE, Brake lock 1

(Machines with serial number 30166 and below)

2H-13B 103655 VALVE, Main lowering 1
2H-13B-1 107269 VALVE, Lift cylinder holding 1
2H-13B-2 107269 VALVE, Lift cylinder holding 1

2H-14B 103655 VALVE, Lift 1

2H-17A 114365 VALVE, Large pump dump 1

(Machines with serial number 30208 and above)

103656 VALVE, Large pump dump 1

(Machines with serial number 30207 and below)

2H-18A 103356 VALVE, Small pump dump 1

2H-25 102626 VALVE, Brake 1

(Machines with serial number 30167 and above)

110655 VALVE W/OVERRIDE, Quick brake 1

(Machines with serial number 30166 and below)
2H-30A-1 103656 VALVE, Brake dump 1
2H-30A-2 103656 VALVE, Brake feed 1

2H-30B 112218 VALVE, Free-wheeling 1

2H-86 104412 VALVE, Hydraulic generator (option) 1
3H-20A 103623 VALVE, Series/parallel 1
4H-15B 103396 VALVE, Reverse drive (includes 4H-16B)(Vickers) 1

128796 VALVE, Reverse drive (includes 4H-16B)(Hytos) 1

4H-16B 103396 VALVE, Forward drive (includes 4H-15B)(Vickers) 1

128796 VALVE, Forward drive (includes 4H-15B)(Hytos) 1

4H-23A 103397 VALVE, Right steer (includes 4H-24A)(Vickers) 1

128797 VALVE, Right steer (includes 4H-24A)(Hytos) 1

4H-24A 103397 VALVE, Left steer (includes 4H-23A)(Vickers) 1

128797 VALVE, Left steer (includes 4H-23A)(Hytos) 1

SJ-600 Series Engine Powered 112715 SECTION 3, Page 7

June 2001

2H-14B

LIFT VALVE

R1

SYSTEM

RELIEF

VALVE

O1

LOWERING

ORIFICE

TO BRAKE

MANIFOLD

FIGURE 3.2-3. HYDRAULIC MANIFOLD COMPONENT AND PORT IDENTIFICATION

TO CENTER

DRIVE

TO STEER
CYLINDER

4H-16B

FORWARD

DRIVE
VALVE

4H-23A

LEFT STEER

VALVE

(shown)

4H-24A

RIGHT STEER

VALVE

TO

LIFT

MANIFOLD

2H-25

BRAKE

VALVE

TO HYDRAULIC

OIL TANK

TO EMERGENCY

LOWERING

MANIFOLD

TO MAIN

MANIFOLD

TO BRAKE
CYLINDER

MB7

AUTO-RESET

BRAKE MANIFOLD

BLOCK

V6

AUTO-RESET

VALVE

HP2
HAND
PUMP

TO

RETURN

FILTER

TO

SMALL

PUMP

2H-17A

LARGE PUMP

DUMP VALVE

TO

EMERGENCY

LOWERING

VALVE

TO

LARGE

PUMP

CV1

CHECK

VALVE

CV3

CHECK

VALVE

2H-30A-2

BRAKE FEED

VALVE

RELIEF

VALVE

2H-18A

SMALL PUMP

DUMP VALVE

R2

LIFT

TO

CENTER

DRIVE

4H-15B

REVERSE

DRIVE
VALVE

2H-13B

MAIN LOWERING

VALVE

2H-30A-1

BRAKE DUMP

VALVE

FIGURE 3.2-3B.

TO BRAKE
CYLINDER

TO HYDRAULIC

OIL TANK

EMERGENCY

TO MAIN

MANIFOLD

HP2
HAND
PUMP

TO

LOWERING

MANIFOLD

AUTO-RESET BRAKE MANIFOLD (Serial Number 30167 and Above)

2H-25

QUICK BRAKE

VALVE

QUICK BRAKE

2H-10A

BRAKE LOCK

VALVE

MB7A

MANIFOLD

BLOCK

SECTION 3, Page 8

FIGURE 3.2-3A. MAIN MANIFOLD

FIGURE 3.2-3C. . QUICK BRAKE MANIFOLD (Serial Number 30166 and Below)

SJ-600 Series Engine Powered 112715

June 2001

FIGURE 3.3-1A. OPERATOR’S CONTROL BOX DIAGRAM - No Options

(Machines With Serial Number 32097 and Below)

1

11

12

8

4

7

9

10

5

6

13

2

SECTION 3, Page 10

June 2001

3

50018AA

SJ-600 Series Engine Powered 112715

FIGURE 3.3-1A. OPERATOR’S CONTROL BOX DIAGRAM - No Options

(Machines With Serial Number 32097 and Below)

Index

No.

Skyjack
Part No.

Description

1 103334 CONTROLLER ASSEMBLY, Drive/steer (S7) 1

(For components, refer to Figure 6-9.)

2 103012 STRIP, Terminal block 1.5
3 114485 CABLE ASSEMBLY, Control box 16 pole 1

(Replaces cable with 28 pole round connector

by also ordering (1) CONNECTOR, 114477)

4 (Ref.) SWIT

CH ASSEMBLY, Lift enable (S9) 1

(For components, refer to Figure 6-8.)

5 (Ref.) SWITCH ASSEMBLY, Throttle select (S14) 1

(For components, refer to Figure 6-8.)

6 (Ref.) SWITCH ASSEMBLY, Range select (S29) 1

(For components, refer to Figure 6-8.)

7 (Ref.) SWITCH ASSEMBLY

, Up/down selector (S5) 1

(For components, refer to Figure 6-8.)

8 (Ref.) SWITCH ASSEMBLY, Emergency stop (S4) 1

(For components, refer to Figure 6-8.)

9 (Ref.) SWITCH ASSEMBLY

, Engine start push-button (S15) 1

(For components, refer to Figure 6-8.)

10 (Ref.) SWITCH ASSEMBLY

, Engine choke or glow plug 1
push-button (S13)

(For components, refer to Figure 6-8.)

11 (Ref.) SWITCH ASSEMBLY, Key select (S3) 1

(For components, refer to Figure 6-8.)

12 (Ref.) SWITCH ASSEMBLY, Power indicator (PL1) 1

(For components, refer to Figure 6-8.)

13 114373 SWITCH, Torque toggle (S41) (Later models) 1

Units

per

Assy.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 11

FIGURE 3.3-1B. OPERATOR’S CONTROL BOX DIAGRAM - No Options

(Machines With Serial Number 32098 To 33047)

12

5

1

11

13

6

8

4

7

10

14

2

9

SECTION 3, Page 12

June 2001

3

50019AA

SJ-600 Series Engine Powered 112715

FIGURE 3.3-1B. OPERATOR’S CONTROL BOX DIAGRAM - No Options

(Machines With Serial Number 32098 To 33047)

Index

No.

Skyjack
Part No.

Description

1 103334 CONTROLLER ASSEMBLY, Drive/steer (S7) 1

(F

or components, refer to Figure 6-9.)
2 103012 STRIP, Terminal block 1.5
3 114485 CABLE ASSEMBLY, Control box 32 pole male 1
4 (Ref.) SWIT

CH ASSEMBLY, Lift enable (S9) 1

(For components, refer to Figure 6-8.)

5 (Ref.) SWITCH ASSEMBLY, Throttle select (S14) 1

(For components, refer to Figure 6-8.)

6 (Ref.) SWITCH ASSEMBLY, Range select (S29) 1

(For components, refer to Figure 6-8.)

7 (Ref.) SWITCH ASSEMBLY, Up/down selector (S5) 1

(For components, refer to Figure 6-8.)

8 (Ref.) SWITCH ASSEMBLY

, Emergency stop (S4) 1

(For components, refer to Figure 6-8.)

9 (Ref.) SWITCH ASSEMBLY

, Engine start push-button (S15) 1

(For components, refer to Figure 6-8.)

10 (Ref.) SWITCH ASSEMBLY

, Engine choke or glow plug 1
push-button (S13)
(For components, refer to Figure 6-8.)

11 (Ref.) SWITCH ASSEMBL

Y, Key select (S3) 1

(For components, refer to Figure 6-8.)

12 (Ref.) SWITCH ASSEMBLY, Power indicator (PL1) 1

(For components, refer to Figure 6-8.)

13 114373 SWITCH, Torque toggle (S41) 1
14 (Ref.) SWITCH ASSEMBLY, Horn push-button (S8) 1

(For components, refer to Figure 6-8.)

Units

per

Assy.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 13

FIGURE 3.3-1C. OPERATOR’S CONTROL BOX DIAGRAM - No Options

(Machines With Serial Numbers From 32048 To 33188)

12

5

13

1

11

8

7

4

9

10

14

6

2

SECTION 3, Page 14

June 2001

3

50020AA

SJ-600 Series Engine Powered 112715

FIGURE 3.3-1C. OPERATOR’S CONTROL BOX DIAGRAM - No Options

(Machines With Serial Numbers From 32048 To 33188)

Index

No.

Skyjack
Part No.

Description

1 103334 CONTROLLER ASSEMBLY, Drive/steer (S7) 1

(F

or components, refer to Figure 6-9.)
2 103012 STRIP, Terminal block 1.5
3 114485 CABLE ASSEMBLY, Control box 32 pole male 1
4 (Ref.) SWIT

CH ASSEMBLY, Enable (S9) 1

(For components, refer to Figure 6-8.)

5 (Ref.) SWITCH ASSEMBLY, Throttle select (S14) 1

(For components, refer to Figure 6-8.)

6 (Ref.) SWITCH ASSEMBLY, Range select (S29) 1

(For components, refer to Figure 6-8.)

7 (Ref.) SWITCH ASSEMBLY, Up/down selector (S5) 1

(For components, refer to Figure 6-8.)

8 (Ref.) SWITCH ASSEMBLY

, Emergency stop (S4) 1

(For components, refer to Figure 6-8.)

9 (Ref.) SWITCH ASSEMBLY, Engine start push-button (S15) 1

(For components, refer to Figure 6-8.)

10 (Ref.) SWITCH ASSEMBLY

, Engine choke or glow plug 1
push-button (S13)
(For components, refer to Figure 6-8.)

11 (Ref.) SWITCH ASSEMBL

Y, Key select (S3) 1

(For components, refer to Figure 6-8.)

12 (Ref.) SWITCH ASSEMBLY, Power indicator (PL1) 1

(For components, refer to Figure 6-8.)

13 114373 SWITCH, Torque toggle (S41) 1
14 (Ref.) SWITCH ASSEMBLY, Horn push-button (S8) 1

(For components, refer to Figure 6-8.)

Units

per

Assy.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 15

FIGURE 3.3-1D. OPERATOR’S CONTROL BOX DIAGRAM - No Options

(Machines With Serial Number 33189 And Above)

1

12

11

8

4

7

14

109

5

6

13

2

SECTION 3, Page 16

3

50079AA

June 2001

SJ-600 Series Engine Powered 112715

FIGURE 3.3-1D. OPERATOR’S CONTROL BOX DIAGRAM - No Options

(Machines With Serial Number 33189 And Above)

Index

No.

Skyjack
Part No.

Description

1 123995 CONTROLLER ASSEMBLY, Drive/steer (S7) 1

(F

or components, refer to Figure 6-9.)
2 103012 STRIP, Terminal block 1.5
3 114485 CABLE ASSEMBLY, Control box 32 pole male 1
4 (Ref.) SWIT

CH ASSEMBLY, Enable (S9) 1

(For components, refer to Figure 6-8.)

5 (Ref.) SWITCH ASSEMBLY, Throttle select (S14) 1

(For components, refer to Figure 6-8.)

6 (Ref.) SWITCH ASSEMBLY, Range select (S29) 1

(For components, refer to Figure 6-8.)

7 (Ref.) SWITCH ASSEMBLY, Up/down selector (S5) 1

(For components, refer to Figure 6-8.)

8 (Ref.) SWITCH ASSEMBLY

, Emergency stop (S4) 1

(For components, refer to Figure 6-8.)

9 (Ref.) SWITCH ASSEMBLY

, Engine start push-button (S15) 1

(For components, refer to Figure 6-8.)

10 (Ref.) SWITCH ASSEMBLY

, Engine choke or glow plug 1
push-button (S13)
(For components, refer to Figure 6-8.)

11 (Ref.) SWITCH ASSEMBL

Y, Key select (S3) 1

(For components, refer to Figure 6-8.)

12 (Ref.) SWITCH ASSEMBLY, Power indicator (PL1) 1

(For components, refer to Figure 6-8.)

13 114373 SWITCH, Torque toggle (S41) 1
14 (Ref.) SWITCH ASSEMBLY, Horn push-button (S8) 1

(For components, refer to Figure 6-8.)

Units

per

Assy.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 17

FIGURE 3.3-2A. OPERATOR’S CONTROL BOX DIAGRAM - All Options

(Machines With Serial Number 32097 and Below)

1

12

8

4

11

7

14

5

6

13

2

9

10

15

3

50021AA

SECTION 3, Page 18

June 2001

SJ-600 Series Engine Powered 112715

FIGURE 3.3-2A. OPERATOR’S CONTROL BOX DIAGRAM - All Options

(Machines With Serial Number 32097 and Below)

Index

No.

Skyjack
Part No.

Description

1 103334 CONTROLLER ASSEMBLY, Drive/steer (S7) 1

(For components, refer to Figure 6-9.)

2 103012 STRIP, Terminal block 1.5
3 115283 CABLE ASSEMBLY, Control box 32 pole 1

(Replaces cable with 28 pole round connector
by also ordering (1) CONNECTOR, 114476)

4 (Ref.) SWIT

CH ASSEMBLY, Lift enable (S9) 1

(For components, refer to Figure 6-8.)

5 (Ref.) SWITCH ASSEMBLY, Throttle select (S14) 1

(For components, refer to Figure 6-8.)

6 (Ref.) SWITCH ASSEMBLY, Range select (S29) 1

(For components, refer to Figure 6-8.)

7 (Ref.) SWITCH ASSEMBLY

, Up/down selector (S5) 1

(For components, refer to Figure 6-8.)

8 (Ref.) SWITCH ASSEMBLY

, Emergency stop (S4) 1

(For components, refer to Figure 6-8.)

9 (Ref.) SWITCH ASSEMBLY

, Engine start push-button (S15) 1

(For components, refer to Figure 6-8.)

10 (Ref.) SWITCH ASSEMBLY

, Engine choke or glow plug 1
push-button (S13)
(For components, refer to Figure 6-8.)

11 (Ref.) SWITCH ASSEMBLY, Key select (S3) 1

(For components, refer to Figure 6-8.)

12 (Ref.) SWITCH ASSEMBLY, Power indicator (PL1) 1

(For components, refer to Figure 6-8.)

13 114373 SWITCH, Torque toggle (S41) (Later models) 1
14 (Ref.) SWITCH ASSEMBLY, Horn push-button (S8) 1

(For components, refer to Figure 6-8.)

15 (Ref.) SWITCH ASSEMBLY, Hydraulic generator (S12) 1

(For components, refer to Figure 6-8.)

Units

per

Assy.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 19

FIGURE 3.3-2B. OPERATOR’S CONTROL BOX DIAGRAM - All Options

(Machines With Serial Number 32098 To 33047)

11

12

7

8

10

4

15

14

9

5

13

6

1

2

SECTION 3, Page 20

June 2001

3

50022AA

SJ-600 Series Engine Powered 112715

FIGURE 3.3-2B. OPERATOR’S CONTROL BOX DIAGRAM - All Options

(Machines With Serial Number 32098 To 33047)

Index

No.

Skyjack
Part No.

Description

1 103334 CONTROLLER ASSEMBLY, Drive/steer (S7) 1

(F

or components, refer to Figure 6-9.)
2 103012 STRIP, Terminal block 1.5
3 114485 CABLE ASSEMBLY, Control box 32 pole male 1
4 (Ref.) SWIT

CH ASSEMBLY, Lift enable (S9) 1

(For components, refer to Figure 6-8.)

5 (Ref.) SWITCH ASSEMBLY, Throttle select (S14) 1

(For components, refer to Figure 6-8.)

6 (Ref.) SWITCH ASSEMBLY, Range select (S29) 1

(For components, refer to Figure 6-8.)

7 (Ref.) SWITCH ASSEMBLY, Up/down selector (S5) 1

(For components, refer to Figure 6-8.)

8 (Ref.) SWITCH ASSEMBLY

, Emergency stop (S4) 1

(For components, refer to Figure 6-8.)

9 (Ref.) SWITCH ASSEMBLY

, Engine start push-button (S15) 1

(For components, refer to Figure 6-8.)

10 (Ref.) SWITCH ASSEMBLY

, Engine choke or glow plug 1
push-button (S13)
(For components, refer to Figure 6-8.)

11 (Ref.) SWITCH ASSEMBL

Y, Key select (S3) 1

(For components, refer to Figure 6-8.)

12 (Ref.) SWITCH ASSEMBLY, Power indicator (PL1) 1

(For components, refer to Figure 6-8.)

13 114373 SWITCH, Torque toggle (S41) 1
14 (Ref.) SWITCH ASSEMBLY, Horn push-button (S8) 1

(For components, refer to Figure 6-8.)

15 (Ref.) SWITCH ASSEMBLY, Hydraulic generator (S12) 1

(For components, refer to Figure 6-8.)

Units

per

Assy.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 21

FIGURE 3.3-2C. OPERATOR’S CONTROL BOX DIAGRAM - All Options

(Machines With Serial Numbers From 32048 To 33188)

11

5

12

13

8

9

4

7

10

15

14

6

1

2

SECTION 3, Page 22

June 2001

3

50023AA

SJ-600 Series Engine Powered 112715

FIGURE 3.3-2C. OPERATOR’S CONTROL BOX DIAGRAM - All Options

(Machines With Serial Numbers From 32048 To 33188)

Index

No.

Skyjack
Part No.

Description

1 103334 CONTROLLER ASSEMBLY, Drive/steer (S7) 1

(F

or components, refer to Figure 6-9.)
2 103012 STRIP, Terminal block 1.5
3 114485 CABLE ASSEMBLY, Control box 32 pole male 1
4 (Ref.) SWIT

CH ASSEMBLY, Enable (S9) 1

(For components, refer to Figure 6-8.)

5 (Ref.) SWITCH ASSEMBLY, Throttle select (S14) 1

(For components, refer to Figure 6-8.)

6 (Ref.) SWITCH ASSEMBLY, Range select (S29) 1

(For components, refer to Figure 6-8.)

7 (Ref.) SWITCH ASSEMBLY, Up/down selector (S5) 1

(For components, refer to Figure 6-8.)

8 (Ref.) SWITCH ASSEMBLY

, Emergency stop (S4) 1

(For components, refer to Figure 6-8.)

9 (Ref.) SWITCH ASSEMBLY

, Engine start push-button (S15) 1

(For components, refer to Figure 6-8.)

10 (Ref.) SWITCH ASSEMBLY

, Engine choke or glow plug 1
push-button (S13)
(For components, refer to Figure 6-8.)

11 (Ref.) SWITCH ASSEMBL

Y, Key select (S3) 1

(For components, refer to Figure 6-8.)

12 (Ref.) SWITCH ASSEMBLY, Power indicator (PL1) 1

(For components, refer to Figure 6-8.)

13 114373 SWITCH, Torque toggle (S41) 1
14 (Ref.) SWITCH ASSEMBLY, Horn push-button (S8) 1

(For components, refer to Figure 6-8.)

15 (Ref.) SWITCH ASSEMBLY, Hydraulic generator (S12) 1

(For components, refer to Figure 6-8.)

Units

per

Assy.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 23

FIGURE 3.3-2D. OPERATOR’S CONTROL BOX DIAGRAM - All Options

(Machines With Serial Number 33189 And Above)

1

12

15

7

14

10

11

8

4

9

5

6

13

2

SECTION 3, Page 24

3

50080AA

June 2001

SJ-600 Series Engine Powered 112715

FIGURE 3.3-2D. OPERATOR’S CONTROL BOX DIAGRAM - All Options

(Machines With Serial Number 33189 And Above)

Index

No.

Skyjack
Part No.

Description

1 123995 CONTROLLER ASSEMBLY, Drive/steer (S7) 1

(F

or components, refer to Figure 6-9.)
2 103012 STRIP, Terminal block 1.5
3 114485 CABLE ASSEMBLY, Control box 32 pole male 1
4 (Ref.) SWIT

CH ASSEMBLY, Enable (S9) 1

(For components, refer to Figure 6-8.)

5 (Ref.) SWITCH ASSEMBLY, Throttle select (S14) 1

(For components, refer to Figure 6-8.)

6 (Ref.) SWITCH ASSEMBLY, Range select (S29) 1

(For components, refer to Figure 6-8.)

7 (Ref.) SWITCH ASSEMBLY, Up/down selector (S5) 1

(For components, refer to Figure 6-8.)

8 (Ref.) SWITCH ASSEMBLY

, Emergency stop (S4) 1

(For components, refer to Figure 6-8.)

9 (Ref.) SWITCH ASSEMBLY

, Engine start push-button (S15) 1

(For components, refer to Figure 6-8.)

10 (Ref.) SWITCH ASSEMBLY

, Engine choke or glow plug 1
push-button (S13)
(For components, refer to Figure 6-8.)

11 (Ref.) SWITCH ASSEMBL

Y, Key select (S3) 1

(For components, refer to Figure 6-8.)

12 (Ref.) SWITCH ASSEMBLY, Power indicator (PL1) 1

(For components, refer to Figure 6-8.)

13 114373 SWITCH, Torque toggle (S41) 1
14 (Ref.) SWITCH ASSEMBLY, Horn push-button (S8) 1

(For components, refer to Figure 6-8.)

15 (Ref.) SWITCH ASSEMBLY, Hydraulic generator (S12) 1

(For components, refer to Figure 6-8.)

Units

per

Assy.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 25

FIGURE 3.4-1. ELECTRICAL PARTS LIST

Ref.

No.

Skyjack

Part No.

Description

Units

per

Assy

A (Ref). ANSI/SIA & CSA Models (Kubota Dual Fuel ) Serial #31801 and Below -
B (Ref.) ANSI/SIA & CSA Models (Kubota Dual Fuel ) Serial #31802 and Above -
C (Ref.) CE Models (Kubota Diesel) -
D (Ref.) All Models with Serial #33188 and Below -

E (Ref.) All Models with Serial #33189 and Above -

B1 103295 BA

TTERY, 12 Volt (starting) 1
BP-29 103056 BEEPER, 12 Volt 1
CAP1 103319 CAPACITOR, 35 Volt, 1000MFD 1
CB1 117326 CIRCUIT BREAKER, 20 Amp 1
CB2 117326 CIRCUIT BREAKER, 20 Amp 1
CB3 117326 CIRCUIT BREAKER, 20 Amp 1
CRD1 (Ref.) CABLE ASSEMBLY, Control box (See Section 6) 1
CRD2 (Ref.) CABLE ASSEMBLY, Scissor arm (See Section 6.) 1
CRD3 (Ref.) CABLE ASSEMBLY, Electrical panel (See Section 6) 1
CRD4 (Ref.) CABLE ASSEMBLY, Engine wiring (See Section 6) 1
CRD5 (Ref.) CABLE ASSEMBLY, Engine electrical (See Section 6) 1
CRD6 (Ref.) CABLE ASSEMBLY, Panel wiring (See Section 6) 1
CS-31A 103007 CHOKE SOLENOID, Engine 1
D10-D86 102921 DIODE AR
DCM1 300248 MOTOR, 12 Volt (powered ext. platform option) 1
F2 111282 FUSE, 100 Amp (powered ext. platform option) 1
F4 119469 FUSE, 200 Amp (Electrical inverter option) 1
FL-13B 103743 FLASHER 1
FL-22 121476 FLASHING LIGHT 1
H1 102850 HORN, 12 Volt 1
HTS-34A 103007 HIGH THROTTLE SOLENOID, Engine, A & B 1
HTS-34A 112721 HIGH THROTTLE SOLENOID, Engine, C 1
INV1 123629 INVERTER, 1500 Watt 120V @ 60hz 1

124047 INVERTER, 1500 Watt 110/220V @ 50hz 1
GPL1 KUBOTA GLOW PLUG INDICATOR LIGHT 1
GPT1 KUBOTA GLOW PLUG TIMER 1
LS4 111356 LIMIT SWITCH, End-of-stroke 1
LS5 102848 LIMIT SWITCH, High speed/tilt override 1
LS6-LS8 102848 LIMIT SWITCH, Scissor guards (Early models), C 3
OPS1 102838 SWITCH, Engine oil pressure 1
PL1 102671 CONTACT BLOCK, Power indicator light 1
S1 119726 SWITCH, Main power disconnect 1
S3 103141 N.O. CONTACT BLOCK, Off/lift/drive key switch 1

103225 N.C. CONTACT BLOCK, Off/lift/drive key switch 3
S4 103225 N.C. CONTACT BLOCK, Emergency stop switch 1
S5 103141 N.O. CONTACT BLOCK, Up/off/down switch 1
S7 103334 CONTROLLER ASSEMBLY, Drive/steer 1

Parts list continued on the following page.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 27

FIGURE 3.4-1. ELECTRICAL PARTS LIST (Continued)

Ref.

No.

Skyjack

Part No.

Description

Units

per

Assy

Parts list continued from the previous page.

S7 103334 CONTROLLER ASSEMBLY, Drive/steer, D 1

123995 CONTROLLER AS

SEMBLY, Drive/steer, E 1

S7-1 102768 • SWITCH W/ACTUATOR, 2nd Speed, D 1

122869 • SWITCH W/ACTUATOR, 2nd Speed, E 1

S7-2 105733 • SWITCH, Right steer, D 1

122877 • SWITCH, Right steer,

E 1

S7-3 105733 • SWITCH, Left steer, D 1

122877

S7-4 102768

• SWITCH, Left steer, E 1

• SWITCH W/ACTUATOR, Reverse drive, D 1

122869 • SWITCH W/ACTUATOR, Reverse drive, E 1

S7-5 102768 • SWITCH W/ACTUATOR, Forward drive, D 1

122869 • SWITCH W/ACTUATOR, Forward drive, E 1

S7-6 102768

• SWITCH W/ACTUATOR, 3rd Speed, D 1

122869 • SWITCH W/ACTUATOR, 3rd Speed, E 1
S7-7 122872 • SWITCH Joystick Enable, E 1
S8 103141 N.O. CONTACT BLOCK, Horn switch 1
S

9 103141 N.O. CONTACT BLOCK, Lift enable switch 1

1 102853 SWITCH, Platform extend/retract toggle 1

S1

(Later models with powered ext. platform option)

103141 N.O. CONTACT BLOCK, Platform extend/retract 1

(Early models with powered ext. platform option)

S12 103141 N.O. CONTACT BLOCK, Hyd. generator option 1

112434 CONTACT BLOCK, Switch and hold (hydraulic generator option) 1
S13 103141 N.O. CONTACT BLOCK, Engine choke switch 1
S14 103141 N.O. CONTACT BLOCK, Low/high throttle switch 1
S15 103141 N.O. CONTACT BLOCK, Engine start 1
S16 103141 N.O. CONTACT BLOCK, Up push-button 1
S17 103141 N.O. CONTACT BLOCK, Down push-button 1
S29 103141 N.O. CONTACT BLOCK, Low/high range switch 1
S30 102572 SWITCH, Engine off/on (engine) 1
S31 102692 SWITCH, Engine choke push-button (engine) 1
S32 102692 SWITCH, Engine start push-button (engine) 1
S33 111627 SWITCH, Fuel select (dual fuel option), A 1

300802 SWITCH, Fuel select (dual fuel ), B 1
S41 114373 SWITCH, Torque toggle 1
S42 102853 SWITCH, Enable toggle (powered ext. platform option) 1

SECTION 3, Page 28

Parts list continued on the following page.

June 2001

SJ-600 Series Engine Powered 112715

FIGURE 3.4-1. ELECTRICAL PARTS LIST (Continued)

Ref.

No.

Skyjack

Part No.

Description

Units

per

Assy

Parts list continued from the previous page.

TPS1 113400 SWITCH, Engine temperature 1
TS1 117880 TILT SWITCH ASSEMBLY 1
TT 103336 HOUR METER 1
VS1 111623 SWITCH, Vacuum (dual fuel option), A 1
1TD 103207 RELAY, 12 Volt DPDT (drive time delay) 1
09CR 111787 CONTACTOR, 12 Volt (powered ext. platform option) 1
10BCR1 103207 RELAY, 12 Volt DPDT (engine on) 1
10BCR2 103207 RELAY, 12 Volt DPDT 1
13CR 103316 RELAY, 12 Volt SPDT (down) 1
14CR 103316 RELAY, 12 Volt SPDT (up) 1
15CR 103207 RELAY, 12 Volt DPDT (reverse drive) 1
16CR 103207 RELAY, 12 Volt DPDT (forward drive) 1
17CR 103316 RELAY, 12 Volt SPDT (2nd speed/large pump) 1
17ACR 103316 RELAY, 12 Volt SPDT (small pump) 1
18CR 103316 RELAY, 12 Volt SPDT (3rd speed) 1
2D37 116745 SOLENOID, Diesel fuel shut off 1
20CR 103316 RELAY, 12 Volt SPDT (series/parallel drive) 1
23CR 103316 RELAY, 12 Volt SPDT (right steer) 1
24CR 103316 RELAY, 12 Volt SPDT (left steer) 1
28CR 103207 RELAY, 12 Volt DPDT (tilt switch) 1
30CR 103316 RELAY, 12 Volt SPDT (brake) 1
31ACR 103731 RELAY, 12 Volt SPDT (engine glow plug) 1
31CR 103316 RELAY, 12 Volt SPDT (engine choke) 1

31CR 103316 RELAY, 12 Volt SPDT (glow plug) 1

32CR 103316 RELAY, 12 Volt SPDT (engine start) 1
32ACR KUBOTA SOLENOID, Engine start 1
32BCR 103316 RELAY, 12 Volt SPDT (throttle) 1
35CR 103207 RELAY, 12 Volt DPDT (tilt override) 1

(Machines with serial number 30986 and above)

111956 RELAY, 12 Volt TPDT (tilt override) 1

(Machines with serial number 30985 and below)
49CR 103316 RELAY, 12 Volt SPDT 1
55CR 103731 RELAY, 12 Volt (vacuum switch) (dual fuel) 1
2G11 111626 SOLENOID, Gasoline valve 1

Parts list continued on the following page.

SJ-600 Series Engine Powered 112715

June 2001

SECTION 3, Page 29

FIGURE 3.4-1. ELECTRICAL PARTS LIST (Continued)

Ref.

No.

Skyjack

Part No.

Description

Units

per

Assy

Parts list continued from the previous page.

2H-10A 103613 COIL, 12 Volt (brake lock valve)

(Machines with serial number 30166 and below) 1

2H-13B 103613 COIL, 12 Volt (main lowering valve) 1
2H-13B-1

104410 COIL, 12 Volt (lift cylinder holding) 1

2H-13B-2 104410 COIL, 12 Volt (lift cylinder holding) 1
2H-14B 103613 COIL, 12 Volt (lift valve) 1
2H-17A 103613 COIL, 12 Volt (large pump dump valve) 1
2H-18A 103613 COIL, 12 Volt (small pump dump valve) 1
2H-25 103613 COIL, 12 Volt (brake valve) 1
2H-30A-1 103613 COIL, 12 Volt (brake dump valve) 1
2H-30A-2 103613 COIL, 12 Volt (brake feed valve) 1
2H-30(B) 103613 COIL, 12 Volt (free-wheeling valve) 1
2H-86 106272 COIL, 12 Volt (hydraulic generator option) 1
2P50 111618 SOLENOID, Propane valve 1
3H-20A 103613 COIL, 12 Volt (series/parallel drive) 1
4H-15B 107441 COIL, Reverse drive valve (Vickers) 1

128322 COIL, Reverse drive valve (Hytos) 1

4H-16B 107441 COIL, Forward drive valve (Vickers) 1

128322 COIL, Forward drive valve (Hytos) 1

4H-23A 107440 COIL, Right steer valve (Vickers) 1

128321 COIL, Right steer valve (Hytos) 1

4H-24A 107440 COIL, Left steer valve (Vickers) 1

128321 COIL, Left steer valve (Hytos) 1

4H-26 107440 COIL, Powered ext. platform extend valve (option) (Vickers) 1

128321 COIL, Powered ext. platform extend valve (option) (Hytos) 1

4H-27 107440 COIL, Powered ext. platform retract valve (option) (Vickers) 1

128321 COIL, Powered ext. platform retract valve (option) (Hytos) 1

SECTION 3, Page 30

June 2001

SJ-600 Series Engine Powered 112715

FIGURE 3.4-2. BASE CONTROL/ELECTRICAL PANEL DIAGRAM (ANSI/SIA and CSA Machines With Serial Number 30985 and Below)

Parts List

A

B

C

D

EF

GH

V

W

X

Y

Z

FIG3-3

SJ-600 Series Engine Powered 112715 SECTION 3, Page 31

June 2001

FIGURE 3.4-3. BASE CONTROL/ELECTRICAL PANEL DIAGRAM (ANSI/SIA and CSA Machines With Serial Number 30986 through 32097)

Parts List

A

B

C

D

EF

GH

V

W

X

Y

Z

SECTION 3, Page 32

50174AA

SJ-600 Series Engine Powered 112715

June 2001

FIGURE 3.4-4. BASE CONTROL/ELECTRICAL PANEL DIAGRAM (ANSI/SIA and CSA Machines With Serial Number 32098 and Above)

Parts List

A

B

C

D

EF

GH

V

W

X

Y

Z

LP-1050AC

SJ-600 Series Engine Powered 112715 SECTION 3, Page 33

June 2001

FIGURE 3.4-5. BASE CONTROL/ELECTRICAL PANEL DIAGRAM (CE Machines With Serial Number 30985 and Below)

Parts List

A

B

C

D

EF

GH

V

W

X

Y

Z

SECTION 3, Page 34

FIG3-4

SJ-600 Series Engine Powered 112715

June 2001

FIGURE 3.4-6. BASE CONTROL/ELECTRICAL PANEL DIAGRAM (CE Machines With Serial Number 30986 through 32097)

Parts List

A

B

C

D

EF

GH

V

W

X

Y

Z

FIG3-2B

SJ-600 Series Engine Powered 112715 SECTION 3, Page 35

June 2001

FIGURE 3.4-7. BASE CONTROL/ELECTRICAL PANEL DIAGRAM (CE Machines With Serial Number 32098 and Above)

Parts List

A

B

C

D

EF

GH

V

W

X

Y

Z

SECTION 3, Page 36

LP-1051AA

SJ-600 Series Engine Powered 112715

June 2001

FIGURE 3.4-8. ELECTRICAL INVERTER DIAGRAM

SJ-600 Series Engine Powered 112715

50077AA

SECTION 3, Page 37

June 2001

FIGURE 3.5-1. ELECTRICAL SCHEMATIC (Machines Equipped With Kubota Dual Fuel Engine and Shown With ANSI/SIA and CSA Options)

Parts List

ABCDE

G

F

H

I

J

K

M

L

SJ-600 Series Engine Powered 112715

NOTE: To determine the correct electrical schematic or

panel diagram that resembles your machine, refer to the
“Table Of Contents” found at the beginning of this section.

600-98

FIGURE 3.5-1.

FIGURE 3.5-2. ELECTRICAL SCHEMATIC - (Machines Equipped With Kubota Dual Fuel Engine and Shown With ANSI and CSA Options)

Parts List

ABCDE

F

G

H

I

J

K

M

L

FIGURE 3.5-2.

NOTE: To determine the correct electrical schematic or

panel diagram that resembles your machine, refer to the
“Table Of Contents” found at the beginning of this section.

600-70

SJ-800 Series Engine Powered 112715

FIGURE 3.5-3. ELECTRICAL SCHEMATIC (Machines Equipped With Kubota Diesel Engine and Shown With CE Options)

Parts List

ABCDE

F

G

H

I

J

K

M

L

SJ-600 Series Engine Powered 112715

NOTE: To determine the correct electrical schematic or

panel diagram that resembles your machine, refer to the
“Table Of Contents” found at the beginning of this section.

50024AA

FIGURE 3.5-3.

FIGURE 3.5-5. ELECTRICAL SCHEMATIC (Machines Equipped With Kubota Dual Fuel Engine and Shown With ANSI and CSA Options)

Parts List

ABCDE

F

G

H

I

J

K

M

L

SJ-600 Series Engine Powered 112715

NOTE: To determine the correct electrical schematic or

panel diagram that resembles your machine, refer to the
“Table Of Contents” found at the beginning of this section.

50078AB

FIGURE 3.5-5.

FIGURE 3.5-6. ELECTRICAL SCHEMATIC (Machines Equipped With Kubota Diesel Engine and Shown With CE Options)

Parts List

ABCDE

F

G

H

I

J

K

M

L

FIGURE 3.5-6.

NOTE: To determine the correct electrical schematic or

panel diagram that resembles your machine, refer to the
“Table Of Contents” found at the beginning of this section.

50024AB

SJ-800 Series Engine Powered 112715

FIGURE 3.5-7. ELECTRICAL SCHEMATIC (Machines Equipped With Kubota Dual Fuel Engine and Shown With ANSI and CSA Options)

Parts List

ABCDE

F

G

H

I

J

K

M

L

SJ-600 Series Engine Powered 112715

NOTE: To determine the correct electrical schematic or

panel diagram that resembles your machine, refer to the
“Table Of Contents” found at the beginning of this section.

50083AA

FIGURE 3.5-7.

FIGURE 3.5-8. ELECTRICAL SCHEMATIC (Machines Equipped With Kubota Diesel Engine and Shown With CE Options)

Parts List

ABCDE

F

G

H

I

J

K

M

L

FIGURE 3.5-8.

NOTE: To determine the correct electrical schematic or

panel diagram that resembles your machine, refer to the
“Table Of Contents” found at the beginning of this section.

50024AD

SJ-800 Series Engine Powered 112715

SECTION 3

6

5421toc

SYSTEM COMPONENT IDENTIFICATION

AND SCHEMATICS ADDENDUM

TABLE OF CONTENTS

ELECTRICAL SYSTEM

FIGURE 3A. IMPORTANT INFORMATION .................................................................................................... Page B

FIGURE 3B. REVISED SCHEMATIC

(ANSI Models Equipped with Lift/Drive Enable) (Machines with serial #33048 and above) ......... Page C

FIGURE 3C. REVISED SCHEMATIC

(Models Equipped with All Motion Alarm) (Machines with serial #32975 and above).................. Page D

3

June 2001

SECTION 3, Page ASJ-600 Series Engine Powered 112715

FIGURE 3A - IMPORTANT INFORMATION

***ATTENTION SERVICE TECHNICIAN***

When performing any maintenance, troubleshooting or service to the 600 Series work platform,
please note:

• The electrical schematic Addendum found in Section 3, Page C must be taken into
consideration when working on machines equipped with a “Lift/Drive” Enable switch on
the platform control box.

• The electrical schematic Addendum found in Section 3, Page D must be taken into
consideration when working on machines equipped with the “All Motion Alarm” Option.

SECTION 3, Page B

June 2001

SJ-600 Series Engine Powered 112715

FIGURE 3B. REVISED SCHEMATIC

(All Models Equipped With Lift/ Drive Enable) (Machines with serial #33048 and above)

June 2001

SECTION 3, Page CSJ-600 Series Engine Powered 112715

FIGURE 3C. REVISED SCHEMATIC

(All Models Equipped With All Motion Alarm) (Machines with serial #32975 and above)

SECTION 3, Page D SJ-600 Series Engine Powered 112715

June 2001

SECTION 4

653

21toc

TROUBLESHOOTING INFORMATION

The following pages contain a Table of Troubleshooting information for locating and correcting most
service trouble which can develop. Careful inspection and accurate analysis of the systems listed in the
Table of Troubleshooting Information will localize the trouble more quickly than any other method. This
manual cannot cover all possible troubles and deficiencies that may occur. If a specific trouble is not listed,
isolate the major component in which the trouble occurs, isolate whether the problem is electrical or
hydraulic, and then isolate and correct the specific problem.

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

ALL CONTROLS
INOPERATIVE

NO POWER TO
PLATFORM
(Machines Without
Base Control Box
Option)

1. Battery disconnected or discharged.

2. Loose or dirty battery cables.

3. Open or defective main power
disconnect switch (S1).

4. Loose or broken wire #03 from main
power disconnect switch (S1) to
circuit breaker (CB1).

5. Tripped or defective circuit breaker
(CB1).

6. Loose or broken wire #05 from
breaker (CB1) to base terminal block
(TB-1).

7. Loose or broken wire #05 from base
terminal block (TB-1) to engine off/
on switch (S30).

8. Loose or broken wire #100 from
battery (B1) to main power
disconnect switch (S1).

1. Open or defective engine off/on
switch (S30).

2. Loose or broken wire #07 from
engine off/on switch (S30) to base
terminal block (TB1).

3. Loose or broken wire #07 from base
terminal block (TB-1) to emergency
stop switch (S4).

4. Open or defective emergency stop
switch (S4).

1. Reconnect battery. Recharge if
discharged.

2. Clean and tighten battery cables.

3. Close switch. Replace if defective.

4. Check continuity. Replace if
defective.

5. Reset breaker. Check for defective
wiring. Replace breaker if defective.

6. Check continuity. Replace if
defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective

4

1. Check switch. Replace if defective.

2. Check continuity. Replace if
defective.

3. Check continuity. Replace if
defective.

4. Check switch. Replace if defective.

NO POWER TO
PLATFORM
(Machines With Base
Control Box Option)

1. Open or defective engine off/on
switch (S30).

2. Loose or broken wire #07 from
engine off/on switch (S30) to base
terminal block (TB-1).

3. Loose or broken wire #07 from base
terminal block (TB-1) to emergency
stop switch (S6).

4. Loose or broken wire #07 from
emergency stop switch (S6) to
platform/base select switch (S10).

June 2001

1. Check switch. Replace if defective.

2. Check continuity. Replace if
defective.

3. Check continuity. Replace if
defective.

4. Check continuity. Replace if
defective.

SECTION 4, Page 1SJ-600 Series Engine Powered 112715

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

NO POWER TO
PLATFORM
(Machines With Base
Control Box Option)
(Continued)

ALL FUNCTIONS
INOPERATIVE FROM
PLATFORM

ENGINE WILL NOT
CRANK FROM
PLATFORM

5. Platform/base select switch (S10) set
to base position.

6. Open or defective platform/base
select switch (S10).

7. Loose or broken wire #7A from
platform/base select switch (S10) to
platform emergency stop switch (S4).

8. Open or defective platform
emergency stop switch (S4).

1. Open or defective emergency stop
switch (S4).

2. Loose or broken wire #08 from
emergency stop switch (S4) to off/
lift/drive select switch (S3).

3. Open or defective off/lift/drive select
switch (S3).

1. Open or defective key select switch
(S3).

2. Loose or broken wire #10 from key
select switch (S3) to start switch
(S15).

3. Defective start switch (S15).

4. Loose or broken wire #32 from start
switch (S15) to relay (32CR).

5. Defective relay (32CR).

6. Loose or broken jumper wire #41 on
relay (32CR).

7. Loose or broken wire #02 from relay
(32CR) to base terminal block.

8. Loose or broken wire #05 from base
terminal block to relay (32CR).

9. Loose or broken wire #32A from
relay (32CR) to base terminal block.

10. Loose or broken wire #32A from
base terminal block to starter
contactor (32ACR).

11. Defective starter contactor (32ACR).

12. Loose or broken wire #00 from
starter contactor (32ACR) to base.

13. Loose or broken wire #103 from
main power disconnect (S1) to starter
contactor (32ACR).

14. Loose or broken wire #104 from
starter contactor (32ACR) to starter
motor.

15. Defective starter motor.

5. Set (S10) to platform position.

6. Check switch. Replace if defective.

7. Check continuity. Replace if
defective.

8. Check switch. Replace if defective.

1. Check switch. Replace if defective.

2. Check continuity. Replace if
defective.

3. Check switch. Replace if defective.

1. Check switch. Replace if defective.

2. Check continuity. Replace if
defective.

3. Check switch. Replace if defective.

4. Check continuity. Replace if
defective.

5. Check relay. Replace if defective.

6. Check continuity. Replace if
defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check continuity. Replace if
defective.

10. Check continuity. Replace if
defective.

11. Check contactor. Replace if
defective.

12. Check continuity. Replace if
defective.

13. Check continuity. Replace if
defective.

14. Check continuity. Replace if
defective.

15. Check motor. Repair or replace if
defective.

ENGINE WILL NOT
CRANK FROM ENGINE
CONTROLS

SECTION 4, Page 2 SJ-600 Series Engine Powered 112715

1. Loose or broken wire #05 from base
terminal block to engine off/on switch
(S30).

June 2001

1. Check continuity. Replace if
defective.

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

ENGINE WILL NOT
CRANK FROM ENGINE
CONTROLS
(Continued)

ENGINE CRANKS BUT
WILL NOT START

2. Loose or broken wire #05A from
off/on switch (S30) to engine start
switch (S32).

3. Defective engine start switch (S32).

4. Loose or broken wire #32A from
engine start switch (S32) to starter
contactor (32ACR).

5. Loose or broken wire #00 from
starter contactor (32ACR) to base.

6. Defective starter contactor (32ACR).

7. Loose or broken wire #103 from main
power disconnect switch (S1) to
starter contactor (32ACR).

8. Loose or broken wire #104 from
starter contactor (32ACR) to starter
motor.

9. Defective starter motor.

1. Open diode (D32A-2) from engine
start switch (S32) to base terminal
block.

2. Open diode (D32A-3).

3. Loose or broken wire #32B from
diode (D32A-3) to vacuum switch
(VS1).

4. Defective vacuum switch (VS1).

5. Loose or broken wire #55 from
vacuum switch (VS1) to fuel relay
(55CR).

6. Defective fuel relay (55CR).

7. Loose or broken wire #02 from fuel
relay (55CR) to base terminal block.

8. Loose or broken wire #37 from fuel
relay (55CR) to ignition coil (Dual
Fuel Only).

9. Loose or broken wire #37 from base
terminal block to diesel valve solenoid
(2D37) (Diesel Only).

10. Loose or broken wire #57 from
starter contactor (32ACR) to diesel
valve solenoid (2D37) (Diesel Only).

11. Defective fuel valve solenoid (2D37)
(Diesel only).

12. Loose or broken wire #56 from fuel
relay (55CR) to fuel select switch
(S33).

13. Defective fuel select switch (S33).

14. Defective fuel relay (55CR).

15. Loose or broken wires #50 (Liquid
Propane) or #11 (Gasoline) from fuel
select switch (S33) to fuel valve (2P50)
(Liquid Propane) or (2G11) (Gasoline).

2. Check continuity. Replace if
defective.

3. Check switch. Replace if defective.

4. Check continuity. Replace if
defective.

5. Check continuity. Replace if
defective.

6. Check contactor. Replace if
defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check motor. Repair or replace if
defective.

1. Check diode. Replace if defective.

2. Check diode. Replace if defective.

3. Check continuity. Replace if
defective.

4. Check switch. Replace if defective.

5. Check continuity. Replace if
defective.

6. Check relay. Replace if defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check continuity. Replace if
defective.

10. Check continuity. Replace if
defective.

11. Check solenoid. Replace if
defective.

12. Check continuity. Replace if
defective.

13. Check switch. Replace if defective.

14. Check relay. Replace if defective.

15. Check continuity. Replace if
defective.

June 2001

SECTION 4, Page 3SJ-600 Series Engine Powered 112715

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

ENGINE CRANKS BUT
WILL NOT START
(Continued)

ENGINE STARTS BUT
WILL NOT CONTINUE
RUNNING

16. Loose or broken wire #11 from fuel
valve (2G11) to fuel pump (FP1).

17. Defective fuel pump (FP1) (Gasoline
Only).

18. Open diode (D57) from starter motor
to ignition coil.

19. Choke inoperative (Dual Fuel).

20. Defective glow plugs (Diesel).

21. No spark (Dual Fuel).

1. Engine oil lever low.

2. Engine overheated.

3. Defective temperature switch (TPS1).

4. Defective oil pressure switch (OPS1).

5. Loose or broken wire #2B from oil
pressure switch (OPS1) to
temperature switch (TPS1).

6. Loose or broken wire #2A from relay
(10BCR2) to oil pressure switch
(OPS1).

7. Loose or broken wire #10B from base
terminal block to relay (10BCR2).

8. Loose or broken wire #10A from base
terminal block to relay (10BCR2).

9. Loose or broken wire #37 from relay
(10BCR2) to ignition coil (Dual fuel).
or diesel valve solenoid (2D37)
(Diesel).

10. Defective relay (10BCR2).

16. Check continuity. Replace if
defective.

17. Check pump. Replace if defective.

18. Check diode. Repair if necessary.

19. Check choke. Repair if necessary.

20. Check glow plugs. Repair if
necessary.

21. Refer to engine manufacturer
service manual.

1. Refill to proper level.

2. Check cooling system.

3. Check switch. Replace if defective.

4. Check switch. Replace if defective.

5. Check continuity. Replace if
defective.

6. Check continuity. Replace if
defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check continuity. Replace if
defective.

10. Check relay. Replace if defective.

CHOKE INOPERATIVE
FROM PLATFORM OR
ENGINE CONTROLS
(Dual Fuel)

CHOKE INOPERATIVE
FROM PLATFORM
(Dual Fuel)

SECTION 4, Page 4 SJ-600 Series Engine Powered 112715

1. Loose or broken wire #31A from
choke switch (S31) to choke solenoid
(CS31A).

2. Defective choke solenoid (CS31A).

1. Loose or broken wire #10 from key
select switch (S3) to choke switch
(S13).

2. Defective choke switch (S13).

3. Loose or broken wire #31 from choke
switch (S13) to choke relay (31CR).

4. Loose or broken wire #02 from relay
(31CR) to base terminal block (TB1).

5. Loose or broken wire #05 from base
terminal block (TB1) to relay (31CR).

6. Loose or broken wire #31A from relay
(31CR) to base terminal block (TB1).

7. Loose or broken wire #31A from base
terminal block (TB1) to choke
solenoid (CS31A).

8. Defective choke relay (31CR).

June 2001

1. Check continuity. Replace if
defective.

2. Check solenoid. Replace if
defective.

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 continuity. Replace if
defective.

8. Check relay. Replace if defective.

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

GLOW PLUGS
INOPERATIVE FROM
PLATFORM OR ENGINE
CONTROLS
(Diesel)

GLOW PLUGS
INOPERATIVE FROM
PLATFORM (Diesel)

1. Loose or broken wire #31A from glow
plug switch (S31) to glow plug relay
(31ACR).

2. Loose or broken wire #02 from glow
plug relay (31ACR) to base terminal
block (TB1).

3. Loose or broken wire #91 from base
terminal block (TB1) to relay (31ACR).

4. Loose or broken wire #91A from relay
(31ACR) to engine glow plugs
(EGP1).

5. Defective glow plug relay (31ACR).

1. Loose or broken wire #10 from key
selector switch (S3) to glow plug
switch (S13).

2. Defective glow plug switch (S13).

3. Loose or broken wire #31 from glow
plug switch (S13) to glow plug relay
(31CR).

4. Loose or broken wire #02 from relay
(31CR) to base terminal block (TB1).

5. Loose or broken wire #05 from base
terminal block (TB1) to relay (31CR).

6. Loose or broken wire #31A from relay
(31CR) to base terminal block (TB1).

7. Loose or broken wire #31A from base
terminal block (TB1) to glow plug
relay (31ACR).

8. Defective relay (31CR).

9. Loose or broken wire #02 from relay
(31ACR) to base terminal block (TB1).

10. Loose or broken wire #91 from base
terminal block (TB1) to relay (31ACR).

11. Loose or broken wire #31A from relay
(31ACR) to engine glow plugs
(EGP1).

12. Defective glow plug relay (31ACR).

13. Defective glow plugs.

1. Check continuity. Replace if
defective.

2. Check continuity. Replace if
defective.

3. Check continuity. Replace if
defective.

4. Check continuity. Replace if
defective.

5. Check relay. Replace if defective.

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 continuity. Replace if
defective.

8. Check relay. Replace if defective.

9. Check continuity. Replace if
defective.

10. Check continuity. Replace if
defective.

11. Check continuity. Replace if
defective.

12. Check relay. Replace if defective.

13. Check glow plugs. Replace if
defective.

HIGH THROTTLE
INOPERATIVE
(Machines Without
Base Control Box
Option)

1. Loose or broken wire #10 from key
select switch (S3) to low/high throttle
switch (S14).

2. Defective high/low throttle switch
(S14).

3. Loose or broken wire #34 from low/
high throttle switch (S14) to relay
(34CR).

4. Defective relay (34CR).

5. Loose or broken wire #42 from relay
(34CR) to relay (10BCR2).

6. Defective relay (10BCR2).

June 2001

1. Check continuity. Replace if
defective.

2. Check switch. Replace if defective.

3. Check continuity. Replace if
defective.

4. Check relay. Replace if defective.

5. Check continuity. Replace if
defective.

6. Check relay. Replace if defective.

SECTION 4, Page 5SJ-600 Series Engine Powered 112715

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

HIGH THROTTLE
INOPERATIVE
(Machines Without
Base Control Box
Option)
(Continued)

HIGH THROTTLE
INOPERATIVE
(Machines With Base
Control Box Option)

7. Loose or broken wire #02 from relay
(10BCR2) to base terminal block
(TB1).

8. Loose or broken wire #05 from base
terminal block (TB1) to relay (32CR).

9. Defective relay (32CR).

10. Loose or broken wire #43 from relay
(32CR) to relay (34CR).

11. Loose or broken wire #34A from relay
(34CR) to high throttle solenoid
(HTS34A).

12. Defective high throttle solenoid
(HTS34A).

13. Loose or broken wire #02 from high
throttle solenoid (HTS34A) to engine
terminal block.

1. Loose or broken wire #10 from key
select switch (S3) to low/high throttle
switch (S14).

2. Defective low/high throttle switch
(S14).

3. Loose or broken wire #34 from low/
high throttle switch (S14) to diode
(D34).

4. Diode (D34) open.

5. Loose or broken wire #34B from
diode (D34) to relay (34BCR).

6. Defective relay (34BCR).

7. Loose or broken wire #42 from relay
(34BCR) to relay (10BCR2).

8. Defective relay (10BCR2).

9. Loose or broken wire #02 from relay
(10BCR2) to base terminal block
(TB1).

10. Loose or broken wire #05 from base
terminal block (TB1) to relay (32CR).

11. Defective relay (32CR).

12. Loose or broken wire #43 from relay
(32CR) to relay (34BCR).

13. Loose or broken wire #34A from relay
(34BCR) to high throttle solenoid
(HTS34A).

14. Defective high throttle solenoid
(HTS34A).

15. Loose or broken wire #02 from high
throttle solenoid (HTS34A) to engine
terminal block.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check relay. Replace if defective.

10. Check continuity. Replace if
defective.

11. Check continuity. Replace if
defective.

12. Check solenoid. Replace if
defective.

13. Check continuity. Replace if
defective.

1. Check continuity. Replace if
defective.

2. Check switch. Replace if defective.

3. Check continuity. Replace if
defective.

4. Check diode. Replace if defective.

5. Check continuity. Replace if
defective.

6. Check relay. Replace if defective.

7. Check continuity. Replace if
defective.

8. Check relay. Replace if defective.

9. Check continuity. Replace if
defective.

10. Check continuity. Replace if
defective.

11. Check relay. Replace if defective.

12. Check continuity. Replace if
defective.

13. Check continuity. Replace if
defective.

14. Check solenoid. Replace if
defective.

15. Check continuity. Replace if
defective.

DRIVE AND STEER
INOPERATIVE

SECTION 4, Page 6 SJ-600 Series Engine Powered 112715

1. Key select switch (S3) in lift position.

2. Defective drive switch in key select
switch (S3).

3. Loose or broken wire #12 from key
select switch (S3) to platform terminal
block.

June 2001

1. Turn switch to drive position.

2. Check switch. Replace if defective.

3. Check continuity. Replace if
defective.

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

DRIVE AND STEER
INOPERATIVE
(Continued)

BRAKES WILL NOT
RELEASE

4. Loose or broken wire #12 from
platform terminal block to joystick
controller (S7).

5. Loose or broken wire #10A from base
terminal block to relay (28CR).

6. Loose or broken wire #04 from relay
(28CR) to base terminal block.

7. Defective relay (28CR).

1. Loose or broken wire #30 from
diodes (D15A-2) and (D16A-2) to relay
(30CR).

2. Defective relay (30CR).

3. Loose or broken wire #02 from relay
(30CR) to base terminal block.

4. Loose or broken wire #10A from base
terminal block to relay (30CR).

5. Loose or broken wire #30A from relay
(30CR) to base terminal block.

6. Loose or broken wire #30A from base
terminal block to brake dump valve
(2H 30A-1) or brake feed valve (2H30A-

2).

7. Defective valve coil (2H30A-1) brake
dump or (2H30A-2) brake feed.

8. Loose or broken wire #02 from
(2H30A-1) brake dump or (2H30A-2)
brake feed coils to base terminal
block.

4. Check continuity. Replace if
defective.

5. Check continuity. Replace if
defective.

6. Check continuity. Replace if
defective.

7. Check relay. Replace if defective.

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
defective.

6. Check continuity. Replace if
defective.

7. Check coil. Replace if defective.

8. Check continuity. Replace if
defective.

STEER RIGHT
INOPERATIVE

1. Defective steer right switch (S7-2) in
joystick controller (S7).

2. Loose or broken wire #23 from steer
right switch (S7-2) to platform terminal
block.

3. Loose or broken wire #23 from
platform terminal block to relay
(23CR).

4. Defective relay (23CR).

5. Loose or broken wire #04 from base
terminal block to relay (23CR).

6. Loose or broken wire #23A from
relay (23CR) to base terminal block.

7. Loose or broken wire #02 from relay
(23CR) to base terminal block.

8. Loose or broken wire #23A from base
terminal block to steer right valve coil
(4H23A).

9. Defective steer right valve coil (4H23A).

10. Loose or broken wire #02 from steer
right valve coil (4H32A) to base
terminal block.

11. Open diode (D23A).

1. Check switch. Replace if defective.

2. Check continuity. Replace if
defective.

3. Check continuity. Replace if
defective.

4. Check relay. Replace if defective.

5. Check continuity. Replace if
defective.

6. Check continuity. Replace if
defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check coil. Replace if defective.

10. Check continuity. Replace if
defective.

11. Check diode. Replace if defective.

SECTION 4, Page 7SJ-600 Series Engine Powered 112715

June 2001

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

STEER LEFT
INOPERATIVE

REVERSE DRIVE
INOPERATIVE

1. Defective steer left switch (S7-3) in
joystick controller (S7).

2. Loose or broken wire #24 from steer
left switch (S7-3) to platform terminal
block.

3. Loose or broken wire #24 from
platform terminal block to relay
(24CR).

4. Defective relay (24CR).

5. Loose or broken wire #04 from base
terminal block to relay (24CR).

6. Loose or broken wire #24A from
relay (24CR) to base terminal block.

7. Loose or broken wire #02 from relay
(24CR) to base terminal block.

8. Loose or broken wire #24A from
base terminal block to steer left valve
coil (4H24A).

9. Defective steer left valve coil (4H24A).

10. Loose or broken wire #02 from steer
left valve coil (4H24A) to base terminal
block.

11. Open diode (D24A).

1. Defective drive/reverse switch (S7-4)
in joystick controller (S7).

2. Defective joystick controller (S7).

3. Loose or broken wire #15 from
joystick (S7) to platform terminal
block.

4. Loose or broken wire #15 from
platform terminal block to relay
(15CR).

5. Defective relay (15CR).

6. Loose or broken wire #02 from relay
(15CR) to base terminal block.

7. Loose or broken wire #04 from base
terminal block to relay (15CR).

8. Loose or broken wire #15A from
relay (15CR) to time delay relay
(1TD).

9. Defective time delay relay (1TD).

10. Loose or broken wire #15B from time
delay relay (1TD) to reverse valve coil
(4H15B).

11. Defective reverse valve coil (4H15B).

12. Loose or broken wire #02 from
reverse valve coil (4H15B) to base
terminal block.

13. Open diode (D15A-1) or (D15A-2).

1. Check switch. Replace if defective.

2. Check continuity. Replace if
defective.

3. Check continuity. Replace if
defective.

4. Check relay. Replace if defective.

5. Check continuity. Replace if
defective.

6. Check continuity. Replace if
defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check coil. Replace if defective.

10. Check continuity. Replace if
defective.

11. Check diode. Replace if defective.

1. Check switch. Replace if defective.

2. Check joystick. Replace if defective.

3. Check continuity. Replace if
defective.

4. Check continuity. Replace if
defective.

5. Check relay. Replace if defective.

6. Check continuity. Replace if
defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check relay. Replace if defective.

10. Check continuity. Replace if
defective.

11. Check coil. Replace if defective.

12. Check continuity. Replace if
defective.

13. Check diodes. Replace if defective.

FORWARD DRIVE
INOPERATIVE

SECTION 4, Page 8 SJ-600 Series Engine Powered 112715

1. Defective drive forward switch (S7-5)
in joystick controller (S7).

2. Defective joystick controller (S7).

June 2001

1. Check switch. Replace if defective.

2. Check joystick. Replace if defective.

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

FORWARD DRIVE
INOPERATIVE
(Continued)

FORWARD DRIVE
SPEED AND STEERING
INOPERATIVE

3. Loose or broken wire #16 joystick
controller (S7) to platform terminal
block.

4. Loose or broken wire #16 from
platform terminal block to relay
(16CR).

5. Defective relay (16CR).

6. Loose or broken wire #02 from relay
(16CR) to base terminal block.

7. Loose or broken wire #04 from base
terminal block to relay (16CR).

8. Loose or broken wire #16A from
relay (16CR) to time delay relay
(1TD).

9. Defective time delay relay (1TD).

10. Loose or broken wire #16B from time
delay relay (1TD) to reverse valve coil
(4H16B).

11. Defective forward valve coil (4H16B).

12. Loose or broken wire #02 from
forward valve coil (4H16B) to base
terminal block.

13. Open diode (D16A-1) or (D16A-2).

1. Loose or broken wire #21 from base
terminal block to relay (17ACR).

2. Defective relay (17ACR).

3. Loose or broken wire #18A from
relay (17ACR) to small pump dump
valve solenoid.

4. Defective small pump dump valve
coil (2H18A).

5. Loose or broken wire #02 from small
pump dump solenoid (2H18A) to
base terminal block.

3. Check continuity. Replace if
defective.

4. Check continuity. Replace if
defective.

5. Check relay. Replace if defective.

6. Check continuity. Replace if
defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check relay. Replace if defective.

10. Check continuity. Replace if
defective.

11. Check coil. Replace if defective.

12. Check continuity. Replace if
defective.

13. Check diodes. Replace if defective.

1. Check continuity. Replace if
defective.

2. Check relay. Replace if defective.

3. Check continuity. Replace if
defective.

4. Check coil. Replace if defective.

5. Check continuity. Replace if
defective.

SECOND DRIVE SPEED
INOPERATIVE

1. Defective second speed switch (S7-

1) in joystick controller (S7).

2. Defective joystick controller (S7).

3. Loose or broken wire #19 from
joystick controller (S7) to platform
terminal block.

4. Loose or broken wire #19 from
platform terminal block to relay
(35CR).

5. Defective relay (35CR).

6. Loose or broken wire #10A from
base terminal block to high drive/tilt
override limit switch (LS5).

7. Misadjusted or defective high drive/
tilt override limit switch (LS5).

8. Loose or broken wire #35 from high
drive/tilt override limit switch (LS5) to
base terminal block.

June 2001

1. Check switch. Replace if defective.

2. Check joystick. Replace if defective.

3. Check continuity. Replace if
defective.

4. Check continuity. Replace if
defective.

5. Check relay. Replace if defective.

6. Check continuity. Replace if
defective.

7. Adjust switch. Replace if defective.

8. Check continuity. Replace if
defective.

SECTION 4, Page 9SJ-600 Series Engine Powered 112715

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

SECOND DRIVE SPEED
INOPERATIVE
(Continued)

9. Loose or broken wire #35 from base
terminal block to relay (35CR).

10. Loose or broken wire #02 from relay
(35CR) to base terminal block.

11. Defective relay (35CR).

12. Loose or broken wire #17 from relay
(35CR) to relay (17CR).

13. Defective relay (17CR).

14. Loose or broken wire #02 from relay
(17CR) to base terminal block.

15. Loose or broken wire #10A from
base terminal block to relay (17CR).

16. Loose or broken wire #17A from
relay (17CR) to base terminal block.

17. Loose or broken wire #17A from
relay (17CR) to relay (17ACR).

18. Defective relay (17ACR).

19. Loose or broken wire #02 from relay
(17ACR) to base terminal block.

20. Loose or broken wire #17A from
base terminal block to large pump
dump valve solenoid (2H17A).

21. Loose or broken wire #02 from large
pump dump valve solenoid (2H17A)
to base terminal block.

22. Defective large pump dump valve
solenoid (2H17A).

9. Check continuity. Replace if
defective.

10. Check continuity. Replace if
defective.

11. Check relay. Replace if defective.

12. Check continuity. Replace if
defective.

13. Check relay. Replace if defective.

14. Check continuity. Replace if
defective.

15. Check continuity. Replace if
defective.

16. Check continuity. Replace if
defective.

17. Check continuity. Replace if
defective.

18. Check relay. Replace if defective.

19. Check continuity. Replace if
defective.

20. Check continuity. Replace if
defective.

21. Check continuity. Replace if
defective.

22. Check solenoid. Replace if
defective.

THIRD DRIVE SPEED
INOPERATIVE

1. Low/high torque switch (S41) in low
position or defective.

2. Defective third speed switch (S7-6)
in joystick controller (S7).

3. Defective joystick controller (S7).

4. Loose or broken wire #18B from
joystick controller (S7) to low/high
torque switch (S41).

5. Loose or broken wire #18 from low/
high torque switch (S41) to platform
terminal block.

6. Loose or broken wire #18 from
platform terminal block to relay
(18CR).

7. Defective relay (18CR).

8. Loose or broken wire #02 from relay
(18CR) to base terminal block.

9. Loose or broken wire #10A from
base terminal block to relay (18CR).

10. Loose or broken wire #18A from
relay (18CR) to small pump dump
valve (2H18A).

11. Loose or broken wire #02 from small
pump dump valve (2H18A) to base
terminal block.

12. Defective small pump dump valve
solenoid.

1. Turn low/high switch to high
position. Replace if defective.

2. Check switch. Replace if defective.

3. Check joystick. 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 continuity. Replace if
defective.

10. Check continuity. Replace if
defective.

11. Check continuity. Replace if
defective.

12. Check solenoid. Replace if
defective.

SECTION 4, Page 10 SJ-600 Series Engine Powered 112715

June 2001

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

HIGH/LOW RANGE
SPEED INOPERATIVE

1. Loose or broken wire #12 from key
select switch (S3) to low/high range
switch (S29).

2. Defective low/high range switch
(S29).

3. Loose or broken wire #20B from low/
high range switch (S29) to low/high
torque switch (S41).

4. Defective low/high torque switch
(S41).

5. Loose or broken wire #20 from high/
low torque switch (S41) to relay (20CR).

6. Defective relay (20CR).

7. Loose or broken wire #02 from relay
(20CR) to base terminal block.

8. Loose or broken wire #04 from base
terminal block to relay (35CR).

9. Defective relay (35CR).

10. Loose or broken wire #44 from relay
(35CR) to relay (20CR).

11. Loose or broken wire #20A from
relay (20CR) to base terminal block.

12. Loose or broken wire #20A from
base terminal block to series parallel
valve coil (3H20A).

13. Defective series/parallel valve coil
(3H20A).

14. Loose or broken wire #02 from
series/parallel valve coil (3H20A) to
base terminal block.

1. Check continuity. Replace if
defective.

2. Check switch. Replace if defective.

3. Check continuity. Replace if
defective.

4. Check switch. Replace if defective.

5. Check continuity. Replace if
defective.

6. Check relay. Replace if defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check relay. Replace if defective.

10. Check continuity. Replace if
defective.

11. Check continuity. Replace if
defective.

12. Check continuity. Replace if
defective.

13. Check coil. Replace if defective.

14. Check continuity. Replace if
defective.

UP CIRCUIT
INOPERATIVE FROM
PLATFORM OR BASE

1. Lift/off/drive switch (S3) in drive
position or defective.

2. Loose or broken wire #09 from off/
lift/drive switch (S3) to hydraulic
generator switch (S12) or lift enable
switch (S9).

3. Loose or broken wire #09A from
hydraulic generator switch (S12) to
lift enable switch (S9).

4. Defective hydraulic generator switch
(S12).

5. Defective lift enable switch (S9).

6. Loose or broken wire #09B from lift
enable switch (S9) to up/off/down
switch (S5).

7. Defective up/off/down switch (S5).

8. Loose or broken wire #14 from up/
off/down switch (S5) to diode (D14).

9. Diode (D14) open.

10. Loose or broken wire #14 from diode
(D14) to base terminal block.

11. Loose or broken wire #14 from base
terminal block to relay (14CR).

June 2001

1. Select lift position. Check switch.
Replace if defective.

2. Check continuity. Replace if
defective.

3. Check continuity. Replace if
defective.

4. Check switch. Replace if defective.

5. Check switch. Replace if defective.

6. Check continuity. Replace if
defective.

7. Check switch. Replace if defective.

8. Check continuity. Replace if
defective.

9. Check diode. Replace if defective.

10. Check continuity. Replace if
defective.

11. Check continuity. Replace if
defective.

SECTION 4, Page 11SJ-600 Series Engine Powered 112715

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

UP CIRCUIT
INOPERATIVE FROM
PLATFORM OR BASE
(Continued)

UP CIRCUIT
INOPERATIVE FROM
BASE

12. Loose or broken wire #02 from relay
(14CR) to base terminal block.

13. Defective relay (14CR).

14. Loose or broken wire #10A from
base terminal block to end of stroke
limit switch (LS4).

15. Defective end of stroke limit switch
(LS4).

16. Loose or broken wire #36B from end
of stroke limit switch (LS4) to relay
(14CR).

17. Loose or broken wire #14A from
relay (14CR) to relay (28CR).

18. Loose or broken wire #14B from
relay (28CR) to base terminal block.

19. Loose or broken wire #14B from
base terminal block to lift valve
solenoid (2H14B).

20. Loose or broken wire #02 from lift
valve solenoid (2H14B) to base
terminal block.

21. Defective lift valve solenoid (2H14B).

1. Loose or broken wire #10A from
base terminal block to base up switch
(S16)

2. Loose or broken wire #14 from base
up switch (S16) to base terminal
block.

3. Defective base up switch (S16).

12. Check continuity. Replace if
defective.

13. Check relay. Replace if defective.

14. Check continuity. Replace if
defective.

15. Check switch. Replace if defective.

16. Check continuity. Replace if
defective.

17. Check continuity. Replace if
defective.

18. Check continuity. Replace if
defective.

19. Check continuity. Replace if
defective.

20. Check continuity. Replace if
defective.

21. Check solenoid. Replace if
defective.

1. Check continuity. Replace if
defective.

2. Check continuity. Replace if
defective.

3. Check switch. Replace if defective.

UP CIRCUIT
INOPERATIVE FROM
BASE (Base Control
Box Option)

DOWN CIRCUIT
INOPERATIVE FROM
PLATFORM OR BASE

SECTION 4, Page 12 SJ-600 Series Engine Powered 112715

1. Loose or broken wire #10E from
base terminal block to up/off/down
switch (S2)

2. Loose or broken wire #14 from up/
off/down switch (S2) to base terminal
block.

3. Defective up/off/down switch (S2).

1. Lift/off/drive switch (S3) in drive
position or defective.

2. Loose or broken wire #09 from off/
lift/drive switch (S3) to hydraulic
generator switch (S12) or lift enable
switch (S9).

3. Loose or broken wire #09A from
hydraulic generator switch (S12) to
lift enable switch (S9).

4. Defective hydraulic generator switch
(S12).

5. Defective lift enable switch (S9).

6. Loose or broken wire #13 from lift
enable switch (S9) to diode (D13).

June 2001

1. Check continuity. Replace if
defective.

2. Check continuity. Replace if
defective.

3. Check switch. Replace if defective.

1. Select lift position. Check switch.
Replace if defective.

2. Check continuity. Replace if
defective.

3. Check continuity. Replace if
defective.

4. Check switch. Replace if defective.

5. Check switch. Replace if defective.

6. Check continuity. Replace if
defective.

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

DOWN CIRCUIT
INOPERATIVE FROM
PLATFORM OR BASE
(Continued)

7. Diode (D13) Open.

8. Loose or broken wire #13 from diode
(D13) to base terminal block.

9. Loose or broken wire #13 from base
terminal block to platform limit switch
(LS7).

10. Loose or broken wire #13A from
platform limit switch (LS7) to relay
(13CR).

11. Loose or broken wire #02 from relay
(13CR) to base terminal block.

12. Defective relay (13CR).

13. Loose or broken wire #05 from base
terminal block to relay (13CR).

14. Loose or broken wire #13B from
relay (13CR) to base terminal block.

15. Loose or broken wire #13B from
base terminal block to holding valve
solenoid (2H13B-1) or (2H13B-2).

16. Loose or broken wire #02 from
holding valve solenoid (2H13B-1) or
(2H13B-2) to base terminal block.

17. Defective holding valve solenoid
(2H13B-1) or (2H13B-2).

18. Loose or broken wire #13B from
base terminal block to lowering valve
solenoid (2H13B).

19. Loose or broken wire #02 from
lowering valve solenoid (2H13B) to
base terminal block.

20. Defective lowering valve solenoid
(2H13B).

7. Check diode. Replace if defective.

8. Check continuity. Replace if
defective.

9. Check continuity. Replace if
defective.

10. Check continuity. Replace if
defective.

11. Check continuity. Replace if
defective.

12. Check relay. Replace if defective.

13. Check continuity. Replace if
defective.

14. Check continuity. Replace if
defective.

15. Check continuity. Replace if
defective.

16. Check continuity. Replace if
defective.

17. Check solenoid. Replace if
defective.

18. Check continuity. Replace if
defective.

19. Check continuity. Replace if
defective.

20. Check solenoid. Replace if
defective.

DOWN CIRCUIT
INOPERATIVE FROM
BASE

DOWN CIRCUIT
INOPERATIVE FROM
BASE (Base Control
Box Option)

POWERED EXTENSION
DECK INOPERATIVE

1. Loose or broken wire #05 from base
terminal block to base down switch
(S17).

2. Loose or broken wire #13A from
base down switch (S17) to base
terminal block.

3. Defective base down switch (S17).

1. Loose or broken wire #10E from
base terminal block to up/off/down
switch (S2).

2. Loose or broken wire #13 from up/
off/down switch (S2) to base terminal
block.

3. Defective base up/off/down switch
(S2).

1. Loose or broken battery cable from
main power disconnect switch (S1)
to 100 Amp. fuse (F2).

2. Open 100 Amp. fuse (F2).

June 2001

1. Check continuity. Replace if
defective.

2. Check continuity. Replace if
defective.

3. Check switch. Replace if defective.

1. Check continuity. Replace if
defective.

2. Check continuity. Replace if
defective.

3. Check switch. Replace if defective.

1. Check continuity. Replace if
defective.

2. Check fuse. Replace if open.

SECTION 4, Page 13SJ-600 Series Engine Powered 112715

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

POWERED EXTENSION
DECK INOPERATIVE
(Continued)

3. Loose or broken battery cable #103A
from fuse (F2) to contactor (09ACR).

4. Defective contactor (09ACR).

5. Loose or broken battery cable #103B
from contactor (09ACR) to motor
contactor (99CR).

6. Defective motor contactor (99CR).

7. Loose or broken wire #103B from
battery cable #103B to circuit breaker
(CB2).

8. Tripped or defective circuit breaker
(CB2).

9. Loose or broken wire #103C from
circuit breaker (CB2) to powered
platform enable switch (S42).

10. Loose or broken wire #103D from
enable switch (S42) to platform
extend retract switch (S11).

11. Defective platform extend/retract
switch (S11).

12. Defective platform enable switch
(S42).

13. Loose or broken battery cable #00
from platform power unit (DCM1) to
battery (B1).

14. Defective platform power unit
(DCM1).

3. Check continuity. Replace if
defective.

4. Check contactor. Replace if
defective.

5. Check continuity. Replace if
defective.

6. Check contactor. Replace if
defective.

7. Check continuity. Replace if
defective.

8. Reset breaker. Replace if defective.

9. Check continuity. Replace if
defective.

10. Check continuity. Replace if
defective.

11. Check switch. Replace if defective.

12. Check switch. Replace if defective.

13. Check continuity. Replace if
defective.

14. Check power unit. Repair or
replace if defective.

POWERED EXTENSION
DECK WILL NOT
EXTEND

POWERED EXTENSION
DECK WILL NOT
RETRACT

SECTION 4, Page 14 SJ-600 Series Engine Powered 112715

1. Defective platform extend/retract
switch (S11).

2. Loose or broken wire #26 from
platform extend/retract switch (S11)
to platform extend valve coil (4H26).

3. Diode (D26) open.

4. Defective platform extend valve coil
(4H26).

5. Loose or broken wire #00 from
platform extend valve coil (4H26) to
battery cable #00.

1. Defective platform extend/retract
switch (S11).

2. Loose or broken wire #27 from
platform extend/retract switch (S11)
to platform retract valve coil (4H27).

3. Diode (D27) open.

4. Defective platform retract valve coil
(4H27).

5. Loose or broken wire #00 from
platform retract valve coil (4H27) to
battery cable #00.

1. Check switch. Replace if defective.

2. Check continuity. Replace if
defective.

3. Check diode. Replace if defective.

4. Check coil. Replace if defective.

5. Check continuity. Replace if
defective.

1. Check switch. Replace if defective.

2. Check continuity. Replace if
defective.

3. Check diode. Replace if defective.

4. Check coil. Replace if defective.

5. Check continuity. Replace if
defective.

June 2001

TROUBLESHOOTING INFORMATION

ELECTRICAL SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

HYDRAULIC
GENERATOR
INOPERATIVE

1. Key select switch (S3) in drive
position.

2. Loose or broken wire #09 from key
select switch (S3) to generator switch
(S12).

3. Defective hydraulic generator switch
(S12).

4. Loose or broken wire #85 from
generator switch (S12) to base
terminal block.

5. Loose or broken wire #85 from base
terminal block to relay (85CR).

6. Defective relay (85CR).

7. Loose or broken wire #02 from relay
(85CR) to base terminal block.

8. Loose or broken wire #87 from base
circuit breaker (CB4) to relay (85CR).

9. Diode (D85) open.

10. Loose or broken wire #86 from relay
(85CR) to generator valve coil (2H86).

11. Defective generator valve coil (2H86).

12. Loose or broken wire #02 from
generator valve coil (2H86) to base
terminal block.

1. Turn switch to lift position.

2. Check continuity. Replace if
defective.

3. Check switch. Replace if defective.

4. Check continuity. Replace if
defective.

5. Check continuity. Replace if
defective.

6. Check relay. Replace if defective.

7. Check continuity. Replace if
defective.

8. Check continuity. Replace if
defective.

9. Check diode. Replace if defective.

10. Check continuity. Replace if
defective.

11. Check coil. Replace if defective.

12. Check continuity. Replace if
defective.

June 2001

SECTION 4, Page 15SJ-600 Series Engine Powered 112715

TROUBLESHOOTING INFORMATION

HYDRAULIC SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

ALL FUNCTIONS
INOPERATIVE

STEERING
INOPERATIVE

STEER AND FIRST
DRIVE SPEED
INOPERATIVE

LIFT AND SECOND
DRIVE SPEED
INOPERATIVE

1. Hydraulic oil level low.

2. Defective pump (P1).

3. Broken engine to pump coupler.

4. Relief valve (R1) open

1. Stuck or defective brake feed valve
(2H30A-2).

2. Stuck or defective steer right valve
(4H23A) or steer left valve (4H24A).

3. Steer cylinder (C7) damaged or
bypassing internally.

1. Small pump dump valve (2H18A)
stuck open.

2. Worn or defective small pump
section of pump (P1).

3. Check valve (CV1) or (CV2) stuck.

1. Large pump dump valve (2H17A)
stuck open.

2. Worn or defective large pump section
of pump (P1).

3. Check valve (CV1) or (CV2) stuck.

1. Refill tank to proper level.

2. Check pump. Repair or replace if
defective.

3. Check coupler. Replace if defective.

4. Check valve. Replace if defective.

1. Check valve. Repair or replace if
defective.

2. Check valves. Replace if defective.

3. Check cylinder. Repair or replace if
defective.

1. Check valve. Repair or replace if
defective.

2. Check pump. Repair or replace if
defective.

3. Check valves. Clean or replace if
defective.

1. Check valve. Repair or replace if
defective.

2. Check pump. Repair or replace if
defective.

3. Check valves. Clean or replace if
defective.

DRIVE INOPERATIVE

REVERSE DRIVE
INOPERATIVE

FORWARD DRIVE
INOPERATIVE

1. Stuck or defective drive reverse valve
(4H15B) or drive forward valve
(4H16B).

2. Defective motion control valve (MC1).

3. Missing or defective check balls in
series/parallel valve manifold
(3H20A).

4. Stuck or defective main series/parallel
valve spool (V3) in drive motor.

5. Defective drive motor (M1).

6. Free wheeling valve (2H30B) stuck.

7. Cushion cylinder (C8) bypassing
internally.

1. Stuck or defective drive valve
(4H15B).

2. Stuck or defective check valve in
motion control assembly (MC1).

1. Stuck or defective drive valve
(4H16B).

2. Stuck or defective check valve in
motion control assembly (MC1).

1. Check valves. Repair or replace if
defective.

2. Check valve. Repair or replace if
defective.

3. Repair or replace balls. Refer to
Section 5 for proper location.

4. Check valve. Repair or replace if
defective.

5. Check motor. Repair or replace if
defective.

6. Check valve. Repair or replace if
defective.

7. Check cylinder. Repair or replace
if defective.

1. Check valve. Repair or replace if
defective.

2. Check valves. Clean or replace if
defective.

1. Check valve. Repair or replace if
defective.

2. Check valves. Clean or replace if
defective.

SECTION 4, Page 16 SJ-600 Series Engine Powered 112715

June 2001

TROUBLESHOOTING INFORMATION

HYDRAULIC SYSTEM

TROUBLE PROBABLE CAUSE REMEDY

BRAKES WILL NOT
RELEASE

UP CIRCUIT
INOPERATIVE

1. Stuck or defective brake feed valve
(2H30A-2).

2. Stuck or defective brake dump valve
(2H30A-1).

3. Stuck or defective brake valve (2H25).

4. Stuck or defective auto reset valve
(V6).

5. Defective disc brake cylinder (C5)

1. Stuck or defective lift valve (2H14B).

2. Stuck check valve (CV3).

3. Misadjusted or defective lift relief valve
(R2).

4. Stuck or defective lowering valve
(2H13B).

5. Stuck or defective manual lowering
valve (V1).

6. Open or defective brake feed valve
(2H30A-2).

7. Open manual override on holding
valve (2H13B-1) or (2H13B-2).

8. Stuck holding valve (2H13B-1) or
(2H13B-2)

1. Check valve. Repair or replace if
defective.

2. Check valve. Repair or replace if
defective.

3. Check valve. Repair or replace if
defective.

4. Check valve. Repair or replace if
defective.

5. Check cylinder. Repair or replace if
defective.

1. Check valve. Repair or replace if
defective.

2. Check valve. Replace if defective.

3. Adjust valve. Replace if defective.

4. Check valve. Repair or replace if
defective.

5. Check valve. Repair or replace if
defective.

6. Check valve. Repair or replace if
defective.

7. Depress and turn manual override
clockwise to close. Replace if
defective.

8. Check valves. Repair or replace if
defective.

DOWN CIRCUIT
INOPERATIVE

POWERED EXTENSION
DECK INOPERATIVE

HYDRAULIC
GENERATOR
INOPERATIVE

1. Stuck or defective lowering valve
(2H13B).

2. Stuck holding valve (2H13B1) or
(2H13B2).

3. Plugged lowering orifice (O1).

1. Defective powered extension pump
(P2).

2. Misadjusted or defective relief valve
(R5).

3. Stuck or defective deck extend valve
(4H26) or retract valve (4H27).

4. Defective powered extension cylinder
(C3).

1. Stuck or defective hydraulic
generator valve (2H85).

2. Misadjusted or defective flow control
valve (FC1).

3. Stuck or defective large pump dump
valve (2H17A).

4. Defective hydraulic generator
hydraulic motor (M2).

1. Check valve. Repair or replace if
defective.

2. Check valves. Repair or replace if
defective.

3. Clean or replace orifice.

1. Check pump. Repair or replace if
defective.

2. Adjust valve. Replace if defective.

3. Check valves. Repair or replace if
defective.

4. Check cylinder. Repair or replace
if defective.

1. Check valve. Repair or replace if
defective.

2. Adjust valve. Replace if defective.

3. Check valve. Repair or replace if
defective.

4. Check motor. Repair or replace if
defective.

June 2001

SECTION 4, Page 17SJ-600 Series Engine Powered 112715

SECTION 5

6

4321toc

MAINTENANCE AND SERVICE

Table Of Contents

Description Page No.

Operators Responsibility For Maintenance ............................................................................................ 2

Maintenance And Inspection Schedule ................................................................................................. 2

Owners Annual Inspection Record ......................................................................................................... 2

General Maintenance Hints .................................................................................................................... 2

Hydraulic System And Component Maintenance And Repair ............................................................... 3

General Specifications ........................................................................................................................... 4

Tire Specifications .................................................................................................................................. 5

Torque Specifications .............................................................................................................................5

Brake Adjustment Procedure ................................................................................................................. 6

Winching And Towing Procedures & Parking Brake System................................................................. 6

System And Lift Pressure Adjustments .................................................................................................. 8

2 Speed Motor Assembly ....................................................................................................................... 9

Wheel Bolt/Nut Inspection And Torquing Procedure ........................................................................... 10

Wheel Reinstallation And Torquing Procedure .....................................................................................10

List Of Tables

Table 5-1. General Specifications ............................................................................ Section 5, Page 4

Table 5-2. Tire Specifications ................................................................................... Section 5, Page 5

Table 5-3. Torque Specifications .............................................................................. Section 5, Page 5

5

SJ-600 Series Engine Powered 112715

June 2001

SECTION 5, Page 1

OPERATOR’S RESPONSIBILITY FOR
MAINTENANCE

Death or injury can result if the work platform is not kept
in good working order. Inspection and maintenance
should be performed by competent personnel who are
familiar with mechanical procedures.

The operator should be assured that the work platform
has been properly maintained before using it. Included
in this section is information on lubrication and
inspection points that require maintenance.

Even if the operator is not responsible for the
maintenance of this work platform, the operator should
perform the daily inspections found in Table 2-4.

Maintenance and Inspection Schedule.

IMPORTANT NOTE

Replace all worn or damaged parts or labels
discovered during this inspection. Any problems or
malfunctions that may affect the safe operation of this
work platform MUST be repaired immediately.

DANGER

MAINTENANCE AND INSPECTION
SCHEDULE

The actual operating environment of the work platform
governs the use of the maintenance schedule. The
inspection points covered in Table 2-4. Maintenance

and Inspection Schedule indicates the areas of the

work platform to be checked and the intervals at which
they should be checked.

OWNER’S ANNUAL INSPECTION
RECORD

It is the responsibility of the owner to arrange daily,
weekly, monthly and annual inspections of the work
platform. Table 2-1. Owner’s Annual Inspection Record
in section 2 is to be used for recording the date of
inspection, owner’s name and the person responsible
for the inspection of this work platform.

GENERAL MAINTENANCE HINTS

• Before attempting any repair work, disconnect
battery ground negative (-) lead.

• Properly position safety bar if the scissors
assembly is raised.

CRUSHING HAZARD

DO NOT reach through scissors assembly without the

safety bar properly positioned. Failure to avoid this

hazard will result in death or serious injury!

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

SECTION 5, Page 2

June 2001

SJ-600 Series Engine Powered 112715

HYDRAULIC SYSTEM AND COMPONENT
MAINTENANCE AND REPAIR

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

1. Any structure has limits of strength and
durability. To prevent failure of structural parts
of hydraulic components, relief valves which
limit pressure to safe operating values are
included in the hydraulic circuits.

2. Tolerance of working parts in the hydraulic
system are very close. Even small amounts of
dirt or foreign material in the system can cause
wear or damage to components, as well as
general faulty operation of the hydraulic
system. Every precaution must be taken to
assure absolute cleanliness of the hydraulic oil.

3. Samples of hydraulic oil should be drawn from
the reservoir every six months. These samples
should be about two quarts and should be
taken while the oil is warmed through normal
operation of the system. If possible, the sample
should be analyzed by a qualified lubrication
specialist to determine whether it is suitable
for further use. The intervals between oil
changes depend on operating conditions and
on the care used in keeping the oil clean.

4. Whenever there is a hydraulic system failure
which gives reason to believe that there are
metal particles or foreign materials in the
system, drain and flush the entire system and
replace the filter cartridges. A complete
change of oil must be made under these
circumstances.

5. Whenever the hydraulic system is drained,
check the magnets in the hydraulic reservoir
for metal particles. If metal particles are
present, flush the entire system and add a new
change of oil. The presence of metal particles
also may indicate the possibility of imminent
component failure. A very small amount of fine
particles is normal.

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 filler opening. The use of cloth to strain the
oil should be avoided to prevent lint from
getting into the system.

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

9. All hydraulic components must be
disassembled in spotlessly clean surroundings.
During disassembly, pay particular attention to
the identification of parts to assure proper
reassembly. Clean all metal parts in a clean
mineral oil solvent. Be sure to thoroughly clean
all internal passages. After the parts have been
dried thoroughly, lay them on a clean, lint-free
surface for inspection.

10. Replace all o-rings and seals when overhauling
any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
amounts of petroleum jelly to hold o-rings in
place during assembly.

11. Be sure to replace any lost hydraulic oil when
completing the installation of the repaired
component, and bleed any air from the system
when required.

12. All hydraulic connections must be kept tight.
A loose connection in a pressure line will permit
the oil to leak out or air to be drawn into the
system. Air in the system can cause damage
to the components and noisy or erratic system
operation.

MAINTENANCE. Three simple maintenance
procedures have the greatest effect on hydraulic
system performance, efficiency and life. Yet, the very
simplicity of them may be reasons they are so often
overlooked. What are they? Simply these:

6. DO NOT use synthetic or fire resistant oils in
this personnel lift. 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.

SJ-600 Series Engine Powered 112715

1. Change filters regularly.

2. Maintain a sufficient quantity of clean hydraulic

3. Keep all connections tight.

June 2001

oil of the proper type and viscosity in the
hydraulic reservoir.

SECTION 5, Page 3

Table 5-1. General Specifications - SJ-600 Series

ENGINE POWER - Kubota gasoline/propane
ENGINE POWER - Kubota gasoline
ENGINE POWER - Kubota diesel
ENGINE POWER - Kubota diesel

BATTERY
TIRES

INSIDE TURNING RADIUS (2WD)
INSIDE TURNING RADIUS (4WD)

OUTSIDE TURNING RADIUS (2WD)
OUTSIDE TURNING RADIUS (4WD)

GROUND UNDERCLEARANCE
FLOOR LOAD RATING
ELEVATED PLATFORM SPEED
HIGH TRAVEL SPEED (High Range/High Speed)
LIFT TIME (with load)
LOWERING TIME (with load)
HIGH SPEED DRIVE CUT OUT HEIGHT
LIFT RELIEF PRESSURE (With no extension platform)

LIFT RELIEF PRESSURE (With extension platform)

23 Hp Water Cooled (DF-750E)

23 Hp Water Cooled (WG-750)

25.5 Hp Water Cooled (D1105-E)

19.5 Hp Water Cooled (DH-950)
12 Volt, 60 Ampere Hour

Refer to Table 5-2.

90” (2.29m)

122” (3.10m)

174” (4.42m)
200” (5.08m)

8” (.20m)

30 psi (2.11 kg/cm2)

0.60 mph (.97 kph)

3.0 mph (4.8 kph)
47 seconds
35 seconds

84” (2.13m) ground to platform

1850 psi
2050 psi

SYSTEM RELIEF PRESSURE

HYDRAULIC PUMP (sml/lrg) (gasoline engines)
HYDRAULIC PUMP (sml/lrg) (diesel engines)

HYDRAULIC SYSTEM CAPACITY
HYDRAULIC TANK CAPACITY

FUEL (gasoline engines)
FUEL (diesel engines)

FUEL TANK CAPACITY
ENGINE RPM (low/high) (DF-750E)

ENGINE RPM (low/high) (WG-750)
ENGINE RPM (low/high) (D1105-E)
ENGINE RPM (low/high) (DH-950)

IGNITION TIMING (DF-750E)
IGNITION TIMING (WG-750)
IGNITION TIMING (D1105-E)
IGNITION TIMING (DH-950)

TAPPET CLEARANCE (int/exh) (DF750E)
TAPPET CLEARANCE (int/exh)

ENGINE TEMPERATURE SWITCH SETTING
POWERED PLATFORM RELIEF VALVE SETTING

2800 psi

.366/.671 ci/rev
.488/.854 ci/rev

17.0 gallons (64.3 liters)

16.5 gallons (62.4 liters)

Non-Blended Automotive

No. 2 Diesel

20.5 gallons (80 liters)
1500/3900

1800/3400
1300/2800
1300/2800

BTDC 18°
BTDC 20°

BTDC 17.5°

BTDC 25°

.0065/.0065
.0057/.0072

230° F (110° C)

500 psi

NOISE LEVEL (at high rpm) 85 DECIBELS

SECTION 5, Page 4 SJ-600 Series Engine Powered 112715

June 2001

Table 5-2. Tire Specifications

WARNING

Air Pressure Can Affect Stability. Temperature Changes Can Affect Air Pressure. It Is Important To

Check Tire Pressures Prior To Use On A Daily Basis In The Operating Conditions Experienced By End

User. If The Measured PSI Reading Is Less Than The Specification And Tolerance, Re-inflate To The

Proper Specification Within The Tolerance Range Specified. Tires Shall Also Not Be Subject To Over-

Inflation Above The Recommended Specification And Tolerance Range.

Tire* Fill Specification

Pressure

Size Fill Type Ply Rating

Factory

#6 30-10-16.5 NHS 8 50 (344.7)* 65 (448.2)
#6 32.3-10-16.5 HD Stabilizer 10 70 (482.6)* 75 (517.1)
#6 30-10-16.5 OTR Outrigger 10 70 (482.6)* 75 (517.1)

Air
#7 31-15.5-15 NHS 8 50 (344.7)* Not Available
#8 31-13.5-15 NHS
#6F 30-10-16.5 NHS 8 **
#7F 31-15.5-15 NHS 8 **
#8F 31-13.5-15 NHS

*

Factory preset @ 20 C, Check pressures regularly as tires can lose pressure over time and over different
ambient temperatures even under normal conditions.

**

Urethane used for filling #6F and #7F tires MUST be 50-55 durometer.

Solid

Urethane

Consult Skyjack Inc.

Consult Skyjack Inc.

Psi (kPa)

Listed Sidewall

Maximum

Table 5-3. Torque Specifications

Directional valve mounting bolts
Wheel mounting bolts
Center drive sprocket mounting bolts

110-115 lbf.ft (242 LOCTITE) 149 – 156 Nm

Hydraulic drive motor mounting bolts

Torque

Lbf.ft (max)

Lbf.in (max)

Nm (max)

08 38 58 10 12 16

20 25 35 50

240 300 420 600

27.12 33.90 47.46 67.80

Torque

Lbf.ft (max)

Lbf.in (max)

Nm (max)

Torque

Lbf.ft (max)

Lbf.in (max)

Nm (max)

2 4 5 6 8 10 12 16
3 10 15 25 30 35

36 120 180 300 360 420

4.07 13.56 20.34 33.90 40.68 47.46

Newton-meter = Nm Pound-force foot = lbf.ft Pound-force inch = lbf.in

28-32 lbf.in 3.16 - 3.61 Nm

135-145 lbf.ft 183 – 196 Nm

120 lbf.ft (242 LOCTITE) 162 Nm

Cartridge

Size

Coils

Size

All coils

4 to 5

48 to 60

5.42 to 6.78

SAE Plugs

Size

SJ-600 Series Engine Powered 112715

June 2001

SECTION 5, Page 5

Brake Adjustment Procedures

1. Place machine on level surface and block wheels
to prevent rolling in either direction.

2. Turn Battery disconnect off.

3. Locate brake manifold in hydraulic/electric side
cabinet.

4. Depress and turn the red knurled knob on the
brake valve counter-clockwise to a fully closed
position or depress black knob. (current manifold)

5. Grasp the red plunger and rapidly depress until
plunger can no longer be depressed and the
brake is fully released.

6. Inspect caliper and brake pads for binding. Pads
should move freely on the pins.

7. Remove pin from brake cylinder clevis and brake
actuating lever. Rotate actuating lever counter­clockwise to the end of it’s stroke.

8. Adjust brake cylinder clevis to obtain 1/2”
between the center of the holes of the actuating
lever and brake cylinder clevis. See Figure 5-1.
Tighten jamb nut on brake cylinder rod against
clevis. Note: It is important that the brake cylinder
reaches it’s maximum stroke before the caliper
to prevent damage to the caliper.

Figure 5-2. Plug Removal and Replacement

11. Using a 1/4” Allen wrench, turn brake adjuster
counter-clockwise until it bottoms out. Turn Allen
wrench clockwise 1/2 turn clockwise to set
adjustment.

12. Replace plastic plug back into the end of the
caliper shaft.

13. Depress red knurled knob on brake valve and turn
clockwise to a fully open position.

14. Remove Wheel blocks. Turn emergency power
disconnect switch on. Operate drive several times
to seat pads to brake disc.

Figure 5-1. Brake Adjustment

9. Reinstall clevis pin back into the clevis actuating
lever.

10. Remove plastic plug located on the end of the
caliper shaft. See Figure 5-2.

Winching And Towing Procedures

Warning

When Towing, DO NOT drive onto a downward slope
or brake the towing vehicle rapidly.

Parking Brake System

3

1

Figure 2-12. Disc Parking Brake

1 - 3. Parking Brake Disc -This device disengages
the brake disc (1) when driving forward or in reverse. A

hydraulic brake cylinder (2), linked to a disc caliper
(3), engages and disengages a brake disc on the rear

axle drive shaft yoke. The brake MUST be manually
disengaged for pushing, towing or winching. DO NOT

push or tow the work platform onto a downward
slope or pull the platform down an incline towards the
winch. The special procedure for manually disengaging

the parking brake is as follows:

2

SECTION 5, Page 6 SJ-600 Series Engine Powered 112715

June 2001

Warning

DO NOT manually disengage the parking brakes if

the work platform is on a slope.

Later Models:

4

Figure 2-13A. Parking Brake Release Hand Pump and

Brake Valve Plunger (Machines With Serial Number

30167 and Above)

Earlier Models:

7

6

Figure 2-13B. Parking Brake Release Hand Pump and

Quick Brake Valve (Machines With Serial Number

30166 and Below)

5

6 - 7. Parking Brake Release Hand Pump (6) and
Brake Valve Knob (7) - Located on the brake manifold in

the hydraulic electric side cabinet, this hand operated
pump MUST be used when pushing or winching the work
platform. To release the parking brake:

4 - 5. Parking Brake Release Hand Pump (4) and
Brake Valve Plunger (5) - Located on the brake

manifold in the hydraulic electric side cabinet, this hand
operated pump MUST be used when pushing, towing
or winching the work platform. To release the parking
brake:

1. Make sure that the work platform is on level
ground. Chock or block the wheels to keep work
platform from rolling.

2. Turn Emergency Power Disconnect Switch to
“OFF” position.

3. Depress the black plunger on the Brake Valve until
the plunger stays in.

4. Grasp the red hand pump plunger and rapidly
depress 60 to 80 times until firm resistance is felt.
The brake is now released.

5. Remove the wheel chocks or blocks, then push,
tow or winch the work platform to the desired
location. When pushing, towing or winching, DO

NOT exceed 2 mph (3.2 km/h). DO NOT push or

tow the platform onto a downward slope or pull
the platform down an incline towards the winch.

6. Position machine on a firm and level surface.
Chock or block the wheels to prevent the platform
from rolling or re-engage the parking brake by
momentarily activating the drive function.

Note

The parking brake will reset automatically when the
work platform is put back into service.

1. 1. Make sure that the work platform is on level
ground. Chock or block the wheels to keep work
platform from rolling.

2. Turn Emergency Power Disconnect Switch to
“OFF” position.

3. Depress and turn the red knurled knob on the
quick brake valve counterclockwise to a fully
closed position.

4. Grasp the red hand pump plunger and rapidly
depress 60 to 80 times until firm resistance is felt.
The brake is now released.

5. Remove the wheel chocks or blocks, then push,
tow or winch the work platform to the desired
location. When pushing, towing or winching,

DO NOT exceed 2 mph (3.2 km/h). DO NOT

push or tow the platform onto a downward
slope or pull the platform down an incline
towards the winch.

6. Position machine on a firm and level surface.
Chock or block the wheels to prevent the platform
from rolling. Re-engage the parking brake. Open
the quick brake valve by depressing, then turning
the red knurled knob on the brake valve clockwise
to a fully open position.

Warning

The quick brake valve MUST be open to restore normal
operation. Failure to follow the procedure

discussed above could result in death or serious
injury!

SJ-600 Series Engine Powered 112715

June 2001

SECTION 5, Page 7

SYSTEM AND LIFT PRESSURE ADJUSTMENTS

All adjustments MUST be made with a Calibrated Hydraulic Gauge.

Refer to the Serial Number Nameplate located on the rear of the machine for System and Lift Pressure values.

SYSTEM RELIEF PRESSURE ADJUSTMENT

1. Locate the Right Steer Hydraulic line at the Main Manifold. (Refer to Hydraulic Manifold Component and
Port Identification found in SECTION 3 for location.)

2. Tee in a Calibrated 3000 PSI Gauge into the Right Steer line.

3. Remove the Operator’s Control Box from the guardrail and disconnect it from the Scissors Control Cable.

4. Locate the Electrical Panel Cable Plug in the Hydraulic/Electric Cabinet.

5. Disconnect the Scissors Control Cable and connect the Operator’s Control Box Cable.

6. At the Main Manifold, loosen the locknut on the System Relief Valve (R1). (Refer to Hydraulic Manifold
Component and Port Identification found in SECTION 3 for location.)

7. Select “DRIVE” position with the Lift/Drive Select Switch on the Platform Control Box.

8. Engage Steer Right Switch on the top of the Controller Handle and hold.

9. Check the reading on Pressure Gauge. Adjust the System Relief Valve (R1) to the pressure listed on the
Serial Number Nameplate. NOTE: Turning the stem on the Relief Valve clockwise increases pressure.
Turning the stem counter-clockwise decreases pressure.

10. Release the Steer Switch and retighten the locknut on the System Relief Valve (R1).

11. Remove the gauge from the Steer line.

LIFT PRESSURE ADJUSTMENT

FULLY LOWER THE PLATFORM

1. Locate the Lift line coming out of the Main Manifold. (Refer to Hydraulic Manifold Component and Port
Identification found in SECTION 3 for location.)

2. Open the Manual Lowering Valve with the platform fully lowered. Remove the Lift line from the Main Manifold.

3. Install a 3000 PSI Gauge into the Lift line port fitting on the Main Manifold. Plug the Lift line going to the Lift
Cylinders.

4. Loosen the locknut on the Lift Relief Valve (R2). (Refer to Hydraulic Manifold Component and Port Identification
found in SECTION 3 for location.)

5. Close the Manual Lowering Valve. Using the Base Controls in the Hydraulic/Electric Cabinet, depress and
hold the Up Push-Button Switch.

6. Observe the reading on the gauge. Adjust the Lift Relief Valve (R2) to the pressure listed on the Serial
Number Nameplate. NOTE: Turning the stem on the Relief Valve clockwise increases pressure.
Turning the stem counter-clockwise decreases pressure.

7. Release the Up Push-Button and retighten the locknut on the Lift Relief Valve (R2).

8. Remove the gauge from the Lift line port fitting and reinstall the Lift line.

ENSURE THAT THE MACHINE DOES

NOT LIFT MORE THAN RATED LOAD

SECTION 5, Page 8 SJ-600 Series Engine Powered 112715

June 2001

2 SPEED MOTOR ASSEMBLY

2

1

3

2

4

TOP OF BLOCK

Index

No.

Skyjack
Part No.

Description

A 109311 MOTOR, 2 Speed drive 1

1 103623 • VALVE, Series/parallel 1
2 115340 • CHECK BALL 4
3 103613 • COIL, Series/parallel valve 1
4 355113 • MANIFOLD, Motor 1

115338 • SEAL KIT AR

Units

per

Assy.

Part Usage:

The 3 smaller holes have O-rings and no Check Balls
The 2 bigger holes get Check Balls
In the Motor piece there are 2 holes that get 1 check ball each (4 Check Balls total)

SJ-600 Series Engine Powered 112715

June 2001

SECTION 5, Page 9

WHEEL BOLT/NUT INSPECTION AND TORQUING PROCEDURE

It is necessary to check the torque on all wheel nuts and wheel bolts at pre-delivery, after 8 hours of operation and
at weekly intervals using the following procedure:

1. Confirm that each wheel fastener is torqued to 140 ft. lbs. (± 5 ft. lbs.) using a suitable torque wrench of
known accuracy. If any fastener falls outside of the specified tolerance, ALL fasteners MUST be torqued
using the tightening sequence shown in Figure 5-5.

Figure 5-5. Wheel Fastener Tightening Sequence

2. Again, confirm that each wheel fastener is torqued to the specified tolerance. Retorque as necessary until
ALL fasteners are properly torqued.

WHEEL REINSTALLATION AND TORQUING PROCEDURE

When a Wheel/Tire Assembly has been removed or replaced, it will be necessary to follow the procedure below to
ensure proper installation:

1. Inspect wheel fastener threads for damage of defects. Replace if defective.

2. Clean the mounting surfaces of the hub and wheel rim of debris, rust, excess paint, etc.

3. Mount wheel on the hub, centering mounting holes on the wheel studs or bolt holes. Use appropriate lifting
device as required.

4. Install the wheel nuts or wheel bolts and hand tighten to center the rim.

5. Tighten the nuts or bolts to approximately 50 ft. lbs. torque using the tightening sequence in Figure 5-5.
above.

6. Tighten to 100 ft. lbs. using the same sequence.

7. Tighten to 140 ft. lbs. using the same sequence.

8. Repeat the tightening sequence to confirm that none have changed from 140 ft. lbs. If any are found below
140 ft. lbs., repeat complete sequence until there is no change in torque values. If possible, drive the
machine prior to checking torques.

9. Check torque values after 8 hours of operation and then at weekly intervals.

SECTION 5, Page 10 SJ-600 Series Engine Powered 112715

June 2001

SECTION 6

543

2

1

toc

PARTS LIST

GENERAL

The information contained in this section is designed to
aid the user in locating and identifying replacement parts.
Component parts of various assemblies and sub­assemblies comprising the work platform are illustrated
and accompanied by a descriptive parts list. Exploded
drawings are used to show relative location of
component parts in disassembly order. If a part cannot
be found in this section, order by work platform model
number and serial number, giving a complete description
of the part.

PARTS ORDERING INFORMATION

When ordering replacement parts, the complete part
number and description should be used to ensure
proper identification and delivery of the desired item.
This complete identification should also be used when
requesting equipment information.

METHOD OF LISTING

Parts are listed in order according to the reference
number shown in the illustration, followed by a full
description based upon the “NOUN FIRST” method. That
is, the noun name of the part is listed first, then the
modifying description information which serves to
specifically identify the item. For example: PIN, Clevis.
Assemblies or groups are shown at the beginning of a
parts list and are identified with the letter references 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.

QUANTITIES (Units per Assy.)

The quantities of each part that are required to
complete the assembly. If quantity is (AR), it is
understood that the quantity may vary when machine
is equipped with certain options. Order quantity as
needed.

HARDWARE

Standard screws, washers, nuts, etc. are not identified
by a reference number. These parts are known as
COMMON HARDWARE items and appear indented
under the major items with which they are used. They
should be ordered separately as listed, since they are
not component parts of the pieces they attach to.

HOW TO ORDER REPAIR PARTS

1. Address all orders to your local SKYJACK dealer.

2. Specify model and serial number of the work
platform (found on the serial number plate).

3. List the quantity needed.

4. List the length needed (if bulk item).

5. List the part number and description as shown in
this manual for each item.

6. Show billing and shipping address and name of
individual if possible.

7. Suggest best routing.

CUSTOMER___________________________________________________________________

DEALER______________________________________________________________________

MODEL NUMBER ______________________________________________________________

SERIAL NUMBER ______________________________________________________________

DATE PURCHASED ____________________________________________________________

USE ONLY SKYJACK AUTHORIZED REPLACEMENT PARTS!

SJ-600 Series Engine Powered 112715

June 2001

SECTION 6, Page 1

6

List Of Illustrations

Description Page No.

Figure 6-1. Main Platform And Railings ..................................................................................... 4, 6

Figure 6-2. Roll-out Extension Platform Assembly ......................................................................... 8

Figure 6-3. Powered Extension Platform Assembly ...............................................................

Figure 6-4. Powered Extension Platform Control Box.................................................................. 14

Figure 6-5. Powered Extension Platform Cylinder Assembly ...................................................... 15

Figure 6-6. Powered Extension Platform Electrical Panel ............................................................ 16

Figure 6-7. Powered Extension Platform Hydraulic Hose Connections ....................................... 17

Figure 6-8A. Control Box Assembly (Serial # 33189 and Above) ........................................... 18, 20

Figure 6-8B. Control Box Assembly (Serial # 33188 and Below) ...................................... 22, 24, 26

Figure 6-9A. Drive/Steer Controller Assembly (Serial # 33189 and Above) .................................. 28

Figure 6-9B. Drive/Steer Controller Assembly (Serial # 33188 and Below) .................................. 30

Figure 6-10. Scissor Arm Assembly ......................................................................................... 32, 34

Figure 6-11. Lift Cylinder Assembly ............................................................................................... 38

Figure 6-12. Scissor Arm Hydraulic Hose Connections ................................................................. 41

Figure 6-13. Base, Axles, And Wheels........................................................................................... 42

Figure 6-14. Base Hydraulic Hose Connections (Serial # 32273 And Above) .............................. 44

Figure 6-15. Base Hydraulic Hose Connections (Serial # 30170 Through 32272) ....................... 46

Figure 6-16. Base Hydraulic Hose Connections (Serial # 30169 And Below) .............................. 48

Figure 6-17. Disc Brake Assembly ................................................................................................. 50

Figure 6-18. Disc Brake Cylinder Assembly .................................................................................. 53

Figure 6-19. Steer Cylinder Assembly ..................................................................................... 54, 55

Figure 6-20. Front Idle Axle Assembly (For 2-wheel Drive Machines) ........................................... 56

Figure 6-21. Front Axle Hardware Assembly (For 4-wheel Drive).................................................. 58

Figure 6-22. Front Axle Assembly (For 4-wheel Drive) ........................................................... 60, 62

Figure 6-23a. Center Drive And Drive Shafts (Haessler Drive Serial #1691 And Above) .............. 64

Figure 6-23b. Center Drive And Drive Shafts (Haessler Drive Serial #1690 And Below) ............... 66

Figure 6-24. Center Drive And Drive Shafts (Serial # 32272 And Below) ............................... 68, 70

Figure 6-25. Rear Drive Axle Assembly ......................................................................................... 72

Figure 6-26. Fuel Tank/Hydraulic Oil Tank Cabinet Assembly ....................................................... 74

Figure 6-27. Fuel Tank Assembly - Gasoline Engines ................................................................... 75

Figure 6-28. Fuel Tank Assembly - Diesel Engines ....................................................................... 76

10, 12

SECTION 6, Page 2

June 2001

SJ-600 Series Engine Powered 112715