section 3 system component identification and...

SJIII Series Load Sensing System 129913ACJan. 2005

SECTION 3,

Section 3System Component Identification

And Schematics

Table Of Contents

Symbols & ChartsFigure 3.1-1. Relay Function Chart ............................................................................................................... 3Figure 3.1-2. Electrical Symbol Chart ........................................................................................................... 4Figure 3.1-3. Hydraulic Symbol Chart ........................................................................................................... 5

Hydraulic SystemFigure 3.2-1. Hydraulic Schematic Part List .................................................................................................. 6Figure 3.2-2. Hydraulic Schematic (Model 3215/3219) ................................................................................. 9Figure 3.2-3. Hydraulic Schematic (Model 3220/4620) ............................................................................... 10Figure 3.2-4. Hydraulic Schematic (Model 3226/4626/4632/4832) ............................................................. 11Figure 3.2-5. Hydraulic Schematic (Model 6826/6832) ............................................................................... 12

Electrical Diagrams And SchematicsFigure 3.3-1. Electrical Schematic And Diagram Parts List ......................................................................... 13Figure 3.3-2. Control Module to Transducers Diagram ............................................................................... 16

Operator’s Control Box DiagramFigure 3.3-3. Control Box Wiring Diagram (Model 3215/3219) ................................................................... 17Figure 3.3-4. Control Box Wiring Diagram - Equipped with All Option (No Rollout Limit)(Model 3220) .... 18Figure 3.3-5. Control Box Wiring Diagram - With No Option (All except Model 3215/3219) ...................... 19Figure 3.3-6. Control Box Wiring Diagram - With All Option (All except Model 3215/3219/3220) .............. 20

Electrical Panel DiagramFigure 3.4-1. Electrical Panel Diagram (Model 3215/3219) ......................................................................... 21Figure 3.4-2. Electrical Panel Diagram (Model 3220/3226/46XX/4832/68XX) .............................................. 22

Electrical SchematicFigure 3.5-1. Electrical Schematic (Model 3215/3219) ............................................................................... 23Figure 3.5-2. Electrical Schematic (Model 3220/3226) ............................................................................... 24Figure 3.5-3. Electrical Schematic (Model 4620/4626/4832) ....................................................................... 25

(Serial No. 66889 (4620), 709588 (4626), and Below)Figure 3.5-4. Electrical Schematic (Model 4620/4626/4632) ....................................................................... 26

(Serial No. 710000 (4620), 710000 (4626), and Above)Figure 3.5-5. Electrical Schematic (Model 68XX) ........................................................................................ 27

3


SECTION 3, Page 3

60045AB

Figure 3.1-1. Relay Function Chart

17CR BRAKE/STEERING RELAY

17CCR CUSHION RELAY (MODEL 3215/3219)

17CR1 BRAKE RELAY (MODEL 3215/3219)

21ACR PROPORTIONAL RELAY

28ACR PROPORTIONAL RELAY

28CR1 TILT RELAY

28CR2 DOWN RELAY

28ECR1 AUXILIARY TILT

28ECR2 AUXILIARY DOWN

RELAY NO. RELAY FUNCTION

CONTROL (B+)

NORMALLYCLOSED

CONTACT

SUPPLY (B+) (Common)

GROUND (B-)

NORMALLYOPEN

CONTACT

Jan. 2005SJIII SeriesLoad Sensing System 129913ACSECTION 3, Page 4

WIRE CROSSING HOURMETER

LEVEL SENSOR

KEY SWITCH

WIRES JOINED LIGHT

SINGLE POLESINGLE THROWNRELAY

FOOT SWITCH

BATTERYHYDRAULICVALVE COIL

SINGLE POLEDOUBLE THROWRELAY

TOGGLE SWITCH

GROUNDPROPORTIONALHYDRAULICVALVE COIL

DOUBLE POLESINGLE THROWRELAY

PUSH BUTTON

FUSEELECTRICMOTOR

DOUBLE POLEDOUBLE THROWRELAY

ROTARY SWITCH

CIRCUITBREAKER

HORN

TRIPLE POLEDOUBLE THROWRELAY

LIMIT SWITCH

BATTERYCHARGEINDICATOR

EMERGENCYSTOP BUTTON

DIODE

CAM OPERATEDLIMIT SWITCH

CAPACITOR RESISTOR

TRANSISTOR

TILT SWITCH

POTENTIOMETER

Figure 3.1-2. Electrical Symbol Chart

ANGLETRANSDUCER

PRESSURETRANSDUCER


SECTION 3, Page 5

LINE CROSSINGVARIABLEDISPLACEMENTPUMP

SHUTTLE VALVE VELOCITY FUSE

HAND PUMPLINE JOINEDACCUMULATOR,GAS CHARGED

SINGLE ACTINGCYLINDER

RELIEF VALVEHYDRAULICTANK

CUSHIONCYLINDER

DOUBLE ACTINGCYLINDER

PRESSUREREDUCINGVALVE

HYDRAULICFILTER WITHBYPASS

PRESSURESWITCH

DOUBLE ACTINGDOUBLERODDED

FIXED ORIFICEELECTRICMOTOR

MOTIONCONTROL VALVE

SPRING APPLIEDHYDRAULICRELEASEDBRAKE

ADJUSTABLEFLOW CONTROLENGINE

FLOW DIVIDERCOMBINER

BRAKECYLINDER

CHECK VALVE

FIXEDDISPLACEMENTPUMP

COUNTERBALANCE VALVE

ROTARYACTUATOR

OIL COOLER

THREE POSITIONFOUR WAYPROPORTIONAL

VALVE COIL

BI DIRECTIONALHYDRAULICMOTOR

TWO POSITIONTWO WAYNORMALLYCLOSED

SERIESPARALLELHYDRAULICMOTOR

TWO POSITIONTHREE WAY

THREE POSITIONFOUR WAYCLOSED CENTEROPEN PORT

TWO POSITIONTHREE WAY

TWO POSITIONTWO WAYNORMALLYOPEN

THREE POSITIONFOUR WAYCLOSED CENTERCLOSED PORT

THREE POSITIONFOUR WAYPROPORTIONAL

Figure 3.1-3. Hydraulic Symbol Chart

PRESSURETRANSDUCER

Jan. 2005SJIII SeriesLoad Sensing System 129913ACSECTION 3, Page 6

C1 124291 1 CYLINDER, CushionC2 120989 AR CYLINDER, Lift (All except Model 4832)

121965 2 CYLINDER, Lift (Model 4832)C3 121087 1 CYLINDER, Steer (Model 3215/3219)

120236 1 CYLINDER, Steer (Model 3220/3226/46XX/4832)120240 1 CYLINDER, Steer (Model 68XX)

C4 127667 2 CYLINDER, Brake (Model 3215/3219)120220 2 CYLINDER, Brake (Model 3220/3226/46XX/4832/68XX)

C5 125737 2 CYLINDER, 6 ft. Powered extension platform (Model 3220)120262 2 CYLINDER, 6 ft. Powered extension platform (Model 46XX/4832)120255 2 CYLINDER, 5 ft. Powered extension platform (Model 68XX)

CB1 104133 1 VALVE, CounterbalanceCMP1 115382 1 VALVE, Pressure compensatorCRV1 115299 1 CROSS-OVER RELIEF VALVE (option)

121877 1 CROSS-OVER, Relief Valve (Model 48XX)CV1 106277 1 VALVE, Pilot Check (Model 68XX)CV2 106277 1 VALVE, Pilot Check (Model 68XX)F1 109568 1 FILTER ASSEMBLY, Return

FD1 103354 1 VALVE, Flow divider/combinerHV1 107269 1 VALVE, Holding

2H-13B 103655 1 VALVE, Lowering2H-13B-1 107269 1 VALVE, Holding2H-13B-2 107269 1 VALVE, Holding2H-18A 104132 1 VALVE, Differential2H-25 128113 1 VALVE, Cushion

2H-59B 115351 1 VALVE, Proportional3H-14 106273 1 VALVE, Lift3H-17 103623 1 VALVE, Brake

3H-17A 103623 1 VALVE, Brake3H-18A 103623 1 VALVE, Pilot

3H-18A-1 103623 1 VALVE, Speed A3H-18A-2 103623 1 VALVE, Speed B

4H-15 128317 1 VALVE, “Hytos” Reverse drive (includes 4H-16)4H-16 128317 1 VALVE, “Hytos” Reverse drive (includes 4H-15)4H-23 128317 1 VALVE, “Hytos” Reverse drive (includes 4H-24)4H-24 128317 1 VALVE, “Hytos” Reverse drive (includes 4H-23)4H-26 113953 1 VALVE, Powered platform extend (includes 4H-27) (Model 3220/4620/4626)

(Order P/N 128317 for Model 46XX machines withSerial No. 66889 (4620), 709588 (4626), and Below)

128317 1 VALVE, Powered platform extend (includes 4H-27) (Model 4832/68XX)4H-27 113953 1 VALVE, Powered platform retract (includes 4H-26) (Model 3220/4620/4626)

(Order P/N 128317 for Model 46XX machines withSerial No. 66889 (4620), 709588 (4626), and Below)

128317 1 VALVE, Powered platform retract (includes 4H-26) (Model 4832/68XX)

Figure 3.2-1. Hydraulic Schematic Parts ListIndexNo.

SkyjackPart No.

DescriptionQty.

MI 310545 1 MOTOR, Hydraulic drive LH (Model 3215/3219)103129 1 MOTOR, Hydraulic drive LH (Model 3220/3226/46XX/4832)102689 1 MOTOR, Hydraulic drive LH (Model 68XX)

Parts list continued on the following page.


SECTION 3, Page 7

Parts list continued from the previous page.

M2 310545 1 MOTOR, Hydraulic drive LH (Model 3215/3219)103129 1 MOTOR, Hydraulic drive RH (Model 3220/3226/46XX/4832)102689 1 MOTOR, Hydraulic drive RH (Model 68XX)

MB1 127629 1 MANIFOLD BLOCK, Main (Model 3215/3219)107354 1 MANIFOLD BLOCK, Main (Model 3220/3226/46XX/4832/68XX)

MB2 127836 1 MANIFOLD BLOCK, Front Axle (Model 3215/3219)107493 1 MANIFOLD BLOCK, Emergency lowering (Model 3220/3226/46XX/4832/68XX)

MB3 128113 1 MANIFOLD BLOCK, Cushion Valve (Model 3215/3219)130481 1 MANIFOLD BLOCK, Holding Valve (Model 3220/4620)130442 1 MANIFOLD BLOCK, Lower Holding Valve (Model 3226/4626/4632/4832/68XX)108778 1 MANIFOLD BLOCK, Upper Holding Valve (Model 3226/4626/4632/4832/68XX)

MB4 130480 1 MANIFOLD BLOCK, Holding Valve (Model 3215/3219)108195 1 MANIFOLD BLOCK, Rear drive (Model 3220/3226/46XX/4832)108196 1 MANIFOLD BLOCK, Rear drive (Model 68XX)

MB5 126761 1 MANIFOLD BLOCK, Lowering Valve (Model 3215/3219)107382 1 MANIFOLD BLOCK, Powered extension (Model 3220/3226/46XX/4832/68XX)

MB9 127841 1 MANIFOLD BLOCK, Proportional (Model 3215/3219)115349 1 MANIFOLD BLOCK, Proportional (Model 3220/3226/46XX/4832/68XX)

O2 129577 1 ORIFICE, Lowering 0.060” dia. (Model 3215/3219)122213 1 ORIFICE, Lowering 0.073” dia. (Model 4620/4832/6832)

(Order P/N 104435 for Model 4620 machines with Serial No. 66889, & below)105530 1 ORIFICE, Lowering 0.081” dia. (Model 4632/6826)

O3 108002 1 ORIFICE, Cushion 0.040” dia. (Model 3215/3219)105811 1 ORIFICE, Steer .040” dia. (Model 3220/3226/46XX/4832/68XX)

O4 130407 2 ORIFICE, Brake 0.051” dia. (Model 3215/3219)105281 2 ORIFICE, Emergency lowering 0.067” dia. (Model 3220/3226/46XX/4832/68XX)

O5 108002 1 ORIFICE, Steering 0.040” dia. (Model 3215/3219)105811 2 ORIFICE, Brake .040” dia. (Model 3220/3226/46XX/4832/68XX)

O6 105281 1 ORIFICE, Emergency lowering 0.067” dia. (Model 3215/3219)104434 1 ORIFICE, Differential .040” dia. (Model 3220/3226/46XX/4832/68XX)

P1 123474 1 PUMP, Hydraulic - Standard (Model 3215/3219)106577 1 PUMP, Hydraulic (.226 cubic inches/rev) (Model 3220/4620)106587 1 PUMP, Hydraulic (.291 cubic inches/rev) (Model 3226/4626/4832/68XX)

PS1 102863 1 SWITCH, Pressure (option)113799 1 • MANIFOLD BLOCK, (for machines with Pressure Switch Option)

PT1 130431 1 TRANSDUCER, Pressure 2000 psi (Model 3215/3220/3226/4626/4832)130432 1 TRANSDUCER, Pressure 3000 psi (Model 3219/4620/68XX)

R1 104534 1 VALVE, System reliefR2 104534 1 VALVE, Lift reliefR3 106557 2 VALVE, ReliefR4 115336 1 VALVE, Cross-over relief (Option)R5 115336 1 VALVE, Cross-over relief (Option)V1 107271 1 VALVE, Emergency loweringV2 103136 1 VALVE, Free-wheeling

Figure 3.2-1. Hydraulic Schematic Parts ListIndexNo.

SkyjackPart No.

DescriptionQty.

SECTION 3, Page 9SJIII Series Load Sensing System 129913ACJan. 2005

A B C D E F G H

10966AB

V

Z

Y

X

W

Figure 3.2-2. Hydraulic Schematic (Model 3215/3219)

SECTION 3, Page 10Jan. 2005

SJIII Series Load Sensing System 129913AC

A B C D E F G H

10967AB

V

Z

Y

X

W

Figure 3.2-3. Hydraulic Schematic (Model 3220/4620)


Figure 3.2-4. Hydraulic Schematic (Model 3226/4626/4632/4832)

A B C D E F G H

10968AC

V

Z

Y

X

W



Figure 3.2-5. Hydraulic Schematic (Model 6826/6832 )

A B C D E F G H

10969AC

V

Z

Y

X

W


SECTION 3, Page 13

129ACR 108589 1 RELAY, 24 Volt (Joystick enable switch)17CCR 108589 1 RELAY, 24 Volt (cushion)17CR 108589 1 RELAY, 24 Volt (steering/transfer)17CR1 108589 1 RELAY, 24 Volt (brake)17CR2 108589 1 RELAY, 24 Volt (steering)21ACR 108589 1 RELAY, 24 Volt (proportional)28CR1 108589 1 RELAY, 24 Volt (Tilt)28CR2 108589 1 RELAY, 24 Volt (Down)

28ECR1 108589 1 RELAY, 24 Volt (Auxiliary Tilt)28ECR2 108589 1 RELAY, 24 Volt (Auxiliary Down)2H-13B 103605 1 COIL, 24 Volt (lowering valve)

2H-13B-X 104493 AR COIL, 24 Volt (holding valve)2H-18A 103605 1 COIL, 24 Volt (differential valve)2H-25 103605 1 COIL, 24 Volt (cushion)

2H-59B 115370 1 COIL, 24 Volt (proportional valve)3H-14 105610 1 COIL, 24 Volt (lift valve)

3H-17A 103605 1 COIL, 24 Volt (brake valve)3H-18A 103605 1 COIL, 24 Volt (pilot Valve)

3H-18A-1 103605 1 COIL, 24 Volt (speed A)3H-18A-2 103605 1 COIL, 24 Volt (speed B)

4H-15 128320 1 COIL, 24 V (reverse drive spool valve)4H-16 128320 1 COIL, 24 V (forward drive spool valve)4H-23 128320 1 COIL, 24 V (right steer spool valve)(Hytos)4H-24 128320 1 COIL, 24 V (left steer spool valve)(Hytos)4H-26 103605 1 COIL, 24 V Powered platform extend spool valve (Model 3220/4620/4626)

(Order P/N 128320 for machines with Serial No. 66889 (4620),709570 (4626), & below)

128320 1 COIL, 24 V “Hytos” Powered platform extend valve ( Model 4832/68XX)4H-27 103605 1 COIL, 24 V Powered platform retract valve Option (Model 3220/4620/4626)


128320 1 COIL, 24 V “Hytos” Powered platform retract valve (Model 4832/68XX)AT1 130440 1 TRANSDUCER, Angle

B1-B4 106552 4 BATTERY, 6 Volt (Interstate #U2500)103480 4 BATTERY, 6 Volt (Interstate #U2200)

BC 128537 1 ASSEMBLY, Battery ChargerBCI 122093 1 INDICATOR, Battery Charge

BP-29 117967 1 BEEPER, 9-28 VDCC1 103101 1 CONTACTOR, 24 Volt

CAP1 103319 1 CAPACITOR, 35 Volt 1000UF (Model 3215/3219)CB1-CB2 117325 2 CIRCUIT BREAKER, 15 Amp


Figure 3.3-1. Electrical Schematic and Diagram Parts ListIndexNo.

SkyjackPart No.

DescriptionQty.

Jan. 2005SJIII Series Load Sensing System 129913ACSECTION 3, Page 14


CM1 130439 1 CONTROL MODULE, Integrated SensorDCM1 123477 1 MOTOR, 24 VoltD02-X 129258 AR DIODEDXX 102921 AR DIODEDA1 119758 1 DIODE PACKDA2 119520 1 DIODE ASSEMBLYDA3 119624 1 DIODE ASSEMBLYF1 117619 1 FUSE, 300 Amp

FL-22 121477 1 LIGHT, FlashingH1 121058 1 HORN, Operator

L1CR 115315 1 RELAY, Battery chargerLB1 102671 1 MOUNT, Load Sensing Light AssemblyLS1 121975 1 LIMIT SWITCH, High speed (Model 3215/3219)

LS1A 121975 1 LIMIT SWITCH, High speed (Model 3220/3226/4832/68XX)133599 1 LIMIT SWITCH, High speed (Model 46XX)


LS1B 121975 1 LIMIT SWITCH, High speed (Model 3220/3226/4832/68XX)133599 1 LIMIT SWITCH, High speed (Model 46XX)


LS2 117079 1 LIMIT SWITCH, Powered extension platform 3 ft. (If Equipped)LS3 121975 1 LIMIT SWITCH, End of stroke (option)LS4 125886 1 LIMIT SWITCH, Pothole protection - battery tray (Model 3215/3219)

125887 1 LIMIT SWITCH, Pothole protection - battery tray (Model 3220/3226/4832/68XX)133601 1 LIMIT SWITCH, Pothole protection - battery tray (Model 46XX)


LS5 125885 1 LIMIT SWITCH, Pothole protection - hydraulic tray (Model 32XX/4832/68XX)133600 1 LIMIT SWITCH, Pothole protection - hydraulic tray (Model 46XX)


LS6 121975 1 LIMIT SWITCH, Drive override (Model 32XX/4832/68XX)133599 1 LIMIT SWITCH, Drive override (Model 46XX)



Figure 3.3-1. Electrical Schematic and Diagram Parts List (Continued)IndexNo.

SkyjackPart No.

DescriptionQty.


SECTION 3, Page 15

Figure 3.3-1. Electrical Schematic and Diagram Parts List (Continued)IndexNo.

SkyjackPart No.

DescriptionQty.


PS1 102863 1 SWITCH, PressurePT1 130431 1 TRANSDUCER, Pressure 2000 psi (Model 3215/3220/3226/4626/4632/4832)

130432 1 TRANSDUCER, Pressure 3000 psi (Model 3219/4620/68XX)PWM 122868 1 CIRCUIT BOARD, Joystick Controller (Model 3215/3219)

117150 1 CIRCUIT BOARD, Joystick Controller (All except Model 3215/3219)RST1 119629 1 RESISTOR, 2.7KRST2 115313 1 RESISTOR, 25W-30 Ohm (Model 3226/46XX/4832)

115312 1 RESISTOR, 25W-40 Ohm (Model 3215/3219/3220)120174 1 RESISTOR, 25W-20 Ohm (Model 6826/6832)

RST3 116505 1 RESISTOR, Low voltage protectionS1 119725 1 SWITCH, Main power disconnectS2 102853 1 SWITCH, Up/down toggle

103141 1 N.O.CONTACT, Up/Down Switch (Model 46XX with Serial No. 710000, & above)S3 103141 2 N.O. CONTACT, Base/off/platform key switchS4 103225 1 N.C. CONTACT, Emergency stop switch (control box)S5 116382 1 SWITCH, Lift/off/drive toggleS7 123994 1 CONTROLLER ASSEMBLY, Proportional

S7-1 122869 1 • SWITCH W/ACTUATOR, NeutralS7-2 122877 1 • SWITCH, Right steerS7-3 122877 1 • SWITCH, Left steerS7-4 122869 1 • SWITCH W/ACTUATOR, Reverse drive / DownS7-5 122869 1 • SWITCH W/ACTUATOR, Forward drive / UpS7-6 122869 1 • SWITCH Joystick Lift/Drive EnableS8 103141 1 N.O. CONTACT, Operator hornS9 103141 1 N.O. CONTACT, Lift/ Drive EnableS10 103414 1 N.O. CONTACT, Base Control Enable Switch (If Equipped)S11 102853 1 SWITCH, Powered ext. platform extend/retract toggle (option)S12 102853 1 SWITCH, Powered extension platform enable toggle (option)S27 115574 1 SWITCH, Torque toggleS28 103281 1 N.C. CONTACT, Emergency stop switch (base)

TMR-19B 132494 1 RELAY, Inverter Timer Cut-OutTT 103336 1 HOURMETER


Figure 3.3-2. Control Module to Transducers Diagram

10921AC


SECTION 3, Page 17

10869AA

Figure 3.3-3. Control Box Wiring Diagram (Model 3215/3219)


10897AA

Figure 3.3-4. Control Box Wiring Diagram - Equipped With All Options (No rollout limit) - (Model 3220)


SECTION 3, Page 19

Figure 3.3-5. Control Box Wiring Diagram - With No Option (All Except Model 3215/3219)

10866AA


Figure 3.3-6. Control Box Wiring Diagram - Equipped With All Option (All Except Model 3215/3219/3220)

10868AB


A B C D E F G H

10874AB

V

Z

Y

X

W

Figure 3.4-1. Electrical Panel Diagram - CE Models Equipped With All Options (Model 3215/3219)



A B C D E F G H

10891AE

V

Z

Y

X

W

Figure 3.4-2. Electrical Panel Diagram - CE Models Equipped With All Options (Model 3220/3226/46XX/4832/68XX)

If Equipped


Figure 3.5-1. Electrical Schematic - CE Models Equipped With All Options (Model 3215/3219)

A B C D E F G H

50209AB

V

Z

Y

X

W



Figure 3.5-2. Electrical Schematic - CE Models Equipped With All Options (Model 3220/3226)

A B C D E F G H

50171AC

V

Z

Y

X

W


Figure 3.5-3. Electrical Schematic - CE Models Equipped With All Options (Model 4620/4626/4832)(For Machines with Serial No. 66889 (4620), 709570 (4626), and below)

A B C D E F G H

50172AB

V

Z

Y

X

W



Figure 3.5-4. Electrical Schematic - CE Models Equipped With All Options (Model 4620/4626/4632)(For machines with Serial No. 710000, and above)

A B C D E F G H

50190AD

V

Z

Y

X

W


Figure 3.5-5. Electrical Schematic - CE Models Equipped With All Options (Model 68XX)

A B C D E F G H

50173AC

V

Z

Y

X

W

section 3 system component identification and...

Documents