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MODELS ZB20044

Service Manual

ZOOM BOOM SERIES TELESCOPIC MATERIAL HANDLER

Part No. 402509AD October 2013


TM

This manual is based on Serial Numbers:


ZB 2044 85,800,072 & Below
Please refer to the website - www.skyjack.com for older Serial Numbers.

Skyjack Service Center


3451 Swenson Ave. St. Charles,
Illinois, 60174 USA
Phone: 630-262-0005
Toll Free: 1-800-275-9522
Fax: 630-262-0006
Email: service@skyjack.com

Parts (North America)


Toll Free: 1-800-965-4626
Toll Free Fax: 1-888-782-4825
E-mail: parts@skyjack.com

Skyjack Australia Pty Ltd.


4 Coates Place
Wetherill Park
New South Wales 2164
Australia
Tel: +61 (0) 28786 3200
Fax: +61(0) 28786 3222

Parts & Service (Europe)


Unit 1 Maes Y Clawdd
Maesbury Road Industrial Estate
Oswestry, Shropshire SY10 8NN UK
Phone: +44-1691-676-235
Fax: +44-1691-676-238
E-mail: info@skyjackeurope.co.uk

Skyjack Brasil
Alameda Jpiter, 710
Loteamento American Park Empresarial
Indaiatuba, SP, Brasil 13347-653
Tel: +55 19 3936 0132

SERVICE AND MAINTENANCE


Table of Contents
Section 1 - Scheduled Maintenance
Table of Contents
Section 2 - Maintenance Tables
List of Tables
Section 3 - Schematics
List of Contents
Section 4 - Troubleshooting
Troubleshooting
Section 5 - Procedures
List of Procedures
List of Tables

TM

Telehandler Series
Model ZB20044
402509

Page 3

The Safety Alert Symbol identifies important


safety messages on telehandlers, safety signs
in manuals or elsewhere. When you see this
symbol, be alert to the possibility of personal
injury or death. Follow the instructions in the
safety message.

This Safety Alert Symbol means attention!


Become alert! Your safety is involved.

DANGER

DANGER indicates an imminently hazardous situation which, if not


avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not


avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not


avoided, may result in minor or moderate injury. It may also be used
to alert against unsafe practices.

IMPORTANT

IMPORTANT indicates a procedure essential for safe operation and


which, if not followed, may result in a malfunction or damage to the
telehandler.

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

Section 1 - Scheduled Maintenance

Operators Responsibility for Maintenance

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.

Service & Maintenance

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

Operators Responsibility for Maintenance

Section 1 - Scheduled Maintenance

Scope of this Manual


a. This manual applies to the ANSI/ASME/ITSDF and CSA versions of the ZB20032 & ZB20044 telehandlers.
- Equipment identified with ANSI meets the ASME/ANSI B56.6 standard.
- Equipment identified with CSA meets the CSA B335-04 standard.
b.

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.

ANSI (United States)


Operators are required by the current ANSI standards to conform to national, territorial/provincial and local
health and safety regulations applicable to the operation of this telehandler.
warning
Failure to comply with your required responsibilities in the use and operation of the telehandler
could result in death or serious injury!

Operator Safety Reminders

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

Section 1 - Scheduled Maintenance

Operators Responsibility for Maintenance

Electrocution Hazard
This telehandler is NOT electrically insulated.

Use extreme caution around high-voltage overhead power lines


and maintain a Minimum Safe Approach Distance (MSAD) of 10 feet from source of power. Adhere to all
federal/national, state/provincial, or local safety regulations for your own protection.
No part of telehandler or payload should be brought closer to any energized overhead electrical conductor
with nominal phase voltage rating as specified below:
Voltage

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.

DO NOT USE TELEHANDLER AS A GROUND FOR WELDING.


DO NOT OPERATE TELEHANDLER DURING LIGHTNING OR STORMS.

TM

Telehandler Series
Model ZB20044
402509

Page 9

AC

Operators Responsibility for Maintenance

Section 1 - Scheduled Maintenance

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.

DO NOT use telehandler


as a man lift or equip this
telehandler with a personnel
work platform.

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 use carriage or


any other portion of the
boom for slinging loads

MAKE SURE all DANGER, WARNING, CAUTION


and INSTRUCTIONAL DECALS are in place and can
be read. Clean or replace decals as required.

KNOW all national, state/provincial and local rules


which apply to your telehandler and jobsite.

DO NOT elevate the boom


in windy or gusty conditions.

WEAR all the protective clothing and personal safety


devices issued to you or called for by job conditions.


DO NOT wear loose clothing,
dangling
neckties,
scarves, rings, wristwatches
or other jewelry while operating this telehandler.

DO NOT drive with boom


elevated.



DO NOT climb on this vehicle for any reason.

DO NOT operate on surfaces not capable of holding


the weight of the telehandler;
including the rated load (e.g.,
covers, drains, and trenches).

DO NOT stand on forks.


Failure to heed could result
in death or serious injury.

DO NOT maneuver a load


while moving. This greatly
increases the chance of spills
and injury.

TM

Page 10

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance

Operators Responsibility for Maintenance

Safety Precautions (Continued)

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

Section 1 - Scheduled Maintenance

Safety Precautions (Continued)

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.

If operation in areas with holes or


dropoffs is absolutely necessary, ensure that
all 4 wheels or outriggers
(if equipped) have contact
with firm surface. Then
level the frame. Once frame
is level the boom can be elevated. After elevation, the drive function must not be
activated.
DRIVE
DOWNHILL
UNLOADED.
Without
a load, the back end is the
heaviest part of the telehandler. Driving downhill
decreases potential for
tipover.

TM

Page 12

Telehandler Series
Model ZB20044
402509

AC
Section 1 - Scheduled Maintenance

Operators Responsibility for Maintenance

Safety Precautions (Continued)

Know and understand all safety precautions before going on to the next section.

DRIVE UPHILL LOADED. When holding a load,


driving uphill decreases potential for load to slip out.

TETHER LOADS that may


swing, keeping them close to
the ground. Provide ample
clearance for personnel to
guide the load safely.


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.

SLINGING LOADS is acceptable only when the load


is appropriately attached to
a jib boom or the throat of
a tilted fork, and the precautions outlined in Section 1.1
are followed.
BE AWARE of the telehandlers travel envelope,
especially when turning.
Keep sufficient clearance at
all times between the telehandler and any obstacles or
people.

KEEP OTHERS AWAY at
all times during operation.


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

Operators Responsibility for Maintenance

Section 1 - Scheduled Maintenance

Safety Precautions (Continued)

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.

DO NOT alter or disable safety devices.


DO NOT burn or drill holes in forks. Modifying any
part of telehandler or attachment affects its capacity
and/or stability.
DO NOT try to start the telehandler by pushing or
towing. Such operation may cause severe damage to
the transmission - Refer to Section 2 of the Operating
Manual.
IF DRIVING ON ROADS OPEN TO PUBLIC
TRAFFIC respect the local regulations.
THE OPERATORS CAB provides a falling object
protection structure (FOPS) and a rollover protection
structure (ROPS). Do not make any modification to
this structure. If damaged, the cab cannot be repaired.
It must be replaced.
STUNT driving and horseplay are prohibited.
ALWAYS USE FRONT steering when traveling at
high speeds; i.e. on highways or public roads.

ALWAYS look in the direction of travel. Reduce


speed and be careful especially when traveling in
reverse and/or turning. Bring the telehandler to a complete stop before changing the direction of travel.

STAY CLEAR of pinch points and rotating


parts on the material handler. Getting caught
in a pinch point or a moving part can cause
serious injury or death. Before performing
any maintenance on telehandler, follow the
shutdown procedure in Section 2.9-9 of the
Operating Manual.
DO NOT position the telehandler against another
object to steady the load.
SHUT DOWN by positioning the telehandler in a
safe location. Lower forks to ground, apply the parking
brake, move all controls to neutral and allow engine
to run at low idle for 3 to 5 minutes after a full load
operation. Stop engine and remove ignition key to prevent unauthorized use. Block tires.
WARNING
Always engage park brake and shut off
engine before leaving the operators cab.

TM

Page 14

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance

Operators Responsibility for Maintenance

Safety Precautions (Continued)

Know and understand the safety precautions before going on to next section.
WARNING

Operator should not use any telehandler


that:
does not appear to be working properly.
has been damaged or appears to have worn or
missing parts.
has alterations or modifications not approved by
the manufacturer.
has safety devices which have been altered or
disabled.
has been tagged or locked out for non-use or
repair.
bears an unapproved attachment.
Failure to avoid these hazards could
result in death or serious injury.

Maintenance and Inspection Schedule


The actual operating environment of the telehandler
governs the use of the maintenance schedule. The
inspection points covered in Table 1.1. Maintenance
and lnspection Checklist, indicates the areas of the
telehandler to be maintained or inspected and at what
intervals the maintenance and inspections are to be
performed.
Owners Annual Inspection Record
It is the responsibility of the owner to arrange quarterly
and annual inspections of the telehandler. Owners
Annual lnspection Record is to be used for recording the
date of the inspection, owners name, and the person
responsible for the inspection of the telehandler.
Replacement Parts
Use only original replacement parts. Parts such as
wheels, etc. with weight and dimensions different from
original parts will affect stability of the telehandler and
must not be used without manufacturers consent.
All replacement tires must be of the same size and load
rating as originally supplied tires; to maintain safety and
stability of telehandler.
Replacement attachments must be equivalent to the
originals and be associated with manufacturer approved
capacity charts.

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

Do not use in hazardous locations.


Perform a thorough jobsite inspection prior to
operating the telehandler, to identify potential
hazards in your work area.
Be aware of moving equipment in the area. Take
appropriate actions to avoid possible collision.

Consult SKYJACKs Service Department for optional


tires specifications and installation.

TM

Telehandler Series
Model ZB20044
402509

Page 15

Operators Responsibility for Maintenance


Hydraulic System & Component Maintenance
and Repair
The following points should be kept in mind when
working on the hydraulic system or any component:

Section 1 - Scheduled Maintenance


6.

All hydraulic components must be disassembled


in spotlessly clean surroundings. During
disassembly, pay particular attention to the
identification of parts to assure proper reassembly.
Clean all metal parts in a clean mineral oil solvent.
Be sure to thoroughly clean all internal passages.
After the parts have been dried thoroughly, lay
them on a clean, lint-free surface for inspection.

7.

Replace all O-rings and seals when overhauling


any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
amounts of petroleum jelly to hold O-rings in place
during assembly.

8.

Be sure to replace any lost hydraulic oil when


completing the installation of the repaired
component, and bleed any air from the system
when required.

9.

All hydraulic connections must be kept tight. A


loose connection in a pressure line will permit
the oil to leak out or air to be drawn into the
system. Air in the system can cause damage
to the components and noisy or erratic system
operation.

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.

Any structure has limits of strength and durability.


To prevent failure of structural parts of hydraulic
components, relief valves which limit pressure to
safe operating values are included in the hydraulic
circuits.
Tolerance of working parts in the hydraulic system
is very close. Even small amounts of dirt or foreign
materials in the system can cause wear or damage
to components, as well as general faulty operation
of the hydraulic system. Every precaution must
be taken to assure absolute cleanliness of the
hydraulic oil.
Whenever there is a hydraulic system failure
which gives reason to believe that there are metal
particles or foreign materials in the system, drain
and flush the entire system and replace the filter
cartridges. A complete change of oil must be
performed under these circumstances.
4. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic
oil reservoir, and fill the reservoir only through
the filter opening. The use of cloth to strain
the oil should be avoided to prevent lint from
getting into the system.

When removing any hydraulic component, be sure
to cap and tag all hydraulic lines involved. Also,
plug the ports of the removed components.

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.

Change filters annually. The filters will need


to be changed more often depending on the
operating conditions. Dirty, dusty, high moisture
environments may cause the hydraulic system to
be contaminated more quickly.

2.

Maintain a sufficient quantity of clean hydraulic oil


of the proper type and viscosity in the hydraulic
reservoir.

3.

Keep all connections tight.

TM

Page 16

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance


About this Section
This section contains the maintenance and inspection
schedule that is to be performed.
References are made to the procedures in Section 5
that outline detailed step-by-step instructions for checks
and replacements.
Service Bulletins
Before performing any scheduled maintenance
inspection procedure, refer to service bulletins found
in our web site: www.skyjack.com for updates related
to service and maintenance of this telehandler.
Maintenance and Inspection
Death or injury can result if the telehandler is not kept
in good working order. Inspection and maintenance
should be performed by competent personnel who are
trained and qualified on maintenance of this telehandler.
WARNING
Failure to perform each procedure as presented and scheduled may cause death,
serious injury or substantial damage.
NOTE
Preventive maintenance is the easiest and
least expensive type of maintenance.
Unless otherwise specified, perform each
maintenance procedure with the telehandler in the
following configuration:

- Telehandler parked on a flat and level surface


- Engine is turned off.

Scheduled Maintenance Inspections


Maintenance Instructions
This manual consists of four schedules to be done
for maintaining on a telehandler. Inspection schedule
frequency is shown below:

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

Make copies of the maintenance and inspection


checklist to be used for each inspection.
Check the schedule on the checklist for the type of
inspection to be performed.
Place a check in the appropriate box after each
inspection procedure is completed.
Use the maintenance and inspection checklist and
step-by-step procedures in Section 5 to perform
these inspections.
If any inspection receives a fail, tag and remove the
telehandler from service.
If any telehandler component(s) has been repaired,
an inspection must be performed again before
removing the tag. Place a check in the repair
column.

Legend

P = Pass
F = Fail
R = Repaired

Repair any damaged or malfunction components


before operating telehandler.
Keep records on all inspections.

TM

Telehandler Series
Model ZB20044
402509

Page 17

Scheduled Maintenance Inspections

Section 1 - Scheduled Maintenance

Table 1.1 MAINTENANCE AND INSPECTION CHECKLIST


Serial Number:
Model:
Hourmeter Reading:

Operator's Name (Printed):

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

Schedule Maintenance Inspections

Daily

Weekly or 40 Hours

A+B

Quarterly or 250 Hours

A+B+C

Annually or 1000 Hours

A+B+C+D

Schedule

Change Transmission Filter

Electrical

Main pins and bushings

C,D

Safety Switches

subcarriage pins and bushings

C,D

Mirrors

Rollers and Tracks

Hydraulic

Slide Pads

Cylinders

A,B,C,D

Chain

C,D
B,C,D
A,C

Boom Angle Indicator

Wheel/Tire Assembly

Proximity Sensor

Batteries and Cables

Lifting Attachment

Engine Air Filter

A,B,C

Engine Coolant

Muffler and Exhaust

Drive Axles

Forks

Fork Bars and Locks

Grease Fittings
Grease Fittings on Frame

Grease Fittings on Boom Assembly

Hub Oil

Change Differential Oil

Operator's Cab

Pinion Seal

ROPS/FOPS

Inner and Outer Shaft Seals

Seat

Hub Seals

Pedals

King Pins

C,D

Manual

Check Drive Shafts and U-Joints

C,D

Operator's Cab Controls

Axle Mounting Pins and Bushings

C,D

Function Tests

Axle Housing

Operator's Cab Controls

Steer Cylinder Assembly

Test Starter Operation

Steer Linkage

Test Horn

Test Reverse Alarm

Test Gauges

Engine Compartment
Engine Oil

A,C

Fuel Leaks

Test Lights

Hydraulic Pump

Test Switches

Belts and Hoses

Test Steering Wheel and Column

Fuel Tank

Test Boom and Attachment Functions

Change Fuel Filter

A,C

Test Frame Leveling and Level Indicator

Drain Water from Fuel Filter

C,D

Test Frame Level Lock

Hydraulic Tank

Test Accelerator Pedal

Hydraulic Oil

A,D

Test Driving and Service Brake Functions

Hydraulic Return Filter

A,C

Test Steering

Change Oil Filters

A,C

Test Parking Brake

Charging System

Test Outriggers (if equipped)

Operate and Check Shifting

Test Outrigger Control & Boom Extension


Interlock System

Check for Leaks

Check Transmission Disconnect

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

Section 1 - Scheduled Maintenance

Scheduled Maintenance Inspections

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

Scheduled Maintenance Inspections

Section 1 - Scheduled Maintenance

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

An over-inflated tire can explode and


may cause death or serious injury.

--

Check each wheel for damage and cracked


welds.

--

Check each lug nut for proper torque to


ensure none are loose.

--

Check each tire with an air pressure gauge


and add air as needed.

Drive Axle
-- Ensure drive axle is properly secured,
there are no loose or missing parts.

-- Grease weekly and check pins and


bushings to ensure there is no evidence
of damage.

WARNING

Check all tire treads and sidewalls for cuts,


cracks, punctures and unusual wear.

To safeguard maximum stability, achieve optimum


telehandler handling and minimize tire wear, it is
essential to maintain proper pressure in all airfilled tires.

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

Section 1 - Scheduled Maintenance

Scheduled Maintenance Inspections

44

200

Rear side View


Exhaust
System

WARNIN Use proper


tires.
DEC-007
tire pressure.
filling
when
correct
Maintain precautions
safety
TION
PER
THEN
AND
1 10
ATTEN
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

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.

5. Replace batteries if damaged or incapable of


holding a lasting charge.
WARNING
Use original or manufacturer-approved
parts and components for the
telehandler.
Engine Air Filter
-- Ensure there are no loose or missing
parts and there is no visible damage.
-- Ensure air cleaner vaccuator valve (if
applicable) is free from dirt or dust by
squeezing the valve lips.
B - Weekly Inspection
-- For engine air filter inspection procedure,
refer to Section 5.
C - Quarterly Inspection
-- For engine air filter replacement
procedure, refer to Section 5.
Engine Coolant
-- The coolant level should be between
the minimum and maximum marks.
Add coolant as needed. Refer to your
engine manual for recommended coolant
mixture.
Muffler and Exhaust
-- Ensure muffler and exhaust systems are
properly secured, with no evidence of
damage.
TM

Telehandler Series
Model ZB20044
402509

Page 21

Scheduled Maintenance Inspections

Section 1 - Scheduled Maintenance

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

1.1-8 Engine Compartment


-- Ensure compartment cover is secure and in
proper working order.
Engine Oil Level
-- Maintaining the engine components
is essential to good performance and
service life of the telehandler.
WARNING
Beware of hot engine components.

Check oil level on dipstick


-- Oil level should be in the safe zone.
Add oil as needed. Refer to Table2.2 for
recommended oil type.
C - Quarterly Inspection
-- For engine oil replacement procedure,
refer toSection 5

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.

Perform a visual inspection around the following


areas:
hoses and fittings
fuel pump
fuel filter
fuel tank
Fuel Filter
-- Ensure there are no loose or missing
parats and there is no visible damage or
evidence of leakage.
C - Quarterly Inspection
-- For fuel filter replacement procedure,
refer toSection 5
Hydraulic Pumps
-- Ensure there are no loose or missing
parts and there is no visible damage.
-- Ensure all bolts are properly tightened.
-- Ensure all fittings and hoses are properly
tightened and there is no evidence of
hydraulic oil leakage.
Belts
-- Ensure belts are in good working
condition and have correct tension.
Replace if belts are cracked, frayed, or
have chunks of material missing. Refer
to service manual for proper replacement
procedure.

TM

Page 22

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance

Scheduled Maintenance Inspections

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.

-- The hydraulic oil level should be between


the minimum and maximum marks on
the sight glass. Add oil as needed. Refer
to Table2.2 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

Scheduled Maintenance Inspections

Section 1 - Scheduled Maintenance

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.
--

Ensure all bolts and pins are properly


tightened.

--

Ensure there are no visible cracks in welds


or structure and there are no signs of
deformation.

--

Ensure all hoses are properly tightened and


there is no evidence of hydraulic leakage.

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

1.1-11 Lifting Attachment


-- Ensure there are no loose or missing parts
and there is no visible damage.
--

Ensure attachment is properly positioned and


secured. (refer to Section 2.14 of the operating
manual for attachments)

1.1-12 Grease Points


Maintaining properly greased components is essential
for good performance and service life of the telehandler.
If components are improperly greased, it could result
in component damage.
WARNING
Ensure that there are no personnel or
obstructions in maintenance area.
Greasing intervals are based on telehandler usage
of 40 hours. Use of telehandler may vary significantly
and greasing frequency must be adjusted to obtain
maximum service life.
B - Weekly Inspection
-- For greasing procedure, refer to Section
5.

TM

Page 24

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance

Scheduled Maintenance Inspections

Axle Grease
Points

Grease Points on Frame


1. Ensure telehandler is on a firm level surface
and is in stowed position.

Grease Points on Boom Assembly


1. Ensure telehandler is on a firm level surface
and is in stowed position.

2. Locate grease fittings (refer to label inside


operators cab) and pump grease in the
following:

2. Locate grease fittings (refer to label inside


operators cab) and pump grease in the
following:

-- king pins

-- main boom pivot bearing pins

-- axle lock cylinder (top and bottom)

-- retract chain rollers

-- lift cylinder (top and bottom, both sides)

-- hose rollers

-- frame level cylinders (top and bottom)

-- extension chains and rollers

-- outrigger pins

-- slide pads

-- slave cylinders (top and bottom)

-- attachment tilt cylinders (top and bottom)

3. Using a creeper, slide under the frame to


locate grease fittings and pump grease in
the following:

-- attachment pivot bearings

-- axle pivot bearings (front and rear)


-- drive shaft U-joint (front and rear)
-- slip joint on drive shaft (front and rear)

TM

Telehandler Series
Model ZB20044
402509

Page 25

Scheduled Maintenance Inspections

Section 1 - Scheduled Maintenance

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

4. TILT FORKS RIGHT

3
4

2. RAISE LOAD

DEC-002

17

15

15

14

18

12

5. TILT FORKS LEFT

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

7. TILT FORKS DOWN

13
14

8. MOVE LOAD BACKWARD

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

1. Only one person

15

11

9. MOVE LOAD FORWARD

17
18
10
PSI

20

19

19

20

CHART FOR REFERENCE


ONLY. SEE SERVICE
MANUALS FOR
AND OPERATOR'S
DETAILED SERVICE/MAINTENANCE
INFORMATION.

21
22

DEC-178

CHECK TIRE PRESSURE

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

Rollover and Falling Object Protective


Structure (ROPS/FOPS)
-- Ensure there is no visible damage.
WARNING
Do not modify, drill or alter the operators
cab in any way.
Seat
-- Ensure seat is properly secured with no
sign of visible damage.
-- Ensure seat belt is working properly with
no sign of visible damage.
Pedals
-- Ensure brake and accelerator pedals are
secure, no loose or missing parts, no sign
of visible damage and movements are
not obstructed.
Manual
-- Check to be sure manual storage box is
present and in good condition.
-- Ensure a copy of operating manual,
and other important documentation are
enclosed in manual storage box.
-- Ensure manual is legible and in good
condition.

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

1.1-13 Operators Cab

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"

-- Always return manual to the manual


storage box after use.
Operators Cab Controls
WARNING
Ensure that you maintain three points
of contact to mount/dismount the cab.
Use the steps of telehandler to access operators
cab.
-- Ensure door and windows (if equipped)
are secure and in proper working order.
-- Ensure steering wheel is secured with no
sign of visible damage.
-- Ensure all switches and controls are
properly secured with no sign of visible
damage.
-- Ensure all switches and controls are
returned to their neutral positions and
movements are not obstructed.
-- Ensure capacity charts are in place and
are legible.
DANGER
Do not operate the telehandler if capacity
charts are missing or not legible.

TM

Page 26

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance

AC

Scheduled Maintenance Inspections

1.1-14 Slinging Loads


CAUTION
Sling loads from appropriate attachment
to the jib boom or a tilted fork ONLY.
1.

Slinging of loads must only be performed following


a complete risk assessment by a qualified person
regarding the rigging and guiding of any such load.

2.

The rated capacity of the unit and attachment


at the sling position must not be exceeded. The
sling must be in good repair and restrained from
movement at all times.

TM

Telehandler Series
Model ZB20044
402509

Page 27

Function Tests

Section 1 - Scheduled Maintenance

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

1.2--1 Operators Cab Controls


WARNING
Ensure that you maintain three points of
contact to mount/dismount the cab.
Test Starter Operation
1. Enter cab and close door (if equipped).
WARNING
The seat belt must be worn at all times.
2. Sit in the drivers seat and fasten seat belt.
3. Using a spotter, adjust the mirrors.
4. Ensure parking brake is engaged.
5. Adjust the boom controller console.

Ensure that there are no personnel or


obstructions in test area and that there
is sufficient room to test all telehandler
functions.

TM

Page 28

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance

Function Tests

Transmission
Lever

WARNING
THIS VEHICLE IS EQUIPPED WITH A
BACKUP ALARM

ALARM MUST SOUND WHEN BACKING


IT IS THE DRIVER'S RESPONSIBILTY
TO OPERATE THIS VEHICLE SAFELY
BE SURE BACKUP ALARM IS OPERATING

THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO

WARNING

WARNING
DEC-013A

DEC-099

FOLLOW PROC

THIS UNIT IS EQUIPPED WITH REAR


AXLE TILT LOCK WHICH IS
ENERGIZED WHEN RED LIGHT IS LIT.
NEVER ATTEMPT TO LEVEL FRAME
WHEN BOOM IS ELEVATED OR
WHEN RED LIGHT IS LIT.
DEC-100

Extending ourselves
for you.

A
INE.
E,
:

VEHICLE BATTER

WARNING

1. ALWAYS LEVEL MACHINE


BEFORE RAISING BOOM.
2. ALWAYS LOWER AND RETRACT
BOOM BEFORE MOVING MACHINE.
3. NEVER USE FRAME LEVELLING
WHEN BOOM IS ELEVATED.

No Riders

DEC-109

IMPORT

CTION

FF for

1. Ensure the Keysw


at least
2. Disconnect the P
3. Disconnect the NE

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

TURN KEY TO ON, WAIT FOR GAUGE


TO INITIALIZE, THEN START ENGINE.

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

Test Lights (if equipped)


1. Use a spotter to check if all the lights are
working well. The spotter should maintain
a safe distance from telehandler.
2. Turn parking brake switch to off position.
Result: Rear brake lights should turn off.
3. Depress service brake pedal.

Result: Rear brake lights should turn on.
4. Select head/tail light (if equipped) switch
to on position.

Result: Head/tail lights should turn on.
5. Turn parking brake switch to on position.
6. Select left turn signal (if equipped) rocker
switch to on position.

Result: The indicator light and left signal
lights should flash.
7. Select right turn signal (if equipped) rocker
switch to on position.

Result: The indicator light and right signal
lights should flash.

2. Depress service brake pedal and shift the


transmission lever backward.

Result: The reverse alarm should sound
and reverse light (if equipped) should turn
on.

TM

Telehandler Series
Model ZB20044
402509

Page 29

Function Tests

Section 1 - Scheduled Maintenance

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

Test Boom and Attachment Functions


WARNING
Ensure that there are no personnel or
obstructions in test area and that there
is sufficient room to test all telehandler
functions.
1. Ensure the parking brake indicator light is
on.
2. Raise the boom by pulling the boom/
attachment joystick backward.

Result: Boom should raise and boom
angle indicator should be functioning.
3. Extend the boom by moving the boom/
attachment joystick to the right.
Result: Boom should extend and boom
extension indicators are visible.

4. Tilt attachment forward by pressing and


holding the thumb button while moving
joystick forward.
Result: Attachment should tilt forward.
5. Tilt attachment backward by pressing and
holding the thumb button while moving
joystick backward.
Result: Attachment should tilt backward.
6. Retract the boom by moving the boom/
attachment joystick to the left.
Result: Boom should retract.
7. Lower the boom by moving the boom/
attachment joystick forward.

Result: Boom should lower.
8. Raise the boom until attachment is 2 feet
above the ground.
IMPORTANT
Test all attachment functions if telehandler
is equipped with optional attachments.
Refer to Section 2.14 in the operating
manual
for
optional
attachments
operation.

TM

Page 30

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance

Function Tests

WARNING

WARNING
THIS VEHICLE IS EQUIPPED WITH A
BACKUP ALARM

ALARM MUST SOUND WHEN BACKING


IT IS THE DRIVER'S RESPONSIBILTY
TO OPERATE THIS VEHICLE SAFELY
BE SURE BACKUP ALARM IS OPERATING

DEC-109

IMPORT
THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO
FOLLOW PROC

WARNING

WARNING
DEC-013A

DEC-099

THIS UNIT IS EQUIPPED WITH REAR


AXLE TILT LOCK WHICH IS
ENERGIZED WHEN RED LIGHT IS LIT.
NEVER ATTEMPT TO LEVEL FRAME
WHEN BOOM IS ELEVATED OR
WHEN RED LIGHT IS LIT.

DEC-016

DEC-100

Extending ourselves
for you.

A
INE.
E,
:

VEHICLE BATTER

WARNING

1. ALWAYS LEVEL MACHINE


BEFORE RAISING BOOM.
2. ALWAYS LOWER AND RETRACT
BOOM BEFORE MOVING MACHINE.
3. NEVER USE FRAME LEVELLING
WHEN BOOM IS ELEVATED.

No Riders

CTION

FF for

1. Ensure the Keysw


at least
2. Disconnect the P
3. Disconnect the NE

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

1. TIGHTEN WHEEL NUTS DAILY


FIRST 150 HOURS OPERATION
2. CHECK AXLE & SPRING
MOUNTING BOLTS REGULARLY

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

4. TILT FORKS RIGHT

3
4

2. RAISE LOAD

DEC-002

17

15

15

14

18

12

5. TILT FORKS LEFT

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

CHECK TIRE PRESSURE

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

CHART FOR REFERENCE


ONLY. SEE SERVICE
MANUALS FOR
AND OPERATOR'S
DETAILED SERVICE/MAINTENANCE
INFORMATION.

PRESSURE

TURN KEY TO ON, WAIT FOR GAUGE


TO INITIALIZE, THEN START ENGINE.

TURN SIGNALS

DOWN

11

9. MOVE LOAD FORWARD

OTHER OBSTRUCTIONS

PARK
BRAKE

14

8. MOVE LOAD BACKWARD

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

1. Only one person

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

Test Frame Leveling and Level Indicator

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

Test Rear Axle Lock

1. Ensure parking brake switch is on.

1. Ensure parking brake switch is on.

2. Tilt frame to the right by moving frame level


joystick to the right.
Result: Frame should tilt to the right.

2. Raise boom above 45 - boom angle and


attempt leveling the frame to the right or
to the left.

Result: Rear axle lock light should
illuminate and frame should not tilt to right
or left.

3. Tilt frame to the left by moving frame level


joystick to the left.
Result: Frame should tilt to the left.
4. Use the frame level indicator to ensure
frame is level.

3. Lower the boom until attachment is 2 feet


above the ground.
Test Accelerator Pedal
1. Ensure parking brake switch is on.
2. Depress accelerator pedal slowly.

Result: The engine RPM should increase.
3. Release the accelerator pedal.

Result: The engine RPM should decrease.

TM

Telehandler Series
Model ZB20044
402509

Page 31

Function Tests

Section 1 - Scheduled Maintenance

Transmission Lever

IT IS THE DRIVER'S RESPONSIBILTY


TO OPERATE THIS VEHICLE SAFELY
BE SURE BACKUP ALARM IS OPERATING

IMPORT

DEC-013A

DEC-099

THIS UNIT IS EQUIPPED WITH REAR


AXLE TILT LOCK WHICH IS
ENERGIZED WHEN RED LIGHT IS LIT.
NEVER ATTEMPT TO LEVEL FRAME
WHEN BOOM IS ELEVATED OR
WHEN RED LIGHT IS LIT.
DEC-100

Extending ourselves
for you.

A
INE.
E,
:

VEHICLE BATTER

WARNING

1. ALWAYS LEVEL MACHINE


BEFORE RAISING BOOM.
2. ALWAYS LOWER AND RETRACT
BOOM BEFORE MOVING MACHINE.
3. NEVER USE FRAME LEVELLING
WHEN BOOM IS ELEVATED.

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

ALARM MUST SOUND WHEN BACKING

CTION

FF for

1. Ensure the Keysw


at least
2. Disconnect the P
3. Disconnect the NE

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

TURN KEY TO ON, WAIT FOR GAUGE


TO INITIALIZE, THEN START ENGINE.

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).

3. Depress service brake pedal.


4. Release parking brake.
Result: Parking brake indicator light
should turn off.
5. Shift transmission lever forward and
release the service brake pedal slowly.

Result: Telehandler should move forward.
6. Depress service brake pedal slowly.

Result: Telehandler should stop.
7. Shift transmission lever backward and
release the service brake pedal slowly.

Result: Telehandler should move
backward.

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.

8. Depress service brake pedal slowly.



Result: Telehandler should stop.
9. Return transmission lever to neutral
position and engage parking brake.

TM

Page 32

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance

Function Tests

Steering Wheel

Hour Meter

IT IS THE DRIVER'S RESPONSIBILTY


TO OPERATE THIS VEHICLE SAFELY
BE SURE BACKUP ALARM IS OPERATING

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

ALARM MUST SOUND WHEN BACKING

DEC-013A

DEC-099

THIS UNIT IS EQUIPPED WITH REAR


AXLE TILT LOCK WHICH IS
ENERGIZED WHEN RED LIGHT IS LIT.
NEVER ATTEMPT TO LEVEL FRAME
WHEN BOOM IS ELEVATED OR
WHEN RED LIGHT IS LIT.
DEC-100

Front Display
Panel

Extending ourselves
for you.

A
INE.
E,
:

VEHICLE BATTER

WARNING

1. ALWAYS LEVEL MACHINE


BEFORE RAISING BOOM.
2. ALWAYS LOWER AND RETRACT
BOOM BEFORE MOVING MACHINE.
3. NEVER USE FRAME LEVELLING
WHEN BOOM IS ELEVATED.

No Riders

CTION

FF for

1. Ensure the Keysw


at least
2. Disconnect the P
3. Disconnect the NE

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

TURN KEY TO ON, WAIT FOR GAUGE


TO INITIALIZE, THEN START ENGINE.

DEC-320

DEC-322

HORN

DEC-308E

RIGHT
ON

FRONT
CRAB

Round Steer

OFF
DEC-216

6. Steer the telehandler straight ahead until


all four wheels are aligned.
7. Depress service brake pedal until the
telehandler stops.
Front Steer

Figure 2-2 Round Steering


1. Ensure path of intended motion is clear.
2. Ensure all four wheels are aligned straight
ahead.
3. Select parking brake switch to off position
and depress service brake pedal.
4. Select rocker switch to forward
position for round steering.

5. Turn the steering wheel to the left or right


and drive forward.

Result: Telehandler should move in the
chosen direction, producing a turning
circle, with front wheels pointing in the
opposite direction to the rear wheels.

Figure 2-3 Front Steering


8. Select rocker switch to middle
position for front steering.

9. Turn the steering wheel to the left or right


and drive forward.

Result: Only front wheels of the telehandler
should turn in the chosen direction.

TM

Telehandler Series
Model ZB20044
402509

Page 33

Function Tests

Section 1 - Scheduled Maintenance

Steering Wheel

Hour Meter

THIS VEHICLE IS EQUIPPED WITH A


BACKUP ALARM

ALARM MUST SOUND WHEN BACKING

DEC-109

DEC-013A

DEC-099

THIS UNIT IS EQUIPPED WITH REAR


AXLE TILT LOCK WHICH IS
ENERGIZED WHEN RED LIGHT IS LIT.
NEVER ATTEMPT TO LEVEL FRAME
WHEN BOOM IS ELEVATED OR
WHEN RED LIGHT IS LIT.
DEC-100

Front Display
Panel

Extending ourselves
for you.

A
INE.
E,
:

FOLLOW PROC

VEHICLE BATTER

WARNING

1. ALWAYS LEVEL MACHINE


BEFORE RAISING BOOM.
2. ALWAYS LOWER AND RETRACT
BOOM BEFORE MOVING MACHINE.
3. NEVER USE FRAME LEVELLING
WHEN BOOM IS ELEVATED.

No Riders

IT IS THE DRIVER'S RESPONSIBILTY


TO OPERATE THIS VEHICLE SAFELY
BE SURE BACKUP ALARM IS OPERATING

IMPORT
THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO

WARNING

WARNING

WARNING

Transmission
Lever

CTION

FF for

1. Ensure the Keysw


at least
2. Disconnect the P
3. Disconnect the NE

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

TURN KEY TO ON, WAIT FOR GAUGE


TO INITIALIZE, THEN START ENGINE.

DEC-320

DEC-322

HORN

DEC-308E

FRONT
CRAB

UP400774

OFF

10. Steer the telehandler straight ahead until


all four wheels are aligned.
11. Depress service brake pedal until the
telehandler stops.
Crab Steer

OFF
DEC-216

13. Turn the steering wheel to the left or right


and drive forward.

Result: Telehandler should move in the
chosen direction with both front and rear
wheels in the same direction.
14. Steer the telehandler straight ahead until
all four wheels are aligned.
15. Depress service brake pedal until the
telehandler stops.

Figure 2-4 Crab Steering


12. Select rocker switch to backward
position for crab steering.

TM

Page 34

Telehandler Series
Model ZB20044
402509

Section 1 - Scheduled Maintenance

Function Tests

Steering Wheel

WARNING
THIS VEHICLE IS EQUIPPED WITH A
BACKUP ALARM

ALARM MUST SOUND WHEN BACKING


IT IS THE DRIVER'S RESPONSIBILTY
TO OPERATE THIS VEHICLE SAFELY
BE SURE BACKUP ALARM IS OPERATING

WARNING

WARNING
DEC-013A

DEC-099

THIS UNIT IS EQUIPPED WITH REAR


AXLE TILT LOCK WHICH IS
ENERGIZED WHEN RED LIGHT IS LIT.
NEVER ATTEMPT TO LEVEL FRAME
WHEN BOOM IS ELEVATED OR
WHEN RED LIGHT IS LIT.
DEC-100

Extending ourselves
for you.

A
INE.
E,
:

VEHICLE BATTER

WARNING

1. ALWAYS LEVEL MACHINE


BEFORE RAISING BOOM.
2. ALWAYS LOWER AND RETRACT
BOOM BEFORE MOVING MACHINE.
3. NEVER USE FRAME LEVELLING
WHEN BOOM IS ELEVATED.

No Riders

DEC-109

IMPORT
THIS VEHICLE IS E
CUMMINS QSB ELE
TO PREVENT CO
FOLLOW PROC

CTION

FF for

1. Ensure the Keysw


at least
2. Disconnect the P
3. Disconnect the NE

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

TURN KEY TO ON, WAIT FOR GAUGE


TO INITIALIZE, THEN START ENGINE.

DEC-320

DEC-322

HORN

DEC-308E

FRONT
CRAB

Parking Brake
Switch

OFF
DEC-216

Outriggers
Switches

Test Parking Brake


CAUTION
Refer to Section 2.9-3 for instructions on
how to drive on a slope.

Test Outriggers (If Equipped)


WARNING

1. Ensure path of intended motion is clear.

Ensure that there are no personnel or


obstructions in test area and that there
is sufficient room to test all telehandler
functions.

2. Ensure parking brake switch is off.

1. Ensure parking brake switch is on.

3. Drive the telehandler on a slope.

2. Lower outriggers by depressing and


holding rocker switch forward

continuously.

Result: Outriggers should lower.

4. Depress service brake pedal slowly until


telehandler stops.
5. Select parking brake rocker switch to
on position and release service brake
pedal.

Result: Parking brake indicator light
should turn on and telehandler should not
roll

3. Raise outriggers by depressing and


holding rocker switch backward

continuously until outriggers are


fully raised.

Result: Outriggers should raise up.

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

Telehandler Specifications and Features..................................................................................................................... 38


Recommended Fluids/Lubrication.............................................................................................................................. 39
Axles Torque Specifications........................................................................................................................................ 40
Tire Specifications....................................................................................................................................................... 41
Pressure Settings......................................................................................................................................................... 42

TM

Telehandler Series
Model ZB20044
402509

Page 37

Service and Maintenance

Section 2 - Maintenance Tables and Diagrams

Table 2.1 Telehandler Specifications and Features


MODEL

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) **

12 volts negative ground


HP-31E
2
725 A
1450 A
1100 A
180 minutes
243 in (617 cm)
102 in (259 cm)
108 in (274 cm)
41,500 lbs. (18,370 kg)
45,000 lbs. (20,000 kg)
20,000 lbs. (9,071 Kg)
138 in (350 cm)
220 in (559 cm)
2
32 ft. 4 in (985 cm)
16 ft 6 in (502 cm)
2 x 6 x 60 in
(6.9 x 15.2 x 152.4 cm)
19
80

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

* Measured with boom fully retracted.


** Under no circumstances should the frame level cycle take less
than 15 seconds to complete in either direction.

TM

Page 38

Telehandler Series
Model ZB20044
402509

Section 2 - Maintenance Tables and Diagrams

Service and Maintenance

Table 2.2 Recommended Fluids/Lubrication

MODEL

En
gi

ne

Fuel Type

on

ZB20044
Diesel

Fuel Tank Capacity

49 gal (185 L)

Recommended
Oil Type

15W40 CC/SF

Coolant Type

60/40 Ethylene glycol/distilled water

Type

ATF Dexron III

Capacity

6.3 gal (24 L)

Tr
an

sm

is

si

ZB20032

SAE 80W-90 GL-5


Planetary Wheel Ends
Type

Anti-wear ISO Gr. 32

yd
ra

ul
ic

O
il

Ax
le
s

Differential

Tank Capacity

Sunaplex 992 E.P. 2

re
a

se

Boom Slide Bearings

55 gal (208 L)

General Greasing

Multi Purpose E.P.


240B

TM

Telehandler Series
Model ZB20044
402509

Page 39

Service and Maintenance

Section 2 - Maintenance Tables and Diagrams


Table 2.3 Axles Torque Specifications
Type of Bolt
8.8

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

Note: 1 Nm = 0.7376 ft-lb


Screw-locking, Sealing and Lubricating Materials
Loctite 242
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Before using it, completely remove any lubricant by using the specific activator.
Loctite 270
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Before using it, completely remove any lubricant by using the specific activator. To remove parts, it may
be necessary to heat them at 80C approx.
TM

Page 40

Telehandler Series
Model ZB20044
402509

Section 2 - Maintenance Tables and Diagrams

Service and Maintenance

Table 2.4 Tire Specifications


Standard Tires
Tire Size

17.50 - 25
90 psi

Pressure
Tire Ply Rating

16 PR

Wheel Nuts Torque

450 - 500 ft.lb


239A

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

Service and Maintenance

Section 2 - Maintenance Tables and Diagrams


Table 2.5 Pressure Settings

Model ZB20044
Maximum Pump Pressure

Stand-by Pump Pressure

P1

3150 psi

P2

3200 psi

P1

500 psi

P2

550 psi
3200 psi

Lift

Maximum pump pressure controlled


3200 psi
3200 psi

Extension

Maximum pump pressure controlled


3200 psi

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

Frame Level Cylinder

Auxiliary Hydraulics

Outrigger

Port Relief

Port Relief

Port Relief

Pressure Reducing Valve

Pilot Pressure

325 psi

Priority Valve Pressure Relief

Steering Pressure

2800 psi
250A

Note: all pressure settings to be checked at idle

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

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.1 Hydraulic Symbol Chart

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

MAIN LINES Solid

PILOT LINES Dashed

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

Service and Maintenance

Section 3 - System Component Identification and Schematics


3.2 Electrical Symbol Chart

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

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.3 Harnesses Color Codes

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

TO INSTRUMENT CLUSTER (exclude PV100)

BLU/RED

OIL TEMPERATURE (TRANSMISSION)

BRN/RED

STARTER SOLENOID

GRN

HORN

PNK

FROM BREAKER TO TO DIFF. LOCK SWITCH

FUEL GAUGE

GRY

FROM SWITCH TO DIFF. LOCK SOLENOID

BRAKE PRESSURE WARNING LIGHT

BLU

FROM DIFF. LOCK SWITCH TO


INSTRUMENT CLUSTER

STEERING

DIFFERENTIAL LOCK
LT GRN

LT GRN/RED

FRAME LEVEL/AXLE LOCK

FROM BREAKER TO STEERING SWITCH

GRN/YEL

FROM BREAKER TO AXLE LOCK RELAY

YEL/BLK

ROUND STEER

GRN/BLK

AXLE LOCK LIGHT

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

FROM SWITCH TO PARK BRAKE LIGHT

FROM BREAKER TO BOX

WHT

FROM BOX TO OUTRIGGER SWITCHES

WHT/BLU

FROM 400425 BOX TO DUMP VALVE

WHT/GRY

LEFT UP

WHT/BLK

FROM SWITCH TO DECLUTCH RELAY

LT BLU/BLK

LEFT DOWN

WHT/BLK/RED

FROM SWITCH TO PARK BRAKE OFF

LT BLU/BLK

RIGHT UP

WHT/RED

RIGHT DOWN

WHT/RED/GRN

FROM 401392 HARNESS TO LIFT CYLINDER


PRESS OR PROXIMITY SWITCHES

WHT/ORG

TRANSMISSION
FORWARD SOLENOID

RED

REVERSE SOLENOID

WHT

OPTIONAL LIGHTS

st

BRN

HEADLIGHTS

ORG/GRN

nd

BLK

HEADLIGHTS AND TAILLIGHTS

ORG/BLK/WHT

BRAKE LIGHTS

ORG/RED

DIVERTER VALVE

TAN

SIGNAL LIGHTS

ORG

LEFT FRONT & LEFT REAR

ORG/BLK

ALTERNATOR EXCITER

PUR

RIGHT FRONT & RIGHT REAR

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

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.4 Hydraulic Schematic Parts List


Index
No.

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)

VALVE, Counterbalance (Lift cylinder)

VALVE, Counterbalance (Lift cylinder)

1
1
1
1
1
1
1
1
1
1

VALVE, Counterbalance (Boom extension cylinder)


VALVE, Counterbalance (Carriage tilt cylinder)
VALVE, Counterbalance (Right, Frame level cylinder)
VALVE, Counterbalance (Left, Frame level cylinder)
VALVE, Counterbalance (Right outrigger)
VALVE, Counterbalance (Left outrigger)
VALVE, Crossover relief
VALVE, Check
VALVE, Check
FILTER, Return line

Parts list continued on following page.

TM

Telehandler Series
Model ZB20044
402509

Page 49

Service and Maintenance

Section 3 - System Component Identification and Schematics


3.4 Hydraulic Schematic Parts List (Continued)

Index
No.

Skyjack
Part No.

Qty.

Description

Parts list continued from previous page.

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

VALVE, Pressure reduce


VALVE, Priority
SWITCH, Pressure
SWITCH, Pressure
SWITCH, Pressure
SWITCH, Pressure
VALVE, Relief (Part of priority valve)

VALVE, Relief (Part of main valve)

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

VALVE, Steering function

Parts list continued on following page.

TEST PORT

VALVE, Diverter
VALVE, Charge

TM

Page 50

Telehandler Series
Model ZB20044
402509

AB
Section 3 - System Component Identification and Schematics

Service and Maintenance

3.4 Hydraulic Schematic Parts List (Continued)


Index
No.

Skyjack
Part No.

Qty.

Description

Parts list continued from previous page.

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

VALVE, Dual brake pedal


VALVE, Park brake
VALVE, Diverter
VALVE, Dump, Frame level
VALVE, Axle lock

TM

Telehandler Series
Model ZB20044
402509

Page 51

Service and Maintenance

Section 3 - System Component Identification and Schematics


3.5 Electrical Component Parts List

SUPPLY (B+) (Common)


COMMON
COIL
CONTROL
(B+)
CONTROL (B+)

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

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.5 Electrical Component Parts List (Continued)


Index
No.

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

CIRCUIT BREAKER, Self resetting (6 A), Diverter valve


CIRCUIT BREAKER, Self resetting (6 A), Outrigger
CIRCUIT BREAKER, Self resetting (10 A), Transmission shifter
CIRCUIT BREAKER, Self resetting (10 A), Dash power
CIRCUIT BREAKER, Self resetting (10 A), Parking brake
CIRCUIT BREAKER, Self resetting (20 A), Signal lights
CIRCUIT BREAKER, Self resetting (6 A), Alternator
CIRCUIT BREAKER, Self resetting (20 A), Axle lock/Frame leveling
CIRCUIT BREAKER, Self resetting (6 A), Steering
CIRCUIT BREAKER, Self resetting (10 A), Auxiliary hydraulic
CIRCUIT BREAKER, Self resetting (20 A), Light power
CIRCUIT BREAKER, Self resetting (20 A), Heater power
CIRCUIT BREAKER, Self resetting (20 A), Wiper power
CIRCUIT BREAKER, Self resetting (20 A), Boom light power
CIRCUIT BREAKER, Self resetting (20 A), Aux light power
CIRCUIT BREAKER, Self resetting (30 A)
CIRCUIT BREAKER, Self resetting (50 A)
DIODE
FUSE, 5 Amp
FUSE, 5 Amp
FUSE, 4 Amp
FUSE, 4 Amp
FUSE, 4 Amp
FUSE, 5 Amp

-
-
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

COIL, Right lower

COIL, Frame leveling

CCP012D

COIL, Axle lock

-
LY2

1
1

SOLENOID, Starter
RELAY, DPDT

Parts list continued on following page.

TM

Telehandler Series
Model ZB20044
402509

Page 53

Service and Maintenance

Section 3 - System Component Identification and Schematics

3.5 Electrical Component Parts List (Continued)


Index
No.

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

Parts list continued from previous page


COIL, Diverter valve

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

SOLENOID, First, Transmission


SOLENOID, Second, Transmission
SOLENOID, Forward, Transmission
SOLENOID, Reverse, Transmission
COIL, 3-way diverter valve
COIL, 3-way diverter valve
HEATER, Optional
HOUR METER
GAUGE, S-W Fuel level
GAUGE, 140-320 Transmission oil temperature
BATTERY (12 V, 725CCA)
BATTERY (12V, 725 CCA))
FUEL SENDER
TEMPERATURE SENDER
SWITCH, Ignition
SWITCH, Horn
SWITCH, Rocker (transmission disconnect)
SWITCH, Rocker SPCO (steering mode selector)
SWITCH, Rocker SPDT (park brake)
SWITCH, Rocker momentary (Left outrigger)
SWITCH, Rocker momentary (Right outrigger)
SWITCH, Rocker (Left turn signal)
SWITCH, Rocker (Right turn signal)
SWITCH, (Push-pull, 75A) lights
SWITCH, Boom lights
SWITCH, Aux lights
LIGHT, Interior (dome)
MOTOR, Top wiper
MOTOR, Front wiper
FAN, Ventilation
SWITCH, Heater fan
MOTOR, Rear wiper
SWITCH, Park brake pressure

SWITCH, Pressure (Brake charge)

SWITCH, Pressure (Reverse Alarm)

1
1
1

SWITCH, Brake light pressure


SWITCH, Battery Disconnect Optional
SWITCH, Mercury, Boom angle

TM

Page 54

Telehandler Series
Model ZB20044
402509

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.6 Priority Valve and Port Identifications

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

Service and Maintenance

Section 3 - System Component Identification and Schematics


3.7 Steering Valve and Port Identifications

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

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.8 Diverter Valve and Port Identifications

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

Service and Maintenance

Section 3 - System Component Identification and Schematics

3.9 Parking Brake Valve and Port Identifications

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

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.10 Brake Charge Valve and Port Identifications

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

Service and Maintenance

Section 3 - System Component Identification and Schematics

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

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.12 Cross-Over Relief Valve and Port Identifications

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

Service and Maintenance

Section 3 - System Component Identification and Schematics

3.13 Dual Charge Brake Pedal and Port Identifications

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

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.14 Orbital Steering Motor and Port Identifications

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

3.15a Main Valve and Main Ports Identifications


A B C D E F G H

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

3.15b Main Valve and Pilot Ports Identifications


A B C D E F G H

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

3.16 Hydraulic Cylinders Identification


A B C D E F G H

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

3.17 Hydraulic Manifolds Location


A B C D E F G H

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

3.18a Instrument Panel Wiring Diagram (Base Model) - Part 1 of 2


A B C D E F G H
CNX

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

CONNECTOR REAR VIEW

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

CONNECTOR REAR VIEW

CONNECTOR REAR VIEW

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

CB10 (6A) STEERING

P29

PIN B

E2

CB9 (20A) AXLE LCK/FRAME LVL

P3

G
H

CONNECTOR REAR VIEW

K1

CB8 (6A) ALTERNATOR

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

CB5 (10A) DASH POWER

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

CONNECTOR REAR VIEW

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

PIN 8 PIN 7 PIN 6 PIN 5

P11

P5

PIN

CONNECTOR REAR VIEW

CB1 (6A) DIVERTER VALVE

J10

PIN A
PIN B
PIN C

K1
TRANS. DISCONNECT RELAY

CB11 (10A) AUX. HYDR.

STEERING
CNX

30

CB3 (10A) OUTRIGGERS

PIN 1 PIN 2 PIN 3 PIN 4

PIN D

LABEL
LEGEND

CNX
85

30

CONNECTOR REAR VIEW

WIRE
ITEM

86

PIN B

PARKING BRAKE/TRANS DISCONNECT


PIN A

LABEL
LEGEND

CB6 (10A) PARKING BRAKE

87

CONNECTOR REAR VIEW


SHOWN WITHOUT BACKSHELL

BLACK

BLUE/YELLOW

85

J8

PIN C

CONNECTOR REAR VIEW

P5

CB7 (20A) SIGNAL LIGHTS

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 / WHITE

16 AWG BLACK / RED / WHITE

16 AWG BLACK

16 AWG BLACK

16 AWG GREEN / YELLOW

16 AWG WHITE / BLACK

16 AWG WHITE / BLACK / RED

16 AWG WHITE / RED

16 AWG WHITE / RED / GREEN

16 AWG WHITE

16 AWG ORANGE

14 AWG RED

16 AWG ORANGE / GREEN

16 AWG TAN

16 AWG L BLUE / RED

16 AWG BLACK

16 AWG BLUE / WHITE

18 AWG PURPLE

16 AWG YELLOW / BLACK

16 AWG BLACK

16 AWG BLUE / YELLOW

16 AWG BLUE / RED

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 GREEN / WHITE

16 AWG GREEN / BLACK

16 AWG WHITE / BLUE

16 AWG ORANGE

16 AWG L BLUE

3
NO

NO

16 AWG L BLUE / BLACK

16 AWG L BLUE / BLACK

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

16 AWG L BLUE / BLACK


16 AWG L BLUE

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

16 AWG GREEN / WHITE


16 AWG BLACK

STEERING

P11
A

OUTRIGGER
POWER

TURN
SIGNALS

HEATER
POWER

KEY

SW11 COM

COM

PARKING
BRAKE

COIL -

TO
MAIN
HARNESS

INSTRUMENT
CLUSTER

GROUND

16 AWG GREEN / BLACK

16 AWG WHITE

A
J17
A

16 AWG ORANGE / BLUE

16 AWG ORANGE / BLACK

2
14 AWG RED

P12
B

16 AWG ORANGE / GREEN

J40

K1
30

J15
1

16 AWG TAN

16 AWG BLACK

16 AWG BLACK / BLUE

J10
B

16 AWG L BLUE / RED

K1
86
16 AWG L BLUE / BLACK

8
18 AWG PURPLE
16 AWG PINK

10

9
16 AWG YELLOW / BLACK

16 AWG BLUE

16 AWG BROWN / RED

18 AWG GRAY

16 AWG YELLOW / BLUE

3
P2
11

J8
1

E2

16 AWG YELLOW / BLUE

18 AWG GRAY

16 AWG BROWN / RED

16 AWG BLUE

16 AWG L BLUE

16 AWG BLUE / RED

16 AWG BLACK

10 AWG BLACK

3.18b Instrument Panel Wiring Diagram (Base Model) - Part 2 of 2


A B C D E F G H

M401949E-3

Telehandler Series
Model ZB20044
402509

3.19 Main Wiring Harness


A B C D E F G H
K220-NO-2
J290
ALTERNATOR +

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

CONNECTOR REAR VIEW


PIN C

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

16 AWG BROWN / RED 1

BRAKE PRESSURE

16 AWG BLUE 9

HORN

16 AWG PINK 39

FUEL SENDER

16 AWG GRAY 6

PIN A PIN B PIN C PIN D

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

16 AWG YELLOW / BLACK 28


16 AWG BLACK

AXLE/FRAME SOLENOIDS

16 AWG GREEN

PARK BRAKE SW.

16 AWG YELLOW

GROUND

CB220-AUX

23

16 AWG YELLOW / BLUE 9

BOOM ANGLE SW. OUTPUT

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

CONNECTOR REAR VIEW


PIN 12

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

3.20 Engine Harness (QSB4.5 Tier 3)


A B C D E F G H

J298 COOLANT LEVEL


CONNECTOR REAR VIEW

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

KEY SWITCH SIGNAL

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

CONNECTOR REAR VIEW

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

OFF IDLE SWITCH

C134
C109
C123

16 AWG WHITE

SIGNAL

18 AWG BLACK

RETURN

18 AWG RED

SUPPLY

18 AWG GRAY

ON IDLE SWITCH

18 AWG GRAY

OFF IDLE SWITCH

18 AWG GREEN

17

SAE J1939 -

18 AWG CLEAR

29

SAE J1939 GROUND

18 AWG YELLOW

28

SAE J1939 +

C122
C111
C101

F102
SAE J1939 - 47

PIN B

SAE J1939 GROUND 37

J1
CONNECTOR REAR VIEW
SCALE = 2:1

SAE J1939 + 46

C147
C137
C146

SPL295B
18 AWG GREEN

SPL295A
18 AWG YELLOW

18 AWG YELLOW

CONNECTOR REAR VIEW


SCALE = 2:1

J102
STARTER
SOLENOID

J299 GRID HEATER

J296 ECM POWER

CONNECTOR REAR VIEW

CONNECTOR REAR VIEW


PIN A

INTAKE AIR HEATER OUTPUT 40

C140

SPL295C
18 AWG CLEAR

J295 ENGINE CONTROL

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

COOLANT LEVEL INPUT 28


COOLANT LEVEL RETURN 32

C128
C132

18 AWG GRAY
18 AWG GRAY

INTAKE AIR HEATER RETURN

J298
COOLANT LEVEL
A
COOLANT LEVEL INPUT
B

COOLANT LEVEL RETURN


M401344D

SKYJACK, Page 72

Telehandler Series
Model ZB20044
402509

3.21 Transmission T32000 Harness


A B C D E F G H

J124

J266 REVERSE SOLENOID


CONNECTOR REAR VIEW

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

J265 FORWARD SOLENOID

WIRING DIAGRAM

SPL270

J263
1ST
SOLENOID

CONNECTOR REAR VIEW


J20
PIN B

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

J264 2ND SOLENOID

D
OI

16 AWG BLACK

+12 VDC

16 AWG BLACK

GROUND

OL

EN

J264

16 AWG BLACK
GROUND E264
(TRANSMISSION
HOUSING)

CONNECTOR REAR VIEW

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

J263 1ST SOLENOID


CONNECTOR REAR VIEW
PIN B

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

3.22 Frame Level Harness


A B C D E F G H
PIN 1
1

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

3.23 Axle Lock Harness


A B C D E F G H

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

CONNECTOR MATING FACE


E210
PIN A

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

3.24 Diverter Valve Harness, 2-Way


A B C D E F G H

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

3.25 Parking Brake Harness


A B C D E F G H

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

CONNECTOR MATING FACE

WIRING DIAGRAM
P10

P123

16 AWG BLACK / BLUE

18 AWG BLACK

16 AWG LIGHT BLUE / BLACK

J127
PARK BRAKE
SOLENOID b

SPL127
B

BRAKE
PRESSURE SWITCH

TRANSMISSION
DISCONNECT

UPPER PARKING
BRAKE SOLENOID

1K
SPL120
D

16 AWG LIGHT BLUE / RED

18 AWG WHITE
CABLE

CABLE

J128
PARK BRAKE
SOLENOID a

18 AWG WHITE

16 AWG LIGHT BLUE

LOWER PARKING
BRAKE SOLENOID

PARKING BRAKE
LIGHT

1K

SPL128
C

18 AWG BLACK

M401336D

Telehandler Series
Model ZB20044
402509

SKYJACK, Page 77

3.26 Steering Harness


A B C D E F G H
K125 SOLENOID B

V
K

AC

L
/B

EE

16

PIN A

PIN B

J11

G
AW

GR

16 AWG GREEN / WHITE

SKYJACK

K124 SOLENOID A

W
PIN C
16

J11
CONNECTOR REAR VIEW

AW
G

BL

AC

X
GROUND

WIRING DIAGRAM
STEERING SOLENOID

J11
ROUND

16 AWG GREEN / BLACK

K125 SOLENOID B

CRAB

16 AWG GREEN / WHITE

K124 SOLENOID A

GROUND

16 AWG BLACK

GROUND

M401949E-3

SKYJACK, Page 78

Telehandler Series
Model ZB20044
402509

3.27 Horn, Fuel & Brake Pressure Switch Harness


A B C D E F G H

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

3.28 Joystick with Horizontal Rocker Switch


A B C D E F G H
ROCKER SWITCH SW75

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

3.29 Three-Speed Shifter


A B C D E F G H

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

CONNECTOR REAR VIEW

M402170B

Telehandler Series
Model ZB20044
402509

SKYJACK, Page 81

3.30 Joystick, Two-Axis with Microswitch


A B C D E F G H

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

3.31 Power Module - Enclosed Cab Harnesses


A B C D E F G H

J51

PIN A
PIN B

P14

PIN C

16 AWG

CK

WG
6A

PIN D

TAPE & STOW


INSIDE ENCLOSURE

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

16 AWG ORANGE / BLACK

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

RESERVED (BOOM LIGHTS)

P15

P50
A

18 AWG BLACK

18 AWG BROWN
16 AWG RED

C
J51
A

16 AWG WHITE

16 AWG BLACK

16 AWG ORANGE / BLACK / WHITE

CONNECTOR REAR VIEW

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

BRAKE LIGHT POWER

14 AWG WHITE

WIPER POWER

14 AWG RED

HEATER POWER

14 AWG BLACK

GROUND

16 AWG ORANGE / RED


16 AWG ORANGE /
BLACK / WHITE

BLACK

SPL15

C
G BLA
14 AW

PIN A
2 X 12 AWG BLACK

K13-86

K13-87
18 A
WG

P50

CONNECTOR REAR VIEW

CB16-ACC

K15-87

K14-87

CONNECTOR REAR VIEW

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

3.32 Power Module - Open Cab Harnesses


A B C D E F G H
PIN A

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

16 AWG ORANGE / BLACK / WHITE

CB18-ACC

SW18-1

K14-87

CONNECTOR REAR VIEW

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

CONNECTOR REAR VIEW

AW

K13-30

12 AWG RED

K15
87

12 AWG RED

K16
87

RA
Y

16 A
WG

16 AWG ORANGE / BLACK / WHITE

SW18
1
SW19
1

16 AWG ORANGE / BLACK / WHITE

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

CONNECTOR REAR VIEW

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

AUX LIGHT SWITCH

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

BRAKE LIGHT POWER

N/C

N/C

16 AWG
ORANGE / BLACK / WHITE

AUX LIGHT POWER

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

16 AWG ORANGE / RED

G OR

PIN 8

BLACK / WHITE

CB15 LIGHT POWER

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

3.33 Lighting Harness


A B C D E F G H
J149
LEFT
HEADLIGHT

ORANGE / BLACK / WHITE

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

CONNECTOR MATING FACE

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

CONNECTOR REAR VIEW


16 AWG
ORANGE / RED

SPL318

M402364C

Telehandler Series
Model ZB20044
402509

SKYJACK, Page 85

3.34 Wiper Harness


A B C D E F G H

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

FRONT WIPER GND

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

BEACON LIGHT J61


GROUND
ER

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

BEACON LIGHT J60


12 VDC

18 AWG WHITE
M400424D

SKYJACK, Page 86

Telehandler Series
Model ZB20044
402509

3.35 Grappler Harness


A B C D E F G H

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

CONNECTOR REAR VIEW

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

3.36 Outrigger Raise/Lower Harness


A B C D E F G H

J134 RIGHT LOWER


CONNECTOR MATING FACE
PIN 1

J134

E137
PIN 2

J135 LEFT LOWER


P18

CONNECTOR MATING FACE

CONNECTOR REAR VIEW


T
H R
IG E
R W
LO

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

J136 RIGHT RAISE

CARELIFT

J136

CONNECTOR MATING FACE

SPL137

PIN 1

+12 VDC

16 AWG WHITE / RED

SPL136

16 AWG WHITE
16 AWG BLACK

SPL136

J136
1
+12 VDC
2

GND

CABLE

T
RIGH E
RAIS

1
3

+12 VDC

16 AWG WHITE / RED / GREEN

SPL134

16 AWG WHITE

J134
1
+12 VDC

2
L
R EF
AI T
SE

16 AWG BLACK
PIN 2

16 AWG WHITE / BLACK

SPL137

CONNECTOR MATING FACE

16 AWG WHITE
16 AWG BLACK

PIN 1

J137
1
+12 VDC
2

GND

CABLE
1

J137

+12 VDC

GROUND

D
E137

16 AWG WHITE / BLACK / RED

SPL135

14 AWG BLACK

16 AWG WHITE
16 AWG BLACK

SPL133
PIN 2

GND

CABLE

+12 VDC

J137 LEFT RAISE

J135
1
+12 VDC
2

GND

CABLE
M402390D

SKYJACK, Page 88

Telehandler Series
Model ZB20044
402509

3.37 Mine Spec. - Brakes Harness


A B C D E F G H

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

3.38 Mine Spec. - Pressure Switches Harness


A B C D E F G H
GROUND

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

3.39 Mine Spec. - Steering Accumulator Harness


A B C D E F G H
GROUND

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

3.40 Hydraulic Schematic

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

JS1 REAR JOYSTICK

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

JS2 FRONT JOYSTICK


PORT
1
2
3
4

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

OPTIONAL 2 STAGE PIPE AND POLE GRAPPLER

OPTIONAL ROTATING PIPE AND POLE HANDLER

OPTIONAL FORK SHIFT/SIDE SHIFT CARRIAGE

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

USE WITH OPTIONAL


LIGHTS

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 RED 109

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 125

18 AWG GRAY 106

18 AWG GRAY 104

18 AWG GRAY 103

18 AWG WHITE 102

18 AWG RED 101

18 AWG GRAY 2A

120

16 AWG RED

K221

16 AWG BLUE 8

16 AWG BLUE / RED

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

16 AWG WHITE / RED / GREEN

18 AWG GREEN

18 AWG WHITE

COM

NO

SW114 PARK BRAKE


PRESSURE SWITCH

FUEL GAUGE
ILLUMINATION

3 NO
1 NO

SW7 LEFT OUTRIGGERS


(MOMENTARY)
16 AWG WHITE / BLACK

16 AWG WHITE / BLACK / RED

K213 WHITE R2-OR

K212 WHITE B2-OR

K211 BLUE B1

K210 BLUE R1

K142 RED B/OR

K137 LEFT RAISE

K135 LEFT LOWER

K136 RIGHT RAISE

K134 RIGHT LOWER

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

K140 RED A/OR

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'

STEERING SOLENOID 'B'

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

INTAKE AIR HEATER RETURN

40

18 AWG RED C140

6 AWG RED

INTAKE AIR HEATER OUTPUT

32

COOLANT LEVEL RETURN

COOLANT LEVEL INPUT


18 AWG GRAY C132

28

OFF IDLE SWITCH


1
18 AWG GRAY C101

18 AWG GRAY C128

69

SWITCH RETURN
18 AWG GRAY C134

70

68

ON IDLE SWITCH
11
34

18 AWG GRAY C111

K141 WHITE B/T

67
ACCELERATOR POSITION RETURN

DS6 OIL GAUGE


ILLUMINATION

J298

66
ACCELERATOR POSITION SIGNAL

65
9

ACCELERATOR POSITION SUPPLY


22
18 AWG RED C122

64

23

KEY SWITCH SIGNAL

39

18 AWG GRAY C139

63

62

61

60

16 AWG WHITE C109

SAE J1939 GROUND

37
18 AWG CLEAR C137

59

58

57

56

55

54

53

52

51

50

49

18 AWG BLACK C123

SAE J1939 47

GROUND

ECM

18 AWG GREEN C147

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

18 AWG YELLOW C146

12 AWG GRAY

12 AWG RED

SW8 RIGHT OUTRIGGERS


1 NO (MOMENTARY)
16 AWG WHITE / RED

3 NO

18 AWG BLACK

16 AWG BLACK

14 AWG BLACK

14 AWG BLACK

16 AWG BROWN / RED

16 AWG BLACK

SW122 BRAKE CHARGE


PRESSURE SWITCH

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

16 AWG WHITE / BLUE

18 AWG BLACK

16 AWG YELLOW / BLACK 28

16 AWG YELLOW / BLUE 9

18 AWG CLEAR

14 AWG GRAY 110

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

NEUTRAL SAFETY RELAY

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 GRAY 206

18 AWG YELLOW

18 AWG RED 201

16 AWG GREEN / WHITE

16 AWG GREEN / BLACK

16 AWG LIGHT BLUE

DISCONNECT

K1 TRANSMISSION

16 AWG L BLUE / BLACK

16 AWG BLACK

16 AWG BLACK

16 AWG BLACK

16 AWG BLACK / GRAY

K270
REVERSE SOLENOID

16 AWG BLACK / BLUE


OVERRIDE = CLOSED

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

16 AWG BLUE / WHITE

16 AWG BLUE / YELLOW


AUX

HOURS METER

M1

14 AWG BLUE / RED

16 AWG YELLOW / BLACK


20A AUX

CB9

10A

CB5

PEDAL

18 AWG GRAY 125

SW4 STEERING

16 AWG BLACK

16 AWG L BLUE / BLACK

16 AWG GREEN

16 AWG GREEN

16 AWG BLACK

16 AWG GREEN

22 AWG GRAY

16 AWG GRAY STRT

SW25

22 AWG PINK

22 AWG YELLOW

PS2

11

BAT

IDLE OFF

18 AWG GRAY 106

18 AWG GRAY 104

18 AWG GRAY 103

18 AWG WHITE 102

18 AWG RED 101

18 AWG GRAY 10A

18 AWG RED 10B

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

2X 2/0 AWG BLACK

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

16 AWG BLACK / WHITE

18 AWG GRAY 2A

22 AWG BLACK

B200
STARTER

2X 2/0 AWG RED

10

BAT

B
C

TPS +5 V

DIAGNOSTIC

NETWORK
TERMINATION

CB6
10A
TRANSMISSION SHIFTER

16 AWG YELLOW

18 AWG GRAY KEY

SHIFTER

DANA

22 AWG BLUE

2X 2/0 AWG RED

DUAL BATTERIES

AJ

AXLE LOCK /
FRAME LEVELING

R6

AUX

120

6A

16 AWG GREEN / YELLOW

16 AWG L BLUE / RED

ST

IGN

F1
IGNITION
SWITCH FUSE
5A

SW26

K220

16 AWG GREEN 21

10 AWG RED 22

OPTIONAL
BATTERY DISCONNECT
SW305

10 AWG BLUE

DASH POWER BAT

BAT

CB10

AUX

SW1 IGNITION SWITCH

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

PARKING BRAKE BAT

ALTERNATOR BAT

BUS BAR

10 AWG RED

3.41 Master Wiring Diagram 1 of 2

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

SW21 OPERATING LIGHTS

SW19 BOOM LIGHTS

SW18 AUX LIGHT

OFF

2.7

14 AWG ORANGE / BLACK / WHITE

14 AWG ORANGE / BLACK / WHITE

14 AWG ORANGE / BLACK / WHITE

12 AWG RED

22 AWG BROWN

22 AWG BLACK

16 AWG RED

AIR CONDITIONER

DOME LIGHT ONLY

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

B69 HEATER FAN

DS312

DS310

DS311

DS313

DS148

DS149

DS313

DS312

DS154

DS312

DS52

DS53

DS386

DS385

DS56

K381

K380

B68 FAN

B66 FRONT WIPER MOTOR

B70 REAR WIPER MOTOR

B64 TOP WIPER MOTOR

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

RIGHT OPERATING LIGHT

LEFT OPERATING LIGHT

RIGHT BOOM LIGHT

LEFT BOOM LIGHT

AUX LIGHT

3-WAY DIVERTER VALVE

FAN

FRONT WIPER

REAR WIPER

TOP WIPER

BEACON LIGHT

DOME LIGHT

MAP LIGHT

HEATER

ENCLOSED CAB RELAY

RIGHT OUTER TAIL LIGHT

RIGHT INNER TAIL LIGHT

LEFT OUTER TAIL LIGHT

LEFT INNER TAIL LIGHT

RIGHT HEADLIGHT

LEFT HEADLIGHT

LEFT REAR BRAKE LIGHT

RIGHT REAR BRAKE LIGHT

LIGHTS RELAY

RIGHT FRONT TURN SIGNAL

RIGHT REAR TURN SIGNAL

LEFT FRONT TURN SIGNAL

LEFT REAR TURN SIGNAL

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

HEATER FAN CONTROL

12 AWG BLACK

16 AWG ORANGE / BLACK / WHITE

16 AWG ORANGE / RED

16 AWG ORANGE / RED

12 AWG BLACK

16 AWG ORANGE / BLUE

16 AWG ORANGE / BLUE

DS155

DS311

14 AWG RED

K17

20A

CB18

18 AWG GRAY

SW75

SW62

16 AWG ORANGE / RED

16 AWG ORANGE / BLACK / WHITE

SW62 DOME LIGHT SWITCH FUNCTION

BOTH LIGHTS

SW62

SW15 LIGHTS

BRAKE PRESSURE
SW90
NO
COM

16 AWG ORANGE / BLUE

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

16 AWG ORANGE / BLACK

16 AWG ORANGE / BLACK

CB22

20A

CB17

20A

CB16

16 AWG ORANGE / RED

14 AWG BROWN

2 COM

16 AWG ORANGE / BLACK

12 AWG RED

K16

12 AWG RED

20A

CB15

3 NO

SW9 LEFT TURN SIGNALS


OPTIONAL

2 COM

SW10 RIGHT TURN SIGNALS


OPTIONAL

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

16 AWG ORANGE / GREEN

SIGNAL LIGHTS BAT

AG

3.41 Master Wiring Diagram 2 of 2

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

Service and Maintenance

Section 4 - Troubleshooting Information

Table of Contents (Continued)


4.2-14 No Left Outrigger Lower............................................................................................................................................... 110
4.2-15 No Left Outrigger Raise................................................................................................................................................. 110
4.2-16 Brake System Charging Constantly or Too Frequently.................................................................................................. 110
4.2-17 Hard or No Steering....................................................................................................................................................... 111
4.2-18 Wheels go out of Synch. When in 4 wheel steer mode................................................................................................ 111
4.2-19 Park Brake will not Release........................................................................................................................................... 111
4.2-20 Park Brake will not Engage............................................................................................................................................ 111

TM

Page 96

Telehandler Series
Model ZB20044
402509

Section 4 - Troubleshooting Information

Service and Maintenance

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:


1. Isolate the major component in which the trouble occurs


2. Isolate whether the problem is electrical or hydraulic
3. Isolate and correct the specific problem
NOTE
If a specific problem is not listed, or after performing all necessary steps a
problem can not be resolved; consult SKYJACKs service department.

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

Service and Maintenance

Section 4 - Troubleshooting Information

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

Section 4 - Troubleshooting Information

Service and Maintenance

Electrical System (Continued)


-- Check continuity. Replace if defective.
26. Loose or broken green wire #21 from starter solenoid K220 to starter motor B200.
-- Check continuity. Replace if defective.
27. Defective starter B200.
-- Replace if defective.
4.1-2 Engine Cranks but will not start.
1. Loose or broken ECM battery cable from J204 to fuse F279.
-- Check continuity. Replace if defective.
2. Defective fuse F279.
-- Check for defective wiring, Replace Fuse.
3. Lose or broken red wire from fuse F297 Connector J296 (pin 3 and 4).
-- Check continuity. Replace if defective.
4. Loose or broken ECM ground from J296 (pin 1 and 2) to ground E204.
-- Check continuity. Replace if defective.
5. Loose or broken grey wire key from ignition switch SW1 to ignition switch fuse F1.
-- Check continuity. Replace if defective.
6. Defective fuse F1.
-- Check for defective wiring, Replace fuse.
7. Loose or broken grey wire 2A from fuse F1 to 32 pin connector P1 (Pin 11).
-- Check continuity. Replace if defective.
8. Loose or broken grey wire from J1 (pin 11) to Connector J295 (Pin 39).
-- Check continuity. Replace if defective.
NOTE
For other engine related problems, consult engine manufacturers
manual.
4.1-3 Can Bus Failure, no data/display on Murphy Powerview.
1. Loose or broken red wire T3 from ignition switch SW1 to fuse F2.
-- Check continuity. Replace if defective.
2. Defective fuse F2.
-- Check for defective wiring, Replace Fuse.
3. Loose or defective red wire 201 from fuse F2 to Connector J7 (pin 1) @ Murphy powerview.
-- Check continuity. Replace if defective.
4. Loose or defective grey wire 206/110 from connector J7 pin (pin 6) to connector P1 (pin 10).
-- Check continuity. Replace if defective.
5. Loose or defective grey wire from connector J1 (pin 10) to ground E204.
-- Check continuity. Replace if defective.
6. Loose or defective green wire from connector J7 (pin3) to connector P1 (pin 17).
-- Check continuity. Replace if defective.
7. Loose or defective green wire from connector J1 (pin 17) to connector J295 (pin 47).
-- Check continuity. Replace if defective.
8. Loose or defective yellow wire from connector J7 (pin 2) to connector P1 (pin 28).
-- Check continuity. Replace if defective.
9. Loose or defective yellow wire from connector J1 (pin 28) to connector J295 (pin 46).
-- Check continuity. Replace if defective.
10. Open or defective resistors R6 and R297.
-- Replace resistors.

TM

Telehandler Series
Model ZB20044
402509

Page 99

Service and Maintenance

Section 4 - Troubleshooting Information

Electrical System (Continued)


11. Defective Murphy Powerview.
-- Replace Murphy Powerview.
NOTE
For other engine related problems, consult engine manufacturers
manual.
4.1-4 No Throttle.
1. Loose or broken red wire 101 from throttle pedal connector J4 (pin 5) to connector P1 (pin 1)
-- Check continuity. Replace if defective.
2. Loose or broken red wire 129 from J1 (pin 1) to ECM connector B (pin 29)
-- Check continuity. Replace if defective.
3. Loose or broken grey wire 103 from throttle pedal connector J4 (pin 4) to connector P1 (pin 3)
-- Check continuity. Replace if defective.
4. Loose or broken black wire from J1 (pin 3) to ECM connecter J295 (pin 23)
-- Check continuity. Replace if defective.
5. Loose or broken white wire 102 from throttle pedal connector J4 (pin 3) to connector P1 (pin 2).
-- Check continuity. Replace if defective.
6. Loose or broken white wire 130 from J1 (pin 2) to ECM connector J294 (pin 9)
-- Check continuity. Replace if defective.
7. Defective throttle pedal
-- Replace throttle pedal.
NOTE
For other engine related problems, consult engine manufacturers
manual.
4.1-5 No Drive (park brake releases)
1. Loose or defective black wire from J269 (pin 2) and J270 (pin2) to single wire connector P124.
-- Check continuity. Replace if defective.
2. Loose or broken red wire from connector J124 to brake pressure switch SW125.
-- Check continuity. Replace if defective.
3. Defective pressure switch SW125.
-- Replace pressure switch.
4. Loose or broken black wire from brake pressure switch SW125 to ground E125.
-- Check continuity. Replace if defective.
5. Defective Shifter.
-- Replace shifter.
4.1-6 No Forward Drive.
1. Loose or broken red wire from connector J20 (pin C) to connector J269 (pin 1)
-- Check continuity. Replace if defective.
2. Defective forward solenoid K269.
-- Replace solenoid
3. Loose or broken black wire from solenoid connector J269 (pin 2) to ground.
-- Check continuity. Replace if defective.
4. Defective shifter.
-- Replace shifter

TM

Page 100

Telehandler Series
Model ZB20044
402509

Section 4 - Troubleshooting Information

Service and Maintenance

Electrical System (Continued)


4.1-7 No reverse drive
1. Loose or broken white wire from connector J20 (pin D) to diode D266
-- Check continuity. Replace if defective.
2. Open or defective diode D266.
-- Replace Diode.
3. Loose or broken white wire from diode D266 to connector J270 (pin1).
-- Check continuity. Replace if defective.
4. Defective reverse solenoid K270.
-- Replace solenoid
5. Loose or broken black wire from solenoid connector J270 (pin B) to ground.
-- Check continuity. Replace if defective.
6. Defective shifter.
-- Replace shifter
4.1-8 3rd speed range only.
1. Loose or broken black wire from connector J20 (pin B) to connector J268 (pin 1).
-- Check continuity. Replace if defective.
2. Defective 2nd solenoid K268.
-- Replace solenoid.
3. Loose or broken wire from connector J268 (pin B) to connector P264 (pin 2).
-- Check continuity. Replace if defective.
4. Loose or broken black wire from connector J264 (pin 2) to ground E267.
-- Check continuity. Replace if defective.
5. Defective shifter.
-- Replace shifter.
4.1-9 No 1st speed range.
1. Loose or broken brown wire from connector J20 (pin A) to connector J263 (pin 1)
-- Check continuity. Replace if defective.
2. Loose or broken brown wire from connector P263 (pin 1) to 1st solenoid connector J267 (pin A).
-- Check continuity. Replace if defective.
3. Defective 1st solenoid K267.
-- Replace solenoid
4. Loose or broken black wire from solenoid connector J267 (pin B) to connector P263 (pin 2).
-- Check continuity. Replace if defective.
5. Loose or broken black wire from connector J263 (pin 2) to ground E267.
-- Check continuity. Replace if defective.
6. Defective shifter.
-- Replace shifter.
4.1-10 No Drive (park brake does not release)
1. Loose or broken red wire from ignition switch SW1 to Accessory Circuit breaker buss bar.
-- Check continuity. Replace if defective.
2. Tripped or defective circuit breaker CB6.
-- Check for defective wiring, Replace circuit breaker.
3. Loose or broken light blue/red wire from circuit breaker CB6 to connecter J10 (pin D).
-- Check continuity. Replace if defective.
4. Loose or broken light blue/red wire from connecter P10 (pin D) to Hirschman connecters J127 and
J128(pins 1).
-- Check continuity. Replace if defective.

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Telehandler Series
Model ZB20044
402509

Page 101

Service and Maintenance

Section 4 - Troubleshooting Information

Electrical System (Continued)


5. Defective park brake release coil K127.
-- Replace Coil.
6. Loose or broken light blue/black wire from Hirschman connecter J127 (pin 2) to connecter P10 (pin B).
-- Check continuity. Replace if defective.
7. Loose or broken light blue/black wire from connecter J 10 (pin B) to park brake switch SW6.
-- Check continuity. Replace if defective.
8. Defective park brake switch SW6.
-- Replace switch.
9. Loose or broken black wire from park brake switch SW6 to ground E2.
-- Check continuity. Replace if defective.
4.1-11 Alternator not charging
1. Loose or broken red wire from ignition switch SW1 to Accessory Circuit breaker buss bar.
-- Check continuity. Replace if defective.
2. Tripped or defective circuit breaker CB8.
-- Check for defective wiring, Replace circuit breaker.
3. Loose or broken purple wire #25 from circuit breaker CB8 to Connecter P2 (pin8).
-- Check continuity. Replace if defective.
4. Loose or broken purple wire #25 from connecter J2 (pin 8) to single wire connecter J220.
-- Check continuity. Replace if defective.
5. Loose or broken purple wire #25 from Connecter P220 to alternator connecter J289 (pin C).
-- Check continuity. Replace if defective.
6. Loose or broken red wire #24 from alternator BAT terminal to starter.
-- Check continuity. Replace if defective.
7. Defective alternator.
-- Replace alternator.
4.1-12 Front steer mode only
1. Loose or broken red wire from ignition switch SW1 to Accessory Circuit breaker buss bar.
-- Check continuity. Replace if defective.
2. Tripped or defective circuit breaker CB10.
-- Check for defective wiring, Replace circuit breaker.
3. Loose or broken green/yellow wire from circuit breaker CB10 to Steer switch SW4.
-- Check continuity. Replace if defective.
4. Defective steer switch SW4.
-- Replace switch
5. Loose or broken black wire from steering solenoid A & B coils K124 and K125 to connecter J11 (pin C).
-- Check continuity. Replace if defective.
6. Loose or broken black wire form connecter P11 (pin C) to ground E1.
-- Check continuity. Replace if defective.
4.1-13 No round steer mode
1. Defective steer switch SW4.
-- Replace switch.
2. Loose or broken green/black wire from steer switch to connecter P11 (pin A).
-- Check continuity. Replace if defective.
3. Loose or broken green/black wire from connecter J11 (pin A) to steering solenoid B coil K125.
-- Check continuity. Replace if defective.
4. Defective steering solenoid K125.
-- Replace solenoid.

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Page 102

Telehandler Series
Model ZB20044
402509

Section 4 - Troubleshooting Information

Service and Maintenance

Electrical System (Continued)


4.1-14 No crab steer mode
1. Defective steer switch SW4.
-- Replace switch.
2. Loose or broken green/white wire from steer switch to connector P11 (pin B).
-- Check continuity. Replace if defective.
3. Loose or broken green/white wire from connecter J11 (pin B) to steering solenoid A coil K124.
-- Check continuity. Replace if defective.
4. Defective steering solenoid K124.
-- Replace solenoid.
4.1-15 No carriage tilt function
1. Loose or broken red wire from ignition switch SW1 to Accessory Circuit breaker buss bar.
-- Check continuity. Replace if defective.
2. Tripped or defective circuit breaker CB1.
-- Check for defective wiring, Replace circuit breaker.
3. Loose or broken tan wire from circuit breaker CB1 to connector J40.
-- Check continuity. Replace if defective.
4. Defective carriage tilt switch SW11.
-- Replace switch.
5. Loose or broken white wire from connecter P41 to Hirschman connector J222 at pilot diverter valve K222.
-- Check continuity. Replace if defective.
6. Defective diverter valve K22.
-- Replace diverter valve.
7. Loose or broken black wire from pilot diverter valve K222 Hirschman connector J222 to ground E222.
-- Check continuity. Replace if defective.
4.1-16 No outrigger function
1. Tripped or defective circuit breaker CB3.
-- Check for defective wiring, Replace circuit breaker.
2. Loose or broken white wire from circuit breaker CB3 to connector J17 (pin A).
-- Check continuity. Replace if defective.
3. Loose or broken white jumper wire on connector J17 (pin A to pin B).
-- Check continuity. Replace if defective.
4. Loose or broken white/blue wire from connector J 17 (pin B) to common on outrigger switches SW7
and SW8
-- Check continuity. Replace if defective.
5. Loose or broken black wire from splice S137 to Ground E137 .
-- Check continuity. Replace if defective.
4.1-17 No right outrigger lower function
1. Defective right outrigger switch SW8.
-- Replace switch.
2. Loose or broken white/red/green wire from right outrigger switch to connector J18 (pin B).
-- Check continuity. Replace if defective.
3. Loose or broken white/red/green wire from connector P18 (pin B) to right lower solenoid connector
J134 (pin 1)
-- Check continuity. Replace if defective.
4. Defective right lower solenoid K134.
-- Replace solenoid.
5. Loose or broken black wire from right lower solenoid connector J134 (pin 2) to ground E137.

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Telehandler Series
Model ZB20044
402509

Page 103

Service and Maintenance

Section 4 - Troubleshooting Information

Electrical System (Continued)


-- Check continuity. Replace if defective.
4.1-18 No right outrigger raise function
1. Defective right outrigger switch SW8.
-- Replace switch.
2. Loose or broken white/red wire from right outrigger switch to connector J18 (pin A).
-- Check continuity. Replace if defective.
3. Loose or broken white/red/green wire from connector P18 (pin A) to right raise solenoid connector J136
(pin 1)
-- Check continuity. Replace if defective.
4. Defective right raise solenoid K136.
-- Replace solenoid.
5. Loose or broken black wire from right raise solenoid connector J136 (pin 2) to ground E137.
-- Check continuity. Replace if defective.
4.1-19 No left outrigger lower function
1. Defective left outrigger switch SW7.
-- Replace switch.
2. Loose or broken white/black/red wire from left outrigger switch to connector J18 (pin D).
-- Check continuity. Replace if defective.
3. Loose or broken white/black/red wire from connector P18 (pin D) to left lower solenoid connector J135
(pin 1)
-- Check continuity. Replace if defective.
4. Defective left lower solenoid K135.
-- Replace solenoid.
5. Loose or broken black wire from left lower solenoid connector J135 (pin 2) to ground E137.
-- Check continuity. Replace if defective.
4.1-20 No left outrigger raise function
1. Defective left outrigger switch SW7.
-- Replace switch.
2. Loose or broken white/black wire from left outrigger switch to connector J18 (pin C).
-- Check continuity. Replace if defective.
3. Loose or broken white/black wire from connector P18 (pin C) to left raise solenoid connector J137 (pin 1)
-- Check continuity. Replace if defective.
4. Defective left raise solenoid K137.
-- Replace solenoid.
5. Loose or broken black wire from left raise solenoid connector J137 (pin 2) to ground E137.
-- Check continuity. Replace if defective.
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.
1. Loose or broken red wire from ignition switch SW1 to Accessory Circuit breaker buss bar.
-- Check continuity. Replace if defective.
2. Tripped or defective circuit breaker CB9.
-- Check for defective wiring, Replace circuit breaker.
3. Loose or defective yellow/black wire from circuit breaker CB9 to connector P2 (pin 10).
-- Check continuity. Replace if defective.
4. Loose or defective yellow/black wire #28 from connector J2 (pin 10) to relay K221 (pin 6).
-- Check continuity. Replace if defective.

TM

Page 104

Telehandler Series
Model ZB20044
402509

Section 4 - Troubleshooting Information

Service and Maintenance

Electrical System (Continued)

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.

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Telehandler Series
Model ZB20044
402509

Page 105

Service and Maintenance

Section 4 - Troubleshooting Information

Electrical System (Continued)


4.1-26 Front frame level does not lock out with brake application above 45 degrees.
1. Lose or defective black wire from relay K221 (pin2) to connector P247 (pin C).
-- Check continuity. Replace if defective.
2. Loose or defective black wire from connector J247 (pin C) to brake pressure switch SW114 connector
(pin 1).
-- Check continuity. Replace if defective.
3. Brake pressure switch SW114 out of adjustment or defective.
-- Adjust switch. Replace if defective.
4. Loose or broken white wire from to brake pressure switch SW114 connector (pin 3) to frame level dump
solenoids K141 and K143 (pin 1).
-- Check continuity. Replace if defective.
5. Defective solenoids K141 or K143.
-- Check continuity. Replace if defective.
6. Loose or defective green wire from solenoids K141 and K143 (pin 2) to ground E113.
-- Check continuity. Replace if defective.
NOTE
If only one relay is bad and one is OK, you will have steer in one direction only.

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Page 106

Telehandler Series
Model ZB20044
402509

Section 4 - Troubleshooting Information

Service and Maintenance

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

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Telehandler Series
Model ZB20044
402509

Page 107

Service and Maintenance

Section 4 - Troubleshooting Information

Hydraulic System (Continued)


1. Stuck or defective joystick JS2.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective extension valve section.
-- 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.
4.2-7 No Carriage Tilt Back
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 carriage tilt valve section.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
4. Stuck or defective port relief valve RV3.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
5. Stuck or defective carriage tilt counterbalance valve CB4.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
6. Defective carriage slave cylinder C8and/or C9.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
7. Defective carriage tilt cylinder C10 and/or C11.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
8. Stuck or defective Crossover relief valve CRV1.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
4.2-8 No Carriage Tilt Forward
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 carriage tilt valve section.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
4. Stuck or defective port relief valve RV2.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
5. Stuck or defective carriage tilt counterbalance valve CB4.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
6. Defective carriage slave cylinder C8 and/or C9.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
7. Defective carriage tilt cylinder C10 and/or C11.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
8. Stuck or defective Crossover relief valve CRV1.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
4.2-9 No Frame Level Right.
1. Stuck or defective joystick JS1.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective frame level valve section.
-- Clean valve. Check operation of valve. Repair or replace valve as required.

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Page 108

Telehandler Series
Model ZB20044
402509

Section 4 - Troubleshooting Information

Service and Maintenance

Hydraulic System (Continued)


3. Stuck or defective port relief valve RV4.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
4. Stuck or defective frame level counterbalance valve CB5 and/or CB6.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
5. Stuck or defective frame level dump valve V9.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
6. Defective frame level cylinder C12 and/or C13.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-10 No Frame Level Left.
1. Stuck or defective joystick JS1.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective frame level valve section.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
3. Stuck or defective port relief valve RV5.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
4. Closed or obstructed flow control valve FC1.
-- Clean valve. Check operation of valve. Adjust, repair or replace valve as required.
5. Stuck or defective frame level counterbalance valve CB4 and/or CB6.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
6. Stuck or defective frame level dump valve V10.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
7. Defective frame level cylinder C11 and/or C12.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-11 No Auxiliary/Optional Hydraulic Control
1. Stuck or defective joystick JS1.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective Auxiliary valve section.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
3. Stuck or defective port relief valve RV7 and/or RV8.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
4. Closed or obstructed flow control valve FC3 and/or FC4.
-- Clean valve. Check operation of valve. Adjust, repair or replace valve as required.
5. Stuck or defective Auxiliary counterbalance valve.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
6. Stuck or defective Diverter valve V6.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
7. Defective Auxiliary cylinder(s).
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.

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Telehandler Series
Model ZB20044
402509

Page 109

Service and Maintenance

Section 4 - Troubleshooting Information

Hydraulic System (Continued)


4.2-12 No Right Outrigger Lower
1. Stuck or defective right lower pilot valve.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective right outrigger valve section.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
3. Stuck or defective port relief valve RV10.
-- Clean valve. Check operation of valve. Adjust, repair or replace valve as required.
4. Stuck or defective right outrigger counterbalance valve CB8.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
5. Defective right outrigger cylinderC16.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-13 No Right Outrigger Raise
1. Stuck or defective right raise pilot valve.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective right outrigger valve section.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
3. Stuck or defective port relief valve RV11.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
4. Stuck or defective right outrigger counterbalance valve CB8.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
5. Defective right outrigger cylinder C16.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-14 No Left Outrigger Lower
1. Stuck or defective left lower pilot valve.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective left outrigger valve section.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
3. Stuck or defective port relief valve RV8.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
4. Stuck or defective left outrigger counterbalance valve CB7.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
5. Defective left outrigger cylinder C15.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-15 No Left Outrigger Raise
1. Stuck or defective left raise pilot valve.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective left outrigger valve section.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
3. Stuck or defective port relief valve RV9.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
4. Stuck or defective left outrigger counterbalance valve CB7.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
5. Defective left outrigger cylinder C15.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-16 Brake System Charging Constantly or Too Frequently.
1. Stuck or defective priority valve PRT1.

TM

Page 110

Telehandler Series
Model ZB20044
402509

Section 4 - Troubleshooting Information

Service and Maintenance

Hydraulic System (Continued)


-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
2. Stuck or defective brake charge valve V3.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
3. Defective accumulators ACC2 and/or ACC3.
-- Charge with nitrogen to specification. Replace if defective.
4. Stuck or defective service brake valve V5.
-- Remove from system, check brake charge cycle time. Replace if defective.
4.2-17 Hard or No Steering
1. Stuck or defective priority valve PRT1.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
2. Stuck or defective steering motor OSM1.
-- Check o-rings and clean valve. Repair or replace valve as required.
3. Defective steer cylinder C1 and/or C2, C3, C4.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-18 Wheels go out of Synch. When in 4 wheel steer mode
1. Stuck or defective steer function valve V1
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Defective steer cylinder C1 and/or C2, C3, C4.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-19 Park Brake will not Release
1. Stuck or defective park brake valve V5.
-- Clean valve. Check o-rings on valve. Repair or replace valve as required.
2. Bypassing or defective parking brake C17.
-- Check seals, replace as necessary. Replace if defective.
4.2-20 Park Brake will not Engage
1. Defective park brake C17.
-- Repair or replace as necessary.
2. Park brake valve V5 stuck in shifted position.
-- Check valve. Replace if defective.
3. Park brake out of adjustment.
-- See section 5 for park brake adjustment procedure.

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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


Boom Hose Replacement...........................................................................................................................142


Boom Chain Replacement and Adjustment................................................................................................143
Extend Chain...............................................................................................................................................143
Retract Chain...............................................................................................................................................143
Chain Adjustment........................................................................................................................................144

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Telehandler Series
Model ZB20044
402509

Page 113

Service and Maintenance

Section 5 - Procedures

List of Procedures (Continued)


5.4-3
5.4-4

Check Slide Pads.........................................................................................................................................144


Replacing and Shimming Slide Pads..........................................................................................................144

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

Check Lug Nut Torque.................................................................................................................................149

TM

Page 114

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

Service and Maintenance

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.

Engine and Transmission


5.1-1 Engine and Components

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.

5.1-2 Fault Codes for Quantum Engines


HHP Quantum 45/60/78 Fault Severity Levels

Fault Severity Level

Fault Severity Function

Action to be taken by operator

Red

Stop

Stop Engine Now - Damage imminent

Yellow

Warning

Warning - Engine may continue to run, but


must be repaired the same day.

No Lamp

Maintenance

Maintenance - Repair at next PM

No Lamp

None - Information only

None - No lamp action

TM

Telehandler Series
Model ZB20044
402509

Page 115

Service and Maintenance

Section 5 - Procedures

5.1-3 PowerView General Information


WARNING
Before beginning installation of this Murphy
product
Disconnect all electrical power to the machine
Make sure the machine cannot operate during
installation
Follow all safety warnings of the manufacturer
Read and follow all installation instructions

Faceplate Features
Amber
Warning LED

Display

Menu Key

Red Shutdown
Derate LED

Bezel

Enter Key

PowerView Unit Back View


Deutsch DT06-6S Style Connections
Plug A
PIN 3 CAN LO

Plug B
PIN 4 CAN SHLD

PIN 2 CAN HI

PIN 3 RS485+

PIN 5 Dimmer
Potentiometer

PIN 1 V+

Right Arrow Key


(Scroll Down)

PIN 6 GRND

Recommended Connectors:
Body: Deustch DT06-6S
Wedge Lock: W6S
Terminals: 0462-201-16141
Sealing Plug: 114017

Display Parameters

The following are some of the engine and transmission


parameters displayed by the PowerView in English or
Metric units as well as in Spanish, French, or German
(when applicable, consult engine or transmission
manufacturer for SAE J1939 supported parameters):













Left Arrow Key


(Scroll Up)

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

The keypad on the PowerView is a capacitive touch


sensing system. There are no mechanical switches
to wear or stick, and the technology has been time
proven in many applications. It operates in extreme
temperatures, with gloves, through ice, snow, mud,
grease, etc., and it allows complete sealing of the
front of the PowerView. The key is touched feedback
is provided by flashing the screen. The keys on the
keypad perform the following functions:
Menu Key - The Menu Key is touched to either enter
or exit the menu screens.
Left Arrow - The Left Arrow Key is touched to scroll
through the screen either moving the parameter
selection toward the left or upward.
Right Arrow - The Right Arrow Key is touched to
scroll through the screen either moving the parameter
selection toward the right or downward.
Enter Key - The Enter Key (also known as Enter Button)
is touched to select the parameter that is highlighted
on the screen.

TM

Page 116

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

Service and Maintenance

PowerView Menus (First Time Start Up)


1.

GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS

When power is first applied to the PowerView, the


Logo is displayed.

3.
2.

The Wait to Start message will be displayed for


engines with a pre-startup sequence. Once the
Wait to Start message is no longer displayed
the operator may start the engine. Note: Displays
only when SAE J1939 message is supported by
engine manufacturer.

Touching the right arrow button will scroll down


to reveal the last items of Main Menu screen
highlighting the next item down.
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES

WAIT TO
START
PREHEAT

4.

Touch the Arrows to scroll to the desired menu


item or touch Menu to exit the Main menu and
return to the engine parameter display.
GO TO 1-UP DISPLAY

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

Main Menu Navigation


1. Starting at the single or four engine parameter
display, touch Menu.
1500

LOAD@RPM

3000

ENG RPM COOL TEMP

98%

LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS

Once the engine has started the single engine


parameter is displayed.

The first seven items of the Main Menu will


be displayed. Touching the Arrow Buttons will
scroll through the menu selection.

The language choices will be displayed. Use the


Arrow buttons to scroll through the selections
and touch Enter to make a selection.
ENGLISH
ESPAOL
FRANAIS
DEUTSCH

TM

Telehandler Series
Model ZB20044
402509

Page 117

Service and Maintenance


3.

Section 5 - Procedures

Now that you have selected the language, touch


the Menu button to return to the main menu
display.

5.

Touch the Menu Button to return to the main


menu.
1 of x

Stored Fault Codes


1. Starting at the main menu display use the
Arrows to scroll to the Language menu and
once highlighted touch the Enter button.
0

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.

Touch the Menu Button to exit the Main menu


and return to the engine parameter display.
GO TO 1-UP DISPLAY

The main menu will pop up on the display. Use


the Arrow Buttons to scroll through the menu
until the Stored Fault Codes is highlighted.
GO TO 1-UP DISPLAY
STORED
CODES
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
OIL PRES

Engine Configuration Data


1. Starting at the single or four engine parameter
display touch the Menu Button.

Once the Stored Fault Codes menu item has


been highlighted touch the Enter Button to
view the Stored Fault Codes (when applicable,
consult engine or transmission manufacturer for
SAE J1939 supported parameters).

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

The main menu will pop up on the display. Use


the Arrow Buttons to scroll through the menu
until the Engine Configuration is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT

If the word MORE appears above the Arrow


Buttons there are more stored fault codes that
may be viewed. Use the Arrow Buttons to scroll
to the next Stored Diagnostic Code.

3.

Once the Engine Configuration menu item has


been highlighted touch the Enter Button to view
the engine configuration data.

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.

Service and Maintenance

Use the Arrow Buttons to scroll through the


engine configuration data.

1 of x

ENGINE OIL PRESSURE


GAGE NOT RESPONDING

ENGINE SPEED PT 1

1000 RPM

HIDE

MORE

3.
5.

To acknowledge and Hide the fault and return


to the single or four parameter display, touch the
Enter Button

Touch the Menu Button to return to the main


menu.

1 of x

ENGINE OIL PRESSURE


GAGE NOT RESPONDING

ENGINE SPEED PT 1

1000 RPM

HIDE

MORE

4.
6.

Touch the Menu Button to exit the Main menu


and return to the engine parameter display.

The display will return to the single or four


parameter screen.
0

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

Indicates Auxiliary Gage Fault

.!

Indicates Fault Warning

Indicates Derate or Shutdown Condition Fault

Faults and Warnings

Auxiliary Gage Fault


1. During normal operation the single or four
parameter screen will be displayed.
0

1500

1800 RPM

ENG RPM

3000

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM
ENG RPM

57 PSI
OIL PRES

5.

Touching the Enter Button will re-display the


hidden fault. Touching the Enter Button once
again will hide the fault and return the screen to
the single or four parameter display.
1 of x

ENGINE OIL PRESSURE


GAGE NOT RESPONDING
HIDE

2.

The PVA Series of auxiliary gages can be


attached to the PowerView. These auxiliary
gages communicate with the Modbus master
PowerView via a daisy-chained RS-485 port. If
at any time during system initialization or normal
operation an auxiliary gage should fail, the single
or four parameter screen will be replaced with the
MLink Gage Fault message.

NOTE
The fault can only be cleared by correcting the cause of the fault condition.

TM

Telehandler Series
Model ZB20044
402509

Page 119

Service and Maintenance

Section 5 - Procedures
5.

Active Fault Codes


1.

During normal operation the single or four


parameter screen will be displayed.
0

1500

1800 RPM

ENG RPM

57 PSI

14.2

When the PowerView receives a fault code


from an engine control unit the single or four
parameter screen will be replaced with the Active
Fault Codes message.

6.

3000

1800 RPM

COOL TEMP

14.2

ENG RPM

57 PSI
OIL PRES

BAT VOLT

Touching the Enter Button once again will hide


the fault and return the screen to the single or
four parameter display.

SPN110 FMI 0

HIGH COOLANT TEMP

SPN110 FMI 0

HIGH COOLANT TEMP


MORE

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

The display will return to the single or four


parameter display, but the display will contain the
Active Fault warning icon. Touching the Enter
Button will re-display the hidden fault.

If the word MORE appears above the Arrow


Buttons there are more active fault codes that
may be viewed. Use the Arrow Buttons to scroll
to the next Active Fault Code

The Single or Four parameter screen will display


the fault icon until the fault condition is corrected.
NOTE: Ignoring active fault codes could result in
severe engine damage.
GO TO 1-UP DISPLAY

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

HIGH COOLANT TEMP


MORE

HIDE

Shutdown Codes
1.

During normal operation the single or four


parameter screen will be displayed.
0

4.

To acknowledge and Hide the fault and return


to the single or four parameter display touch the
Enter Button.
1 of x

ENG RPM

2.

SPN110 FMI 0

HIGH COOLANT TEMP


MORE

HIDE

1500

1800 RPM

3000

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM
ENG RPM

57 PSI
OIL PRES

When the PowerView receives a severe fault


code from an engine control unit the single or
four parameter screen will be replaced with the
Shutdown! message.

TM

Page 120

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

Service and Maintenance


Back Light Adjustment

SHUTDOWN

1 of x

1.

SPN110 FMI 0
HIGH COOLANT TEMP
MORE

HIDE

Starting at the single or four engine parameter


display touch the Menu Button.
0

1500

1800 RPM

ENG RPM

3.

To acknowledge and Hide the fault and return


to the single or four parameter display touch the
Enter Button.
1 of x

2.

SHUTDOWN

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM
ENG RPM

57 PSI
OIL PRES

The main menu will pop up on the display. Use


the Arrow Buttons to scroll through the menu
until the Adjust Backlight is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS

SPN110 FM10
HIGH COOLANT TEMP
MORE

3000

HIDE

ADJUST BACKLIGHT

4.

The display will return to the single or four


parameter display, but the display will contain the
Shut Down icon. Touching the Enter Button
will re-display the hidden fault.
98%

!
0

1500

3000

ADJUST BACKLIGHT

57 PSI
OIL PRES

BAT VOLT

Touching the Enter Button once again will hide


the fault and return the screen to the single or
four parameter display.
1 of x

SHUTDOWN

4.

SPN110 FM10
HIGH COOLANT TEMP
MORE

6.

Once the Adjust Backlight menu item has been


highlighted touch the Enter Button to activate
the Adjust Backlight function.

ENG RPM

14.2

ENG RPM COOL TEMP!

5.

1000 RPM

LOAD & RPM

1800 RPM

3.

Use the Arrow Buttons to select the desired


backlight intensity.
ADJUST BACKLIGHT

HIDE

The Single or Four parameter screen will display


the fault icon until the fault condition is corrected.
NOTE: Ignoring active fault codes could result in
severe engine damage.
!
0

1500

1800 RPM

ENG RPM

3000

COOL TEMP !

98%

1000 RPM

LOAD & RPM

14.2

BAT VOLT

ENG RPM

57 PSI
OIL PRES

5.

Touch the Menu Button to return to the main


menu.

TM

Telehandler Series
Model ZB20044
402509

Page 121

Service and Maintenance


GO TO 1-UP DISPLAY

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

Use the Arrow Buttons to select the desired


contrast intensity.

57 PSI

ADJUST CONTRAST

OIL PRES

Touch the Menu Button to exit the Main menu


and return to the engine parameter display.
GO TO 1-UP DISPLAY

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

Touch the Menu Button to return to the main


menu.
ADJUST CONTRAST

Contrast Adjustment
1.

Starting at the single or four engine parameter


display, touch the Menu Button.
0

1500

1800 RPM

ENG RPM

3000

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM
ENG RPM

57 PSI

6.

OIL PRES

Touch the Menu Button to exit the Main menu


and return to the engine parameter display.
GO TO 1-UP DISPLAY

2.

The main menu will pop up on the display. Use


the Arrow Buttons to scroll through the menu
until Adjust Contrast is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT

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

Starting at the single or four engine parameter


display touch the Menu Button.
1500

1800 RPM

ENG RPM

Once the Adjust Contrast menu item has been


highlighted touch the Enter Button to activate
the Adjust Contrast function.

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

The main menu will pop up on the display. Use


the arrow buttons to scroll through the menu until
the Select Units is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT
SELECTUNITSD
UNITS
ADJUST BACKLIGHT

TM

Page 122

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures
3.

Service and Maintenance

Once the Select Units menu item has been


highlighted touch the Enter Button to access
the Select Units function.

Setup 1-Up Display


1.

GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT
SELECTUNITSD
UNITS
ADJUST BACKLIGHT

4.

Use the arrows to highlight the desired units.


English for Imperial units i.e. PSI, F or Metric
kPa, Metric Bar for IS units i.e. kPa, Bar, C.

2.

Touch the Enter Button to select the highlighted


units.

Touch the Menu Button to return to the Main


Menu.

Touch the Menu Button to exit the Main menu


and return to the engine parameter display.
GO TO 1-UP DISPLAY

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

The main menu will pop up on the display. Use


the Arrow Buttons to scroll through the menu
until the Setup 1-up Display is highlighted.

3.

Once the Setup 1-up Display menu item has


been highlighted touch the Enter Button to
access the setup 1-up display function.
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

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.

Starting at the single engine parameter display,


touch the Menu Button.

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM
ENG RPM

57 PSI
OIL PRES

4.

Three options are available for modification of


the 1-Up display.
a) Use Defaults This option contains a
set of engine parameters: Engine Hours,
Engine RPM, System Voltage, Battery
Voltage, % Engine Load at Current RPM,
Coolant Temperature, Oil Pressure.
b) Custom Setup This option allows for
the modification of what parameter, the
number of parameters, and the order
in which the parameters are being
displayed.
c) Automatic Scan Selecting the scan
function will cause the 1-Up Display
to scroll through the selected set of
parameters one at a time, momentarily
pausing at each.
TM

Telehandler Series
Model ZB20044
402509

Page 123

Service and Maintenance

5.

Use Defaults - To select Use Defaults use the


arrow buttons to scroll to and highlight Use
Defaults in the menu display.

Section 5 - Procedures
USE DEFAULTS
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF

USE DEFAULTS
DEFAULTS
USE
CUSTOM SETUP
AUTOMATIC SCAN OFF

10. Use the Arrow Buttons to scroll to and highlight


a selected parameter (parameter with a # symbol
to right of it).
6.

Touch the Enter Button to activate the Use


Defaults function.

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.

A message indicating the Single Engine


parameter display parameters are reset to the
factory defaults will be displayed, then the display
will return to the Custom Setup menu.

This number indicates


the order of display for
the parameters and
that the parameter is
selected for display.

11. Touch the Enter Button to deselect the selected


parameter removing it from the list of parameters
being displayed on the 1-up display.
USE
DEFAULTS
ENGINE
SPEED
1
PERCENT LOAD AT CURRENT RPM 3
ENGINE OIL PRESSURE
2
ENGINE COOLANT TEMPERATURE

RESTORED TO
DEFAULTS

12. Use the Arrow Buttons to scroll and highlight


the desired parameter that has not been selected
for display.
8.

Custom Setup - To perform a custom setup of


the 1-Up Display, use the arrow buttons to scroll
to and highlight Custom Setup on the display.
USE DEFAULTS
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF

9.

Touching the Enter Button will display a list of


engine parameters.

ENGINE SPEED
PERCENT LOAD AT CURRENT RPM 2
ENGINE OIL PRESSURE
1
ENGINE COOLANT TEMP

Note that the numbers


now indicate the new
order of display for
the parameters.

13. Touch the Enter button to select the highlighted


parameter for inclusion in the Single Engine
Parameter Display.

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

Service and Maintenance


18. Once the Use Defaults, Custom Setup and
Automatic Scan functions have been set touch
the Menu Button to return to the main menu.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
OFF
AUTOMATICSCAN
SCAN
ON

14. Continue to scroll and select additional


parameters for the custom 1-Up Display. Touch
the Menu button at any time to return to the
Custom Setup menu.

19. Touch the Menu Button to exit the Main menu


and return to the engine parameter display.

15. Automatic Scan - Selecting the scan function


will cause the 1- Up Display to scroll through the
selected set of parameters one at a time. Use the
Arrow Buttons to scroll to the Automatic Scan
function.

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

Setup 4-Up Display


1.

From the single or four engine parameter display


touch the Menu Button.
0

16. Touching the Enter Button toggles the


Automatic Scan function on.

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.

The main menu will pop up on the display. Use


the Arrow Buttons to scroll through the menu
until the Setup 4-Up Display is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT

17. Touching the Enter Button again toggles the


Automatic Scan function off.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
OFF
AUTOMATICSCAN
SCAN
OFF

3.

Once the Setup 4-Up Display menu item has


been highlighted touch the Enter Button to
activate the Setup 4-Up Display menu.

TM

Telehandler Series
Model ZB20044
402509

Page 125

Service and Maintenance

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.

Touch the Enter Button to activate the Use


Defaults function. This action will reset the unit
to the factory default.

8.

USE
USE DEFAULTS
DEFAULTS
CUSTOM SETUP

9.
5.

The Use Defaults screen will be displayed


during the resetting period then will automatically
return to the Setup 4-Up Display menu.
RESTORED TO
DEFAULTS

6.

Select the 4-Up Custom Setup from the 4-Up


Setup menu.
USE DEFAULTS
CUSTOM
CUSTOM SETUP
SETUP

125F
COOL TEMP

1000 RPM
ENG RPM

14.2
14.2
BAT VOLT

57 PSI
OIL PRESP

Touch the Enter Button and a list of parameters


will appear.
125F
COOL TEMP

1000 RPM
ENG RPM

14.2
14.2
BAT VOLT

57 PSI
OIL PRESP

The parameter that is highlighted is the selected


parameter for the screen. Use the Arrow Buttons
to highlight the new parameter to be placed in
the quadrant selected in the previous screen.
ENGINE SPEED
ENGINE HOURS
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
TEMPERATURE
ENGINE OIL PRESSURE

3
1
2
4

The number to the right of the


parameter indicates the quadrant
in which it is displayed.
1. = Upper Left Quadrent
2. = Lower Left Quadrent
3. = Upper Right Quadrent
4.= Lower Right Quadrent

10. Touch the Enter Button to change the selected


parameter in the quadrant to the new parameter.
ENGINE SPEED
ENGINE HOURS
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
TEMPERATURE
ENGINE OIL PRESSURE

7.

The quadrant with the backlit parameter value is


the current selected parameter. Use the Arrow
Buttons to highlight the parameter value in the
quadrant you wish to place a new parameter.

3
1
2
4

11. Use the Menu Button to return to the 4-UP


Custom Setup screen.

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

Service and Maintenance


3

Utilities (Information and Troubleshooting)

1.

2
4

Note the number to the right of


the selected parameter indicating
that the parameter is now
assigned to that display location.

Starting at the single or four engine parameter


display, touch the Menu button.
0

1500

1800 RPM

ENG RPM

12. The parameter in the selected quadrant has


changed to the parameter selected in the
previous screen.

125F
COOL TEMP
143F
OIL TEMP

2.

RPM
1000
RPM
ENG RPM
57 PSI
OIL PRESP

3.

14. Touch the Menu Button to return to the main


menu.

143F
OIL TEMP

COOL TEMP

143F
OIL TEMP

1000 RPM
ENG RPM

57 PSI
OIL PRES

The main menu will be displayed. Use the Arrow


buttons to scroll through the menu until the
Utilities is highlighted.

Once the Utilities menu item has been


highlighted, touch the Enter Button to activate
the Utilities functions.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES

RPM
1000
RPM
ENG RPM
57 PSI
OIL PRESP

4.

15. Touch the Menu Button to exit the Main menu


and return to the engine parameter display.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
DISPLAY
SELECT UNITS
ADJUST BACKLIGHT

COOL TEMP

125%

STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES

13. Repeat the parameter selection process until all


spaces are filled.

125F
COOL TEMP

3000

125%
COOL TEMP

143F
OIL TEMP

Touch Select to enter the Gage Data display.


When Gage Data is selected the PowerView
will communicate with the analog gages at a
fixed rate of 38.4 Kilo Baud, 8 data bits, no parity
check, 1 stop bits, half duplex.
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS SETUP
FAULT CONVERSION
DEMO MODE ON

1000 RPM
ENG RPM

57 PSI
OIL PRES

5.

Use the Arrow buttons to scroll through the


items or touch Menu to return to the Utilities
menu.

TM

Telehandler Series
Model ZB20044
402509

Page 127

Service and Maintenance

Section 5 - Procedures
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
FAULT
FAULTCONVERSION
CONVERSION

1 of x

ENGINE OIL PRESSURE


ADDRESS: 20
SOFTWARE REVISION #:
ERRORS: NONE

6.

Touch Menu Button to return to the Utilities


menu.
1 of x

ENGINE OIL PRESSURE


ADDRESS: 20
SOFTWARE REVISION #:
ERRORS: NONE

7.

J1939 VERSION
VERSION 11
J1939 VERSION 2
J1939 VERSION 3
J1939 VERSION 4

Use the Arrows to highlight Remove All


Gages. Touch Select to clear gage data from
memory. It takes a moment to clear all gages.
CLEARING GAGES
PLEASE WAIT

8.

10. Use the Arrows to scroll and highlight the


version then touch Select and an asterisks
appears to the right of the selection.

When the gage data has cleared, the display


automatically returns to the Utilities menu.
Scroll to Software Version. Touch Select
to view the software version currently in the
PowerView.
SOFTWARE
VERSION
MURPHY: X.XX

NOTE
There are four (4) different methods for
converting fault codes.

The PowerView always looks for J1939 Version


4 and can be set to use one of the 3 other J1939
versions. Most engine ECUs use Version 4,
therefore in most cases adjustment of this menu
option will not be required.

Upon receiving an unrecognizable fault, change


to a different J1939 Version. If the fault SPN
does not change when the version is changed,
the ECU generating the fault is using Fault
Conversion method 4. If the SPN number does
change but is still unrecognizable, try changing to
another J1939 Version not yet used and continue
to check the SPN number.

11. Touch the Menu button to return to Utilities


menu. Touch the Menu button again to return
to the Main menu.
9.

Touch Menu to return to Utilities. Highlight


Fault Conversion using the Arrows. Touch
Select to enter the Fault conversion menu.

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

Service and Maintenance

MODBUS Setup
1.

Starting at the single or four engine parameter


display, touch the Menu button.
0

1500

1800 RPM

ENG RPM

2.

3000

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

USE FACTORY DEFAULT


SERIAL PORT
SERIAL
PORT SETUP
SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE

1000 RPM
ENG RPM

57 PSI
OIL PRES

The main menu will be displayed. Use the Arrow


buttons to scroll through the menu until the
Utilities is highlighted, then touch Enter.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES

3.

5. Use the Arrows to scroll to the Serial Port


menu to highlight it, then touch Enter.

6.

Use the Arrow button to scroll to each selection


to configure the MODBUS values for your
application.
BAUD RATE
PARITY
PARITY
DATA BITS
STOP BITS

Once in the Utilities menu use the Arrows to


scroll through the menu until the Modbus Setup
menu is highlighted, then touch Enter.
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS
SETUP
MODBUS SETUP
FAULT CONVERSION

4.

Use the Arrows to scroll down to and highlight


either the Slave Active or Master Active modes.
Touch the Enter button to toggle between
master and slave.
USE FACTORY DEFAULT
SERIAL PORT SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
MASTER
ACTIVE

TM

Telehandler Series
Model ZB20044
402509

Page 129

Service and Maintenance

Section 5 - Procedures

Error Messages

PowerView Error Messages


SPN
28
28
29
29
91
91
91
91
94
94
94
94
94
94
94
94
97
97
97
97
97
100
100
100
100
100
105
105
105
105
107
107
110
110
110
110
110
111
158
158
174

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

Service and Maintenance

Error Messages - Continued

PowerView Error Messages - continued


SPN FMI Description
190
0
ENGINE OVERSPEED
190
2
ENG SPD DATA ERRATIC, INTERMITTENT OR INCORRECT
190
3
ENG SPD VOLT ABOVE NORMAL OR SHORT HIGH
190
4
ENG SPD VOLT BELOW NORMAL OR SHORT LOW
190
5
ENG SPD CIRCUIT IS OPEN
190 16
ENGINE OVERSPEED
611
3
INJ WIRING SHORTED TO BATTERY
611
4
INJ WIRING SHORTED TO GROUND
620
3
SENSOR VOLT1 (+5VDC) ABOVE NORMAL OR SHORT HIGH
620
4
SENSOR VOLT1 (+5VDC) BELOW NORMAL OR SHORT LOW
627
1
POWER SUPPLY LOW VOLT TO INJECTORS
627
4
POWER SUPPLY INTERRUPTION
629 13
REPROGRAM CONTROLLER ECU PROBLEM
629 19
ECU NOT RECEIVING MSG FROM PUMP
632
2
FUEL SHUTOFF VALVE ERR DETECTED
632
5
FUEL SHUTOFF VALVE NON-FUNCTIONAL
632 11
FUEL SHUTOFF VALVE SOLENOID CKT OPEN OR SHORTED
636
2
ENG POS SENSOR TIMING SIGNAL ERROR
636
8
ENG POS SENSOR TIMING SIGNAL ERROR
636 10
ENG POS SENSOR TIMING SIGNAL ERROR
637
2
TIMING (CRANK) SENSOR TIMING SIGNAL ERROR
637
7
TIMING (CRANK) SENSOR TIMING SIGNAL ERROR
637
8
TIMING (CRANK) SENSOR TIMING SIGNAL ERROR
637 10
TIMING (CRANK) SENSOR TIMING SIGNAL ERROR
639

13

CAN BUS FAILURE

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

INJ CYLINDER1 CURRENT LESS THAN EXPECTED


INJ CYLINDER1 CURRENT INCREASE TOO RAPIDLY
INJ CYLINDER1 FUEL FLOW LOWER THAN EXPECTED
INJ CYLINDER2 CURRENT LESS THAN EXPECTED
INJ CYLINDER2 CURRENT INCREASES TOO RAPIDLY
INJ CYLINDER2 FUEL FLOW LOWER THAN EXPECTED
INJ CYLINDER3 CURRENT LESS THAN EXPECTED
INJ CYLINDER3 CURRENT INCREASES TOO RAPIDLY
INJ CYLINDER3 FUEL FLOW LOWER THEN EXPECTED
INJ CYLINDER4 CURRENT LESS THAN EXPECTED
INJ CYLINDER4 CURRENT INCREASES TOO RAPIDLY
INJ CYLINDER4 FUEL FLOW LOWER THAN EXPECTED
INJ CYLINDER5 CURRENT LESS THAN EXPECTED
INJ CYLINDER5 CURRENT INCREASES TOO RAPIDLY
INJ CYLINDER5 FUEL FLOW LOWER THAN EXPECTED
INJ CYLINDER6 CURRENT LESS THAN EXPECTED
INJ CYLINDER6 CURRENT INCREASES TOO RAPIDLY
INJ CYLINDER6 FUEL FLOW LOWER THAN EXPECTED
GLOW PLUG RELAY STUCK ON
GLOW PLUG RELAY WILL NOT TURN ON
INLET AIR HEATER DRIVER1 STUCK ON
INLET AIR HEATER DRIVER1 WILL NOT TURN ON
118A-2

TM

Telehandler Series
Model ZB20044
402509

Page 131

Service and Maintenance

Section 5 - Procedures

Error Messages - Continued

PowerView Error Messages - continued


SPN FMI Description
833
2
RACK POSITION SENSOR ERROR
833
3
RACK POSITION SENSOR VOLT ABOVE NORMAL
833
4
RACK POSITION SENOR VOLT BELOW NORMAL
834
2
RACK ACTUATOR ERROR BLEED AIR IN FUEL SYSTEM
834
3
RACK ACTUATOR CKT VOLT ABOVE NORMAL
834
5
RACK ACTUATOR CKT OPEN
834
6
RACK ACTUATOR CKT GROUNDED
834
7
RACK ACTUATOR POSITION ERROR
970
2
EXT AUX ENG SHUTDOWN SWITCH INTERMITTENT
970
11
EXT ENG PROTECTION SHUTDOWN ACTIVE
970
31
EXT AUX ENG SHUTDOWN SWITCH ACTIVE
971
31
ENG DERATE SWITCH ACTIVATED
1041
2
START SIGNAL MISSING
1041
3
START SIGNAL ALWAYS ACTIVE
1076
0
FUEL INJ PUMP CONT VALVE ERROR
1076
1
FUEL INJ PUMP CONT VALVE ERROR
1076
2
FUEL INJ PUMP CONT VALVE ERROR
1076
3
FUEL INJ PUMP CONT VALVE ERROR
1076
5
FUEL INJ PUMP CONT VALVE ERROR
1076
6
FUEL INJ PUMP CONT VALVE ERROR
1076
7
FUEL INJ PUMP CONT VALVE ERROR
1076 10
FUEL INJ PUMP CONT VALVE ERROR
1076 13
FUEL INJ PUMP CONT VALVE ERROR
1077
7
FUEL INJ PUMP ERROR
1077 11
FUEL INJ PUMP CONT VP44 INPUT VOLT OUT OF RANGE
1077 12
FUEL INJ PUMP CONT VP44 SELF TEST ERROR
1077 19
FUEL INJ PUMP CONT VP44 DETECTED CAN BUS FAILURE
1077 31
FUEL INJ PUMP CONT POWER DERATED
1078
7
FUEL INJ PUMP SPD/POS SENSOR ERROR
1078 11
FUEL INJ PUMP SPD/POS SENSOR ERROR
1078 31
FUEL INJ PUMP SPD/POS VP44 UNABLE TO ACHIEVE TIMING
1079
3
SENSOR VOLT1 (+5VDC) ABOVE NORM OR SHORT HIGH
1079
4
SENSOR VOLT1 (+5VDC) BELOW NORM OR SHORT LOW
1080
3
SENSOR VOLT2 (+5VDC) ABOVE NORM OR SHORT HIGH
1080
4
SENSOR VOLT2 (+5VDC) BELOW NORM OR SHORT LOW
1109 31
ENG PROT SYSTEM APPROACHING SHUTDOWN
1110 31
ENG PROT SYSTEM SHUT ENG DOWN
1347
5
FUEL PUMP ASSY 1 CKT OPEN SHORTED GROUND OR OVLOAD
1347
7
FUEL PUMP ASSY 1 RAIL PRESSURE CONT MISMATCH
1347 10
FUEL PUMP ASSY 1 LOW FUEL FLOW
1348
5
FUEL PUMP ASSY 2 CKT OPEN SHORTED GROUND OR OVLOAD
1348 10
FUEL PUMP ASSY 2 LOW FUEL FLOW
1485
2
ECU MAIN RELAY PUMP POWER RELAY FAULT
1569 31
ENG PROT TORQ FUEL DERATE LIMIT CONDITION EXIST
2000
6
FUEL INJECTION PUMP CONT VALVE ERROR
2000 13
SECURITY VIOLATION PROPER CONT NOT INSTALLED
118A-3

TM

Page 132

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

5.1-4 Replace Engine Oil and Filter

Service and Maintenance


8. Remove oil filter and catch any escaping oil.

Maintaining the engine components is essential to


good performance and service life of the telehandler.

9. Clean inside the filter head.

Periodic replacement of the engine oil and filter is


essential to good engine performance.

11. Apply a thin layer of engine oil to the new oil


filter gasket.

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.

10. Add clean engine oil to oil filter.

12. Install filter and tighten it by hand.


13. Clean up any oil that may have spilled during
this procedure.
14. Refill engine with new oil as per specifications
(refer to Table 2.2).
15. Start engine and allow it to run for 30 seconds
then stop the engine.
16. Check for oil leakage.
17. Check engine oil level on dipstick and add
oil if needed.
18. Close engine side doors and reinstall locking
pins.
NOTE
Refer to your national/local regulations on
how to dispose of used filter and oil.

2. Allow engine to warm up.


3. Locate engine side door behind operators
cab.
4. Remove locking pins and lift up engine
side doors so that engine components are
accessible.
5. Place suitable container under engine.
6. Remove oil drain plug and allow all engine
oil to drain into container.
7. Install oil drain plug with new seal ring and
tighten firmly.

Engine Oil
Filter

TM

Telehandler Series
Model ZB20044
402509

Page 133

Service and Maintenance

Section 5 - Procedures

5.1-5 Check Engine Air Filter

Check the air cleaner vaccuator valve if applicable.


Squeeze the valve lips and remove any dirt or dust.
It should expel dust and dirt continuously when the
engine is running.

7. Apply a thin layer of oil or diesel fuel to rubber


gasket of new fuel filter.

Inspect the condition of both the primary and safety


elements and replace if required.
WARNING
Do not remove the inner safety filter
unless it is damaged or dirty.

Fuel Filter

8. Install fuel filter and tighten it by hand.


9. Connect the water-in-fuel sensor to the wiring
harness.
10. Bleed the fuel lines by loosening the bleed
screws.
11. Operate the hand lever until the fuel flowing
from the fitting is free of air.
12. Tighten the bleed screws.
13. Clean up any fuel that my have spilled during
this procedure.
14. Close engine side door and reinstall locking
pins.

Air Filter

NOTE
Refer to your national/local regulations on
how to dispose of used filter and oil.

5.1-6 Replace Fuel Filter

1. Ensure telehandler is on a firm level surface.


2. Remove locking pins on engine side doors
and lift them up so that engine components
are accessible.
3. Use the filter drain valve to drain fuel out of
the filter for approximately 5 seconds.
4. Disconnect the water-in-fuel sensor from the
wiring harness

5.1-7 Check Fan Drive Belt

Remove the drive belt and check that the automatic


tensioner turns freely:
-

With no play on bearing.

Spring in tensioner hasnt become weak or


broken.

5. Remove fuel filter and catch any escaping


fuel.
6. Clean any dirt from filter carrier sealing
surface.
TM

Page 134

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

Service and Maintenance

Transmission

12. Add oil as needed to fill up to the required


level.

5.1-8 Check Transmission Filter Breather

13. Install transmission cover plates and tighten


bolts.

The transmission and dipstick are accessed underneath


the two transmission cover plates at the transmission
mount.
Clean the transmission breather and surrounding area.

NOTE
Refer to your national/local regulations on
how to dispose of used filter and oil.

5.1-9 Change Transmission Fluid and


Filter
WARNING

Ensure the following:


-- Telehandler is parked on level ground.

Pump 1

Transmission
Oil Filter

-- Engine is turned off.


-- Parking brake on
-- Wheels are blocked
Raise the boom high enough to allow access and lock
out the ignition switch.
1. Remove bolts from two transmission cover
plates.
2. Remove transmission cover plates so that
Transmission components are accessible.
3. Place a suitable container under transmission.
4. Remove the transmission drain plug and
drain the oil.
5. Remove the sump screen and clean with
varsol and compressed air.
6. Replace the sump screen gasket.

Pump 2

7. Install the sump screen and replace the oil


drain plug
8. Replace the Transmission oil filter.
9. Refill the transmission with the correct fluid
and check the level on the dipstick Full.
(refer to Table 2.2)

Transmission
Oil Dipstick

10. Check for oil leakage


11. Start the engine and check oil level with the
engine running.

T32000 Transmission

TM

Telehandler Series
Model ZB20044
402509

Page 135

Service and Maintenance

Hydraulic System

Section 5 - Procedures

5.2-3 Change Hydraulic Oil

1. Ensure telehandler is on a firm level surface


and is in stowed position.

5.2-1 Check Hydraulic Oil

Maintaining the hydraulic components and hydraulic oil


at the proper level are essential to good performance
and service life of the telehandler.

2. Allow hydraulic oil to warm up.


3. Turn off the engine.
4. Place suitable container under the hydraulic
tank.

The telehandler must be on level ground and all


cylinders retracted when checking oil level.

5. Remove oil drain plug and allow all hydraulic


oil to drain into container.

Refer to oil sight gauge on side of tank to check that


the hydraulic fluid is within 4 inches below the top of
the tank.

6. Install oil drain plug with new seal ring and


tighten firmly.
7. Refill hydraulic tank with new oil as per
specifications. (refer to Table 2.2 of this
manual)

5.2-2 Change Hydraulic Tank Filter

8. Check for leakage.

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.

9. Clean up any oil that may have spilled during


this procedure.
10. Check hydraulic oil level. (The hydraulic oil
level should be at or slightly above the top
mark on the sight gauge)
Cap

1. Ensure telehandler is on a firm level surface,


is in stowed position and engine is off.
2 Place suitable container under the hydraulic
tank filter.

Return
Filter

3. Remove oil filter and catch any escaping oil.


4. Clean inside the filter head.
5. Apply a thin layer of clean hydraulic oil to the
new oil filter gasket.
6. Install filter and tighten firmly.
7. Clean up any oil that may have spilled during
this procedure.

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

Service and Maintenance


-

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.

5.2-4 Bleeding Hydraulic Circuits


NOTE
Whenever a hydraulic system is opened
up, it is necessary to bleed or purge the air
from the circuit that was opened.

Bleed Carriage Tilt Circuit

1. Tilt carriage to full forward position.


2. Raise boom fully while extending boom to
keep carriage ahead of the front tires.

Fully raise and lower the boom several times.


Ensure carriage remains ahead of the front
tires.

Bleed Frame Level Circuit


-

Tilt telehandler fully side to side several times


with boom in a low position.

Bleed Auxiliary/Optional Circuits


-

Operate function fully in both directions


several times.

Bleed Outriggers Circuit


-

Fully lower and raise outriggers several times.

Bleed Brake Circuit

1. With engine running depress and hold brake


pedal. The hydraulic pump will constantly
supply fluid; there is no need to pump the
brake pedal.
2. Locate bleeder fittings on top of brake
calipers at each wheel.
3. Starting with the fitting furthest from the pedal
and working your way to the closest, slightly
open each bleeder and close when hydraulic
oil comes out clear.
4. Slowly loosen hose fitting at pressure switch
shuttle valve on left frame rail. Tighten when
fluid comes out clear.

3. Tilt carriage to full backward position.


4. Lower and retract boom fully.
5. Tilt carriage forward as much as possible and
raise boom to facilitate tilting carriage fully
forward.
6. Repeat steps 1 through 5, five times
7. Check for air in the system by leveling forks
and raising and lowering the boom several
times while watching the forks to see if they
stay level. If the forks do not stay level repeat
above steps and re-check.

Bleed Boom Extend/Retract Circuit


-

Fully extend and retract boom several times


with boom level.

Bleed Boom Raise/Lower Circuit

TM

Telehandler Series
Model ZB20044
402509

Page 137

Service and Maintenance

Pressure Adjustment Procedures


NOTE
-- All pressure adjustments are to be
made at idle with telehandler on a level
surface, park brake applied, and wheels
chocked.
-- Procedures require two persons; one to
operate functions and another to check
and adjust pressures.

5.3-1 Piston Pump Pressure

1. Park the machine on a firm level surface,


apply the park brake and chock the wheels.
2. Raise and support the boom so the lifting
attachment is at lease 7 ft. up.

Section 5 - Procedures

5.3-2 Port Relief Pressure

1. Locate the main hydraulic valve mounted


between the main frame rails, in the center
of the frame.
2. Connect a pressure gauge (4000 psi
minimum) to the test port TP6 located on the
fitting at the P port of the main control valve.
3. Dead-end the desired function and note
pressure reading on gauge.
4. Compare gauge reading to pressure settings
chart (refer to Table 2.5) and adjust as
necessary at the corresponding port relief
valve. Adjust by loosening jam nut and
turning center screw clockwise to increase
pressure or counter-clockwise to decrease
pressure. When correct pressure is achieved
tighten jam nut and re-check pressure.

3. Install a pressure gauge (4000 psi minimum)


to test ports TP4 and TP5.
4. Remove and plug load sense lines at both
pumps.
5. With engine running check pressure reading;
500 psi for P1 (TP4), 550 psi for P2 (TP5).
6. Adjust as required at front adjuster by
loosening jam nut and turning center screw
clockwise to increase pressure and counter
clockwise to decrease pressure.
7. When correct pressure is obtained, tighten
jam nut.
8. Shut engine off and re-install load sense lines
at both pumps.
9. With engine running hold the extend function
in the retract position and check pressure
reading; 3150 psi for P1 (TP4), 3200 psi for
P2 (TP5).
10. Adjust as required at rear adjuster by
loosening jam nut and turning center screw
clockwise to increase pressure and counterclockwise to decrease pressure.
11. When correct pressure is obtained, tighten
jam nut.

TM

Page 138

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

Service and Maintenance

5.3-3 Priority Valve Relief Pressure

5.3-4 Pilot Pressure

1. Locate the priority valve PRT1.

1. Locate the pressure reducing valve PRV1.

2. Connect a pressure gauge (3000 psi


minimum) to test port TP5.
3. Turn the steering wheel to full lock position
and note pressure reading on gauge.
4. Compare gauge reading to pressure settings
chart (refer to Table 2.5) and adjust as
necessary by loosening jam nut and turning
center screw clockwise to increase pressure
or counter-clockwise to decrease pressure.

2. Connect a pressure gauge (500 psi minimum)


to test port TP6 at the pressure reducing valve
by removing acorn nut and brass sealing
washer, loosening jam nut and turning center
screw clockwise to increase pressure, or
counter-clockwise to decrease pressure.
When correct pressure is obtained, tighten
jam nut and install acorn nut with brass
sealing washer.

5. Repeat steps 3 and 4 until correct pressure


is achieved. Tighten jam nut and re-check
pressure.

Relief
Adjustment

Test Port

Priority Valve Pressure


Adjustment

TM

Telehandler Series
Model ZB20044
402509

Page 139

Service and Maintenance

5.3-5 Check Brake Accumulators


1. Actuate brake pedal until very little pedal
resistance is felt.
2. Start engine, brake pressure light on the dash
should come on. The engine should have
a slight labouring sound. After idling for 30
seconds, the light should go out and there
should be a noticeable difference in engine
sound when it stops labouring. Accumulators
should now be charged and the brake
pressure light on the dash should now be off.
3. Depress the brake pedal 2 to 3 times and you
should hear the engine again begin to labour
for 10 to 15 seconds. The brake charge
cycle should occur somewhere in the range
between 30 seconds to 5 minutes and more
often when brakes or pilot operated functions
are used.

Section 5 - Procedures

5.3-6 Charging Brake Accumulators


WARNING
Never try to check accumulators with
a tire gauge type tester as it will cause
a loss of nitrogen gas; which is very
cold when discharged.
1. Ensure engine is turned off and depress brake
pedal 10 to 12 times to empty accumulators
of any oil pressure.
2. Attach proper gauge and nitrogen charge kit.
3. Charge accumulators to 650 psi.

4. Turn off engine.


5. Turn ignition key to on position only (do not
restart engine).
6. Depress brake pedal and release, repeating
the process.
NOTE
-- Keep count of the number of times the
pedal is depressed.
-- After 5 to 6 depressions, the brake
pressure light should come on.
-- It may take over 20 depressions to
completely discharge accumulators

Brake
Accumulators

TM

Page 140

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

5.3-7 Charging Rear Axle Lock System


DANGER
Frame leveling should not be attempted when
boom is elevated.
Boom should be in travel position (24 off the
ground).
Very unstable conditions will result if frame
leveling is attempted when rear axle is in the
lock position.

Service and Maintenance


10. Check system for proper operation by
attempting to level frame to the left until the
left wheel starts to lift off the ground. Level
frame fully to the right.
11. Attach ground cable or limit switch cable
connections.
12. Cycle frame level from left to right. (Rear
axle cylinder should stroke fully in both
directions).

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

3. Actuate the frame level control valve to tilt


the frame from side to side while holding the
valve open at end of each cycle for several
seconds to fully pressurize the system. This
will help eliminate any air in the system.
4. Repeat step 3 four times.
5. Tilt the frame fully to the right.
6. Two of the solenoids in the rear solenoidmounting block have manual unlocking
capabilities. These are unlocked by pulling up
on the knob and turning 90 so the point sits
on top of the V stem. This position allows
free flow through the lock valve for charging
and will also equalize the pressure between
the rod and the base ends of the axle lock
cylinder.

Charging Rear Axle


Lock System

7. Relieve the pressure on the axle lock valve


by moving the rear joystick controller from
left to right 4 to 5 times.
8. Remove the quick disconnect hoses at both
ends and leave in frame.
9. The two manual solenoid overrides should
now be returned to their closed position.

TM

Telehandler Series
Model ZB20044
402509

Page 141

Service and Maintenance

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.

2. Extend boom just enough to allow removal


of side access plates on secondary section.
Then retract slightly to put slack in extend
chains

10. Install access plate, tension chain, and bleed


hydraulic circuit (refer to Section 5.2-4 of this
manual).

3. With side access plate off, tie a rope around


tensioning bracket, loosen hydraulic fittings
of hose to be replaced and remove bolts
holding bracket to boom.

TM

Page 142

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

5.4-2 Boom Chain Replacement and


Adjustment
Extend Chain

1. With boom level loosen extend chain


adjustment nut until nut is at the end of the
adjuster.

Service and Maintenance

Retract Chain

1. With boom level and retracted remove retract


chain anchor nut through access hole at rear
bottom sides of boom.
2. With adjustment nut loose extend boom
slightly and secure secondary from moving
out.
3. Remove retract chain anchor bolt at rear
where anchor attaches to secondary boom.

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.

4. Extend boom enough to allow removal of


retract chain anchor from main boom section.
5. Remove rear anchor from chain and attach
new chain to existing chain and anchor to
new chain.
6. Remove retract chain anchor from main boom
section at front of boom and pull through
7. Disconnect old chain from new chain and
attach anchor from old chain onto new chain
8. Bolt front anchor to main boom section
9. Attach chain anchor to secondary section at
rear of boom. It may be necessary to retract
boom and manually, via ratchet strap, retract
secondary section

7. Attach new chain to existing chain and pull


through.
8. Pull the rest of the chain through and
disconnect old chain from new.
9. Remove chain anchor from old chain and
install on new chain with new 5/16 grade 8
bolt and lock nut.
10. Attach chain anchor to primary boom section
with 2 new grade 8 bolts.

TM

Telehandler Series
Model ZB20044
402509

Page 143

Service and Maintenance

Chain Adjustment

Section 5 - Procedures

1. Fully extend boom when level

3. Add shims as required to obtain 0-1/16 (01.5mm) clearance with no drag.

2. Retract boom a few inches and tighten


adjustment nut on top of main boom until
there is no droop in chain

4. Apply Loctite 609 to bolts and torque to 100


ft.lb. Re-torque after 10min. and within 15min.
of initial torque.

3. Repeat above step until there is 1/2 droop


while retracting boom from full extension

5. Raise boom slightly and extend boom


approximately 6 ft. (2M).

5.4-3 Check Slide Pads

1. With telehandler parked on a level surface


and park brake applied remove access door
at rear of boom.
2. Measure slide pad thickness (top and bottom
of each boom section) inside rear of boom.
3. Raise boom slightly and extend boom
approximately 6 (2M). Measure slide pad
thickness (top, bottom and sides of each
boom section) at front end of boom.

6. Use steps 2 through 4 for slide pads at the


front of boom. To remove side front slide pads
pry boom section away from slide pad and
place a support/hook under pad then remove
bolts and pads.

NOTE
Always maintain squareness between the
booms outer and inner tube.

4. Replace any pads that are less than 3/4


(19mm) thick.
5. Shim all slide pads as required. (more than
1/8 or 3mm gap)

5.4-4 Replacing and Shimming Slide


Pads

1. With machine parked on a level surface and


park brake applied remove access door at
rear of boom.
2. Remove grease fittings and bolts of slide
pads to be shimmed/replaced. (Do not use
heat)

TM

Page 144

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

Service and Maintenance

Axles

5.5-2 Check Oil Level in Torque Hub

1. Drive the telehandler to rotate the hub until


the plug is located at 90 degrees.

5.5-1 Change Oil in Axles

2. Remove the plug and check the oil level. The


oil level should be even with the bottom of the
plug hole. Add oil if needed. (refer to Table
2.2 for oil specifications)

1. Ensure telehandler is on a firm level surface


and is in stowed position.
2. Turn off engine.
3. Place suitable container under the axle
4. Remove fill plug.
5. Remove drain plug to allow oil to drain into
container.
6. Reinstall all drain plugs.
7. Remove check plug.

Drive Torque Hub

8. Refill axle with new oil as per specifications.


(refer to Table 2.2)

Fill and Check

Drain

NOTE
Axle is filled when oil is leaking from the
check port.
9. Reinstall both fill and check plugs.
Grease Point

Grease Point

Oil Fill Plug

Grease
Points

Grease
Points

Oil Drain
Plug
Grease Point

Front or Rear Axle

TM

Telehandler Series
Model ZB20044
402509

Page 145

Service and Maintenance

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).

5.6-1 Frame Grease Points

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.

Frame Grease Points

TM

Page 146

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

Service and Maintenance

5.6-2 Boom Grease Points


NOTE
Grease should be applied if any of the following occur:
-- Pulsating or erratic boom operation, especially on retract.
-- Appreciable loading of the hydraulic system also while retracting the boom in the horizontal position, or
-- Noticeable wear of the high-load flange surfaces of the boom
Add grease to the following components. Ensure grease reaches the bearing internals.
Main boom pivot bearings
Carriage tilt cylinders
Carriage pivot bearings
Extension chain rollers
High load slide pads *
Retract chain roller
Hose rollers
Oil extension chain
Extend boom and rest it on the ground. Wipe the exposed portion of the extension chain with oil.
* Lubricate the rear top pads (4 places) on the primary and secondary booms through the door at the rear
of the boom while the boom is fully retracted.
Lubricate the front bottom pads (4 places) on the main and primary booms while the boom is also fully retracted.

Boom Grease Points

TM

Telehandler Series
Model ZB20044
402509

Page 147

Service and Maintenance

Section 5 - Procedures

5.6-3 Drive Axle Grease Points

1. Ensure telehandler is on a firm level surface and is in stowed position.


2. Open axle cover plate and locate grease fitting. (See diagram below)
3. Pump grease into the grease fittings.

5.6-4 Drive Shaft Grease Points

1. Locate the grease fittings on the drive shaft and pump grease. (See diagram below)

Axles & Drive Shafts Grease Points

TM

Page 148

Telehandler Series
Model ZB20044
402509

Section 5 - Procedures

Service and Maintenance

Tires
5.7-1 Check Lug Nut Torque
1.

Tighten wheel nuts to an initial torque reading of


50-100 ft-lbs, dry, in the sequence shown below.

12

10

7
9

11

2.

Re-tighten wheel nuts to a torque of 450-500 ft-lbs


, dry, in the sequence shown above.

3.

When the wheels are removed and reinstalled,


check the nuts after eight (8) hours of operation.

4.

If nuts are tight after the eight hour check, the


interval for checking with a torque wrench can
be extended to 250 hours.

TM

Telehandler Series
Model ZB20044
402509

Page 149

Notes

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