Escolar Documentos
Profissional Documentos
Cultura Documentos
Service Manual
Skyjack Brasil
Alameda Jpiter, 710
Loteamento American Park Empresarial
Indaiatuba, SP, Brasil 13347-653
Tel: +55 19 3936 0132
TM
Telehandler Series
Model ZB20044
402509
Page 3
DANGER
WARNING
CAUTION
IMPORTANT
TM
Page 4
Telehandler Series
Model ZB20044
402509
Section 1
SCHEDULED MAINTENANCE
Table of Contents
Operators Responsibility for Maintenance
Telehandler Definition................................................................................................................................................................... 7
Purpose of Equipment.................................................................................................................................................................... 7
Use of Equipment.......................................................................................................................................................................... 7
Manual........................................................................................................................................................................................... 7
Operator......................................................................................................................................................................................... 7
Service Policy and Warranty.......................................................................................................................................................... 7
Optional Accessories...................................................................................................................................................................... 7
Scope of this Manual..................................................................................................................................................................... 8
Operator Safety Reminders............................................................................................................................................................ 8
Electrocution Hazard..................................................................................................................................................................... 9
Safety Precautions........................................................................................................................................................................ 10
Maintenance and Inspection Schedule......................................................................................................................................... 15
Owners Annual Inspection Record............................................................................................................................................. 15
Replacement Parts........................................................................................................................................................................ 15
Maintenance and Service Safety Tips.......................................................................................................................................... 15
Hydraulic System & Component Maintenance and Repair......................................................................................................... 16
Maintenance Hints....................................................................................................................................................................... 16
Service and Maintenance
About this Section........................................................................................................................................................................ 17
Service Bulletins.......................................................................................................................................................................... 17
Maintenance and Inspection........................................................................................................................................................ 17
Maintenance Instructions............................................................................................................................................................. 17
Tables
1.1 Maintenance and Inspection Checklist.................................................................................................................................. 18
Scheduled Maintenance Inspections
1.1 Scheduled Maintenance Inspections................................................................................................................................ 19
1.2 Function Tests................................................................................................................................................................... 28
TM
Telehandler Series
Model ZB20044
402509
Page 5
Notes
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Telehandler Definition
A material handler designed primarily as a fork truck with a pivoting telescopic boom which enables it to
pick and place loads at distances as well as various lift heights.
Purpose of Equipment
The SKYJACK telehandlers are designed to lift, handle and transport agricultural or industrial products by means
of specific attachments.
Use of Equipment
The telehandler is a highly maneuverable, mobile work station. Lifting, handling and driving must be on
a flat, level, compacted surface. It can be driven over uneven terrain only when the boom is fully lowered.
Manual
Operating
The operating manual is considered a fundamental part of the telehandler. 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 telehandler at all times.
The purpost 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 telehandler.
The updated copy of the manuals are found on the companys website: www.skyjack.com.
Operator
The operator must read and completely understand both this operating manual and the safety panel label located on
the telehandler and all other warnings in this manual and on the telehandler. Compare the labels on the telehandler
with the labels found within this manual. If any labels are damaged or missing, replace them immediately.
Service Policy and Warranty
SKYJACK warrants each new ZB series telehandler to be free of defective parts and workmanship for the first 12
months or 2000 hours, whichever occurs first. Any defective part will be replaced or repaired by your local SKYJACK
dealer at no charge for parts or labor. Contact SKYJACK Service Department for warranty statement extensions or
exclusions.
Optional Accessories
The SKYJACK telehandler is designed to accept a variety of optional accessories. These are listed under Attachments
Installation and Operation in Section 2 of the operating manual. Operating instructions for these options (if equipped)
are located in Section2 of the operating manual.
For non-standard components or systems, contact the SKYJACK Service Department at
( : 800 275-9522
7 : 630 262-0006
Include the model and serial number for each applicable telehandler.
TM
Telehandler Series
Model ZB20044
402509
Page 7
CSA (Canada)
Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this telehandler.
c.
A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to follow simple and fundamental safety rules and precautions.
You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this
telehandler is mandatory. The following pages of this manual should be read and understood completely
before operating the telehandler.
Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety devices to protect your eyes, ears, hands, feet and body.
Some attachments may not be approved for use with certain telehandler models. Use only approved attachments.
Any modifications from the original design are strictly forbidden without written permission from Skyjack.
TM
Page 8
Telehandler Series
Model ZB20044
402509
Electrocution Hazard
This telehandler is NOT electrically insulated.
Distance
750 to 150,000
10 feet
150,000 to 250,000
15 feet
250,000
20 feet
DANGER
Never approach any power line with any part of telehandler. Use extreme caution; serious injury
or death can result with contact from any power line.
IMPORTANT
Always assume electrical power sources and overhead lines are energized.
TM
Telehandler Series
Model ZB20044
402509
Page 9
AC
Safety Precautions
Know and understand all safety precautions before going on to the next section.
WARNING
DO NOT operate this telehandler without
proper authorization and training. Failure
to avoid this hazard could result in death
or serious injury.
WARNING
Failure to heed the following safety
precautions could result in tip over,
falling, crushing, or other hazards leading
to death or serious injury.
DO NOT wear loose clothing,
dangling
neckties,
scarves, rings, wristwatches
or other jewelry while operating this telehandler.
DO NOT climb on this vehicle for any reason.
TM
Page 10
Telehandler Series
Model ZB20044
402509
Know and understand all safety precautions before going on to the next section.
DO NOT exceed the maximum safe operating slope.
DO NOT lower the boom
unless the area below is clear
of personnel and obstruction.
DO NOT elevate the boom
while the telehandler is on a
truck, forklift or other device
or vehicle.
DO NOT use frame leveling
when boom is elevated. It is
recommended that frame
leveling be used only when
boom is retracted and in the
lowered position.
DO NOT use the frame leveling mechanism to compensate for swinging loads.
ENSURE that there are no
personnel or obstructions in
the path of travel, including
blind spots.
BE AWARE of blind spots
when operating the telehandler.
ALWAYS Keep head, arms,
hands, legs and all other
body parts inside the operators cab.
DO NOT enter the danger area under or around the
boom when forks are off the ground or while engine is
running.
AVOID jerks and sudden
stops.
AVOID entanglement with
ropes, cords or hoses.
TM
Telehandler Series
Model ZB20044
402509
Page 11
AC
Operators Responsibility for Maintenance
Know and understand all safety precautions before going on to the next section.
BE AWARE of all obstructions while traveling. Check
for clearance before traveling between obstacles.
USE
CAUTION when
boom is fully extended. The
further out the boom is extended, the less load telehandler can support.
ALWAYS wear your seat
belt when operating this vehicle.
KNOW the weight of the
load you are transporting.
Never lift more than the lifting capacity at any given
extension or elevation of the
boom as listed on the capacity charts.
CHECK for cracks and signs
of stress.
USE
CAUTION when
placing loads at high elevations and on downhill slopes.
TRAVEL SLOWLY over
rough terrain.
WALK AROUND the telehandler before operation and
check for any visible signs of
damage or malfunction.
ALWAYS maintain three
points of contact when entering vehicle. Use provided
hand-holds and steps only.
TM
Page 12
Telehandler Series
Model ZB20044
402509
AC
Section 1 - Scheduled Maintenance
Know and understand all safety precautions before going on to the next section.
ALWAYS LEVEL FRAME
before elevating the boom
WHEN
TRANSPORTING
LOADS fully retract the
boom, keep the load low to
the ground and forks tilted
back slightly. This is the
most stable position possible
for the vehicle.
KEEP forks close to the
ground when in motion to
increase telehandler stability and decrease potential for
injury to others. When fully
stopped, lower forks completely to the ground.
TILT
forks backwards
slightly when traveling to
decrease potential of load
slipping off.
CHECK lights (if equipped)
for proper function before
operating.
SECURE loose loads with
chains or straps to decrease
potential of spills or injury to
others.
ENSURE ALL tires are in
good condition and lug nuts
are properly tightened.
TM
Telehandler Series
Model ZB20044
402509
Page 13
Know and understand the safety precautions before going on to next section.
DO NOT change steering mode while the telehandler is traveling. Change the steering mode only when
telehandler is stopped, and wheels aligned straight
ahead.
TM
Page 14
Telehandler Series
Model ZB20044
402509
Know and understand the safety precautions before going on to next section.
WARNING
WARNING
Any unit that is damaged or not operating
properly must be tagged and removed
immediately from service until proper
repairs are completed.
Maintenance and Service Safety Tips
Maintenance and repair should only be performed by
personnel who are trained and qualified to service this
telehandler.
All maintenance and service procedures should be
performed in a well lighted and well ventilated area.
Anyone operating or servicing this telehandler must read
and completely understand all operating instructions
and safety hazards in this manual and operating manual.
All tools, supports and lifting equipment to be used
must be of proper rated load and in good working order
before any service work begins. Work area should be
kept clean and free of debris to avoid contaminating
components while servicing.
All service personnel must be familiar with employer
and governmental regulations that apply to servicing
this type of equipment.
Keep sparks and flames away from all flammable or
combustible materials.
Properly dispose of all waste material such as lubricants,
rags, and old parts according to the relative law
provisions obtaining in the country.
Preventive maintenance is the easiest and least
expensive type of maintenance.
Jobsite Inspection
TM
Telehandler Series
Model ZB20044
402509
Page 15
7.
8.
9.
WARNING
Escaping fluid from a hydraulic pressure
leak can damage your eyes, penetrate the
skin and cause serious injury. Use proper
personal protection at all times.
1.
2.
3.
5.
Maintenance Hints
Three simple maintenance procedures have the greatest
effect on the hydraulic system performance, efficiency
and life. Yet, the very simplicity of them may be the
reason they are so often overlooked. What are they?
Simply these:
1.
2.
3.
TM
Page 16
Telehandler Series
Model ZB20044
402509
Inspection Schedule
Daily A
Weekly or 40 hours
A+B
Quarterly or 250 hours A + B + C
Annually or 1000 hours A + B + C + D
Legend
P = Pass
F = Fail
R = Repaired
TM
Telehandler Series
Model ZB20044
402509
Page 17
Date:
Time:
Operator's Signature:
Each item shall be inspected using the appropriate section of the Skyjack operating manual.
As each item is inspected, write the appropriate grade in the box.
P
F
R
INSPECTION FREQUENCY
DAILY
WEEKLY or 40 HOURS
QUARTERLY OR 250 HOURS
ANNUALLY or 1000 HOURS
Inspection Schedule
- PASS
- FAIL
- REPAIRED
Schedule
Daily
Weekly or 40 Hours
A+B
A+B+C
A+B+C+D
Schedule
Electrical
C,D
Safety Switches
C,D
Mirrors
Hydraulic
Slide Pads
Cylinders
A,B,C,D
Chain
C,D
B,C,D
A,C
Wheel/Tire Assembly
Proximity Sensor
Lifting Attachment
A,B,C
Engine Coolant
Drive Axles
Forks
Grease Fittings
Grease Fittings on Frame
Hub Oil
Operator's Cab
Pinion Seal
ROPS/FOPS
Seat
Hub Seals
Pedals
King Pins
C,D
Manual
C,D
C,D
Function Tests
Axle Housing
Steer Linkage
Test Horn
Test Gauges
Engine Compartment
Engine Oil
A,C
Fuel Leaks
Test Lights
Hydraulic Pump
Test Switches
Fuel Tank
A,C
C,D
Hydraulic Tank
Hydraulic Oil
A,D
A,C
Test Steering
A,C
Charging System
Transmission
Boom
Labels
Frame
202A
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.7 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every week or 40 hrs. Refer to Section 1.0 of this manual.
C - Perform Scheduled Maintenance Inspection every 3 months or 250 hours. Refer to Section 1.0 of this manual.
D - Perform Scheduled Maintenance Inspection every year or 1000 hours. Refer to Section 1.0 of this manual.
Note: Make a copy of this page or visit the Skyjack web site: www.skyjack.com for a printable copy.
TM
Page 18
Telehandler Series
Model ZB20044
402509
Attachment
20044
CAUTION
PRESSURIZEDCOOLING
REMOVE SYSTEM
SLOWLY CAP
DEC-057
WHEN
USE
60/40ADDING
RECOMMENDED
AND
SOLUTION
OR NOTE
NEVER WATER.
CHANGING
THE
OF
ETHYLENE
DILUTE
CHECKENGINE
*CUMMINS
THE
TANK,
* CUMMINS OR
MAY THE COOLANT, GLYCOL COOLANT,
BE
ALWAYS NOT ADD
THE COOLANT
SERIOUSLY
ENGINEERING
COOLANT
USE
RADIATOR.
OR
DISTILLED
THE
AT
LIFE
STANDARD
THE SHORTENED.
OR
RESERVE
OF
DEIONIZED
(CES)
14603
WATER
bo
WARNINGUse proper
filling
tire pressure.
when
correct
Maintain precautions
safety
tires.
DEC-007
TION
PER
THEN
AND
1 10
ATTEN
12
8 SEQUENCE
PER 5
TORQUE
SEQUENCE 3
7
50-100
9
FT-LBS.
DRY
4
6
2
450-500
FT-LBS.
DRY
DEC-303
11
AIN
90
psi DEC-183
MAINT
GREA
DEC-005R
SE
NING
POINT
WAR
PINCH
POINT
DEC-181
PINCH
WARNING
DEC-181
Operators
Cab
1.1
Scheduled Maintenance Inspections
Before performing the visual and daily maintenance
inspections, ensure that the telehandler is parked on a
firm level surface.
Begin the visual and daily maintenance inspections
by checking each item in sequence for the conditions
listed in this section.
WARNING
To avoid injury, do not operate a
telehandler until all malfunctions have
been corrected.
WARNING
To a v o i d p o s s i b l e i n j u r y, e n s u r e
telehandler power is off during your visual
and daily maintenance inspections.
NOTE
While performing visual and daily
inspections in different areas, be aware
to also inspect all switches, electrical and
hydraulic components.
1.1-2 Electrical
Maintaining the electrical components is essential to
good performance and service life of the telehandler.
Ensure proper operation of all gauges
Check charging system Ammeter/Voltmeter
Inspect the following areas for chafed, corroded
and loose wires:
boom wiring harnesses
frame wiring harnesses
cab wiring harnesses
Ensure electrical devices are properly secured with no
signs of visible damage. Ensure there are no loose or
missing parts.
1.1-3 Safety Switches
Ensure safety switches are properly secured with no
signs of visible damage.
1.1-4 Mirrors
Ensure mirrors are properly secured with no signs of
visible damage.
1.1-1 Labels
Refer to the labels section in the parts manual and
determine that all labels are in place and are legible.
TM
Telehandler Series
Model ZB20044
402509
Page 19
Bottom View
04
20
Outriggers
Rear Drive
Shaft
Front Axle
1.1-5 Hydraulic
Maintaining the hydraulic components is essential to
good performance and service life of the telehandler
Perform a visual inspection and check for leaks around
the following areas:
hydraulic tank, filter(s), fittings, hoses, pump,
and frame surface
all hydraulic cylinders
all hydraulic manifolds
underside of the frame
ground area under the telehandler
--
--
--
Drive Axle
-- Ensure drive axle is properly secured,
there are no loose or missing parts.
WARNING
1.1-6 Cylinders
-- Ensure all cylinders are properly secured
and there is no evidence of leakage.
1.1-7 Frame
Wheel/Tire Assembly
The telehandler is either equipped with air
tires or foam-filled tires. Tire and/or wheel
failure could result in a telehandler tipover.
Component damage may also result if
problems are not discovered and repaired in
a timely fashion.
--
D - Annual Inspection
-- For differential oil replacement procedure,
refer to Section 5.
Steer Cylinder Assembly
-- Ensure steer cylinder assembly is
properly secured, there are no loose
or missing parts, all fittings and hoses
are properly tightened and there is no
evidence of hydraulic oil leakage.
Steer Linkage
-- Ensure there are no loose or missing
parts, steer linkage studs are locked and
there is no visible damage.
TM
Page 20
Telehandler Series
Model ZB20044
402509
44
200
PER 5
TORQUE
SEQUENCE 3
50-100
7
9
FT-LBS.
DRY
4
6
2
450-500
FT-LBS.
DRY
DEC-303
11
TAIN
90
psi DEC-183
MAIN
Turbo
Rear
Door
Standard
Batteries
Batteries
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.
WARNING
Explosion hazard. Keep flames
and sparks away. Do not smoke
near batteries.
WARNING
Battery acid is extremely corrosive Wear proper eye and facial protection as
well as appropriate protective clothing.
If contact occurs, immediately flush with
cold water and seek medical attention.
1. Check batteries case for damage.
2. Clean terminals and cable ends thoroughly
with a terminal cleaning tool or wire brush.
3. Ensure all connections are tight.
4. If applicable, check battery fluid level. If plates
are not covered by at least 1/2 (13 mm) of
solution, add distilled or demineralized water.
Telehandler Series
Model ZB20044
402509
Page 21
Exhaust
Engine
Compartment
Turbo
WAR
Maintai
NING
n
safety correct tire
precau
pressu
tions
re. Use
when
filling proper
tires.
MAIN
TAIN
ATT
DEC-007
90
EN
psi
DEC-183
TORQU
SEQUE E PER
12 1
50-100 NCE
10
5
AND
FT-LBS.
THEN
8
3
SEQUE PER
DRY
4 450-500NCE
7
TIO
2 11
FT-LBS.
DRY
DEC-303
Rear Axle
& Tire
Fuel Leaks
Failure to detect and correct fuel leaks will
result in an unsafe condition. An explosion or
fuel fire may cause death or serious injury.
DANGER
Engine fuels are combustible. Inspect
the telehandler in an open, wellventilated area away from heaters,
sparks and flames. Always have an
approved fire extinguisher within easy
reach.
TM
Page 22
Telehandler Series
Model ZB20044
402509
44
200
WARNINGUse proper
tires.
DEC-007
tire pressure.
filling
when
correct
Maintain precautions
safety
ION
PER
THEN
AND
1 10
ATTENT
12
8 SEQUENCE
PER 5
TORQUE
SEQUENCE 3
50-100
7
9
FT-LBS.
DRY
4
6
2
450-500
FT-LBS.
DRY
DEC-303
11
AIN
MAINT
90
psi DEC-183
Turbo
Hydraulic Oil
Tank
Fuel Tank
IMPORTANT
Before using your telehandler ensure
there is enough fuel for expected use.
-- Ensure fuel filler cap is secure.
-- Ensure tank shows no visible damage
and no evidence of fuel leakage.
Hydraulic Tank
-- Ensure hydraulic filler cap is secure.
-- Ensure tank shows no visible damage
and no evidence of hydraulic leakage.
Hydraulic Oil
-- Be sure that the boom is in the stowed
position, and then visually inspect the
sight gauge located on the side of the
hydraulic oil tank.
Fuel Tank
Hydraulic Return Filter
-- Ensure filter element is secure.
-- Ensure there are no signs of leakage or
visible damage.
1.1-9 Transmission
-- Ensure transmission shifter is working
properly and there is no evidence of damage.
Check oil level on dipstick
-- Oil level should be in the safe zone.
Add oil as needed. Refer to Table 2.2 for
recommended oil type.
D - Annual Inspection
-- For hydraulic oil and filter replacement
procedures, refer toSection 5.
TM
Telehandler Series
Model ZB20044
402509
Page 23
Boom Assembly
20
04
Lifting Attachment
Boom Extend
Cylinder
1.1-10 Boom
-- Ensure there are no loose or missing parts
and there is no visible damage.
--
--
--
Slide Pads
-- Ensure all bolts are tight, there is no
visible damage to the slide pads and that
no parts are missing.
Chain
-- Ensure there are no loose or missing
parts and there is no visible damage
C - Quarterly Inspection
-- Check chain tension and adjust as
required (refer toSection 5).
Boom Angle Indicator
-- Ensure all bolts are tight, and there is no
visible damage
TM
Page 24
Telehandler Series
Model ZB20044
402509
Axle Grease
Points
-- king pins
-- hose rollers
-- outrigger pins
-- slide pads
TM
Telehandler Series
Model ZB20044
402509
Page 25
Operators Cab
WARNING
Steering
Wheel
DEC-016
Controllers
Console
DANGER
FORKLIFT SIGNALS
ELECTROCUTION
HAZARD
KEEP CLEAR
ZB10044/10056
21
EVERY 40 HRS
PSI
OF SERVICE UNLESS
NOTED
CLEAN AND OIL
BRAKE PEDAL
PIVOT PIN
GREASE AXLE
FRONT & REARPIVOT BEARINGS
4 PLS
GREASE LIFT CYLINDERS
TOP & BOTTOM
BOTH SIDES 4
PLS
GREASE MAIN
BOTH SIDES 2 BOOM PIVOT BEARING PINS
PLS
GREASE AXLE
LOCK CYLINDER
TOP & BTM
GREASE AXLE
FRNT & REAR 4KING PINS
PLS
GREASE SLIP JOINT
ON DRIVE SHAFT
FRNT & REAR 2
PLS
1
2
10
DEATH OR SERIOUS
INJURY CAN
CONTACT WITH
RESULT FROM
LOAD, MACHINE
IF THEY BECOME
OR
ELECTRICALLY VEHICLE
CHARGED
1. STOP
3. LOWER LOAD
5
6
22
PSI
3
4
2. RAISE LOAD
DEC-002
17
15
15
14
18
12
11
6. TILT FORKS UP
16
GREASE DRIVE
FRNT & REAR 4 SHAFT U JOINT
PLS
GREASE FRAME
TOP & BOTTOM, LEVEL CYLINDER
BOTH CYLINDERS
10
15
GREASE OUTRIGGER
PINS
GREASE SLAVE
TOP & BOTTOM,CYLINDER
BOTH CYLINDERS
GREASE CARRIAGE
TILT CYLINDER
TOP & BOTTOM,
BOTH CYLINDERS
GREASE CARRIAGE
PIVOT BEARINGS
GREASE EXTENSION
CHAIN AND ROLLER
3 PLS
GREASE SLIDE
PADS 30 PLS
GREASE RETRACT
CHAIN ROLLERS
3 PLS
GREASE HOSE
ROLLERS 2 PLS
OIL EXTENSION
AFTER 500 HRS CHAINS
OF SERVICE
CHECK TORQUE
DAILY FOR FIRST ON WHEEL LUG NUTS
450-500 FT-LBS 150 HRS OF SERVICE
11
15
12
13
13
14
OTHER OBSTRUCTIONS
DEC-024
LIGHTS
16
INSTRUCTIONS
TO SIGNAL MEN
to be signalman
3. Signalman must
2. Make sure the
watch the load
operator can see
the operator is watching
you
and is able to acknowledge
you
the
signal given
4. Never raise or
lower the load over
other
workmen, warn
them to keep out
WATCH FOR OVERHEAD
of the way
LINES OR
15
11
17
18
10
PSI
20
19
19
20
21
22
DEC-178
65-70 PSI
CHECK AXLE LOCK
175-200 PSI, EVERY ACCUMULATOR PRESSURE
6 MONTHS
CHECK BRAKE
ACCUMULATOR
475-500 PSI, EVERY
PRESSURE
6 MONTHS
DEC-302
The
Reach
Machine
ON
JOYSTIC
3 FUNCTI
HOLD
AND TILT
PUSH FORK
FOR
FORWARD
FORK
TILT
BACK
BOOM
LOWER
BOOM
EXTEND
DEC-142
BOOM
RETRACT
BOOM
RAISE
EL
T F
DEC-055
FRAME
LEVEL
G
TH
I R
Brake Pedal
CHECK DAILY
GENERAL:
AXLES:
BRAKES:
ELECTRICAL:
ENGINE:
TIRES:
OPERATING
:Hydraulic Cylinders
:Radiator and
battery level
:Hydraulic Hoses
and Fittings
:Transmission
Fluid, Hydraulic
Oil
:Pedal Response
:Clean Mud and
Debris from Brake
Pedal Assembly
:All Exposed
Wiring
:Proper Operation
:Charging System of All Gauges
Ammeter/Voltmeter
TRAVELLING:
- Keep Telescopic
Booms Fully
Retracted
- Keep Carriage
Tilted Back to
Avoid
- Travel with Load
at Lowest PracticalSpills
- Always Have
Height
Forks
- Travel in Reverse Pointed Up Hill on a Grade
if Load Obstructs
Forward Vision
PARKING PROCEDURE:
1. Apply Park
Brake
2. Place Transmission
in "NEUTRAL"
3. Park Machine
on Flat, Level
Surface or Chock
4. Park Machine
with Forks, Slightly
Wheels
in Mud during
Winter Operation Clear of Ground to Avoid
Freezing
:Hoses
:Belts
:Fluid Levels/
Leaks
WORK SAFETY:
:Gouges, cuts,
punctures
:13:00 and 14:00
X24 Grader Lug
:Rims -- Examine
-- 65
for Cracks, Distortion,PSI Unloaded
Ring Assembly
Lock
"SPECIALISTS
INSTRUCTIONS:
- Centre Load
on Forks
- Beware of Overhead
Obstacles
- Observe All
Operating and
Safety Decals
- Bring Unit to
on Machine
a Full Stop Before
- Use High Gear
Changing Direction
for Road Travel
- Disengage Park
of Unloaded Unit
Brake
ONLY
- Never Exceed
Rated Lifting
Capacity -- See
- Feather Hydraulic
Factory
Controls when
- Inspect Lift
Nearing Maximum Load Chart
Component( Mast
Mast/Boom Extension
or Boom ) Chains,
Components
Rollers, Pins
- Cycle Each
and Welded
Hydraulic Function
at Start of Day
Operation
to ensure Proper
:Mounting Bolts
:Wheel Studs/
Nuts
:Oil Leaks at
Drive
:Two Wheel Drive Hubs and Differential
Units Only--Steer
- No Riders at
any time
- Only Trained,
Authorized Operators
- Operate Machine
Only From Operator
- Use Only Approved
Seat
Personnel Platforms
- Do Not Use
Control Levers
or Steering Wheel
- Never Make
any Unauthorized
as Grab Handles
- Never Tilt Carriage
Alterations or
Adjustments
when Personnel
- Thoroughly
Read and Understand Platform is Used
Operator Manual
before Operating
IN ROUGH TERRAIN
FORKLIFTS"
TM
Page 26
Telehandler Series
Model ZB20044
402509
AC
2.
TM
Telehandler Series
Model ZB20044
402509
Page 27
Function Tests
Boom Joystick
Frame Level/Optional
Attachment Joystick
Ignition
Switch
ON
JOYSTIC
3 FUNCTI
HOLD
AND TILT
PUSH FORK
FOR
FORWARD
FORK
TILT
BACK
BOOM
LOWER
BOOM
EXTEND
DEC-142
BOOM
RETRACT
BOOM
RAISE
EL
T F
DEC-055
FRAME
LEVEL
G
TH
I R
Joystick
Controller
Console
1.2
Function Tests
Function tests are designed to discover any malfunctions
before telehandler is put into service. The operator must
understand and follow step-by-step instructions to test
all telehandler functions.
IMPORTANT
Never use a malfunctioning telehandler. If
malfunctions are discovered, telehandler
must be tagged and placed out of service.
Repairs to telehandler may only be made
by a qualified service technician.
After repairs are completed, operator must perform a
pre-operation inspection and a series of function tests
again before putting telehandler into service.
Prior to performing function tests, be sure to read and
understand Section2.9 of the operating manual - Start
Operation.
WARNING
TM
Page 28
Telehandler Series
Model ZB20044
402509
Function Tests
Transmission
Lever
WARNING
THIS VEHICLE IS EQUIPPED WITH A
BACKUP ALARM
THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO
WARNING
WARNING
DEC-013A
DEC-099
FOLLOW PROC
Extending ourselves
for you.
A
INE.
E,
:
VEHICLE BATTER
WARNING
No Riders
DEC-109
IMPORT
CTION
FF for
Cable.
y Cable.
BATTER
ON
NEG
POS
able.
able.
DEC-318
DANGER
20044
DO NOT OPERATE
THIS MACHINE
WITHOUT SEAT
BELT FASTENED
DEC-023
IMPORTANT
1. TIGHTEN WHEEL NUTS DAILY
FIRST 150 HOURS OPERATION
2. CHECK AXLE & SPRING
MOUNTING BOLTS REGULARLY
DEC-022
IMPORTANT
ALL TURBO-ENGINES
AIR CLEANER AND EXHAUST
MUST BE SEALED DURING
TRANSPORT DEC-052
BRAKE ACTUATED
TRANSMISSION
DISCONNECT
NORMAL
OPERATION
TRANSMISSION
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
ONLY
OUTRIGGERS
LEFT
RIGHT
STEERING
PARKING
BRAKE
ROUND
ON
DOWN
OFF
UP
TURN SIGNALS
DOWN
LEFT
ON
UP400774
OFF
PARK
BRAKE
AXLE
LOCK
DIFF
LOCK
CHARGE
PRESSURE
DEC-320
DEC-322
HORN
DEC-308E
RIGHT
ON
FRONT
CRAB
OFF
DEC-216
Right Turn
Switch
6. Insert key into ignition switch and select
on position. The red and amber lights
at the top of electronic dash display will
illuminate. Once red and amber lights are
no longer displayed, and the electronic
gauges are visible on the display panel;
turn the key to start position.
7. Allow engine to idle for 30 seconds until
low brake pressure light is off.
Test Horn
1. Push
horn push-button.
Result: Horn should sound.
WARNING
If the warning indicator lights illuminate
when engine is running, immediately
shut down the telehandler and have it
serviced.
Test Reverse Alarm
1. Ensure parking brake switch is on.
Horn Push
Button
TM
Telehandler Series
Model ZB20044
402509
Page 29
Function Tests
Boom Joystick
Frame Level/Optional
Attachment Joystick
Ignition
Switch
ON
JOYSTIC
3 FUNCTI
HOLD
AND TILT
PUSH FORK
FOR
FORWARD
FORK
TILT
BACK
BOOM
LOWER
BOOM
EXTEND
DEC-142
BOOM
RETRACT
BOOM
RAISE
EL
T F
DEC-055
FRAME
LEVEL
G
TH
I R
Joystick
Controller
Console
TM
Page 30
Telehandler Series
Model ZB20044
402509
Function Tests
WARNING
WARNING
THIS VEHICLE IS EQUIPPED WITH A
BACKUP ALARM
DEC-109
IMPORT
THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO
FOLLOW PROC
WARNING
WARNING
DEC-013A
DEC-099
DEC-016
DEC-100
Extending ourselves
for you.
A
INE.
E,
:
VEHICLE BATTER
WARNING
No Riders
CTION
FF for
Frame level
Indicator
Cable.
y Cable.
BATTER
ON
NEG
POS
able.
able.
DEC-318
DANGER
20044
DO NOT OPERATE
THIS MACHINE
WITHOUT SEAT
BELT FASTENED
DEC-023
DANGER
IMPORTANT
FORKLIFT SIGNALS
ELECTROCUTION
HAZARD
KEEP CLEAR
ZB10044/10056
21
EVERY 40 HRS
PSI
1
2
10
DEATH OR SERIOUS
INJURY CAN
CONTACT WITH
RESULT FROM
LOAD, MACHINE
IF THEY BECOME
OR
ELECTRICALLY VEHICLE
CHARGED
1. STOP
3. LOWER LOAD
5
6
22
PSI
3
4
2. RAISE LOAD
DEC-002
17
15
15
14
18
12
11
6. TILT FORKS UP
16
OF SERVICE UNLESS
NOTED
CLEAN AND OIL
BRAKE PEDAL
PIVOT PIN
GREASE AXLE
FRONT & REARPIVOT BEARINGS
4 PLS
GREASE LIFT CYLINDERS
TOP & BOTTOM
BOTH SIDES 4
PLS
GREASE MAIN
BOTH SIDES 2 BOOM PIVOT BEARING PINS
PLS
GREASE AXLE
LOCK CYLINDER
TOP & BTM
GREASE AXLE
FRNT & REAR 4KING PINS
PLS
GREASE SLIP JOINT
ON DRIVE SHAFT
FRNT & REAR 2
PLS
GREASE DRIVE
FRNT & REAR 4 SHAFT U JOINT
PLS
15
15
13
DEC-022
7. TILT FORKS DOWN
ALL TURBO-ENGINES
AIR CLEANER AND EXHAUST
MUST BE SEALED DURING
TRANSPORT DEC-052
BRAKE ACTUATED
TRANSMISSION
DISCONNECT
NORMAL
OPERATION
STEERING
ROUND
PARKING
BRAKE
OUTRIGGERS
LEFT
RIGHT
ON
DOWN
OFF
UP
LEFT
ON
UP400774
OFF
AXLE
LOCK
DIFF
LOCK
CHARGE
DEC-024
20
19
LIGHTS
19
20
21
22
DEC-178
65-70 PSI
CHECK AXLE LOCK
175-200 PSI, EVERY ACCUMULATOR PRESSURE
6 MONTHS
CHECK BRAKE
ACCUMULATOR
475-500 PSI, EVERY
PRESSURE
6 MONTHS
DEC-302
DEC-320
RIGHT
ON
The
Reach
e
Machin
DEC-322
HORN
DEC-308E
JOYSTICK
3 FUNCTION
HOLD
AND TILT
PUSH FORK
FOR
FORWARD
FORK
TILT
BACK
BOOM
LOWER
BOOM
EXTEND
DEC-142
BOOM
RETRACT
BOOM
TRANSMISSION
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
ONLY
GREASE FRAME
TOP & BOTTOM, LEVEL CYLINDER
BOTH CYLINDERS
10 GREASE OUTRIGGER
PINS
11 GREASE SLAVE
TOP & BOTTOM,CYLINDER
BOTH CYLINDERS
12 GREASE CARRIAGE
TILT CYLINDER
TOP & BOTTOM,
BOTH CYLINDERS
13 GREASE CARRIAGE
PIVOT BEARINGS
GREASE EXTENSION
CHAIN AND ROLLER
3 PLS
15 GREASE SLIDE
PADS 30 PLS
16 GREASE RETRACT
CHAIN ROLLERS
3 PLS
17 GREASE HOSE
ROLLERS 2 PLS
OIL EXTENSION
AFTER 500 HRS CHAINS
OF SERVICE
CHECK TORQUE
DAILY FOR FIRST ON WHEEL LUG NUTS
450-500 FT-LBS 150 HRS OF SERVICE
18
10
PSI
PRESSURE
TURN SIGNALS
DOWN
11
OTHER OBSTRUCTIONS
PARK
BRAKE
14
INSTRUCTIONS
TO SIGNAL MEN
to be signalman
3. Signalman must
2. Make sure the
watch the load
operator can see
the operator is watching
you
and is able to acknowledge
you
the
signal given
4. Never raise or
lower the load over
other
workmen, warn
them to keep out
WATCH FOR OVERHEAD
of the way
LINES OR
IMPORTANT
RAISE
FRONT
CRAB
OFF
DEC-216
EL
T F
DEC-055
Axle Lock
Light
Parking Brake
Switch
I R
CHECK DAILY
GENERAL:
AXLES:
BRAKES:
ELECTRICAL:
ENGINE:
TIRES:
Parking Brake
Indicator Light
OPERATING
:Hydraulic Cylinders
:Radiator and
battery level
:Hydraulic Hoses
and Fittings
:Transmission
Fluid, Hydraulic
INSTRUCTIONS:
- Centre Load
on Forks
- Beware of Overhead
Obstacles
- Observe All
Operating and
Safety Decals
- Bring Unit to
on Machine
a Full Stop Before
- Use High Gear
Changing Direction
for Road Travel
- Disengage Park
of Unloaded Unit
Brake
ONLY
- Never Exceed
Rated Lifting
Capacity -- See
- Feather Hydraulic
Factory
Controls when
- Inspect Lift
Nearing Maximum Load Chart
Component( Mast
Mast/Boom Extension
or Boom ) Chains,
Components
Rollers, Pins
- Cycle Each
and Welded
Hydraulic Function
at Start of Day
Operation
to ensure Proper
Oil
:Mounting Bolts
:Wheel Studs/
Nuts
:Oil Leaks at
Drive
:Two Wheel Drive Hubs and Differential
Units Only--Steer
:Pedal Response
:Clean Mud and
Debris from Brake
Pedal Assembly
:All Exposed
Wiring
:Proper Operation
:Charging System of All Gauges
Ammeter/Voltmeter
TRAVELLING:
- Keep Telescopic
Booms Fully Retracted
- Keep Carriage
Tilted Back to
Avoid
- Travel with Load
at Lowest PracticalSpills
- Always Have
Height
Forks
- Travel in Reverse Pointed Up Hill on a Grade
if Load Obstructs
Forward Vision
PARKING PROCEDURE:
1. Apply Park
Brake
2. Place Transmission
in "NEUTRAL"
3. Park Machine
on Flat, Level
Surface or Chock
4. Park Machine
with Forks, Slightly
Wheels
in Mud during
Winter Operation Clear of Ground to Avoid
Freezing
:Hoses
:Belts
:Fluid Levels/
Leaks
WORK SAFETY:
:Gouges, cuts,
punctures
:13:00 and 14:00
X24 Grader Lug
:Rims -- Examine
-- 65
for Cracks, Distortion,PSI Unloaded
Ring Assembly
Lock
"SPECIALISTS
Brake Pedal
FRAME
LEVEL
G
TH
- No Riders at
any time
- Only Trained,
Authorized Operators
- Operate Machine
Only From Operator
- Use Only Approved
Seat
Personnel Platforms
- Do Not Use
Control Levers
or Steering Wheel
- Never Make
any Unauthorized
as Grab Handles
- Never Tilt Carriage
Alterations or
Adjustments
when Personnel
- Thoroughly
Read and Understand Platform is Used
Operator Manual
before Operating
IN ROUGH TERRAIN
FORKLIFTS"
Accelerator
Pedal
TM
Telehandler Series
Model ZB20044
402509
Page 31
Function Tests
Transmission Lever
IMPORT
DEC-013A
DEC-099
Extending ourselves
for you.
A
INE.
E,
:
VEHICLE BATTER
WARNING
No Riders
DEC-109
THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO
FOLLOW PROC
WARNING
WARNING
WARNING
THIS VEHICLE IS EQUIPPED WITH A
BACKUP ALARM
CTION
FF for
Cable.
y Cable.
BATTER
ON
NEG
POS
able.
able.
DEC-318
DANGER
20044
DO NOT OPERATE
THIS MACHINE
WITHOUT SEAT
BELT FASTENED
DEC-023
IMPORTANT
1. TIGHTEN WHEEL NUTS DAILY
FIRST 150 HOURS OPERATION
2. CHECK AXLE & SPRING
MOUNTING BOLTS REGULARLY
DEC-022
IMPORTANT
ALL TURBO-ENGINES
AIR CLEANER AND EXHAUST
MUST BE SEALED DURING
TRANSPORT DEC-052
BRAKE ACTUATED
TRANSMISSION
DISCONNECT
NORMAL
OPERATION
TRANSMISSION
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
ONLY
OUTRIGGERS
LEFT
RIGHT
STEERING
PARKING
BRAKE
ROUND
ON
DOWN
OFF
UP
TURN SIGNALS
DOWN
LEFT
ON
UP400774
OFF
RIGHT
ON
PARK
BRAKE
AXLE
LOCK
DIFF
LOCK
CHARGE
PRESSURE
DEC-320
DEC-322
HORN
DEC-308E
FRONT
CRAB
Steering
Selector Switch
Test Driving & Service Brake Functions
1. Ensure path of intended motion is clear.
2. Ensure all four wheels are aligned straight
ahead.
OFF
DEC-216
Ignition Switch
Test Steering
CAUTION
Before changing steering modes, bring
all four wheels into alignment (i.e., in the
straight-ahead position).
WARNING
Before driving on public roads and
highways check the alignment of the
wheels and drive with FRONT steering
only.
WARNING
Do not change steer mode while
telehandler is traveling.
NOTE
Avoid steering the wheels while telehandler
is stationary.
TM
Page 32
Telehandler Series
Model ZB20044
402509
Function Tests
Steering Wheel
Hour Meter
DEC-109
IMPORT
Transmission
Lever
THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO
FOLLOW PROC
WARNING
WARNING
WARNING
THIS VEHICLE IS EQUIPPED WITH A
BACKUP ALARM
DEC-013A
DEC-099
Front Display
Panel
Extending ourselves
for you.
A
INE.
E,
:
VEHICLE BATTER
WARNING
No Riders
CTION
FF for
Cable.
y Cable.
BATTER
ON
NEG
POS
able.
able.
DEC-318
DANGER
20044
DO NOT OPERATE
THIS MACHINE
WITHOUT SEAT
BELT FASTENED
DEC-023
IMPORTANT
1. TIGHTEN WHEEL NUTS DAILY
FIRST 150 HOURS OPERATION
2. CHECK AXLE & SPRING
MOUNTING BOLTS REGULARLY
DEC-022
IMPORTANT
ALL TURBO-ENGINES
AIR CLEANER AND EXHAUST
MUST BE SEALED DURING
TRANSPORT DEC-052
BRAKE ACTUATED
TRANSMISSION
DISCONNECT
NORMAL
OPERATION
Steering
Selector Switch
TRANSMISSION
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
ONLY
STEERING
ROUND
PARKING
BRAKE
OUTRIGGERS
LEFT
RIGHT
ON
DOWN
OFF
UP
PARK
BRAKE
TURN SIGNALS
DOWN
LEFT
ON
UP400774
OFF
AXLE
LOCK
DIFF
LOCK
CHARGE
PRESSURE
DEC-320
DEC-322
HORN
DEC-308E
RIGHT
ON
FRONT
CRAB
Round Steer
OFF
DEC-216
TM
Telehandler Series
Model ZB20044
402509
Page 33
Function Tests
Steering Wheel
Hour Meter
DEC-109
DEC-013A
DEC-099
Front Display
Panel
Extending ourselves
for you.
A
INE.
E,
:
FOLLOW PROC
VEHICLE BATTER
WARNING
No Riders
IMPORT
THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO
WARNING
WARNING
WARNING
Transmission
Lever
CTION
FF for
Cable.
y Cable.
BATTER
ON
NEG
POS
able.
able.
DEC-318
DANGER
20044
DO NOT OPERATE
THIS MACHINE
WITHOUT SEAT
BELT FASTENED
DEC-023
IMPORTANT
1. TIGHTEN WHEEL NUTS DAILY
FIRST 150 HOURS OPERATION
2. CHECK AXLE & SPRING
MOUNTING BOLTS REGULARLY
DEC-022
IMPORTANT
ALL TURBO-ENGINES
AIR CLEANER AND EXHAUST
MUST BE SEALED DURING
TRANSPORT
DEC-052
BRAKE ACTUATED
TRANSMISSION
DISCONNECT
Steering
Selector Switch
NORMAL
OPERATION
TRANSMISSION
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
ONLY
OUTRIGGERS
LEFT
RIGHT
STEERING
PARKING
BRAKE
ROUND
ON
DOWN
OFF
UP
TURN SIGNALS
LEFT
ON
DOWN
RIGHT
ON
PARK
BRAKE
AXLE
LOCK
DIFF
LOCK
CHARGE
PRESSURE
DEC-320
DEC-322
HORN
DEC-308E
FRONT
CRAB
UP400774
OFF
OFF
DEC-216
TM
Page 34
Telehandler Series
Model ZB20044
402509
Function Tests
Steering Wheel
WARNING
THIS VEHICLE IS EQUIPPED WITH A
BACKUP ALARM
WARNING
WARNING
DEC-013A
DEC-099
Extending ourselves
for you.
A
INE.
E,
:
VEHICLE BATTER
WARNING
No Riders
DEC-109
IMPORT
THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO
FOLLOW PROC
CTION
FF for
Cable.
y Cable.
BATTER
ON
NEG
POS
able.
able.
DEC-318
DANGER
20044
DO NOT OPERATE
THIS MACHINE
WITHOUT SEAT
BELT FASTENED
DEC-023
IMPORTANT
1. TIGHTEN WHEEL NUTS DAILY
FIRST 150 HOURS OPERATION
2. CHECK AXLE & SPRING
MOUNTING BOLTS REGULARLY
DEC-022
IMPORTANT
ALL TURBO-ENGINES
AIR CLEANER AND EXHAUST
MUST BE SEALED DURING
TRANSPORT DEC-052
BRAKE ACTUATED
TRANSMISSION
DISCONNECT
NORMAL
OPERATION
TRANSMISSION
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
ONLY
OUTRIGGERS
LEFT
RIGHT
STEERING
PARKING
BRAKE
ROUND
ON
DOWN
OFF
UP
TURN SIGNALS
DOWN
LEFT
ON
UP400774
OFF
RIGHT
ON
PARK
BRAKE
AXLE
LOCK
DIFF
LOCK
CHARGE
PRESSURE
DEC-320
DEC-322
HORN
DEC-308E
FRONT
CRAB
Parking Brake
Switch
OFF
DEC-216
Outriggers
Switches
continuously.
Result: Outriggers should lower.
TM
Telehandler Series
Model ZB20044
402509
Page 35
Notes
Section 2
MAINTENANCE TABLES AND DIAGRAMS
Table of Contents
Tables
Table 2.1
Table 2.2
Table 2.3
Table 2.4
Table 2.5
TM
Telehandler Series
Model ZB20044
402509
Page 37
ZB20032
ZB20044
Engine
Type
Max RPM
Horsepower @ 2300 RPM
Horsepower @ 2500 RPM
Fuel type
Transmission
Type
Speeds forward
Speeds Reverse
Top Speed
Gear Ratios
Cummins QSB4.5C160T3
2500 rpm
168 HP
163 HP
Diesel
DANA T32000
3
3
20.5 mph (33 km/h)
4.64 : 1
2.23 : 1
0.82 : 1
1st Gear
2nd Gear
3rd Gear
Electrical
System voltage
Standard Batteries
Type
Quantity
Cranking amperes @ 0F (-17C)
Total cranking amps @ 0F (-17C)
Cranking amperes @ 32F (0C)
Reserve capacity
Dimensions
Overall length (less forks)
Overall width
Overall Height
Curb weight (standard machine with open cab)
Maximum capacity
Wheelbase
Round steer turning Radius (inside)
Boom
Number of sections
Maximum lift height
Maximum forward reach
Standard Forks
Carriage rollback
Carriage forward tilt
Operating Times
Boom extend (at max. boom angle)
Boom retract (at max. boom angle)
Boom raise*
Boom lower*
Carriage roll forward
Carriage roll back
Frame level right (stop to stop) **
Frame level left (stop to stop) **
3
44 ft. 10 in (1366 cm)
27 ft 5 in (835 cm)
2 x 6 x 60 in
(6.9 x 15.2 x 152.4 cm)
19
80
13 seconds
9.5 seconds
19 seconds
20 seconds
12 seconds
12 seconds
15 - 20 seconds
15 - 20 seconds
238-A
TM
Page 38
Telehandler Series
Model ZB20044
402509
MODEL
En
gi
ne
Fuel Type
on
ZB20044
Diesel
49 gal (185 L)
Recommended
Oil Type
15W40 CC/SF
Coolant Type
Type
Capacity
Tr
an
sm
is
si
ZB20032
yd
ra
ul
ic
O
il
Ax
le
s
Differential
Tank Capacity
re
a
se
55 gal (208 L)
General Greasing
TM
Telehandler Series
Model ZB20044
402509
Page 39
Fine Pitch
Course Pitch
Size of Bolt
10.9
12.9
Normali
Loctite 242
(Nm)
Loctite 270
(Nm)
Normali
Loctite 242
(Nm)
Loctite 270
(Nm)
Normali
Loctite 242
(Nm)
Loctite 270
(Nm)
M6 x 1
9.5-10.5
10.5-11.5
14.3-15.7
15.2-16.8
16.2-17.8
18.1-20.0
M8 x 1.25
23.8-26.2
25.6-28.4
34.2-37.8
36.7-40.5
39.0-43.0
43.7-48.3
M10 x 1.5
48-53
52-58
68-75
73-81
80-88
88-97
M12 x 1.75
82-91
90-100
116-128
126-139
139-153
152-168
M14 x 2
129-143
143-158
182-202
200-221
221-244
238-263
M16 x 2
200-221
219-242
283-312
309-341
337-373
371-410
M18 x 2.5
276-305
299-331
390-431
428-473
466-515
509-562
M20 x 2.5
390-431
428-473
553-611
603-667
660-730
722-798
M22 x 2.5
523-578
575-635
746-824
817-903
893-987
974-1076
M24 x 3
675-746
732-809
950-1050
1040-1150
1140-1260
1240-1370
M27 x 3
998-1103
1088-1202
1411-1559
1539-1701
1710-1890
1838-2032
M30 x 3.5
1378-1523
1473-1628
1914-2115
2085-2305
2280-2520
2494-2757
M8 x 1
25.7-28.3
27.5-30.5
36.2-39.8
40.0-44.0
42.8-47.2
47.5-52.5
M10 x 1.25
49.4-54.6
55.2-61.0
71.5-78.5
78.0-86.0
86.0-94.0
93.0-103.0
M12 x 1.25
90-100
98-109
128-142
139-154
152-168
166-184
M12 x 1.5
86-95
94-104
120-132
133-147
143-158
159-175
M14 x 1.5
143-158
157-173
200-222
219-242
238-263
261-289
M16 x 1.5
214-236
233-257
302-334
333-368
361-399
394-436
M18 x 1.5
312-345
342-378
442-489
485-536
527-583
580-641
M20 x 1.5
437-483
475-525
613-677
674-745
736-814
808-893
M22 x 1.5
581-642
637-704
822-908
903-998
998-1103
1078-1191
M24 x 2
741-819
808-893
1045-1155
1140-1260
1235-1365
1363-1507
M27 x 2
1083-1197
1178-1302
1520-1680
1672-1848
1834-2027
2000-2210
M30 x 2
1511-1670
1648-1822
2138-2363
2332-2577
2565-2835
2788-3082
60571AA
Page 40
Telehandler Series
Model ZB20044
402509
17.50 - 25
90 psi
Pressure
Tire Ply Rating
16 PR
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.
IMPORTANT
For proper function of each axle differential, all four wheels must have same tire size installed at
all times. Failure to comply with this requirement will reduce the life of the differentials and reduce
overall mobility of telehandler.
TM
Telehandler Series
Model ZB20044
402509
Page 41
Model ZB20044
Maximum Pump Pressure
P1
3150 psi
P2
3200 psi
P1
500 psi
P2
550 psi
3200 psi
Lift
Extension
Rod End
3100 psi
Base End
1500 psi
Rod End
3400 psi
Base End
1800 psi
Rod End
1500 psi
Base End
1500 psi
Rod End
2000 psi
Base End
2000 psi
Rod End
2500 psi
Base End
2500 psi
Port Relief
Carriage Tilt Cylinder
Crossover Relief
Auxiliary Hydraulics
Outrigger
Port Relief
Port Relief
Port Relief
Pilot Pressure
325 psi
Steering Pressure
2800 psi
250A
TM
Page 42
Telehandler Series
Model ZB20044
402509
Section 3
SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Table of Contents
Charts
3.1 Hydraulic Symbol Chart....................................................................................................................................................... 45
3.2 Electrical Symbol Chart........................................................................................................................................................ 46
3.3 Harnesses Color Codes......................................................................................................................................................... 47
Diagrams and Schematics
3.4 Hydraulic Schematic Parts List ............................................................................................................................................ 49
3.5 Electrical Component Parts List........................................................................................................................................... 52
3.5 Electrical Component Parts List (Continued)....................................................................................................................... 53
3.5 Electrical Component Parts List (Continued)....................................................................................................................... 54
3.6 Priority Valve and Port Identifications.................................................................................................................................. 55
3.7 Steering Valve and Port Identifications................................................................................................................................. 56
3.8 Diverter Valve and Port Identifications................................................................................................................................. 57
3.9 Parking Brake Valve and Port Identifications....................................................................................................................... 58
3.10 Brake Charge Valve and Port Identifications...................................................................................................................... 59
3.11 Frame Level and Axle Lock Valves and Port Identifications.............................................................................................. 60
3.12 Cross-Over Relief Valve and Port Identifications............................................................................................................... 61
3.13 Dual Charge Brake Pedal and Port Identifications............................................................................................................. 62
3.14 Orbital Steering Motor and Port Identifications.................................................................................................................. 63
3.15 Main Valve and Main Ports Identifications......................................................................................................................... 65
3.16 Hydraulic Cylinders Identification...................................................................................................................................... 67
3.17 Hydraulic Manifolds Location............................................................................................................................................ 68
3.18 Instrument Panel Wiring Diagram (Base Model)............................................................................................................... 69
3.19 Main Wiring Harness.......................................................................................................................................................... 71
3.20 Engine Harness (QSB4.5 Tier 3)........................................................................................................................................ 72
3.21 Transmission T32000 Harness............................................................................................................................................ 73
3.22 Frame Level Harness.......................................................................................................................................................... 74
3.23 Axle Lock Harness.............................................................................................................................................................. 75
3.24 Diverter Valve Harness, 2-Way........................................................................................................................................... 76
3.25 Parking Brake Harness........................................................................................................................................................ 77
3.26 Steering Harness................................................................................................................................................................. 78
3.27 Horn, Fuel & Brake Pressure Switch Harness.................................................................................................................... 79
3.28 Joystick with Horizontal Rocker Switch............................................................................................................................. 80
3.29 Three-Speed Shifter............................................................................................................................................................ 81
3.30 Joystick, Two-Axis with Microswitch................................................................................................................................ 82
3.31 Power Module - Enclosed Cab Harnesses.......................................................................................................................... 83
3.32 Power Module - Open Cab Harnesses................................................................................................................................ 84
3.33 Lighting Harness................................................................................................................................................................. 85
3.34 Wiper Harness..................................................................................................................................................................... 86
3.35 Grappler Harness................................................................................................................................................................ 87
3.36 Outrigger Raise/Lower Harness.......................................................................................................................................... 88
3.37 Mine Spec. - Brakes Harness.............................................................................................................................................. 89
3.38 Mine Spec. - Pressure Switches Harness............................................................................................................................ 90
3.39 Mine Spec. - Steering Accumulator Harness...................................................................................................................... 91
3.40 Hydraulic Schematic........................................................................................................................................................... 92
3.41 Master Wiring Diagram...................................................................................................................................................... 93
TM
Telehandler Series
Model ZB20044
402509
Page 43
Notes
LINE CROSSING
HAND PUMP
ACCUMULATOR,
GAS CHARGED
SINGLE ACTING
CYLINDER
LINE JOINED
RELIEF VALVE
PRESSURE
SWITCH
DOUBLE ACTING
CYLINDER
HYDRAULIC
TANK
PRESSURE
REDUCING
VALVE
SHUTTLE VALVE
A2
A1
HYDRAULIC
FILTER WITH
BYPASS
FIXED ORIFICE
DOUBLE ACTING
DOUBLE
RODDED
CYLINDER
SW
LS
CHARGE VALVE
DUAL
SPRING APPLIED
HYDRAULIC
RELEASED
BRAKE
CHARGE VALVE
SINGLE
BRAKE
CYLINDER
SW
LS
ELECTRIC
MOTOR
ADJUSTABLE
FLOW CONTROL
T
ENGINE
CHECK VALVE
FIXED
DISPLACEMENT
PUMP
OIL COOLER
VARIABLE
DISPLACEMENT
PUMP
TWO POSITION
THREE WAY VALVE
THREE POSITION
VARIABLE
FOUR WAY
DISPLACEMENT
PROPORTIONAL
HYDRAULIC
MOTOR
TWO POSITION
TWO WAY
NORMALLY
CLOSED VALVE
BI DIRECTIONAL
HYDRAULIC
MOTOR
L
THREE POSITION
SIX WAY
OPEN CENTER
CLOSED PORT
COUNTER
BALANCE VALVE
VALVE COIL
TWO POSITION
TWO WAY
NORMALLY
OPEN VALVE
THREE POSITION
FOUR WAY
CLOSED CENTER
OPEN PORT
THREE POSITION
FOUR WAY
CLOSED CENTER
CLOSED PORT
DYNAMIC SIGNAL
PRIORITY VALVE
ORBITAL
STEERING
MOTOR
EF
CF
LS
STATIC SIGNAL
PRIORITY VALVE
PRESSURE
TRANSDUCER
LS
P
TM
Telehandler Series
Model ZB20044
402509
Page 45
CIRCUITS CROSSING
NO CONNECTION
CIRCUITS
CONNECTED
ACC
HOURMETER
B+
IGN
KEY SWITCH
ST
LIMIT SWITCH
N.O.
LIMIT SWITCH
N.O. HELD
CLOSED
LIGHT
FOOT SWITCH
BATTERY
HYDRAULIC
VALVE COIL
TOGGLE SWITCH
GROUND
PROPORTIONAL
HYDRAULIC
VALVE COIL
PUSH BUTTON
LIMIT SWITCH
N.C HELD OPEN
FUSE
ELECTRIC
MOTOR
ROTARY SWITCH
SILICON
CONTROLLED
RECTIFIER
CIRCUIT
BREAKER
HORN
LIMIT SWITCH
PROXIMITY
SWITCH
VOLT METER
EMERGENCY
STOP BUTTON
CAM OPERATED
LIMIT SWITCH
PNP
TRANSISTOR
CAPACITOR
RESISTOR
TILT SWITCH
NPN
TRANSISTOR
POTENTIOMETER
LEVEL SENSOR
SINGLE POLE
SINGLE THROWN
RELAY
PRESSURE
VACUUM
SWITCH
SINGLE POLE
DOUBLE THROW
RELAY
DOUBLE POLE
SINGLE THROW
RELAY
DOUBLE POLE
DOUBLE THROW
RELAY
TEMPERATURE
SWITCH
TRIPLE POLE
DOUBLE THROW
RELAY
DIODE
RHEOSTAT
LIMIT SWITCH
N.C.
TM
Page 46
Telehandler Series
Model ZB20044
402509
FUNCTION
WIRE
COLOR
GROUND
FROM ALTERNATOR B+ TO STARTER
MOTOR
FROM ACC ON KEY SWITCH TO BREAKER
BUS BAR
BLK
IGNITION
FUNCTION
WIRE
COLOR
DASH POWER
RED
TO HOUR METER
BLU/YEL
RED
TO HORN
BLU/WHT
YEL
BLU/RED
BRN/RED
STARTER SOLENOID
GRN
HORN
PNK
FUEL GAUGE
GRY
BLU
STEERING
DIFFERENTIAL LOCK
LT GRN
LT GRN/RED
GRN/YEL
YEL/BLK
ROUND STEER
GRN/BLK
YEL/BLU
CRAB STEER
GRN/WHT
OUTRIGGERS
PARK BRAKE
FROM BREAKER TO PARK BRAKE SOLENOID
FROM SWITCH TO PARK BRAKE SOLENOID
LT BLU/RED
LT BLU
WHT
WHT/BLU
WHT/GRY
LEFT UP
WHT/BLK
LT BLU/BLK
LEFT DOWN
WHT/BLK/RED
LT BLU/BLK
RIGHT UP
WHT/RED
RIGHT DOWN
WHT/RED/GRN
WHT/ORG
TRANSMISSION
FORWARD SOLENOID
RED
REVERSE SOLENOID
WHT
OPTIONAL LIGHTS
st
BRN
HEADLIGHTS
ORG/GRN
nd
BLK
ORG/BLK/WHT
BRAKE LIGHTS
ORG/RED
DIVERTER VALVE
TAN
SIGNAL LIGHTS
ORG
ORG/BLK
ALTERNATOR EXCITER
PUR
ORG/BLU
1 SOLENOID
2
SOLENOID
225A
This table is to be used as a wire function/color reference for all electrical drawings and schematics.
TM
Telehandler Series
Model ZB20044
402509
Page 47
Notes
ACC1
ACC2
ACC3
ACC4
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25
CB1
CB2
CB3
CB4
CB5
CB6
CB7
CB8
CRV1
CV1
CV2
F1
Skyjack
Part No.
400947
400947
400947
400947
9-180
9-180
9-180
9-180
401061
401061
9-163
9-158
9-158
9-158
9-158
9-161
9-161
9-155
9-160
9-160
-
9-101
401401
401401
-
-
-
-
-
CAGALHNCBGALHNYVSNB120
CAGALHNCBGALHNYVSNB120
CAGALHNCBGALHNYVSNB120
CX434_A
CBCH-LJN-YY
CBCH-LJN-YY
CBCH-LJN-YY
CBCH-LJN-YY
133603
3C14-12T-65
3C14-12T-65
149177
Qty.
Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
ACCUMULATOR, Joystick
ACCUMULATOR, Brake Charge
ACCUMULATOR, Brake Charge
ACCUMULATOR, Rear axle lock
CYLINDER, Front steer (LH) (Part of axle assembly)
CYLINDER, Front steer (RH) (Part of axle assembly)
CYLINDER, Rear steer (RH) (Part of axle assembly)
CYLINDER, Rear steer (LH) (Part of axle assembly)
CYLINDER, Boom lift
CYLINDER, Boom lift
CYLINDER, Boom extension
CYLINDER, Slave
CYLINDER, Slave
CYLINDER, Carriage Tilt
CYLINDER, Carriage Tilt
CYLINDER, Frame Level (Right)
CYLINDER, Frame Level (Left)
CYLINDER, Rear axle lock
CYLINDER, Left outrigger
CYLINDER, Right outrigger
CYLINDER, Parking Brake (Part of front axle only)
CYLINDER, Carriage shift (Optional)
CYLINDER, Fork shift (Optional fork/side shift carriage)
CYLINDER, Fork shift (Optional fork/side shift carriage)
CYLINDER, Clamp (Optional rotating pipe & pole grappler)
CYLINDER, Clamp (Optional rotating pipe & pole grappler)
CYLINDER, Rotate (Optional rotating pipe & pole grappler)
CYLINDER, Clamp (Optional 2 stage pipe & pole grappler)
CYLINDER, Clamp (Optional 2 stage pipe & pole grappler)
1
1
1
1
1
1
1
1
1
1
TM
Telehandler Series
Model ZB20044
402509
Page 49
Index
No.
Skyjack
Part No.
Qty.
Description
JS1
401473
JS2
401349
MB1
WA10-175-1
OSM1
21-1085-002
P1 thru
78493-RAJ
P2
78493-RAJ
PRV1
RD10A_
0S1B_J11
PRT1
402902
PS1
DNB-150-K
PS2
20-580-038
PS3
20-580-038
PS4
20-580-038
RV1
-
RV2 thru
RV11
-
QD1 thru
QD2
FD45-1040-02
QD3 thru
QD4
FD45-1040-02
QD5 thru
QD10
2071-4-4
STR1
FST212-1SA
STR2
FST212-1SA
SV1
VFC-NC-14
SV2
VFC-NC-14
SV3
VFC-NC-14
1
1
1
1
1
1
JOYSTICK, Rear
JOYSTICK, Front
MANIFOLD, Return
MOTOR, Drive Steering
PUMP, Hydraulic gear (Front)
PUMP, Hydraulic gear (Rear)
1
1
1
1
1
1
1
AR
QUICK DISCONNECT
QUICK DISCONNECT
1
1
1
1
1
1
QUICK DISCONNECT
SUCTION STRAINER
SUCTION STRAINER
VALVE, Shuttle
VALVE, Shuttle
VALVE, Shuttle
TP1 thru
FD45-1002
5
TP6
-02-02
V1 DSG-3C60-01-
D1-2090
1
V2 DFE5_6H18
ES-Y202
1
V3
06-463-100
1
TEST PORT
VALVE, Diverter
VALVE, Charge
TM
Page 50
Telehandler Series
Model ZB20044
402509
AB
Section 3 - System Component Identification and Schematics
Skyjack
Part No.
Qty.
Description
V4
403338
1
V5 DSG-3C4-N01-
D1-2090
1
V6 DFE5_6H18
ES-Y202
1
V7 thru
V10
9S002904A
4
V11 thru
V14
9S000469A
1
TM
Telehandler Series
Model ZB20044
402509
Page 51
NORMALLY
CLOSED
NORMALLY
CONTACT
CLOSED
CONTACT
COIL
CONTROL
(B-)
12 VOLT
RELAY
(SPDT)
SINGLE
POLE
DOUBLE
THROW
GROUND (B-)
NORMALLY
OPEN
CONTACT
NORMALLY
OPEN
CONTACT
COMMON
COIL
CONTROL
(B+)
COIL
CONTROL
(B-)
12 VOLT
RELAY
(DPDT)
DOUBLE
POLE
DOUBLE
THROW
NORMALLY
CLOSED
CONTACT
NORMALLY
CLOSED
CONTACT
NORMALLY
OPEN
CONTACT
TM
Page 52
Telehandler Series
Model ZB20044
402509
CB1
CB3
CB4
CB5
CB6
CB7
CB8
CB9
CB10
CB11
CB15
CB16
CB17
CB18
CB21
CB23
CB220
DXX
F1
F2
F64
F66
F70
F100 thru
F104
F201
F279
F300
H1
K1
K13 , K14
K15
K16
K20
K124
K125
K127
K128
K134
K135
K140 thru
K143
K210 thru
K213
K220
K221
Skyjack
Part No.
30055-6
30055-6
661-10
661-10
661-10
661-20
30055-6
661-20
30055-6
661-10
661-20
661-20
661-20
661-20
661-20
661-30
661-50
102921
ATC5
ATC5
AGC4A
AGC4A
AGC4A
ATC5
Qty.
Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
AR
1
1
1
1
1
1
-
-
0298125
19-1040
0332-019-110
CCP012D
0-1432772-1
0332-019-110
0332-019-110
4210835
4210835
-
-
V.813-12VDC-
SD10-11-16
V.813-12VDC-
SD10-11-16
CCP012D
1
1
1
1
1
2
1
1
1
1
1
1
1
1
FUSE, 5 Amp
FUSE, 30 Amp
FUSE, 125 Amp
HORN, 12 Volt,
RELAY, Transmission disconnect, 10 Amp, 12V,
RELAY, Power module
RELAY, (SPST-NO, 40A, 12 VDC)
RELAY, Enclosed cab power module
RELAY, 12V, Shifter (Neutral Safety)
SOLENOID, Steering A
SOLENOID, Steering B
COIL, Upper, part of parking brake valve V6
COIL, Lower, part of parking brake valve V6
COIL, Right lower
CCP012D
-
LY2
1
1
SOLENOID, Starter
RELAY, DPDT
TM
Telehandler Series
Model ZB20044
402509
Page 53
Skyjack
Part No.
K222
DFE5/6H18ES-
Y202
K267
4210835
K268
4210835
K269
4210835
K270
4210835
K380
-
K381
-
M
892032
M1
85099
M2
457-CE
M3
467-JL
PS1
24-725
PS2
24-725
R208
391D
R223
334J
SW1
956-3126
SW2
19-1040
SW3
58031-01
SW4
58031-02
SW6
58031-03
SW7
58031-08
SW8
58031-08
SW9
58031-01
SW10
58031-01
SW15
660-135
SW18
660-135
SW19
660-135
SW62
193362
SW64
P190130
SW66
P190130
SW68
193876
SW69
1151
SW70
P190130
SW114
DNB-070-
22B-NPT
SW122
DNB-150-
22B-NPT
SW125
DNB-070-
22B-NPT
SW150
32-580-002
SW305
402742
SW360
A1002
Qty.
Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TM
Page 54
Telehandler Series
Model ZB20044
402509
Port 3
To Priority Valve
Port T
Test Port 3
Pressure Reducing
Valve
Port 1
To Port Joystick
Accumulator
Test Port
5
Port T
To Return Manifold
Pressure Relief
Adjustment
Port T
To Pressure Reducing
Valve Port 3
Port T
To Main Valve
(Outrigger-Return Port)
Port P
To Port P on
pump 2
Port CF
To Port P on
Brake Charge Valve
Port LS
To Port LS on
Shuttle Valve at
Port LS
Pump 2
To Port LS on
OSM
Port LS
To Port LS
On Brake Charge
Valve
Shuttle
Valve
Port CF
To Port L
on Steering Motor
Port EF
To Main Valve
Port P
MPRTVS3L
TM
Telehandler Series
Model ZB20044
402509
Page 55
Port A
To Rear Left Outer
Steering Bulkhead
Port B
To Rear Left Inner
Steering Bulkhead
Port P
To Port R on
Orbital Steering Motor
Port T
To Front Left
Steering Bulkhead
MSTRVS3L
TM
Page 56
Telehandler Series
Model ZB20044
402509
Port B
To Port 3
On Front Joystick
Port A
To Port P on Front
Joystick
Port E
To Main Valve
Front Pilot (Lift)
Port T
To Port T on Brake
Charge Valve
Port C
To Main Valve
Tilt Base
Port F
To Main Valve
Rear Pilot (Lift
Port D
To Main Valve
Tilt Rod
MDVRTVS3L
TM
Telehandler Series
Model ZB20044
402509
Page 57
Port A
To Parking Brake
Caliper
Port P
To Port P on
Service Brake Valve
Port B
To Front Axle
Brake Bulkhead
Port T
To Port T on
Brake Charge Valve
Port B
To Pressure Switches
MPRKBRKVS3L
TM
Page 58
Telehandler Series
Model ZB20044
402509
Pressure Switch
Port A1
To Top Brake
Accumulator
Port A2
To Bottom Brake
Accumulator
Port P
To Port CF
on Poriority Valve
Port LS
To Port LS on
Priority Valve
Port T
To Port T on Park
Brake Valve
Port T
To Port T on
Diverter Valve
Port T
To Return Manifold
Port T
To Port T On
Frame Level Valve
M414197
TM
Telehandler Series
Model ZB20044
402509
Page 59
3.11 Frame Level and Axle Lock Valves and Port Identifications
Port B
To Main Valve Base
Port A
To Main Valve Rod
Port CB
To Front Left
Bulkhead
Port CR
To Front Right
Bulkhead
Port T
To Port T on
Brake Charge Valve
Test Port
Port R
To Cylinder Rod
Port A
To Rear Accumulator
Port B
To Cylinder Base
M402445-S3_M402448-S3
TM
Page 60
Telehandler Series
Model ZB20044
402509
Port D2
To Tee fitting at Left
Slave Cylinder Rod End
Port D1
To Tee fitting at
Bulkhead
Port D1
Connected to
Left Slave Cylinder
M402447-S3
TM
Telehandler Series
Model ZB20044
402509
Page 61
Port A
To Rear Axle
Brake Tee
Port P
To Top Brake
Accumulator
Port T
To Return Manifold
Port A
To Front Axle
Brake Tee
Port P
To Bottom Brake
Accumulator
M06-462-364-E-L
TM
Page 62
Telehandler Series
Model ZB20044
402509
Port T
To Return Manifold
Port L
To Front Left
Steering Bulkhead
LS
P R
Port P
To Port CF on
Poriority Valve
Port R
To Port P
on Steering Function
Valve
Port LS
To Port LS on
Priority Valve
M213-1085-E-1
TM
Telehandler Series
Model ZB20044
402509
Page 63
Notes
To Port B on
Frame Level Valve
To Rear Bulkhead
welded to Frame
To Upper Lift
Bulkhead
To Port P on
Pump 1 (mounted
to Transmission)
To Port EF on
Priority Valve
To Aux.
To Lower Lift
Bulkhead
To Rear Bulkhead
welded to Frame
To Port V2 on
Left Outriggers
Lock Valve
To Tee fitting on
Return filter at
Hyd. Oil Tank
W
To Port V2 on
Right Outriggers
Lock Valve
To Rear Bulkhead
welded to Frame
To Rear Bulkhead
welded to Frame
To Port A on
Frame Level Valve
Test Port
Y
To Return Manifold
To Port V1 on
Right Outriggers
Lock Valve
To Aux.
To Port V1 on
Left Outriggers
Lock Valve
MDS16-S3-2
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 65
To Port 4 on
Rear Joystick
To Port 3 on
Rear Joystick
To Port D on
Diverter Valve
To Port T on
Priority Valve
To Port 2 on
Front Joystick
To Port F on
Diverter Valve
To Port T on
Front Joystick
Test Port TP6
Main Relief Valve
To Port P on
Front Joystick
X
To Port 1 on
Rear Joystick
To Joystick
Accumulator
Y
To Port 2 on
Rear Joystick
To Port LS
on Pump 1
To Port C on
Diverter Valve
Test Port TP4
To Port E on
Diverter Valve
To Port 4 on
Front Joystick
MDS16-S3-1_2
SKYJACK, Page 66
Telehandler Series
Model ZB20044
402509
V
Carriage Tilt
Cylinders
C10 & C11
Lock Valve
CB3
Overcenter Valve
CB4
Slave Cylinders
C8 & C9
Boom Extend
Cylinder
C7
Frame Level
Cylinder C13
Lock Valve
CB6
Boom Lift
Cylinders
C5 & C6
Lock Valves
CB1 & CB2
Frame Level
Cylinder C12
Lock Valve
CB5
Right Outrigger
Cylinder
C14
Lock Valve
CB7
Left Outrigger
Cylinder
C15
Lock Valve
CB8
ZB20044T3_Hyd_Cyl_Identification
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 67
Axle Lock
ChargeAccumulator
ACC4
Axle Lock
Control Vavle
Rear Joystick
JS1
Orbital Steering
Motor
OSM1
W
Crossover
Relief
Valve
CRV1
Rear Axle
Lock Cylinder
C14
Battery
Pilot
Pressure
Accumulator
ACC1
Dual Charge
Brake Pedal
V4
Pressure
Steer Function Brake Charge
Reducing Valve
Valve
Valve
PRV1
V1
V3
Front Joystick
JS2
Main Valve
Assembly
Diverter
Valve
V2
Return Line
Filter
F1
Hydraulic
Pump
P1
Hydraulic
Pump
P2
SKYJACK, Page 68
Priority
Valve
PRT1
Suction
Strainer
STR1
Return
Manifold
MB1
Frame Level
Control Manifold
Z
Park Brake
Valve
V5
Brake Charge
Accumulators
ACC2 & ACC3
Telehandler Series
Model ZB20044
402509
WIRE LABEL
ITEM LEGEND
PIN
P2
CNX
WIRE LABEL
ITEM LEGEND
PIN
BR/R
GRA
N/U
PRP
N/U
BLU
PNK
P2
N/U
12
PIN 7
PIN 6
PIN 8
PIN 5
PIN 4
PIN 3
PIN 9
PIN 10
PIN 2
PIN 11
PIN 1
PIN 12
21
ECM
P1
AUX.
POWER
22
23
10
11
12
J40 J16
24
20
9
3
4
13
25
31
8
19
1
5
15
14
WIRE LABEL
CNX
ITEM LEGEND
WIRE LABEL
ITEM LEGEND
PIN
PIN 6
PIN 1
CNX
PIN
WIRE LABEL
ITEM LEGEND
RED
101
16
N/U
WHT
102
17
GRN
GRA
103
18
N/U
GRA
104
19
N/U
GRA
125
20
N/U
N/U
GRA
106
21
N/U
GRA
N/U
22
N/U
16
N/U
23
N/U
27
RED
109
24
N/U
10
GRA
110
25
N/U
11
GRA
2A
26
RED
126
12
GRA
STRT
27
GRA
127
13
N/U
28
YEL
14
N/U
29
CLR
15
N/U
30
N/U
31
N/U
30
18
17
PIN
N/U
BOOM AND
CARRIAGE TILT
JOYSTICK
P2
AXLE LOCK/FRAME
LVL ALTERNATOR
CNX
11 Y/BLU
N/U
10 Y/BLK
29
P1
28
26
P2
P1
CONNECTOR REAR VIEW
SCALE = 2:1
P1
PIN 5
PIN 4
PIN 2
PIN 3
J7
J7
MURPHY
POWERVIEW
RED
YEL
GRN
CLR
PIN 6
PIN 1
PIN 5
PIN 2
CNX
201
PIN 4
206
J4
THROTTLE PEDAL
K1
TRANS. DISCONNECT RELAY
CNX
F2
PIN
WIRE
ITEM
LABEL
LEGEND
RED
T3
RED
201
PIN B
PIN A
CNX
PIN
WIRE
ITEM
LABEL
LEGEND
GRA
2A
GRA
KEY
F1
PIN B
PIN
PIN 3
J4
PIN
WIRE
LABEL
ITEM
LEGEND
GRA
106
GRA
125
WHT
102
GRA
103
RED
101
GRA
104
WIRE ITEM
85
BLAC/RED/WHITE
86
BLUE/BLACK
87
BLACK
30
BLACK
DIAGNOSTIC
PIN A
P5
IGNITION POWER
F2 (5A)
F1 (5A)
P3
A
PIN A
CNX
P3
PIN
WIRE
ITEM
LABEL
LEGEND
RED
23
BLK
M1
HOUR METER
J29
E1
P29
PIN B
E2
P3
G
H
K1
NEUTRAL SAFETY
PIN A
CNX
J9
CNX
J10
PIN
LABEL
WIRE
ITEM LEGEND
BK/W
GRN
GRN
PIN
PIN B
WIRE
ITEM
BK/BL
LBL/BK
LBLU
LBL/R
J9
J9
PIN B
PIN C
86
87
P11
PIN
G/BK
J10
G/W
BLK
J6/P6
PIN A
PIN C
ST
SW2
HORN
P11
IGN
BAT
CNX
J8
PIN
WIRE
ITEM
BLK
PIN
BLU
Y/BLU
N/U
ACC
T3 RED
BLU
BAT
23 RED/RED
BR/R
GRA
LABEL
LEGEND
SW2
CNX
SW4
SW6
BAT
ACC
J6
PARKING
BRAKE
CB4 (10A)
TRANS. SHIFTER
SW1
STEERING
10B
YEL
GRN
CLR
RED
126
GRA
127
SW6
SW4
WIRE ITEM
IGN
YELLOW/GRAY
BLUE/BLACK
GREEN/WHITE
BLACK
ST
GREEN
BLACK
GREEN/YELLOW
BLACK/BLUE
BLACK
GREEN/BLACK
WIRE ITEM
PIN
WIRE LABEL
ITEM LEGEND
YEL
GRN
CLR
SW3
PINK
PIN
PIN
SW3
PIN
BLUE/WHITE
1OA
RED
TRANS.
DISCONNECT
WIRE ITEM
WIRE ITEM
GRA
J6
ACC
SW1
KEY SWITCH
WIRE LABEL
ITEM LEGEND
CAN J1939
P11
P5
PIN
J10
PIN A
PIN B
PIN C
K1
TRANS. DISCONNECT RELAY
STEERING
CNX
30
PIN D
LABEL
LEGEND
CNX
85
30
WIRE
ITEM
86
PIN B
LABEL
LEGEND
87
BLACK
BLUE/YELLOW
85
J8
PIN C
P5
INSTRUMENT
CLUSTER
PIN
WIRE ITEM
M402794AA
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 69
SKYJACK, Page 70
C
P3
A
B
C
D
AUX POWER
GROUND
GROUND
B
J16
AUX POWER A
GROUND
POWER
BUSBAR
CB4
TRANSMISSION
BAT
SHIFTER
NEUTRAL
SAFETY
CB4
TRANSMISSION
ACC
SHIFTER
J9
A
E2
E1
CB10
STEERING ACC
OUTRIGGERS
CB7
SIGNAL LIGHTS ACC
CB3
OUTRIGGERS ACC
J18
B
CB1
DIVERTER VALVE ACC
CB7
SIGNAL LIGHTS ACC
J69
HEATER
POWER
CB6
PARKING BRAKE ACC
E2
CB5
DASH POWER ACC
CB9
AXLE LOCK/
ACC
FRAME LEVELING
CB8
ALTERNATOR ACC
E2
CB5
DASH POWER ACC
E1
E1
12 AWG BLACK
12 AWG BLACK
12 AWG RED
12 AWG RED
10 AWG BLACK
10 AWG RED
10 AWG RED
16 AWG YELLOW
16 AWG GREEN
16 AWG GREEN
16 AWG BLACK
16 AWG BLACK
16 AWG WHITE
16 AWG ORANGE
14 AWG RED
16 AWG TAN
16 AWG BLACK
18 AWG PURPLE
16 AWG BLACK
16 AWG BLACK
10 AWG BLACK
NO COM
NO
COM NO
1
3
NO
NO
3
SW4
NO COM
1
SW7
SW8
U1
X
16 AWG ORANGE
16 AWG ORANGE
16 AWG L BLUE
3
NO
NO
16 AWG L BLUE
16 AWG PINK
NO
NC
COM
COM
SW3
NO
SW2
M1
SW6
NO
COM
COM
NO
NO
12 AWG BLACK
12 AWG BLACK
10 AWG BLACK
SW10
SW9
E1
E1
E1
B
16 AWG WHITE / BLUE
COIL +
K1
85
16 AWG BLACK
16 AWG BLACK /RED / WHITE
IGN
ACC
B+
16 AWG YELLOW
10 AWG RED
10 AWG RED
B+
12 AWG RED
GROUND
GROUND
B+
12 AWG RED
GROUND
ST
P29
16 AWG GREEN
16 AWG GREEN
SW1
STRT
NO
K1
87
STEERING
P11
A
OUTRIGGER
POWER
TURN
SIGNALS
HEATER
POWER
KEY
SW11 COM
COM
PARKING
BRAKE
COIL -
TO
MAIN
HARNESS
INSTRUMENT
CLUSTER
GROUND
16 AWG WHITE
A
J17
A
2
14 AWG RED
P12
B
J40
K1
30
J15
1
16 AWG TAN
16 AWG BLACK
J10
B
K1
86
16 AWG L BLUE / BLACK
8
18 AWG PURPLE
16 AWG PINK
10
9
16 AWG YELLOW / BLACK
16 AWG BLUE
18 AWG GRAY
3
P2
11
J8
1
E2
18 AWG GRAY
16 AWG BLUE
16 AWG L BLUE
16 AWG BLACK
10 AWG BLACK
M401949E-3
Telehandler Series
Model ZB20044
402509
J289 ALTERNATOR
CONNECTOR REAR VIEW
K221-6
PORTION A
K221-4
K220-COIL +
J272
ALTERNATOR -
K221-8
28
PIN B
PIN D
PIN A
PIN C
K221-5
21
CB220-BAT
36
J289
K221-2
J287
STARTER
SOLENOID
CB220-AUX
22
24
ALTERNATOR
E220
21
J223 TRANSMISSION
TEMPERATURE
25
23
J288
J291
STARTER + STARTER +
J278
J278
E220
1
PIN B
22
J271
STARTER 24
PIN A
WIRING DIAGRAM
J293
STARTER -
P247
P247
CONNECTOR REAR VIEW
J3
CONNECTOR REAR VIEW
J223
TRANSMISSION TEMPERATURE
J2
1
BRAKE PRESSURE
16 AWG BLUE 9
HORN
16 AWG PINK 39
FUEL SENDER
16 AWG GRAY 6
PIN B
TRANSMISSION TEMPERATURE
J278
B BRAKE PRESSURE
A
HORN
C FUEL SENDER
J289
A
PORTION A
B
ALTERNATOR EXCITER
J3
PIN A
11
10
P247
SWITCH POWER A
CB POWER
K220-NO-1
AXLE/FRAME SOLENOIDS
16 AWG GREEN
16 AWG YELLOW
GROUND
CB220-AUX
23
PORTION B
+12 VDC
D
J3
16 AWG RED
10 AWG BLACK
10 AWG RED 23
J288
STARTER +
J2
PIN 11
PIN 2
PIN 10
PIN 3
PIN 9
PIN 4
PIN 8
PIN 5
PIN 7
PIN 6
SOLENOID ENABLE
16 AWG GREEN 36
J287
K221-1
PORTION C
16 AWG GREEN 21
STARTER ENABLE
J293
STARTER -
K221-7
10 AWG BLACK
J272
36
PIN 1
10 AWG RED 22
P102
ALTERNATOR EXCITER
D
AXLE LOCK LIGHT
J2
18 AWG PURPLE 25
E220
K220 CHASSIS
P102
10 AWG BLACK
ALTERNATOR J290
ALTERNATOR +
K220-CHASSIS
GROUND
E220
GROUND
CB220
12 VDC AUX
8 AWG BLACK 24
PORTION C
16 AWG BLACK
PORTION B
10 AWG RED 23
K221
5
K221
6
K221
2
K221
4
COMMON
COMMON
NORMALLY CLOSED
RELAY N.O.
K221
8 RELAY COIL +
E220
GROUND
CB220
AUX +12 VDC
CB220
BAT +12 VDC
K220
COIL +
K220
NORMALLY OPEN
E220
GROUND
J271
STARTER J291
STARTER +
K221
1 NORMALLY CLOSED
K221
7 COIL K220
NORMALLY OPEN
M401712AC
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 71
J298
PIN B
E204
ECM/BLOCK
GROUND
J297 DIAGNOSTIC
CONNECTOR REAR VIEW
WIRING DIAGRAM V
J296
ECM POWER
PIN A
PIN B
PIN A
12 VDC
SPL279
16 AWG RED
12 VDC
16 AWG RED
J279
FUSE
A
16 AWG RED
F279
30 A
PIN C
16 AWG RED
P297
SPL297
J204
BATTERY
B+
B
12 AWG RED
J1
BULKHEAD
J297
16 AWG GRAY
GROUND
16 AWG GRAY
14 AWG GRAY
SPL296
16 AWG RED
12 VDC
16 AWG GRAY
10
GROUND
16 AWG GREEN
12
12 VDC
18 AWG GRAY
11
18 AWG GRAY
SWITCH RETURN
E204
ECM / BLOCK GROUND
GROUND
12 AWG GRAY
J102
STARTER SOLENOID
12 VDC
16 AWG GREEN
SKYJACK
401344
40
SPL204
J1
TO CAB
HARNESS
J295
GROUND
F102
32V 30 A
J295 ENGINE
CONTROL
C139
KEY SWITCH SIGNAL 39
J279
SWITCH RETURN 34
F279
31
30
J279 FUSE
18
KEY LOCATION
FAR SIDE
17
28
11 12 13 14 15
16 17 18 19 20
21 22 23 24 25
26 27 28 29 30
31 32 33 34 35
36 37 38 39 40
41 42 43 44 45
15
22
14
SIGNAL
RETURN
23
SUPPLY
22
11
23
26
10
10
16
ACCELERATOR
POSITION
21
3
1
6
27
2
7
29
PIN A
19
20
8
12
13
24
ON IDLE SWITCH
11
C134
C109
C123
16 AWG WHITE
SIGNAL
18 AWG BLACK
RETURN
18 AWG RED
SUPPLY
18 AWG GRAY
ON IDLE SWITCH
18 AWG GRAY
18 AWG GREEN
17
SAE J1939 -
18 AWG CLEAR
29
18 AWG YELLOW
28
SAE J1939 +
C122
C111
C101
F102
SAE J1939 - 47
PIN B
J1
CONNECTOR REAR VIEW
SCALE = 2:1
SAE J1939 + 46
C147
C137
C146
SPL295B
18 AWG GREEN
SPL295A
18 AWG YELLOW
18 AWG YELLOW
J102
STARTER
SOLENOID
C140
SPL295C
18 AWG CLEAR
18 AWG RED
SAE J1939
J297 P297
1
1
18 AWG CLEAR
18 AWG GREEN
R297
120
J299
GRID HEATER
A
INTAKE AIR HEATER OUTPUT
PIN 4
INTAKE AIR HEATER RETURN 42
PIN 2
ACCELERATOR
POSITION
25
46 47 48 49 50
PIN 3
C142
18 AWG GRAY
PIN B
PIN 1
J296
J204 BATTERY +
J299
C128
C132
18 AWG GRAY
18 AWG GRAY
J298
COOLANT LEVEL
A
COOLANT LEVEL INPUT
B
SKYJACK, Page 72
Telehandler Series
Model ZB20044
402509
J124
V
PIN A
PIN B
PIN B
SKYJACK
J266
PIN C
PIN A
PIN D
J20
J273
J20
CONNECTOR REAR VIEW
BACKUP
ALARM
RE
VE
RS
SO
LE
NO
ID
D266
WIRING DIAGRAM
SPL270
J263
1ST
SOLENOID
J265
12 VDC
FORWARD SOLENOID
GROUND E264
(TRANSMISSION
HOUSING)
PIN A
OID
EN
OL
S
2ND
16 AWG BROWN
+12 VDC
16 AWG BLACK
GROUND
J264
2ND
SOLENOID
SPL273
12 VDC
D
OI
16 AWG BLACK
+12 VDC
16 AWG BLACK
GROUND
OL
EN
J264
16 AWG BLACK
GROUND E264
(TRANSMISSION
HOUSING)
J265
FORWARD
SOLENOID
1S
TS
PIN B
16 AWG BROWN
12 VDC
16 AWG RED
16 AWG RED
+12 VDC
16 AWG BLACK
GROUND
PIN A
J266
REVERSE
SOLENOID
SPL273
12 VDC
J263
16 AWG WHITE
16 AWG WHITE
SPL270
16 AWG BLACK
E264
16 AWG BLACK
+12 VDC
GROUND
D266
J124
16 AWG BLACK
PIN A
E264
TO BRAKE PRESSURE SW
J42
16 AWG BLACK / GRAY
TO BACKUP ALARM +
M402391B
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 73
J140 RED
B/OR
PIN A
PIN B
PIN 2
J140 RED
B/
PIN C
OR
J247
J245
PIN D
J142 RED
A/OR
PIN 1
1
3
A/O
R
PIN A
PIN 2
PIN B
J142 RED
P246
NT
FRO
SPL143
PIN C
PIN D
P246
SPL147
E140
SPL140
SPL142
SKY
JACK
SPL148
SPL146 BLACK
L146
SP
B/T
PIN 1
SPL1
44
L1
SP
45
SPL144 WHITE
3
2
J141 WHITE
B/T
PIN 2
WIRING DIAGRAM
SPL145 RED
J141 WHITE
T
A/
B/T
WHITE
GROUND
J141
2
14 AWG BLACK
CABLE
12 VDC
E140
SPL140
18 AWG BLACK
18 AWG WHITE
SPL143
18 AWG WHITE
PIN 1
1
3
J143 WHITE
A/T
A/T
WHITE
J143
12 VDC 1
18 AWG WHITE
CABLE
GROUND
J143 WHITE
B / OR
RED
A / OR
RED
J140
GROUND 2
CABLE
1
12 VDC
J142
1
18 AWG WHITE
18 AWG BLACK
SPL144
SPL145
18 AWG BLACK
SPL146
TO
SW114
BRAKE
PRESSURE
SWITCH
J247
SPL147
18 AWG BLACK
12 VDC
18 AWG WHITE
18 AWG GREEN
(RED SLEEVE)
CABLE
18 AWG BLACK
SPL148
PIN 2
GROUND
18 AWG WHITE
SPL142
18 AWG GREEN
18 AWG RED
18 AWG BLACK
18 AWG GREEN
18 AWG YELLOW
18 AWG YELLOW
P246
B
18 AWG GREEN
18 AWG WHITE
18 AWG RED
TO
401395
MAIN
HARNESS
CABLE
GROUND
CABLE
TO
402160
AXLE LOCK
HARNESS
M401396-S3
SKYJACK, Page 74
Telehandler Series
Model ZB20044
402509
PIN 2
J212 WHITE
B2-OR
J215
PIN 1
B2
J212 WHITE
CONNECTOR MATING FACE
-O
R
P216
J215
E210
PIN 2
1
P2
3
1
J210 BLUE
R1
R1
PIN 1
J210 BLUE
PIN B
REAR
PIN C
SKYJACK
PIN D
SPL210
X
PIN 2
B1
J211 BLUE
B1
SPL212
PIN 1
J211 BLUE
CONNECTOR MATING FACE
R2
WIRING DIAGRAM
R
-O
J215
12 VDC
PIN 2
18 AWG BLACK
18 AWG BLACK
J246
B
18 AWG RED
18 AWG RED
P216
SWITCH OUTPUT
J213 WHITE
r2-OR
J210 BLUE
12 VDC
18 AWG WHITE
GROUND
18 AWG BLACK
PIN 1
J213 WHITE
CONNECTOR MATING FACE
CABLE
CABLE
J211 BLUE
12 VDC
18 AWG WHITE
18 AWG GREEN
CABLE
GROUND
18 AWG BLACK
18 AWG WHITE
GROUND
J212 WHITE
12 VDC
18 AWG GREEN
E210
SPL210
SPL212
18 AWG WHITE
18 AWG WHITE
CABLE
GROUND
18 AWG BLACK
J213 WHITE
12 VDC
18 AWG WHITE
GROUND
18 AWG BLACK
CABLE
E210
GROUND
M402160-S3
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 75
P41
J222
CARELIFT
W
PIN 1
1
3
PIN 3
2
PIN 2
J222
CONNECTOR MATING FACE
E222
Y
WIRING DIAGRAM
18 AWG BLACK
18 AWG BLACK
CABLE
P41
J222
18 AWG WHITE
18 AWG WHITE
18 AWG BLACK
18 AWG BLACK
E222
3
M402746D
SKYJACK, Page 76
Telehandler Series
Model ZB20044
402509
J127
CONNECTOR MATING FACE
PIN 2
P123
PIN 1
A
J127
P10
C
D
SKYJACK
SPL128
SPL127
UPPER
PARK BRAKE
SOLENOID
SPL120
PIN 2
2
PIN A
PIN B
PIN C
PIN D
P10
CONNECTOR REAR VIEW
PIN 1
J128
J128
LOWER
PARK BRAKE
SOLENOID
WIRING DIAGRAM
P10
P123
18 AWG BLACK
J127
PARK BRAKE
SOLENOID b
SPL127
B
BRAKE
PRESSURE SWITCH
TRANSMISSION
DISCONNECT
UPPER PARKING
BRAKE SOLENOID
1K
SPL120
D
18 AWG WHITE
CABLE
CABLE
J128
PARK BRAKE
SOLENOID a
18 AWG WHITE
LOWER PARKING
BRAKE SOLENOID
PARKING BRAKE
LIGHT
1K
SPL128
C
18 AWG BLACK
M401336D
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 77
V
K
AC
L
/B
EE
16
PIN A
PIN B
J11
G
AW
GR
SKYJACK
K124 SOLENOID A
W
PIN C
16
J11
CONNECTOR REAR VIEW
AW
G
BL
AC
X
GROUND
WIRING DIAGRAM
STEERING SOLENOID
J11
ROUND
K125 SOLENOID B
CRAB
K124 SOLENOID A
GROUND
16 AWG BLACK
GROUND
M401949E-3
SKYJACK, Page 78
Telehandler Series
Model ZB20044
402509
J120
PIN 1
1
3
J122
PIN 3
2
PIN 2
J122
CONNECTOR MATING FACE
PIN A
PIN B
P278
J208
SKYJACK
PIN C
P278
CONNECTOR REAR VIEW
WIRING DIAGRAM
J120
16 AWG PINK
16 AWG PINK
P278
A
J122
1
16 AWG BLUE
16 AWG BLUE
16 AWG BLACK
HORN +
COM
NC
GROUND
N0
FUEL SENDER
3
J208
16 AWG GRAY
16 AWG GRAY
C
M402392A
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 79
Y
PIN A
WIRING DIAGRAM
PIN B
J50
SKYJACK
J50
A
22 AWG GRAY
COMMON POWER
22 AWG BLACK
RIGHT POWER
NO
PIN C
JOYSTICK
J50
CONNECTOR REAR VIEW
SW75
C
22 AWG BROWN
LEFT POWER
COM
NO
M402187D
SKYJACK, Page 80
Telehandler Series
Model ZB20044
402509
ND
WIRING DIAGRAM X
WPS-4
MALE
WEATHER
PACK
PIN A
PIN B
PIN C
P20
P20
A
22 AWG BLUE
22 AWG BLACK
22 AWG YELLOW
22 AWG PINK
P9
A
22 AWG RED
DANA
SHIFTER
PIN D
C
D
P20
CONNECTOR REAR VIEW
P9
K2
PIN C
P9
85
16 AWG BLACK
86
SKYJACK
PIN A
PIN B
22 AWG GRAY
E1
E1
WPS-3
FEMALE
WEATHER
PACK
B
16 AWG GREEN
16 AWG GREEN
30
16 AWG GREEN
16 AWG GREEN
87
COIL -
K2
COIL +
COM
NO
M402170B
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 81
SW11
PUSH BUTTON
SWITCH SW11
UNDER RUBBER COVER
J41
GRAY WIRE
WIRING DIAGRAM
SKYJACK
22 AWG BROWN
P40
P40
BLACK WIRE
BROWN WIRE
CUT OFF
FLUSH WITH
CABLE JACKET
22 AWG BLACK
SW11
JOYSTICK
J41
22 AWG GRAY
M402620D
SKYJACK, Page 82
Telehandler Series
Model ZB20044
402509
J51
PIN A
PIN B
P14
PIN C
16 AWG
CK
WG
6A
PIN D
HITE
BLA
K/W
E / BLAC
ORANG
16 AWG WHITE
J51
16 AWG
PIN A
PIN B
PIN C
12 AWG RED
BUSSBAR 2
RED
K16-87
BRO
WN
18
P50
AW
G
WIRING DIAGRAM
BL
AC
18
K14-85
BUSSBAR 1
AW
K13-30
12 AWG RED
K15
87
12 AWG RED
K16
87
GR
AY
BUSSBAR 2
16 AWG RE
K13-85
K16-85
16 AWG RED
14 AWG RED
K15-85
K14-30
K13
30
K14
COMMON POWER 30
CB-11
COMMON POWER AUX
K13
RIGHT POWER 85
K14
LEFT POWER 85
K13
SWITCHED RIGHT POWER 87
K14
SWITCHED LEFT POWER 87
P14
GROUND
COMMON POWER
CB11-ACC
14 AW
G RE
CB16 H
EATER
+
14 AWG
CB17 WIPER +
RED
PIN 1
PIN 8
PIN 2
PIN 7
14 AWG WHITE
CB17-ACC
P15
/ WHITE
SW15 LIGHTS +
CK
16 AWG
SW15-2
ORANGE
/ RED
WG
14 A
BLA
PIN 3
PIN 6
PIN 4
PIN 5
16 AWG RED
16 AWG RED
18 AWG GRAY
P15
P50
A
18 AWG BLACK
18 AWG BROWN
16 AWG RED
C
J51
A
16 AWG WHITE
16 AWG BLACK
WER
GHT PO
CB15 LI
16 AWG ORAN
GE / BLACK
K16
85
K15
COIL + 85
SW15
LIGHT SWITCH 2
CB15
LIGHT POWER AUX
COIL +
/ WHITE
CB15-ACC
P13
SW15-1
SW15
LIGHT SWITCH 1
CB17
WIPER POWER AUX
CB16
HEATER POWER AUX
P13
GROUND
K15-86
J14
14 A
WG
BLA
K16-86
16
14 AWG
AC
CK
G
AW
BL
J13
14 AWG RED
14 AWG RED
16 AWG ORANGE / BLACK / WHITE
P15
1
KEY
LIGHT POWER
14 AWG WHITE
WIPER POWER
14 AWG RED
HEATER POWER
14 AWG BLACK
GROUND
BLACK
SPL15
C
G BLA
14 AW
PIN A
2 X 12 AWG BLACK
K13-86
K13-87
18 A
WG
P50
CB16-ACC
K15-87
K14-87
12 AWG RED
BUSBAR 1
SKYJACK
402405
ACK
16 AWG BL
PIN B
P16
PIN C
PIN D
WG
16 A
CK
BLA
12 AWG
RED
K15-30
D
G RE
12 AW
K14-86
K16-30
P16
CONNECTOR REAR VIEW
K16
HEATER & WIPER POWER 30
K15
LIGHT & DIVERTER POWER 30
J13
P15 GROUND
J14
J51 GROUND
K15
COIL - 86
K16
COIL - 86
K13
COIL - 86
K14
COIL - 86
12 AWG RED
P16
A
12 AWG RED
14 AWG BLACK
12 AWG BLACK
16 AWG BLACK
12 AWG BLACK
14 AWG BLACK
SPL15
14 AWG BLACK
16 AWG BLACK
16 AWG BLACK
M402405C
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 83
J51
PIN B
SW18-2
P14
SW19-1
PIN C
CK
PIN D
WG
16 A
J51
BLA
16 AWG
K / WHIT
E / BLAC
ORANG
SW18
GHTS
BOOM LI
TE
ACK / WHI
ANGE / BL
16 AWG OR
CB18-ACC
SW18-1
K14-87
16 AWG WHITE
16 AWG
18 AW
12 AWG RED
BUSBAR
RED
K13-87
K15-87
12 AWG RED
CB18-BAT
K18-87
G BR
PIN A
PIN B
PIN C
18 A
WG
P50
OWN
WIRING DIAGRAM
K14-85
BLA
CK
CB18
AUX
K13-85
P50
18
AW
K13-30
12 AWG RED
K15
87
12 AWG RED
K16
87
RA
Y
16 A
WG
SW18
1
SW19
1
BUSSBAR
RED
CB18
BAT
K14-30
K13
30
K14
COMMON POWER 30
CB-11
COMMON POWER AUX
K13
RIGHT POWER 85
K14
LEFT POWER 85
K13
SWITCHED RIGHT POWER 87
K14
SWITCHED LEFT POWER 87
P14
GROUND
SW18
BOOM LIGHT POWER 2
CB11-AUX
16 AWG RED
K15-85
COMMON POWER
K16-85
14 AWG RED
SW19-2
14 AW
SW19 AU
G RE
X LIGHT
16 AWG
SW15-2
SW15 LIGHTS +
ORANG
E / BLAC
K / WHIT
16 AWG ORANGE /
CB15-AUX
ANGE
G
14 AW
/ BLA
PIN 2
PIN 7
PIN 3
PIN 6
PIN 4
PIN 5
K
BLAC
K16
85
K15
COIL + 85
SW15
LIGHT SWITCH 2
CB15
LIGHT POWER AUX
COIL +
P15
CK / W
HITE
SW15-1
16 AWG RED
18AWG GRAY
18 AWG BLACK
18 AWG BROWN
16 AWG RED
C
J51
A
16 AWG WHITE
16 AWG BLACK
16 AWG
ORANGE / BLACK / WHITE
SW15
LIGHT SWITCH 1
P13
CK
WG
14 A
BLACK
14 AWG RED
16 AWG
ORANGE / BLACK / WHITE
ACK
J14
PIN A
SKYJACK
402407
ACK
16 AWG BL
K15-30
K14-86
WG
16 A
CK
PIN B
P16
PIN C
PIN D
12 AWG RE
BLA
P16
CONNECTOR REAR VIEW
K16-30
WG
12 A
RED
KEY
LIGHT POWER
N/C
N/C
16 AWG
ORANGE / BLACK / WHITE
14 AWG BLACK
GROUND
N/C
16 AWG
ORANGE / RED
16 AWG
ORANGE / BLACK / WHITE
BL
16 AWG BL
SPL15
SW19
2
P13
P15
1
4
ACK
2 X 12 AWG BLACK
K13-86
14 AWG RED
GROUND
J13
BLA
K16-86
14 AWG
TO JOYSTICK
TO BOOM CABLE
K15-86
14 A
WG
P50
A
P15
G OR
PIN 8
BLACK / WHITE
16 AW
PIN 1
16 AWG RED
K16
BOOM & AUX LIGHT POWER 30
K15
LIGHT POWER 30
J13
P15 GROUND
J14
J51 GROUND
K15
COIL - 86
K16
COIL - 86
K13
COIL - 86
K14
COIL - 86
12 AWG RED
P16
A
12 AWG RED
14 AWG BLACK
12 AWG BLACK
16 AWG BLACK
12 AWG BLACK
14 AWG BLACK
SPL15
14 AWG BLACK
16 AWG BLACK
16 AWG BLACK
M402407C
SKYJACK, Page 84
Telehandler Series
Model ZB20044
402509
J148
LEFT
TURN
SIGNAL
ORAN
J311
J313
LEFT OUTER
TAIL LIGHT
LEFT INNER
TAIL LIGHT
J312
PIN 1 (RED)
PIN 2 (BLACK)
PIN 3 (WHITE)
J312
ER
OUT
INNE
R
J313
CONNECTOR MATING FACE
LEFT
LEFT
J311
CONNECTOR MATING FACE
RIGH
PIN 1 (RED)
PIN 2 (BLACK)
PIN 3 (WHITE)
PIN 2 (BLACK)
PIN 3 (WHITE)
ER
T INN
SPL312
GE / B
LACK
RIGHT
INNER
TAIL
LIGHT
PIN 1 (RED)
SPL316
RIGH
J310
T OU
TER
RIGHT
OUTER
TAIL
LIGHT
PIN 1 (RED)
PIN 2 (BLACK)
PIN 3 (WHITE)
SPL315
SPL313
J310
CONNECTOR MATING FACE
SPL310
SPL148
SPL311
E311
SPL314
LUE
GE / B
ORAN
J154
RIGHT
TURN
SIGNAL
SPL317
WIRING DIAGRAM
ORANGE / BLACK / WHITE
J148
RIGHT
HEADLIGHT
SPL312
SPL312
BRAKE
SWITCH
BRAKE
SWITCH
P151
BRAKE SWITCH B
P151
B
P150
A
SPL318
16 AWG
ORANGE / RED
16 AWG
ORANGE / RED
SPL317
16 AWG
ORANGE / RED
J313
LEFT
1
BRAKE LIGHT
18 AWG
BLACK
LEFT INNER
TAIL LIGHT
18 AWG
WHITE
GROUND
SPL22
OR
BRAKE
LIGHT
POWER
GE
AN
SPL21
ED
/R
P150
BRAKE SWITCH A
OR
LIGHT
POWER
J15
5
J15
4
AN
GE
E311
18 AWG
WHITE
16 AWG
ORANGE /
BLACK / WHITE
SPL315
18 AWG
WHITE
/R
ED
E
AK CH
BR IT
SW
16 AWG
ORANGE /
BLACK / WHITE
SPL20
LEFT FRONT
TURN SIGNAL
LEFT
HEADLIGHT
J155
J149
LIGHT
POWER
SPL21
16 AWG
ORANGE / BLACK
16 AWG
ORANGE / BLACK
18 AWG
BLACK
LEFT OUTER
TAIL LIGHT
SPL313
18 AWG
RED
LEFT REAR
TURN SIGNAL
16 AWG
ORANGE / BLACK
16 AWG
ORANGE /
BLACK / WHITE
16 AWG
ORANGE / BLUE
J311
GROUND
3
SPL311
ORANGE / RED
J12
B
LEFT TURN
SIGNAL POWER
RIGHT TURN
SIGNAL POWER
INSERT
INTO
LIGHT
POWER
J15
SKYJACK
RIGHT
HEADLIGHT
BRAKE
LIGHT
POWER
18 AWG
RED
ORANGE / WHITE
/ BLACK
RIGHT FRONT
TURN SIGNAL
J148
J154
16 AWG
ORANGE /
BLACK / WHITE
16 AWG
ORANGE / BLUE
SPL148
16 AWG
ORANGE /
BLACK / WHITE
SPL22
16 AWG
ORANGE /
BLACK / WHITE
16 AWG
ORANGE / BLUE
SPL310
16 AWG
ORANGE /
BLACK / WHITE
SPL319
SPL20
16 AWG
ORANGE / BLUE
SI TU
G R
N N
AL
S
16 AWG
WHITE
J310
RIGHT OUTER
2
TAIL LIGHT
SPL312
18 AWG
RED
RIGHT REAR
TURN SIGNAL
SPL314
18 AWG
WHITE
GROUND
PIN A
18 AWG
WHITE
PIN B
J12
J12
18 AWG
BLACK
J312
3
GROUND
18 AWG
BLACK
RIGHT INNER
TAIL LIGHT
18 AWG
RED
RIGHT REAR
BRAKE LIGHT
SPL318
M402364C
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 85
J66
FRO
NT W
IPER
J68
XF66
FAN B+
F66
18 A
WG
WHIT
J67
ITE
H
GW
18 AWG BLACK
SPL66
J15
18 AWG WHITE
DOM
B+
W
18 A
SPL65
J62
FAN
BEACON +
SKYJAC
E LIG
HT +
18 AWG
J60
18
SPL62
J61
18 A
WG
AW
G
WHITE
BLA
CK
J15
SPL67
WHIT
LACK
ND
GB
18 AW
NG
O
AC
CK
BE
WG
8A
J63
TE
HI
CK
A
BL
G
AW
18
ND
HT G
E LIG
DOM
18
BLA
AW
ER
J65
P
TO
WIP
GN
4
F6
F6
WIRING DIAGRAM
18 AWG BLACK
J63
18 AWG BLACK
IP
P
TO
J64
J65
SPL67
J15
8
GROUND
18 AWG BLACK
J67
18 AWG BLACK
18 AWG BLACK
DOME LIGHT
GROUND
TOP WIPER
GROUND
FRONT WIPER
GROUND
SPL65
12 VDC
J15
3
18 AWG WHITE
J68
FAN 12 VDC
SPL66
18 AWG WHITE
18 AWG WHITE
J66
FRONT WIPER
12 VDC
J64
TOP WIPER
12 VDC
18 AWG WHITE
F66
4A
SPL62
18 AWG WHITE
18 AWG WHITE
F64
4A
18 AWG WHITE
J62
DOME LIGHT
12 VDC
18 AWG WHITE
M400424D
SKYJACK, Page 86
Telehandler Series
Model ZB20044
402509
SPL255
18
SPL256
AW
D
RE
18 A
WG
WH
ITE
PIN A
P51
SKYJACK
PIN B
G RE
PIN C
BR
18 AW
P51
AW
SPL256
18
SPL257
WIRING DIAGRAM
RIGHT POWER
16 AWG RED
P51
A
16 AWG WHITE
LEFT POWER
16 AWG BLACK
GROUND
16 AWG BROWN
BOOM LIGHT +
RIGHT POWER
SPL255
3-WAY DIVERTER
VALVE
LEFT POWER
SPL256
GROUND
POWER
MODULE
SPL257
BOOM LIGHT +
SPL258
CABLE TO BOOM
402188
M402188C
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 87
J134
E137
PIN 2
PIN 1
PIN D
D
PIN B
PIN C
P18
PIN 2
PIN A
LEF
LOW T
ER
SPL133
J135
SPL135
SPL134
WIRING DIAGRAM
P18
CARELIFT
J136
SPL137
PIN 1
+12 VDC
SPL136
16 AWG WHITE
16 AWG BLACK
SPL136
J136
1
+12 VDC
2
GND
CABLE
T
RIGH E
RAIS
1
3
+12 VDC
SPL134
16 AWG WHITE
J134
1
+12 VDC
2
L
R EF
AI T
SE
16 AWG BLACK
PIN 2
SPL137
16 AWG WHITE
16 AWG BLACK
PIN 1
J137
1
+12 VDC
2
GND
CABLE
1
J137
+12 VDC
GROUND
D
E137
SPL135
14 AWG BLACK
16 AWG WHITE
16 AWG BLACK
SPL133
PIN 2
GND
CABLE
+12 VDC
J135
1
+12 VDC
2
GND
CABLE
M402390D
SKYJACK, Page 88
Telehandler Series
Model ZB20044
402509
PRIMARY
B SOL.
PIN 2
PIN 1
PRIMARY
A SOL.
PIN 2
PIN 1
TRANS DISC.
PSW.
16 AWG ORANGE
P26
16 AWG ORANGE/BLACK
PIN 1
SPL1
SECONDARY
B SOL.
D
16 AWG LT BLUE/RED
PIN 2
16 AWG LT BLUE
PIN 1
P10
16 AWG LT BLUE/BLACK
16 AWG LT BLACK
SECONDARY
A SOL.
PIN 2
WIRING DIAGRAM
PRIMARY
B SOL.
16 AWG LT BLUE/RED
16 AWG ORANGE
16 AWG LT BLUE
PRIMARY
A SOL.
16 AWG LT BLUE/RED
SECONDARY
A SOL.
16 AWG LT BLUE/BLACK
16 AWG LT BLUE/RED
P26
16 AWG ORANGE
16 AWG ORANGE/BLACK
PANEL
CONNECTOR
P10
SECONDARY
B SOL.
1
2
16 AWG LT BLUE/RED
16 AWG ORANGE/BLACK
16 AWG LT BLUE/RED
S1
16 AWG LT BLUE/BLACK
TRANS DISC.
PSW.
16 AWG BLACK
16 AWG BLACK
16 AWG LT BLUE
PANEL
CONNECTOR
M156735 - SERVICE
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 89
PIN 1
PIN 3
SW128
PRESS. SW.
16 AWG ORANGE/GREEN
PIN 2
PIN 1
16 AWG ORANGE/BLACK/WHITE
P25
16 AWG ORANGE/BLUE
PIN 3
16 AWG ORANGE/RED
SW127
PRESS. SW.
A
PIN 2
1
SW128
PRESS. SW.
2
3
1
SW127
PRESS. SW.
2
3
16 AWG BLACK
16 AWG BLACK
WIRING DIAGRAM
16 AWG BLACK
16 AWG ORANGE/BLUE
16 AWG ORANGE/RED
16 AWG BLACK
P25
16 AWG ORANGE/GREEN
16 AWG ORANGE/GREEN
16 AWG ORANGE/BLACK/WHITE
16 AWG ORANGE/BLACK/WHITE
16 AWG ORANGE/BLUE
16 AWG ORANGE/BLUE
A
A
A
PANEL
CONNECTOR
M156736 - SERVICE
SKYJACK, Page 90
Telehandler Series
Model ZB20044
402509
PIN 1
K126
SOL.
PIN 2
PIN 1
PIN 3
16 AWG PINK/PURPLE
K126
PRESS. SW.
16 AWG GREEN/YELLOW
P27
PIN 2
16 AWG BLACK
WIRING DIAGRAM
K126
SOL.
2
1
3
SW126
PRESS. SW.
16 AWG BLACK
16 AWG PURPLE/PINK
16 AWG PURPLE/PINK
16 AWG PINK/PURPLE
P27
16 AWG PINK/PURPLE
2
16 AWG GREEN/YELLOW
1
16 AWG GREEN/YELLOW
Z
PANEL
CONNECTOR
M156737 - SERVICE
Telehandler Series
Model ZB20044
402509
SKYJACK, Page 91
CB6
C6
BOOM LIFT
CLYLINDER
C5
BOOM LIFT
CLYLINDER
C7
BOOM EXTEND
CYLINDER
C11
CARRIAGE
TILT
CYLINDER
C10
CARRIAGE
TILT
CYLINDER
C9
SLAVE
CYLINDER
C8
SLAVE
CYLINDER
V1
R
V2
CB4
V1
C1
D2
D1
V2
V7
C2
V11
C2
V2
V13
ACC4
175psi
CR
QD3
V8
A
C1
QD4
CRV1
CB2
C2
C13
LEFT
FRAME LEVEL
CYLINDER
CB5
CB
V1
CB1
AXLE LOCK
CONTROL VALVE
C2
FRAME LEVEL
CONTROL VALVE
CR
CB3
C1
AXLE LOCK
CHARGE
ACCUMULATOR
CB
C2
V2
V10
V9
TP2
TP1
V1
C1
V1
C12
RIGHT
FRAME LEVEL
CYLINDER
T
D2
D1
C1
C2
V14
V12
V2
V2
C1
V1
QD1
TP7
C14
REAR AXLE LOCK
CYLINDER
QD2
TP8
A6
TP6
FUNCTION
BOOM UP/CARRIAGE TILT BACK
BOOM RETRACT
BOOM DOWN/CARRIAGE TILT FORW.
BOOM EXTEND
E
C
F
D
VA
B7
CB7
VA
VA
VA
RV2
1500psi
A3
RV3
3100psi
B3
VA
RV4
1500psi
A4
RV5
1500psi
B4
VA
RV6
2000psi
A5
RV7
2000psi
B5
VA
RV8
2500psi
VB
RV9
2500psi
VA
RV10
2500psi
VB
V6
DIVERTER
VALVE
RV11
2500psi
V1
QD9
E
F
C
D
QD10
G
H
C1
C15
LEFT
OUTRIGGER
CYLINDER
V2
C2
V2
DIVERTER
VALVE
FUNCTION
OPT. HYD.
FRAME LEVEL LEFT
OPT. HYD.
FRAME LEVEL RIGHT
VA
A7
B2
MAIN
VALVE
ASSEMBLY
PORT
1
2
3
4
A2
B1
A1
B6
QD5 QD6
QD7 QD8
SEE OPTIONAL
HYDRAULICS
LS
CB8
4
V1
BOOM
LIFT
C1
FRONT (LH)
STEER
CYLINDER
C3
REAR (RH)
STEER
CYLINDER
C2
FRONT (RH)
STEER
CYLINDER
VB
VB
CARRIAGE
TILT
BOOM
EXTEND
BOOM
EXTEND
BOOM
LIFT
VB
VB
VB
VB
OUTRIGGER
LEFT
OPT
FRAME
LEVEL
HYD
OUTRIGGER
RIGHT
C1
VB
C4
REAR (LH)
STEER
CYLINDER
C16
RIGHT
OUTRIGGER
CYLINDER
V2
C2
R
OSM1
ORBITAL
STEERING
MOTOR
V1
STEER
FUNCTION
VALVE
C17
PARKING BRAKE
(FRONT AXLE ONLY)
ELECTRICAL
CONNECTION TO FRAME
LEVEL DISCONNECT
LS
PS2
TO "C" PORT ON
DIVERTER VALVE
ACC1
325psi
TO "D" PORT ON
DIVERTER VALVE
PS3
TO "E" PORT ON
DIVERTER VALVE
TO "F" PORT ON
DIVERTER VALVE
TO "G" PORT ON
DIVERTER VALVE
TO "H" PORT ON
DIVERTER VALVE
TO "C" PORT ON
DIVERTER VALVE
TO "G" PORT ON
DIVERTER VALVE
TO "D" PORT ON
DIVERTER VALVE
TO "H" PORT ON
DIVERTER VALVE
TO "C" PORT ON
DIVERTER VALVE
TO "D" PORT ON
DIVERTER VALVE
SV3
ELECTRICAL CONNECTION
TO TRANSMISSION
DISCONNECT
CV1
CV2
TP3
TP4
PRV1
PRESSURE
REDUCING
VALVE
325psi
EF
PRT1
PRIORITY
VALVE
3
2
CF
SV2
LS
BRAKE
CHARGE
ACCUMULATORS
RV1
2800psi
ACC2
650psi
V5
PARK BRAKE
VALVE
X
C18
CARRIAGE SHIFT
CYLINDER
ACC3
650psi
SV1
LS
A1
C20
FORK SHIFT
CYLINDER
C21
CLAMP
CYLINDER
C22
CLAMP
CYLINDER
C23
ROTATE CYLINDER
C24
CLAMP
CYLINDER
C25
CLAMP
CYLINDER
OPTIONAL WINCH
LS
PS1
MB1
RETURN
MANIFOLD
LEFT
RIGHT
SW
LS
V3
CHARGE
VALVE
STR2
SUCTION
STRAINER
C19
FORK SHIFT
CYLINDER
V4
SERVICE BRAKE
VALVE
A2
P2
REAR
PUMP
STR1
SUCTION
STRAINER
TP5
P1
FRONT
PUMP
REAR AXLE
ELECTRICAL
CONNECTION TO
LOW PRESSURE
WARNING LIGHT
(INSTRUMENT
PANEL)
P
WINCH MOTOR
WINCH
BRAKE
BRAKE
VALVE
PS4
TO "C" PORT ON
DIVERTER VALVE
TO "D" PORT ON
DIVERTER VALVE
F1
RETURN
LINE
FILTER
RIGHT
FRONT AXLE
LEFT
M402796AA
SKYJACK, Page 92
NOTE: To determine the correct hydraulic/electrical schematic that resembles your telehandler, refer to the Table Of Contents found at the beginning of this section.
Telehandler Series
Model ZB20044
402509
Telehandler Series
Model ZB20044
402509
NOTE: To determine the correct hydraulic/electrical schematic that resembles your telehandler, refer to the Table Of Contents found at the beginning of this section.
16 AWG WHITE
16 AWG TAN
22 AWG BLACK
16 AWG PINK 39
16 AWG BLACK
16 AWG YELLOW
18 AWG BLACK
18 AWG BLACK
18 AWG BLACK
18 AWG BLACK
JOYSTICK
CARRIAGE TILT
BOOM AND
SW11
DS4
DS2
BRAKE PRESSURE
AXLE LOCK
22 AWG GRAY
DS3
DIFFERENTIAL LOCK
18 AWG CLEAR
18 AWG GREEN
16 AWG BLUE 8
16 AWG L BLUE
16 AWG TAN
>45 = OPEN
<45 = CLOSED
BOOM ANGLE
SW300
18 AWG GRAY 2A
120
16 AWG RED
K221
16 AWG BLUE 8
G
S
14 AWG BLACK
14 AWG BLACK
14 AWG GREEN
14 AWG BLACK
16 AWG GRAY 6
F300
125 A
COOLANT LEVEL
2 COM
2 COM
42
18 AWG GRAY C142
6 AWG RED
HORN
DS5
NC
18 AWG GREEN
18 AWG WHITE
COM
NO
FUEL GAUGE
ILLUMINATION
3 NO
1 NO
K211 BLUE B1
K210 BLUE R1
16 AWG BLACK
16 AWG BLACK
16 AWG BLACK
16 AWG BLACK
16 AWG BLACK
K222 DIVERTER VALVE
18 AWG WHITE
18 AWG WHITE
18 AWG WHITE
18 AWG WHITE
18 AWG WHITE
18 AWG WHITE
AH ZN B1
OUTRIGGERS
SHT 12
139
138
137
136
135
134
133
132
AXLE
LOCK
FRAME
LEVEL
DIVERTER VALVE
HORN
INSTRUMENT CLUSTER
TRANSMISSION TEMPERATURE
FUEL SENDER
GRID HEATER
ECM
MURPHY POWERVIEW
STEERING SOLENOID'A'
PARKING BRAKE
REVERSE ALARM
131
130
129
128
127
126
125
124
123
122
121
120
119
118
117
116
115
114
113
112
111
110
109
108
107
106
105
104
103
102
101
100
99
K143 WHITE A/T
98
18 AWG WHITE
97
96
95
94
93
92
91
90
89
88
87
86
85
84
83
82
81
80
79
78
77
76
75
74
73
72
71
18 AWG WHITE
R223 TRANSMISSION
0-X TEMPERATURE
FUEL SENDER
R208
21 FULL
52 EMPTY
GRID
HEATER
40
6 AWG RED
32
28
69
SWITCH RETURN
18 AWG GRAY C134
70
68
ON IDLE SWITCH
11
34
67
ACCELERATOR POSITION RETURN
J298
66
ACCELERATOR POSITION SIGNAL
65
9
64
23
39
63
62
61
60
37
18 AWG CLEAR C137
59
58
57
56
55
54
53
52
51
50
49
SAE J1939 47
GROUND
ECM
GROUND
J295
46 SAE J1939 +
12 AWG GRAY
12 AWG GRAY
12 VDC
12 VDC
48
47
46
45
44
K124 SOLENOID
A
43
42
41
40
39
38
37
36
35
34
33
32
31
30
K125 SOLENOID
B
12 AWG GRAY
12 AWG RED
3 NO
18 AWG BLACK
16 AWG BLACK
14 AWG BLACK
14 AWG BLACK
16 AWG BLACK
M3
OIL TEMP
6 AWG RED
16 AWG BLACK
16 AWG RED
18 AWG CLEAR
18 AWG GREEN
18 AWG YELLOW
K220
J297
1
16 AWG BLACK
NETWORK
TERMINATION
18 AWG BLACK
18 AWG CLEAR
18 AWG BLACK
DS1
PARKING BRAKE
18 AWG GREEN
R297
12 AWG RED
12 AWG RED
J296
ECM POWER
16 AWG BLACK
16 AWG BLACK
NC
29
STEERING SOLENOID
PARKING BRAKE
SW6
COM
NO
28
27
REVERSE SOLENOID
IGNITION SWITCH
FORWARD SOLENOID
DANA SHIFTER
2ND SOLENOID
1ST SOLENOID
STARTER SOLENOID
SHT 12
ZN G1
10A AUX
CB3
6A AUX
HORN
SW2
TT
18 AWG YELLOW
MURPHY
POWERVIEW
F279
30 A
12 AWG RED
12 AWG GRAY
APPLY
RELEASE
16 AWG BLACK
16 AWG BLACK
SW125
PRESSURE SWITCH
REVERSE ALARM
26
25
24
23
22
21
20
19
18
BATTERIES
STARTER
CB1
M2
FUEL
18 AWG YELLOW
DISCONNECT
K1 TRANSMISSION
16 AWG BLACK
16 AWG BLACK
16 AWG BLACK
K270
REVERSE SOLENOID
DISCONNECT
K269
FORWARD SOLENOID
16 AWG WHITE
14 AWG BLACK
D266
NORMAL = OPEN
SW3 TRANSMISSION
K20
16 AWG WHITE
16 AWG RED
K268
2ND SOLENOID
K267
1ST SOLENOID
17
16
15
14
13
12
AG
BAT
OUTRIGGER
HOURS METER
M1
CB9
10A
CB5
PEDAL
SW4 STEERING
16 AWG BLACK
16 AWG GREEN
16 AWG GREEN
16 AWG BLACK
16 AWG GREEN
22 AWG GRAY
SW25
22 AWG PINK
22 AWG YELLOW
PS2
11
BAT
IDLE OFF
18 AWG CLEAR
18 AWG GREEN
18 AWG YELLOW
F2
POWERVIEW
LAMP FUSE
5A
1
CRAB
ROUND
3
K128 APPLY
K127 RELEASE
16 AWG BLACK
16 AWG GREEN
22 AWG RED
4205320
16 AWG BLACK
16 AWG BROWN
PS1
12 AWG RED
ALTERNATOR
DIVERTER
VALVE
THROTTLE
IDLE ON
TPS SIGNAL
TPS RETURN
IDLE RETURN
18 AWG CLEAR
18 AWG GREEN
18 AWG YELLOW
18 AWG RED T3
2 COM
16 AWG WHITE
16 AWG WHITE
PARKING BRAKE
18 AWG GRAY 2A
22 AWG BLACK
B200
STARTER
10
BAT
B
C
TPS +5 V
DIAGNOSTIC
NETWORK
TERMINATION
CB6
10A
TRANSMISSION SHIFTER
16 AWG YELLOW
SHIFTER
DANA
22 AWG BLUE
DUAL BATTERIES
AJ
AXLE LOCK /
FRAME LEVELING
R6
AUX
120
6A
ST
IGN
F1
IGNITION
SWITCH FUSE
5A
SW26
K220
16 AWG GREEN 21
10 AWG RED 22
OPTIONAL
BATTERY DISCONNECT
SW305
10 AWG BLUE
BAT
CB10
AUX
ACC
F201
5A
16 AWG GREEN 36
10 AWG RED 23
30A
STEERING
B+
10 AWG RED 23
SHT 12
ZN H1
10A
AUX
10 AWG RED 22
18 AWG PURPLE 25
10 AWG RED
SHT 12
ZN E6
CB6
50A
CB220
18 AWG PURPLE
AUX
BAT
50A
BUS BAR BUS BAR
BAT
AUX
8 AWG RED 24
CB23
AF
6A
CB8
G200
ALTERNATOR
ALTERNATOR BAT
BUS BAR
10 AWG RED
M402360AA
SKYJACK, Page 93
AF
SHT 11
ZN A7
SKYJACK, Page 94
NOTE: To determine the correct hydraulic/electrical schematic that resembles your telehandler, refer to the Table Of Contents found at the beginning of this section.
12 AWG RED
12 AWG RED
20A
CB21
OFF
2.7
12 AWG RED
22 AWG BROWN
22 AWG BLACK
16 AWG RED
AIR CONDITIONER
SW62
1 1.7
1.3
16 AWG WHITE
18 AWG BROWN
18 AWG BLACK
16 AWG WHITE
16 AWG WHITE
16 AWG WHITE
16 AWG WHITE
16 AWG WHITE
K13
K14
F66
4A
F70
4A
F64
4A
14 AWG WHITE
14 AWG BLACK
18 AWG BROWN
14 AWG BLACK
14 AWG BLACK
16 AWG WHITE
14 AWG BLACK
14 AWG BLACK
16 AWG RED
10 AWG BLACK
16 AWG WHITE
16 AWG WHITE
16 AWG WHITE
16 AWG WHITE
16 AWG WHITE
16 AWG RED
SW68
SW66
SW70
SW64
6.0
4.8
2.9
5.5
2.9
5.5
2.9
5.5
16 AWG WHITE
SW62
DS60
DS62
DS63
DS312
DS310
DS311
DS313
DS148
DS149
DS313
DS312
DS154
DS312
DS52
DS53
DS386
DS385
DS56
K381
K380
B68 FAN
16 AWG BLACK
16 AWG BLACK
16 AWG BLACK
16 AWG BLACK
16 AWG BLACK
16 AWG BLACK
16 AWG RED
16 AWG RED
16 AWG GREEN
16 AWG RED
110
109
108
107
AUX LIGHT
FAN
FRONT WIPER
REAR WIPER
TOP WIPER
BEACON LIGHT
DOME LIGHT
MAP LIGHT
HEATER
RIGHT HEADLIGHT
LEFT HEADLIGHT
LIGHTS RELAY
106
105
104
103
102
101
100
99
98
97
96
95
94
93
82
91
90
89
88
87
86
85
84
83
82
81
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
14 AWG BLACK
SW69
12 AWG BLACK
12 AWG BLACK
DS155
DS311
14 AWG RED
K17
20A
CB18
18 AWG GRAY
SW75
SW62
BOTH LIGHTS
SW62
SW15 LIGHTS
BRAKE PRESSURE
SW90
NO
COM
16 AWG GREEN
16 AWG RED
12 AWG RED
14 AWG BLACK
BUS BAR
10A
CB11
20A
AJ
10 AWG BLACK
SHT 11
ZN D8
14 AWG WHITE
14 AWG RED
3 NO
CB22
20A
CB17
20A
CB16
14 AWG BROWN
2 COM
12 AWG RED
K16
12 AWG RED
20A
CB15
3 NO
2 COM
16 AWG ORANGE
16 AWG ORANGE
14 AWG RED
12 AWG RED
U1 FLASHER UNIT
OPTIONAL
11
10
14 AWG BLACK
12 AWG RED
14 AWG BLACK
16 AWG ORANGE
AH
14 AWG RED
K16
ACC
SHT 11
ZN D1
12 AWG RED
K15
20A
CB7
SHT 11
ZN A1
14 AWG RED
AG
L
M
N
O
M402360A_12
Telehandler Series
Model ZB20044
402509
Section 4
TROUBLESHOOTING INFORMATION
Table of Contents
Introduction.................................................................................................................................................................................. 97
Electrical System
4.1-1 All Controls Inoperative (No Crank)............................................................................................................................... 98
4.1-2 Engine Cranks but will not start....................................................................................................................................... 99
4.1-3 Can Bus Failure, no data/display on Murphy Powerview................................................................................................ 99
4.1-4 No Throttle..................................................................................................................................................................... 100
4.1-5 No Drive (park brake releases)....................................................................................................................................... 100
4.1-6 No Forward Drive.......................................................................................................................................................... 100
4.1-7 No reverse drive............................................................................................................................................................. 101
4.1-8 3rd speed range only....................................................................................................................................................... 101
4.1-9 No 1st speed range......................................................................................................................................................... 101
4.1-10 No Drive (park brake does not release).......................................................................................................................... 101
4.1-11 Alternator not charging.................................................................................................................................................. 102
4.1-12 Front steer mode only..................................................................................................................................................... 102
4.1-13 No round steer mode...................................................................................................................................................... 102
4.1-14 No crab steer mode......................................................................................................................................................... 103
4.1-15 No carriage tilt function................................................................................................................................................. 103
4.1-16 No outrigger function..................................................................................................................................................... 103
4.1-17 No right outrigger lower function.................................................................................................................................. 103
4.1-18 No right outrigger raise function.................................................................................................................................... 104
4.1-19 No left outrigger lower function..................................................................................................................................... 104
4.1-20 No left outrigger raise function...................................................................................................................................... 104
4.1-21 Rear axle locked, Front frame level in slow mode, brakes do not lock axle out, Axle lock light on,
all boom angles............................................................................................................................................................... 104
4.1-22 Rear axle and front frame level in slow mode, brake application locks out both axles, axle lock light on,
all boom angles............................................................................................................................................................... 105
4.1-23 Rear axle locked and front frame level operates normally, brake application locks out frame level,
axle lock light on, all boom angles................................................................................................................................. 105
4.1-24 Rear axle locked, front frame level operates normally, axle lock light off, below 45 degrees...................................... 105
4.1-25 Rear axle lock works normally, front frame level in slow mode, axle lock, light off, below 45 degrees...................... 105
4.1-26 Front frame level does not lock out with brake application above 45 degrees.............................................................. 106
Hydraulic System
4.2-1 All controls inoperative.................................................................................................................................................. 107
4.2-2 All Boom Functions Inoperative.................................................................................................................................... 107
4.2-3 No Boom Raise.............................................................................................................................................................. 107
4.2-4 No Boom Lower............................................................................................................................................................. 107
4.2-5 No Boom Extend............................................................................................................................................................ 107
4.2-6 No Boom Retract............................................................................................................................................................ 107
4.2-7 No Carriage Tilt Back.................................................................................................................................................... 108
4.2-8 No Carriage Tilt Forward............................................................................................................................................... 108
4.2-9 No Frame Level Right.................................................................................................................................................... 108
4.2-10 No Frame Level Left...................................................................................................................................................... 109
4.2-11 No Auxiliary/Optional Hydraulic Control...................................................................................................................... 109
4.2-12 No Right Outrigger Lower............................................................................................................................................. 110
4.2-13 No Right Outrigger Raise............................................................................................................................................... 110
TM
Telehandler Series
Model ZB20044
402509
Page 95
TM
Page 96
Telehandler Series
Model ZB20044
402509
Introduction
The following pages contain the necessary troubleshooting information for locating and correcting electrical and
hydraulic malfunctions that may arise. Careful and accurate analysis of the systems listed, will localize the problem
more quickly than any other method.
Prior to performing any troubleshooting procedure, observe the following recommendations:
The content of this section is divided into probable cause and remedy. The information preceded by a number
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
TM
Telehandler Series
Model ZB20044
402509
Page 97
Electrical System
4.1-1 All Controls Inoperative (No Crank)
1. Battery cable(s) loose or disconnected.
-- Tighten or connect battery cable(s).
2. Battery discharged.
-- Charge battery.
3. Loose or broken wire #22 from starter to circuit breaker CB220.
-- Check continuity. Replace if defective.
4. Circuit breaker CB220 tripped or defective.
-- Check for defective wiring. Replace if defective.
5. Loose or broken wire #23 from circuit breaker CB220 to starter solenoid K220.
-- Check continuity. Replace if defective
6. Loose or broken wire #23 from circuit breaker CB220 to Ignition switch SW1.
-- Check continuity. Replace if defective.
7. Defective ignition switch SW1.
-- Replace if defective.
8. Loose or broken green wire from ignition switch SW1 to 3pin connector J9 (pin B).
-- Check continuity. Replace if defective.
9. Loose or broken green wire from 3pin connector P9 (pin B) to neutral safety relay K20 (pin30).
-- Check continuity. Replace if defective.
10. Loose or broken green wire from neutral safety relay K20 (pin 87) to 3pin connector P9 (pin C).
-- Check continuity. Replace if defective.
11. Loose or broken yellow wire from ignition switch SW1 to transmission shifter circuit breaker CB4.
-- Check continuity. Replace if defective.
12. Circuit breaker CB4 tripped or defective.
-- Check for defective wiring. Replace if defective.
13. Loose or broken black/white wire from CB4 to 3pin connector J9 (pin A).
-- Check continuity. Replace if defective.
14. Loose or broken red wire from 3pin connector P9 (pin A) to transmission shifter.
-- Check continuity. Replace if defective.
15. Defective shifter.
-- Check shifter. Replace if defective.
16. Loose or broken grey wire from shifter to neutral start relay K20 (pin 85).
-- Check continuity. Replace if defective.
17. Loose or broken black wire relay K20 (pin 86) to ground E1.
-- Check continuity. Replace if defective.
18. Defective neutral start relay K20.
-- Replace if defective.
19. Loose or broken green wire from 3pin connector J9 (pin C) to single wire connector P29.
-- Check continuity. Replace if defective.
20. Loose or broken grey wire from single pin connector P29 to 32pin connector P1 (pin12).
-- Check continuity. Replace if defective.
21. Loose or broken grey wire from 32pin connector J1 (pin12) to fuse F201.
-- Check continuity. Replace if defective.
22. Defective fuse F201.
-- Replace fuse.
23. Loose or broken red wire from fuse F201 to single pin connector J102.
-- Check continuity. Replace if defective.
24. Loose or broken green wire #36 from single pin connector P102 to starter solenoid K220.
-- Check continuity. Replace if defective.
25. Loose or broken black wire from starter solenoid K220 to ground.
TM
Page 98
Telehandler Series
Model ZB20044
402509
TM
Telehandler Series
Model ZB20044
402509
Page 99
TM
Page 100
Telehandler Series
Model ZB20044
402509
TM
Telehandler Series
Model ZB20044
402509
Page 101
TM
Page 102
Telehandler Series
Model ZB20044
402509
TM
Telehandler Series
Model ZB20044
402509
Page 103
TM
Page 104
Telehandler Series
Model ZB20044
402509
4.1-22 Rear axle and front frame level in slow mode, brake application locks out both
axles, axle lock light on, all boom angles.
1. Loose or broken yellow wire from relay K221 (pin 6) to connector P247 (pin A).
-- Check continuity. Replace if defective.
2. Loose or broken black wire form connector J247 (pin A) to single wire connector J215.
-- Check continuity. Replace if defective.
3. Loose or broken wire from connector P215 to mercury switch SW300.
-- Check continuity. Replace if defective.
4. Defective mercury switch SW360.
-- Replace if defective.
5. Loose or broken wire from mercury switch SW300 to single wire connector J216.
-- Check continuity. Replace if defective.
6. Loose or broken white wire from connector P216 to splice SPL210.
-- Check continuity. Replace if defective.
4.1-23 Rear axle locked and front frame level operates normally, brake application locks
out frame level, axle lock light on, all boom angles.
1. Loose or broken green wire from connector P247 (pin B) to relay K221 (pin 8).
-- Check continuity. Replace if defective.
2. Defective relay K221.
-- Replace if defective.
3. Loose or broken black wire from relay K221 (pin 7) to ground E221.
-- Check continuity. Replace if defective.
4.1-24 Rear axle locked, front frame level operates normally, axle lock light off, below 45
degrees.
1. Loose or broken white wires from splice SPL210 to solenoids K210 and K211.
-- Check continuity. Replace if defective.
2. Defective solenoid K210 or K211.
-- Replace if defective.
3. Defective black wire from solenoids K210 and K211 to ground E210.
-- Check continuity. Replace if defective.
4.1-25 Rear axle lock works normally, front frame level in slow mode, axle lock, light off,
below 45 degrees.
1. Loose or defective green wire from connector J247 (pin B) to solenoids K140 and K142 (pin 1).
-- Check continuity. Replace if defective.
2. Defective solenoid K140 or K142.
-- Replace if defective.
3. Loose or defective black wire from solenoids K140 and K142 (pin 2) to ground E140.
-- Check continuity. Replace if defective.
TM
Telehandler Series
Model ZB20044
402509
Page 105
TM
Page 106
Telehandler Series
Model ZB20044
402509
Hydraulic System
4.2-1 All controls inoperative
1. Worn or defective pump shaft or coupling.
-- Check pump shaft and coupling. Replace if defective.
2. No PTO rotation.
-- Repair transmission, or flex plate.
3. Hydraulic oil level low.
-- Check oil level. Fill to proper level.
4. System pump P2 is out of adjustment or is defective.
-- Refer to section 5 for pump set up procedure. Repair or replace if defective.
4.2-2 All Boom Functions Inoperative.
1. Stuck or defective pressure reducing valve PRV1.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
2. Stuck or defective priority valve PRT1 .
-- Clean valve. Check operation of valve. Repair or replace valve as required.
4.2-3 No Boom Raise
1. Stuck or defective joystick JS2.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective carriage tilt diverter valve V2.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
3. Stuck or defective lift valve sections.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
4. Stuck or defective lift counterbalance valves CB1, CB2.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
5. Defective lift cylinder C5 and/or C6.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-4 No Boom Lower
1. Stuck or defective joystick JS2.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective carriage tilt diverter valve V2.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
3. Stuck or defective lift valve sections.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
4. Stuck or defective lift counterbalance valves CB1, CB2.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
5. Defective lift cylinder C5 and/or C6.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-5 No Boom Extend
1. Stuck or defective joystick JS2.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective extension valve sections.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
3. Stuck or defective extension counterbalance valve CB3.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
4. Defective extension cylinder C7.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-6 No Boom Retract
TM
Telehandler Series
Model ZB20044
402509
Page 107
TM
Page 108
Telehandler Series
Model ZB20044
402509
TM
Telehandler Series
Model ZB20044
402509
Page 109
TM
Page 110
Telehandler Series
Model ZB20044
402509
TM
Telehandler Series
Model ZB20044
402509
Page 111
Notes
Section 5
PROCEDURES
List of Procedures
Engine and Transmission
General....................................................................................................................................................................................... 115
Safety and Workmanship........................................................................................................................................................... 115
5.1-1 Engine and Components.............................................................................................................................115
5.1-2 Fault Codes for Quantum Engines..............................................................................................................115
5.1-3 PowerView General Information..................................................................................................................116
Display Parameters......................................................................................................................................116
Keypad Functions........................................................................................................................................116
PowerView Menus (First Time Start Up)......................................................................................................117
Error Messages............................................................................................................................................130
5.1-4 Replace Engine Oil and Filter......................................................................................................................133
5.1-5 Check Engine Air Filter................................................................................................................................134
5.1-6 Replace Fuel Filter.......................................................................................................................................134
5.1-7 Check Fan Drive Belt...................................................................................................................................134
5.1-8 Check Transmission Filter Breather............................................................................................................135
5.1-9 Change Transmission Fluid and Filter.........................................................................................................135
Hydraulic System
5.2-1 Check Hydraulic Oil.....................................................................................................................................136
5.2-2 Change Hydraulic Tank Filter......................................................................................................................136
5.2-3 Change Hydraulic Oil...................................................................................................................................136
5.2-4 Bleeding Hydraulic Circuits.........................................................................................................................137
Bleed Carriage Tilt Circuit............................................................................................................................137
Bleed Boom Extend/Retract Circuit.............................................................................................................137
Bleed Boom Raise/Lower Circuit.................................................................................................................137
Bleed Frame Level Circuit............................................................................................................................137
Bleed Auxiliary/Optional Circuits.................................................................................................................137
Bleed Outriggers Circuit..............................................................................................................................137
Bleed Brake Circuit......................................................................................................................................137
Pressure Adjustment Procedures
5.3-1 Piston Pump Pressure.................................................................................................................................138
5.3-2 Port Relief Pressure.....................................................................................................................................138
5.3-3 Priority Valve Relief Pressure.......................................................................................................................139
5.3-4 Pilot Pressure...............................................................................................................................................139
5.3-5 Check Brake Accumulators.........................................................................................................................140
5.3-6 Charging Brake Accumulators....................................................................................................................140
5.3-7 Charging Rear Axle Lock System................................................................................................................141
Boom
5.4-1
5.4-2
TM
Telehandler Series
Model ZB20044
402509
Page 113
Section 5 - Procedures
Axles
5.5-1 Change Oil in Axles.....................................................................................................................................145
5.5-2 Check Oil Level in Torque Hub....................................................................................................................145
Grease Points
5.6-1 Frame Grease Points...................................................................................................................................146
5.6-2 Boom Grease Points....................................................................................................................................147
5.6-3 Drive Axle Grease Points.............................................................................................................................148
5.6-4 Drive Shaft Grease Points............................................................................................................................148
Tires
5.7-1
TM
Page 114
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
General
The following information is provided to assist you in the use and application of servicing and maintenance procedures
contained in this chapter.
Safety and Workmanship
Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support
is provided.
The engine used on the ZB200XX Zoom Boom models is a Cummins QSB4.5C160T3.
Engine service information can be found in the Cummins Engine Manuals. It should be noted that engine warranty
service work is to be directed to and administered by your nearest authorized Cummins dealer/distributor.
Skyjack cannot enter into any warranty service work requirements.
The basic Cummins engine warranty covers the entire engine from the fan to the fly wheel including all internal parts
as well as the following list of parts supplied with the engine as original:
1.
2.
3.
4.
5.
6.
Starter
Alternator
Injectors
Fuel Pump
Fuel Solenoid
Water Pump
The air cleaner and exhaust system are not part of the engine package, and are covered later in this manual.
The cooling system including radiator and hoses are also not part of the engine package and are covered later in
this manual.
Red
Stop
Yellow
Warning
No Lamp
Maintenance
No Lamp
TM
Telehandler Series
Model ZB20044
402509
Page 115
Section 5 - Procedures
Faceplate Features
Amber
Warning LED
Display
Menu Key
Red Shutdown
Derate LED
Bezel
Enter Key
Plug B
PIN 4 CAN SHLD
PIN 2 CAN HI
PIN 3 RS485+
PIN 5 Dimmer
Potentiometer
PIN 1 V+
PIN 6 GRND
Recommended Connectors:
Body: Deustch DT06-6S
Wedge Lock: W6S
Terminals: 0462-201-16141
Sealing Plug: 114017
Display Parameters
B
PIN 1 V+
PIN 6 GRND
PIN 4 RS485
Engine RPM
Engine Hours
Machine Hours
System Voltage
% Engine Load at the current RPM
Coolant Temperature
Oil Pressure
Fuel Economy
Throttle Position
Engine Manifold Air Temperature
Current Fuel Consumption
Active Service Codes
Stored Service Codes (when supported)
Set Units for Display (English or Metric)
Keypad Functions
TM
Page 116
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
3.
2.
WAIT TO
START
PREHEAT
4.
3.
1500
1800 RPM
ENG RPM
ENG RPM
57 PSI
OIL PRES
Selecting a Language
1. Starting at the main menu display use the
Arrows to scroll to the Language menu and
once highlighted touch the Enter button.
3000
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
GO TO 1-UP DISPLAY
LANGUAGES
LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
1000 RPM
ENG RPM
57 PSI
OIL PRES
2.
2.
14.2
BAT VOLT
1000 RPM
1800 RPM
LOAD@RPM
3000
98%
LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
TM
Telehandler Series
Model ZB20044
402509
Page 117
Section 5 - Procedures
5.
1500
1800 RPM
ENG RPM
98%
3000
LOAD@RPM
14.2
COOL TEMP
BAT VOLT
SPN110 FMI10
HIGH COOLANT TEMP
MORE
1000 RPM
ENG RPM
57 PSI
OIL PRES
6.
2.
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
1500
1800 RPM
ENG RPM
2.
GO TO 1-UP DISPLAY
STORED
CODES
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
4.
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
3.
HIDE
3000
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
3.
1 of x
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
GO TO 1-UP DISPLAY
STORED CODES
ENGINE
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
TM
Page 118
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
4.
1 of x
ENGINE SPEED PT 1
1000 RPM
HIDE
MORE
3.
5.
1 of x
ENGINE SPEED PT 1
1000 RPM
HIDE
MORE
4.
6.
1500
1800 RPM
ENG RPM
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
98%
LOAD@RPM
14.2
BAT VOLT
3000
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
1000 RPM
ENG RPM
57 PSI
OIL PRES
.!
1500
1800 RPM
ENG RPM
3000
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
5.
2.
NOTE
The fault can only be cleared by correcting the cause of the fault condition.
TM
Telehandler Series
Model ZB20044
402509
Page 119
Section 5 - Procedures
5.
1500
1800 RPM
ENG RPM
57 PSI
14.2
6.
3000
1800 RPM
COOL TEMP
14.2
ENG RPM
57 PSI
OIL PRES
BAT VOLT
SPN110 FMI 0
SPN110 FMI 0
MORE
HIDE
HIDE
7.
3.
1000 RPM
LOAD@RPM
1 of x
WARNING
1 of x
1500
ENG RPM
OIL PRES
BAT VOLT
98%
1000 RPM
LOAD@RPM
COOL TEMP
ENG RPM
2.
98%
3000
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1 of x
1000 RPM
LOAD@RPM
14.2
BAT VOLT
ENG RPM
57 PSI
OIL PRES
SPN110 FMI 0
HIDE
Shutdown Codes
1.
4.
ENG RPM
2.
SPN110 FMI 0
HIDE
1500
1800 RPM
3000
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
TM
Page 120
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
SHUTDOWN
1 of x
1.
SPN110 FMI 0
HIGH COOLANT TEMP
MORE
HIDE
1500
1800 RPM
ENG RPM
3.
2.
SHUTDOWN
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
SPN110 FM10
HIGH COOLANT TEMP
MORE
3000
HIDE
ADJUST BACKLIGHT
4.
!
0
1500
3000
ADJUST BACKLIGHT
57 PSI
OIL PRES
BAT VOLT
SHUTDOWN
4.
SPN110 FM10
HIGH COOLANT TEMP
MORE
6.
ENG RPM
14.2
5.
1000 RPM
1800 RPM
3.
HIDE
1500
1800 RPM
ENG RPM
3000
COOL TEMP !
98%
1000 RPM
14.2
BAT VOLT
ENG RPM
57 PSI
OIL PRES
5.
TM
Telehandler Series
Model ZB20044
402509
Page 121
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
6.
Section 5 - Procedures
LOAD@RPM
14.2
BAT VOLT
1000 RPM
4.
ENG RPM
57 PSI
ADJUST CONTRAST
OIL PRES
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
5.
OIL PRES
Contrast Adjustment
1.
1500
1800 RPM
ENG RPM
3000
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
6.
OIL PRES
2.
1.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
1800 RPM
ENG RPM
LOAD@RPM
Select Units
3.
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
2.
3000
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
TM
Page 122
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
3.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT
SELECTUNITSD
UNITS
ADJUST BACKLIGHT
4.
2.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
3.
ENGLISH
METRIC KPA
METRIC BAR
7.
1800 RPM
3000
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP1-UP
1-UPDISPLAY
DISPLAY
SETUP
SETUP 4-UP DISPLAY
SELECT UNITSD
ADJUST BACKLIGHT
ENGLISH
METRIC KPA
METRIC BAR
6.
1500
ENG RPM
ENGLISH
METRIC KPA
METRIC BAR
5.
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
4.
Telehandler Series
Model ZB20044
402509
Page 123
5.
Section 5 - Procedures
USE DEFAULTS
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF
USE DEFAULTS
DEFAULTS
USE
CUSTOM SETUP
AUTOMATIC SCAN OFF
USE
DEFAULTS
ENGINE
SPEED
1
PERCENT LOAD AT CURRENT RPM 3
ENGINE OIL PRESSURE
2
ENGINE COOLANT TEMPERATURE
USE
USEDEFAULTS
DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
7.
RESTORED TO
DEFAULTS
9.
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM 2
ENGINE OIL PRESSURE
1
ENGINE COOLANT TEMP
TM
Page 124
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM 2
ENGINE OIL PRESSURE
1
ENGINE COOLANT TEMP
3
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1500
1800 RPM
ENG RPM
3000
COOL TEMP
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
OFF
AUTOMATICSCAN
SCAN
OFF
1500
1800 RPM
ENG RPM
3000
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
OFF
AUTOMATICSCAN
SCAN
ON
2.
3.
TM
Telehandler Series
Model ZB20044
402509
Page 125
Section 5 - Procedures
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP
SETUP 4-UP
4-UP DISPLAY
DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
4.
8.
USE
USE DEFAULTS
DEFAULTS
CUSTOM SETUP
9.
5.
6.
125F
COOL TEMP
1000 RPM
ENG RPM
14.2
14.2
BAT VOLT
57 PSI
OIL PRESP
1000 RPM
ENG RPM
14.2
14.2
BAT VOLT
57 PSI
OIL PRESP
3
1
2
4
7.
3
1
2
4
TM
Page 126
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
ENGINE SPEED
ENGINE HOURS
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
TEMPERATURE
2
ENGINE OIL PRESSURE
1.
2
4
1500
1800 RPM
ENG RPM
125F
COOL TEMP
143F
OIL TEMP
2.
RPM
1000
RPM
ENG RPM
57 PSI
OIL PRESP
3.
143F
OIL TEMP
COOL TEMP
143F
OIL TEMP
1000 RPM
ENG RPM
57 PSI
OIL PRES
RPM
1000
RPM
ENG RPM
57 PSI
OIL PRESP
4.
COOL TEMP
125%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
125F
COOL TEMP
3000
125%
COOL TEMP
143F
OIL TEMP
1000 RPM
ENG RPM
57 PSI
OIL PRES
5.
TM
Telehandler Series
Model ZB20044
402509
Page 127
Section 5 - Procedures
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
FAULT
FAULTCONVERSION
CONVERSION
1 of x
6.
7.
J1939 VERSION
VERSION 11
J1939 VERSION 2
J1939 VERSION 3
J1939 VERSION 4
8.
NOTE
There are four (4) different methods for
converting fault codes.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
TM
Page 128
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
MODBUS Setup
1.
1500
1800 RPM
ENG RPM
2.
3000
COOL TEMP
98%
LOAD@RPM
14.2
BAT VOLT
1000 RPM
ENG RPM
57 PSI
OIL PRES
3.
6.
4.
TM
Telehandler Series
Model ZB20044
402509
Page 129
Section 5 - Procedures
Error Messages
FMI Description
3
% ACCEL POS3 VOLT ABOVE NORM OR SHORT HIGH
4
% ACCEL POS3 VOLT BELOW NORM OR SHORT LOW
3
% ACCEL POS2 VOLT ABOVE NORM OR SHORT HIGH
4
% ACCEL POS2 VOLT BELOW NORM OR SHORT LOW
3
ACCEL PEDAL POS VOLT ABOVE NORM OR SHORT HIGH
4
ACCEL PEDAL POS VOLT BELOW NORMAL OR SHORT LOW
9
ACCEL PEDAL POS A VALID THROTTLE MSG NOT RCVD
14
ACCEL PEDAL POS THROTTLE SIG VOLT OUT OF RANGE
1
FUEL DELIVERY PRESSURE VERY LOW
3
FUEL RAIL PRESSURE VOLTAGE OUT OF RANGE HIGH
4
FUEL RAIL PRESSURE VOLTAGE OUT OF RANGE LOW
10
FUEL DELIVERY PRESSURE DROPPING TO FAST
13
FUEL DELIVERY PRESSURE OUT OF CALIBRATION
16
FUEL DELIVERY PRESSURE HIGH
17
NO RAIL FUEL PRESSURE
18
FUEL DELIVERY PRESSURE LOW
0
WATER IN FUEL DETECTED
3
WATER IN FUEL INDICATOR VOLTAGE OUT OF RANGE HIGH
4
WATER IN FUEL INDICATOR VOLTAGE OUT OF RANGE LOW
16
WATER IN FUEL DETECTED
31
WATER IN FUEL DETECTED
1
ENGINE OIL PRESSURE LOW
3
ENGINE OIL PRESS VOLT ABOVE NORM OR SHORT HIGH SOURCE
4
ENGINE OIL PRESS VOLT BELOW NORM OR SHORT LOW SOURCE
16
ENGINE OIL PRESSURE READING INCORRECT
18
ENGINE OIL PRESS LOW
0
INTAKE MAN1 AIR TEMP HIGH
3
INTAKE MAN1 TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
4
INTAKE MAN1 TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
16
INTAKE MAN1 AIR TEMP HIGH
0
AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED
31
AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED
0
ENG COOL TEMP HIGH
3
ENG COOL TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
4
ENG COOL TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
15
ENG COOL TEMP HIGH
16
ENG COOL TEMP HIGH
1
LOW COOLANT LEVEL
2
KEYSWITCH INTERMITTENT
17
KEYSWITCH CIRCUIT PROBLEM
0
FUEL TEMP HIGH
118A
TM
Page 130
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
13
651
651
651
652
652
652
653
653
653
654
654
654
655
655
655
656
656
656
676
676
729
729
5
6
7
5
6
7
5
6
7
5
6
7
5
6
7
5
6
7
3
5
3
5
TM
Telehandler Series
Model ZB20044
402509
Page 131
Section 5 - Procedures
TM
Page 132
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
NOTE
Perform this operation after warming the
engine to normal operating temperature.
CAUTION
Beware of hot engine components.
Contact with hot engine components
may cause severe burns.
CAUTION
When draining hot oil, there is a risk of
scalding. Do not let used oil run into
the soil, rather collect it in a container.
Dispose of this in accordance with
environmental regulations.
1. Ensure telehandler is on a firm level surface.
Engine Oil
Filter
TM
Telehandler Series
Model ZB20044
402509
Page 133
Section 5 - Procedures
Fuel Filter
Air Filter
NOTE
Refer to your national/local regulations on
how to dispose of used filter and oil.
Page 134
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
Transmission
NOTE
Refer to your national/local regulations on
how to dispose of used filter and oil.
Pump 1
Transmission
Oil Filter
Pump 2
Transmission
Oil Dipstick
T32000 Transmission
TM
Telehandler Series
Model ZB20044
402509
Page 135
Hydraulic System
Section 5 - Procedures
NOTE
The filter does not need to be changed unless
the service indicator is showing at the top of the
filter. If the indicator is past the 3.4 green mark,
change the filter. Should the indicator not be
showing at 250 hours, check the unit. Check the
service indicator daily. Change the return filter
when the filter gauge indicates a dirty element.
Return
Filter
Filter
Element
8. Start engine.
9. Check for leakage.
NOTE
Refer to your national/local regulations
on how to dispose of used filter and oil.
Sight
Gauge
Hydraulic Oil
Suction Strainer
Hydraulic Oil Tank
TM
Page 136
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
NOTE
Refer to your national/local regulations on
how to dispose of used filter and oil.
NOTE
Samples of hydraulic oil should be drawn from
the reservoir and tested annually. These samples
should be taken when the oil is warmed through
normal operation of the system. The sample
should be analyzed by a qualified lubrication
specialist to determine if it is suitable for
continued use. Oil change intervals will depend
on the care used in keeping the oil clean, and
the operating conditions. Dirt and/or moisture
contamination will dictate that the oil should be
changed more often. Under normal use and
operating conditions , the hydraulic oil should
be changed every two years. Refer to Table 1.1
of this manual.
TM
Telehandler Series
Model ZB20044
402509
Page 137
Section 5 - Procedures
TM
Page 138
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
Relief
Adjustment
Test Port
TM
Telehandler Series
Model ZB20044
402509
Page 139
Section 5 - Procedures
Brake
Accumulators
TM
Page 140
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
NOTE
The accumulator is pre-charged with nitrogen gas to 175 psi.
1. Connect the ends of 2 test hoses supplied
with telehandler to the quick disconnect
ports at the main valve (Frame level section)
and the other ends to the rear axle lock valve
ports. (See picture below).
2. Remove the ground cable or the limit switch
cable connections
Main Valve
Test Hoses
Axle Lock
Valve
TM
Telehandler Series
Model ZB20044
402509
Page 141
Boom
5.4-1 Boom Hose Replacement
IMPORTANT
If there is evidence of a fluid leak in
the boom sections, check first to make
sure there are no loose hydraulic fittings
before attempting to change the hoses
in the boom.
Section 5 - Procedures
4. Remove hose from bulkhead on main boom
section (bottom of boom) and attach new
hose to old hose with a short union.
5. Remove hose from bulkhead on tension
bracket and pull hose through front of boom
taking care not to pull too far and lose hose
inside bottom of boom. It may be necessary
to either temporarily remove roller or raise
primary section at the rear to get the fittings
around the roller.
NOTE
The hydraulic hoses inside the boom
(carriage tilt, optional hydraulics) are
stretched over the roller to prevent
sagging and premature wear. Use only the
size, spec. and length of hose as specified
in the parts manual.
1. Loosen chain adjusting nut to end of adjuster.
6. Attach new hose at both ends and leave
loose.
7. Pull rope attached to tension bracket and bolt
bracket to boom.
8. Extend and retract boom several times.
9. Tighten hose fittings 38-42 ft. lb (52-58 Nm)
taking care not to twist hose.
TM
Page 142
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
Retract Chain
2. Extend boom 8.
3. Retract boom just enough to put slack in
extend chain.
4. Remove access door at rear of boom and
remove center bracket.
5. Remove two bolts holding extend chain
anchor to primary boom section.
6. Remove bolt that attaches extend chain to
adjuster.
TM
Telehandler Series
Model ZB20044
402509
Page 143
Chain Adjustment
Section 5 - Procedures
NOTE
Always maintain squareness between the
booms outer and inner tube.
TM
Page 144
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
Axles
Drain
NOTE
Axle is filled when oil is leaking from the
check port.
9. Reinstall both fill and check plugs.
Grease Point
Grease Point
Grease
Points
Grease
Points
Oil Drain
Plug
Grease Point
TM
Telehandler Series
Model ZB20044
402509
Page 145
Section 5 - Procedures
Grease Points
NOTE
Brush-on dry lubricant may be applied in the field where greasing is undesirable. This may be the
case in extremely sandy conditions, where abrasive particles can become entrapped in the grease.
(refer to Table 2.2 for recommended grease and fluid types and greasing intervals).
Add grease to the following components. Ensure grease reaches the bearing internals.
Brake pedal pivot pin
Lift cylinders
Axle lock cylinder
Frame level cylinder
Slave cylinders
Outrigger pins
NOTE
When greasing cylinders, pump grease into grease fittings located on both the base end and the rod
end of the cylinder.
TM
Page 146
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
TM
Telehandler Series
Model ZB20044
402509
Page 147
Section 5 - Procedures
1. Locate the grease fittings on the drive shaft and pump grease. (See diagram below)
TM
Page 148
Telehandler Series
Model ZB20044
402509
Section 5 - Procedures
Tires
5.7-1 Check Lug Nut Torque
1.
12
10
7
9
11
2.
3.
4.
TM
Telehandler Series
Model ZB20044
402509
Page 149
Notes
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