Skyjack - Sjiii 3220-26 - Service

IMPORTANT
Verify if your machine is hydraulically proportional or motor

controlled.
Motor controller machines can be identified by the MC label

located on the side of the machine or on the platform control
box.
For motor controller-specific diagrams, schematics and

troubleshooting information, see Section 6 - Appendix A.
.
SERVICE MANUAL (ANSI/CSA)
DC ELECTRIC SCISSORS
MODELS SJIII 3220 SJIII 3226 SJIII 4620 SJIII 4626 SJIII 4632
157928AP January 17, 2022

This manual is based on Serial Number(s):
SJIII 3220 60 002 259 to 60 999 999

SJIII 3226 27 006 432 to 27 999 999
SJIII 46xx 70 007 139 to 70 999 999
Please refer to the website www.skyjack.com for older Serial Numbers.
Skyjack Service Center Parts & Service (Europe)

3451 Swenson Ave. St. Charles, Unit 1 Maes Y Clawdd
Illinois, 60174 USA Maesbury Road Industrial Estate
Phone: 630-262-0005 Oswestry, Shropshire SY10 8NN UK
Toll Free: 1-800-275-9522 Phone: +44-1691-676-235
Fax: 630-262-0006 Fax: +44-1691-676-238
Email: [email protected] E-mail: [email protected]
Parts (North America) Skyjack Brasil

Toll Free: 1-800-965-4626 Alameda Júpiter, 710
Toll Free Fax: 1-888-782-4825 Loteamento American Park Empresarial
E-mail: [email protected] Indaiatuba, SP, Brasil 13347-653
Tel: +55 19 3936 0132
Skyjack Australia Pty Ltd.
Unit 1, 35 Honeycomb Drive
Eastern Creek
New South Wales 2766
Australia
Tel: +61 (0) 2 9854 0700
Fax: +61 (0) 2 9854 0777
SERVICE AND MAINTENANCE
Table of Contents
Section 1 - Scheduled Maintenance

Table of Contents
Section 2 - Maintenance Tables and Diagrams

Table of Contents
Section 3 - System Component Identification and Schematics

Table of Contents
Section 4 - Troubleshooting Information

Table of Contents
Section 5 - Procedures
Table of Contents
Section 6 - Motor Controller

Table of Contents
SJIII DC Electric
SJIII 3220 SJIII 3226 SJIII 4620 SJIII 4626 SJIII 4632 Page 4
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Operator’s Responsibility for Maintenance Section 1 - Scheduled Maintenance
The Safety Alert Symbol identifies important

safety messages on aerial platforms, safety This Safety Alert Symbol means attention!
signs in manuals or elsewhere. When you
see this symbol, be alert to the possibility of Become alert! Your safety is involved.
personal injury or death. Follow the instructions
in the safety message.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.
IMPORTANT
IMPORTANT indicates a procedure) essential for safe operation and which,
if not followed, may result in a malfunction or damage to the aerial platform.
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Page 5 SJIII 3220 SJIII 3226 SJIII 4620 SJIII 4626 SJIII 4632
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1
Section 1 - SCHEDULED MAINTENANCE
Operator’s Responsibility for Maintenance

Aerial Platform and Mobile Elevating Work Platform Definition ..................................................................................8
Purpose of Equipment .................................................................................................................................................8
Use of Equipment ........................................................................................................................................................8
Manuals ........................................................................................................................................................................8
Service Policy and Warranty ........................................................................................................................................8
Operator Safety Reminders, Warnings and Precautions ............................................................................................8
Maintenance and Inspection Schedule .......................................................................................................................9
Owner’s Annual Inspection Record .............................................................................................................................9
Replacement Parts .......................................................................................................................................................9
Maintenance and Service Safety Tips .........................................................................................................................9
Hydraulic System & Component Maintenance and Repair ......................................................................................10
Maintenance Hints .....................................................................................................................................................11
Railing Maintenance and Repair................................................................................................................................11
Service and Maintenance

About this Section ......................................................................................................................................................12
Service Bulletins.........................................................................................................................................................12
Maintenance and Inspection .....................................................................................................................................12
Maintenance Instructions ...........................................................................................................................................12
Tables
Table 1.1 Owner’s Annual Inspection Record ..........................................................................................................13
Table 1.2 Pre-Delivery/Maintenance Inspection Checklist .......................................................................................14
Scheduled Maintenance
1.1 Scheduled Maintenance Inspections..............................................................................................................15
1.2 Function Tests..................................................................................................................................................25
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Notes
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Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Aerial Platform and Mobile Elevating Work Platform Definition

A mobile device that has a positionable platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK SJIII DC Electric series aerial platforms are designed to transport and raise personnel, tools and
materials to overhead work areas.
Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Work platform elevation and elevated driving
must only be done on a firm level surface.
Manuals
Operating
The operating manual is considered a fundamental part of the aerial platform. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the aerial platform at all times.
Service & Maintenance

The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.
All information in this manual should be read and understood before any attempt is made to service the machine.
The updated copy of the manuals are found on the company’s website: www.skyjack.com.
Service Policy and Warranty

SKYJACK warrants each new SJIII Series work platform to be free of defective parts and workmanship for the first
24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or
labor. Contact the SKYJACK Service Department for warranty statement extensions or exclusions.
Operator Safety Reminders, Warnings and Precautions

Operator safety is SKYJACK’s priority. The operator should comply with all applicable safety-related reminders,
warnings and precautions found in the Operating Manual. They should be read and understood completely before
operating the aerial platform.
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Maintenance and Inspection Schedule Maintenance and Service Safety Tips

The actual operating environment of the work platform Maintenance and repair should only be performed by
governs the use of the maintenance schedule. The personnel who are trained and qualified to service this
inspection points covered in Table 1.2 Pre-Delivery/ aerial platform.
Maintenance Inspection Checklist. Maintenance and
lnspection Checklist, indicates the areas of the aerial All maintenance and service procedures should be
platform to be maintained or inspected and at what performed in a well lighted and well ventilated area.
intervals the maintenance and inspections are to be
performed. Anyone operating or servicing this aerial platform
must read and completely understand all operating
Owner’s Annual Inspection Record instructions and safety hazards in this manual and
It is the responsibility of the owner to arrange quarterly operating manual.
and annual inspections of the aerial platform. Table 1.1.
Owner’s Annual lnspection Record is to be used for All tools, supports and lifting equipment to be used
recording the date of the inspection, owner’s name, must be of proper rated load and in good working order
and the person responsible for the inspection of the before any service work begins. Work area should be
work platform. kept clean and free of debris to avoid contaminating
components while servicing.
Replacement Parts
Use only original replacement parts. Parts such All service personnel must be familiar with employer
as batteries, wheels, railings, etc. with weight and and governmental regulations that apply to servicing
dimensions different from original parts will affect this type of equipment.
stability of the aerial platform and must not be used
without manufacturer’s consent. Keep sparks and flames away from all flammable or
combustible materials.
All replacement tires must be of the same size and load
rating as originally supplied tires; to maintain safety and Properly dispose of all waste material such as lubricants,
stability of aerial platform. rags, and old parts according to the relative law
provisions obtaining in the country.
Consult SKYJACK’s Service Department for optional
tires specifications and installation. Before attempting any repair work, turn Battery
Disconnect Switch to the “OFF” position.
WARNING Preventive maintenance is the easiest and least
Any unit that is damaged or not operating expensive type of maintenance.
properly must be immediately tagged and
removed from service until proper repairs
are completed.
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Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance
Hydraulic System & Component 6. When removing any hydraulic component, be sure
Maintenance and Repair to cap and tag all hydraulic lines involved. Also,
The following points should be kept in mind when plug the ports of the removed components.
working on the hydraulic system or any component:
NOTE
Samples of hydraulic oil should be drawn
WARNING
from the reservoir and tested annually.
Escaping fluid from a hydraulic pressure These samples should be taken when the
leak can damage your eyes, penetrate the oil is warmed through normal operation of
skin and cause serious injury. Use proper the system. The sample should be analyzed
personal protection at all times. by a qualified lubrication specialist to
determine if it is suitable for continued use.
1. Any structure has limits of strength and durability. Oil change intervals will depend on the
To prevent failure of structural parts of hydraulic care used in keeping the oil clean, and the
components, relief valves which limit pressure to operating conditions. Dirt and/or moisture
safe operating values are included in the hydraulic cotamination will dictate that the oil should
circuits. be changed more often. Under normal use
and operating conditions, the hydraulic oil
2. Tolerance of working parts in the hydraulic system should be changed every two years. Refer
is very close. Even small amounts of dirt or foreign to Table 1.2 Pre-Delivery/Maintenance
materials in the system can cause wear or damage Inspection Checklist of this manual.
to components, as well as general faulty operation
of the hydraulic system. Every precaution must 7. All hydraulic components must be dis-assembled
be taken to assure absolute cleanliness of the in spotlessly clean surroundings. During
hydraulic oil. disassembly, pay particular attention to the
identification of parts to assure proper reassembly.
3. Whenever there is a hydraulic system failure Clean all metal parts in a clean mineral oil solvent.
which gives reason to believe that there are metal Be sure to thoroughly clean all internal passages.
particles or foreign materials in the system, drain After the parts have been dried thoroughly, lay
and flush the entire system and replace the filter them on a clean, lint-free surface for inspection.
cartridges. A complete change of oil must be
made under these circumstances. 8. Replace all O-rings and seals when overhauling
any component. Lubricate all parts with clean
4. Whenever the hydraulic system is drained, check hydraulic oil before reassembly. Use small
the magnets in the hydraulic reservoir for metal amounts of petroleum jelly to hold O-rings in place
particles. If metal particles are present, flush the during assembly.
entire system and add a new change of oil. The
presence of metal particles also may indicate the 9. Be sure to replace any lost hydraulic oil when
possibility of imminent component failure. A very completing the installation of the repaired
small amount of fine particles is normal. component, and bleed any air from the system
when required.
5. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a 10. All hydraulic connections must be kept tight. A
funnel when necessary for filling the hydraulic oil loose connection in a pressure line will permit
reservoir, and fill the reservoir only through the the oil to leak out or air to be drawn into the
filter opening. The use of cloth to strain the oil system. Air in the system can cause damage
should be avoided to prevent lint from getting into to the components and noisy or erratic system
the system. operation.
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Maintenance Hints Railing Maintenance and Repair

Three simple maintenance procedures have the Skyjack MEWPs have been designed to ensure
greatest effect on the hydraulic system performance, compliance with the relevant design standards
efficiency and life. Yet, the very simplicity of them may applicable for that particular unit at the time of
be the reason they are so often overlooked. What are manufacture. As such, any repairs made to the
they? Simply these: guardrail or basket structure need to ensure this
compliance is not compromised and must return the
1. Change filters annually. The filters will need structure to its original condition.
to be changed more often depending on Any damage must be repaired by returning the railing
the operating conditions. Dirty, dusty, high assembly to its undamaged state. Damage includes,
moisture environments may cause the
but is not limited to, the items listed below:
hydraulic system to be contaminated more
quickly. ▪ bent/deformed guardrail sections
2. Maintain a sufficient quantity of clean hydraulic ▪ cracks or broken welds in railing sections
oil of the proper type and viscosity in the ▪ damaged pin connections
hydraulic reservoir.
3. Keep all connections tight. ▪ missing pins or broken pin lanyards
▪ missing railing hardware
▪ loose or missing parts
▪ additional holes in guardrail sections other than
those approved by Skyjack
Additionally, the guardrails must be properly
positioned and secured, and the entry gate/chain
must be in good working order.
The strength of the guardrail system, and therefore
its ability to provide fall protection for platform
occupants, depends upon the design being secure
and undamaged.
Skyjack railings are designed for modular
replacement, and Skyjack recommends replacement
of any damaged railing section. Skyjack-approved
replacement parts will meet this requirement.
To improve the resistance of extension railing
assemblies to damage, Skyjack approves
modification of the guardrail assembly by a qualified
person, in the manner outlined in the procedure titled:
5.1-5 Railing Modification to Enhance Resistance to
Damage.
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Section 1 - Scheduled Maintenance Service and Maintenance
About this Section Maintenance Instructions

This section contains the maintenance and inspection This manual consists of four schedules to be done for
schedule that is to be performed. maintaining on an aerial platform. Inspection schedule
frequency is shown below:
References are made to the procedures in Section 5
that outline detailed step-by-step instructions for checks Inspection Schedule
and replacements. PDI / Frequent B
Annual B+C
Additional *
Service Bulletins
Before performing any scheduled maintenance
B - Perform PDI prior to each delivery, or Frequent
inspection procedure, refer to service bulletins found in
Inspection every 3 months or 150 hours.
our web site: www.skyjackinc.com for updates related
C - Perform Scheduled Maintenance Inspections
to service and maintenance of this aerial platform.
every year.
* - Perform at time sensitive maintenance intervals.
Maintenance and Inspection
Death or injury can result if the aerial platform is not kept • Make copies of the maintenance and inspection
in good working order. Inspection and maintenance checklist to be used for each inspection.
should be performed by competent personnel who • Check the schedule on the checklist for the type of
are trained and qualified on mantenance of this aerial inspection to be performed.
platform. • Place a check in the appropriate box after each
inspection procedure is completed.
WARNING • Use the maintenance and inspection checklist and
step-by-step procedures in Section 1 to perform
Failure to perform each procedure as pre-
these inspections.
sented and scheduled may cause death,
• If any inspection receives a fail, tag and remove the
serious injury or substantial damage.
aerial platform from service.
• If any aerial platform component(s) has been
NOTE
repaired, an inspection must be performed again
Preventive maintenance is the easiest and
before removing the tag. Place a check in the repair
least expensive type of maintenance.
column.
• Unless otherwise specified, perform each
maintenance procedure with the aerial platform in Legend
the following configuration: P = Pass
F = Fail
- Aerial platform parked on a flat and level R = Repaired
surface N/A = Not applicable
- Disconnect the battery by turning the main
power disconnect switch to the “OFF” position.
• Repair any damaged or malfunction components

before operating aerial platform.
• Keep records on all inspections.
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Service and Maintenance Section 1 - Scheduled Maintenance
Table 1.1 Owner’s Annual Inspection Record
**
This decal is located on the scissor assembly. It must be completed after an annual inspection has been
completed. Do not use the aerial platform if an inspection has not been recorded in the last 13 months.
Pictorial Description
Inspection Date
Inspector Signature
**
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Pre-Delivery/Maintenance Inspection Checklist

Vertical Mast, SJIII, & Rough Terrain
Serial Number: Product Owner:
Model:
Hourmeter Reading: Product User:
Date/Time:
Use this form for Pre-Delivery Inspections (PDI) prior to each rental, lease or sale, or as a guide for all Frequent Inspections and Annual Inspections. Refer to the
applicable Operating and Service Manuals for inspection details (eg. Visual Inspection and Function Tests, Torque Specs., Engine Oil, Chain Inspection Intervals, etc.).
Inspection Type Schedule P - Pass

 PDI B B - Perform PDI prior to each delivery or Frequent Inspections every 3 months or 150 hrs. For further details refer to Service & Operating F - Fail
 Frequent B Manuals. R - Repaired
 Annual B+C C - Perform Scheduled Maintenance Inspections every year. For further details refer to Service & Operating Manuals. N/A - Not Applicable
Check the appropriate box as each item is inspected. If an item is found to be not acceptable, please describe the issue in the comments box provided.
Items for Inspection P F R N/A Items for Inspection P F R N/A

Refer to skyjack.com for the latest service bulletins. B Engine Control Console. Secure & no damage. B
Ensure Annual Inspection has been completed within the Engine Air Filter. No damage or missing parts. B, C
B
last 13 months. Engine Oil. Level between "L" and "H". Ensure oil change
B
Manuals & Required Documents. In storage box, in interval has not been exceeded.
B
good condition & legible. Radiator. Secure & no damage or missing parts. Check
B, C
Labels. In place, secure & legible. B coolant level.
Limit Switches. Secured & no obstructions or damage. B Muffler and Exhaust. Secure & no damage. B
Main Power Disconnect Switch. Cables secure & in Fuel Shut-off Valve. No damage or missing parts. B
B
working order. Fuel Tank. Filler cap is secure & no damage. B
Battery/ Hydraulic Tray. Latch is secure, & no missing Fuel Leaks. Tight fittings and hoses & no damage or
B B
parts. leaks.
Battery Charger. Secure, & no damage. B Propane Tank. Straps fastened to brackets & coupler
B
Battery. No damage, tight connections, fluid levels correct. tight.
B
Clean terminals and cable ends. Propane Tank Leaks. No leaks (refer to service manual
B
Manifolds. Tight fittings and hoses & no damage or leaks. for procedure).
B, C
Tight wire connections & no missing parts. Scissor Assembly. No deformation/damage. Pins secure.
B
Motor Controller. Secure & no damage. No loose Cables & wires routed with no damage.
B
connections. Mast Assembly. No damage or deformation. Lubricated B, C
Electrical Panel / Control Module. Secure & no Mast Chains. No damage or missing parts. B, C
B
damage. Tight wire connections and fasteners. Control Cables. No damage or missing parts. B, C
Hydraulic Tank. Filler cap secure & no damage or leaks. B Rollers. Secure & no obstructions, dirt, or damage/wear. B, C
Hydraulic Oil. Level at, or slightly above top mark. B, C Wear Pads. No damage/wear or missing parts. Fasteners
B, C
Hydraulic Components & Hoses. Secure & no damage tightened.
B
or leaks. Scissor Bumpers. Secure & no damage. B
Base Weldment. No deformation or cracks. B Sliders. Secure & no obstructions, dirt, or damage/wear. B
Base Control Switches. Switches to neutral position & no Maintenance Support. Secure & no damage. B
B
damage. Lift Cylinder(s). No damage or missing parts. Tight
B
Free-wheeling Valve Knob. Secure & no damage or fittings and hoses & no leaks.
B
missing parts. Scissor Pins. No damage/wear or missing parts. B
Ladder. Secure & no damage. B Platform Control Console. Switches to neutral position &
B
AC Power to Platform (Plug Cord Receptacle). No secure. No missing parts.
B
obstructions, dirt or damage. Raillings and Gate/Chain. Secure & no damage or
B
Pothole Protection Device. Check both sides for missing parts.
B
obstructions, dirt, or damage. Lanyard Attachment Anchorage. Attachment rings
B
Brakes. Secure & no damage or leaks. B, C secure & no damage.
Steer Cylinder Assembly. Secure & no damage, leaks or AC Outlet. No obstructions, dirt, or damage. B
B
missing parts. Powered Extension Control Console. Switches to
B
Wheel/Tire Assembly. Check all tires for damage, wear neutral position & secure. No missing parts.
B
& proper alignment. Lug nuts torqued as recommended. Extension Deck. Secure & no damage or missing parts.
B
Axles. Secure & no missing parts. Tight fittings and hoses Check fluid level (if applicable).
B
& no leaks. Outriggers. No damage or missing parts. B
Tie Rod. End studs locked & no damage. B Scissor Guards. Secure & no damage. B
Tilt (Load) Sensor. Secure & no damage. B Greasing Points. No obstructions, dirt, or damage. B, C
Emergency Lowering Access Rod. Secure & no Function Tests (Refer to your corresponding Serial #'s Operating  PASS
B
damage. Manual for information on running these tests.)  FAIL
Engine Tray. No damage or missing parts. B
Comments:
The undersigned confirms that all areas listed have been inspected, and any and all discrepancies have been brought to the attention of the owner. Furthermore, the
undersigned confirms that all discrepancies have been corrected prior to using this machine.
Owner: ________________________________________________ / _____________________________________________ / ______________________________________________________

Print Name Signature Date (DD/MM/YY)
User: _________________________________________________ / _____________________________________________ / _______________________________________________________

Print Name Signature Date (DD/MM/YY)
Note: Visit skyjack.com for a printable copy of this form. 167830AC
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High Speed
Limit Switch
Pothole Protection
Limit Switch
1.1 Scheduled Maintenance Hydraulic

Inspections Maintaining the hydraulic components is essential to
Begin the scheduled maintenance inspections by good performance and service life of the aerial platform.
checking each item in sequence for the conditions listed
in this section. Perform a visual inspection around the following
areas:
• hoses and fittings
WARNING
• all hydraulic cylinders
To avoid injury, do not operate an aerial • all hydraulic manifolds
platform until all malfunctions have been • the underside of the base
corrected. • ground area under the aerial platform
WARNING 1.1-1 Manuals (B)

Ensure a copy of operating manual and other important
To avoid possible injury, ensure aerial documents are enclosed in manual storage box.
platform power is off during your visual
and daily maintenance inspections. • Check to be sure manual storage box is
present and in good condition.
Electrical • Ensure manuals are legible and in good
Maintaining the electrical components is essential to condition.
good performance and service life of the aerial platform. • Always return manuals to the manual storage
box after use.
Inspect the following areas for chafed, corroded and
loose wires: 1.1-2 Labels (B)
• base to platform cables and wiring harness Refer to the labels section in the operating manual and
• battery tray wiring harnesses determine that all labels are in place and are legible.
• hydraulic/electrical wiring harnesses
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Back View
Ladder
AC Outlet
Receptacle
Free-wheeling
Valve
Base Main Power

Control Console Disconnect
Switch
Brakes
1.1-3 Limit Switches (B) • Free-wheeling Valve Knob (B)

Detecting limit switch malfunction is essential to safe - Ensure there are no loose or missing
aerial platform operation. Ensure limit switches are parts and there is no visible damage.
properly secured and movement is not obstructed.
• Brakes (B, C)
Visually inspect all limit switch located inside the scissor - Ensure there are no loose or missing
arms and the outrigger assemblies for the following: parts and there is no visible damage.
• broken or missing actuator arm - Ensure brake override is not engaged.
• missing fasteners
• loose wire connections • AC Outlet Receptacle (B)
- Ensure receptacle is free from dirt and
1.1-4 Entrance Side obstructions.
• Ladder (B)
• Main Power Disconnect Switch (B) - Ensure there are no loose or missing
- Turn main power disconnect switch to parts and there is no visible damage.
“ ” off position.
- Ensure all cables are secure and switch
is in proper working condition.
• Base Control Switches (B)
- Ensure there are no signs of visible
damage and all switches are in their
neutral positions.
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Fuse Box
Battery
Charger
Battery
Battery Tray
1.1-5 Battery Tray Side

WARNING
• Pothole Protection Device (B)
- Ensure mechanisms have no sign of Battery acid is extremely corrosive - Wear
visible damage and are free from dirt and proper eye and facial protection as well
obstructions. as appropriate protective clothing. If
contact occurs, immediately flush with
• Battery Tray (B) cold water and seek medical attention.
- Ensure tray latch is secure and in proper
working order. 1. Check battery case for damage.
• Battery Charger (B)
2. B - Frequent Inspection
(Compacts - Entrance Side)
Clean battery terminals and cable ends
- Ensure charger is secure and shows no
thoroughly with a terminal cleaning tool
visible damage.
or wire brush.
• Battery (B)
Proper battery condition is essential to 3. Ensure all battery connections are tight.
good performance and operational safety.
Improper fluid levels or damaged cables and 4. If applicable, check battery fluid level.
connections can result in component damage
and hazardous conditions. B - Frequent Inspection
If plates are not covered by at least 1/2”
WARNING (13 mm) of solution, add distilled or
demineralized water.
Explosion hazard. Keep flames
and sparks away. Do not smoke 5. B - Frequent Inspection
near batteries. Replace battery if damaged or incapable
of holding a lasting charge.
WARNING
Use original or manufacturer-ap-
proved parts and components for the
aerial platform.
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Wheel/Tire
Steer Cylinder
Wheel/Tire
Greasing Point
Wheel Motor Tie Rod
• Steer Cylinder Assembly (B) • Wheel/Tire Assembly (B)

- Ensure steer cylinder assembly is A small amount of wear is permitted. But if
properly secured and there are no loose any of the wear or damage meets the criteria
or missing parts. mentioned below, the tire should be replaced.
- Ensure there are no signs of hydraulic WARNING
leakage Do not use tires other than the tires
that Skyjack specifies for this MEWP.
• Tie Rod (B)
Do not mix different types of tires or
- Ensure there are no loose or missing
use tires that are not in good condi-
parts, tie rod end studs are locked and
tion. Only replace the tires with the
there is no visible damage.
same types that are approved by
• Greasing Points (B, C) Skyjack. The use of other tires can
- Ensure greasing points have no sign of make the MEWP less stable. If you do
visible damage and are free from dirt and not obey, there is a risk of death or
obstructions. serious injury.
B - Frequent Inspection
- Locate grease fittings and pump grease
as needed.
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The tire treads have

been removed from the
illustration for clarity.
Figure 02
▪ B - Frequent/periodic/pre-delivery inspection Do a check for cuts or missing chunks in the edges

Do a check for damage or wear on each tire and rim. and tread face of the tire. Refer to Figure 02.
▪ Look for damage or cracked welds on each rim. ▪ The cut or missing chunk must not extend
The rims should be round. more than 10 mm (3/8”) towards the centre of
the tire.
▪ Look for uneven or unusual wear on the tire.
▪ Each cut or chunk should not be larger than
▪ Look for flat spots on the tread face of the tire.
25 mm x 10 mm (1” x 3/8”), or deeper than
▪ The tire tread should be visible and not worn 20 mm (3/4”).
down completely. Refer to Figure 01.
▪ There should be no more than 2 cuts or
chunks in each 1/4 section of the tire. There
must be no more than 6 cuts or chunks in total
in the tire.
▪ There should be no embedded debris.
Do a check of the wheel components and mounts.

▪ Make sure the wheels are correctly aligned
vertically and horizontally.
▪ Make sure the wheel motors have no loose or
missing parts and there is no visible damage.
▪ C - Annual inspection
▪ Make sure the castle nuts and/or wheel nuts
are in position and are tight.
Figure 01
▪ Make sure the cotter pins are correctly
installed.
▪ If the cotter pin is not installed, refer to Table
2.4 Torque Specifications for proper torque
information.
▪ See 5.2-5 Wheel Replacement and
Torquing Procedure for procedures.
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Emergency Lowering
Access Rod
Hydraulic Tank Hydraulic/Electric Main Manifold

Electrical Panel
Tray
1.1-6 Hydraulic/Electric Tray Side • Electrical Panel (B)

- Ensure tray latch is secure and in proper - Ensure panel is properly secured and
working order. there is no visible damage.
• Pothole Protection Device (B) - Ensure there are no loose wire
- Ensure mechanisms have no sign of connections or missing fasteners.
visible damage and are free from dirt and
obstructions. • Hydraulic Manifolds (B, C)
- Ensure all fittings and hoses are properly
• Hydraulic Tank (B) tightened and there is no evidence of
- Ensure hydraulic filler cap is secure. hydraulic leakage.
- Ensure tank shows no visible damage - Ensure there are no loose wire
and no evidence of hydraulic leakage. connections or missing fasteners.
• Hydraulic Oil (B, C) • Tilt Sensor (If Equipped) (B)
- Ensure platform is fully lowered, and then - Ensure tilt sensor is properly secured and
visually inspect the sight gauge located there is no visible damage.
on the side of the hydraulic oil tank.
• Load Sensor (If Equipped) (B)
- The hydraulic oil level should be at or - Ensure load sensor is properly secured
slightly above the top mark of the sight and there is no visible damage.
glass.
• Emergency Lowering Access Rod
C - Annual Inspection (If Equipped) (B)
- Refer to Section 1 - Hydraulic System - Ensure rod is properly secured and there
& Component Maintenance and Repair is no visible damage.
• Hydraulic Pump and Motor (B)
- Ensure there are no loose or missing
parts and there is no visible damage.
SJIII DC Electric
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AF
Powered Extension
Platform Control Console
Control Console
Platform
Railing
Manual Storage
Box Lanyard
Attachment
Platform Anchorage
Assembly
1.1-7 Platform Assembly • Platform Control Console (B)

- Ensure all switches and controller are
WARNING returned to neutral and are properly
secured.
Ensure that you maintain three points of
contact to mount/dismount platform. - Ensure there are no loose or missing
parts and there is no visible damage.
1. Use the ladder of aerial platform to access
• Powered Extension Control Console
platform.
(If Equipped) (B)
- Ensure all switches are returned to
2. Close the gate/Secure chain.
neutral and are properly secured.
- Ensure there are no loose or missing - Ensure there are no loose or missing
parts and there is no visible damage. parts and there is no visible damage.
- Ensure all fasteners are securely in place.
WARNING
- Ensure all railings are properly positioned
Ensure that you maintain three points
and secured.
of contact to mount/dismount platform.
- Ensure gate is in good working order.
3. Use the ladder to dismount from platform.
• Lanyard Attachment Anchorage (B)
- Ensure attachment rings are secure and
no visible damage.
• AC Outlet on Platform (B)
- Ensure outlet has no visible damage and
free from dirt or obstructions.
SJIII DC Electric
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Maintenance
Support
Lift Cylinder
Scissor Bumper
Scissor Assembly
Roller
1.1-8 Lifting Mechanism • Scissor Pin Inspection (B)

- Complete a structural inspection of
1. Raise the platform until there is adequate clearance the scissor pin connections, looking
to swing down the maintenance support. for indicators of pin and/or scissor arm
damage. These indicators include, but
• Maintenance Support (B) are not limited to:
- Ensure maintenance support is properly
secured and shows no visible damage. - Noise coming from binding/seized pins
• Scissor Assembly (B) - Rust forming near pin joint

- Ensure scissor assembly shows no visible - Cracks in welds or in surrounding metal
damage and no signs of deformation in
weldments. - Evidence of metal dust or shavings from
wearing components
- Ensure all pins are properly secured.
- Broken/missing pin retainer bolts
- Ensure cables and wires are properly
routed and shows no signs of wear and/ - Broken/missing pin retainers
or physical damage. - Rotated pin
• Scissor Bumpers (B) - Elongation/enlargement of pin hole
- Ensure bumpers are secure and shows
no sign of visible damage.
• Rollers (B)
- Ensure rollers are secure and there is no
visible damage.
- Ensure rollers’ path of travel are free from
dirt and obstructions.
SJIII DC Electric
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AF
Maintenance
Support
Lift Cylinder
Scissor Bumper
Scissor Assembly
Roller
Examples of pivot pin connections with no

damage:
Pin retainer bolts
- No rust in place
- Pin has not rotated

- Area is clear of dust/metal shaving
- Pin retainer/retainer bolts are in place
Center pin pivot - Outer
Pin retainer in place
Center pin pivot - Middle
No rust. Pin has

not rotated. Area is
clean of dust/metal
shavings
Center pin pivot - Inner
SJIII DC Electric
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AF
Maintenance
Support
Lift Cylinder
Scissor Bumper
Scissor Assembly
Roller
Examples of damaged pin connections: the scissor arms, the pins and bushings can be
replaced with new components.
Broken retainer
bolt WARNING
Any units showing the above listed and/
or depicted signs of damage should be
immediately removed from service and
Rust is evident repaired by a qualified technician.
around pin
Any units with structural damage to any
pin connection or scissor arm must be
Retainer bolt hole out of line immediately removed from service and
indicates pin has rotated repaired by a qualified technician. Contact
Skyjack Service for direction on how to
repair the unit.
Rust around pin
boss • Lift Cylinder(s) (B)
- Ensure each lift cylinder is properly
Thrust washer secured, there are no loose or missing
parts and there is no evidence of damage.
Pin boss is broken - Ensure all fittings and hoses are properly
out of the scissor arm tightened and there is no evidence of
hydraulic leakage.
2. Raise the platform until there is adequate
Stress cracks
clearance to swing up the maintenance support
Scissor end pin connections showing symptoms into storage bracket.
of damage must be inspected after removing the
applicable pins and bushings. The scissor bore 3. Fully lower the platform.
should also be inspected at this time for any signs
of damage, specifically elongation or ovality of the
hole. Provided there is no structural damage to
SJIII DC Electric
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Function Tests Section 1 - Scheduled Maintenance
1.2 Function Tests

Function tests are designed to discover any malfunctions
before aerial platform is put into service. The operator
must understand and follow step-by-step instructions
to test all aerial platform functions.
WARNING
Never use a malfunctioning aerial
platform. If malfunctions are discovered,
aerial platform must be tagged and
placed out of service. Repairs to aerial
platform may only be made by a qualified
service technician.
After repairs are completed, perform a pre-operation

inspection and a series of function tests again before
putting aerial platform into service.
Prior to performing function tests, be sure to read and

understand Start Operation section of the operating
manual.
For function tests that are to be run, please refer

to the operating manual that corresponds to the
correct serial number. Here, there will be detailed
instructions for which tests to perform, as well as
how to properly and successfully perform them.
SJIII DC Electric
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Section 2 - MAINTENANCE TABLES AND DIAGRAMS
Tables
Table 2.1 Specifications and Features ......................................................................................................................27
Table 2.1 Specifications and Features (Continued) .................................................................................................28
Table 2.2 Floor Loading Pressure .............................................................................................................................29
Table 2.3
Table 2.4
Table 2.5
Table 2.6
Maximum Platform Capacities (Evenly Distributed) .................................................................................31
Torque Specifications ................................................................................................................................32
Torque Specifications for Fasteners (Imperial) .........................................................................................33
Torque Specifications for Fasteners (Metric) ............................................................................................34
2
Table 2.7 Torque Specifications for Hydraulic Couplings & Hoses..........................................................................35
SJIII DC Electric
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Service and Maintenance Section 2 - Maintenance Tables and Diagrams
Table 2.1 Specifications and Features

MODEL 3220 3226
3510 lb. 4135 lb.
Weight *
1592 kg 1876 kg
32" 32"
Overall width
0.81 m 0.81 m
91" 91"
Overall length
2.3 m 2.3 m
28” x 83” 28” x 83”
Platform Size (inside)
0.71 x 2.1 m 0.71 x 2.1 m
Height
26’ 32’
Working Height
8.1 m 9.9 m
20’ 26’
Platform Elevated Height
6.1 m 7.9 m
38" 45"
Stowed Platform Height
0.97 m 1.1 m
82" 89"
Stowed Height (Railings Up)
2.1 m 2.3 m
Drive Height FULL
Standard Operating Time

Lift Time (No Load) 27 s 47 s
Lower Time (No Load) 41 s 63 s
Lift Time (Rated Load) 33 s 51 s
Lower Time (Rated Load) 29 s 46 s
Chassis
1.9 mph 2.4 mph
Normal Drive Speed
3.0 km/h 3.8 km/h
0.64 mph 0.64 mph
Elevated Drive Speed
1.0 km/h 1.0 km/h
0.95 mph 1.2 mph
High Torque Drive Speed
1.5 km/h 1.9 km/h
Gradeability (Ramp Angle) 25%
16 x 5 x 12
Tires
Solid Rubber
Hydraulic Oil
ATF Dexron III
Type
Shell Naturelle HF-E 32
5.8 gal.
Tank Capacity
24L
1059AE_ANSI_Specs_32XX
* Weight with standard 3' (0.9 m) or 4' (1.2 m) extension platform.
Refer to nameplate for aerial platforms with 5' (1.5 m) or 6' (1.8 m) extension platform.
SJIII DC Electric
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Section 2 - Maintenance Tables and Diagrams Service and Maintenance
Table 2.1 Specifications and Features (Continued)
MODEL 4620 4626 4632

4100 lb. 4700 lb. 5075 lb.
Weight *
1860 kg 2132 kg 2302 kg
46"
Overall width
1.17 m
91"
Overall length
2.31 m
42" x 84"
Platform Size (inside)
1.07 m x 2.13 m
Height
26' 32' 38'
Working Height
7.92 m 9.75 m 11.6 m
20' 26' 32'
Platform Elevated Height
6.1 m 7.9 m 9.8 m
38" 45" 48.5"
Stowed Platform Height
0.97 m 1.14 m 1.23 m
77.25" 84.5" 88"
Stowed Height Railings Up
1.96 m 2.15 m 2.24 m
Drive Height FULL
Standard Operating Time

Lift Time (No Load) 24 s 48 s 50 s
Lower Time (No Load) 48 s 45 s 62 s
Lift Time (Rated Load) 32 s 49 s 54 s
Lower Time (Rated Load) 32 s 37 s 57 s
Chassis
2.20 mph
Normal Drive Speed
3.5 km/h
0.56 mph
Elevated Drive Speed
0.90 km/h
1.20 mph
High Torque Drive Speed
1.9 km/h
Gradeability 25%
16 x 5 x 12
Tires
Solid Rubber
Hydraulic Oil
ATF Dexron III
Type
Shell Naturelle HF-E 32
5.8 gal.
Tank Capacity
24 L
1059AD_ANSI_Specs_46XX
* Weight with standard 3' (0.9 m) or 4' (1.2 m) extension platform.
Refer to serial nameplate for specific applications.
1
Fill hardness: 55 Durometer
SJIII DC Electric
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Table 2.2 Floor Loading Pressure
Total Aerial Total Aerial Platform Load

Platform Weight Wheel LCP** OUP**
MODEL
KPa KPa
lb. kg lb. kg psi psf
(kN/m2) (kN/m2)
min* 3400 1542 1396 633 110 758.5 175 8.5
3220
max* 4299 1950 1936 878 130 896.5 245 11.5
min* 4100 1860 1644 746 120 827.5 210 10.0

3226
max* 4610 2091 1844 836 130 896.5 235 11.5
min* 4100 1860 1640 744 191 1316.9 146 7.0

4620
max* 5620 2549 2251 1021 222 1530.6 199 9.5
min* 4700 2132 1880 853 206 1420.3 168 8.0

4626
max* 5920 2685 2300 1040 224 1544.4 210 10.1
min* 5075 2302 2030 921 208 1434.1 180 8.6

4632
max* 5775 2620 2310 1048 223 1537.5 205 9.8
1059_ANSI_FL_T4.4AE_AA
* min - Total aerial platform weight with no options

max - Aerial platform weight + all options + full capacity
LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the
** areas in direct contact with the floor. The floor covering (tile, carpet, etc.) must be able to withstand more
that the indicated values above.
OUP - Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the
whole surface directly underneath it. The structure of the operating surface (beams, etc.) must be able to
withstand more than the indicated values above.
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is
generally determined by the engineer or architect for that particular structure.
SJIII DC Electric
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Floor Loading Pressure
Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP):
Foot Print Area = Length x Width Base Area = Length x Width
Weight of Aerial Platform + Capacity Weight of Aerial Platform + Capacity

LCP = 0.4 X OUP =
Foot Print Area Base Area
Width Width
Length
Length
WARNING
Intermixing tires of different types or using tires of types other than those originally supplied with
this equipment can adversely affect stability. Therefore, replace tires only with the exact original
Skyjack-approved type. Failure to operate with matched approved tires in good condition may
result in death or serious injury.
SJIII DC Electric
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Table 2.3 Maximum Platform Capacities (Evenly Distributed)
Manual Extension Platform Powered Extension Platform Maximum Tilt

MODEL Wind Cutout
Total Capacity Extension Capacity Total Capacity Extension Capacity Speed Setting
900 lb. 300 lb. 800 lb. 300 lb. 28 mph
3220 2 Persons 1 Person 2 Persons 1 Person 1.5 x 3.5
408 kg 136 kg 363 kg 136 kg 12.5 m/s
500 lb. 250 lb. 28 mph

3226 2 Persons 1 Person N/A 1.5 x 3.5
227 kg 113 kg 12.5 m/s
1300 lb. 250 lb. 28 mph

590 kg 113 kg 12.5 m/s
1000 lb. 300 lb. 1000 lb. 300 lb. 28 mph

4626 3 Persons 1 Person 3 Persons 1 Person 2.5 x 4.5
454 kg 136 kg 454 kg 136 kg 12.5 m/s
700 lb. 250 lb. 28 mph

318 kg 113 kg 12.5 m/s
1059_ANSI_MPC_T4.5AC_AA
NOTE: Overall Capacity - Occupants and materials not to exceed rated load.
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Table 2.4 Torque Specifications
Base Torque Torque

Directional Valve Mounting Bolts 2.3-2.7 lb-ft (28-32 lb-in) 3.2 – 3.6 Nm
Wheel Mounting Bolts 90 lb-ft 122 Nm
Rear Wheel Castle Nut 150 lb-ft* 203 Nm*
Rear Wheel Motor Nut 280 lb-ft 380 Nm
Front Wheel Castle Nut Finger tight until snug*
Hydraulic Motor Mounting Bolts 85 lb-ft 115 Nm
*See section 5 for the full torque procedure.
Cartridge Coils
Valve Size 8 38 58 10 12 16 All coil sizes
Torque (lb-ft) max 20 20 20 25 35 50 4 to 5
Torque (lb-in) max 240 240 240 300 420 600 48 to 60
Torque (Nm) max 27.12 27.12 27.12 33.9 47.46 67.8 5.42 to 6.78
SAE Plugs
Port Size 2 4 5 6 8 10 12 16
Torque (lb-ft) max 3 10 15 15 25 25 30 35
Torque (lb-in) max 36 120 180 180 300 300 360 420
Torque (Nm) max 4.07 13.56 20.34 20.34 33.9 33.9 40.68 47.46
Newton-meter = Nm Pound-foot = lb-ft Pound-inch = lb-in

Additional Torque Specifications may be found in Section 3.
60655AE
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Table 2.5 Torque Specifications for Fasteners (Imperial)
IMPERIAL BOLT TORQUE CHART IMPERIAL BOLT TORQUE CHART
SAE 2 SAE 5 SAE 8 Torque SAE 2 SAE 5 SAE 8
Size Torque Type Size
Dry Lubed Dry Lubed Dry Lubed Type Dry Lubed Dry Lubed Dry Lubed
(in‐lb) (5) (4) (8) (6) (12) (9) ft‐lb 70 55 110 80 150 110
4-40 9/16-12
Nm 0.6 0.5 0.9 0.7 1.4 1.0 Nm 95 75 149 108 203 149
(in‐lb) (6) (5) (9) (7) (13) (10) ft‐lb 80 60 120 90 170 130
4-48 9/16-18
Nm 0.7 0.6 1.0 0.8 1.5 1.1 Nm 108 81 163 122 230 176
(in‐lb) (10) (8) (16) (12) (23) (17) ft‐lb 100 75 150 110 220 170
6-32 5/8-11
Nm 1.1 0.9 1.8 1.4 2.6 1.9 Nm 136 102 203 149 298 230
(in‐lb) (12) (9) (18) (13) (25) (19) ft‐lb 110 85 180 130 240 180
6-40 5/8-18
Nm 1.4 1.0 2.0 1.5 2.8 2.1 Nm 149 115 244 176 325 244
(in‐lb) (19) (14) (30) (22) (41) (31) ft‐lb 175 130 260 200 380 280
8-32 3/4-10
Nm 2.1 1.6 3.4 2.5 4.6 3.5 Nm 237 176 353 271 515 380
(in‐lb) (20) (15) (31) (23) (43) (32) ft‐lb 200 150 300 220 420 320
8-36 3/4-16
Nm 2.3 1.7 3.5 2.6 4.9 3.6 Nm 271 203 407 298 569 434
(in‐lb) (27) (21) (43) (32) (60) (45) ft‐lb 170 125 430 320 600 460
10-24 7/8-9
Nm 3.1 2.4 4.9 3.6 6.8 5.1 Nm 230 169 583 434 813 624
(in‐lb) (31) (23) (49) (36) (68) (51) ft‐lb 180 140 470 360 660 500
10-32 7/8-14
Nm 3.5 2.6 5.5 4.1 7.7 5.8 Nm 244 190 637 488 895 678
(in‐lb) / ft‐lb (66) (50) 8 (75) 12 9 ft‐lb 250 190 640 480 900 680
1/4-20 1-8
Nm 7.5 5.6 11 8.5 16 12 Nm 339 258 868 651 1220 922
(in‐lb) / ft‐lb (76) (56) 10 (86) 14 10 ft‐lb 270 210 710 530 1000 740
1/4-28 1-12
Nm 8.6 6.3 14 9.7 19 14 Nm 366 285 963 719 1356 1003
ft‐lb 11 8 17 13 25 18 ft‐lb 280 210 730 540 1020 760
5/16-18 1-14
Nm 15 11 23 18 34 24 Nm 380 285 990 732 1383 1030
ft‐lb 12 9 19 14 25 20 ft‐lb 350 270 800 600 1280 960
5/16-24 1 1/8-7
Nm 16 12 26 19 34 27 Nm 475 366 1085 813 1735 1302
ft‐lb 20 15 30 23 45 35 ft‐lb 400 300 880 660 1440 1080
3/8-16 1 1/8-12
Nm 27 20 41 31 61 47 Nm 542 407 1193 895 1952 1464
ft‐lb 23 17 35 25 50 35 ft‐lb 500 380 1120 840 1820 1360
3/8-24 1 1/4-7
Nm 31 23 47 34 68 47 Nm 678 515 1519 1139 2468 1844
ft‐lb 32 24 50 35 70 55 ft‐lb 550 420 1240 920 2000 1500
7/16-14 1 1/4‐12
Nm 43 33 68 47 95 75 Nm 746 569 1681 1247 2712 2034
ft‐lb 36 27 55 40 80 60 ft‐lb 670 490 1460 1100 2380 1780
7/16-20 1 3/8‐6
Nm 49 37 75 54 108 81 Nm 908 664 1979 1491 3227 2413
ft‐lb 50 35 75 55 110 80 ft‐lb 750 560 1680 1260 2720 2040
1/2-13 1 3/8‐12
Nm 68 47 102 75 149 108 Nm 1017 759 2278 1708 3688 2766
ft‐lb 55 40 90 65 120 90 ft‐lb 870 650 1940 1460 3160 2360
1/2-20 1 1/2‐6
Nm 75 54 122 88 163 122 Nm 1180 881 2630 1979 4284 3200
Inch‐Pound Force = in‐lb Foot‐Pound Force = ft‐lb Newton‐Meter = Nm ft‐lb 980 730 2200 1640 3560 2660
1 1/2‐12
NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite. Nm 1329 990 2983 2224 4827 3606
SJIII DC Electric
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Table 2.6 Torque Specifications for Fasteners (Metric)
METRIC BOLT TORQUE CHART
Torque 8.8 10.9
Size
Units Dry Lubed Dry Lubed
(in‐lb) (54) (41) (78) (59)
M5 x 0.80
Nm 6.1 4.6 8.8 6.7
(in‐lb) (92) (69) (133) (99)
M6 x 1.00
Nm 10.4 7.8 15 11.2
(in‐lb) (156) (116) (222) (167)
M7 x 1.00
Nm 17.6 13.1 25.1 18.9
(in‐lb) (225) (169) (333) (242)
M8 x 1.25
Nm 25.4 19.1 37.6 27.3
ft‐lb 37 28 53 40
M10 x 1.50
Nm 50 38 72 54
ft‐lb 65 49 93 69
M12 x 1.75
Nm 88 66 126 94
ft‐lb 104 78 148 111
M14 x 2.00
Nm 141 106 201 150
ft‐lb 161 121 230 172
M16 x 2.00
Nm 218 164 312 233
ft‐lb 222 167 318 238
M18 x 2.50
Nm 301 226 431 323
ft‐lb 314 235 449 337
M20 x 2.50
Nm 426 319 609 457
ft‐lb 428 321 613 460
M22 x 2.50
Nm 580 435 831 624
ft‐lb 543 407 776 582
M24 x 3.00
Nm 736 552 1052 789
ft‐lb 796 597 1139 854
M27 x 3.00
Nm 1079 809 1544 1158
ft‐lb 1079 809 1543 1158
M30 x 3.50
Nm 1463 1097 2092 1570
ft‐lb 1468 1101 2101 1576
M33 x 3.50
Nm 1990 1493 2849 2137
ft‐lb 1886 1415 2699 2024
M36 x 4.00
Nm 2557 1918 3659 2744
Inch‐Pound Force = in‐lb Foot‐Pound Force = ft‐lb Newton‐Meter = Nm
NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite.
SJIII DC Electric
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Table 2.7 Torque Specifications for Hydraulic Couplings & Hoses
HYDRAULIC COUPLING TORQUE CHART
O‐Ring Port Connectors
Steel Ports Non‐ferrous Ports
SAE Size
ft‐lb Nm ft‐lb Nm
4 14‐16 20‐22 9‐10 12‐13
6 24‐26 33‐35 15‐16 20‐21
8 50‐60 68‐78 30‐36 41‐47
10 72‐80 98‐110 43‐48 60‐66
12 125‐135 170‐183 75‐81 102‐110
16 200‐220 270‐300 120‐132 162‐180
20 210‐280 285‐380 126‐168 171‐228
24 270‐360 370‐490 162‐216 222‐294
32 ‐ ‐ ‐ ‐
HOSE END TORQUE CHART HOSE END TORQUE CHART
for JIC for Flat‐Face O‐Ring Seal (Steel)
Size Steel Brass Size Torque Specification
ft‐lb Nm ft‐lb Nm ft‐lb Nm
Dash Frac. Dash Frac.
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
‐4 1/4" 10 11 13 15 5 6 6.75 9 ‐4 1/4" 10 12 14 16
‐6 3/8" 17 19 23 26 12 15 17 20 ‐6 3/8" 18 20 24 27
‐8 1/2" 34 38 47 52 20 24 27.66 33 ‐8 1/2" 32 40 43 54
‐10 5/8" 50 56 69 76 34 40 46.33 55 ‐10 5/8" 46 56 60 75
‐12 3/4" 70 78 96 106 53 60 72.33 82 ‐12 3/4" 65 80 90 110
‐16 1" 94 104 127 141 74 82 100.5 111 ‐14 1" 65 80 90 110
‐20 1 1/4" 124 138 169 188 75 83 101.5 113 ‐16 1 1/4" 92 105 125 240
‐24 1 1/2 156 173 212 235 79 87 107 118 ‐20 1 1/2 125 140 170 190
‐32 2" 219 243 296 329 158 175 214 237 ‐24 2" 150 180 200 245
SJIII DC Electric
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Section 3 - SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Charts
3.1 Electrical Symbol Chart ......................................................................................................................................38
3.2 Hydraulic Symbol Chart ......................................................................................................................................39
3.3 Wire Number and Color Code ............................................................................................................................40
3.4 AC Cord Color Code ...........................................................................................................................................41
Parts List
3.5 Hydraulic Schematic Parts List ...........................................................................................................................42
3.5 Hydraulic Schematic Parts List (Continued).......................................................................................................43
3.6 Electrical Components Parts List ........................................................................................................................44
3.6a Electrical Component Parts List (Continued) ...................................................................................................45
3.6b Electrical Component Parts List (Continued) ...................................................................................................46
3.7a Hydraulic Manifold and Port Identifications ......................................................................................................47
3.7b Hydraulic Manifold and Port Identifications......................................................................................................48
Diagrams and Schematics

3.8a Platform Control Console Diagram...................................................................................................................49
3.8b Platform Control Console Diagram - Long Cable Option ................................................................................50
3.9a Powerdeck Platform Modification Diagram ......................................................................................................51
3.9b Powerdeck Platform Modification Diagram ......................................................................................................52
3.10a Powered Extension Platform Control Console and Harness .........................................................................53
3
3.10b Powered Extension Platform Control Console ...............................................................................................54
3.11a Base Control Console Diagram (Including EE-Rated) ...................................................................................55
3.11b Base Control Console Diagram (Non EE-Rated Only)...................................................................................56
3.12a Scissor Arm Control Cable Diagram ..............................................................................................................57
3.12b Scissor Arm Control Cable Diagram (EE-Rated) ...........................................................................................58
3.13 Limit Switch Assembly Wire Diagrams .............................................................................................................59
3.14 Harness Wire Diagrams ....................................................................................................................................60
3.15 Telematics Harness - ZTR .................................................................................................................................61
3.16a Hydraulic Schematic (Models 322x) ...............................................................................................................62
3.16b Hydraulic Schematic (Models 322x) ..............................................................................................................63
3.17a Hydraulic Schematic (Models 46xx) ...............................................................................................................64
3.17b Hydraulic Schematic (Models 46xx) ...............................................................................................................65
3.17c Hydraulic Schematic (Models 46xx) ...............................................................................................................66
3.18 Main Manifold Harness .....................................................................................................................................67
3.19 Main Manifold Harness (EE-Rated) ..................................................................................................................68
3.20 Elevate Telematics Harness ..............................................................................................................................69
3.21a Electrical Panel Diagram .................................................................................................................................70
3.21b Electrical Panel Diagram.................................................................................................................................71
3.22a Electrical Panel Diagram with Power Deck.....................................................................................................72
3.22b Electrical Panel Diagram with Power Deck ....................................................................................................73
3.23a Electrical Panel Diagram (EE Rated) ..............................................................................................................74
3.23b Electrical Panel Diagram (EE Rated) ..............................................................................................................75
3.23c Electrical Panel Diagram (EE Rated) ..............................................................................................................76
3.24a Electrical Panel Diagram (EE Rated) with Power Deck ..................................................................................77
3.24b Electrical Panel Diagram (EE Rated) with Power Deck ..................................................................................78
3.24c Electrical Panel Diagram (EE Rated) with Power Deck ..................................................................................79
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3.25a Electrical Panel Diagram - Inverter .................................................................................................................80
3.25b Electrical Panel Diagram - Inverter .................................................................................................................81
3.26a Electrical Panel Diagram with Power Deck - Inverter .....................................................................................82
3.26b Electrical Panel Diagram with Power Deck - Inverter .....................................................................................83
3.27 Horn/Tilt Switch/Flashing Light Diagram ..........................................................................................................84
3.28a Electrical Schematic (ANSI/CSA except EE rated - Equipped with no options) ...........................................85
3.28b Electrical Schematic (ANSI/CSA except EE rated - Equipped with no options) ...........................................86
3.29a Electrical Schematic (EE Rated - Equipped with no options) ........................................................................87
3.29b Electrical Schematic (EE Rated - Equipped with no options)........................................................................88
3.29c Electrical Schematic (EE Rated - Equipped with no options) ........................................................................89
3.30a Electrical Schematic (All Models - Equipped with all options) .......................................................................90
3.30b Electrical Schematic (All Models - Equipped with all options).......................................................................91
3.30c Electrical Schematic (All Models - Equipped with all options) .......................................................................92
3.30d Electrical Schematic (All Models - Equipped with all options) - EE-Rated ....................................................93
SJIII DC Electric
157928
Section 3 - System Component Identification and Schematics Service and Maintenance
3.1 Electrical Symbol Chart
CIRCUITS CROSSING LIMIT SWITCH

NO CONNECTION HOURMETER KEY SWITCH
LIMIT SWITCH
CIRCUITS LIGHT FOOT SWITCH
CONNECTED CLOSED
LIMIT SWITCH
HYDRAULIC
BATTERY TOGGLE SWITCH
VALVE COIL
PROPORTIONAL LIMIT SWITCH

GROUND HYDRAULIC PUSH BUTTON
VALVE COIL
SILICON
ELECTRIC CONTROLLED
FUSE ROTARY SWITCH
MOTOR RECTIFIER
CIRCUIT PROXIMITY
HORN LIMIT SWITCH
BREAKER SWITCH
EMERGENCY CAM OPERATED PNP

VOLT METER STOP BUTTON LIMIT SWITCH TRANSISTOR
CAPACITOR RESISTOR NPN

TILT SWITCH
TRANSISTOR
SINGLE POLE
POTENTIOMETER LEVEL SENSOR SINGLE THROWN VACUUM
RELAY SWITCH
SINGLE POLE DOUBLE POLE DOUBLE POLE TEMPERATURE

DOUBLE THROW SINGLE THROW DOUBLE THROW SWITCH
RELAY RELAY RELAY
TRIPLE POLE
DOUBLE THROW DIODE RHEOSTAT
RELAY
SJIII DC Electric
157928
Service and Maintenance Section 3 - System Component Identification and Schematics
3.2 Hydraulic Symbol Chart
VARIABLE
LINE CROSSING DISPLACEMENT SHUTTLE VALVE VELOCITY FUSE
PUMP
ACCUMULATOR, SINGLE ACTING

LINE JOINED HAND PUMP GAS CHARGED CYLINDER
HYDRAULIC CUSHION DOUBLE ACTING

TANK RELIEF VALVE CYLINDER CYLINDER
DOUBLE ACTING
HYDRAULIC PRESSURE
PRESSURE DOUBLE
FILTER WITH REDUCING
SWITCH RODDED
BYPASS VALVE
CYLINDER
ELECTRIC MOTION SPRING APPLIED

MOTOR FIXED ORIFICE CONTROL VALVE HYDRAULIC
RELEASED
BRAKE
ADJUSTABLE FLOW DIVIDER BRAKE

ENGINE FLOW CONTROL COMBINER CYLINDER
FIXED
DISPLACEMENT COUNTER ROTARY
CHECK VALVE BALANCE VALVE ACTUATOR
PUMP
VARIABLE BI DIRECTIONAL
DISPLACEMENT HYDRAULIC
OIL COOLER VALVE COIL
HYDRAULIC MOTOR MOTOR
SERIES TWO POSITION THREE POSITION

PARALLEL TWO WAY FOUR WAY
HYDRAULIC TWO POSITION CLOSED CENTER
NORMALLY
MOTOR THREE WAY VALVE OPEN PORT
CLOSED VALVE
TWO POSITION THREE POSITION

TWO WAY TWO POSITION FOUR WAY
NORMALLY THREE WAY VALVE CLOSED CENTER
OPEN VALVE CLOSED PORT
PRESSURE PILOT LINES Dashed

MAIN LINES Solid
TRANSDUCER
SERVO
SJIII DC Electric
157928
3.3 Wire Number and Color Code
WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE

WIRE COLOR
NO. COLOR NO. NO. COLOR NO. COLOR NO. COLOR
00 WHT 20 ORG/BLU 44 YEL/WHT 67 ORG/BRN 92 GRN SHLD
000 WHT 21 WHT/RED 45 YEL/ORG 68 GREY 93 BLK SHLD
B1 BLU/PINK 23 BLK/WHT 46 RED/BLK 69 WHT/GRN 95 YEL/GREY
01 PUR/BLK 24 BLU/BLK 47 PUR/ORG 70 ORG/PINK 96 WHT/GREY
02 WHT 25 BRN/BLK 48 YEL/GREY 71 RED/ORG 97 ORG/GREY
03 GRN/PUR 26 BLU/YEL 49 GRN/RED 72 RED/BRN 98 RED SHLD
04 RED/YEL 27 RED/BLK/WHT 50 BRN 73 RED/PINK 98A BLK SHLD
GRN/
05 PUR 28 GRN 51 BLK/GRN 74 99 BLK/GREY
GREY
06 29 GREY/ORG 52 GRN/BLU 75 GREY/PUR 103 BLK/PUR
07 RED 30 RED/GRN 53 BRN/RED 76 BRN/BLU 104 GRN/ORG
08 PUR/WHT 31 RED/WHT 54 PUR/RED 77 BRN/GREY 105 GRN/BRN
09 YEL 32 GRN/BLK 55 YEL/PUR 78 RED/BLU 106 GRN/PINK
10 BLU/WHT 33 GRN/WHT 56 YEL/BLK 79 BRN/PUR 107 BLK/BLU

GREY/
11 WHT/ORG 34 ORG/BLK 57 BRN/GRN 80 WHT 108 YEL/BRN
RED/YEL/
12 35 ORG/WHT 58 WHT/PUR 81 GREY/BLK 109 GRN/YEL
BLK
13 ORG 36 RED/PUR 59 YEL/BLU 82 BRN/WHT 110A BLU
WHT/RED/
14 BLK 37 60 WHT/BLU 83 BLU/GREY 110B BRN
BLK
WHT/BLK/
15 BLU 38 ORG/RED 61 GREY/BRN 84 111 GREY/GRN
PUR
16 WHT/BLK 39 BLK/RED 62 GREY/RED 85 GREY/BLU 112 BLU/ORG
17 BLU/GRN 40 BLU/RED 63 GREY/YEL 86/87 PUR/BLU 113 BLU/BRN
18 GRN/BLU 41 BLU/PUR 64 WHT/BRN 88 BLK/ORG 114 YEL/RED
19 ORG/GRN 42 PINK 65 YEL/PINK 90 RED/GREY 115 WHT/PUR
22 PUR/GRN 43 WHT/YEL 66 ORG/YEL 91 RED SHLD 118 PUR/PINK
This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire
numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red.
SJIII DC Electric
157928
3.4 AC Cord Color Code AH

Standard Definition NEC Colours IEC Colours
Protective Ground/Protective Earth Green Green-Yellow
Neutral White Blue
Line, Single Phase Black Black/Brown/Grey
Note: Standard colours referenced from IEC 60445:2010, Annex A:Table A.1
SJIII DC Electric
157928
AK 3.5 Hydraulic Schematic Parts List

Index Skyjack
Qty. Description
No. Part No.
2H-13 103655 1 VALVE, Control (Lowering)

2H-13-1 107269 1 VALVE, Control (Holding)
2H-13-2 107269 1 VALVE, Control (Holding)
2H-18A 104132 1 VALVE, Control (Differential)
2H-59B 132749 1 VALVE, Control (Proportional)
3H-14 106273 1 VALVE, Control (Lift)
3H-17A 103623 1 VALVE, Control (Brake)
3H-18A-1 103623 1 VALVE, Control (Speed A)
3H-18A-2 103623 1 VALVE, Control (Speed B)
4H-15 153334 1 VALVE, Control (Reverse drive) (Hytos) (includes 4H-16)
4H-16 - 1 VALVE, Control (Forward drive) (Hytos)
4H-23 153334 1 VALVE, Control (Right steer) (Hytos) (includes 4H-24)
4H-24 - 1 VALVE, Control (Left steer) (Hytos)
4H-26 113953 1 VALVE, Powered platform extend (includes 4H-27) (Models 3220/4626)
4H-27 - 1 VALVE, Powered platform retract (Models 3220/4626)
C1 124291 1 CYLINDER (Cushion)
C2 120989 1 CYLINDER (Lift) (Model 3220)
120989 2 CYLINDER (Lift) (Models 3226/4626/4632)
C3 120236 1 CYLINDER (Steer)
C4 120220 2 CYLINDER (Brake) (Models 322x)
C5 127100 1 CYLINDER (Powered extension platform) (Model 3220)
127100 2 CYLINDER (Powered extension platform) (Model 4626)
CB1 147889 1 VALVE, Counterbalance
CRV1 115299 1 VALVE, Cross-Over Relief (Option)
F1 109568 1 FILTER ASSEMBLY, Return
FD1 103354 1 VALVE, Flow divider/combiner
M1 103129 1 MOTOR, Hydraulic Wheel (Left hand) (Models 322x)
M2 103129 1 MOTOR, Hydraulic Wheel (Right hand) (Models 322x)
M3 134573 1 MOTOR, Hydraulic Wheel (Left hand) (Models 46xx)
M4 134573 1 MOTOR, Hydraulic Wheel (Right hand) (Models 46xx)
MB1 107354 1 BLOCK, Manifold (Main)
MB2 107493 1 BLOCK, Manifold (Emergency lowering)
MB3 130481 1 BLOCK, Manifold (Holding valve) (Model 3220)
111320 1 BLOCK, Manifold (Upper holding valve) (Models xx26/4632)
111316 1 BLOCK, Manifold (Lower holding valve) (Models xx26/4632)
MB4 108195 1 BLOCK, Manifold (Rear drive)
MB5 160454 1 BLOCK, Manifold (Powered extension platform)
MB7 146563 1 MANIFOLD BLOCK (Brake release) (Models 46xx)
MB9 132748 1 MANIFOLD BLOCK (Proportional control)
O2 105530 1 ORIFICE (0.081” diameter) (Lowering) (Model 4632)
O3 105811 1 ORIFICE (0.040” diameter) (Steer)
O4 105281 1 ORIFICE (0.067” diameter) (Emergency lowering) (Model 3220)
105281 2 ORIFICE (0.067” diameter) (Emergency lowering) (Models 3226/4626/4632)
O6 104434 1 ORIFICE (0.040” diameter) (Differential)
O7 104434 1 ORIFICE (0.040” diameter) (Brake) (Models 322x)
137127 1 ORIFICE (0.020” diameter) (Brake) (Models 46xx)
Parts list continued on the following page.
SJIII DC Electric
157928
3.5 Hydraulic Schematic Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.
Parts list continued from the previous page.
P1 106587 1 PUMP, Hydraulic (Models 4626/4632, except EE rated)

129961 1 PUMP, Hydraulic (EE rated)
129965 1 PUMP, Hydraulic (EE rated)
310567 1 PUMP, Hydraulic (Standard)
P2 146560 1 PUMP, Handle (Brake release) (Models 46xx)
PS1 102863 1 SWITCH, Pressure (Option)
113799 1 • BLOCK, Manifold
R1 104534 1 VALVE, Relief (System)
R2 104534 1 VALVE, Relief (Lift)
R3 106557 2 VALVE, Relief (Holding valve) (Models 3226/4626/4632)
V1 107271 1 VALVE (Emergency lowering)
V2 103136 1 VALVE (Free-wheeling)
V3 146562 1 VALVE (Auto reset - brake release) (Models 46xx)
SJIII DC Electric
157928
AH 3.6 Electrical Components Parts List
SUPPLY (B+) (Common)
CONTROL (B+) GROUND (B-)
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Qty. Description
No. Part No.
17CR 108589 1 RELAY, 24 Volt (Transfer)

21CCR 108589 1 RELAY, 24 Volt (Proportional)
28CR 108589 1 RELAY, 24 Volt (Tilt switch)
9ACR-1 108589 1 RELAY, 24 Volt (Powerdeck #1)
9ACR-2 108589 1 RELAY, 24 Volt (Powerdeck #2)
2H-13 103605 1 COIL, 24 Volt (Lowering valve)
2H-13-1 104493 1 COIL, 24 Volt (Holding valve)
2H-13-2 104493 1 COIL, 24 Volt (Holding valve)
2H-18A 103605 1 COIL, 24 Volt (Differential valve)
2H-59 115370 1 COIL, 24 Volt (Proportional valve)
3H-14A 105610 1 COIL, 24 Volt (Lift valve)
3H-17A 103605 1 COIL, 24 Volt (Brake valve)
3H-18A-1 103605 1 COIL, 24 Volt (Speed A)
3H-18A-2 103605 1 COIL, 24 Volt (Speed B)
4H-15 153335 1 COIL, 24 Volt (Reverse drive spool valve) (Hytos)
4H-16 153335 1 COIL, 24 Volt (Forward drive spool valve) (Hytos)
4H-23 153335 1 COIL, 24 Volt (Right steer spool valve) (Hytos)
4H-24 153335 1 COIL, 24 Volt (Left steer spool valve) (Hytos)
4H-26 103605 1 COIL, 24 Volt (Power extension platform extend) (option)
4H-27 103605 1 COIL, 24 Volt (Power extension platform retract) (option)
AT1 130440 1 TRANSDUCER, Angle
B1-B4 103480 4 BATTERY, 6 Volt (U2200)
B1-B4 106552 4 BATTERY, 6 Volt (U2500)
SJIII DC Electric
157928
3.6a Electrical Component Parts List (Continued) AJ

Index Skyjack
Qty. Description
No. Part No.
BC 128537 1 CHARGER, 24VDC Battery (superior universal)

BCI 122093 1 BATTERY CHARGE INDICATOR
BP-29 103057 1 BEEPER, 24 VDC
C1 146475 1 CONTACTOR, Solenoid (hydraulic proportional control)
165865 1 CONTACTOR, Solenoid (Motor controller/MC models)
CAP1 110699 1 CAPACITOR (.47UF 50 Volts)
CB1 117325 2 BREAKER, Circuit (15 Amp)
CB2 117325 2 BREAKER, Circuit (15 Amp)
D02-X 129258 AR DIODE
D19A - ALARM OPTION
DA1 119758 1 DIODE PACK
DA2 119520 1 DIODE ASSEMBLY
DA3 119624 1 DIODE ASSEMBLY
DCM1 147664 1 MOTOR (24 VDC)
123477 1 MOTOR (24 VDC) (EE rated)
DXX 102921 AR DIODE
F1 310517 1 FUSE (300 Amp in-line fuse)
FL-22 121477 1 FLASHING LIGHT, 24VDC (Option)
FL-29 103743 1 FLASHER (Option)
H1 146649 1 HORN, Operator (Low tone)
LED-1 147061 1 POWER INDICATOR LIGHT (Platform control console)
LED-2 147061 1 POWER INDICATOR LIGHT (Base control console)
LS1A 121975 1 LIMIT SWITCH (High speed)
- - - (For model 3220 with serial number 60007078 & Above)
- - - (For model 46xx with serial number 70032134 & Above)
199485 1 LIMIT SWITCH (High speed)
LS1B 121975 1 LIMIT SWITCH (High speed)
LS3 122014 1 LIMIT SWITCH (End of stroke - option)
LS4 125887 1 LIMIT SWITCH, Pothole protection (Battery tray)
LS4 126051 1 LIMIT SWITCH, Pothole protection (Battery tray) (EE rated)
LS5 125885 1 LIMIT SWITCH, Pothole protection (Hydraulic tray)
LS5 126060 1 LIMIT SWITCH, Pothole protection (Hydraulic tray) (EE rated)
LS6 121975 1 LIMIT SWITCH (Drive override)
199485 1 LIMIT SWITCH (Drive override)
RST1 119629 1 RESISTOR (2.7K ohm)
RST2 168596 1 RESISTOR (25 ohm)
RST3 116505 1 RESISTOR, Low voltage protection (56 Ohms)
SJIII DC Electric
157928
AI 3.6b Electrical Component Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.
S1 119725 1 SWITCH, Main power disconnect

S2 147054 2 N.O. CONTACT (Raise/Lower)
S3 116382 1 SWITCH, Toggle (Lift/Off/Drive)
S4 147053 2 N.C. CONTACT (Emergency stop) (Platform control console)
S7 123994 1 CONTROLLER ASSEMBLY, Proportional
S7-1 122869 1 SWITCH (Neutral)
S7-2 122877 1 SWITCH (Right steer)
S7-3 122877 1 SWITCH (Left steer)
S7-6 122872 1 SWITCH, Pushbutton (Enable)
S8 147054 1 N.O. CONTACT (Horn)
S10 147053 2 N.C. CONTACT (Off/Platform)
147054 1 N.O. CONTACT (Base)
S11 102853 1 SWITCH (Powered extension platform extend/retract)
S12 102853 1 SWITCH (Powered extension platform enable)
S27 115574 1 SWITCH, Toggle (Torque)
S28 147053 1 N.C. CONTACT (Emergency stop) (Base control console)
TS1 146658 1 TILT SWITCH (Models 322x)
146661 1 TILT SWITCH (Models 46xx)
TT 195940 1 HOURMETER, Digital
TIMER 137417 1 TIMER, Relay - Delay-On-Release
SJIII DC Electric
157928
3.7a Hydraulic Manifold and Port Identifications
2H-18A 2H-59B
If equipped Proportional Valve
Differential Valve
(Internal Compensator Valve) To Main Manifold
3H-18A-2
Speed Valve B
To Main Manifold
FD1
Flow Divider/Combiner
Valve
To Pump
V2 V3
Free-wheeling Valve Auto Reset Valve
Hydraulic Fitting
P2
3H-18A-1 Hand Pump
Speed Valve A 3H-14
Lift Valve
CB1
Counterbalance
Valve
02
Lowering Orifice R4
(Model 4632 Only) Relief Valve
3H-17A
Brake Valve
4H-16
Forward Valve
R2
Lift Relief Valve
R5 2H-13
Relief Valve Lowering Valve
4H-23
4H-15 Right Steer Valve
Reverse Drive Valve
R1 Quick Disconnect
4H-24 System Relief Valve (If equipped)
Left Steer Valve
M138117AA_S3
SJIII DC Electric
157928
AE 3.7b Hydraulic Manifold and Port Identifications

Serial Breakdown
Reference Chart
Model Serial Number
SJ3 3220 60003929 & above
SJ3 4620/26 70015230 & above
3H-14
Lift Valve
CB1
Counterbalance
R2 Valve
Lift Relief Valve
02
Lowering Orifice 4H-16 3H-17A
(Model 4632 Only) Forward Valve Brake Valve
4H-26
Extend Platform
Valve
4H-27
Retract Platform
Valve
MB5
P. Deck Manifold
4H-23
4H-15 Right Steer Valve
Reverse Drive Valve
2H-13
Lowering Valve
4H-24
Left Steer Valve
R1
System Relief Valve
Quick Disconnect
(If equipped)
M138117AA_S3
SJIII DC Electric
157928
3.8a Platform Control Console Diagram
15 16 12B
S8 - HORN
S27 - TORQUE
12B
B
18 A 8A
12B 08
08
49
13 14
S3 - LIFT/OFF/DRIVE
00
S4 - EMERGENCY STOP
RST1
8C 08
02
60/7A LED-1 02
X2
X1
08 07 7A
21B GREEN/BLACK - TIED BACK
MALE
(7A) GREEN 8 16 RED WHITE (60/7A)

(49) GREEN WHITE 7 15 BLACK WHITE (23)
9 PIN CONNECTOR SUB-ASSEMBLY (8C) BLUE WHITE 6 14 BLUE BLACK (24)
(07) RED 5 13 GREEN BLACK (21B) (OPT)
(14) BLACK 4 12 ORANGE BLACK (59)
(13) ORANGE 3 11 RED BLACK (18)
(15) BLUE 2 10 WHITE BLACK (16)
(02) WHITE 1 9 (NOT USED)
CTRL BOX
HARNESS
BACK VIEW
PIN # - FUNCTION CTRL BOX HARNESS JOYSTICK HARNESS

JOYSTICK HARNESS
PIN 1 - LEFT 24 BLUE/BLACK WHITE/RED
PIN 2 - STEERING VS+ 12B BROWN/RED WHITE/GREEN
PIN 3 - RIGHT 23 BLACK/WHITE WHITE
PIN 4 - FWD/UP B RED YELLOW
PIN 5 - JOYSTICK VS+ 08 BLUE WHITE/BLACK CRD1
PIN 6 - REV/DOWN A PURPLE/WHITE GREY
PIN 7 - PWM 59 ORANGE/BLACK BLUE
PIN 8 - GND 02 WHITE BLACK
PIN 9 - ENABLE VS+ 8A BLUE WHITE/ BLUE
M156881AA
SJIII DC Electric
157928
3.8b Platform Control Console Diagram - Long Cable Option
S27 - TORQUE S3 - LIFT/OFF/DRIVE
15 16 12B
S8 - HORN
12B
B
18 A 8A
12B 08
08
49
13 14
00
S4 - EMERGENCY STOP
RST1
8C 08
02
60/7A LED-1 02
X2
X1
08 07 7A
MALE

9 PIN CONNECTOR SUB-ASSEMBLY (8C) BLUE WHITE 6 14 BLUE BLACK (24)
CTRL BOX
HARNESS
BACK VIEW

JOYSTICK HARNESS PIN 1 - LEFT 24 BLUE/BLACK WHITE/RED
XX
HYDRAULIC PROPORTIONAL

PIN 4 - FWD/UP B RED YELLOW
PIN 5 - JOYSTICK VS+ 08 BLUE WHITE/BLACK CRD1
118711-0
M156992AA
SJIII DC Electric
157928
3.9a Powerdeck Platform Modification Diagram

Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60003928 & Below
S3 - LIFT/OFF/DRIVE
SJIII 4620/4626 70015229 & Below
S8 - HORN
S27 - TORQUE
08
09
S4 - EMERGENCY STOP
08 02
LED-1
X2
X1
21B
D26 D27
MALE
21B
02 26 27 09 (7A) GREEN 8 16 RED WHITE (60/7A)
(8C) BLUE WHITE 6 14 BLUE BLACK (24)
BACK VIEW
TO PWR DECK
SOLENOID VALVES
PIN 1 - 27 BLACK
PIN 2 - 02 WHITE
PIN 3 - 26 GREEN
PIN 4 - N / U
PIN 5 - N / U
TO PWR DECK
CONTROL BOX
PIN 1 - 27 BLACK
PIN 2 - 09 WHITE
PIN 3 - 26 GREEN
PIN 4 - N / U
PIN 5 - N / U
M156955AA1
SJIII DC Electric
157928
3.9b Powerdeck Platform Modification Diagram

Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60003929 & Above
SJIII 4620/4626 70015230 & Above
S3 - LIFT/OFF/DRIVE
S8 - HORN
S27 - TORQUE
08
09
S4 - EMERGENCY STOP
08
LED-1
X2
X1
9A GREEN/BLACK - TIED BACK
CONNECT HERE CONNECT 23 AND 24 FROM HARNESS TO THE 9 PIN CONNECTOR
9A
CTRL BOX
HARNESS
JOYSTICK HARNESS
PIN 1 - 23 BLK/WHT
1 2
PIN 2 - 24 BLUE/BLK
MALE
PIN # - FUNCTION CTRL BOX HARNESS JOYSTICK HARNESS (7A) GREEN 8 16 RED WHITE (60/7A)
REMOVE BLUE/BLK (24) AND BLK/WHT (23) FROM (49) GREEN WHITE 7 15 BLACK WHITE (23)
PIN 2 - STEERING VS+ 12B BROWN/RED WHITE/GREEN THE 9 PIN CONNECTOR AND CONNECT TO 2 PIN CONNECTOR (8C) BLUE WHITE 6 14 BLUE BLACK (24)
PIN 3 - RIGHT 23 BLACK/WHITE WHITE (07) RED 5 13 GREEN BLACK (21B) (OPT)
PIN 4 - FWD/UP B RED YELLOW (14) BLACK 4 12 ORANGE BLACK (59)
PIN 5 - JOYSTICK VS+ 08 BLUE WHITE/BLACK (13) ORANGE 3 11 RED BLACK (18)
PIN 6 - REV/DOWN A PURPLE/WHITE GREY (15) BLUE 2 10 WHITE BLACK (16)
PIN 7 - PWM 59 ORANGE/BLACK BLUE (02) WHITE 1 9 (NOT USED)
BACK VIEW
TO PWR DECK
CONTROL BOX
1.BLACK (27)
2.WHITE (09)
3.GREEN (26)
4.RED (9A)
M164704AC_1
SJIII DC Electric
157928
3.10a Powered Extension Platform Control Console and Harness

Serial Breakdown
Reference Chart
Model Serial Number
EXTENSION PLATFORM CONTROL CONSOLE SJIII 3220 60003928 & Below
SJIII 4620/4626 70015229 & Below
BOX
WHITE BLACK
GREEN
1
1
2
2
3
TO POWER CONTROL CONSOLE BACK VIEW W/ALL FUNCTION CUTOUT

MALE 1 BLACK (27)
3 2
2 WHITE (08)
3 GREEN (26)
4 1 4 (N/U)
TO POWER CONTROL CONSOLE BACK VIEW

EXTENSION PLATFORM CYLINDER HARNESS MALE
3
1 BLACK (27)
2
2 WHITE (02)
3 GREEN (26)
27 4 1 4 (N/U)
26
02
M115592AI1_S3
SJIII DC Electric
157928
3.10b Powered Extension Platform Control Console

Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60003929 & Above
SJIII 4620/4626 70015230 & Above
M160494AD1
SJIII DC Electric
157928
AI 3.11a Base Control Console Diagram (Including EE-Rated)

Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60006146 & Below
SJIII 3226 27028841 & Below
S10 - IDLE SW S2 - UP SWITCH
SJIII 46xx 70028673 & Below
N.C. CONTACT N.O. CONTACT
SJIII 3220 EE-Rated 60002259 & Above PIN 3 - 10E WHITE/BLACK (X2)
PIN 1 - 5A PURPLE/WHITE
SJIII 3226 EE-Rated 27006432 & Above PIN 2 - 07 RED (X2) PIN 4 - 14E BLACK
SJIII 46xx EE-Rated 70007139 & Above S2 - DOWN SWITCH
S10 - BASE SW N.O. CONTACT
N.O. CONTACT
PIN 3 - 10E WHITE/BLACK
PIN 3 - 10E WHITE/BLACK (X2) PIN 4 - 13 ORANGE
PIN 4 - 7A RED/BLACK
S10 - PLATFORM SWITCH

N.C. CONTACT S28 - EMERGENCY STOP
PIN 1 - 8C BLUE N.C. CONTACT
PIN 2 - 07 RED PIN 1 - 5A PURPLE/WHITE
PIN 2 - 05 ORANGE/BLACK
LED 2 - POWER ON/LSS LIGHT

PIN X1 - 02 WHITE
PIN X2 - 7A RED/BLACK (X2)
TO ELECTRIC PANEL
PIN 1 - 07 (RED)
PIN 2 - 05 (ORANGE/BLACK)
PIN 3 - 13 (ORANGE)
PIN 4 - 14E (BLACK)
PIN 5 - 10E (WHITE/BLACK) (CE)
PIN 6 - 8C (BLUE)
PIN 7 - 7A (RED/BLACK)
PIN 8 - 02 (WHITE)
BACK VIEW
DEUTSCH
5 4
6 3
7 2
8 1
M149553AA_S3
SJIII DC Electric
157928
3.11b Base Control Console Diagram (Non EE-Rated Only) AI

Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60006147 & Above
SJIII 3226 27028842 & Above
SJIII 46xx 70028674 & Above
S28 - EMERGENCY STOP

N.C. CONTACT TO ELECTRIC PANEL
S2 - DOWN SWITCH PIN 1 - 5A PURPLE/WHITE
N.O. CONTACT PIN 1 - 07 (RED)
PIN 2 - 05 ORANGE/BLACK PIN 2 - 05 (ORANGE/BLACK)
PIN 3 - 10E WHITE /BLACK (X2)
PIN 3 - 13 (ORANGE)
PIN 4 - 13 ORANGE LED 2 - POWER ON/LSS LIGHT
PIN 4 - 14E (BLACK)
PIN X1 - 02 WHITE
S2 - UP SWITCH PIN 5 - 10E (WHITE/BLACK) (CE)
PIN X2 - 7A RED/BLACK (X2) PIN 6 - 8C (BLUE)
N.O. CONTACT
PIN 3 - 10E WHITE /BLACK (X2) PIN 7 - 7A (RED/BLACK)
PIN 4 - 14E BLACK PIN 8 - 02 (WHITE)
S10 - KEY SWITCH BACK VIEW

A B C D E F
PIN A - 5A PURPLE/WHITE
DEUTSCH
1 8
PIN B - 07 RED 2 7
3 6
PIN C - 10E WHITE/BLACK 4 5
PIN D - 7A RED/BLACK
PIN E - N/U REFERENCE (INCL W/ 213697):
PIN F - 8C BLUE 137441 (1X)
137442 (5X)
137443 (1X)
M195843AB
SJIII DC Electric
157928
3.12a Scissor Arm Control Cable Diagram
CONTROL CABLE OPTIONS

EUROPE N.A
WIRE COLOUR WIRE NUMBER WIRE NUMBER
GREEN/BLACK 21B 21B
RED/WHITE 60 7A
BACK VIEW FRONT VIEW TO ELECTRIC PANEL

CONTROL CABLE
MALE
(7A) GREEN 8 16 RED WHITE (OPT) 16 8
(49) GREEN WHITE 7 15 BLACK WHITE (23) 15 7
(8C) BLUE WHITE 6 14 BLUE BLACK (24) 14 6
(07) RED 5 13 GREEN BLACK (OPT) 13 5

12 4
(13) ORANGE 3 11 RED BLACK (18) 11 3
10 2
(02) WHITE 1 9 (NOT USED) 9 1
TO PLATFORM CONTROL CONSOLE FRONT VIEW BACK VIEW

CONTROL CABLE
FEMALE
8 16 (OPT) RED WHITE 16 8 GREEN (7A)

7 15 (23) BLACK WHITE 15 7 GREEN WHITE (49)
6 14 (24) BLUE BLACK 14 6 BLUE WHITE (8C)
5 13 (OPT) GREEN BLACK 13 5 RED (07)
4 12 (59) ORANGE BLACK 12 4 BLACK (14)
3 11 (18) RED BLACK 11 3 ORANGE (13)
2 10 (16) WHITE BLACK 10 2 BLUE (15)
1 9 (NOT USED) 9 1 WHITE (02)
M146650AB_S3
SJIII DC Electric
157928
3.12b Scissor Arm Control Cable Diagram (EE-Rated) AF
CONTROL CABLE OPTIONS

EUROPE N.A
WIRE COLOUR WIRE NUMBER WIRE NUMBER
GREEN/BLACK 21B 9A
RED/WHITE 60 7A
BACK VIEW FRONT VIEW TO ELECTRIC PANEL

CONTROL CABLE
MALE
(7A) GREEN 8 16 RED WHITE (OPT) 16 8
(49) GREEN WHITE 7 15 BLACK WHITE (23) 15 7
(8C) BLUE WHITE 6 14 BLUE BLACK (24) 14 6
(07) RED 5 13 GREEN BLACK (OPT) 13 5

12 4
(13) ORANGE 3 11 RED BLACK (18) 11 3
10 2
(02) WHITE 1 9 (NOT USED) 9 1
TO PLATFORM CONTROL CONSOLE FRONT VIEW BACK VIEW

CONTROL CABLE
FEMALE
8 16 (OPT) RED WHITE 16 8 GREEN (7A)

7 15 (23) BLACK WHITE 15 7 GREEN WHITE (49)
6 14 (24) BLUE BLACK 14 6 BLUE WHITE (8C)
5 13 (OPT) GREEN BLACK 13 5 RED (07)
4 12 (59) ORANGE BLACK 12 4 BLACK (14)
3 11 (18) RED BLACK 11 3 ORANGE (13)
2 10 (16) WHITE BLACK 10 2 BLUE (15)
1 9 (NOT USED) 9 1 WHITE (02)
M159307AB
SJIII DC Electric
157928
AF 3.13 Limit Switch Assembly Wire Diagrams
BROWN BLACK
19
NO NC
LS6
71
BLUE BLACK/WHITE
BROWN BLACK
18B 18A PIN 1 - 71 (BLACK/WHITE) PIN 5 - 7A(CE/AS)/13(KC) (BLUE)
LS1B
NO NC PIN 2 - 21 (BLACK) PIN 6 - 18B(CE/AS)/13A(KC) (BROWN)
7A 18 PIN 3 - 18 (BLACK/WHITE) PIN 7 - 19 (BLACK)
BLUE BLACK/WHITE PIN 4 - 18A (BLACK) PIN 8 - 71 (BLACK/WHITE)
DEUTSCH
BROWN BLACK 1 8
2 7
21 3 6
NO NC 4 5
LS1A
71
BLUE BLACK/WHITE
M130560AD
SJIII DC Electric
157928
AB
3.14 Harness Wire Diagrams
HORN/FLASHING LIGHT HARNESS

TO FLASHING LIGHT 22
02 - WHITE
22 - GREEN 02
TO HORN 02
02 - WHITE TO ELECTRIC PANEL
49 - BLACK 22 - GREEN
49 02 - WHITE
49 - BLACK
TILT SWITCH HARNESS

DEUTSCH
4 1
3 2
TO TILT SWITCH TO ELECTRIC PANEL

PIN 1 - 19 (BLACK) 19 - BLACK
PIN 2 - 28 (GREEN) 28 - GREEN
PIN 3 - 02 (WHITE) 02 - WHITE
PIN 4 - N/U
CHARGER CUTOUT HARNESS

BACK VIEW
2 1
TO ELECTRIC PANEL
3A - BLACK PIN 1 - 3A BLACK
05 - WHITE PIN 2 - 05 WHITE
(OPT) - GREEN
CHARGER CUTOUT HARNESS - EE RATED MODELS
PIN 1 - 3A (WHITE) PIN 1 - 3A (WHITE)

PIN 2 - 05 (BLACK) PIN 2 - 05 (BLACK)
HOLDING VALVE HARNESS - MODEL XX20

HOLDING VALVE
1
13
13 - BLACK PIN 1 - 13 BLACK
2
02 - WHITE 02 PIN 2 - 02 WHITE
HOLDING VALVE HARNESS - MODEL XX26 / XX32

HOLDING VALVE (LOWER)
1
PIN 1 - 13 BLACK
13 - BLACK 13
HOLDING VALVE (UPPER)
PIN 2 - 02 WHITE
2
02 - WHITE 02 PIN 1 - 13 BLACK

2 1
PIN 2 - 02 WHITE
M146588AA4_S3
SJIII DC Electric
157928
AG
3.15 Telematics Harness - ZTR
TO LOWER BASE BOX
BLUE
FROM ELECTRIC PANEL REAR MANIFOLD HARNESS TO CHARGER CUTOUT
YEL
TO HIGH SPEED LIMIT

TO POTHOLE LIMIT
18A
02
8C
TO MASTER DISCONNECT(+)
BATTERY SIDE
19A
18A
8C
02
02
19A
8C
02
+
18A
02
TO REAR MANIFOLD
18A
02
SJ3D
32XX/46XX
WIRING
DIAGRAM
8 PIN CONNECTOR
1 +
2 02
3 19A
4 8C
5
6
7
8
TO TELEMATICS UNIT
M170996AA1_S
SJIII DC Electric
157928
3.16a Hydraulic Schematic (Models 322x)
A B C D E F G H
C4 BRAKE C4 BRAKE Serial Breakdown
CYLINDER O7 CYLINDER M4 Reference Chart
BRAKE RIGHT DRIVE 04
MOTOR C2 Model Serial Number
ORIFICE Ø.040 EMERGENCY
UPPER LIFT
CYLINDER LOWERING SJIII 3220 60003928 & Below
ORIFICE
2H-18A
3226
Ø.067
V
MB4 SJIII 3226 27015200 & Below
DIFFERENTIAL
VALVE REAR DRIVE
MANIFOLD BLOCK
O6
4H-27 C5 P.DECK R3 2H-13-2
DIFFERENTIAL
RETRACT CYLINDER PT1 RELIEF VALVE HOLDING VALVE PT1
ORIFICE Ø.040
PLATFORM FD1 PRESSURE PRESSURE
VALVE C1
FLOW DIVIDER OVERLOAD OVERLOAD
CUSHION
3H-18A-2 COMBINER TRANSDUCER TRANSDUCER
CYLINDER
SPEED VALVE B OPTION C2 04 OPTION C2 04
OPTIONAL POWERED T A LOWER LIFT EMERGENCY LOWER LIFT EMERGENCY
EXTENSION DECK SJ3D 3220 CYLINDER LOWERING CYLINDER LOWERING
P B
V2 3226 ORIFICE 3220 ORIFICE
3H-18A-1 Ø.067 Ø.067
SPEED VALVE A FREE-WHEELING W
VALVE 2H-13-1 (ANSI/CSA)
4H-26 MB3 MB3 2H-13B-1 (CE)
MB5 P. DECK EXTEND HOLDING VALVE HOLDING VALVE HOLDING VALVE
MANIFOLD BLOCK PLATFORM MANIFOLD BLOCK MANIFOLD BLOCK
R3 2H-13-1
VALVE RELIEF VALVE HOLDING VALVE
M3
LEFT DRIVE PS1
MOTOR C3 STEERING OPTIONAL
CYLINDER PRESSURE
SWITCH
O3
STEER ORIFICE
Ø.040 REFERENCE TABLE
X
SJ3D ORIFICE
MB9 4H-23
PR0PORTIONAL 4H-15 RIGHT STEER MODEL LOWERING LIFT
REVERSE DRIVE 2H-13 (ANSI/CSA) ORIFICE ORIFICE

MANIFOLD VALVE
VALVE 3H-14 2H-13B (CE)
BLOCK SJ3 3220 NONE
LIFT VALVE LOWERING VALVE
3H-17A P A P A SJ3 3226
0.067
NONE
BRAKE VALVE B
T B T SJ3 4620 0.073" DIA
2H-59 CRV1 CROSS-OVER
4H-16
PRESSURE- RELIEF VALVE OPTION
SJ3 4626 NONE
FORWARD DRIVE 4H-24
COMPENSATED R2 LIFT
R1 VALVE LEFT STEER O2 SJ3 4632
PROPORTIONAL RELIEF
0.081" DIA
VALVE SYSTEM RELIEF VALVE LOWERING ORIFICE
CB1 VALVE
VALVE SEE REFERENCE TABLE
COUNTERBALANCE VALVE
Y
DCM1
DC MOTOR MB1
P1 MAIN MANIFOLD BLOCK MB2 V1 EMERGENCY
M HYDRAULIC LOWERING LOWERING
PUMP VALVE VALVE
BLOCK (MANUAL)
F1
RETURN
FILTER Z
RESERVOIR
M132308AD1
SJIII DC Electric Page 62

SJIII 3220 SJIII 3226 SJIII 4620 SJIII 4626 SJIII 4632
157928
3.16b Hydraulic Schematic (Models 322x) AE
A B C D E F G H
Serial Breakdown
Reference Chart
C4 BRAKE C4 BRAKE Model Serial Number
CYLINDER O7 CYLINDER M4 C2
BRAKE RIGHT DRIVE UPPER 04 SJIII 3220 60003929 & Above
ORIFICE Ø.040 MOTOR LIFT EMERGENCY V
CYLINDER LOWERING SJIII 3226 27015201 & Above
3226 ORIFICE
2H-18A Ø.067
DIFFERENTIAL MB4
VALVE REAR DRIVE
MANIFOLD BLOCK
O6
R3 2H-13-2
DIFFERENTIAL
RELIEF VALVE HOLDING VALVE PT1
ORIFICE Ø.040
FD1 PRESSURE
C1
FLOW DIVIDER OVERLOAD
CUSHION
3H-18A-2 COMBINER C2 TRANSDUCER C2
CYLINDER
SPEED VALVE B LOWER 04 OPTION LOWER 04
LIFT EMERGENCY LIFT EMERGENCY
CYLINDER LOWERING CYLINDER LOWERING
3H-18A-1 V2 3226 ORIFICE 3220 ORIFICE W
FREE-WHEELING Ø.067 Ø.067
SPEED VALVE A
VALVE
MB3 MB3
HOLDING VALVE HOLDING VALVE
C5 P.DECK MANIFOLD BLOCK MANIFOLD BLOCK
CYLINDER R3 2H-13-1 2H-13-1
RELIEF VALVE HOLDING VALVE HOLDING VALVE
EXTENSION DECK (SJ3D 3220 ONLY)
M3
4H-27 LEFT DRIVE PS1
RETRACT MOTOR C3 STEERING OPTIONAL
PRESSURE
OPTIONAL POWERED
PLATFORM CYLINDER
SWITCH
B
VALVE
O3
A
STEER ORIFICE
Ø.040 REFERENCE TABLE
X
SJ3D ORIFICE
MB9 4H-15 4H-27 4H-23
PR0PORTIONAL REVERSE DRIVE RETRACT 4H-26 RIGHT STEER MODEL LOWERING LIFT
B
A
ORIFICE ORIFICE
MANIFOLD VALVE PLATFORM EXTEND
VALVE
VALVE PLATF VLV 3H-14 2H-13
0.067
BLOCK SJ3 3220 NONE
LIFT VALVE LOWERINGVALVE
T
P
3H-17A P A P A SJ3 3226 NONE
BRAKE VALVE B
T B T MB5 P. DECK
2H-59B MANIFOLD BLOCK
CRV1 CROSS-OVER O2
PRESSURE-
4H-16 RELIEF VALVE OPTION 4H-24 LOWERING ORIFICE
COMPENSATED R2 LIFT
PROPORTIONAL R1 FORWARD DRIVE LEFT STEER SEE REFERENCE
SYSTEM RELIEF VALVE TABLE RELIEF
VALVE VALVE
VALVE VALVE
CB1 COUNTERBALANCE VALVE
Y
DCM1
DC MOTOR MB1
PUMP VALVE VALVE
BLOCK (MANUAL)
F1
RETURN
FILTER
RESERVOIR
M160984AA
Page 63 SJIII DC Electric

157928
AE 3.17a Hydraulic Schematic (Models 46xx)
A B C D E F G H
M4 Serial Breakdown
RIGHT DRIVE C2 Reference Chart
MOTOR/BRAKE UPPER LIFT 04
V3 EMERGENCY Model Serial Number
AUTO RESET CYLINDER
LOWERING
VALVE CASE DRAIN 4626/4632 SJIII 4620/26 70015229 & below
ORIFICE
Ø.067 V
P2 SJIII 4632 70007139 & above
MB4
HAND PUMP REAR DRIVE
O6 2H-18A MB3
DIFFERENTIAL DIFFERENTIAL MANIFOLD BLOCK HOLDING VALVE
MB7 ORIFICE Ø.040 VALVE MANIFOLD BLOCK
BRAKE RELEASE R3 2H-13-2
MANIFOLD BLOCK PT1 RELIEF VALVE HOLDING VALVE PT1
O7 PRESSURE PRESSURE
BRAKE ONE-WAY FD1 OVERLOAD OVERLOAD
ORIFICE Ø.020 FLOW DIVIDER TRANSDUCER TRANSDUCER
COMBINER C2 C2
OPTION LOWER LIFT 04 OPTION 04
3H-18A-2 LOWER LIFT
CYLINDER EMERGENCY EMERGENCY
SPEED VALVE B CYLINDER
LOWERING LOWERING
4626/4632 4620
C1 ORIFICE ORIFICE
V2 CUSHION Ø.067 Ø.067 W
3H-18A-1 FREE-WHEELING CYLINDER
SPEED VALVE A VALVE MB3 MB3
C5 P.DECK C5 P.DECK
MANIFOLD BLOCK R3 2H-13-1 MANIFOLD BLOCK 2H-13-1
CYLINDER CYLINDER C3 STEERING
CASE DRAIN RELIEF VALVE HOLDING VALVE HOLDING VALVE
M3 CYLINDER
LEFT DRIVE
PS1 OPTIONAL
EXTENSION DECK (SJ3D 4626)
4H-27 4H-26 MOTOR/BRAKE O3

PRESSURE
B
A
RETRACT EXTEND STEER ORIFICE

SWITCH
OPTIONAL POWERED
PLATFORM PLATFORM Ø.040

T
P
VALVE VALVE
REFERENCE TABLE X
MB5 P. DECK
MANIFOLD BLOCK SJ3D ORIFICE
MB9 LOWERING LIFT
4H-15 MODEL ORIFICE ORIFICE
PR0PORTIONAL 4H-23
C5 P.DECK MANIFOLD REVERSE DRIVE RIGHT STEER
VALVE 3H-14 2H-13 SJ3 3220 NONE
CYLINDER BLOCK VALVE LIFT VALVE LOWERINGVALVE
3H-17A SJ3 3226 NONE
P A
BRAKE VALVE
0.067
P A SJ3 4620 0.073" DIA
4H-27 4H-26 T B
B
A
RETRACT EXTEND T B
4H-16 CRV1 CROSS-OVER SJ3 4626 NONE
OPTIONAL POWERED
PLATFORM PLATFORM
FORWARD DRIVE RELIEF VALVE OPTION
T
P
VALVE VALVE
VALVE 4H-24 O2 R2 LIFT SJ3 4632 0.081" DIA
R1 LEFT STEER LOWERING ORIFICE RELIEF
2H-59B SYSTEM RELIEF CB1 SEE REFERENCE TABLE VALVE Y
VALVE
MB5 P. DECK PRESSURE- VALVE COUNTERBALANCEVALVE
MANIFOLD BLOCK COMPENSATED
PROPORTIONAL
VALVE
MB1
MAIN MANIFOLD BLOCK MB2 V1 EMERGENCY
LOWERING LOWERING
VALVE VALVE
DCM1
DC MOTOR BLOCK (MANUAL)
P1
M HYDRAULIC
F1
PUMP
RETURN
FILTER
Z
RESERVOIR
M137018AE

157928
3.17b Hydraulic Schematic (Models 46xx) AE
A B C D E F G H
M4 Serial Breakdown
AUTO RESET CYLINDER
LOWERING
VALVE CASE DRAIN 4626/4632 SJIII 4620/26 70015230 & 70032758
ORIFICE
Ø.067 V
P2 SJIII 4632 70007139 & 70032758
MB4
O6 2H-18A MB3
COMBINER C2 C2
3H-18A-2 LOWER LIFT
LOWERING LOWERING
4626/4632 4620
C1 ORIFICE ORIFICE
V2 CUSHION Ø.067 Ø.067 W
C5 P.DECK C5 P.DECK
M3 CYLINDER
LEFT DRIVE
PS1 OPTIONAL
MOTOR/BRAKE O3
STEER ORIFICE PRESSURE
SWITCH
OPTIONAL POWERED
Ø.040
B
A
REFERENCE TABLE X
SJ3D ORIFICE
MB9 4H-15 LOWERING LIFT
PR0PORTIONAL REVERSE DRIVE 4H-23 MODEL ORIFICE ORIFICE
4H-27
C5 P.DECK MANIFOLD VALVE RETRACT 4H-26 RIGHT STEER
VALVE 3H-14 2H-13 SJ3 3220 NONE
B
A
CYLINDER BLOCK PLATFORM EXTEND
VALVE
PLATF VLV LIFT VALVE LOWERINGVALVE
3H-17A A
SJ3 3226 NONE
P
T
P
BRAKE VALVE
0.067
P A SJ3 4620
4H-27 T B 0.073" DIA

RETRACT MB5 P. DECK T B
CRV1 CROSS-OVER SJ3 4626 NONE
OPTIONAL POWERED
PLATFORM MANIFOLD BLOCK

RELIEF VALVE OPTION
B
VALVE 4H-16 O2 R2 LIFT SJ3 4632 0.081" DIA

FORWARD DRIVE 4H-24
A
R1 LOWERING ORIFICE RELIEF

2H-59B SYSTEM RELIEF
VALVE LEFT STEER SEE REFERENCE TABLE VALVE Y
PRESSURE- VALVE
VALVE
COMPENSATED
PROPORTIONAL
VALVE
MB1
LOWERING LOWERING
VALVE VALVE
DCM1
P1
M HYDRAULIC
F1
PUMP
RETURN
FILTER
Z
RESERVOIR
M160889AB

157928
AK 3.17c Hydraulic Schematic (Models 46xx)
A B C D E F G H
C4 BRAKE C4 BRAKE Serial Breakdown
CYLINDER M4
O7 CYLINDER
BRAKE 04
MOTOR UPPER LIFT Model Serial Number
ORIFICE Ă.040 EMERGENCY
CYLINDER
LOWERING SJIII 46xx 70032759 & Above
4626/4632
ORIFICE V
Ă.067
MB4
2H-18A REAR DRIVE MB3
DIFFERENTIAL MANIFOLD BLOCK HOLDING VALVE
VALVE MANIFOLD BLOCK
R3 2H-13-2
O6 PT1 RELIEF VALVE HOLDING VALVE PT1
DIFFERENTIAL PRESSURE PRESSURE
ORIFICE Ă.040 FD1 OVERLOAD OVERLOAD
FLOW DIVIDER TRANSDUCER TRANSDUCER
COMBINER C2 C2
3H-18A-2 LOWER LIFT
LOWERING LOWERING
4626/4632 4620
C1 ORIFICE ORIFICE W
V2 CUSHION Ă.067 Ă.067

C5 P.DECK C5 P.DECK
M3 CYLINDER
LEFT DRIVE
O3 PS1 OPTIONAL
MOTOR
STEER ORIFICE PRESSURE
Ă.040 SWITCH
OPTIONAL POWERED
B
A
MB9 4H-15
PR0PORTIONAL REVERSE DRIVE 4H-23
4H-27
C5 P.DECK MANIFOLD VALVE RETRACT 4H-26 RIGHT STEER 3H-14 2H-13
B
A
CYLINDER BLOCK PLATFORM EXTEND VALVE
VALVE
PLATF VLV LIFT VALVE LOWERING VALVE
3H-17A P A
T
P
BRAKE VALVE
P A
4H-27 T B
RETRACT T B
CRV1 CROSS-OVER MB5 P. DECK
PLATFORM
OPTIONAL POWERED
RELIEF VALVE OPTION MANIFOLD BLOCK

B
VALVE 4H-16
4H-24 O2 R2 LIFT
FORWARD DRIVE
A
R1
VALVE LEFT STEER LOWERING ORIFICE RELIEF Y
2H-59B SYSTEM RELIEF VALVE SEE REFERENCE TABLE VALVE
PRESSURE- VALVE
COMPENSATED
PROPORTIONAL
VALVE
MB1
LOWERING LOWERING
VALVE VALVE
DCM1
P1
M HYDRAULIC
F1
PUMP
RETURN
FILTER Z
RESERVOIR
M211626AA

157928
AB 3.18 Main Manifold Harness
A B C D E F G H
V
INSERT ORIENTATION
BOTTOM VIEW
FORWARD VALVE RIGHT STEER VALVE
REVERSE PIN 1 - 16 WHITE/BLACK PIN 1 - 23 BLACK/WHITE
15
02 PIN 2 - 02 WHITE PIN 2 - 02 WHITE
LEFT
24 CLE FORWARD REVERSE VALVE LEFT STEER VALVE
AR
16
02 PIN 1 - 15 BLUE PIN 1 - 24 BLUE/BLACK
02
PIN 2 - 02 WHITE PIN 2 - 02 WHITE
CLE
CLE
AR
AR
W
RIGHT
23
02
CLE
AR
X
TO ELECTRIC PANEL - 9 WIRES
02
02 - WHITE
13 - ORANGE
14 - BLACK 02 02 LOWERING VALVE
15 - BLUE 13 - ORANGE
16 - WHITE/BLACK 13 13 02 - WHITE
17A - BLUE/RED
23 - BLACK/WHITE HOLDING VALVE
24 - BLUE/BLACK 13 - ORANGE PROPORTIONAL VALVE
LIFT VALVE Y
59 - ORANGE/BLACK 02 - WHITE 02 59 - ORANGE/BLACK
14 - BLACK
02 - WHITE
02 02 - WHITE
02 02 02
59
14 BRAKE VALVE
17A 17A - BLUE/RED
02 - WHITE
M146669AA1_S3

157928
AK 3.19 Main Manifold Harness (EE-Rated)
A B C D E F G H
V
INSERT ORIENTATION
BOTTOM VIEW
FORWARD VALVE RIGHT STEER VALVE
REVERSE PIN 1 - 16 WHITE/BLACK PIN 1 - 23 BLACK/WHITE
15
02 PIN 2 - 02 WHITE PIN 2 - 02 WHITE
LEFT
24 CLE FORWARD
REVERSE VALVE LEFT STEER VALVE
AR
16
02 PIN 1 - 15 BLUE PIN 1 - 24 BLUE/BLACK
02
CLE
CLE
AR
AR
RIGHT W
23
02
CLE
AR
02
02 - WHITE X
13 - ORANGE
02 02 LOWERING VALVE
14 - BLACK
15 - BLUE 13 - ORANGE
13 13 02 - WHITE
16 - WHITE/BLACK HOLDING VALVE
17A - BLUE/RED 13 - ORANGE
23 - BLACK/WHITE 02 - WHITE PROPORTIONAL VALVE
24 - BLUE/BLACK 02 59 - ORANGE/BLACK
59 - ORANGE/BLACK 02 - WHITE
02
02 02 02
59
14 LIFT VALVE BRAKE VALVE
14 - BLACK 17A - BLUE/RED
Y
17A
02 - WHITE 02 - WHITE
M207955AA

157928
3.20 Elevate Telematics Harness
A B C D E F G H
18X-RD/BK-18-TEW
B+-GN/PU-18-TEW
B+-GN/PU-18-TEW
CANH-BK-18-TEW
CANL-WH-18-TEW
00-WH-18-TEW
V
SCL CANL-WH-18-TEW
8
19E
SCH CANH-BK-18-TEW 19D 07
7
CONNECTIONS TO BATTERY
5
FOR POSITIVE TERMINAL (+) 19A
19D-WH/RD-18-TEW 19D-WH/RD-18-TEW
CHARGER
9
10
B+
17-BLUE/RED-18-TEW 17-BLUE/RED-18-TEW 19E 07
12
CANH
J1 TO TERMINAL W
CANL
6
00
STRIP
18X-RD/BK-18-TEW
11
07-RED-18-TEW 07-RED-18-TEW 19A
2
1A
19A-WH/RD-18-TEW 19A-WH/RD-18-TEW
1
S00 00-WH-18-TEW
4
SB+ B+-GN/PU-18-TEW
3
B+
B+-GN/PU-18-TEW
CANH-BK-18-TEW
CANL-WH-18-TEW
19A
00-WH-18-TEW
PIN 1 - 19A-WHITE/RED X
PIN 2 - 07-RED
PIN 3 -B+-GREEN/PURPLE
PIN 4 - 00 WHITE
7 6 PIN 5 - PLUGGED
8 5 PIN 6 - PLUGGED
9 4 PIN 7 - CAN H-BLACK TRIP
AL S 19D
10
11
3
2
PIN 8 - CAN L-WHITE
O TE
RMIN 07
19A
PIN 9 -19D-WHITE/RED T
12 1
PIN 10 - PLUGGED
PIN 11 - 18X-RED/BLACK
PIN 12 - 17-BLUE/RED
NORMALLY
J1 CONNECTED
S00 SCH
YELLOW
17
SCL SB+
Y
TO TERMINAL STRIP
TO TELEMATICS UNIT
NH
CA CONNECTIONS FOR LIMIT SWITCH
NL
B+
CA
B+
00
18
MOTOR CONTACTOR
X
CONNECTIONS UE
BL
FOR BMS
REAR MANIFOLD HARNESS TO CHARGER CUTOUT
YE
L
Z
M266433AB_Service

157928
3.21a Electrical Panel Diagram AI
A B C D E F G H
Serial Breakdown
TO BASE CONTROLS
Reference Chart
PIN 1 - 07 (RED) PIN 5 - N/U
Model Serial Number
DEUTSCH
8 1
7 2 PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE)
TIED BACK 6 3
PIN 3 - 13 (ORANGE) PIN 7 - 7A (GREEN)
- BLUE/BLACK 5 4
- GREEN/WHITE BLUE PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE) SJIII 3220 60006146 & Below V
SJIII 3226 27028841 & Below
02 YEL PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U SJIII 46xx 70028673 & Below
DEUTSCH
8 1
02 02 02 7 2 PIN 2 - 21 (ORANGE/BLACK) PIN 6 - N/U
6 3
5 4
PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE)
02 8C 8C PIN 4 - 18A (RED/BLACK) PIN 8 - 71 (WHITE/BLACK)
19A
18A 18A 18A TO HIGH SPEED LIMIT
18A TO POTHOLE LIMIT
29 29
LEGEND:
BEEPER
02 02
TO JOYSTICK BOX TO BASE CONTROLS W
TO TERMINAL BLOCK TO TILT SWITCH
19A 02
REAR HARNESS TO ENGINE TO BATTERY
02 - WHITE +
02
05 - GREEN/BLACK 03 TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH
07 - RED
TO REAR MANIFOLD TO POWER DECK
7A - GREEN
FROM MAIN DISCONNECT
4
8C - BLUE/WHITE TO OUTRIGGER TO END OF STROKE

13 - ORANGE SOLENOID CABLES
14E - BLACK TO FLASHER TO HORN/FLASHING LIGHT
19A
18 - RED/BLACK
TO FLASHER IF EQUIPPED
19 - BLUE
21 - ORANGE/BLACK OTHERWISE TIE BACK
TO (+) AT MOTOR
4
71 - BLACK/WHITE
71 - WHITE/BLACK 29 22
N/U - GREEN/WHITE
N/U - BLUE/BLACK TO (-) AT MOTOR 00 03 02
+ TILT SWITCH RELAY BRAKE/STEERING RELAY
19A - RED/WHITE PIN 30 - 19 PIN 30 - 17B
00 02
3A D17C-1 D17C PIN 85 - 28
PIN 86 - 02
PIN 85 - 17
PIN 86 - 02
X
30 30
86 TILT BRAKE/
PIN 87 - 19A PIN 87 - 17A
87a 87a
SWITCH STEERING
D14E
D21-1
D17-1
D14E-1
D14
D13 D15 D16 D21A D23 D24 PIN 87a - 28A PIN 87a - 17C
05 - WHITE R R
85 87 86 85 87 RELAY RELAY
3A - BLACK
END VIEW
TO CHARGER 7A 8C 49 02 02 05 07 13 14 14E 18 72 19 21 19A 29 21B 59 71 17 15 16 14 21A 17B 23 24
PROP. CONTROL RELAY
GREEN - TIED BACK PIN 30 - 59A
W R W W
86 87 PROPORTIONAL PIN 85 - 02
D19A
D13X D14X
D21 D17 87a
85
CONTROL PIN 86 - 21C
30 59A RELAY PIN 87 - N/U
D28A
PIN 87a - 59
MAIN MANIFOLD BATTERY TRAY

02 - WHITE 72 - BLACK/WHITE
13 - ORANGE 71 - BLACK
14 - BLACK Y
15 - BLUE
16 - WHITE/BLACK HYDRAULIC TRAY
17A - BLUE/RED 72 - BLACK/WHITE
23 - BLACK/WHITE 19 - BLACK
118711-0 XX
24 - BLUE/BLACK
HYDRAULIC PROPORTIONAL 59 - ORANGE/BLACK
MAIN MANIFOLD
PLATFORM CONTROL BOX
REAR HARNESS
TILT SWITCH
PIN 9 - (NOT USED)
PIN 1 - 02 WHITE
PIN 2 - 15 BLUE PIN 10 - 16 WHITE/BLACK HORN/FLASHING LIGHT
PIN 3 - 13 ORANGE PIN 11 - 18 RED/BLACK
PIN 4 - 14 BLACK PIN 12 - 59 ORANGE/BLACK TILT SWITCH TO HORN TO FLASHING LIGHT (OPT)
PIN 5 - 07 RED PIN 13 - 21B GREEN/BLACK (OPT) 02 - WHITE 02 - WHITE
19 - BLACK 49 - BLACK 22 - GREEN
PIN 6 - 8C BLUE/WHITE
PIN 7 - 49 GREEN/WHITE
PIN 14 - 24 BLUE/BLACK 28 - GREEN Z
PIN 15 - 23 BLACK/WHITE 02 - WHITE
PIN 8 - 7A GREEN PIN 16 - 60/7A RED/WHITE
NOTE: TIE BACK 21B (GREEN/BLACK)

FROM CONTROL CABLE
M149583AF1

157928
AI 3.21b Electrical Panel Diagram
A B C D E F G H
TO BASE CONTROLS
PIN 1 - 07 (RED) PIN 5 - N/U
Serial Breakdown
PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE) Reference Chart
DEUTSCH
8 1
7 2
6 3
BLUE
5 4
PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE)
Model Serial Number
SJIII 3220 60006147 & Above V
02
YEL PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U SJIII 3226 27028842 & Above
DEUTSCH
8 1
02 02 02 7 2 PIN 2 - 21 (ORANGE/BLACK) PIN 6 - N/U
6 3 SJIII 46xx 70028674 & Above
8C 8C 5 4 PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE)
02
PIN 4 - 18A (RED/BLACK) PIN 8 - 71 (WHITE/BLACK)
19A TO HIGH SPEED LIMIT
18A 18A 18A
TO POTHOLE LIMIT
18A
29 29
LEGEND:
BEEPER
TO JOYSTICK BOX TO BASE CONTROLS
02 02
W
19A 02 TO TERMINAL BLOCK TO TILT SWITCH
REAR HARNESS
+ TO ENGINE TO BATTERY
02 - WHITE
02
05 - GREEN/BLACK 03
TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH
07 - RED
7A - GREEN
FROM MAIN DISCONNECT TO REAR MANIFOLD TO POWER DECK
4
8C - BLUE/WHITE
13 - ORANGE TO OUTRIGGER
14E - BLACK TO END OF STROKE
SOLENOID CABLES
19A
18 - RED/BLACK
TO FLASHER IF EQUIPPED TO FLASHER TO HORN/FLASHING LIGHT
19 - BLUE
21 - ORANGE/BLACK OTHERWISE TIE BACK
TO (+) AT MOTOR
4
71 - BLACK/WHITE
71 - WHITE/BLACK
29 22
N/U - GREEN/WHITE
N/U - BLUE/BLACK TO (-) AT MOTOR
+ TILT SWITCH RELAY BRAKE/STEERING RELAY
00 03 02 PIN 30 - 19 PIN 30 - 17B
19A - RED/WHITE
3A 00 D17C-1 D17C 02 PIN 85 - 28 PIN 85 - 17
30 30
86
PIN 86 - 02 TILT BRAKE/ PIN 86 - 02 X
87a 87a PIN 87 - 19A PIN 87 - 17A
SWITCH STEERING
D14E
D21-1
D17-1
D14E-1
D8C
D14
D13 D15 D16 D21A D23 D24 PIN 87a - 28A PIN 87a - 17C
05 - WHITE R R
RELAY RELAY
85 87 86 85 87
3A - BLACK
END VIEW
TO CHARGER 7A 8C 49 02 02 05 07 13 14 14E 18 72 19 21 19A 29 21B 59 71 17 15 16 14 21A 17B 23 24
PROP. CONTROL RELAY
GREEN - TIED BACK PIN 30 - 59A
W R W W
D19A
D13X D14X D21 D17 87a
85
CONTROL PIN 86 - 21C
30 59A RELAY PIN 87 - N/U
D28A
PIN 87a - 59
BATTERY TRAY
72 - BLACK/WHITE
71 - BLACK
Y
HYDRAULIC TRAY
72 - BLACK/WHITE
19 - BLACK
118711-0 XX
MAIN MANIFOLD
REAR HARNESS
PLATFORM CONTROL BOX TILT SWITCH
PIN 1 - 02 WHITE PIN 9 - (NOT USED) HORN/FLASHING LIGHT
PIN 2 - 15 BLUE PIN 10 - 16 WHITE/BLACK
PIN 3 - 13 ORANGE PIN 11 - 18 RED/BLACK MAIN MANIFOLD TILT SWITCH TO HORN TO FLASHING LIGHT (OPT)
PIN 4 - 14 BLACK PIN 12 - 59 ORANGE/BLACK
02 - WHITE 17A - BLUE/RED 19 - BLACK 02 - WHITE 02 - WHITE
Z
PIN 5 - 07 RED PIN 13 - 21B GREEN/BLACK (OPT) 23 - BLACK/WHITE 49 - BLACK 22 - GREEN
13 - ORANGE 28 - GREEN
PIN 6 - 8C BLUE/WHITE PIN 14 - 24 BLUE/BLACK 24 - BLUE/BLACK
14 - BLACK 02 - WHITE
PIN 7 - 49 GREEN/WHITE PIN 15 - 23 BLACK/WHITE 59 - ORANGE/BLACK
15 - BLUE
PIN 8 - 7A GREEN PIN 16 - 60/7A RED/WHITE 16 - WHITE/BLACK
M195906AA1

157928
3.22a Electrical Panel Diagram with Power Deck AI
A B C D E F G H
Serial Breakdown
Reference Chart
LEGEND: TO BASE CONTROLS
TO JOYSTICK BOX TO BASE CONTROLS BLUE

Model Serial Number
TO TERMINAL BLOCK TO TILT SWITCH SJIII 3220 60006146 & Below V
TO ENGINE TO BATTERY
02
YEL SJIII 3226 27028841 & Below
TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH TO CHARGER TO HIGH SPEED LIMIT
02 02 02
TO POTHOLE LIMIT SJIII 46xx 70028673 & Below
TO OUTRIGGER TO END OF STROKE 18A 18A 18A
SOLENOID CABLES
18A
TO FLASHER TO HORN/FLASHING LIGHT
29 29
BEEPER
4
02 02
TO (+) AT MOTOR 19A 02 W
4
TO (-) AT MOTOR 00 27
+
9A GR/BLK
26
REAR HARNESS
02 - WHITE
05 - GREEN/BLACK 24
07 - RED D26A D27A
7A - GREEN P.DECK RELAY #1 23
9A
9A
8C - BLUE/WHITE PIN 30 -23 TO FLASHER IF EQUIPPED
13 - ORANGE PIN 85 - 02 OTHERWISE TIE BACK
14E - BLACK PIN 86 - 9A
18 - RED/BLACK PIN 87 - 26A 29 22
26A
27A
03
02
02
23
02
19 - BLUE PIN 87a - 23A
24
21 - ORANGE/BLACK + TILT SWITCH RELAY BRAKE/STEERING RELAY
71 - BLACK/WHITE P.DECK RELAY #2 PIN 30 - 19 PIN 30 - 17B
71 - WHITE/BLACK PIN 30 - 24 PIN 85 - 28 PIN 85 - 17
N/U - GREEN/WHITE PIN 85 - 02 PIN 86 - 02 PIN 86 - 02
PIN 86 - 9A P.DECK P.DECK 00 30 30
TILT BRAKE/
N/U - BLUE/BLACK 86
PIN 87 - 19A PIN 87 - 17A
87a 02 87a
SWITCH STEERING
N/U - RED/WHITE PIN 87 - 27A
PIN 87a - 24A
RELAY #2 RELAY #1
3A 85 87 86 85 87
PIN 87a - 28A
RELAY RELAY
PIN 87a - 17C X
END VIEW
7A 8C 49 02 02 05 07 13 14 14E 18 72 19 21 19A 29 21B 59 71 17 15 16 14 21A 17B 23 24
PROP. CONTROL RELAY
PIN 30 - 59A
W W
D21B-1 D21B-2 87a
85
59A CONTROL PIN 86 - 21C
30 RELAY PIN 87 - N/U
PIN 87a - 59
3A - BLACK
05 - WHITE BATTERY TRAY
72 - BLACK/WHITE
71 - BLACK
HYDRAULIC TRAY
72 - BLACK/WHITE Y
19 - BLACK
MAIN MANIFOLD
118711-0
HYDRAULIC PROPORTIONAL XX
REAR HARNESS
TILT SWITCH
HORN/FLASHING LIGHT
PIN 1 - 02 WHITE PIN 9 - (NOT USED)

27
26
PIN 4 - 14 BLACK
PIN 5 - 07 RED
PIN 12 - 59 ORANGE/BLACK Z
PIN 13 - 21B GREEN/BLACK (OPT)
02
02
02
PIN 6 - 8C BLUE/WHITE PIN 14 - 24 BLUE/BLACK

PIN 7 - 49 GREEN/WHITE
27
PIN 15 - 23 BLACK/WHITE
26
PIN 8 - 7A GREEN PIN 16 - 60/7A RED/WHITE

TO P.DECK MANIF.
M160818AA

157928
AI 3.22b Electrical Panel Diagram with Power Deck
A B C D E F G H
Serial Breakdown
TO BASE CONTROLS
Reference Chart
BLUE Model Serial Number
SJIII 3220 60006147 & Above V
YEL SJIII 3226 27028842 & Above
TO CHARGER
02
02 02 02 TO HIGH SPEED LIMIT
TO POTHOLE LIMIT SJIII 46xx 70028674 & Above
18A 18A 18A
18A
29 29
BEEPER LEGEND:
4

02 02
TO (+) AT MOTOR 19A 02 TO TERMINAL BLOCK TO TILT SWITCH W

4
+ TO ENGINE TO BATTERY
TO (-) AT MOTOR 00 02 WH 27
9A GR/BLK
26
REAR HARNESS
8.125
02 - WHITE
05 - GREEN/BLACK 24 TO OUTRIGGER TO END OF STROKE
07 - RED D26A D27A SOLENOID CABLES
7A - GREEN P.DECK RELAY #1 23 TO FLASHER TO HORN/FLASHING LIGHT
9A
9A
8C - BLUE/WHITE PIN 30 -23 TO FLASHER IF EQUIPPED

13 - ORANGE PIN 85 - 02 OTHERWISE TIE BACK
14E - BLACK PIN 86 - 9A
18 - RED/BLACK PIN 87 - 26A 29 22
26A
27A
03
02
02
23
02
19 - BLUE PIN 87a - 23A

24
21 - ORANGE/BLACK + TILT SWITCH RELAY BRAKE/STEERING RELAY

71 - BLACK/WHITE P.DECK RELAY #2 PIN 30 - 19 PIN 30 - 17B
71 - WHITE/BLACK PIN 30 - 24 PIN 85 - 28 PIN 85 - 17
N/U - GREEN/WHITE PIN 85 - 02 PIN 86 - 02 PIN 86 - 02
00 30 30
TILT BRAKE/
N/U - BLUE/BLACK
N/U - RED/WHITE
PIN 86 - 9A
PIN 87 - 27A
P.DECK
RELAY #2
P.DECK
RELAY #1
87a 02 87a
86
PIN 87 - 19A
SWITCH STEERING
PIN 87 - 17A X
3A PIN 87a - 28A PIN 87a - 17C
PIN 87a - 24A 85 87 86 85 87 RELAY RELAY
END VIEW
7A 8C 49 02 02 05 07 13 14 14E 18 72 19 21 19A 29 21B 59 71 17 15 16 14 21A 17B 23 24
PROP. CONTROL RELAY
1.125 1.125 PIN 30 - 59A
W W
D21B-1 D21B-2 87a
85
59A CONTROL PIN 86 - 21C
30 RELAY PIN 87 - N/U
PIN 87a - 59
3A - BLACK
05 - WHITE BATTERY TRAY
72 - BLACK/WHITE
71 - BLACK
Y
HYDRAULIC TRAY
72 - BLACK/WHITE
19 - BLACK
MAIN MANIFOLD
118711-0
HYDRAULIC PROPORTIONAL XX
REAR HARNESS
TILT SWITCH
HORN/FLASHING LIGHT
TILT SWITCH MAIN MANIFOLD TO HORN TO FLASHING LIGHT (OPT)
19 - BLACK 02 - WHITE 49 - BLACK 22 - GREEN
PIN 9 - (NOT USED)
PIN 1 - 02 WHITE
28 - GREEN
02 - WHITE
13 - ORANGE
14 - BLACK
Z
PIN 3 - 13 ORANGE PIN 11 - 18 RED/BLACK 15 - BLUE
27
26
PIN 4 - 14 BLACK PIN 12 - 59 ORANGE/BLACK 16 - WHITE/BLACK

PIN 5 - 07 RED PIN 13 - 21B GREEN/BLACK (OPT) 17A - BLUE/RED
02
02
02
PIN 6 - 8C BLUE/WHITE PIN 14 - 24 BLUE/BLACK 23 - BLACK/WHITE

PIN 7 - 49 GREEN/WHITE 24 - BLUE/BLACK
27
PIN 15 - 23 BLACK/WHITE
26
PIN 8 - 7A GREEN PIN 16 - 60/7A RED/WHITE 59 - ORANGE/BLACK

TO P.DECK MANIF.
M195911AA

157928
3.23a Electrical Panel Diagram (EE Rated) AI
A B C D E F G H
TO CHARGER CUTOUT
Serial Breakdown
PIN 1 - 3A (GREEN/WHITE)
PIN 2 - 05 (BLUE/BLACK) Reference Chart
1 2 3 4 1 2 3 4
PIN 1 - 07 (RED) PIN 5 - N/U PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U
PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE) DEUTSCH DEUTSCH
PIN 2 - 21 (ORANGE/BLACK) PIN 6 - N/U Model Serial Number
PIN 3 - 13 (ORANGE) PIN 7 - 7A (GREEN) PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE)
PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE) 8 7 6 5 8 7 6 5 PIN 4 - 18A (RED/BLACK) PIN 8 - 71 (WHITE/BLACK) SJIII 3220 60006146 & Below V
TO BASE CONTROLS TO HIGH SPEED LIMIT SJIII 3226 27029032 & Below
TO TILT SWITCH TO POTHOLE LIMIT
TO (-) AT MOTOR TILT SWITCH RELAY BRAKE/STEERING RELAY PROP. CONTROL RELAY
00 PIN 30 - 19 PIN 30 - 17B PIN 30 - 59A
TO (+) AT MOTOR PIN 85 - 28 PIN 85 - 17 PIN 85 - 21C
PIN 86 - 02 PIN 86 - 02 PIN 86 - 02
BLUE
4
YEL
PIN 87 - 19A PIN 87 - 17A PIN 87 - N/U
PIN 87a - 28A PIN 87a - 17C PIN 87a - 59
18A
15/16 CABLE
02 - WHITE (03 BLUE - 14 AWG)
05 - GREEN/BLACK (00 WHITE - 14 AWG)
07 - RED
02
7A - GREEN 29
8C - BLUE/WHITE
W
8C
18A
13 - ORANGE BEEPER
14E - BLACK
19A
02
18 - RED/BLACK
19 - BLUE 02
21 - ORANGE/BLACK
71 - BLACK/WHITE
19A
8C
02
02
71 - WHITE/BLACK
22
3A
03
02
00
N/U - GREEN/WHITE
29
18A
N/U - BLUE/BLACK
N/U - RED/WHITE
02 MAIN DISCONNECT
18A
MAIN MANIFOLD
02 - WHITE
13 - ORANGE TILT BRAKE/ PROPORTIONAL
14 - BLACK SWITCH STEERING CONTROL
15 - BLUE 02 19A RELAY RELAY RELAY X
02
16 - WHITE/BLACK +
17A - BLUE/RED
23 - BLACK/WHITE
24 - BLUE/BLACK 02 19A 28 02 17A 17 02 21C
59 - ORANGE/BLACK 02
28A 17C 59
19 17B 59A
REAR HARNESS
MAIN MANIFOLD HARNESS
+
PLATFORM CONTROL BOX 59A
03
HORN/FLASHING LIGHT
TILT SWITCH
D17-1 D14E D21A D17
TO TILT SWITCH
D14E-1
D28A D17C-1 D17C
PIN 1 - 19 (BLACK) D13 D15 D16 D14 D23 D24 LEGEND:
PIN 2 - 28 (GREEN)
BATTERY TRAY Y
72 - BLACK/WHITE TO JOYSTICK BOX TO LOWER KEYSWITCH BOX
PIN 3 - 02 (WHITE) 71 - BLACK 02 05 13 18 72 19 19A 21 29 14E 59 71 17 15 16 14 21A 23 24 07 7A 8C
PIN 4 - N/U
D21-1 D21 TO ENGINE TO BATTERY
118711-0 XX
D19A
HYDRAULIC TRAY
72 - BLACK/WHITE TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH
19 - BLACK D13X D14X
FEMALE 22 TO FLASHING LIGHT TO OUTRIGGER

SOLENOID CABLES
TO END OF STROKE
BACK VIEW 02 - WHITE
(7A) RED WHITE 16 8 GREEN (7A)
TO FLASHER HORN
(23) BLACK WHITE 15 7 GREEN WHITE (49)
02 22 - GREEN
(24) BLUE BLACK 14 6 BLUE WHITE (8C)
MAIN MANIFOLD
(21B) (OPT) GREEN BLACK 13 5 RED (07) PLATFORM CONTROL BOX
(59) ORANGE BLACK 12 4 BLACK (14)
(18) RED BLACK 11 3 ORANGE (13) REAR HARNESS
(16) WHITE BLACK 10 2 BLUE (15) 02 TO HORN
(NOT USED) 9 1 WHITE (02)
02 - WHITE
TILT SWITCH Z
49 - BLACK HORN/FLASHING LIGHT 49 49
49
TO CHARGER
1" LG X Ø1/4" HEAT-SHRINK TUBING MUST COVER
TERMINAL END, REMAINDER OVER WIRE TYP. M147790AJ1

157928
AI 3.23b Electrical Panel Diagram (EE Rated)
A B C D E F G H
TO CHARGER CUTOUT Serial Breakdown

PIN 2 - 05 (BLUE/BLACK) Reference Chart
1 2 3 4 1 2 3 4
PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U
PIN 1 - 07 (RED)
PIN 2 - 05 (GREEN/BLACK)
PIN 5 - N/U
PIN 6 - 8C (BLUE/WHITE) PIN 2 - 21 (ORANGE/BLACK) PIN 6 - N/U
Model Serial Number
DEUTSCH DEUTSCH
PIN 3 - 13 (ORANGE) PIN 7 - 7A (GREEN) PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE)
PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE) 8 7 6 5 8 7 6 5 PIN 4 - 18A (RED/BLACK) PIN 8 - 71 (WHITE/BLACK) SJIII 3220 60006147 & 60007077 V
TO (-) AT MOTOR SJIII 3226 27029033 & 27032454
TO BASE CONTROLS TO HIGH SPEED LIMIT TILT SWITCH RELAY BRAKE/STEERING RELAY PROP. CONTROL RELAY
TO TILT SWITCH TO POTHOLE LIMIT 00 PIN 30 - 19 PIN 30 - 17B PIN 30 - 59A SJIII 46xx 70029137 & 70032134
PIN 85 - 28 PIN 85 - 17 PIN 85 - 21C
TO (+) AT MOTOR PIN 86 - 02 PIN 86 - 02 PIN 86 - 02
PIN 87 - 19A PIN 87 - 17A PIN 87 - N/U
BLUE
4
YEL
PIN 87a - 28A PIN 87a - 17C PIN 87a - 59
18A
15/16 CABLE
07 - RED
02
7A - GREEN 29
8C - BLUE/WHITE W
8C
18A
13 - ORANGE BEEPER
14E - BLACK
19A
02
18 - RED/BLACK
19 - BLUE 02
21 - ORANGE/BLACK
71 - BLACK/WHITE
19A
8C
02
02
71 - WHITE/BLACK
22
3A
03
02
00
N/U - GREEN/WHITE
29
18A
N/U - BLUE/BLACK
N/U - RED/WHITE
02
MAIN DISCONNECT
18A
MAIN MANIFOLD
02 - WHITE
14 - BLACK SWITCH STEERING CONTROL X
15 - BLUE 02 19A RELAY RELAY RELAY
02
16 - WHITE/BLACK
17A - BLUE/RED
23 - BLACK/WHITE
24 - BLUE/BLACK 02 19A 28 02 17A 17 02 21C
28A 17C 59
19 17B 59A
REAR HARNESS
+
03
HORN/FLASHING LIGHT
TILT SWITCH
D17-1 D14E D21A D17 LEGEND:
TO TILT SWITCH TO JOYSTICK BOX TO LOWER KEYSWITCH BOX
Y
D14E-1
D28A D17C-1 D17C
D8C
D13 D15 D16 D14 D23 D24
PIN 1 - 19 (BLACK) TO TERMINAL BLOCK TO TILT SWITCH
BATTERY TRAY
PIN 2 - 28 (GREEN) 72 - BLACK/WHITE
02 05 13 18 72 19 19A 21 29 14E 59 71 17 15 16 14 21A 23 24 07 7A 8C TO ENGINE TO BATTERY
PIN 3 - 02 (WHITE) 71 - BLACK
118711-0 XX
PIN 4 - N/U TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH
HYDRAULIC PROPORTIONAL D21-1 D21 D19A
HYDRAULIC TRAY TO REAR MANIFOLD TO POWER DECK
72 - BLACK/WHITE
19 - BLACK D13X D14X TO OUTRIGGER TO END OF STROKE
SOLENOID CABLES
TO FLASHER HORN
FEMALE 22 TO FLASHING LIGHT
02 22 - GREEN
BLUE WHITE (8C)
MAIN MANIFOLD
(24) BLUE BLACK 14 6
(18) RED BLACK 11 3 ORANGE (13) REAR HARNESS
(16) WHITE BLACK 10 2 BLUE (15) 02 TO HORN Z
02 - WHITE
TILT SWITCH
49
TO CHARGER
M195921AA1

157928
AK 3.23c Electrical Panel Diagram (EE Rated)
A B C D E F G H
TO CHARGER CUTOUT
Serial Breakdown
TO (-) AT MOTOR TILT SWITCH RELAY BRAKE/STEERING RELAY PROP. CONTROL RELAY SPEED SOLENOID RELAY
Reference Chart
TO BASE CONTROLS
TO TILT SWITCH TO HIGH SPEED LIMIT
00 PIN 30 - 19 PIN 30 - 17B PIN 30 - 59A PIN 30 - 18 Model Serial Number
PIN 85 - 28 PIN 85 - 17 PIN 85 - 21C PIN 85 - 21
PIN 86 - 02 PIN 86 - 02 PIN 86 - 02 PIN 86 - 02 SJIII 3220 60007078 & Above V
TO (+) AT MOTOR
PIN 87 - 19A PIN 87 - 17A PIN 87 - N/U PIN 87 - 18A SJIII 3226 27032455 & Above
PIN 87a - 28A PIN 87a - 17C PIN 87a - 59 PIN 87a - N/U
BLUE
4
YEL
18A
15/16 CABLE
02 - WHITE
3A - GREEN/WHITE
05 - GREEN/BLACK
02
05 - BLUE/BLACK 29
07 - RED
8C
18A
7A - GREEN BEEPER
8C - BLUE/WHITE
19A
02
13 - ORANGE
14E - BLACK 02
18A - RED/BLACK W
19 - BLUE
19A
8C
02
02
21 - ORANGE/BLACK
22
3A
03
02
00
71 - BLACK/WHITE
SPEED
18A
29
71 - WHITE/BLACK
19A - RED/WHITE SOLENOID TO FLASHER IF EQUIPPED
RELAY
02
02 18A 21
MAIN DISCONNECT
18A
MAIN MANIFOLD 18
02 - WHITE
14 - BLACK SWITCH STEERING CONTROL
15 - BLUE 02 19A RELAY RELAY RELAY
02
16 - WHITE/BLACK
17A - BLUE/RED
23 - BLACK/WHITE
X
24 - BLUE/BLACK 02 19A 28 02 17A 17 02 21C
28A 17C 59
19 17B 59A
REAR HARNESS
+
03
HORN/FLASHING LIGHT
TILT SWITCH
D17-1 D14E D21A D17
TO TILT SWITCH
D14E-1
D28A D17C-1 D17C
D8C
D13 D15 D16 D14 D23 D24
PIN 1 - 19 (BLACK)
BATTERY TRAY
PIN 2 - 28 (GREEN) 72 - BLACK/WHITE Y
PIN 3 - 02 (WHITE) 71 - BLACK 02 05 13 18 72 19 19A 21 29 14E 59 71 17 15 16 14 21A 23 24 07 7A 8C
118711-0 XX
PIN 4 - N/U
HYDRAULIC PROPORTIONAL D21-1 D21 D19A
HYDRAULIC TRAY
18A
72 - BLACK/WHITE LEGEND:
19 - BLACK D13X D14X
18A
FEMALE 22 TO FLASHING LIGHT TO TERMINAL BLOCK TO TILT SWITCH

BACK VIEW 02 - WHITE TO ENGINE TO BATTERY
02 22 - GREEN
BLUE WHITE (8C)
MAIN MANIFOLD TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH
(24) BLUE BLACK 14 6
(9A) (OPT) GREEN BLACK 13 5 RED (07) PLATFORM CONTROL BOX
(59) ORANGE BLACK 12 4 BLACK (14) TO OUTRIGGER TO END OF STROKE
(18) RED BLACK 11 3 ORANGE (13) REAR HARNESS SOLENOID CABLES
(16) WHITE BLACK 10 2 BLUE (15) 02 TO HORN TO FLASHER TO HORN/FLASHING LIGHT Z
02 - WHITE
TILT SWITCH
49
TO CHARGER
M204067AB1

157928
3.24a Electrical Panel Diagram (EE Rated) with Power Deck AI
A B C D E F G H
TO BASE CONTROLS
TO TILT SWITCH
TO HIGH SPEED LIMIT
TO POTHOLE LIMIT
Serial Breakdown
Reference Chart
PIN 1 - 07 (RED) PIN 5 - N/U PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U
DEUTSCH
8 1
DEUTSCH
8 1
PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE) PIN 2 - 21 (ORANGE/BLACK) PIN 6 - N/U
7
6
2
3
7
6
2
3
PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE)
Model Serial Number
5 4 5 4
PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE) PIN 4 - 18A (RED/BLACK) PIN 8 - 71 (WHITE/BLACK)
SJIII 3220 60006146 & Below V
PIN 2 - 05 (BLUE/BLACK)
TO CHARGER CUTOUT SJIII 3226 27029032 & Below
TILT SWITCH RELAY BRAKE/STEERING RELAY PROP. CONTROL RELAY SJIII 46xx 70029136 & Below
TO (-) AT MOTOR 00
PIN 30 - 19 PIN 30 - 17B PIN 30 - 59A
PIN 85 - 28 PIN 85 - 17 PIN 85 - 21C
PIN 86 - 02 PIN 86 - 02 PIN 86 - 02
PIN 87 - 19A PIN 87 - 17A PIN 87 - N/U
BLUE
4
YEL
PIN 87a - 28A PIN 87a - 17C PIN 87a - 59
TO (+) AT MOTOR
15/16 CABLE
07 - RED
29
7A - GREEN W
18A
02
8C - BLUE/WHITE
13 - ORANGE BEEPER
14E - BLACK
19A
02
18 - RED/BLACK
19 - BLUE 02
21 - ORANGE/BLACK
71 - BLACK/WHITE
71 - WHITE/BLACK
22
18A
02
3A
03
02
00
N/U - GREEN/WHITE
29
N/U - BLUE/BLACK
N/U - RED/WHITE
18A
02
MAIN DISCONNECT
MAIN MANIFOLD
02 - WHITE
P.DECK RELAY #1 P.DECK RELAY #2
TILT BRAKE/ PROPORTIONAL PIN 30 -23
13 - ORANGE
14 - BLACK
P.DECK P.DECK SWITCH STEERING CONTROL PIN 30 - 24
15 - BLUE RELAY #2 RELAY #1 RELAY RELAY RELAY PIN 85 - 02 PIN 85 - 02 X
18A
02
16 - WHITE/BLACK +
PIN 86 - 9A PIN 86 - 9A
17A - BLUE/RED
23 - BLACK/WHITE PIN 87 - 26A PIN 87 - 27A
24 - BLUE/BLACK PIN 87a - 23A
59 - ORANGE/BLACK
02 27A 9A 02 26A 9A 02 19A 28 02 17A 17 02 21C
PIN 87a - 24A
24A 23A 28A 17C 59 02
REAR HARNESS
23 24 19 17B 59A TILT SWITCH RELAY BRAKE/STEERING RELAY PROP. CONTROL RELAY
D27A D26A PIN 30 - 19 PIN 30 - 17B PIN 30 - 59A
MAIN MANIFOLD HARNESS PIN 85 - 28 PIN 85 - 17 PIN 85 - 21C
+
PLATFORM CONTROL BOX PIN 86 - 02 PIN 86 - 02 PIN 86 - 02
59A PIN 87 - 19A PIN 87 - 17A PIN 87 - N/U
HORN/FLASHING LIGHT
PIN 87a - 28A PIN 87a - 17C PIN 87a - 59
TILT SWITCH
TO P.DECK MANIF. 21B 21B
LEGEND:
TO TILT SWITCH D21B-1 D21B-2
TO JOYSTICK BOX TO LOWER KEYSWITCH BOX
PIN 1 - 19 (BLACK)
PIN 2 - 28 (GREEN) TO TERMINAL BLOCK TO TILT SWITCH
Y
PIN 3 - 02 (WHITE) BATTERY TRAY 02 05 13 18 72 19 19A 21 29 14E 59 71 17 15 16 14 21A 23 24 07 7A 8C
72 - BLACK/WHITE TO ENGINE TO BATTERY
118711-0 XX
PIN 4 - N/U 71 - BLACK
HYDRAULIC TRAY TO REAR MANIFOLD TO POWER DECK
26
72 - BLACK/WHITE 02 WH
27
19 - BLACK TO OUTRIGGER TO END OF STROKE
SOLENOID CABLES
TO FLASHING LIGHT TO FLASHER HORN
FEMALE 22
02 22 - GREEN
(18) RED BLACK 11 3 ORANGE (13)
02 - WHITE
49 - BLACK
49 Z
27
26
02
02
02
27
26
TO P.DECK MANIF.
M160819AB

157928
AI 3.24b Electrical Panel Diagram (EE Rated) with Power Deck
A B C D E F G H
TO BASE CONTROLS TO HIGH SPEED LIMIT
TO TILT SWITCH TO POTHOLE LIMIT Serial Breakdown
PIN 1 - 07 (RED) PIN 5 - N/U PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U Reference Chart
DEUTSCH
8 1
DEUTSCH
8 1
PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE) 7 2 7 2 PIN 2 - 21 (ORANGE/BLACK) PIN 6 - N/U
6 3
PIN 3 - 13 (ORANGE)
PIN 4 - 14E (BLACK)
PIN 7 - 7A (GREEN)
PIN 8 - 02 (WHITE)
6
5
3
4
5 4
PIN 3 - 18 (RED/BLACK)
PIN 4 - 18A (RED/BLACK)
PIN 7 - 19 (BLUE)
PIN 8 - 71 (WHITE/BLACK)
Model Serial Number
PIN 2 - 05 (BLUE/BLACK)
TO CHARGER CUTOUT SJIII 3220 60006147 & 60007077
V
00
SJIII 3226 27029033 & 27032454
TO (-) AT MOTOR
SJIII 46xx 70029137 & 70032133
BLUE
4
YEL
TO (+) AT MOTOR
15/16 CABLE
07 - RED
7A - GREEN 29
18A
02
8C - BLUE/WHITE
13 - ORANGE BEEPER
14E - BLACK W
19A
02
18 - RED/BLACK
19 - BLUE 02
21 - ORANGE/BLACK
71 - BLACK/WHITE
71 - WHITE/BLACK
22
18A
02
3A
03
02
00
N/U - GREEN/WHITE
29
N/U - BLUE/BLACK
N/U - RED/WHITE
18A
02
MAIN DISCONNECT
MAIN MANIFOLD
02 - WHITE
14 - BLACK
P.DECK P.DECK SWITCH STEERING CONTROL P.DECK RELAY #1 P.DECK RELAY #2
RELAY #1 RELAY #2 RELAY RELAY RELAY PIN 30 -23
15 - BLUE PIN 30 - 24
18A
02
16 - WHITE/BLACK
+
17A - BLUE/RED PIN 85 - 02 PIN 85 - 02 X
23 - BLACK/WHITE PIN 86 - 9A PIN 86 - 9A
24 - BLUE/BLACK 02 27A 9A 02 26A 9A 02 19A 28 02 17A 17 02 21C
59 - ORANGE/BLACK PIN 87 - 26A PIN 87 - 27A
24A 23A 28A 17C 59 02
23 24 19 17B 59A
PIN 87a - 23A PIN 87a - 24A
REAR HARNESS
D26A
D27A
TILT SWITCH RELAY BRAKE/STEERING RELAY PROP. CONTROL RELAY
PIN 30 - 19 PIN 30 - 17B PIN 30 - 59A
+
PLATFORM CONTROL BOX PIN 85 - 28 PIN 85 - 17 PIN 85 - 21C
59A
HORN/FLASHING LIGHT PIN 86 - 02 PIN 86 - 02 PIN 86 - 02
TILT SWITCH PIN 87 - 19A PIN 87 - 17A PIN 87 - N/U
TO P.DECK MANIF. 21B 21B PIN 87a - 28A PIN 87a - 17C PIN 87a - 59
PIN 1 - 19 (BLACK)
PIN 2 - 28 (GREEN) LEGEND:
PIN 3 - 02 (WHITE) BATTERY TRAY
72 - BLACK/WHITE
02 05 13 18 72 19 19A 21 29 14E 59 71 17 15 16 14 21A 23 24 07 7A 8C
Y
PIN 4 - N/U 71 - BLACK
118711-0 XX
HYDRAULIC TRAY
72 - BLACK/WHITE 26
02 WH
27
19 - BLACK
TO FLASHING LIGHT TO REAR MANIFOLD TO POWER DECK
FEMALE 22
BACK VIEW 02 - WHITE TO OUTRIGGER TO END OF STROKE
SOLENOID CABLES
02 22 - GREEN TO FLASHER HORN
(18) RED BLACK 11 3 ORANGE (13)
02 - WHITE
49 - BLACK Z
49
27
26
02
02
02
27
26
TO P.DECK MANIF.
M195926AA

157928
AK 3.24c Electrical Panel Diagram (EE Rated) with Power Deck
A B C D E F G H
Serial Breakdown
TO CHARGER CUTOUT
TO (-) AT MOTOR TILT SWITCH RELAY BRAKE/STEERING RELAY PROP. CONTROL RELAY SPEED SOLENOID RELAYP.DECK RELAY #1 Reference Chart
TO BASE CONTROLS
P.DECK RELAY #2
TO TILT SWITCH TO HIGH SPEED LIMIT 00 PIN 30 - 19 PIN 30 - 17B PIN 30 - 59A PIN 30 - 18 PIN 30 -23 PIN 30 - 24 Model Serial Number
PIN 85 - 28 PIN 85 - 17 PIN 85 - 21C PIN 85 - 21 PIN 85 - 9A PIN 85 - 9A SJIII 3220 60007078 & Above
PIN 86 - 02 PIN 86 - 02 PIN 86 - 02 PIN 86 - 02 PIN 86 - 02 PIN 86 - 02 V
PIN 87 - 19A PIN 87 - 17A PIN 87 - N/U PIN 87 - 18A PIN 87 - 26A PIN 87 - 27A SJIII 3226 27032455 & Above
BLUE
4
YEL
PIN 87a - 28A PIN 87a - 17C PIN 87a - 59 PIN 87a - N/U PIN 87a - 23A PIN 87a - 24A SJIII 46xx 70032134 & Above
TO (+) AT MOTOR
15/16 CABLE
02 - WHITE
05 - GREEN/BLACK
07 - RED (03 BLUE - 14 AWG)
7A - GREEN (00 WHITE - 14 AWG)
8C - BLUE/WHITE 29
13 - ORANGE
18A
02
14E - BLACK BEEPER
18A - RED/BLACK
19A
02
19 - BLUE 02
21 - ORANGE/BLACK
71 - BLACK/WHITE W
22
18A
02
71 - WHITE/BLACK
3A
03
02
00
SPEED
29
N/U - GREEN/WHITE
SOLENOID
N/U - BLUE/BLACK RELAY TO FLASHER IF EQUIPPED
N/U - RED/WHITE
18A
02
02 18A 21
MAIN DISCONNECT
MAIN MANIFOLD 1.125
18
(4X)
02 - WHITE TILT BRAKE/ PROPORTIONAL
13 - ORANGE P.DECK P.DECK SWITCH STEERING CONTROL
RELAY #1 RELAY #2 RELAY RELAY RELAY
14 - BLACK
18A
02
+
15 - BLUE
16 - WHITE/BLACK
17A - BLUE/RED 02 27A 9A 02 26A 9A 02 19A 28 02 17A 17 02 21C
X
23 - BLACK/WHITE 23A 24A 28A 17C 59 02
24 - BLUE/BLACK REAR HARNESS
23 24 19 17B 59A
59 - ORANGE/BLACK D27A D26A

+
59A
HORN/FLASHING LIGHT
TILT SWITCH
TO P.DECK MANIF. 21B 21B
PIN 1 - 19 (BLACK)
PIN 2 - 28 (GREEN)
PIN 3 - 02 (WHITE) BATTERY TRAY 02 05 13 18 72 19 19A 21 29 14E 59 71 17 15 16 14 21A 23A 24A 07 7A 8C
72 - BLACK/WHITE
118711-0 XX
PIN 4 - N/U 71 - BLACK Y
HYDRAULIC TRAY
26
72 - BLACK/WHITE 02 WH
27
19 - BLACK
TO FLASHING LIGHT
FEMALE 22
(7A) RED WHITE 16 8 GREEN (7A) 02 22 - GREEN
(23) BLACK WHITE 15 7 GREEN WHITE (49) LEGEND:
(24) BLUE BLACK 14 6 BLUE WHITE (8C) PLATFORM CONTROL BOX
(9A) (OPT) GREEN BLACK 13 5 RED (07) TO JOYSTICK BOX TO LOWER KEYSWITCH BOX
ORANGE (13)
02 TO HORN TO TERMINAL BLOCK TO TILT SWITCH
(18) RED BLACK 11 3
(16) WHITE BLACK 10 2 BLUE (15) 02 - WHITE
WHITE (02) 49 - BLACK
(NOT USED) 9 1
49 Z
27
26

02
TO OUTRIGGER
02
02
TO END OF STROKE
SOLENOID CABLES
27
26
TO P.DECK MANIF. TO FLASHER HORN

M204097AB

157928
AL 3.25a Electrical Panel Diagram - Inverter
A B C D E F G H
Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60006146 & Below V
SJIII 3226 27028841 & Below
BEEPER
TIMER RELAY
02
PIN COM - 02 WHITE 19A 02
PIN PWR - 05 RED

PIN LOAD - 85 PURPLE W2
W
+ 02
PIN TRIG - 19A WHITE/RED 03 W1 05
02 85
19A
19A
W3 X
+
14/3 CABTIRE 03 02
GREEN - 85
3A 00
FROM BATTERY BLACK - 3A 02 02 05 07 13 14E 14 18 72 19 19A 21 29 59 71 17 15 16 14 21A 17B 23 24
TRAY WHITE - 05
Y
85
M194851AA

157928
AL 3.25b Electrical Panel Diagram - Inverter
A B C D E F G H
Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60006147 & Above
V
SJIII 3226 27028842 & Above
BEEPER
TIMER RELAY
02
PIN COM - 02 WHITE 19A 02
PIN PWR - 05 RED

PIN LOAD - 85 PURPLE W2
W
+ 02
PIN TRIG - 19A WHITE/RED 03 W1 05
02 85
19A
19A
W3 X
+
14/3 CABTIRE 03 02
GREEN - 85
3A 00
FROM BATTERY BLACK - 3A 02 02 05 07 13 14E 14 18 72 19 19A 21 29 59 71 17 15 16 14 21A 17B 23 24
TRAY WHITE - 05
Y
85
M195917AA_1

157928
3.26a Electrical Panel Diagram with Power Deck - Inverter AI
A B C D E F G H
29 29
V
BEEPER
4
02 02
19A 02
4
02
02 WH 27
+
9A GR/BLK
26
W2 02
24
D26A D27A W1 05
23
W4
9A
85
9A
19A
19A
26A
27A 03
02
23
02
02
24
+
W3
P.DECK P.DECK 00 30
RELAY #2 RELAY #1
87a 02
3A 85 87 86
85 7A 8C 49 02 02 05 07 13 14 14E 18 72 19 21 19A 29 21B 59 71 17 15 16 14 21A 17B 23 24

86 87
D21B-1 D21B-2 87a
85
59A X
30
Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60006146 & Below
Z
27
26
SJIII 3226 27028841 & Below

02
02

02
27
26
TO P.DECK MANIF.
M194853AA

157928
AI 3.26b Electrical Panel Diagram with Power Deck - Inverter
A B C D E F G H
V
29 29
BEEPER
4
02 02
19A 02
4
02
02 WH 27
+
9A GR/BLK
26
W2 02
24
D26A D27A W1 05
23
W4
9A
85
9A
19A
19A
26A
27A
03
02
23 02
02
24
+
W3
P.DECK P.DECK 00 30
RELAY #2 RELAY #1
87a 02
3A 85 87 86
85 7A 8C 49 02 02 05 07 13 14 14E 18 72 19 21 19A 29 21B 59 71 17 15 16 14 21A 17B 23 24

86 87
D21B-1 D21B-2 87a
85
59A
30 X
Y
Serial Breakdown
Reference Chart
27
Model Serial Number

26
Z
02
SJIII 3220 60006147 & Above

02
02
27
26
SJIII 3226 27028842 & Above

TO P.DECK MANIF.
M195918AA

157928
AK 3.27 Horn/Tilt Switch/Flashing Light Diagram
A B C D E F G H
BLACK - 22
WHITE - 02
02
22
BLACK - 22
WHITE - 02
1
2
02
W
DEUTSCH 22
3
4
PIN 1 - 19 (RED)
PIN 2 - 28 (WHITE)
PIN 3 - 02 (BLACK)
PIN 4 - N/U
DUAL FLASHING LIGHT HARNESS
X
22
02
FL-22 BLACK - 22 02
WHITE - 02 (ANSI - FEM. TERM.)
24V
FLASHING LIGHT 22
WHITE - 02 (CE - RING TERM.)
02
TS1 Y
TILT SWITCH (ANSI/CSA)
22
02
02
22 HORN/FLASHING LIGHT HARNESS

02 - WHITE 02 FROM ELEC. PANEL
22 - GREEN 49
H1
HORN Z
M146648AA_S4D1

157928
3.28a Electrical Schematic (ANSI/CSA except EE rated - Equipped with no options) AI
A B C D E F G H
110 VAC
LINE VOLTAGE
Serial Breakdown
Reference Chart
BC 24V CHARGER
Model Serial Number
L1CR SJIII 3220 60006146 & Below V
CHARGER
CUTOUT RELAY
SJIII 3226 27028841 & Below
1 CHARGER
B4 6V B3 6V B2 6V B1 6V
F1 2
BATTERY 300A BATTERY BATTERY BATTERY
S10 24V FUSE
CONTROL BOX BASE 00 BATTERY
S4 IDLE/PLTF/BASE 3
PACK
EMERGENCY KEY SWITCH
S1 MAIN
STOP (IN IDLE POSITION) DISCONNECT C1
MOTOR 4
CONTACTOR DCM1
08 8C 8C BLUE/WHITE 8C 8C 07 S28
M 5 PUMP MOTOR
NCHO EMERGENCY
STOP
SWITCH 15A CIRCUIT
6
BREAKER
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 3A 03 00 02
7
15A CIRCUIT
NCHO BREAKER
7A GREEN 7A 00 02
8 W
02 60 60 RED/WHITE 7A 7A 02
9 POWER ON LED
S8 LED-1 LED-2
HORN POWER ON/LSS 10E 7A POWER ON LIGHT
SWITCH LIGHT 10
NO
H1
08 49 49 GREEN/WHITE 49 HORN 49
11 HORN
2H-13
12 DOWN SOLENOID
13 ORANGE 13 D13X 13 13 2H-13-1 HOLDING VALVE

13
SINGLE CYLINDER
DO2-1
2H-13-2 HOLDING VALVE
D13 14
DO2-2 TWO CYLINDERS
14 BLACK 14 D14X 14 3H-14
15 UP SOLENOID
S2
BCI UP/DOWN 19 28A D28A
BATTERY CHARGE
INDICATOR
SWITCH D14E D14
29 29
BP-29
16 BEEPER X
13
08 02 10E
V D19A 17 0.47uF CAPACITOR
14E CAP1
02 CRD1 CRD2 CRD3 19 19A 19A 02
18 MOTOR CONTACTOR
POTHOLE PROTECTION D14E-1 D21A
LIMIT SWITCHES N.C.H.O. 19A 02
RST1 TT 19 HOURMETER
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
20 TILT RELAY
LS6
28CR
71 19 19 02
21 TILT SWITCH
DRIVE OVERRIDE
LIMIT SWITCH N.C. TS1
02 02 WHITE 02
22
S3
3H-18A-1
LIFT/ 23 SPEED A SOLENOID
OFF/ S27 HIGH SPEED
DRIVE TORQUE LIMIT SWITCHES N.C. D21-1
19A 2H-18A
SWITCH SWITCH LS1B 24 DIFF. SOLENOID
Y
S7 12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2
25 SPEED B SOLENOID
JOYSTICK
21CCR
D21 RST3
71 21 21A 21C 02 PROPORTIONAL
26
JOYSTICK PCB RELAY
LOW VOLTAGE
ORANGE/BLACK LS1A PROTECTION RST2
08 PWM 59 59 59 59 59 59A
OUTPUT 27
D17C-1
02 2H-59 PROPORTIONAL
28
13 SOLENOID
A A D17-1 D17C
REV/DN 15 BLUE 15 4H-15
29 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
30 TRANSFER RELAY
14
B B D16
FWD/UP 16 WHITE/BLACK 16 4H-16
31 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 8A 8A 17B 17C
ENABLE
12B
32
Z
23 23 BLACK/WHITE 23 4H-23
33 RIGHT SOLENOID
S7-2 D23 DO2-5
RIGHT 12B 17A 3H-17A
17B
34 BRAKE SOLENOID
S7-3
LEFT D24
24 24 BLUE/BLACK 24 4H-24
35 LEFT SOLENOID
DO2-6
M146647AC2

157928
AI 3.28b Electrical Schematic (ANSI/CSA except EE rated - Equipped with no options)
A B C D E F G H
110 VAC
LINE VOLTAGE
Serial Breakdown
Reference Chart
BC 24V CHARGER
Model Serial Number
L1CR
CHARGER
CUTOUT RELAY SJIII 3220 60006147 & Above V
1 CHARGER
SJIII 3226 27028842 & Above
B4 6V F1 B3 6V B2 6V B1 6V
2 SJIII 46xx 70028674 & Above
S10 24V FUSE
S4 IDLE/PLTF/BASE 3
PACK
S1 MAIN
MOTOR 4
CONTACTOR DCM1
M 5 PUMP MOTOR
NCHO EMERGENCY
STOP
SWITCH 15A CIRCUIT
6
BREAKER
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 3A 03 00 02
7
15A CIRCUIT
NCHO
7A GREEN 7A BREAKER 00 02
8
W
02 60 60 RED/WHITE 7A 7A 02
9 POWER ON LED
S8 LED-1 LED-2
SWITCH LIGHT 10
NO
H1
11 HORN
2H-13
12 DOWN SOLENOID

13
SINGLE CYLINDER
DO2-1
D13 14
TWO CYLINDERS
DO2-2
14 BLACK 14 D14X 14 3H-14
15 UP SOLENOID
S2
BCI UP/DOWN D28A
19 28A 29 29
BATTERY CHARGE SWITCH D14E D14 16 BEEPER
INDICATOR
13
BP-29 X
08 02 10E
V D19A 17 0.47uF CAPACITOR
14E CAP1
02 CRD1 CRD2 CRD3 19 19A 19A 02
18 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
20 TILT RELAY
LS6
28CR
71 19 19 02
21 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
22
S3
3H-18A-1
OFF/ S27 HIGH SPEED
19A 2H-18A
3H-18A-2
Y
S7 12B 18 RED/BLACK 18 18 18A 18A
25 SPEED B SOLENOID
JOYSTICK
RST3 21CCR
D21 56 OHM
26
JOYSTICK PCB RELAY
LOW VOLTAGE
08 PWM 59 59 59 59 59 59A
OUTPUT 27
25 OHM
D17C-1
28
13 SOLENOID
A A D17-1 D17C
29 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
30 TRANSFER RELAY
14
B B D16
31 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 32
12B
4H-23
Z
23 23 BLACK/WHITE 23
33 RIGHT SOLENOID
S7-2 DO2-5
D23
RIGHT 12B 3H-17A
17B 17A
34 BRAKE SOLENOID
S7-3
LEFT D24
35 LEFT SOLENOID
DO2-6
M146647AD1

157928
3.29a Electrical Schematic (EE Rated - Equipped with no options) AI
A B C D E F G H
110 VAC
LINE VOLTAGE Serial Breakdown
24V CHARGER
Reference Chart
110 VAC Model Serial Number
BC 1 CHARGER
SJIII 3220 60006146 & Below V
B4 6V F1 B3 6V B2 6V B1 6V
2 SJIII 3226 27028841 & Below
TO BATTERIES FUSE
S10 24V 00 BATTERY
CONTROL BOX BASE
S4 IDLE/PLTF/BASE 3
PACK SJIII 46xx 70028673 & Below
S1 MAIN
MOTOR 4
CONTACTOR DCM1
M 5 PUMP MOTOR
NCHO EMERGENCY
STOP
SWITCH 15A CIRCUIT
6
BREAKER
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 05 03 00 02
7
15A CIRCUIT
NCHO BREAKER
7A GREEN 7A 00 02
8
02 60 60 RED/WHITE 7A 7A 02
S8 LED-1 LED-2
9 POWER ON LED W
SWITCH LIGHT 10
NO
H1
11 HORN
2H-13
12 DOWN SOLENOID

13
SINGLE CYLINDER
DO2-1
D13 14
DO2-2 TWO CYLINDERS
14 BLACK 14 D14X 14 3H-14
15 UP SOLENOID
S2
BCI UP/DOWN 19 28A D28A 29 29
INDICATOR BP-29
13
08 02 10E
V D19A 17 0.47uF CAPACITOR X
14E CAP1
02 CRD1 CRD2 CRD3 19 19A 19A 02
18 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
20 TILT RELAY
LS6
28CR
71 19 19 02
21 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
22
S3
3H-18A-1
OFF/ S27 HIGH SPEED
19A 2H-18A
S7
JOYSTICK
12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2
25 SPEED B SOLENOID Y
21CCR
D21 RST3
26
JOYSTICK PCB RELAY
LOW VOLTAGE
08 PWM 59 59 59 59 59 59A
OUTPUT 27
D17C-1
28
13 SOLENOID
A A D17-1 D17C
29 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
30 TRANSFER RELAY
14
B B D16
31 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 32
12B
33 RIGHT SOLENOID
Z
S7-2 D23 DO2-5
17B
34 BRAKE SOLENOID
S7-3
LEFT D24
35 LEFT SOLENOID
DO2-6
M150851AB-2

157928
AI 3.29b Electrical Schematic (EE Rated - Equipped with no options)
A B C D E F G H
110 VAC
24V CHARGER
Reference Chart
BC 1 CHARGER
SJIII 3220 60006147 & 60007077 V
B4 6V F1 B3 6V B2 6V B1 6V
2 SJIII 3226 27028842 & 27032454
TO BATTERIES FUSE
S10 24V 00 BATTERY
CONTROL BOX BASE
S4 IDLE/PLTF/BASE 3
PACK SJIII 46xx 70028674 & 70032133
S1 MAIN
MOTOR 4
CONTACTOR DCM1
08 8C 8C BLUE/WHITE 8C 8C 8C 07 S28
M 5 PUMP MOTOR
NCHO EMERGENCY
STOP
D8C SWITCH 15A CIRCUIT
6
BREAKER
CB2 CB1
7A 07 07 RED 07 07 07 5A 5A 05 05 03 00 02
7
15A CIRCUIT
NCHO BREAKER
7A GREEN 7A 00 02
8
02 60 60 RED/WHITE 7A 7A 02
S8 LED-1 LED-2
9 POWER ON LED W
SWITCH LIGHT 10
NO
H1
11 HORN
2H-13
12 DOWN SOLENOID

13
SINGLE CYLINDER
DO2-1
D13 14
TWO CYLINDERS
DO2-2
14 BLACK 14 D14X 14 3H-14
15 UP SOLENOID
S2
BCI UP/DOWN D28A
19 28A 29 29
INDICATOR BP-29
13
08
V
02 10E
D19A 17 0.47uF CAPACITOR X
14E CAP1
02 CRD1 CRD2 CRD3 19 19A 19A 02
18 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
20 TILT RELAY
LS6
28CR
71 19 19 02
21 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
22
S3
3H-18A-1
OFF/ S27 HIGH SPEED
19A 2H-18A
S7 12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2

25 SPEED B SOLENOID
Y
JOYSTICK
RST3 21CCR
D21 56 OHM
26
JOYSTICK PCB RELAY
LOW VOLTAGE
08 ORANGE/BLACK LS1A PROTECTION RST2
PWM 59 59 59 59 59 59A
OUTPUT 27
25 OHM
D17C-1
28
13 SOLENOID
A A D17-1 D17C
29 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
30 TRANSFER RELAY
14
B B D16
31 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 32
23
12B
23 BLACK/WHITE 23 4H-23 Z
33 RIGHT SOLENOID
S7-2 DO2-5
D23
RIGHT 12B 3H-17A
17B 17A
34 BRAKE SOLENOID
S7-3
LEFT D24
35 LEFT SOLENOID
DO2-6
M150851AD1

157928
3.29c Electrical Schematic (EE Rated - Equipped with no options) AK
A B C D E F G H
110 VAC
LINE VOLTAGE
Serial Breakdown
24V CHARGER
Reference Chart
BC 1 CHARGER
SJIII 3220 60007078 & Above V
B4 6V F1 B3 6V B2 6V B1 6V
2
TO BATTERIES
BATTERY 300A BATTERY BATTERY BATTERY SJIII 3226 27032455 & Above
S10 24V FUSE
S4 IDLE/PLTF/BASE
KEY SWITCH
3
PACK SJIII 46xx 70032134 & Above
EMERGENCY S1 MAIN
S28 MOTOR 4
EMERGENCY CONTACTOR DCM1
08 8C 8C BLUE/WHITE 8C 8C NCHO 5A STOP
SWITCH M 5 PUMP MOTOR
D8C CB2 15A CIRCUIT

5A 05 05 03 6
BREAKER
15A CIRCUIT CB1
7A 07 07 RED 07 07 00 02
BREAKER 7
7A GREEN 7A
8
02 60 60 RED/WHITE 7A 7A 02
9 POWER ON LED
S8 LED-1 LED-2 W
SWITCH LIGHT 10
NO
H1
11 HORN
2H-13
12 DOWN SOLENOID

13
SINGLE CYLINDER
DO2-1
D13 14
TWO CYLINDERS
DO2-2
14 BLACK 14 D14X 14 3H-14
15 UP SOLENOID
S2
BCI UP/DOWN D28A
19 28A 29 29
INDICATOR BP-29
13
08 02 10E
D19A
V
14E CAP1
17 0.47uF CAPACITOR
X
02 CRD1 CRD2 CRD3 19 19A 19A 02
18 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
20 TILT RELAY
LS6
28CR
71 19 19 02
21 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
22
3H-18A-1
23 SPEED A SOLENOID
S27
S3 TORQUE D21-1
19A 2H-18A
LIFT/ SWITCH 24 DIFF. SOLENOID
OFF/
DRIVE 3H-18A-2
12B 18 RED/BLACK 18 18 18A 18A
SWITCH 25 SPEED B SOLENOID
Y
S7 71 21 21 02
26 SPEED SOLENOID RELAY
JOYSTICK
21CR1 RST3 21CCR
LS1A D21 56 OHM
21A 21C 02 PROPORTIONAL
27
JOYSTICK PCB HIGH SPEED RELAY
LOW VOLTAGE
LIMIT SWITCH N.C.
ORANGE/BLACK PROTECTION RST2
08 PWM 59 59 59 59 59 59A
OUTPUT 28
25 OHM
D17C-1
29
13 SOLENOID
A A D17-1 D17C
30 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
31 TRANSFER RELAY
14
B B D16
32 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 33 Z
12B
34 RIGHT SOLENOID
S7-2 DO2-5
D23
RIGHT 12B 3H-17A
17B 17A
35 BRAKE SOLENOID
S7-3
LEFT D24
36 LEFT SOLENOID
DO2-6
M204120AB1

157928
3.30a Electrical Schematic (All Models - Equipped with all options) AI
A B C D E F G H
110 VAC
LINE VOLTAGE
Serial Breakdown
CONTROL BOX BASE Reference Chart
POWERED PLATFORM OPTION
BC 24V CHARGER
Model Serial Number
EXTEND/
EXTEND SOLENOID ENABLE
RETRACT
SWITCH
SWITCH L1CR
CHARGER SJIII 3220 60003928 & Below
26
CUTOUT RELAY V
4H-26 EXT 9A 09
1 CHARGER SJIII 3226 27015200 & Below
RET
27
S11 S12
4H-27 B4 6V F1 B3 6V B2 6V B1 6V
2 SJIII 46xx 70015229 & Below
RETRACT SOLENOID 21B 21B GREEN/BLACK 21B BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
D26 D27 00 BATTERY
3
PACK
S1 MAIN
S10 C1
DISCONNECT 4
S4 IDLE/PLTF/BASE MOTOR
EMERGENCY KEY SWITCH CONTACTOR DCM1
STOP (IN IDLE POSITION)
M 5 PUMP MOTOR
F2
6 INVERTER OPTION
NCHO EMERGENCY
(UNAVAILABLE ON EE
STOP 50A FUSE RATED MACHINES)
SWITCH
7
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 3A 03 00 02 15A CIRCUIT
8
BREAKER
15A CIRCUIT
NCHO 85
7A GREEN 7A BREAKER 7A
TIMER
02
9 INVERTER TIMER W
02 60 60 RED/WHITE 7A 7A 02 19A
10 POWER ON LED
S8 LED-1 LED-2
HORN POWER ON/LSS 10E 7A POWER ON LIGHT 00 02
SWITCH LIGHT 11
NO
H1
12 HORN
FLASHER FL-22
29 22 FLASHING LIGHT
13
OPTION
FL-29
BCI 2H-13
BATTERY CHARGE 14 DOWN SOLENOID
INDICATOR
S3
08 02 13 ORANGE 13 D13X 13 13 2H-13-1 HOLDING VALVE
V LIFT/ 15
OFF/ SINGLE CYLINDER
DO2-1
DRIVE D13
02 END OF STROKE 2H-13-2 HOLDING VALVE
SWITCH 16
LIMIT SWITCH N.C. DO2-2 TWO CYLINDERS
LS3
14 BLACK 14 D14X 14 14A 3H-14A
17 UP SOLENOID
S2
UP/DOWN D28A
X
09 19 28A 29 29
08 08 SWITCH D14E D14A 18 BEEPER
BP-29
13
10E
D19A 19 0.47uF CAPACITOR
14E CAP1
CRD1 CRD2 CRD3 19 19A 19A 02
20 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
22 TILT RELAY
LS6
28CR
71 19 19 02
23 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
24
3H-18A-1
25 SPEED A SOLENOID
S27 HIGH SPEED
D21B-2 LIMIT SWITCHES N.C.
TORQUE D21-1
SWITCH LS1B
19A 2H-18A
26 DIFF. SOLENOID Y
S7 12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2
27 SPEED B SOLENOID
JOYSTICK
21CCR
D21 RST3
28
JOYSTICK PCB RELAY
D21B-1 LOW VOLTAGE
08 PWM 59 59 59 59 59 59A
OUTPUT 29
D17C-1
30
13 SOLENOID
A A D17-1 D17C
31 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
32 TRANSFER RELAY
14
B B D16
33 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 34
23
12B
23 BLACK/WHITE 23 4H-23
Z
35 RIGHT SOLENOID
S7-2 D23 DO2-5
17B
36 BRAKE SOLENOID
S7-3
LEFT D24
37 LEFT SOLENOID
DO2-6
M146624AE2

157928
AI 3.30b Electrical Schematic (All Models - Equipped with all options)
A B C D E F G H
110 VAC
CONTROL BOX BASE
Reference Chart
POWERED PLATFORM OPTION
EXTEND/
ENABLE
BC 24V CHARGER Model Serial Number
RETRACT L1CR
SWITCH
SWITCH CHARGER
CUTOUT RELAY SJIII 3220 60003929 & 60006146
26
EXT 9A 09
1 CHARGER V
RET
27
SJIII 3226 27015201 & 27028841
D26 D27 S11 S12
B4 6V F1 B3 6V B2 6V B1 6V
2
9A GREEN/BLACK 9A BATTERY 300A
FUSE
BATTERY BATTERY BATTERY
SJIII 46xx 70015230 & 70028673
24V 00 BATTERY
3
PACK
S1 MAIN
S10 C1
DISCONNECT 4
M 5 PUMP MOTOR
F2
6 INVERTER OPTION
NCHO EMERGENCY
(UNAVAILABLE ON EE
SWITCH
7
CB2 CB1
8
BREAKER
15A CIRCUIT
NCHO BREAKER 85
7A GREEN 7A 7A 02
TIMER 9 INVERTER TIMER
02 60 60 RED/WHITE 7A 7A 02 19A
10 POWER ON LED
W
S8 LED-1 LED-2
SWITCH LIGHT 11
NO
H1
12 HORN
FLASHER FL-22
13
OPTION
FL-29
BCI 2H-13
INDICATOR
S3
08 02 13 ORANGE 13 D13X 13 13 2H-13-1 HOLDING VALVE
V LIFT/ 15
DO2-1
DRIVE D13 2H-13-2
02 SWITCH END OF STROKE HOLDING VALVE
16
LIMIT SWITCH N.C. DO2-2 TWO CYLINDERS
LS3
14 BLACK 14 D14X 14 14A 3H-14A
17 UP SOLENOID
S2
09 UP/DOWN 19 28A D28A 29 29
BP-29
10E
13
X
14E CAP1
CRD1 CRD2 CRD3 19 19A 19A 02
20 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
22 TILT RELAY
LS6
28CR
71 19 19 02
23 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
24
3H-18A-1
25 SPEED A SOLENOID
S27 HIGH SPEED
TORQUE D21-1 2H-18A
19A
SWITCH LS1B 26 DIFF. SOLENOID
S7 12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2

27 SPEED B SOLENOID
JOYSTICK
71 21
D21
21A
RST3
21C
21CCR
02 PROPORTIONAL
Y
28
JOYSTICK PCB RELAY
D21B-1 LOW VOLTAGE
08 ORANGE/BLACK LS1A PROTECTION RST2
PWM 59 59 59 59 59 59A
OUTPUT 29
D17C-1
30
13 SOLENOID
A A D17-1 D17C
31 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
32 TRANSFER RELAY
14
B B D16
33 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 8A 8A 17CR 17B 17C
ENABLE 9A 02 34
12B
23 23 BLACK/WHITE 23 23 23A 4H-23
35 RIGHT SOLENOID
S7-2 26 23 26A DO2-5
D23
RIGHT 12B 17CR 17A 3H-17A
17B
9A 02 36 BRAKE SOLENOID
S7-3
LEFT
24 27 24 BLUE/BLACK 24 24 24A
D24
4H-24
Z
37 LEFT SOLENOID
24 27A DO2-6
4H-26
38 EXTEND SOLENOID
D26A
4H-27
39 RETRACT SOLENOID
D27A
M160926AA1

157928
3.30c Electrical Schematic (All Models - Equipped with all options) AI
A B C D E F G H
110 VAC
CONTROL BOX BASE

LINE VOLTAGE
Serial Breakdown
POWERED PLATFORM OPTION Reference Chart
BC 24V CHARGER
EXTEND/
RETRACT
ENABLE
L1CR
Model Serial Number
SWITCH
SWITCH CHARGER
EXT
26
CUTOUT RELAY SJIII 3220 60006147 & 60007077 V
9A 09
1 CHARGER
RET
D26 D27
27
S11 S12
B4 6V B3 6V B2 6V B1 6V
SJIII 3226 27028842 & 27032454
F1 2
9A GREEN/BLACK 9A BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
00 BATTERY
SJIII 46xx 70028674 & 70032133
3
PACK
S1 MAIN
S10 C1
DISCONNECT 4
M 5 PUMP MOTOR
F2
6 INVERTER OPTION
NCHO EMERGENCY
(UNAVAILABLE ON EE
SWITCH
D8C 7
CB2 CB1
8
BREAKER
15A CIRCUIT
NCHO BREAKER 85
7A GREEN 7A 7A 02
02 60 60 RED/WHITE 7A 7A 02 19A
W
10 POWER ON LED
S8 LED-1 LED-2
SWITCH LIGHT 11
NO
H1
12 HORN
FLASHER FL-22
13
OPTION
FL-29
BCI 2H-13
INDICATOR
S3 D13X
08 02 LIFT/ 13 ORANGE 13 13 13 2H-13-1 HOLDING VALVE
V 15
DO2-1
DRIVE D13
02 END OF STROKE 2H-13-2 HOLDING VALVE
SWITCH 16
LIMIT SWITCH N.C. TWO CYLINDERS
LS3 DO2-2
14 BLACK 14 D14X 14 14A 3H-14A
17 UP SOLENOID
S2
09 UP/DOWN D28A
19 28A 29 29
13
BP-29 X
10E
14E CAP1
CRD1 CRD2 CRD3 19 19A 19A 02
20 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
22 TILT RELAY
LS6
28CR
71 19 19 02
23 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
24
3H-18A-1
25 SPEED A SOLENOID
S27 HIGH SPEED
TORQUE D21-1 2H-18A
19A
S7 12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2

JOYSTICK
D21
RST3 21CCR
27 SPEED B SOLENOID
Y
71 21 21A 56 OHM 21C 02 PROPORTIONAL
28
JOYSTICK PCB RELAY
D21B-1 LOW VOLTAGE RST2
08 PWM 59 59 ORANGE/BLACK 59 LS1A 59 PROTECTION 59 59A 25 OHM
OUTPUT 29
D17C-1
30
13 SOLENOID
A A D17-1 D17C
31 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
32 TRANSFER RELAY
14
B B D16
33 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 9A 02 34
12B
23 23 BLACK/WHITE 23 23 23A 4H-23
35 RIGHT SOLENOID
S7-2 26 23 26A DO2-5
D23
RIGHT 12B 17CR 3H-17A
17A
S7-3 9A 02
17B
36 BRAKE SOLENOID Z
LEFT D24
24 27 24 BLUE/BLACK 24 24 24A 4H-24
37 LEFT SOLENOID
24 27A DO2-6
4H-26
38 EXTEND SOLENOID
D26A
4H-27
39 RETRACT SOLENOID
D27A
M160926AC1

157928
3.30d Electrical Schematic (All Models - Equipped with all options) - EE-Rated AK
A B C D E F G H
110 VAC
CONTROL BOX BASE

LINE VOLTAGE
Serial Breakdown
POWERED PLATFORM OPTION Reference Chart
BC 24V CHARGER
EXTEND/
RETRACT
ENABLE
SWITCH L1CR
Model Serial Number
SWITCH CHARGER
CUTOUT RELAY
RET
27
9A 09
SJIII 3220 60007078 & Above V
1 CHARGER
EXT
26
S11 S12
B4 6V F1 B3 6V B2 6V B1 6V
SJIII 3226 27032455 & Above
D27 D26 2
9A GREEN/BLACK 9A BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
00
3
BATTERY SJIII 46xx 70032134 & Above
PACK
S1 MAIN
S10 S28 C1
DISCONNECT 4
EMERGENCY
STOP
STOP (IN IDLE POSITION) SWITCH
M 5 PUMP MOTOR
F2
08 8C 8C BLUE/WHITE 8C 8C NCHO 5A 5A 05
6 INVERTER OPTION
(UNAVAILABLE ON EE
50A FUSE RATED MACHINES)
D8C 7
CB2 CB1
7A 07 07 RED 07 07 3A 03 00 02 15A CIRCUIT
8
BREAKER
15A CIRCUIT
BREAKER 85
7A GREEN 7A 07 02
02 60 60 RED/WHITE 7A 7A 02 19A
10 POWER ON LED W
S8 LED-1 LED-2
SWITCH LIGHT 11
NO
H1
12 HORN
FLASHER FL-22
13
OPTION
FL-29
BCI 2H-13
INDICATOR
S3
08 02 LIFT/ 13 ORANGE 13 D13X 13 13 2H-13-1 HOLDING VALVE
V 15
DO2-1
DRIVE D13
02 2H-13-2 HOLDING VALVE
SWITCH 16
TWO CYLINDERS
DO2-2
14 BLACK 14
D14X 14 3H-14A
17 UP SOLENOID
S2
09 UP/DOWN D28A
19 28A 29 29
08 08 SWITCH D14E D14 18 BEEPER
BP-29
13
10E
D19A 19 0.47uF CAPACITOR X
14E CAP1
CRD1 CRD2 CRD3 19 19A 19A 02
20 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
22 TILT RELAY
LS6
28CR
71 19 19 02
23 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
24
3H-18A-1
25 SPEED A SOLENOID
S27 D21B-2
TORQUE D21-1 2H-18A
19A
SWITCH 26 DIFF. SOLENOID
12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2

27 SPEED B SOLENOID
S7 71 21 21 02
JOYSTICK
21CR1 RST3 21CCR
28 SPEED SOLENOID RELAY
Y
LS1A D21 56 OHM
21A 21C 02 PROPORTIONAL
29
JOYSTICK PCB HIGH SPEED RELAY
D21B-1 LOW VOLTAGE RST2
LIMIT SWITCH N.C. 25 OHM
08 PWM 59 59 ORANGE/BLACK 59 59 PROTECTION 59 59A
OUTPUT 30
D17C-1
31
13 SOLENOID
A A D17-1 D17C
32 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
33 TRANSFER RELAY
14
B B D16
34 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 9A 02 35
12B
23 23 BLACK/WHITE 23 23 23A 4H-23
36 RIGHT SOLENOID
S7-2 23 26A DO2-5
D23
RIGHT 12B 17CR 3H-17A
17B 17A
37 BRAKE SOLENOID
S7-3
LEFT
9A 02
D24
Z
24 24 BLUE/BLACK 24 24 24A 4H-24
38 LEFT SOLENOID
24 27A DO2-6
4H-26
39 EXTEND SOLENOID
D26A
4H-27
40 RETRACT SOLENOID
D27A
M204121AC

157928
Section 4 - TROUBLESHOOTING INFORMATION
Introduction ................................................................................................................................................................96
Electrical System
4.1-1 All Controls Inoperative ...................................................................................................................................97
4.1-2 All Controls Except for Down Function Inoperative .......................................................................................97
4.1-3 All Controls Inoperative From Base Control Console .....................................................................................98
4.1-4 All Controls Inoperative From Platform Control Console ...............................................................................98
4.1-5 No Drive or Up Function from Platform or Base Controls (CE only) ..............................................................99
4.1-6 No Down or Reverse Only Function from Platform Controls ..........................................................................99
4.1-7 No Up or Forward Only Function from Platform Control Console .................................................................99
4.1-8 No Up Function from Platform or Base Control Console ...............................................................................99
4.1-9 No Down Function from Platform or Base Control Console (ANSI/CSA) ....................................................100
4.1-10 No Down Function from Platform or Base Control Console (CE) ................................................................100
4.1-11 No Up Function from Base Control Console ................................................................................................101
4.1-12 No Down Function from Base Control Console ...........................................................................................101
4.1-13 Steer Only Inoperative ...................................................................................................................................101
4.1-14 Drive Only Inoperative ...................................................................................................................................101
4.1-15 No Drive or Steer when Platform Fully Lowered ...........................................................................................101
4.1-16 No Drive or Steer when Platform Elevated ...................................................................................................102
4.1-17 Elevated Drive Speed Does not Activate ......................................................................................................102
4.1-18 Work Platform Drives in Slow Speed Only ....................................................................................................102
4.1-19 Forward Drive Function Inoperative ..............................................................................................................103
4.1-20 Reverse Drive Function Inoperative ..............................................................................................................103
4.1-21 Brake will not Release ...................................................................................................................................103
4.1-22 High/Low Torque Inoperative ........................................................................................................................103
4.1-23 Right Steer Inoperative .................................................................................................................................104
4.1-24 Left Steer Inoperative ...................................................................................................................................104
4.1-25 Power Extension Platform will not Extend or Retract....................................................................................105
4.1-26 Power Extension Platform will not Extend ....................................................................................................105
4
4.1-27 Power Extension Platform will not Retract ....................................................................................................105
4.1-28 Two or more Functions at one time...............................................................................................................105
Hydraulic Systems
4.2-1 All Function Inoperative .................................................................................................................................106
4.2-2 Platform Drifts Down......................................................................................................................................106
4.2-3 Platform Lifts Slowly ......................................................................................................................................106
4.2-4 Platform does not Lift ....................................................................................................................................106
4.2-5 Platform will not Lower ..................................................................................................................................106
4.2-6 Platform Drives Slow .....................................................................................................................................107
4.2-7 Platform will not Drive in Forward or Reverse ...............................................................................................107
4.2-8 Brake(s) will not Release ...............................................................................................................................107
4.2-9 Brake(s) will not Release (Additional for machines with Integral Brakes) ....................................................107
4.2-10 Aerial Platform will not hold on a Grade (Machines with Integrals Brakes) .................................................108
4.2-11 Platform does not Steer ................................................................................................................................108
4.2-12 All System sluggish .......................................................................................................................................108
4.2-13 Power Extension Platform will not Extend or Retract....................................................................................108
4.2-14 High/Low Torque Inoperative ........................................................................................................................108
SJIII DC Electric
157928
Notes
SJIII DC Electric
157928
Section 4 - Troubleshooting Information Service and Maintenance
Introduction
The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble
which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information
will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and
deficiencies that may occur. If a specific trouble is not listed, isolate the major component in which the trouble oc-
curs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem.
The content of this section is separated into “probable cause” and “remedy.” The information preceded by a num-
ber represents the “probable cause.” The following line, noted by a dash represents the “remedy” to the “probable
cause” directly above it. See example below for clarification.
1. Probable Cause
- Remedy
SJIII DC Electric
157928
Service and Maintenance Section 4 - Troubleshooting Information
Electrical System
4.1-1 All Controls Inoperative

1. Battery Charger plugged into external power source.
- Disconnect charger cord.
2. Batteries disconnected.
- Connect batteries.
3. Dirty or loose battery terminals.
- Clean and tighten connections.
4. Battery charge low.
- Check each cell with hydrometer. Reading should be 1.275 (fully charged). Recharge if low
reading. Replace if reading difference between cells is 0.050.
5. Main battery cables open or defective.
- Check continuity. Replace if defective.
6. Fuse F1 defective.
- Replace fuse.
7. Main battery disconnect switch S1 open or defective.
- Close switch. Check continuity. Replace if defective.
8. Loose or broken wire #3 from motor contactor C1 to circuit breaker CB2.
9. Loose or broken wire #3A from circuit breaker CB2 to charger relay L1CR.
10. Defective battery charger relay L1CR.
- Check relay. Replace if defective.
11. Defective or tripped circuit breaker CB2.
- Reset circuit breaker. Replace if defective.
12. Loose or broken wire #5 from charger relay L1CR to base terminal block TB-1.
13. Loose or broken wire #5 from base terminal block TB-1 to base emergency stop switch S28.
14. Open or defective base emergency stop switch S28.
- Close switch. Check switch. Replace if defective.
15. Loose or broken wire #5A from base emergency stop switch S28 to base key switch S10.
16. Open or defective base key switch S10.
- Select function with switch. Check switch. Replace if defective.
17. Loose or broken wire #00 from pump motor DCM1 to circuit breaker CB1.
19. Loose or broken wire #2 from circuit breaker CB1 to base terminal block TB-1.
20. Loose or broken wire #7A from base terminal block to CM1 control module pin P2-12. (CE)
21. Loose or broken wire #02 from base terminal block to CM1 control module pin P2-11. (CE)
4.1-2 All Controls Except for Down Function Inoperative

1. Loose or broken wire #19A (ANSI/CSA) or wire #19B (CE) from base terminal block TB-1 to contactor
C1.
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Electrical System (Continued)
2. Contactor C1 defective.
- Check contactor. Replace if defective.
3. Defective pump motor DCM1.
- Check motor. Replace if defective.
4. Loose or broken wire #59 from relay 21CCR (ANSI/CSA) or relay 21ACR (CE) to proportional valve
coil 2H-59.
5. Loose or broken wire #02 from proportional valve coil 2H-59 to base terminal block TB-1.
6. Defective proportional valve coil 2H-59.
- Check continuity through coil. Reading should be 19ohms. Replace if defective.
4.1-3 All Controls Inoperative From Base Control Console

1. Loose or broken wire #07 from base terminal block to platform emergency stop switch S4.
2. Open or defective platform emergency stop switch S4.
- Close switch. Replace if defective.
3. Loose or broken wire #7A from platform emergency stop switch S4 to base terminal block.
4. Loose or broken wire #7A from base terminal block to base key switch S10.
6. Loose or broken wire #10E from base key switch S10 to base up/down switch S2.
7. Loose or broken wire #10E from base terminal block TB-1 to CM1 control module pin P2-2. (CE)
4.1-4 All Controls Inoperative From Platform Control Console

1. Loose or broken wire #8C from base key switch S10 to base terminal block.
2. Loose or broken wire #8C or wire #02 from base terminal block to platform emergency stop switch
S4.
4. Loose or broken wire #8 or wire #02 from emergency stop switch S4 to battery charge indicator BCI.
5. Loose or broken wire #8 or wire #02 from battery charge indicator BC1 to joystick S7.
6. Defective joystick enable switch S7-6.
- Check switch. Replace if defective.
7. Defective joystick neutral switch S7-1.
8. Defective joystick S7.
- Check joystick. Replace if defective.
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4.1-5 No Drive or Up Function from Platform or Base Controls (CE only)

1. Defective tilt relay 28CR1 or Aux. tilt relay 28ECR1.
2. Loose or broken wire #02 from base terminal block to tilt relay 28CR1 or Aux. tilt relay 28ECR1.
3. Loose or broken wire #28 from CM1 control module pin P3-4 to tilt relay 28CR1.
4. Loose or broken wire #28E from CM1 control module pin P3-6 to Aux. tilt relay 28ECR1.
5. Loose or broken wire #19 from base terminal block to Aux. tilt relay 28ECR1.
6. Loose or broken wire #19A from Aux. tilt relay 28ECR1 to tilt relay 28CR1.
7. Loose or broken wire #19B from tilt relay 28CR1 to base terminal block.
8. Loose or broken wire #19B from base terminal block to motor contactor C1.
4.1-6 No Down or Reverse Only Function from Platform Controls

1. Loose or broken wire “A” from proportional controller S7 to lift/drive switch S3.
2. Lift/Drive switch S3 defective.
3. Defective PWM card on joystick S7.
- Check joystick card. Replace if defective.
4. Loose or broken wire #13 down or #15 reverse from lift/drive switch S3 to base terminal block.
4.1-7 No Up or Forward Only Function from Platform Control Console

1. Loose or broken wire “B” from proportional controller S7 to lift/drive switch S3.
4. Loose or broken wire #14 up or #16 forward from lift/drive switch S3 to base terminal block.
4.1-8 No Up Function from Platform or Base Control Console

1. Loose or broken wire #14 from base terminal block to up valve coil 3H-14.
2. Defective up valve coil 3H-14.
- Check continuity through coil. Replace if defective.
3. Open diode D14.
- Check diode. Replace if defective.
4. Open diode D21A (ANSI/CSA) or D21 (CE).
5. Machine not level. (Above high speed limit switch)
- Use on level surface.
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6. Loose or broken wire #19 from base terminal block to tilt switch TS1 (ANSI/CSA).
7. Defective tilt switch TS1 (ANSI/CSA).
- Test tilt switch. Replace if defective.
8. Loose or broken wire #28 from tilt switch TS1 to tilt relay 28CR (ANSI/CSA).
9. Loose or broken wire #02 from tilt switch TS1 to base terminal strip (ANSI/CSA).
10. Defective tilt relay 28CR (ANSI/CSA).
11. Loose or broken wire #19A from tilt relay 28CR to pump motor contactor (ANSI/CSA).
12. See 4.1-5 of this section for more troubleshooting information for (CE).
4.1-9 No Down Function from Platform or Base Control Console (ANSI/CSA)
NOTE
Down function is not proportionally controlled.
1. Loose or broken wire #13 from base terminal block to down valve 2H-13 or holding valve 2H-13-1 or
holding valve 2H-13-2.
2. Loose or broken wire #02 from base terminal block to down valve 2H-13 or holding valve 2H-13-1 or
holding valve 2H-13-2.
3. Defective down valve 2H-13.
4. Defective lift cylinder holding valve 2H-13-1 or holding valve 2H-13-2.
4.1-10 No Down Function from Platform or Base Control Console (CE)
NOTE
1. Loose or broken wire #13 from base terminal block to CM1 control module pin P2-4.
2. Defective down relay 28CR2 or Aux. down relay 28ECR2.
3. Loose or broken wire #02 from base terminal block to down relay 28CR2 or Aux. down relay 28ECR2.
4. Loose or broken wire #13 from base terminal block to Aux. down relay 28ECR2.
5. Loose or broken wire #13A from Aux. down relay 28ECR2 to down relay 28CR2.
6. Loose or broken wire # 13B from down relay 28CR2 to down valve 2H-13B or holding valve 2H-13B-1
or holding valve 2H-13B-2.
7. Defective down valve 2H-13B.
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8. Defective lift cylinder holding valve 2H-13B-1 or holding valve 2H-13B-2.
9. Loose or broken wire #02 from holding valve 2H-13B-1 or holding valve 2H-13B-2 or down valve 2H-13B
to base terminal block.
4.1-11 No Up Function from Base Control Console

1. Defective up/down switch S2.
2. Loose or broken wire #14E from up/down switch S2 to base terminal switch.
3. Open diode D14E-1.
4. Open diode D14E (ANSI/CSA) or diode D14E-2 (CE).
4.1-12 No Down Function from Base Control Console

2. Loose or broken wire #13 from up/down switch S2 to base terminal block.
4.1-13 Steer Only Inoperative

1. Defective relay 17CR.
2. Loose or broken wire #17B from diodes D23 and D24 to base terminal block TB1.
3. Loose or broken wire #17B from 17CR steer relay to base terminal block TB1.
4. Loose or broken wire #17C from 17CR steer relay to diodes D17C and D17C-1.
5. Open or defective diode D17C or diode D17C-1.
4.1-14 Drive Only Inoperative

1. Open or defective diode D17-1.
4.1-15 No Drive or Steer when Platform Fully Lowered

1. Loose or broken wire #71 from base terminal block to drive override limit switch LS6.
2. Defective drive override switch LS6.
3. Loose or broken wire #19 from drive override limit switch LS6 to base terminal block.
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4.1-16 No Drive or Steer when Platform Elevated

1. Pothole protection bars not fully lowered.
- Clear obstructions. Repair as needed.
2. Loose or broken wire #71 from base terminal block to pothole protection limit switch LS4.
3. Defective pothole protection limit switch LS4.
4. Loose or broken wire #72 from pothole protection limit switch LS4 to base terminal block.
4.1-17 Elevated Drive Speed Does not Activate

1. Loose or broken wire #59 from base terminal strip proportional relay 21CCR (ANSI/CSA) or 21ACR
(CE).
1. Loose or broken wire #59A from proportional relay 21CCR (ANSI/CSA) or 21ACR (CE) to resistor
RST2.
2. Resistor RST2 open.
- Check resistor ohms, it should be 30 ohms. Replace if defective.
3. Loose or broken wire #02 from resistor RST2 to base terminal block.
4. Proportional relay 21CCR (ANSI/CSA) or 21ACR (CE) defective.
- Check relay, replace if defective.
4.1-18 Work Platform Drives in Slow Speed Only

1. Loose or broken wire #71 from base terminal block to high speed limit switch LS1A.
2. Open or defective high speed limit switch LS1A.
3. Loose or broken wire #21 from high speed limit switch LS1A to low voltage protection resistor RST3.
4. Defective low voltage protection resistor RST3.
- Check resistor. Replace if defective.
5. Loose or broken wire #21C (ANSI/CSA) or #21A (CE) from low voltage protection resistor RST3 to
proportional relay 21CCR (ANSI/CSA) or 21ACR (CE).
6. Proportional relay 21CCR (ANSI/CSA) or 21ACR (CE) defective.
7. Loose or broken wire #02 from proportional relay 21CCR (ANSI/CSA) or 21ACR (CE) to base terminal
block.
8. Proportional controller S7 out of adjustment.
- Adjust controller. Refer to Section 5, Joystick Adjusting Procedure.
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4.1-19 Forward Drive Function Inoperative

1. Loose or broken wire #16 from lift/drive switch S3 to base terminal block.
2. Loose or broken wire #16 from base terminal block to forward drive valve coil 4H-16.
3. Forward drive valve coil 4H-16 defective.
4. Loose or broken wire #02 from forward drive valve coil 4H-16 to base terminal block.
5. Open diode D16.
4.1-20 Reverse Drive Function Inoperative

2. Loose or broken wire #15 from base terminal block to reverse drive valve coil 4H-15.
3. Reverse drive valve coil 4H-15 defective.
4. Loose or broken wire #02 from reverse drive valve coil 4H-15 to base terminal block.
5. Open diode D15.
4.1-21 Brake will not Release

1. Diode D-16 forward or D-15 reverse is shorted or open.
2. Loose or broken wire #17 from base terminal strip to transfer relay 17CR.
3. Loose or broken wire #02 from base terminal strip to transfer relay 17CR.
4. Defective transfer relay 17CR.
5. Open or defective diode D17.
6. Loose or broken wire #17B from base terminal strip to transfer relay 17CR.
7. Loose or broken wire #17A from transfer relay 17CR to brake coil 3H-17A.
8. Brake valve coil 3H-17A defective.
9. Loose or broken wire #02 from brake valve coil 3H-17A to base terminal block.
4.1-22 High/Low Torque Inoperative

1. Open diode D15-1 (reverse) or D16-1 (forward).
2. Loose or broken wire #7B from diodes D15-1 and D16-1 to lift/drive switch S3.
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3. Defective lift/drive switch S3.

4. Loose or broken wire #18 from lift/drive switch S3 to base terminal block TB-1.
5. Loose or broken wire #18 from base terminal block TB-1 to high speed limit switch LS1-B.
6. Defective high speed limit switch LS1-B.
7. Loose or broken wire #18A from high speed limit switch LS1-B to rear drive manifold.
8. Defective speed valve coil 3H-18A-1 or 3H-18A-2.
9. Loose or broken wire #02 from rear drive manifold to base terminal block TB-1.
4.1-23 Right Steer Inoperative

1. Loose or broken wire #12B from lift/drive switch S3 to right steer switch S7-2.
2. Defective right steer switch S7-2.
3. Loose or broken wire #23 from right steer switch S7-2 to base terminal block TB-1.
4. Loose or broken wire #23 from base terminal block TB-1 to steer right valve coil 4H-23.
5. Defective steer right valve coil 4H-23.
6. Loose or broken wire #02 from steer right valve coil 4H-23 to base terminal block TB-1.
7. Open diode D23.
4.1-24 Left Steer Inoperative

1. Loose or broken wire #12B from lift/drive switch S3 to left steer switch S7-3.
2. Defective left steer switch S7-3.
3. Loose or broken wire #24 from left steer switch S7-3 to base terminal block TB-1.
4. Loose or broken wire #24 from base terminal block TB-1 to steer left valve coil 4H-24.
5. Defective steer left valve coil 4H-24.
6. Loose or broken wire #02 from steer left valve coil 4H-24 to base terminal block TB-1.
7. Open diode D24.
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4.1-25 Power Extension Platform will not Extend or Retract

1. Lift/Drive switch S3 not in lift position.
- Move switch to lift position.
2. Loose or broken wire #09 from lift/drive switch S3 to power extension platform enable switch S12.
3. Power extension platform enable switch S12 defective.
4. Loose or broken wire #09A from power extension platform enable switch S12 to platform extend/retract
switch S11.
5. Loose or broken wire #21B from platform control box to base terminal block TB-1.
6. Open diode D21B-1.
8. Loose or broken wire #02 from extend valve coil 4H-26 to retract valve coil 4H-27 to platform control
box.
4.1-26 Power Extension Platform will not Extend

1. Powered extension platform extend/retract switch S11 defective.
2. Loose or broken wire #26 from power extension platform extend/retract switch S11 to extend valve coil
4H-26.
3. Extend valve coil 4H-26 defective.
- Check continuity through coil, replace if defective.
4. Open diode D26.
5. Loose or broken wire #02 from extend valve coil 4H-26 to platform control box.
4.1-27 Power Extension Platform will not Retract

1. Powered Platform extend/retract switch S11 defective.
2. Loose or broken wire #27 from power extension platform extend/retract switch S11 to retract valve coil
4H-27.
3. Retract valve coil 4H-27 defective.
- Check continuity through coil, replace if defective.
4. Open diode D27.
5. Loose or broken wire #02 from retract valve coil 4H-27 to platform control box.
4.1-28 Two or more Functions at one time

1. Shorted Diode.
- Check continuity of all diodes. Replace if defective.
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Hydraulic System
4.2-1 All Function Inoperative

1. Proportional valve 2H-59 defective or is sticking.
- Check valve. Replace if defective.
2. Pump P1 defective.
- Check pump. Replace if defective.
4.2-2 Platform Drifts Down

1. Defective lift cylinder seals at the gland or holding valve manifold.
- Replace if damaged. Note: There are no piston seals, just wear rings.
2. Combination of defective holding valves 2H-13-1 and 2H-13-2, and either defective lowering valve 2H-
13 or relief valve R2 or manual lowering valve V1. (ANSI/CSA)
- Check valves. Replace if defective.
Combination of defective holding valves 2H-13B-1 and 2H-13B-2, and either defective lowering valve
2H-13B or relief valve R2 or manual lowering valve V1. (CE)
4.2-3 Platform Lifts Slowly

1. Open or leaking manual lowering valve V1.
- Close valve. Replace if defective.
2. Lift relief valve R2 defective.
3. Open manual override on holding valve 2H-13-1 or 2H-13-2. (ANSI/CSA)
- Depress and turn manual override clockwise to close. Replace if defective.
Open manual override on holding valve 2H-13B-1 or 2H-13B-2. (CE)
4.2-4 Platform does not Lift

1. Open manual lowering valve V1.
2. Hydraulic oil level too low.
- Fully lower the platform. Fill hydraulic tank until fluid is at or slightly above the top mark on the
sight glass.
3. Platform weight excessive.
- Reduce platform load to maximum capacity.
4. Up valve 3H-14 or 3H-14A (Machines with end of stroke limit switch LS3 only) defective or is sticking.
4.2-5 Platform will not Lower
NOTE
ANSI/CSA Machines only

1. Lowering valve 2H-13 defective or is sticking.
- Clean valve. Replace if defective.
2. Defective holding valve 2H-13-1 or 2H-13-2.
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Hydraulic System (Continued)
CE Machines only
4. Defective holding valve 2H-13B-1 or 2H-13B-2.
4.2-6 Platform Drives Slow

1. Free-wheeling valve V2 open or defective.
2. Flow divider/combiner FD1 defective or is plugged.
3. Drive motor M1 or M2 defective.
- Check motors. Replace if defective.
4. Cushion cylinder C1 defective.
- Check cylinder. Replace if defective.
4.2-7 Platform will not Drive in Forward or Reverse

1. Open free-wheeling valve V2.
- Close Valve. Replace if defective.
2. Forward drive valve 4H-16 or reverse drive valve 4H-15 defective or is sticking.
3. Flow/Divider/Combiner valve FD1 defective or is plugged.
4. Counterbalance valve CB1 defective or is plugged.
4.2-8 Brake(s) will not Release

1. Brake valve 3H-17A defective or is sticking.
2. Brake orifice(s) 07 plugged.
- Remove orifice(s). Clean and reinstall.
3. Brake cylinder(s) C4 defective.
- Rebuild cylinder(s). Replace if damaged.
4.2-9 Brake(s) will not Release (Additional for machines with Integral
Brakes)
1. Stuck or defective auto reset value V3.
- Check valve operation. Clean valve. Replace if defective.
2. Stuck or defective hand pump P2.
- Check pump operation. Clean pump. Replace if defective.
3. Defective internal brake piston seals.
- Check brake pack will maintain pressure. If pressure is not maintained replace seals.
4. Plugged or defective brake orifice 07.
- Clear obstruction. Replace if defective.
5. Damaged integral brake in wheel motor.
- Inspect wheel motor assembly. Repair and replace as necessary.
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4.2-10 Aerial Platform will not hold on a Grade (Machines with Integrals
Brakes)
1. Worn or damaged brake discs.
- Inspect brake discs for wear. Replace if worn or damaged.
2. Broken or damaged brake compression springs.
- Check springs. Replace if defective.
4.2-11 Platform does not Steer

1. Right steer valve 4H-23 or left steer valve 4H-24 defective or sticking.
2. Steer cylinder C3 seals leaking.
3. Mechanical binding in king pins.
- Check for binding. Repair as needed.
4. Orifices 03 plugged.
- Clean orifices, and reinstall.
4.2-12 All System sluggish

1. System Relief Valve defective or not adjusted properly.
- Adjust valve. Replace if defective.
2. Hydraulic pump P1 worn.
3. Proportional valve 2H-59 contaminated or defective.
- Clean. Replace if defective.

1. Platform extend valve 4H-26 or platform retract valve 4H-27 defective or is sticking.
2. Powered platform cylinder C5 seals defective.
- Rebuild cylinder. Replace if damaged.
3. Mechanical binding in power extension platform mechanism.

1. Stuck speed valve 3H-18A-1.
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Notes
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Section 5 - PROCEDURES
Service & Maintenance

General .....................................................................................................................................................................111
Safety and Workmanship.........................................................................................................................................111
Platform
5.1-1 OEM Controller Electronics Information .......................................................................................................111
5.1-2 OEM Controller Troubleshooting ..................................................................................................................112
5.1-3 OEM Controller Switch Wiring ......................................................................................................................113
5.1-4 Gate Spring Hinge Adjustment .....................................................................................................................114
5.1-5 Railing Modification to Enhance Resistance to Damage..............................................................................115
5.2-1 System Relief Pressure Adjustment ..............................................................................................................117
5.2-2 Lift Pressure Adjustment ...............................................................................................................................117
Base
5.2-3 Electronic Tilt Switch Setup Procedure.........................................................................................................118
5.2-4 Pothole Limit Switches (LS4 & LS5) Replacement and Adjustment ............................................................122
5.2-5 Wheel Replacement and Torquing Procedure ..............................................................................................123
5.2-6 Tightening and Torque Recommendations for Hydraulic Couplings and Hoses .......................................129
5.2-7 Battery Maintenance ......................................................................................................................................131
5.2-8 Charger Maintenance - Delta-Q.....................................................................................................................131
Scissors
5.3-1 High Speed Cutout Limit Switches (LS1A & LS1B) & Drive Override Limit Switch (LS6) Replacement and
Adjustment ...............................................................................................................................................................139
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Service and Maintenance Section 5 - Procedures
General Clockwise (CW) adjustment of the trimpot increases

The following information is provided to assist you in the output.
the use and application of servicing and maintenance
procedures contained in this chapter. Counter-clockwise (CCW) adjustment of the trimpot
decreases the output.
Safety and Workmanship
Your safety, and that of others, is the first consideration Adjustments affect output current, voltage or percentage
when engaging in the maintenance of equipment. Al- of duty cycle to the coil. The minimum and maximum
ways be conscious of weight. Never attempt to move output is preset at the factory. However, for optimum
heavy parts without the aid of a mechanical device. Do performance, they must be adjusted while the
not allow heavy objects to rest in an unstable position. equipment is operating.
When raising a portion of the equipment, ensure that
adequate support is provided. Although the following adjustments affect the current/
voltage or percentage of duty cycle, the best way
Unless specifically noted otherwise, before beginning to adjust the function is to observe the response or
any procedure: speed of the function. The following adjustments affect
function response, or speed. There may be some
1. Park the mobile elevating work platform (MEWP)
interaction between adjustments, making it necessary
on a firm, level surface.
to repeat the adjustment in order to achieve the desired
2. Fully lower the machine. response.
3. Push in the “ ” emergency stop buttons
on the platform control console and the base “Threshold” Adjustments
control console. Adjusts the initial current flow or duty cycle, affecting
the function response or speed when the handle is
4. Turn the off/platform/base key switch to the
first moved from the off position. Deflect the handle
“ ” off position. Remove the key. slowly to the position where the controller first turns on.
5. Turn the main power disconnect switch to the Adjust the threshold trimpot screw to the point where
“ ” off position. the controlled function just starts to move, then turn
the trimpot screw one, full turn in the counterclockwise
direction. This adjustment should be done first.
After completing any procedure which involves
modifying, adjusting, or replacing any hydraulic or “Maxout” Adjustments
electrical components, perform all of the function Adjusts the full stroke current or duty cycle affecting the
tests given in your unit’s Operating Manual. maximum function response, or speed when the handle
is deflected to its full travel. Fully deflect the handle,
and adjust the maxout trimpot for maximum desired
Platform function response or speed. To obtain proportional
resolution, it is important that the function starts to slow
5.1-1 OEM Controller Electronics down as soon as the handle is moved back from the
Information fully deflected position.
Flow Control The ideal adjustment occurs when the function just
Single coil or solenoid for single direction. The coil has begins to move when the handle is deflected, and the
two connections; one is wired to the P.C. Board (A) output increases until it reaches its maximum desired
terminal and the other is wired to (-), or the negative side response or speed at the end of handle travel.
of the supply voltage. Switches to control directional
valves may be provided on the controller.
Adjustment Procedures
Adjustments are made by turning a trimpot adjustment
screw. The trimpots are multi-turn, end to end-devices. It
may be necessary to turn the adjustment screw several
turns to observe a change in output.
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Section 5 - Procedures Service and Maintenance
5.1-2 OEM Controller Troubleshooting IRS Option

1. Function speed reacts too slowly or too quickly
Problem in relation to handle deflection.
1. The function will not operate when the handle is A. Check “IRS” (Ramp) trimpot adjustment.
moved. The LEDs do not light “CW ” increases ramp time, “CCW ”
A. Check that voltage is present at the positive decreases ramp time.
(+)input terminal.
B. Check that ground is connected to the Integrated Ramp System (IRS)
negative (-) terminal. Provides smooth function response ,when reacting to
C. If there is an in-line fuse, check to see if it is an abrupt change in handle deflection. “CW” rotation of
good. the trimpot increases ramp time and slows the response
time. “CCW” decreases ramp time and increases the
D. Check the controller on/off switch and the response time. To increase the ramp time, turn the
connectors. Voltage should be present at adjusting screw “CW” a few turns, then move the
the (X) terminal when the controller is turned controller handle abruptly. Continue to adjust until a
on. smooth response is observed. Most controllers have
E. Check that valve wiring is not shorted to on/off contacts which remove power from the P.C. Board
ground. The LEDs will not light. when the handle is returned to the off position. When
F. Check that valve wiring is not open. The the handle is abruptly returned to neutral, the output
LEDs will light, but the intensity will not vary. will not ramp down, and the function will stop.
G. Check trimpot settings. Fully “CCW” turns
Ramp Thru Off
output off, “CW” turns output fully on.
The P.C. Board should be adjusted as outlined in the
2. The function jumps or lurches when turned on. IRS adjustment procedure. If the handle is abruptly
A. Perform “Threshold” adjustment procedures. returned to neutral (OFF) the output will ramp down
3. The function reaches maximum speed before the to off. Ramp time is factory set to 2 seconds, unless
handle is fully deflected, otherwise specified.
A. Perform “Maxout” adjustment procedures.
NOTE
4. The function speed remains constant regardless
Trimpots should be sealed with nail polish
of the degree of handle deflection.
or enamel based paint.
WARNING
Do not use RTV silicone.
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5.1-3 OEM Controller Switch Wiring
WIRE CHART
COLOR FROM TO
WHT/RED STEER LEFT PIN #1
WHT/GRN STEER COMMON PIN #2
WHT STEER RIGHT PIN #3
YEL FORWARD/UP PIN #4
WHT/BLK +24V INPUT PIN #5
GRY REVERSE/DOWN PIN #6
BLU PWM OUT (A) PIN #7
BLK GROUND (-) PIN #8
WHT/BLU ENABLE OUT PIN #9
DOUBLE DOT
(STEER RIGHT)
STEER COMMON WHT/GRN SINGLE DOT

(STEER LEFT)
STEER RIGHT WHT
STEER LEFT WHT/RED
ENABLE OUT WHT/BLU
+24V INPUT WHT/BLK

ENABLE
15589 PCB
H1
H2 (+24V INPUT) WHT/BLK

BLU PWD OUT (A) (ENABLE) WHT/YEL
H10 H3
BLK GROUND (-)
H7 H4
YEL FORWARD/UP H9
GRY REVERSE/DOWN H8
H6 S1
H5
RED NO
BLK
CONNECTOR
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5.1-4 Gate Spring Hinge Adjustment If Locking Screw Located at the Side of the
Spring Hinge,
1. The tension of the spring hinges should be
NOTE
such that when the gate is opened halfway and
released, it will close fully and latch. Adjusting the tension on the spring
hinge is a two handed operation.
2. To adjust the tension of the spring hinges, first
remove the safety locking screw of each hinge. 6. To increase the tension, insert a 5/32” hex wrench
Retain the screws for reinstallation later. in the screw socket. Turn the wrench clockwise
to desired tension as well as aligning the locking
If Locking Screw Located at the Top or screw hole. Hold the wrench in place, maintaining
Bottom of the Spring Hinge, the selected tension, while reinstalling the locking
screw.
3. To increase the tension, insert a 5/32” hex
NOTE
wrench in the screw socket, and turn the
wrench clockwise. To release the tension, Ensure the holes inside the hinges are
depress the hex wrench in the socket, let it aligned before inserting the locking
rotate counterclockwise, then release the hex screw.
wrench.
7. Adjust the tension on both hinges until the gate

releases and latches from a half open position.
5. Reinstall the safety locking screws into the hinges

when tension adjustment is complete.
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5.1-5 Railing Modification to Enhance Guardrail Modification

Resistance to Damage
WARNING
Applies to the following serial numbers: Ensure that you maintain three points of contact
SJIII 3220 - 60 003 548 & below when using the ladder to mount/dismount the
SJIII 3226 - 27 013 592 & below platform.
SJIII 46XX - 70 013 810 & below
1. Enter the scissor lift and close the gate or entry
Machine Preparation chain.
1. Ensure the mobile elevating work platform
2. Slide out the extension deck fully, exposing the
(MEWP) is on a firm, level surface.
vertical strut completely, and lock it in place with
2. Fully lower the machine. pins.
3. Ensure there is enough room to extend the
3. Use an appropriate metal cutting saw or grinder
extension deck fully.
such as an angle grinder with a cut-off disc for
4. Push in the “ ” emergency stop buttons the following step.
on the platform control console and the base
control console.
5. Turn the off/platform/base key switch to the WARNING
Risk of severe injury. Ensure your angle grinder is
“ ” off position. Remove the key.
in good working condition and wear appropriate
6. Turn the main power disconnect switch to the personal protective equipment (PPE).
“ ” off position.
4. Cut through the top of the vertical strut, as
Tools Neededrinder shown below. Do not cut into the horizontal
▪ Cut off disc or metal saw square tube.
▪ Grinding disc
▪ 1/2” (13 mm) wrenches x 2
▪ Touch up paint
Verti
ca l Stru
Hardware Needed t
▪ 103865 - BOLT, Hex Hd Zinc - 5/16”-18 x 2” Gr. 5
Qty. 2 Cut o
ff
▪ 103984 - NUT, Hex Lock - 5/16”-18 Gr. B
Qty. 2
5. Remove and throw out the hardware from the
vertical strut hinge. Remove and throw out the
strut.
6. Use a grinding disc on the upper horizontal rail
to remove as much of the remaining strut as
possible, without grinding into the square tube.
Remove all sharp edges.
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7. Remove and discard the two hex head bolts and

lock nuts from the rear of the extension handrail.
8. Install a single new hex head bolt (103865 -

5/16”-18 x 2” Gr. 5) and lock nut (103984 - 5/16”-
18 Gr. B). Position the bolt with the hex head on
the inside of the platform. Use two 1/2” (13 mm)
wrenches to tighten the nut and bolt.
9. Repeat steps 3 to 8 on the other side of the

platform.
10. To prevent rust, paint the exposed steel.
11. When the paint is completely dry, slide the
extension deck in completely.
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Base
5.2-1 System Relief Pressure 5.2-2 Lift Pressure Adjustment

Adjustment
NOTE
1. Locate the system pressure quick disconnect port Adequate area to raise the platform to full
on the main manifold. height is required for the following steps.
2. Install a calibrated 5000 psi gauge to the system 1. Locate the lift pressure test port on the main
pressure quick disconnect port. manifold.
3. Remove the platform control console the guardrail 2. Install a calibrated 3000 psi gauge to the lift
and disconnect from the main control cable. pressure quick disconnect port.
4. Locate the main control cable plug at the rear of 3. At the main manifold, loosen the locknut on the
the aerial platform. lift relief valve R2.
5. Disconnect the main cable and connect the 4. Close the manual lowering valve. Use the lift
platform control console into the plug. switch at the base control console to raise the
platform to full height and hold the lift up switch
6. At the main manifold, loosen the locknut on the on.
system relief valve R1.
5. Observe the reading on the gauge. Adjust the
7. Select drive with the lift/drive select switch on the R2 relief valve to the value listed on the serial
platform control console. number plate. Turning the stem of the relief valve
clockwise will increases pressure. Turning the
8. Engaged steer right and hold. stem counterclockwise will decreases pressure.
9. Observe reading on gauge. Adjust the R1 system 6. Remove the gauge from lift pressure test port.
relief value listed on the serial number plate.
Turning the stem on the relief valve clockwise
will increases pressure. Turning the stem NOTE
counterclockwise will decreases pressure. Pressure setting may vary as aerial platform
components wear. The lift pressure should
10. Release steer switch and tighten the locknut. be set for rated load only.
11. Remove the gauge from system pressure test

port.
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AI
5.2-3 Electronic Tilt Switch Setup 9. Disconnect all wires #02 from motor contactor.
Procedure
10. Install jumper wire between #7 and #19 to
The following information is supplied for replacement
terminal strip.
or reprogramming of the electronic tilt switch. Also
included are test and verification instructions. Follow
11. Pull out “ ” emergency stop button and turn
the appropriate procedures below.
main disconnect switch to “ ” ON position.
Tilt Switch Replacement 12. Verify switch is powered. (Red or green LED will
turn on solid)
Y AXIS
X AXIS
Red LED Red LED
Green LED Green LED
13. Program the Tilt Switch

a. Press and release the set up button 3 times.
b. Observe program
1. Ensure aerial platform is parked on a firm level delay / stabilization
Red LED
surface. time. (Only the red Green LED
LED will blink for 4
2. Chock or block wheels to keep the aerial platform seconds)
from rolling forward or backward.
c. Both LEDs will
3. Lower/Raise the platform and secure the scissors flash for 1 second. Red LED
using the maintenance bars. (Refer to Operating Results: The switch is Green LED
manual for Maintenance Supports Procedure) learning the new zero

position.
4. Push in “ ” emergency stop buttons and turn
d. Both LEDs will turn
main disconnect switch to “ ” off position. Red LED
on solid for 1 second. Green LED
5. Remove any covers to locate and view the tilt Results: The new zero
switch. position has been
learned.
6. Disconnect tilt switch from 4 pin connector.
e. The green LED will flash and then the
7. Remove old tilt switch from mount. red LED will turn on solid for 2 seconds.
Results: The switch is
8. Install new switch to mount (in the same verifying the new zero position.
orientation as the old switch) and connect switch
plug to 4-pin connector.
Red LED
NOTE Red LED
Green LED Green LED
The tilt circuit is only powered when
activating a function.
f. The green LED

will turn on solid.
Results: The switch Red LED
Green LED
is ready for normal
operation.
14. Turn main disconnect switch to “ ” off position.
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AI
15. Remove jumper wire between #7 and #19 from

terminal block.
16. Reattach all wires #02 to motor contactor.
17. Reinstall any covers that was removed.
18. Remove chock or wheel blocks.
19. Proceed to Test and Verify Tilt Circuit.
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AI
Reprogramming Existing Tilt Switch 9. Reprogram the Tilt Switch

a. P r e s s a n d h o l d t h e
Set up button is located on this setup button until both
Light Indicators face next to harness lights start to flash. Red LED
(Approximately 5 sec.) Green LED
Results: Both LEDs will

be OFF.
R
Gre ed LE
en
LE
D Red LED
D
b. Both LEDs will flash. Green LED
IMPORTANT
Step “c” must be completed within
a 5 second period, or the switch will
automatically exit program mode and return
to normal operation using previously stored
1. Ensure aerial platform is parked on a firm level data.
surface.
c. Press and release set up button 3 times.
2. Chock or block wheels to keep the aerial platform
from rolling forward or backward. d. If 5 second period has expired prior completion,
repeat Step “a”, “b” and “c”.
3. Lower/Raise the platform and secure the scissors
using the maintenance bars. (Refer to Operating e. Observe program delay
manual for Maintenance Supports Procedure) / stabilization time. (Only
the red LED will blink for Red LED
NOTE Green LED
4 seconds)
The tilt circuit is only powered when
activating a function. f. Both LEDs will
flash for 1 second.
4. Remove any covers to locate and view the tilt switch. Results: The switch is Red LED
learning the new zero Green LED
5. Disconnect all wires #02 from motor contactor.
position.
6. Install jumper wire between #7 and #19 to terminal
g. Both LEDs will turn
strip.
on solid for 1 second.
7. Turn main disconnect switch to “ ” ON position. Results: The new Red LED
zero position has been Green LED
8. Verify switch is powered. (Red or green LED will learned.
turn on solid)
h. The green LED will flash and then the
red LED will turn on solid for 2 seconds.
Red LED Red LED

Green LED Green LED
Red LED Red LED

Green LED Green LED
Results:
The switch is verifying the new zero position.
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AI
i. The green LED Test and Verify Tilt Circuit

will turn on solid. Red LED
Results: The switch Green LED
Set up button is located on this
Light Indicators face next to harness
is ready for normal
operation.
10. Turn main disconnect switch to “ ” off position.

R
Gre ed LE
11. Remove jumper wire between #7 and #19 from en
LE
D
D
terminal block.
12. Reattach all wires #02 to motor contactor.
13. Reinstall any covers that was removed.
14. Remove chock or wheel blocks.
15. Proceed to Test and Verify Tilt Circuit.

Operations of Tilt Switch
The following describes the LED’s and what they indicate.
Illuminated whenever both tilt

axes are within the specified
degrees of the zero/ home
Green LED learned position.
Flashes when transitioning in or
out of tilt angle limits, but built in
time delay has not fully occurred.
Illuminated whenever tilt on one
or more axes is more than the
Red LED
specified degrees out from the
zero/ home position.
On together, no blinking when
Green & Red LED
fault detected.
Tilt Circuit Test
1. Refer to section 2 for test tilt sensor procedure.
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AI
5.2-4 Pothole Limit Switches (LS4 & Limit Switch Electrical Connections
LS5) Replacement and Adjustment 1. Route the new limit switch cable(s) along the same
path as the old one(s) into the electrical panel
Machine Preparation cabinet. Use tie wraps as needed to secure them
1. Ensure the aerial platform is parked on a firm level at regular intervals.
surface.
2 Strip the cable jacket back to separate the wires.
2. Chock or block the wheels to keep the aerial Cut the wires to length if needed.
platform from rolling forward or backward.
3. Strip the ends of wires 72-Black/
Limit Switch Removal White and 71-Black from the Battery Tray Limit
1. Raise the platform until the pothole bars are Switch as well as wires 72-Black/White and
deployed. 19-Black from the Hydraulic Tray Limit Switch and
connect them to the electrical panel (refer to 3.19
2. Swing out the hydraulic tray and the battery Electrical Panel Wiring Diagram).
tray to gain access to the pothole limit switches
underneath the base. Limit Switch Setup
1. Loosen the hardware securing the limit switch
3. Remove the bolts and nuts (x2) securing each to the pothole lock plate. Adjust and move the
limit switch to the pothole lock plate. Set the limit switch towards the lever bar until it makes
hardware aside for later reinstallation. contact inside the notch with the lever bar without
depressing the plunger roller.
4. Remove the limit switch and free the limit switch

cable by cutting the tie wraps. 2. Fully tighten the bolts securing the limit switch.
Ensure the limit switch does not move while
5. Follow the cable into the electrical panel, and tightening the bolts and the plunger roller
disconnect the limit switch wires from the retaining pin is fully visible.
electrical panel. Discard the limit switches.
Limit Switch Testing
Limit Switch Replacement
1. Mount loosely the new limit switch assemblies: 1. Place a block, approximately 1.5” (3.75 cm),
166003 (Battery Tray) & 125885 (Hydraulic Tray), under the hydraulic/electric tray and then raise
using the hardware removed previously. the platform to an approximate height of 7 feet
(2 meters) or until the pothole protection is
activated. Attempt to drive forward or reverse.
Aerial platform should not move forward or
backward.
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AI
5.2-5 Wheel Replacement and Torquing 5. From the back side of the wheel, place the
Procedure grease seal on the hub with the tapered end
facing inwards.
Tools Needed
Inner Bearing
▪ Adjustable Torque Wrench
Capacity 380 Nm (280 ft-lb)
Grease Seal
▪ Hub Puller
Grease Application -
New Front Wheels Only (if required)
Model Recommended Grease Type
STARPLEX EP2
SJIII 3220, SJIII 3226,
UNIREX EP2
SJIII 4626, SJIII 4632
SHELL GADUS S2
1. If the bearings are provided separately, they will

need to be coated in grease before installing on Grease seal
the front wheels. section view
Outer Bearing Inner Bearing
Back side shown
6. Lightly tap the grease seal into place using a

hammer, protecting the grease seal with a flat
piece of wood.
Front side shown
2. Thoroughly clean the bearings using solvent

and allow them to dry.
3. Coat the inner and outer bearings with grease
completely. Be careful not to contaminate the
grease. This could cause internal damage
and shorten the life span of the bearings.
Contaminants include dust, dirt, sand, water or
other foreign particles.
4. Install the inner and outer bearings. The grease
should allow the bearings to stick to the bearing
cups inside the wheel assembly.
NOTE
The inner bearing has a larger diameter than
the outer bearing. When installing, ensure the
bearings are inserted tapered-end first.
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AF
Hub/Integrated Hub Wheel Removal

1. Use an appropriately rated lifting device to raise
up the MEWP until all the wheels are off the
ground. Set the MEWP on stands adequately
rated to support the weight of the machine.
2. Remove and set aside the wheel motor nut or

castle nut.
3. Remove and discard the locktooth washer or

cotter pin. A new one will be required for re-
installating the hub/integrated hub wheel. Remove Hub
4. Use a hub puller to remove and discard the hub/

integrated hub wheel from the wheel motor or
brake.
5. For integrated hub wheels, use two 3/8”-24 bolts

with a hub puller to remove the wheel.
Remove Integrated Hub Wheel
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Front Hub/Integrated Hub Wheel Installation

1. Install the hub/integrated hub wheel onto the 10. Ensure the cotter pin is pushed in completely.
spindle.
2. Install the castle nut and the flat washer. Finger 11. Bend the ends of the cotter pin to secure the
tighten the nut. castle nut.
3. For integrated hub wheels, use a wrench to 12. Install the dust cap over the castle nut. Be sure
manually disengage the pin brakes on both sides. not to damage the castle nut while installing the
This will allow you to rotate the wheel. dust cap.
4. Rotate the hub/wheel slowly while tightening the

castle nut to approximately 68 Nm (50 ft-lb). This
is to seat all the bearings in the wheel assembly.
NOTE
Do not over-torque the castle nut as the bearing
life would be reduced.
Hub Install
5. Loosen the castle nut to remove the torque. Do

not rotate the wheel.
6. Finger tighten the castle nut until it is snug.

Integrated Hub Wheel Install
NOTE
The castle nut should be free to rotate, with the
only restraint being the cotter pin.
7. Use a wrench to re-engage the pin brakes on

both sides. Do not lower the machine while the
pin brakes are disengaged.
8. Turn the castle nut back slightly until the next

cotter pin hole is visible on the spindle.
9. Install a 3/16” x 1-1/2” cotter pin.
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Rear Hub/Integrated Hub Wheel Installation - If using a wheel motor nut

Pin Brakes 7. Install a wheel motor nut and the new locktooth
1. Install the hub/integrated hub wheel onto the washer onto the hub/wheel.
spindle.
8. Torque the wheel motor nut to 380 Nm (280 ft-lb).
2. Install a 1” castle nut onto the brake. 9. Apply torque seal to the wheel motor nut.
3. Tighten the castle nut to 203 Nm (150 ft-lb) and

insert the 1/8” x 1-1/2” cotter pin.
4. If the holes do not align to install the cotter pin,

continue to torque the castle nut clockwise until
the next hole is visible.
5. Ensure the cotter pin is pushed in completely.
6. Bend the ends of the cotter pin to secure the Hub Install
castle nut.
Hub Install
Integrated Hub Install
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Rear Hub/Integrated Hub Wheel Installation - If using a wheel motor nut

Wet Brakes 7. A new 1” locktooth washer will be required for
1. Install the hub/integrated hub wheel onto the hub installation using a wheel motor nut.
spindle.
8. Torque the wheel motor nut to 380 Nm (280 ft-lb).
2. Install a 1” castle nut onto the the brake. 9. Apply torque seal to the wheel motor nut.
3. Tighten the castle nut to 203 Nm (150 ft-lb) and

insert the 1/8” x 1-1/2” cotter pin.
4. If the holes do not align to install the cotter pin,

continue to torque the castle nut clockwise until
the next hole is visible.
5. Ensure the cotter pin is pushed in completely.
6. Bend the ends of the cotter pin to secure the Hub Install
castle nut.
Hub Install
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Wheel Installation (If applicable)

1. Install the wheel onto the hub.
2. Center the wheel mounting holes with the bolt
holes from the hub.
3. Secure the wheel using wheel bolts and hand
tighten to center the rim.
Raised holes
face outward
4. Torque the bolts to 68 Nm (50 ft-lb) in a criss-

cross sequence.
1
4
3
2 5
5. Tighten the bolts to 122 Nm (90 ft-lb) in a criss-

cross sequence.
6. Repeat the tightening sequence to confirm that
none have changed from 122 Nm (90 ft-lb). If
any are found below 122 Nm (90 ft-lb), repeat
complete sequence until there is no change in
torque values. If possible, drive the machine prior
to checking torques.
7. Apply dots of torque seal at the base of the wheel
bolts.
8. Check torque values after 8 hours of operation.
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5.2-6 Tightening and Torque Torquing Using a Torque Wrench

Recommendations for Hydraulic 1. This method is applicable for JIC (37°) and
Couplings and Hoses FFOR (Flat Face O-Ring) hose ends and fittings,
wherever the components are accessible with
General Work Practices torque wrench / crow’s foot tools.
1. All components must be free of damage or
2. Align the hose end or fitting to the mating
contamination. O-rings cannot be reused anytime
component.
the component has been installed beyond finger
tight. Clean or replace components, as required. 3. Install the nut two or three turns by hand to assure
proper alignment. Jiggle the hose while tightening
2. Over-tightening a coupling may result in
to ensure the faces contact fully.
overstressing and/or cracking, and may lead to
leaking or failure. 4. Using a properly calibrated torque wrench, tighten
the coupling using a smooth, even motion until
3. When tightening hose couplings, ensure the hose
an indication (audible click) is heard and felt.
does not twist on the adapter. Twisting will shorten
Do NOT over tighten. For recommended torque
hose life and scar the sealing surfaces of swivel
values, refer to Table 2.8 Torque Specifications
type couplings (JIC, 45°, etc.), which can create
for Hydraulic Couplings & Hoses.
leaks.
5. Apply a drop of torque seal to the connection.
4. When tightening hose couplings, use a torque
wrench (with crow’s foot) on the hose end hex
swivel nut, and a standard box wrench on the Torquing Using the Flats From Wrench
hose end stem hex to hold the hose from twisting. Resistance Method
1. This method is applicable for JIC (37°) and FFOR
(Flat Face O-Ring) hose ends only, wherever the
components are inaccessible with torque wrench/
crow’s foot tools, or when a properly calibrated
torque wrench is not available.
2. Align the hose end or fitting to the mating

component.
Box
Wrench 3. Install the swivel hose end nut hand tight to the
fitting to assure proper alignment. Jiggle the hose
while tightening to ensure the faces contact fully.
4. Tighten the nut using a box wrench until minor

resistance is felt.
Torque Wrench
with Crow’s Foot
5. Lubricate all o-ring surfaces with suitable

hydraulic oil prior to installation in the flange head
and o-ring seal grooves. This will minimize the
possibility of damage to the O-ring when installed.
6. Install any 45° and 90° hydraulic hose ends first,

then align direction and tighten. Adjust the swivel
nut on the straight hose end before tightening to
create the desired flow.
SJIII DC Electric
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AF
5. Note the position of the nut relative to the fitting with This example shows the
a marking device (i.e., paint marker). nut tightened 1 flat past
the mark.
Mark the hose
end and fitting
6. Referencing the chart below, use a second box

wrench to tighten the nut the appropriate number Using two Box Wrenches, tighten
of flats past the mark. Do NOT over tighten. the nut the appropriate number
of flats past the mark (refer to the
FLATS FROM WRENCH RESISTANCE CHART FFWR chart above).
for JIC Hose Ends
Size FFWR
37° Tube 7. Apply a drop of torque seal to the connection.

Dash Frac. (in.) Swivel Nut
Nut
-4 1/4" 2 1.5
-5 5/16" 2 2
-6 3/8" 1.5 1.5
-8 1/2" 1.5 1.25
-10 5/8" 1.5 -
-12 3/4" 1.25 -
-16 1" 1 -
-20 1 1/4" 1 -
-24 1 1/2 1 -
-32 2" 1 -
SJIII DC Electric
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5.2-7 Battery Maintenance 5.2-8 Charger Maintenance - Delta-Q

This section provides the operator with procedures
on how to service and charge the battery. This also
provides the charger operation instructions. 3
2b
Servicing the battery
2a
WARNING
Explosion hazard. Keep flames and

sparks away. Do not smoke near 1
4
batteries. Battery acid releases
explosive gas while charging. Charge 5
batteries in a well-ventilated area. 6
WARNING
Indicator Description/action
Battery acid is extremely corrosive – wear proper No. State
type required
eye and facial protection as well as appropriate
protective clothing. If contact occurs, immediately Battery charger is
AC
flush with cold water and seek medical attention. 1 Blue connected to the AC
power
power.
1. Turn the main power disconnect switch to the off
Flashing Low charge— continue
position.
2. Check the battery case for damage. Battery green charging.
3. Check the battery fluid level in each battery. If the
2a charging
<80% Solid High charge—
plates are not covered by at least 13 mm (1/2 in)
green continue charging.
of solution, add distilled or demineralized water.
4. Make sure all the battery connections are tight. Flashing High charge— can
Battery green discontinue charging.
2b charging
NOTE >80% Solid Charge complete—
Do not use any batteries other than the flooded green discontinue charging.
lead-acid batteries of the proper Ah rating.
Charger fault—refer to
Solid red
WARNING the service manual.
Fault/
3
Use the original or equivalent to the original parts error Error encountered—
Flashing
and components for the MEWP. refer to the service
amber
manual.
Charging Solid Charger output is
4
output yellow active.
Charge Current
profile/ algorithm
5 N/A.
error or fault/
display error code
Select Current
6 charge charging N/A.
profile algorithm
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Charger Profiles 5. Continue to hold the button for approximately 10

seconds or until the Error Indicator turns orange
and the Battery Charging Indicator starts flashing
IMPORTANT green.
Charge profiles differ depending on the battery
6. The current charger profile displays up to three
type and manufacturer. Only use charge profiles
times.
with the batteries they were designed for. Using
other incompatible batteries may cause poor
charging performance and a decreased battery NOTE
health. The process times out and the profile remains
unchanged if there are 15 seconds of inactivity, or
1. Place the charger near a power outlet, but leave it if the charging profile is allowed to display three
unplugged. times.
2. Find your battery type in the following chart, and 7. Press and release the button to scroll through the
make a note of the profile number (starting with charging profiles.
P).
8. Select a profile, and press and hold the button for
3. Press and hold the Select Charger Profile button 10 seconds or until the Error Indicator and Battery
(wrench icon) on the Delta-Q charger. You will Charging Indicator lights turn off.
hear a small click when you press the button.
9. Press the button again to confirm the selected
4. Continue to hold the Select Charger Profile profile.
button, and connect the charger to a power outlet.
10. Disconnect the charger from the power outlet.
Battery Brand Compatible with Profiles
U.S. Battery - US 2200 XC/XC2 Flooded, 6V, 232 Ah 200 - 255 Ah flooded #11 (P-0-1-1)
Discover Energy - EVGC6A-A AGM, 6V, 220 Ah

220 - 400 Ah AGM #43 (P-0-4-3)
Discover Energy - EV12A-A AGM, 12V, 140 Ah*
U.S. Battery - US 12V XC2 Flooded, 12V, 155 Ah*

330 - 425 Ah flooded #73 (P-0-7-3)
U.S. Battery - US 250 XC/XC2 Flooded-lead, 6V, 255 Ah
Trojan - T105 ELPT Flooded, 6V, 225 Ah 150 - 250 Ah 6V, 8V, 12V flooded #3 (P-0-0-3)
*The batteries used for these charger profiles are connected in a series-parallel circuit.
SJIII DC Electric
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Charger Troubleshooting
The IC Series charger is continuously monitoring itself and its environment for unusual conditions. There are a few
indications that may require the user’s attention.
Symptom Recommended Action
No Indicator Lights Check AC voltage and connection to wall power.
Charger is connected to AC and is waiting for a battery to be connected, or for CAN remote
Only Blue AC Light On control commands. Battery voltage must rise over 0.1V/cell before charging will begin.
Some charging algorithms require a higher battery voltage to begin.
Read fault code (e.g., F-0-0-1) number on the Charge Algorithm/Error Display and refer to
Solid Red Fault/Error Indicator
the fault code table.
Flashing Amber Fault/Error Read error code (e.g., E-0-0-1) number on the Charge Algorithm/Error Display and refer to
Indicator the error code table.
Charger Fault Codes
Fault
Description Troubleshooting/Customer Actions
Code
F-0-0-1 DC-DC Failure: LLC excessive leakage fault. Internal charger fault. Disconnect AC and battery from
Power Factor Correction (PFC) Failure: PFC charger for a minimum of 30 seconds. If it fails again, contact
F-0-0-2 Skyjack service.
excessive leakage fault.
F-0-0-3 PFC has taken too long to boost.
The charger has been unable to calibrate the
F-0-0-4
current offset.
The voltage drop across the DC relay is too high
F-0-0-5
while the relay is closed.
Large difference between internal DC-DC and
F-0-0-6
battery sense currents.
SJIII DC Electric
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Charger Error Codes

Fault
Description Troubleshooting/Customer Actions
Code
E-0-0-1 Battery voltage over limit in software. Typically ▪ Check the battery voltage and cable connections.
2.5V/cell. At the start of a charger cycle only and
only for lead acid batteries. It is acceptable for ▪ Check charger voltage model is appropriate for
the voltage to go above this during charging batteries.
and when charging Lithium batteries. ▪ This error automatically clears once the condition has
been corrected.
E-0-0-2 Battery voltage too low to start a charge cycle. ▪ Check the battery voltage and cable connections.
Algorithm dependent. Typically 0.1V/cell.
▪ Check the charger is the correct voltage for the batteries
it is connected to.
▪ Check battery size and condition. Batteries may be
overdischarged. Use another charger to bring the
batteries above the minimum voltage.
▪ This error automatically clears once the condition has
been corrected.
E-0-0-3 Charge time limit reached. Algorithm ▪ Charger output reduced due to high temperatures.
dependent. Operate at lower ambient temperature.
▪ Charger output reduced due to low AC voltages. Check
AC voltages.
▪ Check for shorted or damaged cells.
▪ Poor battery health. Replace the battery.
▪ Batteries too large for the charger. Replace batteries.
▪ Very deeply discharged battery. Retry charge.
▪ Battery connections are loose or corroded. Check
connections.
▪ Extra loads. Turn off other devices running on the battery
▪ This error automatically clears once the charger is reset
by cycling DC or by loss of AC for over 10 minutes.
E-0-0-4 Battery could not be trickle charged up to ▪ Check for shorted or damaged cells.
the minimumvoltage. May also be used for
other battery-related errors depending on the ▪ Poor battery health. Replace the battery.
algorithm. ▪ Check DC connections.
▪ May be caused because of output reduced due to high
temperature.
▪ Some new batteries may trigger these alarms as there
voltage dips
▪ when charging starts before it goes onto rise.
E-0-0-7 Charge amp-hour Limit reached. Algorithm ▪ Charger output reduced due to high temperatures.
dependent. Operate at lower ambient temperature
▪ Charger output reduced due to low AC voltages. Check
AC voltage.
▪ Check for shorted or damaged cells.
▪ Poor battery health. Replace the battery.
▪ Very deeply discharged battery. Retry charge.
▪ Battery connections are loose or corroded. Check
connections.
▪ Extra loads. Turn off other devices running on the battery
▪ This error automatically clears once the charger is reset
by cycling
▪ DC or by loss of AC for over 10 minutes.
SJIII DC Electric
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E-0-0-8 Battery temperature out of range. Algorithm ▪ Cool or warm batteries as needed.
dependent.
▪ Check temperature sensor and connections.
been corrected.
E-0-1-1 Charge disabled by external command ▪ Charger has been disabled by an external controller
over the CANbus network.
▪ This error automatically clears once the command has
been removed.
E-0-1-2 Reverse polarity ▪ Battery is connected the wrong way around. Check the
battery connections.
been corrected.
E-0-1-3 Battery does not take current ▪ Check for an electrical component or loose connection
between the charger and the battery.
▪ When charging lithium batteries, make sure the charger
is properly connected to the battery and battery
management system.
▪ This error automatically clears once the charger is
disconnecting DC or AC.
E-0-1-9 Hardware build does not support software ▪ The charger hardware does not support the new
version software version.
▪ Existing SW is left running. Contact Delta-Q
Technologies.
E-0-2-0 No active algorithm selected ▪ Reprogram the charger with its original software,
algorithms, and settings.
▪ Use the wrench button to select the correct algorithm if
still available on the charger.
▪ The problem clears automatically when an available
algorithm is set on the charger, as default.
E-0-2-1 High battery voltage while charging. Algorithm ▪ When already charged, some new batteries may exhibit
dependent. Typically 2.8V/cell. this error.
▪ Disconnect the battery connection and wait for the
battery voltage to fall. Reconnect the batteries to see if
the condition reoccurs.
▪ Check battery size and condition. Batteries in poor
condition, with a high internal resistance, may cause
this error. New batteries, if charged when already full,
may also cause this error. Disconnect and reconnect the
batteries a few times.
▪ Check the battery voltage and cable connections.
been corrected.
SJIII DC Electric
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E-0-2-2 Low battery voltage while charging. Algorithm ▪ Another device may be drawing current from the battery.
dependent. Typically 0.1V/cell.
▪ Check the battery voltage and cable connections.
▪ Check battery size and condition. Batteries may be
overdischarged.
▪ Use another charger to bring the batteries above the
minimum voltage.
been corrected.
E-0-2-3 High AC voltage error (>270 VAC) ▪ AC voltage is too high. Connect charger to an AC
source that has a stable AC voltage between 85 and 270
VAC/45-65 Hz.
▪ In newer software versions this does not prevent
charging.
▪ This error will automatically clear once the condition has
been corrected.
E-0-2-4 Charger failed to turn on properly ▪ Disconnect AC input and battery for 30 seconds. If the
error persists, contact Delta-Q Technologies.
E-0-2-5 AC voltage has dipped below 80 VAC 3 times in ▪ AC source is unstable. This could be caused by an
30 seconds undersized generator and/or input cables that are too
long or too small.
▪ Connect the charger to an AC source with a stable AC
voltage between 85 and 270 VAC/45-65 Hz.
▪ This error will automatically clear once the condition has
been corrected.
E-0-2-8 Attempt to select algorithm incompatible with ▪ Update charger software, continue to use existing
this software algorithm* or select a different charging algorithm that is
compatible.
* Notes
▪ If selecting a different algorithm, the existing algorithm
will remain in the charger.
▪ If upgrading an existing algorithm, the existing algorithm
will be deleted. Contact Delta-Q Technologies for a
software upgrade to run the new algorithm.
E-0-2-9 Cannot transmit on CAN bus ▪ Check the physical CAN connector, electrical bus
conditions, and other CAN modules for correct
functioning. For example, check that termination
resistance is approximately 60 ohms.
E-0-3-0 CAN heartbeat timeout on Battery module ▪ May be caused by a missing heartbeat message. Check
the CAN bus battery module for correct function.
been corrected.
E-0-3-1 The Vref for the ADC measurements ▪ Internal charger error. Disconnect AC and the battery for
has triggered an alarm a minimum of 30 seconds and retry.
▪ If the problem persists, contact Delta-Q Technologies.
been corrected.
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E-0-3-2 CAN Heartbeat Lost ▪ An error was detected with the CAN heartbeat
communications with a registered node being guarded.
▪ Check the networked CANbus device(s) for correct
functioning.
▪ This alarm does not display or get logged on the
charger but does appear on the CAN bus via an
emergency message.
E-0-3-6 Battery temperature sensor is missing or ▪ Check sensor connections.
shorted
▪ The charger behavior when this fault occurs can be
configured. OEMs may contact Delta-Q Technologies for
more information.
been corrected.
E-0-3-8 Fan will not turn (Fan-equipped models only)
▪ Check fan connections.
▪ Check to make sure the fan turns freely and is not
obstructed.
been corrected.
E-0-4-0 Fan voltage pulled low (Fan-equipped models only)
▪ Check to make sure the fan turns freely.
▪ Battery disconnected
E-0-4-5 Battery disconnected
▪ Reconnect the battery or check the wiring
▪ Check to make sure all PDOs are valid length.

E-0-4-6 Invalid PDO Length ▪ This error automatically clears once the condition has
been corrected
▪ A battery or some other source has been connected to

E-0-4-7 Platform overvoltage alarm
the charger that exceeds the hardware’s design limits.
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Notes
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AF
Scissors Limit Switch Replacement

1. Mount the new limit switch assembly, 130559,
5.3-1 High Speed Cutout Limit using the hardware removed previously.
Switches (LS1A & LS1B) & Drive
NOTE: High Speed Cutout Limit Switch (LS1A)
Override Limit Switch (LS6)
is the one closest to the scissor arm, then LS1B
Replacement and Adjustment adjacent to it, and Drive Override Limit Switch
(LS6) on the opposite side.
Machine Preparation
1. Ensure the aerial platform is parked on a firm level
2. Slide the limit switch cover back onto the pin.
surface.
Secure it with the gear clamp removed previously.
2. Chock or block the wheels to keep the aerial
Limit Switch Electrical Connections
platform from rolling forward or backward.
1. Route the limit switch cable(s) along the same
path as the old one(s) into the 4-pin connector
Limit Switch Removal in the rear harness. Use tie wraps as needed to
1. Raise the platform to give access to the limit secure them at regular intervals.
switch cable, and deploy the maintenance stand.
2. Stow the maintenance stand and fully lower the
2. Turn the emergency main power disconnect platform.
switch to the OFF position.
Limit Switch Cam Setup
3. Remove the gear clamp securing the limit switch 1. Turn the emergency main power disconnect
cover, and slide the limit switch cover off of the switch to the ON position.
pin. Set aside the clamp for reinstallation later.
2. Attach the end of a measuring tape to the side of
4. Remove the bolts, washers, and nuts securing the platform with a tie wrap, in such a way that
the limit switches to the cover. Set the cover the measuring tape will hang down freely to the
and hardware aside for reinstallation later. ground. Note: The end of the measuring tape
should be level with the standing surface of the
platform.
LS1A LS1B LS6
3. For High Speed Cutout Limit Switches: Raise
the platform until the distance from the standing
surface of the platform to the ground measures
96”.
4. Loosen the set screws (x2) on the High Speed

limit switch cam, and then rotate the cam until it
depresses the limit switch plunger and a click is
heard inside the limit switch. Repeat this step for
the other high speed limit switch.
5. Remove the limit switches and free the limit switch

cable(s) by cutting the tie wraps.
6. Follow the cable into the plug and disconnect it

from the rear harness. Discard the limit switches.
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AF
Limit Switch Testing

1. For High Speed Cutout Limit Switch: Raise
the platform less than 93”, and drive the unit at
full speed. The unit should move at high speed.
Then raise the platform over 93”. The unit should
automatically switch from high speed to low
speed. Note: High Speed Cutout should occur
within the tolerance zone of 93” to 99”.
2. For Drive Override Limit Switch: Place a block,

approximately 1.5” (3.75 cm), under the hydraulic/
electric tray and then raise the platform to an
approximate height of 7 feet (2 meters) or until
the pothole protection is activated. Attempt to
drive forward or reverse. Aerial platform should
5. For Drive Override Limit Switch: Place a block, not move forward or backward.
approximately 1.5” (3.75 cm), under the hydraulic/
electric tray and then raise the platform to an
approximate height of 7 feet (2 meters) or until
the pothole protection is activated.
6. Loosen the set screws (x2) on the Drive Override

limit switch cam, and rotate the cam until it
depresses the limit switch plunger and a click is
heard inside the limit switch.
7. Fully lower the platform.
SJIII DC Electric
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Notes
SJIII DC Electric
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AF
Section 6 - APPENDIX A
Motor Controller Option
This section is for MEWPs with serial numbers:

SJIII 3220 60 004 852 & Above
SJIII 3226 27 021 943 & Above
SJIII 46xx 70 021 720 & Above
Please refer to the website www.skyjack.com for older Serial Numbers.
SJIII DC Electric
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Notes
SJIII DC Electric
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AF
Section 6 - APPENDIX A
Parts List
6.1 Electrical Component Parts List........................................................................................................................146
Diagrams and Schematics

6.2 Platform Control Console Diagram...................................................................................................................147
6.3 Scissor Assembly Limit Switches .....................................................................................................................148
6.4a Electrical Panel Diagram - Motor Controller ....................................................................................................150
6.4b Electrical Panel Diagram - Motor Controller ....................................................................................................151
6.4c Electrical Panel Diagram - Motor Controller ....................................................................................................152
6.5a Electrical Panel Diagram Powerdeck - Motor Controller .................................................................................153
6.5b Electrical Panel Diagram Powerdeck - Motor Controller .................................................................................154
6.5c Electrical Panel Diagram Powerdeck - Motor Controller .................................................................................155
6.6a Electrical Panel Diagram - Motor Controller - Inverter Option .........................................................................156
6.6b Electrical Panel Diagram - Motor Controller - Inverter Option.........................................................................157
6.6c Electrical Panel Diagram - Motor Controller - Inverter Option .........................................................................158
6.7a Electrical Panel Diagram Powerdeck - Motor Controller - Inverter Option......................................................159
6.7b Electrical Panel Diagram Powerdeck - Motor Controller - Inverter Option .....................................................160
6.7c Electrical Panel Diagram Powerdeck - Motor Controller - Inverter Option......................................................161
6.8 Main Manifold Harness - Motor Controller .......................................................................................................162
6.9 Hydraulic Schematic (Models 32XX) - Motor Controller ...................................................................................163
6.10a Hydraulic Schematic (Models 46XX) - Motor Controller ...............................................................................164
6.10b Hydraulic Schematic (Models 46XX) - Motor Controller ...............................................................................165
6
6.11a Electrical Schematic - Motor Controller .........................................................................................................167
6.11b Electrical Schematic - Motor Controller.........................................................................................................168
6.11c Electrical Schematic - Motor Controller .........................................................................................................169
Troubleshooting
Introduction - Troubleshooting ................................................................................................................................170
Electrical System
6.12-1 All Controls Inoperative................................................................................................................................172
6.12-2 All Controls Except for Down Function Inoperative ....................................................................................173
6.12-3 All Controls Inoperative From Base Control Console .................................................................................173
6.12-4 No Up Function from Base Control Console...............................................................................................173
6.12-5 Up Function Slow from Base Control Console ...........................................................................................174
6.12-6 No Down Function from Base Control Console ..........................................................................................174
6.12-7 All Controls Inoperative From Platform Control Console ............................................................................175
6.12-8 No Up Function from Platform Controls ......................................................................................................175
6.12-9 Up Function Slow from Platform Control Console ......................................................................................176
6.12-10 No Down Function from Platform Controls ................................................................................................176
6.12-11 Steer Only Inoperative ................................................................................................................................176
6.12-12 Right Steer Inoperative (Without power deck option) ................................................................................177
6.12-13 Right Steer Inoperative (With power deck option) .....................................................................................177
6.12-14 Left Steer Inoperative (Without power deck option) ..................................................................................177
6.12-15 Left Steer Inoperative (With power deck option)........................................................................................178
6.12-16 Drive Only Inoperative ................................................................................................................................178
6.12-17 No Drive or Steer when Platform Fully Lowered ........................................................................................178
6.12-18 No Drive or Steer when Platform Elevated .................................................................................................178
6.12-19 Platform Drives in Slow Speed Only...........................................................................................................179
6.12-20 High/Low Torque Inoperative......................................................................................................................179
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AF
6.12-21 Brake will not Release.................................................................................................................................179

6.12-22 Forward Drive Function Inoperative ...........................................................................................................179
6.12-23 Reverse Drive Function Inoperative............................................................................................................180
6.12-24 Power Extension Platform will not Extend or Retract .................................................................................180
6.12-25 Power Extension Platform will not Extend ..................................................................................................180
Hydraulic System
6.12-26 Power Extension Platform will not Retract ..................................................................................................181
6.13-1 All Function Inoperative ...............................................................................................................................181
6.13-2 All System sluggish .....................................................................................................................................181
6.13-3 Platform Drifts Down ....................................................................................................................................181
6.13-4 Platform Lifts Slowly.....................................................................................................................................181
6.13-5 Platform does not Lift ...................................................................................................................................182
6.13-6 Platform will not Lower.................................................................................................................................182
6.13-7 Platform Drives Slow ....................................................................................................................................182
6.13-8 Platform will not Drive in Forward or Reverse .............................................................................................182
6.13-9 Brake(s) will not Release (Pin brakes)..........................................................................................................182
6.13-10 Brake(s) will not Release (Integral brakes)................................................................................................182
6.13-11 Aerial Platform will not hold on a Grade (Integral brakes) .........................................................................183
6.13-12 Platform does not Steer ..............................................................................................................................183
6.13-13 Power Extension Platform will not Extend or Retract .................................................................................183
6.13-14 High/Low Torque Inoperative......................................................................................................................183
Procedure
General .....................................................................................................................................................................184
Safety and Workmanship.........................................................................................................................................184
Platform
6.14-1 OEM Controller Electronics Information .......................................................................................................184
6.14-2 OEM Controller Troubleshooting ..................................................................................................................185
6.14-3 OEM Controller Switch Wiring ......................................................................................................................186
6.14-4Gate Spring Hinge Adjustment......................................................................................................................187
Base
6.15-3Resistor - Voltage Divider ..............................................................................................................................189
SJIII DC Electric
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AK
Section 6 Appendix A
6.1 Electrical Component Parts List

Index Skyjack
Qty. Description
No. Part No.
21CR 108589 1 RELAY, 24 Volt (Cushion)

14CR 108589 1 RELAY, 24 Volt (Lift Speed)
14CR1 108589 1 RELAY, 24 Volt (Lift Speed 2)
59JCR 108589 1 RELAY, 24 Volt (Base Control)
9ACR-1 108589 1 RELAY, 24 Volt (Powerdeck Relay #1)
9ACR 108589 1 RELAY, 24 Volt (Powerdeck Relay #2)
RST1 119629 1 RESISTOR (2.7K ohm)
RST2 166243 1 WIRE, Motor Controller (6.25” / 68 OHM)
151647 1 • RESISTOR, (68 ohm)
168987 1 • RESISTOR, (360 ohm)
151647 1 • RESISTOR, (68 ohm)
RST5 166245 1 WIRE, Motor Controller (5.25” / 4.75 KOHM)
151645 1 • RESISTOR, (4.75k ohm)
RST6 198792 1 WIRE, Motor Controller (5.25” / 1.2 KOHM)
163253 1 • RESISTOR, (1.2k ohm)
RST7 151643 1 RESISTOR, (250 ohm)
RST8 156564 1 RESISTOR, (1.5 ohm)
LS4 166007 1 LIMIT SWITCH, Pothole protection (Battery tray)
- - - (For model 3220 with serial number 60007077 & Below)
- - - (For model 46xx with serial number 70032133 & Below)
199745 1 LIMIT SWITCH, Pothole protection (Battery tray)
LS5 133600 1 LIMIT SWITCH, Pothole protection (Hydraulic tray)
- - - (For model 46xx with serial number 70032133 & Below)
199459 1 LIMIT SWITCH, Pothole protection (Hydraulic tray)
S7 159111 1 JOYSTICK, Motor Controller
S7-1 122869 1 SWITCH, Neutral
S7-2 159613 1 SWITCH, Right Steer
S7-3 159613 1 SWITCH, Left Steer
S7-6 159067 1 SWITCH, Pushbutton - Enable
TIMER 137417 1 TIMER, Relay - Delay-On-Release - -
TT 195940 1 HOURMETER, Digital
C1 146475 1 CONTACTOR, Solenoid (hydraulic proportional control)
165865 1 CONTACTOR, Solenoid (Motor controller/MC models
SJIII DC Electric
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AF
Appendix A Section 6
6.2 Platform Control Console Diagram
S27 - TORQUE S3 - LIFT/OFF/DRIVE
15 16 12B
S8 - HORN
12B
B
18 A 8A
12B 08
08
49
13 14
00
S4 - EMERGENCY STOP
RST1
8C 08
02
60/7A LED-1 02
X2
X1
08 07 7A
FEMALE
9 PIN CONNECTOR SUB-ASSEMBLY
(8C) BLUE WHITE 6 14 BLUE BLACK (24)
CTRL BOX
HARNESS
BACK VIEW
JOYSTICK HARNESS PIN 4 - FWD/UP B RED YELLOW
PIN 5 - JOYSTICK VS+ 08 BLUE WHITE/BLACK
8A BLUE
CRD1
PIN 9 - ENABLE VS+ WHITE/ BLUE
M163169AA
SJIII DC Electric
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AK
6.3 Scissor Assembly Limit Switches
Serial Breakdown
BROWN BLACK
19
Reference Chart
LS6
NO NC
Model Serial Number
71
BLUE BLACK/WHITE SJIII 3220 60007077 & Below
SJIII 3226 27032454 & Below
SJIII 46XX 70032133 & Below
BROWN BLACK
18B 18A PIN 1 - 71 (BLACK/WHITE) PIN 5 - 7A(CE/AS)/13(KC) (BLUE)
LS1B
NO NC PIN 2 - 21 (BLACK) PIN 6 - 18B(CE/AS)/13A(KC) (BROWN)
7A 18 PIN 3 - 18 (BLACK/WHITE) PIN 7 - 19 (BLACK)
BLUE BLACK/WHITE PIN 4 - 18A (BLACK) PIN 8 - 71 (BLACK/WHITE)
DEUTSCH
BROWN BLACK 1 8
2 7
21 3 6
NO NC 4 5
LS1A
71
BLUE BLACK/WHITE
BROWN BLACK Serial Breakdown

19 Reference Chart
LS6 NO NC
71 Model Serial Number

BLUE BLACK/WHITE
SJIII 3220 60007078 & Above
SJIII 3226 27032455 & Above
BROWN BLACK SJIII 46XX 70032134 & Above
18B 21
LS1A NO NC
PIN 1 - 71 (BLACK/WHITE) PIN 4 - 18B(CE/AS)/13A(KC) (BROWN)
7A 71 PIN 2 - 21 (BLACK) PIN 5 - 19 (BLACK)
BLUE BLACK/WHITE PIN 3 - 7A(CE/AS)/13(KC) (BLUE) PIN 6 - 71 (BLACK/WHITE)
6 1
5 2
4 3
M130560AD_M204106AA-S
SJIII DC Electric
157928
Notes
SJIII DC Electric
157928
AI 6.4a Electrical Panel Diagram - Motor Controller
A B C D E F G H
TO LOWER BASE BOX
Serial Breakdown
PIN 1 - 07 (RED) PIN 5 - N/U
17CR Reference Chart
DEUTSCH
8 1
7 2 PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE) 28CR 21CR 14CR 14CR1 59JCR
6 3
PIN 3 - 13 (ORANGE) PIN 7 - 7A (GREEN) STEER RELAY
5 4 AUX. TILT RELAY HIGH SPEED RELAY LIFT SPEED RELAY LIFT SPEED RELAY 2 BASE CONTROL RELAY
BLUE PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE)
PIN 30 - 17A
Model Serial Number
PIN 30 - 19 PIN 30 - 59B PIN 30 - 59 PIN 30 - 7A PIN 30 - 59I
PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 SJIII 3220 60006146 & Below V
YEL PIN 86 - 28 PIN 86 - 17 PIN 86 - 21 PIN 86 - 14 PIN 86 - 14 PIN 86 - 59J
PIN 87 - 19A PIN 87 - N/U PIN 87 - 59E PIN 87 - 59A PIN 87 - 59D PIN 87 - 59H SJIII 3226 27028841 & Below
DEUTSCH
8 1
02 7 2 PIN 2 - 21 (ORANGE/BLACK) PIN 6 - N/U
02 02 02 6
5
3
4
PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE) PIN 87a -28A PIN 87a - 17B PIN 87a - 59F PIN 87a - 59B PIN 87a - 59C PIN 87a - 59G SJIII 46XX 70028673 & Below
02
TO HIGH SPEED LIMIT
8C 8C TO POTHOLE LIMIT
19A
29 29
18A 18A 18A
18A BEEPER
REAR HARNESS 02 02
02 - WHITE
19A
02
05 - GREEN/BLACK
07 - RED
28CR 17CR 21CR 14CR 14CR1 59JCR
7A - GREEN
8C - BLUE/WHITE
W
13 - ORANGE
14E - BLACK 28 02 17 02 21 59E 02 14 59A 02 14 02 59J 59H 02
19A 59D
18 - RED/BLACK TO FLASHER IF EQUIPPED
28A 17B 59F 59B 59C 59G
19 - BLUE OTHERWISE TIE BACK
21 - ORANGE/BLACK 19 17A 59B 59 7A 59I
71 - BLACK/WHITE 29 22
71 - WHITE/BLACK
N/U - GREEN/WHITE
N/U - BLUE/BLACK
19A - RED/WHITE
05 - WHITE
TO CHARGER
3A - BLACK
D14A
D23 D24
02 3A
RST7
D17B-2
D16
D17
D28A D14E D17B-1
RST4
RST2
RST6
RST3
RST5
D19A
D14E-1
D13
LEGEND:
D15
R TO JOYSTICK BOX TO BASE CONTROLS
R R R R R
X
00 03 02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19B 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24
R
W W
RST8
D21
D13X D14X
TO OUTRIGGER TO END OF STROKE
SOLENOID CABLES
MAIN MANIFOLD
00 - GREEN/YELLOW
02 - WHITE
03 - BLUE BATTERY TRAY HYDRAULIC TRAY
13 - ORANGE 72 - BLACK/WHITE 72 - BLACK/WHITE
14 - BLACK
15 - BLUE
71 - BLACK 19 - BLACK
Y
16 - WHITE/BLACK MAIN MANIFOLD
17A - BLUE/RED
19A - WHITE/RED
23 - BLACK/WHITE
24 - BLUE/BLACK PLATFORM CONTROL BOX
59I - ORANGE/BLACK
REAR HARNESS
TILT SWITCH
GREEN WHITE (49)
BLUE WHITE (8C)
ORANGE (13)
GREEN (7A)
BLACK (14)
WHITE (02)
BLUE (15)
RED (07)
8
7
6
5
4
3
2
1
HORN/FLASHING LIGHT
MALE
TILT SWITCH TO HORN TO FLASHING LIGHT (OPT)

19 - BLACK 49 - BLACK 22 - GREEN Z
9
16
15
14
13
12
11
10
28 - GREEN
02 - WHITE
(NOT USED)
(OPT) RED WHITE
(OPT) GREEN BLACK

(59) ORANGE BLACK
(16) WHITE BLACK

(23) BLACK WHITE
(18) RED BLACK

(24) BLUE BLACK

M170333AD1

157928
6.4b Electrical Panel Diagram - Motor Controller AI
A B C D E F G H
TO LOWER BASE BOX Serial Breakdown

PIN 1 - 07 (RED) PIN 5 - N/U Reference Chart
DEUTSCH
8 1
7 2 PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE) 28CR 17CR 21CR 14CR 14CR1 59JCR
6 3
5 4
PIN 3 - 13 (ORANGE)
PIN 4 - 14E (BLACK)
PIN 7 - 7A (GREEN)
PIN 8 - 02 (WHITE) AUX. TILT RELAY STEER RELAY HIGH SPEED RELAY LIFT SPEED RELAY LIFT SPEED RELAY 2 BASE CONTROL RELAY Model Serial Number
BLUE
PIN 30 - 19 PIN 30 - 17A PIN 30 - 59B PIN 30 - 59 PIN 30 - 7A PIN 30 - 59I
PIN 85 - 02
SJIII 3220 60006147 & 60007077 V
PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02
YEL PIN 86 - 28 PIN 86 - 17 PIN 86 - 21 PIN 86 - 14 PIN 86 - 14 PIN 86 - 59J SJIII 3226 27028842 & 27032454
PIN 87 - 19A PIN 87 - N/U PIN 87 - 59E PIN 87 - 59A PIN 87 - 59D PIN 87 - 59H
DEUTSCH
8 1
02 02 02 6
5
3
4
PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE) PIN 87a -28A PIN 87a - 17B PIN 87a - 59F PIN 87a - 59B PIN 87a - 59C PIN 87a - 59G SJIII 46XX 70028674 & 70032133
02
TO HIGH SPEED LIMIT
TO POTHOLE LIMIT
8C 8C
19A
29 29
18A 18A 18A
18A BEEPER
REAR HARNESS 02 02
02 - WHITE
19A
02
05 - GREEN/BLACK
07 - RED
7A - GREEN
28CR 17CR 21CR 14CR 14CR1 59JCR W
8C - BLUE/WHITE
13 - ORANGE
14E - BLACK 28 02 17 02 21 59E 02 14 59A 02 14 02 59J 59H 02
19A 59D
18 - RED/BLACK TO FLASHER IF EQUIPPED
28A 17B 59F 59B 59C 59G
19 - BLUE OTHERWISE TIE BACK
21 - ORANGE/BLACK 19 17A 59B 59 7A 59I
71 - BLACK/WHITE 29 22
71 - WHITE/BLACK
N/U - GREEN/WHITE
N/U - BLUE/BLACK
19A - RED/WHITE
05 - WHITE
TO CHARGER
3A - BLACK
D14A
D23 D24
02 3A
RST7
D17B-2
D16
D17
D28A D14E D17B-1
RST4
RST2
RST6
RST3
RST5
D19A
D13
D14E-1
D15
D8C
R R R R R R
00 03 02 02 05 07 07A 8C 72 13 14 14E 18 49 19 19A 19B 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24 LEGEND: TO JOYSTICK BOX TO BASE CONTROLS
13A
R
W W
RST8
D21
D13X D14X

SOLENOID CABLES
MAIN MANIFOLD
00 - GREEN/YELLOW
02 - WHITE
03 - BLUE BATTERY TRAY HYDRAULIC TRAY
13 - ORANGE 72 - BLACK/WHITE 72 - BLACK/WHITE Y
14 - BLACK 71 - BLACK 19 - BLACK
15 - BLUE
16 - WHITE/BLACK MAIN MANIFOLD
17A - BLUE/RED
19A - WHITE/RED
23 - BLACK/WHITE
24 - BLUE/BLACK PLATFORM CONTROL BOX
59I - ORANGE/BLACK
REAR HARNESS
TILT SWITCH
GREEN WHITE (49)
BLUE WHITE (8C)
ORANGE (13)
GREEN (7A)
BLACK (14)
WHITE (02)
BLUE (15)
RED (07)
8
7
6
5
4
3
2
1
MALE
HORN/FLASHING LIGHT
TILT SWITCH TO HORN TO FLASHING LIGHT (OPT) Z
9
16
15
14
13
12
11
10
19 - BLACK 02 - WHITE 02 - WHITE

(NOT USED)
(OPT) RED WHITE
28 - GREEN 49 - BLACK 22 - GREEN

(OPT) GREEN BLACK
(59) ORANGE BLACK
(16) WHITE BLACK

(23) BLACK WHITE
(18) RED BLACK

(24) BLUE BLACK
02 - WHITE

M195913AA1

157928
6.4c Electrical Panel Diagram - Motor Controller
A B C D E F G H
Serial Breakdown
Reference Chart
28CR 17CR 21CR 14CR 14CR1 59JCR 21CR1
TO LOWER BASE BOX AUX. TILT RELAY STEER RELAY HIGH SPEED RELAY LIFT SPEED RELAY LIFT SPEED RELAY 2 BASE CONTROL RELAY SPEED SOLENOID RELAY Model Serial Number
BLUE PIN 30 - 19 PIN 30 - 17A PIN 30 - 59B PIN 30 - 59 PIN 30 - 7A PIN 30 - 59I PIN 30 - 18 SJIII 3220 60007078 & Above
PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 V
PIN 86 - 28 PIN 86 - 17 PIN 86 - 21 PIN 86 - 14 PIN 86 - 14 PIN 86 - 59J PIN 86 - 21 SJIII 3226 27032455 & Above
YEL
02 PIN 87 - 19A PIN 87 - N/U PIN 87 - 59E PIN 87 - 59A PIN 87 - 59D PIN 87 - 59H PIN 87 - 18A SJIII 46XX 70032134 & Above
02 02 02
TO HIGH SPEED LIMIT PIN 87a -28A PIN 87a - 17B PIN 87a - 59F PIN 87a - 59B PIN 87a - 59C PIN 87a - 59G PIN 87a - N/U
02
8C 8C
19A
29 29
18A 18A 18A
18A BEEPER
02 02
REAR HARNESS
19A
02
02 - WHITE 19 - BLUE
05 - GREEN/BLACK 21 - ORANGE/BLACK 28CR 17CR 21CR 14CR 14CR1 59JCR 21CR1 W
07 - RED 71 - BLACK/WHITE
7A - GREEN 71 - WHITE/BLACK
8C - BLUE/WHITE N/U - GREEN/WHITE 28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02 21 18A 02
13 - ORANGE N/U - BLUE/BLACK 28A 17B 59F 59B 59C 59G
OTHERWISE TIE BACK
14E - BLACK 19A - RED/WHITE 19 17A 59B 59 7A 59I 18
29 22
18A - RED/BLACK
05 - WHITE
TO CHARGER
3A - BLACK
D14A
D23 D24
02 3A LEGEND: X
RST7
D17B-2
D16
D17
D28A D14E D17B-1
RST4
RST2
RST6
RST3
RST5
D13
D19A
D14E-1
D15
D8C
R R R R R R

00 03 02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19A 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24 18A
R
W W
RST8
D21
D13X D14X

SOLENOID CABLES
MAIN MANIFOLD
00 - GREEN/YELLOW
02 - WHITE BATTERY TRAY HYDRAULIC TRAY
Y
72 - BLACK/WHITE 72 - BLACK/WHITE
03 - BLUE 71 - BLACK 19 - BLACK
13 - ORANGE
14 - BLACK MAIN MANIFOLD
15 - BLUE
16 - WHITE/BLACK
17 - BLUE/RED PLATFORM CONTROL BOX
19A - WHITE/RED REAR HARNESS
23 - BLACK/WHITE
24 - BLUE/BLACK
TILT SWITCH
PIN 9 - (NOT USED) 59I - ORANGE/BLACK
PIN 1 - 02 WHITE
PIN 4 - 14 BLACK PIN 12 - 59 ORANGE/BLACK
PIN 5 - 07 RED PIN 13 - 9A GREEN/BLACK HORN/FLASHING LIGHT
PIN 6 - 8C BLUE/WHITE TILT SWITCH TO HORN TO FLASHING LIGHT (OPT) Z
PIN 14 - 24 BLUE/BLACK 19 - BLACK 02 - WHITE 02 - WHITE
PIN 7 - 49 GREEN/WHITE PIN 15 - 23 BLACK/WHITE 28 - GREEN 49 - BLACK 22 - GREEN
PIN 8 - 7A GREEN PIN 16 - 60/7A RED/WHITE 02 - WHITE
M199658AA1

157928
AI 6.5a Electrical Panel Diagram Powerdeck - Motor Controller
A B C D E F G H
TO LOWER BASE BOX
PIN 1 - 07 (RED) PIN 5 - N/U

17CR
DEUTSCH
8 1
7 2 PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE) 28CR 21CR 14CR 14CR1 59JCR
6
5
3
4
PIN 3 - 13 (ORANGE) PIN 7 - 7A (GREEN) AUX. TILT RELAY STEER RELAY HIGH SPEED RELAY LIFT SPEED RELAY LIFT SPEED RELAY 2 BASE CONTROL RELAY P.DECK RELAY #1 P.DECK RELAY #2
BLUE PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE)
PIN 30 - 19 PIN 30 - 17A PIN 30 - 59B PIN 30 - 59 PIN 30 - 7A PIN 30 - 59I PIN 30 - 24 PIN 30 - 23
13 V
PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02
YEL
PIN 86 - 28 PIN 86 - 17 PIN 86 - 21 PIN 86 - 14 PIN 86 - 14 PIN 86 - 59J PIN 86 - 9A PIN 86 - 9A
02 PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U PIN 87 - 19A PIN 87 - N/U PIN 87 - 59E PIN 87 - 59A PIN 87 - 59D PIN 87 - 59H PIN 87 - 27A PIN 87 - 26A
DEUTSCH
8 1
7
6
2
3 PIN 87a -28A PIN 87a - 17B PIN 87a - 59F PIN 87a - 59B PIN 87a - 59C PIN 87a - 59G PIN 87a - 24A PIN 87a - 23A
8C 8C PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE)
02 5 4
19A
18A 18A 18A TO HIGH SPEED LIMIT
18A TO POTHOLE LIMIT
REAR HARNESS REAR MANIFOLD LEGEND:

05 - GREEN/BLACK 18A - RED/BLACK 29 29
07 - RED BEEPER
7A - GREEN 02 02
8C - BLUE/WHITE
19A
02
02
13 - ORANGE P.DECK P.DECK

14E - BLACK 28CR 17CR 21CR 14CR 14CR1 59JCR RELAY #1 RELAY #2
TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH W
18 - RED/BLACK
19 - BLUE TO REAR MANIFOLD TO POWER DECK
21 - ORANGE/BLACK 28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02 9A 27A 02 9A 26A 02
71 - BLACK/WHITE 28A 17B 59F 59B 59C 59G 24A 23A
SOLENOID CABLES
71 - WHITE/BLACK 19 17A 59B 59 7A 59I 24 23
N/U - GREEN/WHITE TO CONTROL MODULE TO HORN

N/U - BLUE/BLACK D14-1 D19C-2
19A - RED/WHITE 27
27
05 - WHITE
TO CHARGER TO P.DECK 02
3A - BLACK MANIFOLD 26 D27A D26A
26
02
02 D19C D19C-1
02 3A
24A 23A
X
00 03 02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19A 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24
9A
R
W W
RST8
D13X D14X
MAIN MANIFOLD
00 - GREEN/YELLOW (14 AWG) BATTERY TRAY HYDRAULIC TRAY
02 - WHITE 72 - BLACK/WHITE 72 - BLACK/WHITE
03 - BLUE (14 AWG) 71 - BLACK 19 - BLACK Y
13 - ORANGE MAIN MANIFOLD
14 - BLACK
15 - BLUE
16 - WHITE/BLACK PLATFORM CONTROL BOX
17A - BLUE/RED REAR HARNESS
19A - WHITE/RED
TILT SWITCH
23 - BLACK/WHITE
GREEN WHITE (49)
BLUE WHITE (8C)
24 - BLUE/BLACK
ORANGE (13)
GREEN (7A)
BLACK (14)
WHITE (02)
BLUE (15)
TILT SWITCH
RED (07)
59L - ORANGE/BLACK Serial Breakdown

PIN 1 - 19 (BLACK)
PIN 2 - 28 (GREEN) Reference Chart
8
7
6
5
4
3
2
1
PIN 3 - 02 (WHITE)
Model Serial Number
MALE
PIN 4 - N/U
SJIII 3220 60006146 & Below Z
9
16
15
14
13
12
11
10
SJIII 3226 27028841 & Below

(NOT USED)
(OPT) RED WHITE
(OPT) GREEN BLACK

(59) ORANGE BLACK
(16) WHITE BLACK

(23) BLACK WHITE
(18) RED BLACK

(24) BLUE BLACK
PLATFORM CONTROL BOX M170385AD_2

157928
6.5b Electrical Panel Diagram Powerdeck - Motor Controller AI
A B C D E F G H
Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60006147 & 60007077
V
SJIII 3226 27028842 & 27032454
SJIII 46XX 70028674 & 70032133
TO LOWER BASE BOX 28CR 17CR 21CR 14CR 14CR1 59JCR
AUX. TILT RELAY STEER RELAY HIGH SPEED RELAY LIFT SPEED RELAY LIFT SPEED RELAY 2 BASE CONTROL RELAY P.DECK RELAY #1 P.DECK RELAY #2
BLUE
13 PIN 30 - 19 PIN 30 - 17A PIN 30 - 59B PIN 30 - 59 PIN 30 - 7A PIN 30 - 59I PIN 30 - 24 PIN 30 - 23
PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02
YEL PIN 86 - 28 PIN 86 - 17 PIN 86 - 21 PIN 86 - 14 PIN 86 - 14 PIN 86 - 59J PIN 86 - 9A PIN 86 - 9A
02 PIN 87 - 27A PIN 87 - 26A
02 02 02 TO HIGH SPEED LIMIT PIN 87 - 19A PIN 87 - N/U PIN 87 - 59E PIN 87 - 59A PIN 87 - 59D PIN 87 - 59H
TO POTHOLE LIMIT PIN 87a -28A PIN 87a - 17B PIN 87a - 59F PIN 87a - 59B PIN 87a - 59C PIN 87a - 59G PIN 87a - 24A PIN 87a - 23A
02 8C 8C
19A
18A 18A 18A
18A
LEGEND: W
29 29
BEEPER
02 02
19A
02
02
P.DECK P.DECK
28CR 17CR 21CR 14CR 14CR1 59JCR RELAY #1 RELAY #2 TO REAR MANIFOLD TO POWER DECK
SOLENOID CABLES
28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02 9A 27A 02 9A 26A 02
28A 17B 59F 59B 59C 59G 24A 23A
19 17A 59B 59 7A 59I 24 23
D14-1 D19C-2
27
X
27
05 - WHITE
26
02
02 D19C D19C-1
02 3A
24A 23A
00 03 02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19A 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24
9A
R
W W
RST8
D13X D14X
BATTERY TRAY HYDRAULIC TRAY

MAIN MANIFOLD

REAR HARNESS
TILT SWITCH
Z
M195916AA_2

157928
AK 6.5c Electrical Panel Diagram Powerdeck - Motor Controller
A B C D E F G H
28CR 17CR 21CR 14CR 14CR1 59JCR 21CR1 LEGEND:

TO LOWER BASE BOX STEER RELAY
AUX. TILT RELAY HIGH SPEED RELAY LIFT SPEED RELAY LIFT SPEED RELAY 2 BASE CONTROL RELAY SPEED SOLENOID RELAY
BLUE
PIN 30 - 19 PIN 30 - 17A PIN 30 - 59B PIN 30 - 59 PIN 30 - 7A PIN 30 - 59I PIN 30 - 18
PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 TO TERMINAL BLOCK TO TILT SWITCH
PIN 86 - 28 PIN 86 - 17 PIN 86 - 21 PIN 86 - 14 PIN 86 - 14 PIN 86 - 59J PIN 86 - 21 TO ENGINE TO BATTERY V
YEL
02 PIN 87 - 19A PIN 87 - N/U PIN 87 - 59E PIN 87 - 59A PIN 87 - 59D PIN 87 - 59H PIN 87 - 18A
02 02 02 TO HIGH SPEED LIMIT PIN 87a -28A PIN 87a - 17B PIN 87a - 59F PIN 87a - 59B PIN 87a - 59C PIN 87a - 59G PIN 87a - N/U TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH
02 8C 8C
19A
18A 18A 18A TO OUTRIGGER TO END OF STROKE
18A SOLENOID CABLES
29 29
BEEPER
02 02
19A
02
P.DECK P.DECK
28CR 17CR 21CR 14CR 14CR1 59JCR 21CR1 RELAY #1 RELAY #2
W
28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02 21 18A 02 9A 27A 02 9A 26A 02
28A 17B 59F 59B 59C 59G 24A 23A
19 17A 59B 59 7A 59I 18 24 23
D14-1 D19C-2
27
27
05 - WHITE
26
02
02 D19C D19C-1
02 3A
24A 23A
00 03 02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19A 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24 18A
X
9A
R
W W
RST8
D13X D14X
BATTERY TRAY HYDRAULIC TRAY

MAIN MANIFOLD Y

REAR HARNESS
TILT SWITCH
Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60007078 & Above Z
SJIII 3226 27032455 & Above
SJIII 46XX 70032134 & Above
M199761AA1

157928
AI 6.6a Electrical Panel Diagram - Motor Controller - Inverter Option
A B C D E F G H
29 29
BEEPER
02
02 02
W2 02
19A
02
W1 05
W4 85
W
28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02
19A
28A 17B 59F 59B 59C 59G
19 17A 59B 59 7A 59I

W3
Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60006146 & Below X
SJIII 3226 27028841 & Below
85
02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19B 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24
M194856AA_1

157928
AI 6.6b Electrical Panel Diagram - Motor Controller - Inverter Option
A B C D E F G H
29 29
BEEPER
02
02 02
W2 02
19A
02
W1 05
W4 85
W
28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02
19A
28A 17B 59F 59B 59C 59G
19 17A 59B 59 7A 59I

W3
Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60006147 & 60007077 X
SJIII 3226 27028842 & 27032454
SJIII 46XX 70028674 & 70032134
85
02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19B 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24
M195919AA

157928
AK 6.6c Electrical Panel Diagram - Motor Controller - Inverter Option
A B C D E F G H
29 29
BEEPER
02
02 02
W1 02
19A
02
W2 07
28CR 17CR 21CR 14CR 14CR1 59JCR 21CR1
W4 85
W
28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02 21 18A 02
19A
28A 17B 59F 59B 59C 59G
19 17A 59B 59 7A 59I 18

W3
Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60007078 & Above X
SJIII 3226 27032455 & Above
SJIII 46XX 70032134 & Above
85
02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19B 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24 18A
M204042AA

157928
AI 6.7a Electrical Panel Diagram Powerdeck - Motor Controller - Inverter Option
A B C D E F G H
Serial Breakdown
28CR 17CR 21CR 14CR 14CR1 59JCR Reference Chart
AUX. TILT RELAY STEER RELAY HIGH SPEED RELAY LIFT SPEED RELAY LIFT SPEED RELAY 2 BASE CONTROL RELAY P.DECK RELAY #1 P.DECK RELAY #2
LEGEND: PIN 30 - 19 PIN 30 - 17A PIN 30 - 59B PIN 30 - 59 PIN 30 - 7A PIN 30 - 59I PIN 30 - 24 PIN 30 - 23
Model Serial Number
PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 SJIII 3220 60006146 & Below
TO JOYSTICK BOX TO LOWER KEYSWITCH BOX V
PIN 86 - 28 PIN 86 - 17 PIN 86 - 21 PIN 86 - 14 PIN 86 - 14 PIN 86 - 59J PIN 86 - 9A PIN 86 - 9A SJIII 3226 27028841 & Below
PIN 87 - 19A PIN 87 - N/U PIN 87 - 59E PIN 87 - 59A PIN 87 - 59D PIN 87 - 59H PIN 87 - 27A PIN 87 - 26A
TO TERMINAL BLOCK TO TILT SWITCH PIN 87a -28A PIN 87a - 17B PIN 87a - 59F PIN 87a - 59B PIN 87a - 59C PIN 87a - 59G PIN 87a - 24A PIN 87a - 23A SJIII 46XX 70028673 & Below

29 29
TO REAR MANIFOLD TO POWER DECK BEEPER W2 02

02 02 02
TO OUTRIGGER TO END OF STROKE W1
19A
05
02
SOLENOID CABLES
P.DECK P.DECK W4 W
TO CONTROL MODULE TO HORN 28CR 17CR 21CR 14CR 14CR1 59JCR RELAY #1 RELAY #2 85
19A
28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02 9A 27A 02 9A 26A 02
MAIN MANIFOLD 28A 17B 59F 59B 59C 59G 24A 23A
19 17A 59B 59 7A 59I 24 23
00 - GREEN/YELLOW (14 AWG) W3
02 - WHITE D14E-2 D19C-2
03 - BLUE (14 AWG) 27

13 - ORANGE
14A - BLACK TO P.DECK MANIFOLD 27
02 X
15 - BLUE
26 D27A D26A
16 - WHITE/BLACK
26
17 - BLUE/RED 02
02
19A - WHITE/RED D19C D19C-1
23 - BLACK/WHITE
24 - BLUE/BLACK 24A 23A
59L - ORANGE/BLACK 02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19A 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24
9A
85 9A
Y
PLATFORM CONTROL BOX 23 24
MALE
GREEN (7A) 8 16 (OPT) RED WHITE

GREEN WHITE (49) 7 15 (23) BLACK WHITE
BLUE WHITE (8C) 6 14 (24) BLUE BLACK
RED (07) 5 13 (OPT) GREEN BLACK
BLACK (14) 4 12 (59) ORANGE BLACK
ORANGE (13) 3 11 (18) RED BLACK Z
BLUE (15) 2 10 (16) WHITE BLACK MAIN MANIFOLD
WHITE (02) 1 9 (NOT USED)

M194858AB

157928
AI 6.7b Electrical Panel Diagram Powerdeck - Motor Controller - Inverter Option
A B C D E F G H
Serial Breakdown
28CR 17CR 21CR 14CR 14CR1 59JCR Reference Chart
AUX. TILT RELAY STEER RELAY HIGH SPEED RELAY LIFT SPEED RELAY LIFT SPEED RELAY 2 BASE CONTROL RELAY P.DECK RELAY #1 P.DECK RELAY #2 Model Serial Number
LEGEND: PIN 30 - 19 PIN 30 - 17A PIN 30 - 59B PIN 30 - 59 PIN 30 - 7A PIN 30 - 59I PIN 30 - 24 PIN 30 - 23
PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 PIN 85 - 02 SJIII 3220 60006147 & 60007077 V
TO JOYSTICK BOX TO LOWER KEYSWITCH BOX PIN 86 - 28 PIN 86 - 17 PIN 86 - 21 PIN 86 - 14 PIN 86 - 14 PIN 86 - 59J PIN 86 - 9A PIN 86 - 9A SJIII 3226 27028842 & 27032454
PIN 87 - 19A PIN 87 - N/U PIN 87 - 59E PIN 87 - 59A PIN 87 - 59D PIN 87 - 59H PIN 87 - 27A PIN 87 - 26A
TO TERMINAL BLOCK TO TILT SWITCH PIN 87a -28A PIN 87a - 17B PIN 87a - 59F PIN 87a - 59B PIN 87a - 59C PIN 87a - 59G PIN 87a - 24A PIN 87a - 23A SJIII 46XX 70028674 & 70032133

29 29
TO REAR MANIFOLD TO POWER DECK BEEPER W2 02

02 02 02
TO OUTRIGGER TO END OF STROKE W1
19A
05
02
SOLENOID CABLES P.DECK P.DECK W4 W
TO CONTROL MODULE TO HORN 28CR 17CR 21CR 14CR 14CR1 59JCR RELAY #1 RELAY #2 85
19A
28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02 9A 27A 02 9A 26A 02
MAIN MANIFOLD 17B 59B
28A 59F 59C 59G 24A 23A
19 17A 59B 59 7A 59I 24 23

00 - GREEN/YELLOW (14 AWG) W3
02 - WHITE D14E-2 D19C-2
03 - BLUE (14 AWG)

27
13 - ORANGE
14A - BLACK TO P.DECK MANIFOLD 27
15 - BLUE 02 X
16 - WHITE/BLACK 26 D27A D26A
17 - BLUE/RED 26
02
19A - WHITE/RED 02 D19C D19C-1
23 - BLACK/WHITE
24 - BLUE/BLACK 24A 23A
59L - ORANGE/BLACK
02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19A 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24
9A
85 9A
Y
PLATFORM CONTROL BOX 23 24
MALE
GREEN (7A) 8 16 (OPT) RED WHITE

GREEN WHITE (49) 7 15 (23) BLACK WHITE
BLUE WHITE (8C) 6 14 (24) BLUE BLACK
RED (07) 5 13 (OPT) GREEN BLACK
BLACK (14) 4 12 (59) ORANGE BLACK
ORANGE (13) 3 11 (18) RED BLACK Z
BLUE (15) 2 10 (16) WHITE BLACK MAIN MANIFOLD
WHITE (02) 1 9 (NOT USED)

M195920AA

157928
6.7c Electrical Panel Diagram Powerdeck - Motor Controller - Inverter Option AK
A B C D E F G H
Serial Breakdown
Reference Chart
Model Serial Number
SJIII 3220 60007078 & Above V
29 29
SJIII 3226 27032455 & Above
BEEPER W1 02 SJIII 46XX 70032134 & Above
02 02 02
W2
19A
07
02
P.DECK P.DECK W4
28CR 17CR 21CR 14CR 14CR1 59JCR 21CR1 RELAY #1 RELAY #2 85
19A
28 19A 02 17 02 21 59E 02 14 59A 02 14 59D 02 59J 59H 02 21 18A 02 9A 27A 02 9A 26A 02
28A 17B 59F 59B 59C 59G 24A 23A W

19 17A 59B 59 7A 59I 18 24 23
W3
D14E-2 D19C-2
27
TO P.DECK MANIFOLD 27
02
26 D27A D26A
26
02
02 D19C D19C-1
X
24A 23A
02 02 05 07 07A 8C 72 13 13A 14 14E 18 49 19 19A 19A 29 59 59G 59G 59H 59H 59J 59I 21 15 16 17 17 71 23 24 18A
9A
85 9A
Y
23 24
Z
MAIN MANIFOLD

M204049AA

157928
AK 6.8 Main Manifold Harness - Motor Controller
A B C D E F G H
REVERSE
15
02 FORWARD VALVE RIGHT STEER VALVE
LEFT
PIN 1 - 16 WHITE/BLACK PIN 1 - 23 BLACK/WHITE
24 CLE FORWARD
AR PIN 2 - 02 WHITE PIN 2 - 02 WHITE
16
02
02
CLE
CLE REVERSE VALVE LEFT STEER VALVE
AR W
AR
PIN 1 - 15 BLUE PIN 1 - 24 BLUE/BLACK
RIGHT
23
02
CLE
AR
00 - GREEN/YELLOW (14 AWG)

02 - WHITE
03 - BLUE (14 AWG) X
13 - ORANGE 19A
02
14 - BLACK
15 - BLUE
02 02 LOWERING VALVE
16 - WHITE/BLACK 13 - ORANGE
17 - BLUE/RED 13 13 02 - WHITE
HOLDING VALVE
19A - WHITE/RED
13 - ORANGE
23 - BLACK/WHITE 02 - WHITE
24 - BLUE/BLACK 02 LIFT VALVE 02
59I - ORANGE/BLACK 14 - BLACK
14 02 - WHITE 19A
02 02
Y
59I
02 BRAKE VALVE 00
17 - BLUE/RED 03
17 02 - WHITE
M170360AC

157928
6.9 Hydraulic Schematic (Models 32XX) - Motor Controller AF
A B C D E F G H
C4 BRAKE C4 BRAKE
CYLINDER O7 CYLINDER M4 C2
BRAKE RIGHT DRIVE UPPER 04
ORIFICE Ø.040 MOTOR LIFT EMERGENCY
CYLINDER LOWERING V
3226 ORIFICE
2H-18A Ø.067
DIFFERENTIAL MB4
VALVE REAR DRIVE
MANIFOLD BLOCK
O6
R3 2H-13-2
DIFFERENTIAL
RELIEF VALVE HOLDING VALVE PT1
ORIFICE Ø.040
FD1 PRESSURE
C1
FLOW DIVIDER OVERLOAD
CUSHION
3H-18A-2 COMBINER C2 TRANSDUCER C2
CYLINDER
SPEED VALVE B LOWER 04 OPTION LOWER 04
LIFT EMERGENCY LIFT EMERGENCY
CYLINDER LOWERING CYLINDER LOWERING
V2 3226 ORIFICE 3220 ORIFICE
3H-18A-1
FREE-WHEELING Ø.067 Ø.067 W
SPEED VALVE A
VALVE
MB3 MB3
C5 P.DECK MANIFOLD BLOCK MANIFOLD BLOCK
CYLINDER R3 2H-13-1 2H-13-1
C3 STEERING RELIEF VALVE HOLDING VALVE HOLDING VALVE
CYLINDER
EXTENSION DECK (SJ3D 3220 ONLY)
M3
4H-27 LEFT DRIVE O3 PS1
RETRACT MOTOR STEER ORIFICE OPTIONAL
PRESSURE
OPTIONAL POWERED
PLATFORM Ø.040
SWITCH
B
VALVE
O5
A
STEER ORIFICE
Ø.030
X
4H-15 4H-27 4H-23A
REVERSE DRIVE RETRACT 4H-26 RIGHT STEER
B
A
VALVE PLATFORM EXTEND
VALVE
VALVE PLATF VLV 3H-14 2H-13
LIFT VALVE LOWERING VALVE
T
P
3H-17A P A P A
BRAKE VALVE B
T B T MB5 P. DECK
MANIFOLD BLOCK
CRV1 CROSS-OVER O2
4H-16 RELIEF VALVE OPTION 4H-24A LOWERING ORIFICE
R1 LEFT STEER SEE REFERENCE R2 LIFT
FORWARD DRIVE
SYSTEM RELIEF VALVE TABLE RELIEF
VALVE
VALVE VALVE
CB1 COUNTERBALANCE VALVE Y
DCM1
DC MOTOR MB1
PUMP VALVE VALVE
BLOCK (MANUAL)
F1
RETURN
FILTER Z
RESERVOIR
M170665AA

157928
AF 6.10a Hydraulic Schematic (Models 46XX) - Motor Controller
A B C D E F G H
M4
Serial Breakdown
AUTO RESET CYLINDER
LOWERING
VALVE 4626/4632 SJIII 46XX 70032758 & Below
CASE DRAIN ORIFICE V
Ø.067
P2 MB4
O6 2H-18A MB3
COMBINER C2 C2
3H-18A-2 LOWER LIFT
LOWERING LOWERING
4626/4632 4620
C1 ORIFICE ORIFICE
Ø.067 Ø.067 W
V2 CUSHION
C5 P.DECK C5 P.DECK
CYLINDER CYLINDER
M3
LEFT DRIVE C3 STEERING
CYLINDER PS1 OPTIONAL
MOTOR/BRAKE
PRESSURE
O3
SWITCH
OPTIONAL POWERED
STEER ORIFICE
B
Ø.040
O5
A
STEER
ORIFICE X
Ø.030
4H-15
REVERSE DRIVE
4H-27 4H-23A
C5 P.DECK VALVE 4H-26
RETRACT RIGHT STEER 3H-14 2H-13
B
A
CYLINDER PLATFORM EXTEND
VALVE
VALVE
3H-17A P A
T
P
BRAKE VALVE
P A
4H-27 T B
RETRACT MB5 P. DECK T B
CRV1 CROSS-OVER
OPTIONAL POWERED
PLATFORM MANIFOLD BLOCK

RELIEF VALVE OPTION
B
VALVE 4H-16 O2 R2 LIFT

FORWARD DRIVE 4H-24A
A

VALVE LEFT STEER SEE REFERENCE TABLE VALVE
SYSTEM RELIEF VALVE Y
VALVE
MB1
LOWERING LOWERING
VALVE VALVE
DCM1
P1
M HYDRAULIC
F1
PUMP
RETURN
FILTER
RESERVOIR
M170666AA

157928
AK 6.10b Hydraulic Schematic (Models 46XX) - Motor Controller
A B C D E F G H
Serial Breakdown
C4 BRAKE C4 BRAKE
Reference Chart
CYLINDER CYLINDER M4
O7
RIGHT DRIVE C2 Model Serial Number
BRAKE 04
MOTOR UPPER LIFT SJIII 46XX 70032759 & Above
ORIFICE Ă.040 EMERGENCY
CYLINDER
LOWERING
V
4626/4632
ORIFICE
Ă.067
MB4
2H-18A REAR DRIVE MB3
DIFFERENTIAL MANIFOLD BLOCK HOLDING VALVE
VALVE MANIFOLD BLOCK
R3 2H-13-2
PT1 RELIEF VALVE HOLDING VALVE PT1
O6
DIFFERENTIAL PRESSURE PRESSURE
ORIFICE Ă.040 FD1 OVERLOAD OVERLOAD
FLOW DIVIDER TRANSDUCER TRANSDUCER
COMBINER C2 C2
3H-18A-2 LOWER LIFT
LOWERING LOWERING
4626/4632
ORIFICE
4620
ORIFICE
W
C1
V2 CUSHION Ă.067 Ă.067

C5 P.DECK C5 P.DECK
CYLINDER CYLINDER
M3
C3 STEERING
LEFT DRIVE
CYLINDER PS1 OPTIONAL
MOTOR
PRESSURE
O3
SWITCH
OPTIONAL POWERED
STEER ORIFICE
B
Ă.040
O5
A
STEER X
ORIFICE
Ă.030
4H-15
REVERSE DRIVE
4H-27 4H-23A
C5 P.DECK VALVE 4H-26
RETRACT RIGHT STEER 3H-14 2H-13
B
A
CYLINDER PLATFORM EXTEND
VALVE
VALVE
3H-17A P A
T
P
BRAKE VALVE
P A
4H-27 T B
RETRACT T B
CRV1 CROSS-OVER MB5 P. DECK
PLATFORM
OPTIONAL POWERED
RELIEF VALVE OPTION MANIFOLD BLOCK

B
VALVE 4H-16 O2 R2 LIFT

FORWARD DRIVE 4H-24A
A

VALVE LEFT STEER SEE REFERENCE TABLE VALVE Y
SYSTEM RELIEF VALVE
VALVE
MB1
LOWERING LOWERING
VALVE VALVE
DCM1
P1
M HYDRAULIC
F1
PUMP
RETURN
FILTER
Z
RESERVOIR
M211627AA

157928
Notes
A B C D E F G H

157928
6.11a Electrical Schematic - Motor Controller AI
A B C D E F G H
110 VAC
BASE
CONTROL BOX LINE VOLTAGE
Serial Breakdown
24V CHARGER
Reference Chart
POWERED PLATFORM OPTION BC
EXTEND/
RETRACT ENABLE
L1CR
CHARGER
CUTOUT RELAY
Model Serial Number
SWITCH SWITCH
1 CHARGER
EXT 26 9A 09 SJIII 3220 60006146 & Below V
RET 27 S11 F1 2
S12 B4 6V 300A B3 6V B2 6V B1 6V
D26 D27 9A GREEN/BLACK 9A
BATTERY FUSE BATTERY BATTERY BATTERY 00
3 BATTERY SJIII 3226 27028841 & Below
PACK
S10 S1 MAIN
C1
S4 IDLE/PLTF/BASE DISCONNECT
MOTOR M M- 4 MOTOR CONTROLLER SJIII 46XX 70028673 & Below
EMERGENCY KEY SWITCH CONTACTOR
STOP (IN IDLE POSITION) 5 PUMP MOTOR
B+ B-
08 8C 8C BLUE/WHITE 8C 8C 07 S28 19A 6
NCHO EMERGENCY ENABLE
STOP 59I
SWITCH SPEED 7
CB2 03
7A 07 07 RED 07 07 5A 5A 05 3A 8 15A CIRCUIT
NCHO 15A CIRCUIT BREAKER
7A GREEN 7A BREAKER
9
02 60 60 RED/WHITE 7A 7A 02
10 POWER ON LED
S8 LED-1 LED-2
SWITCH LIGHT NO 11
H1
08 49 49 GREEN/WHITE 49 HORN 49 12 HORN
29 FLASHER 22 FL-22 13 FLASHING LIGHT
FL-29 OPTION W
14
15 LOWERING ALARM
CUT-OUT RELAY
2H-13 16 DOWN SOLENOID
DO2-1
13 13 D13X 13 13 2H-13-1
ORANGE 17 HOLDING VALVE
SINGLE CYLINDER
D13 DO2-2
29 2H-13-2 18 HOLDING VALVE
LS3 1.5 OHM DO2-3 TWO CYLINDERS
14 BLACK 14 D14X 14 RST8 3H-14 19 UP SOLENOID
S3
S2 DO2-4
BCI UP/DOWN 29 29
BATTERY CHARGE LIFT/
OFF/
SWITCH D14E D14 20 MOTION/TILT BEEPER
INDICATOR DRIVE
13 19 28A D28A BP-29
08 02 SWITCH 10E 21 0.47uF CAPACITOR
V
02
14E D19A
22
08 08
09 23
CRD1 CRD2 CRD3 19 19A 19A 02 24 MOTOR CONTACTOR
POTHOLE PROTECTION D14E-1 D02-13
19A TT 02
RST1
2.7K OHMS LS4
LIMIT SWITCHES N.C.H.O.
LS5
25 HOURMETER X
02 00 71 72 19 28 28CR 26 TILT RELAY
LS6
71 19 19 02 27 TILT SWITCH
DRIVE OVERRIDE TS1
02 02 WHITE 02 LIMIT SWITCH N.C.
28
3H-18A-1 29 SPEED A SOLENOID
S27 HIGH SPEED DO2-5
TORQUE LIMIT SWITCHES N.C. D21-1 19A 2H-18A
DO2-6
12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2 31 SPEED B SOLENOID
21CR DO2-7
71 21 21 02 32 HIGH SPEED RELAY
D19C
LS1A 68 33
OHM
RST2 59JCR
59B 59E 59J 02 34 BASE CONTROL RELAY
360 OHM
59B 59F RST3 HIGH SPEED DRIVE RESISTOR
35
14 14CR 02 36 ELEVATED DRIVE RESISTOR
68 OHM
59 59A RST4 37 LIFT SPEED RELAY Y
59 ORANGE/BLACK 59 59 59B 59G 38 PLATFORM LIFT RESISTOR
250 OHM
59H RST7 39 VOLTAGE DIVIDER RESISTOR
14CR1 4.75K OHM
07A 59C RST5 STEER ONLY RESISTOR
S7 40
JOYSTICK 1.2K OHM
07A 59D RST6 BASE LIFT RESISTOR
41
JOYSTICK PCB
D14-1 D19C-2 14 02
08 PWM 59 42 LIFT SPEED RELAY 2
OUTPUT 19C
02 D19C-1 43
13
A A D17B-2
REV/DN 15 BLUE 15 4H-15 44 REVERSE SOLENOID
S7-1 15 17CR DO2-8
NUETRAL D17 D15
17 02 45 TRANSFER RELAY
14 D16
B B
FWD/UP 16 WHITE/BLACK 16 4H-16 46 FORWARD SOLENOID
S7-6 16 DO2-9
ENABLE 8A 8A 9ACR
ENABLE 9A 02 47 P.DECK RELAY
12B D23
23 23 BLACK/WHITE 23 23 23A 4H-23A 48 RIGHT SOLENOID
S7-2
RIGHT 12B 27
23
9ACR-1
26A D23A
17A 17B D17B-1 DO2-10
3H-17 Z
S7-3 26 9A 02 49 BRAKE SOLENOID
LEFT D24A DO2-11
24 24 BLUE/BLACK 24 24 24A 4H-24A 50 LEFT SOLENOID
DO2-12
D24 24 27A
4H-26A 51 P.DECK EXTEND SOLENOID
D26A
4H-27A 52 P.DECK RETRACT SOLENOID
D27A
M170483AB2

157928
AI 6.11b Electrical Schematic - Motor Controller
A B C D E F G H
110 VAC
CONTROL BOX BASE LINE VOLTAGE

Serial Breakdown
POWERED PLATFORM OPTION BC 24V CHARGER
Reference Chart
L1CR
EXTEND/
RETRACT ENABLE CHARGER
CUTOUT RELAY
Model Serial Number
SWITCH SWITCH
26 1 CHARGER
EXT 9A 09 SJIII 3220 60006147 & 60007077 V
RET 27 S11 F1 2
S12 B4 6V 300A B3 6V B2 6V B1 6V
D26 D27 9A GREEN/BLACK 9A
BATTERY FUSE BATTERY BATTERY BATTERY 00
3 BATTERY
PACK
SJIII 3226 27028842 & 27032454
S1 MAIN
S10 C1
DISCONNECT
M M- 4 MOTOR CONTROLLER
S4
EMERGENCY
IDLE/PLTF/BASE
KEY SWITCH
MOTOR
CONTACTOR SJIII 46XX 70028674 & 70032133
5 PUMP MOTOR
B+ B-
08 8C 8C BLUE/WHITE 8C 8C NCHO 5A S28 19A 6
EMERGENCY ENABLE
STOP 59I
D8C SWITCH SPEED 7
CB2
7A 07 07 RED 07 07 5A 05 3A 03 8 15A CIRCUIT
15A CIRCUIT BREAKER
7A GREEN 7A BREAKER
9
02 60 60 RED/WHITE 7A 7A 02
10 POWER ON LED
S8 LED-1 LED-2
SWITCH LIGHT 11
NO H1
FL-29 OPTION W
14
15 LOWERING ALARM
CUT-OUT RELAY
DO2-1
13 13 D13X 13 13 2H-13-1
DO2-2 SINGLE CYLINDER
D13 29 2H-13-2 HOLDING VALVE
18 TWO CYLINDERS
LS3 1.5 OHM DO2-3
14 BLACK 14 D14X 14 RST8 3H-14 19 UP SOLENOID
S3
S2 DO2-4
BCI LIFT/
UP/DOWN 29 29
BATTERY CHARGE OFF/
INDICATOR DRIVE 19 28A D28A BP-29
08 02 SWITCH 10E 13
V 21 0.47uF CAPACITOR
02
14E D19A
22
08
09 23
08
CRD1 CRD2 CRD3 19 19A 19A 02 24 MOTOR CONTACTOR
POTHOLE PROTECTION D14E-1 D02-13 19A TT 02
RST1
2.7K OHMS
LS4 LS5
25 HOURMETER X
02 00 71 72 19 28 28CR 26 TILT RELAY
LS6
71 19 19 02 27 TILT SWITCH
DRIVE OVERRIDE TS1
02 02 WHITE 02 LIMIT SWITCH N.C. 28
S27 HIGH SPEED DO2-5
TORQUE LIMIT SWITCHES N.C. D21-1 19A 2H-18A
DO2-6
21CR DO2-7
71 21 21 02 32 HIGH SPEED RELAY
D19C
LS1A 68 33
OHM
RST2 59JCR
59B 59E 59J 02 34 BASE CONTROL RELAY
360 OHM
35
68 OHM
59 59A RST4 37 LIFT SPEED RELAY Y
250 OHM
14CR1 4.75K OHM
S7 40
JOYSTICK 1.2K OHM
41
JOYSTICK PCB
D14-1 D19C-2 14 02
OUTPUT 19C
02 D19C-1 43
13
A A D17B-2
REV/DN 15 BLUE 15 4H-15 44 REVERSE SOLENOID
S7-1 15 17CR DO2-8
NUETRAL D17 D15
14
FWD/UP
B B D16
16 WHITE/BLACK 16 4H-16 46 FORWARD SOLENOID
S7-6 16 DO2-9
ENABLE 8A 8A 9ACR
12B D23
S7-2
RIGHT 12B 27
23
9ACR-1
26A D23A
17A 17B D17B-1
DO2-10
3H-17
Z
S7-3 9A 02 49 BRAKE SOLENOID
26 D24A DO2-11
LEFT
24 24 BLUE/BLACK 24 24 24A 4H-24A 50 LEFT SOLENOID
DO2-12
D24 24 27A
D26A
D27A
M170483AC1

157928
6.11c Electrical Schematic - Motor Controller AK
A B C D E F G H
24V DELTA-Q CHARGER
110 VAC
LINE VOLTAGE 24V SIGNET CHARGER
110 VAC
Serial Breakdown
BASE LINE VOLTAGE
CONTROL BOX
Reference Chart
DELTA-Q
POWERED PLATFORM OPTION SIGNET Model Serial Number

EXTEND/ ENABLE
RETRACT
SWITCH SWITCH
B+
C1
B-
SJIII 3220 60007078 & Above V
1 CHARGER
RET 27 9A 09 L1CR
SJIII 3226 27032455 & Above

CHARGER
CUTOUT RELAY
EXT 26 S11 L1CR1 F1 2
S12 CHARGER
CUTOUT RELAY
B4 6V 300A B3 6V B2 6V B1 6V
D27 D26 9A 9A 24V BATTERY FUSE BATTERY BATTERY BATTERY 00 BATTERY
GREEN/BLACK 3
S1 MAIN
PACK SJIII 46XX 70032134 & Above
S10 C1
S4 IDLE/PLTF/BASE 2 1 2 1
DISCONNECT
MOTOR M M- 4 MOTOR CONTROLLER
EMERGENCY KEY SWITCH CONTACTOR
5 PUMP MOTOR
B+ B-
F2
08 8C 8C BLUE/WHITE 8C 8C NCHO 5A S28 19A 6 INVERTER OPTION
EMERGENCY ENABLE
STOP 50A FUSE
59I
D8C SWITCH F3 SPEED 7
1A CB2 CB1
7A 07 07 RED 07 07 5A 05 FUSE 3A 03 00 02
8 15A CIRCUIT
15A CIRCUIT
85
BREAKER
7A GREEN 7A BREAKER 07 02
02 60 60 RED/WHITE 7A 7A 02 19A
10 POWER ON LED
S8 LED-1 LED-2
SWITCH LIGHT B+ 11
NO 00 H1
W
B+ 00 FL-29 OPTION
07 19A 14 TRACKUNIT
TRACKUNIT TELEMATICS OPTION
TELEMATICS
D19D
OPTION
15 LOWERING ALARM
17 17 19D 19DCR CUT-OUT RELAY
7A DO2-1
13 13 D13X 13 07 19D 13 2H-13-1
RST8 DO2-2 SINGLE CYLINDER
18X D13 29 2H-13-2 HOLDING VALVE
1.5 OHM STD 18 TWO CYLINDERS
LS3 DO2-3
14 BLACK 14 D14X 14 10 OHM W/ AGM OPT 3H-14 19 UP SOLENOID
S3
S2 DO2-4
BCI LIFT/
UP/DOWN 29 29
BATTERY CHARGE OFF/
INDICATOR DRIVE 19 28A D28A BP-29
08 02 SWITCH 10E 13
V 21 0.47uF CAPACITOR
02
14E D19A
POTHOLE PROTECTION 22
08
09 LS4 LS5 23
08 71 72 19
CRD1 CRD2 CRD3 D14E-1 19 19A 19A 19E 02 24 MOTOR CONTACTOR
D02-13 19A TT 02 25 HOURMETER
X
RST1 B+ 18X
2.7K OHMS N.O.
02 00 28 28CR
LS6 26 TILT RELAY
71 19 19 02 27 TILT SWITCH
DRIVE OVERRIDE TS1
02 02 WHITE 02 LIMIT SWITCH N.C. 28
S27
D21-1 DO2-5
TORQUE
SWITCH
19A 2H-18A 30 DIFF. SOLENOID
DO2-6
DO2-7
71 21 21 02 32 SPEED SOLENOID RELAY
D19C 21CR
LS1A 21CR1 21 02 33 HIGH SPEED RELAY
HIGH SPEED 68 OHM
RST2 59JCR
LIMIT SWITCH N.C. 59B 59E 59J 02 34 BASE CONTROL RELAY
360 OHM
35
59 59A
68 OHM
RST4 37 LIFT SPEED RELAY
Y
250 OHM
14CR1 4.75K OHM
S7 40
JOYSTICK 1.2K OHM
41
JOYSTICK PCB
D14-1 D19C-2 14 02
OUTPUT 19C
02 D19C-1 43
13 17
A A D17B-2
REV/DN 15 BLUE 15 17 4H-15 44 REVERSE SOLENOID
S7-1 15 17CR DO2-8
NUETRAL D17 D15
14
FWD/UP
B B D16
16 WHITE/BLACK 16 4H-16 46 FORWARD SOLENOID
S7-6 16 DO2-9
ENABLE 8A 8A 9ACR
12B D23
S7-2
RIGHT
26 23 26A D23A
17A 17B D17B-1
DO2-10
3H-17
Z
9A 9ACR-1 02
12B
S7-3 49 BRAKE SOLENOID
LEFT D24A DO2-11
24 27 24 BLUE/BLACK 24 24 24A 4H-24A 50 LEFT SOLENOID
DO2-12
D24 24 27A
D26A
D27A
M204119AE

157928
AF
Introduction - Troubleshooting
The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble
which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information
will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and
deficiencies that may occur. If a specific trouble is not listed, isolate the major component in which the trouble oc-
curs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem.
The content of this section is separated into “probable cause” and “remedy.” The information preceded by a num-
ber represents the “probable cause.” The following line, noted by a dash represents the “remedy” to the “probable
cause” directly above it. See example below for clarification.
1. Probable Cause
- Remedy
SJIII DC Electric
157928
Notes
SJIII DC Electric
157928
AF
Electrical System
6.12-1 All Controls Inoperative
1. Battery charger plugged into external power source.
- Disconnect charger cord.
2. Batteries disconnected.
- Connect batteries.
3. Dirty or loose battery terminals.
- Clean and tighten connections.
4. Battery charge low.
- Check each cell with a hydrometer. Reading should be 1.275 (fully charged). Recharge if low reading.
Replace if reading difference between cells is 0.050.
5. Main battery cables open or defective.
6. Fuse F1 defective.
- Replace fuse.
7. Main battery disconnect switch S1 open or defective.
- Close switch. Check continuity. Replace if defective.
8. Loose or broken wire #3 from motor contactor C1 to circuit breaker CB2.
10. Loose or broken wire #3A from circuit breaker CB2 to charger relay L1CR.
11. Defective battery charger relay L1CR.
12. Loose or broken wire #5 from charger relay L1CR to base emergency stop switch S28.
13. Open or defective base emergency stop switch S28.
- Close switch. Check switch. Replace if defective.
14. Loose or broken wire #5A from base emergency stop switch S28 to base key switch S10.
- Select function with switch. Check switch. Replace if defective.
16. Loose or broken wire #07 from base key switch S10 to base terminal block.
17. Loose or broken wire #07 from base terminal block to platform emergency stop switch S4.
19. Loose or broken wire #7A from platform emergency stop switch S4 to base terminal block.
20. Loose or broken wire #7A from base terminal block to base key switch S10.
22. Loose or broken wire #00 from motor controller to circuit breaker CB1.
24. Loose or broken wire #02 from circuit breaker CB1 to base terminal block.
SJIII DC Electric
157928
AF

6.12-2 All Controls Except for Down Function Inoperative
1. Loose or broken wire #59I from base terminal block to motor controller.
2. Loose or broken wire #19 or #02 from base terminal block to tilt switch TS1.
3. Loose or broken wire #28 from tilt switch to tilt relay 28CR.
4. Defective tilt relay 28CR.
5. Loose or broken wire #19A from tilt relay 28CR to base terminal block.
6. Loose or broken wire #19A from base terminal block to motor controller.
7. Defective resistor RST7. (With joystick fully stroked)
- Check resistor and make sure it is secure. Replace if defective.
8. Loose or broken B- cable from batteries to B- lug on motor controller.
9. Loose or broken B+ cable from main battery disconnect switch S1 to motor contactor C1.
10. Loose or broken B+ cable from motor contactor C1 to motor DCM1.
11. Loose or broken B+ cable from motor DCM1 to B+ lug on motor controller.
12. Loose or broken B- cable from motor DCM1 to M- lug on motor controller.
13. Defective motor controller.
- Check motor controller input and output voltage. Replace if defective.
14. Defective motor DCM1.
- Check motor for operation with 24 volt supply. Replace if defective.
6.12-3 All Controls Inoperative From Base Control Console

1. Loose or broken wire #10E from base key switch S10 to base up/down switch S2.
6.12-4 No Up Function from Base Control Console

2. Loose or broken wire #14E from up/down switch S2 to base terminal block.
3. Open or defective diode D14E-1.
4. Open or defective diode D14E-2.
5. Open diode D14.
6. Loose or broken wire #14A from base terminal block to relay 14ACR.
7. Loose or broken wire #14 from relay 14CR to relay 14CR1.
SJIII DC Electric
157928
AF
9. Loose or broken wire #14A from base terminal block to up valve coil 3H-14A.
- Check continuity. Replace if defective
10. Loose or broken wire #02 from base terminal block to up valve coil 3H-14A.
11. Defective up valve coil 3H-14A.
13. Loose or broken wire #59J from base terminal block to base control relay 59JCR.
14. Loose or broken wire #02 from base terminal block to base control relay 59JCR.
15. Defective base control relay 59JCR.
16. Loose or broken wire #7A from base terminal block to lift speed relay 14CR1.
17. Loose or broken wire #59D from lift speed relay 14CR1 to base terminal block.
18. Defective base lift resistor RST6.
19. Loose or broken jumper wire #59H at base terminal block.
20. Loose or broken wire #59H from base terminal block to base control relay 59JCR.
6.12-5 Up Function Slow from Base Control Console

1. Loose or broken wire #14 from base terminal block to lift speed relay 14CR1.
2. Loose or broken wire #02 from base terminal block to lift speed relay 14CR1.
3. Defective lift speed relay 14CR1.
6.12-6 No Down Function from Base Control Console
NOTE

2. Loose or broken wire #13 from up/down switch S2 to base terminal block.
3. Loose or broken wire # 13 from base terminal block to down valve 2H-13 or holding valve 2H-13-1 and 2H-13-2
(if equipped).
4. Defective down valve coil 2H-13.
5. Defective lift cylinder holding valve coil 2H-13-1 or 2H-13-2 (if equipped).
6. Loose or broken wire #02 from holding valve coil 2H-13-1 or 2H-13-2 (if equipped) or down valve coil 2H-13 to
base terminal block.
SJIII DC Electric
157928
AF

6.12-7 All Controls Inoperative From Platform Control Console
1. Loose or broken wire #8C from base key switch S10 to base terminal block.
2. Loose or broken wire #8C or wire #02 from base terminal block to platform emergency stop switch
S4.
4. Loose or broken wire #8 or wire #02 from emergency stop switch S4 to battery charge indicator BCI.
5. Loose or broken wire #8 or wire #02 from battery charge indicator BC1 to joystick S7.
6. Defective joystick enable switch S7-6.
7. Defective joystick neutral switch S7-1.
8. Defective joystick S7.
- Check joystick. Replace if defective.
6.12-8 No Up Function from Platform Controls

1. Loose or broken wire “B” from proportional controller S7 to lift/drive switch S3.
6. Loose or broken wire #14 or #02 from base terminal block to relay 14CR.
7. Loose or broken wire #59 from proportional controller S7 to base terminal block.
8. Loose or broken wire #59 from base terminal block to relay 14CR.
9. Defective lift speed relay 14CR.
11. Loose or broken wire #14A or #02 from base terminal block to up valve coil 3H-14A.
12. Defective up valve coil 3H-14A.
14. Loose or broken wire #59A from lift speed relay 14CR to base terminal block.
15. Defective base lift resistor RST4.
SJIII DC Electric
157928
AF
16. Loose or broken wire #59G from base terminal block to base control relay 59JCR.
17. Defective base control relay 59JCR.
6.12-9 Up Function Slow from Platform Control Console

1. Loose or broken wire #14 from base terminal block to lift speed relay 14CR.
2. Loose or broken wire #02 from base terminal block to lift speed relay 14CR.
3. Defective lift speed relay 14CR.
6.12-10 No Down Function from Platform Controls

1. Loose or broken wire “A” from proportional controller S7 to lift/drive switch S3.
4. Loose or broken wire # 13 from base terminal block to down valve 2H-13 or holding valve 2H-13-1 and 2H-13-2
(if equipped).
5. Defective down valve coil 2H-13.
6. Defective lift cylinder holding valve coil 2H-13-1 or 2H-13-2 (if equipped).
7. Loose or broken wire #02 from holding valve coil 2H-13-1 or 2H-13-2 (if equipped) or down valve coil 2H-13 to
base terminal block.
6.12-11 Steer Only Inoperative

1. Loose or broken wire #8A from proportional controller S7 to lift/off/drive switch S3.
2. Lift/Off/Drive switch S3 defective.
3. Loose or broken wire #12B from steer switches S7-2 and S7-3 to lift/off/drive switch S3.
4. Loose or broken wire #17A from base terminal block to relay 17CR.
6. Loose or broken wire #17B from relay 17CR to base terminal block.
9. Defective lift speed relay 14CR1.
SJIII DC Electric
157928
AF

10. Loose or broken wire #59C from 14CR1 lift speed relay to base terminal block.
11. Defective steer only resistor RST5.
6.12-12 Right Steer Inoperative (Without power deck option)

2. Loose or broken wire #23 from right steer switch S7-2 to base terminal block.
3. Loose or broken wire #23 from base terminal block to steer right valve coil 4H-23.
4. Defective steer right valve coil 4H-23.
5. Loose or broken wire #02 from steer right valve coil 4H-23 to base terminal block.
6. Open diode D23.
6.12-13 Right Steer Inoperative (With power deck option)

3. Loose or broken wire #23 from base terminal block to power deck relay 9ACR.
4. Defective relay 9ACR.
5. Loose or broken wire #23A from power deck relay 9ACR to steer right valve coil 4H-23A.
6. Defective steer right valve coil 4H-23A.
7. Loose or broken wire #02 from steer right valve coil 4H-23A to base terminal block.
8. Open diode D23A.
6.12-14 Left Steer Inoperative (Without power deck option)

2. Loose or broken wire #24 from left steer switch S7-3 to base terminal block.
3. Loose or broken wire #24 from base terminal block to steer left valve coil 4H-24.
4. Defective steer left valve coil 4H-24.
5. Loose or broken wire #02 from steer left valve coil 4H-24 to base terminal block.
6. Open diode D24.
SJIII DC Electric
157928
AF
Electrical System
6.12-15 Left Steer Inoperative (With power deck option)
3. Loose or broken wire #24 from base terminal block to power deck relay 9ACR-1.
4. Defective relay 9ACR-1.
5. Loose or broken wire #24A from power deck relay 9ACR-1 to steer left valve coil 4H-24A.
6. Defective steer left valve coil 4H-24A.
7. Loose or broken wire #02 from steer left valve coil 4H-24A to base terminal block.
8. Open diode D24A.
6.12-16 Drive Only Inoperative

2. Loose or broken wire #59B from lift speed relay 14CR to base terminal block.
4. Loose or broken wire #59B from base terminal block to high speed relay 21CR.
6.12-17 No Drive or Steer when Platform Fully Lowered

1. Loose or broken wire #71 from base terminal block to drive override limit switch LS6.
2. Defective drive override switch LS6.
3. Loose or broken wire #19 from drive override limit switch LS6 to base terminal block.
6.12-18 No Drive or Steer when Platform Elevated

1. Pothole protection bars not fully lowered.
- Clear obstructions. Repair as needed.
SJIII DC Electric
157928
AF
Electrical System
6.12-19 Platform Drives in Slow Speed Only

1. Loose or broken wire #71 from base terminal block to high speed limit switch LS1A.
2. Open or defective high speed limit switch LS1A.
3. Loose or broken wire #21 from high speed limit switch LS1A to base terminal block.
4. Loose or broken wire #59E from high speed relay 21CR to base terminal block.
5. High speed relay 21CR defective.
6. Defective high speed resistor RST2.

1. Loose or broken wire #12B from joystick card to torque switch S27.
2. Defective torque switch S27.
3. Loose or broken wire #18 from torque switch S27 to base terminal block.
4. Loose or broken wire #18 from base terminal block to high speed limit switch LS1B.
5. Defective high speed limit switch LS1B.
6. Loose or broken wire #18A from high speed limit switch LS1B to rear drive manifold.
7. Defective speed valve coil 3H-18A-1 or 3H-18A-2.
8. Loose or broken wire #02 from rear drive manifold to base terminal block.
6.12-21 Brake will not Release

1. Diode D16 forward or D15 reverse is shorted or open.
2. Loose or broken wire #17 from base terminal block to brake valve coil 3H-17.
3. Brake valve coil 3H-17 defective.
4. Loose or broken wire #02 from brake valve coil 3H-17 to base terminal block.
6.12-22 Forward Drive Function Inoperative

2. Loose or broken wire #16 from base terminal block to forward drive valve coil 4H-16.
3. Forward drive valve coil 4H-16 defective.
4. Loose or broken wire #02 from forward drive valve coil 4H-16 to base terminal block.
SJIII DC Electric
157928
AF
Electrical System
6.12-23 Reverse Drive Function Inoperative

2. Loose or broken wire #15 from base terminal block to reverse drive valve coil 4H-15.
3. Reverse drive valve coil 4H-15 defective.
4. Loose or broken wire #02 from reverse drive valve coil 4H-15 to base terminal block.

1. Lift/Drive switch S3 not in lift position.
- Move switch to lift position.
2. Loose or broken wire #09 from lift/drive switch S3 to power extension platform enable switch S12.
3. Power extension platform enable switch S12 defective.
4. Loose or broken wire #09A from power extension platform enable switch S12 to platform extend/retract switch
S11.
5. Loose or broken wire #9A from platform control box to base terminal block.
6. Loose or broken wire #9A from base terminal block to 9ACR extend relay or 9ACR-1 retract relay.
7. Defective relay 9ACR or 9ACR-1.
6.12-25 Power Extension Platform will not Extend

2. Open diode D26.
3. Loose or broken wire #26 from diode D26 to wire #23.
5. Loose or broken wire #23 from base terminal block to power deck relay 9ACR.
6. Defective relay 9ACR.
7. Loose or broken wire #26A from power deck relay 9ACR to extend valve coil 4H-26A.
8. Defective extend valve coil 4H-26A.
9. Loose or broken wire #02 from extend valve coil 4H-26A to base terminal block.
10. Open diode D26A.
11. Loose or broken wire #19C from diode D26A to base terminal block.
12. Open diode D19C or D19C-1 or D19C-2.
SJIII DC Electric
157928
AF
6.12-26 Power Extension Platform will not Retract

2. Open diode D27.
3. Loose or broken wire #27 from diode D27 to wire #24.
5. Loose or broken wire #24 from base terminal block to power deck relay 9ACR-1.
6. Defective relay 9ACR-1.
7. Loose or broken wire #27A from power deck relay 9ACR-1 to retract valve coil 4H-27A.
8. Defective retract valve coil 4H-27A.
9. Loose or broken wire #02 from extend valve coil 4H-27A to base terminal block.
10. Open diode D27A.
11. Loose or broken wire #19C from diode D27A to base terminal block.
12. Open diode D19C or D19C-1 or D19C-2.
Hydraulic System
6.13-1 All Function Inoperative

1. Pump P1 defective.
6.13-2 All System sluggish

1. System Relief Valve defective or not adjusted properly.
- Adjust valve. Replace if defective.
2. Hydraulic pump P1 worn.
6.13-3 Platform Drifts Down

1. Defective lift cylinder seals at the gland or holding valve manifold.
- Replace if damaged. Note: There are no piston seals, just wear rings.
2. Combination of defective holding valves 2H-13C-1 and 2H-13-2, and either defective lowering valve
2H-13 or relief valve R2 or manual lowering valve V1.
6.13-4 Platform Lifts Slowly

1. Open or leaking manual lowering valve V1.
2. Lift relief valve R2 defective.
3. Open manual override on holding valve 2H-13-1 or 2H-13-2.
SJIII DC Electric
157928
AF

6.13-5 Platform does not Lift
1. Open manual lowering valve V1.
2. Hydraulic oil level too low.
- Fully lower the platform. Fill hydraulic tank until fluid is at or slightly above the top mark on the sight
glass.
3. Platformweight excessive.
- Reduce platform load to maximum capacity.
4. Up valve 3H-14A defective or is sticking.
6.13-6 Platform will not Lower
NOTE

2. Defective holding valve 2H-13-1 or 2H-13-2.
6.13-7 Platform Drives Slow

1. Free-wheeling valve V2 open or defective.
2. Flow divider/combiner FD1 defective or is plugged.
3. Drive motor M3 or M4 defective.
- Check motors. Replace if defective.
4. Cushion cylinder C1 defective.
- Check cylinder. Replace if defective.
6.13-8 Platform will not Drive in Forward or Reverse

1. Open free-wheeling valve V2.
2. Forward drive valve 4H-16 or reverse drive valve 4H-15 defective or is sticking.
- Check Valve. Replace if defective.
3. Flow/Divider/Combiner valve FD1 defective or is plugged.
4. Counterbalance valve CB1 defective or is plugged.
6.13-9 Brake(s) will not Release (Pin brakes)

1. Brake valve 3H-17 defective or is sticking.
2. Brake orifice 04 plugged.
- Remove orifice. Clean and reinstall.
3. Brake cylinders C4 defective.
6.13-10 Brake(s) will not Release (Integral brakes)

1. Brake valve 3H-17 defective or is sticking.
SJIII DC Electric
157928
AF
2. Brake orifice(s) 07 plugged.

- Remove orifice(s). Clean and reinstall.
3. Defective internal brake piston seals.
- Check brake pack will maintain pressure. If pressure is not maintained replace seals.
4. Damaged integral brake in wheel motor.
- Inspect wheel motor assembly. Repair and replace as necessary.
6.13-11 Aerial Platform will not hold on a Grade (Integral brakes)

1. Worn or damaged brake discs.
- Inspect brake discs for wear. Replace if worn or damaged.
2. Broken or damaged brake compression springs.
- Check springs. Replace if defective.
6.13-12 Platform does not Steer

1. Right steer valve 4H-23 or left steer valve 4H-24 defective or sticking.
2. Steer cylinder C3 seals leaking.
3. Mechanical binding in kingpins.
4. Orifices 03 or O5 plugged.
- Clean orifices, and reinstall.

1. Platform extend valve 4H-26A or platform retract valve 4H-27A defective or is sticking.
2. Powered platform cylinder C5 seals defective.
3. Mechanical binding in power extension platform mechanism.

SJIII DC Electric
157928
AI
General “Threshold” Adjustments

The following information is provided to assist you in Adjusts the initial current flow or duty cycle, affecting
the use and application of servicing and maintenance the function response or speed when the handle is
procedures contained in this chapter. first moved from the off position. Deflect the handle
slowly to the position where the controller first turns on.
Safety and Workmanship Adjust the threshold trimpot screw to the point where
Your safety, and that of others, is the first consideration the controlled function just starts to move, then turn
when engaging in the maintenance of equipment. Al- the trimpot screw one, full turn in the counterclockwise
ways be conscious of weight. Never attempt to move direction. This adjustment should be done first.
heavy parts without the aid of a mechanical device. Do
not allow heavy objects to rest in an unstable position. “Maxout” Adjustments
When raising a portion of the equipment, ensure that Adjusts the full stroke current or duty cycle affecting the
adequate support is provided. maximum function response, or speed when the handle
is deflected to its full travel. Fully deflect the handle,
Platform and adjust the maxout trimpot for maximum desired
function response or speed. To obtain proportional
resolution, it is important that the function starts to slow
6.14-1 OEM Controller Electronics
down as soon as the handle is moved back from the
Information fully deflected position.
Flow Control
The ideal adjustment occurs when the function just
Single coil or solenoid for single direction. The coil has
begins to move when the handle is deflected, and the
two connections; one is wired to the P.C. Board (A)
output increases until it reaches its maximum desired
terminal and the other is wired to (-), or the negative side
response or speed at the end of handle travel.
of the supply voltage. Switches to control directional
valves may be provided on the controller.
Adjustment Procedures
Adjustments are made by turning a trimpot adjustment
screw. The trimpots are multi-turn, end to end-devices. It
may be necessary to turn the adjustment screw several
turns to observe a change in output.
Clockwise (CW) adjustment of the trimpot increases

the output.
Counter-clockwise (CCW) adjustment of the trimpot

decreases the output.
Adjustments affect output current, voltage or percentage

of duty cycle to the coil. The minimum and maximum
output is preset at the factory. However, for optimum
performance, they must be adjusted while the
equipment is operating.
Although the following adjustments affect the current/

voltage or percentage of duty cycle, the best way
to adjust the function is to observe the response or
speed of the function. The following adjustments affect
function response, or speed. There may be some
interaction between adjustments, making it necessary
to repeat the adjustment in order to achieve the desired
response.
SJIII DC Electric
157928
AI
6.14-2 OEM Controller IRS Option

Troubleshooting 1. Function speed reacts too slowly or too quickly
in relation to handle deflection.
Problem A. Check “IRS” (Ramp) trimpot adjustment.
1. The function will not operate when the handle is “CW ” increases ramp time, “CCW ”
moved. The LEDs do not light decreases ramp time.
A. Check that voltage is present at the positive
(+)input terminal. Integrated Ramp System (IRS)
B. Check that ground is connected to the Provides smooth function response ,when reacting to
negative (-) terminal. an abrupt change in handle deflection. “CW” rotation of
the trimpot increases ramp time and slows the response
C. If there is an in-line fuse, check to see if it is
time. “CCW” decreases ramp time and increases the
good.
response time. To increase the ramp time, turn the
D. Check the controller on/off switch and the adjusting screw “CW” a few turns, then move the
connectors. Voltage should be present at controller handle abruptly. Continue to adjust until a
the (X) terminal when the controller is turned smooth response is observed. Most controllers have
on. on/off contacts which remove power from the P.C. Board
E. Check that valve wiring is not shorted to when the handle is returned to the off position. When
ground. The LEDs will not light. the handle is abruptly returned to neutral, the output
F. Check that valve wiring is not open. The will not ramp down, and the function will stop.
LEDs will light, but the intensity will not vary.
Ramp Thru Off
G. Check trimpot settings. Fully “CCW” turns The P.C. Board should be adjusted as outlined in the
output off, “CW” turns output fully on. IRS adjustment procedure. If the handle is abruptly
2. The function jumps or lurches when turned on. returned to neutral (OFF) the output will ramp down
A. Perform “Threshold” adjustment procedures. to off. Ramp time is factory set to 2 seconds, unless
3. The function reaches maximum speed before the otherwise specified.
handle is fully deflected,
A. Perform “Maxout” adjustment procedures. NOTE
Trimpots should be sealed with nail polish
4. The function speed remains constant regardless
or enamel based paint.
of the degree of handle deflection.
WARNING
Do not use RTV silicone.
SJIII DC Electric
157928
AI
6.14-3 OEM Controller Switch Wiring
WIRE CHART
COLOR FROM TO
WHT/RED STEER LEFT PIN #1
WHT/GRN STEER COMMON PIN #2
WHT STEER RIGHT PIN #3
YEL FORWARD/UP PIN #4
RED Vbat PIN #5
GRY REVERSE/DOWN PIN #6
BLU PROP. OUTPUT PIN #7
BLK GROUND (-) PIN #8
WHT/BLU ENABLE OUT PIN #9
SJIII DC Electric
157928
AI
6.14-4Gate Spring Hinge Adjustment If Locking Screw Located at the Side of the
Spring Hinge,
1. The tension of the spring hinges should be
NOTE
such that when the gate is opened halfway and
released, it will close fully and latch. Adjusting the tension on the spring
hinge is a two handed operation.
2. To adjust the tension of the spring hinges, first
remove the safety locking screw of each hinge. 6. To increase the tension, insert a 5/32” hex wrench
Retain the screws for reinstallation later. in the screw socket. Turn the wrench clockwise
to desired tension as well as aligning the locking
If Locking Screw Located at the Top or screw hole. Hold the wrench in place, maintaining
Bottom of the Spring Hinge, the selected tension, while reinstalling the locking
screw.
3. To increase the tension, insert a 5/32” hex
NOTE
wrench in the screw socket, and turn the
wrench clockwise. To release the tension, Ensure the holes inside the hinges are
depress the hex wrench in the socket, let it aligned before inserting the locking
rotate counterclockwise, then release the hex screw.
wrench.

5. Reinstall the safety locking screws into the hinges

when tension adjustment is complete.
SJIII DC Electric
157928
AK
Base 6.15-2Lift Pressure Adjustment
6.15-1System Relief Pressure NOTE

Adjustment Adequate area to raise the platform to full
1. Locate the system pressure fitting or quick height is required for the following steps.
disconnect port on the main manifold.
1. Locate the lift pressure test port on the main
2. Install a calibrated 5000 psi gauge to the system manifold.
pressure fitting or quick disconnect port.
2. Install a calibrated 3000 psi gauge to the lift
3. At the main manifold, loosen the locknut on the pressure quick disconnect port.
system relief valve R1.
3. At the main manifold, loosen the locknut on the
4. Remove black 14 wire from the lift coil. lift relief valve R2.
5. Select lift with the lift/drive select switch on the 4. Close the manual lowering valve. Use the lift
platform control console. switch at the base control console to raise the
platform to full height and hold the lift up switch
6. Engaged lift and hold. on.
7. Observe reading on gauge. Adjust the R1 system 5. Observe the reading on the gauge. Adjust the
relief value listed on the serial number plate. R2 relief valve to the value listed on the serial
Turning the stem on the relief valve clockwise number plate. Turning the stem of the relief valve
will increases pressure. Turning the stem clockwise will increases pressure. Turning the
counterclockwise will decreases pressure. stem counterclockwise will decreases pressure.
8. Release lift function and tighten the locknut. 6. Remove the gauge from lift pressure test port.
9. Remove the gauge from system pressure test NOTE

port. Pressure setting may vary as aerial platform
components wear. The lift pressure should
be set for rated load only.
SJIII DC Electric
157928
AF
6.15-3Resistor - Voltage Divider
RST2,3,4,5 and 6
+ Resistor +
Voltage RST7 Voltage

In Resistor Out
- -
Common Resistor Resistor Ohm Function Input Voltage* Output Voltage**

RST4 68 Platform lift resistor 4.8 3.8
RST2 68 Hi speed drive resistor 4.8 3.8
RST7
RST3 360 Elevated drive resistor 4.8 2.0
250 Ohm
RST5 4.75K Steer only resistor 24 1.2
RST6 1.2K Base lift resistor 24 4.1
* 4.8 volts refers to full stroke on the joystick. 24 volts represents a full charge on the battery pack.
** Values given are with all connections tight and free from corrosion + or - 10%.
SJIII DC Electric
157928
Notes
SJIII DC Electric
157928
Reliable liftwww.skyjack.com
solutions by people who care.

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IMPORTANT

Verify if your machine is hydraulically proportional or motor

Motor controller machines can be identified by the MC label

For motor controller-specific diagrams, schematics and

157928AP January 17, 2022

SJIII 3220 60 002 259 to 60 999 999

Please refer to the website www.skyjack.com for older Serial Numbers.

Skyjack Service Center Parts & Service (Europe)

Parts (North America) Skyjack Brasil

Section 1 - Scheduled Maintenance

Section 2 - Maintenance Tables and Diagrams

Section 3 - System Component Identification and Schematics

Section 4 - Troubleshooting Information

Section 6 - Motor Controller

The Safety Alert Symbol identifies important

Operator’s Responsibility for Maintenance

Service and Maintenance

Aerial Platform and Mobile Elevating Work Platform Definition

Service & Maintenance

Service Policy and Warranty

Operator Safety Reminders, Warnings and Precautions

Maintenance and Inspection Schedule Maintenance and Service Safety Tips

Maintenance Hints Railing Maintenance and Repair

About this Section Maintenance Instructions

• Repair any damaged or malfunction components

Table 1.1 Owner’s Annual Inspection Record

Pre-Delivery/Maintenance Inspection Checklist

Serial Number: Product Owner:

Hourmeter Reading: Product User:

Inspection Type Schedule P - Pass

Items for Inspection P F R N/A Items for Inspection P F R N/A

Owner: ________________________________________________ / _____________________________________________ / ______________________________________________________

User: _________________________________________________ / _____________________________________________ / _______________________________________________________

Note: Visit skyjack.com for a printable copy of this form. 167830AC

1.1 Scheduled Maintenance Hydraulic

WARNING 1.1-1 Manuals (B)

Base Main Power

1.1-3 Limit Switches (B) • Free-wheeling Valve Knob (B)

1.1-5 Battery Tray Side

• Steer Cylinder Assembly (B) • Wheel/Tire Assembly (B)

The tire treads have

▪ B - Frequent/periodic/pre-delivery inspection Do a check for cuts or missing chunks in the edges

Do a check of the wheel components and mounts.

Hydraulic Tank Hydraulic/Electric Main Manifold

1.1-6 Hydraulic/Electric Tray Side • Electrical Panel (B)

1.1-7 Platform Assembly • Platform Control Console (B)

1.1-8 Lifting Mechanism • Scissor Pin Inspection (B)

• Scissor Assembly (B) - Rust forming near pin joint

Examples of pivot pin connections with no

- Pin has not rotated

Pin retainer in place

Center pin pivot - Middle

No rust. Pin has

Center pin pivot - Inner

1.2 Function Tests

After repairs are completed, perform a pre-operation

Prior to performing function tests, be sure to read and

For function tests that are to be run, please refer

Table 2.1 Specifications and Features

Drive Height FULL

Owner: __________________________ / _ / ________________________________

User: ___________________________ / _ / _________________________________