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MODELS SJ 8831E SJ 8841E
Service Manual
DC Electric Full-Size Rough Terrain
Part No. 155154AB February 2014
Skyjack Service Center
Parts & Service (Europe)
3451 Swenson Ave. St. Charles,
Illinois, 60174 USA
Phone: 630-262-0005
Toll Free: 1-800-275-9522
Fax: 630-262-0006
Email: [email protected]
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: [email protected]
Parts (North America)
Skyjack Brasil
Toll Free: 1-800-965-4626
Toll Free Fax: 1-888-782-4825
E-mail: [email protected]
Skyjack Australia Pty Ltd.
4 Coates Place
Wetherill Park
New South Wales 2164
Australia
Tel: +61 (0) 28786 3200
Fax: +61(0) 28786 3222
Alameda Júpiter, 710
Loteamento American Park Empresarial
Indaiatuba, SP, Brasil 13347-653
Tel: +55 19 3936 0132
DC Electric Full-Size Rough Terrain
Service Manual
Table of Contents
Section 1 - Scheduled Maintenance
Table of Contents
Section 2 - Maintenance Tables
List of Tables
Section 3 - Schematics
Table of Contents
Section 4 - Troubleshooting
Table of Contents
Section 5 - Procedures
Table of Contents
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 3
Service and Maintenance
Operator’s Responsibility for Maintenance
The Safety Alert Symbol identifies important
safety messages on aerial platforms, 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 aerial platform.
SKYJACK, Page 4
DC Electric Full-Size
Rough Terrain
1
Section 1
schedule maintenance
Table of Contents
Operator’s Responsibility for Maintenance
Aerial Platform Definition...............................................................................................................................................7
Purpose of Equipment..................................................................................................................................................7
Use of Equipment.........................................................................................................................................................7
Manuals.........................................................................................................................................................................7
Operator........................................................................................................................................................................7
Service Policy and Warranty.........................................................................................................................................7
Optional Accessories....................................................................................................................................................7
Scope of this Manual....................................................................................................................................................8
Operator Safety Reminders..........................................................................................................................................9
Electrocution Hazard....................................................................................................................................................9
Safety Precautions......................................................................................................................................................10
Maintenance and Inspection Schedule......................................................................................................................13
Owner’s Annual Inspection Record............................................................................................................................13
Replacement Parts......................................................................................................................................................13
Maintenance and Service Safety Tips........................................................................................................................13
Hydraulic System & Component Maintenance and Repair.......................................................................................14
Maintenance Hints......................................................................................................................................................14
Service and Maintenance
About this Section.......................................................................................................................................................15
Service Bulletins..........................................................................................................................................................15
Maintenance and Inspection......................................................................................................................................15
Maintenance Instructions............................................................................................................................................15
Schedule Maintenance Inspections
1.1
1.2
Scheduled Maintenance Inspections...............................................................................................................18
Function Tests..................................................................................................................................................26
Tables
1.1 Owner’s Annual Inspection Record.................................................................................................................16
1.2 Maintenance and Inspection Checklist............................................................................................................17
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 5
Notes
SKYJACK, Page 6
DC Electric Full-Size
Rough Terrain
Operator’s Responsibility for Maintenance
Service and Maintenance
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Aerial Platform Definition
A mobile device that has an adjustable position platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK DC Electric Full-size Rough Terrain (Models 8831E & 8841E) aerial platforms are designed to transport
and raise personnel, tools and materials to overhead work areas.
Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level,
compacted surface. It can be driven over uneven terrain only when the platform is fully lowered.
Manuals
Operating
The operating manual is considered a fundamental part of the aerial platform. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the aerial platform at all times.
Service & Maintenance
The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.
All information in this manual should be read and understood before any attempt is made to service the machine.
The updated copy of the manuals are found on the company’s website: www.skyjack.com.
Operator
The operator must read and completely understand both this operating manual and the safety panel label located on
the platform and all other warnings in this manual and on the aerial platform. Compare the labels on the aerial platform
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 SJRT series work platform to be free of defective parts and workmanship for the first
24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or
labor. Contact the SKYJACK Service Department for warranty statement extensions or exclusions.
Optional Accessories
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under “Standard
and Optional Features” in Table 2.1 of the operating manual. Operating instructions for these options (if equipped)
are located in section 2 of the operating manual.
For non-standard components or systems, contact the SKYJACK Service Department at
(: 44-1691-676-235
7 : 44-1691-676-238
Include the model and serial number for each applicable aerial platform.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 7
Service and Maintenance
Operator’s Responsibility for Maintenance
Scope of this Manual
a.
This manual applies to the CE version of DC Electric Full-size Rough Terrain aerial platform models listed on
Table 2.1.
- Equipment identified with “CE” meets the requirements for the European countries, i.e., Machinery Directive
2006/42/EC and EMC Directive 2004/108/EEC and the corresponding EN standards.
b.
Operators are required to conform to national, state or territorial/provincial and local health and safety regulations
applicable to the operation of this aerial platform.
SKYJACK, Page 8
DC Electric Full-Size
Rough Terrain
Operator’s Responsibility for Maintenance
Service and Maintenance
WARNING
Failure to comply with your required responsibilities in the use and operation of the aerial platform
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 accidenvt. Therefore, proper usage of this aerial platform
is mandatory. The following pages of this manual should be read and understood completely before operating the
aerial platform.
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.
Any modifications from the original design are strictly forbidden without written permission from SKYJACK.
Electrocution Hazard
This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from energized
power lines and parts as listed below. The operator must allow for the platform to sway, rock or sag. This aerial
platform does not provide protection from contact with or proximity to an electrically charged conductor.
DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING.
DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS.
DANGER
Avoid Power Lines
Minimum Safe Approach Distance
CE Guidance Note
“Avoidance of danger from overhead lines”
Adhere strictly to the governmental rulings and regulations applicable in your country.
FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!
60023AE-CE
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 9
Service and Maintenance
Operator’s Responsibility for Maintenance
Safety Precautions
Know and understand the safety precautions before going on to next section.
warning
Failure to heed the following safety precautions could result in tip over, falling,
crushing, or other hazards leading to
death or serious injury.
• KNOW all national, state/provincial and local
rules which apply to your aerial platform and jobsite.
• TURN the (emergency) main power disconnect
switch off when leaving the aerial platform unattended. Remove the key to prevent unauthorized
use of the aerial platform.
• AVOID entanglement
ropes, cords or hoses.
with
• AVOID falling. Stay within the
boundaries of the guardrails.
• DO NOT raise the aerial platform in windy or gusty conditions.
SKYJACK, Page 10
• DO NOT wear loose clothing,
dangling neckties, scarves,
rings, wristwatches or other
jewelry while operating this
aerial platform.
• WEAR all the protective clothing and personal
safety devices issued to you or called for by job
conditions.
• DO NOT increase the lateral
surface area of the platform.
Increasing the area exposed
to the wind will decrease aerial
platform stability.
• DO NOT drive or elevate the
aerial platform if it is not on a
firm level surface. Do not drive
elevated near depressions
or holes of any type, loading
docks, debris, drop-offs and
surfaces that may affect the
stability of the aerial platform.
• If operation in areas with
holes or drop-offs is absolutely necessary, elevated
driving shall not be allowed.
Position the aerial platform
horizontally only with the
platform fully lowered. After
ensuring that all 4 wheels or
outriggers (if equipped) have
contact with level firm surface,
the aerial platform can be elevated. After elevation, the
drive function must not be activated.
• Elevated driving must only
be done on a firm level surface.
• DO NOT ascend or descend
a grade when elevated. When
fully lowered, ascending or
descending, only grades up
to rated maximum listed in
Table 2.3 are permissible.
DC Electric Full-Size
Rough Terrain
Operator’s Responsibility for Maintenance
Service and Maintenance
Safety Precautions (Continued)
Know and understand the safety precautions before going on to next section.
• DO NOT operate on surfaces not capable of
holding the weight of the aerial platform including
the rated load, e.g. covers, drains, and trenches.
• DO NOT operate an aerial
platform that has ladders,
scaffolding or other devices
mounted on it to increase its size
or work height. It is prohibited.
• DO NOT raise the platform
while the aerial platform is on a
truck, fork lift or other device or
vehicle.
• BE
AWARE of crushing
hazards. Keep all body parts
inside platform guardrail.
• DO NOT exert side forces on
aerial platform while elevated.
• DO NOT lower the platform
unless the area below is
clear of personnel and
obstructions.
• DO NOT use the aerial platform
as a crane. It is prohibited.
• ENSURE that there are no personnel or
obstructions in the path of travel, including blind
spots.
• DO NOT sit, stand or climb on
the guardrails. It is prohibited.
• BE AWARE of blind spots when operating the
aerial platform.
• DO NOT climb on scissor arm
assembly. It is prohibited.
• STUNT driving and horseplay are prohibited.
• ENSURE ALL tires are in good condition and lug
nuts are properly tightened.
• DO NOT alter or disable limit switches or other
safety devices.
• BE AWARE of overhead
obstructions or other possible
hazards around the aerial
platform when driving or lifting.
DC Electric Full-Size
Rough Terrain
• DO NOT use the aerial platform without
guardrails, locking pins and the entry gate/chain/
bar in place.
SKYJACK, Page 11
Service and Maintenance
Operator’s Responsibility for Maintenance
Safety Precautions (Continued)
Know and understand the safety precautions before going on to next section.
• DO NOT exceed the rated capacity of the aerial
platform. Do make sure the load is evenly distributed on the platform.
• DO NOT attempt to free a snagged platform with
lower controls until personnel are removed from
the platform.
• DO NOT position the aerial platform against another object to steady the platform.
• DO NOT place materials on the guardrails or materials that exceed the confines of the guardrails
unless approved by Skyjack.
WARNING
Entering and exiting the aerial platform
should only be done using the three
points of contact.
• Use only equipped access openings.
• Enter and exit only when the aerial
platform is in the fully retracted position.
• Do use three points of contact to enter and exit
the platform. Enter and exit the platform from
the ground only. Face the aerial platform when
entering or exiting the platform.
WARNING
An operator should not use any aerial
platform 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 blocked out for non-use or
repair.
Failure to avoid these hazards could
result in death or serious injury.
Jobsite Inspection
• Do not use in hazardous locations.
• Perform a thorough jobsite inspection prior to
operating the aerial platform, to identify potential
hazards in your work area.
• Be aware of moving equipment in the area. Take
appropriate actions to avoid collision.
• Three points of contact means that two hands
and one foot or one hand and two feet are in
contact with the aerial platform or the ground at
all times during entering and exiting.
SKYJACK, Page 12
DC Electric Full-Size
Rough Terrain
Operator’s Responsibility for Maintenance
Maintenance and Inspection Schedule
The actual operating environment of the work platform
governs the use of the maintenance schedule. The
inspection points covered in Table 1.2. Maintenance
and lnspection Checklist, indicates the areas of the
aerial platform to be maintained or inspected and at
what intervals the maintenance and inspections are to
be performed.
Owner’s Annual Inspection Record
It is the responsibility of the owner to arrange quarterly
and annual inspections of the aerial platform. Table 1.1.
Owner’s Annual lnspection Record is to be used for
recording the date of the inspection, owner’s name,
and the person responsible for the inspection of the
work platform.
Replacement Parts
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and
dimensions different from original parts will affect
stability of the aerial platform and must not be used
without manufacturer’s consent.
All replacement tires must be of the same size and load
rating as originally supplied tires; to maintain safety and
stability of aerial platform.
Consult SKYJACK’s Service Department for optional
tires specifications and installation.
WARNING
Any unit that is damaged or not operating properly must be immediately tagged
and removed from service until proper
repairs are completed.
DC Electric Full-Size
Rough Terrain
Service and Maintenance
Maintenance and Service Safety Tips
Maintenance and repair should only be performed by
personnel who are trained and qualified to service this
aerial platform.
All maintenance and service procedures should be
performed in a well lighted and well ventilated area.
Anyone operating or servicing this aerial platform
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.
Before attempting any repair work, turn Battery
Disconnect Switch to the “OFF” position.
Preventive maintenance is the easiest and least
expensive type of maintenance.
SKYJACK, Page 13
Service and Maintenance
Operator’s Responsibility for Maintenance
Hydraulic System & Component
Maintenance and Repair
Oil change intervals will depend on the
care used in keeping the oil clean, and the
operating conditions. Dirt and/or moisture
cotamination 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 1.2 of this manual.
The following points should be kept in mind when
working on the hydraulic system or any component:
1.
2.
3.
4.
5.
6.
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
made under these circumstances.
Whenever the hydraulic system is drained, check
the magnets in the hydraulic reservoir for metal
particles. If metal particles are present, flush the
entire system and add a new change of oil. The
presence of metal particles also may indicate the
possibility of imminent component failure. A very
small amount of fine particles is normal.
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.
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.
SKYJACK, Page 14
7.
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.
8.
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.
9.
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.
10. All hydraulic connections must be kept tight. A
loose connection in a pressure line will permit
the oil to leak out or air to be drawn into the
system. Air in the system can cause damage
to the components and noisy or erratic system
operation.
Maintenance 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.
DC Electric Full-Size
Rough Terrain
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 aerial platform.
Maintenance and Inspection
Death or injury can result if the aerial platform is not kept
in good working order. Inspection and maintenance
should be performed by competent personnel who
are trained and qualified on mantenance of this aerial
platform.
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.
Service and Maintenance Inspections
Maintenance Instructions
This manual consists of four schedules to be done for
maintaining on an aerial platform. Inspection schedule
frequency is shown below:
Inspection Schedule
Daily
Frequently
Annually
Bi-annually
A
A+B
A+B+C
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
aerial platform from service.
• If any aerial platform 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
• Unless otherwise specified, perform each
maintenance procedure with the aerial platform in
the following configuration:
- Aerial platform parked on a flat and level
surface
- Disconnect the battery by turning the main
power disconnect switch to the “OFF” position.
• Repair any damaged or malfunction components
before operating aerial platform.
• Keep records on all inspections.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 15
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Table 1.1 Owner’s Annual Inspection Record
Model Number: ________________________
Serial Number: _________________________
Inspection
Date
Recording
Year
New
Owner’s
Name
Skyjack
Inc.
Inspected
By
Skyjack
Inc.
1
2
3
4
5
6
7
8
9
158AA
As described earlier in this section, this decal is located on the scissor assembly. It must be completed after an annual
inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 6
months.
SKYJACK, Page 16
DC Electric Full-Size
Rough Terrain
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Table 1.2 MAINTENANCE AND INSPECTION CHECKLIST
Serial Number:
Model:
Hourmeter Reading:
Name (Printed):
Date:
Time:
Signature:
Each item shall be inspected using the the appropriate section of the Skyjack service manual.
As each item is inspected, write the apropriate grade in the box.
Inspection Schedule
INSPECTION FREQUENCY
Daily
A
‰ DAILY
Frequently*†
A+B
P - PASS
‰ FREQUENTLY
Annually†
A+B+C
F - FAIL
‰ ANNUALLY
Bi-annually†
A
+B+C+D
R - REPAIRED
BI-ANNUALLY
‰
Schedule
P
F
Schedule Maintenance Inspections
Schedule
R
P
Labels
A
Limit Switches
A, B
Battery Compartment
Base Weldment
A, B
Wheel/Tire Assembly
A, B
Axles
A, B
Battery Tray
A, B
Steer Cylinder Assembly
A, B
Battery
A, B
Tie Rod
A, B
Battery Connectors
A, B
Disc Brake
A, B
Fuse Box
A, B
Drive Motor
A, B
Ladder
A, B
Outriggers (If Equipped)
A, B
Hydraulic/Electrical Compartment
Electrical Panel
Manifolds
A, B
A, B, C
Manual
Base Control Switches
A, B
Function Tests
Emergency Lowering Access Rod
A, B
Test Battery Connectors
Battery Charger/Hydraulic Compartment
A, B
Base Control Console
A, B
Test Base Emergency Stop
Hydraulic Oil
A, B
Test Off/Platform/Base Switch
A, B
Battery Charger
A, B
Test Lower/Neutral/Raise Switch
A, B
Test Emergnency Lowering
A, B
Platform Assembly
A
A, B
Platform Control Console
AC Outlet on Platform
A, B
Test Platform Emergency Stop
A, B
Platform Control Console
A, B
Test Enable Trigger Switch
A, B
Test Platform Raising/Lowering
A, B
Test Lowering Warning - CE
A, B
Test Steering
A, B
Powered Extension Control Console
(If Equipped)
R
A, B
Hydraulic Tank
Lanyard Attachment Anchors
F
Base
A, B
Lift Mechanism
Scissor Guards (If Equipped)
A, B
Test Driving
A, B
Sliders
A, B
Test Brakes
A, B
Maintenance Support
A, B
Test Elevated Drive Speed
A, B
Scissor Assembly
A, B
Test Horn
A, B
Scissor Bumpers
A, B
Lift Cylinder(s)
A, B
184AA
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.7 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every three months or 150 hrs. Refer to Section 1.0 of this manual.
C - Perform Scheduled Maintenance Inspection every year. Refer to Section 1.0 of this manual.
D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1.0 of this manual.
* Perform scheduled inspection every three months or 150 hours.
† Refer to Skyjack's webiste @ www.skyjack.com for latest service bulletins prior to performing quarterly or yearly inspection.
Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 17
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Platform Control
Console
Platform
Assembly
Scissor
Assembly
Limit Switch
Outrigger
Ladder
Electrical/Hydraulic
Compartment
1.1 Scheduled Maintenance Inspections
Begin the scheduled maintenance inspections by
checking each item in sequence for the conditions listed
in this section.
WARNING
To avoid injury, do not operate an aerial
platform until all malfunctions have been
corrected.
WARNING
To avoid possible injury, ensure aerial
platform power is off during your visual
and daily maintenance inspections.
Electrical
Maintaining the electrical components is essential
to good performance and service life of the aerial
platform.
Inspect the following areas for chafed, corroded
and loose wires:
• base to platform cables and wiring harness
• engine compartment electrical panel
• engine wiring harness
• hydraulic/electrical wiring harnesses
Hydraulic
Maintaining the hydraulic components is essential
to good performance and service life of the aerial
platform.
SKYJACK, Page 18
Base
Perform a visual inspection around the following
areas:
• hydraulic tank filter, fittings, hoses, emergency
power unit (if equipped) and base surfaces
• engine compartment fittings, hoses, main
pump, and filter
• all hydraulic cylinders
• all hydraulic manifolds
• the underside of the base
• ground area under the aerial platform
• outriggers
1.1-1 Labels
Refer to the labels section in this manual and determine
that all labels are in place and are legible.
1.1-2 Limit Switches
Detecting limit switch malfunction is essential to safe
aerial platform operation. Ensure limit switches are
properly secured with no signs of visible damage and
movement is not obstructed.
Visually inspect all limit switch located inside the
scissor arms and the outrigger assemblies for the
following:
• broken or missing actuator arm
• missing fasteners
• loose wiring
DC Electric Full-Size
Rough Terrain
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Batteries
Battery Connectors
Battery Tray
1.1-3 Battery Compartment
• Battery Tray
-- Ensure tray is properly secured and there
is no visible damage.
-- Ensure compartment latch is secure and
in proper working order.
• Battery
Proper battery condition is essential to
good performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in 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.
DC Electric Full-Size
Rough Terrain
Fuse Box
1. Check battery case for damage.
2. Clean battery terminals and cable ends
thoroughly with a terminal cleaning tool or
wire brush.
3. Ensure all battery connections are tight.
4. If applicable, check battery fluid level. If plates
are not covered by at least 13 mm of solution,
add distilled or demineralized water.
5. Replace battery if damaged or incapable of
holding a lasting charge.
WARNING
Use original or manufacturer-approved
parts and components for the aerial
platform.
• Battery Connectors
-- Ensure battery connectors are properly
secured and there is no visible
damage.
• Fuse Box
-- Ensure fuse box is properly secured and
there is no visible damage.
SKYJACK, Page 19
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Main Manifold
Base Control
Switches
Electrical Panel
Hydraulic Pump/Motor
Assembly
1.1-4 Hydraulic/Electrical Compartment
-- Ensure all compartment latches are secure
and in proper working order.
• Electrical Panel
-- Ensure panel is properly secured and
there is no visible damage.
-- Ensure there are no loose wires or
Brake Manifold
• Base Control Switches
-- Ensure there are no signs of visible
damage and all switches are in their
neutral positions.
• Emergency Lowering Access Rod
-- Ensure rod is properly secured and there
is no visible damage.
missing fasteners.
• Manifolds
-- Ensure all fittings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.
-- Ensure there are no loose wires or
missing fasteners.
SKYJACK, Page 20
DC Electric Full-Size
Rough Terrain
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Battery Charger
Hydraulic Tank
Sight Gauge
1.1-5 Battery Charger/Hydraulic Compartment
-- Ensure all compartment latches are
secure and in proper working order.
• Battery Chargers
-- Ensure chargers are secure and shows
no visible damage.
• Hydraulic Tank
-- Ensure hydraulic filler cap is secure.
-- Ensure tank shows no visible damage
and no evidence of hydraulic leakage.
• Hydraulic Oil
-- Ensure platform is fully lowered, and
outriggers retracted, and then visually
inspect the sight gauge located on the
side of the hydraulic oil tank. Check oil
level against label that indicates minimum
and maximum oil levels.
C - Annual Inspection
-- For hydraulic oil replacement procedure,
refer to section 5.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 21
Service and Maintenance Inspections
Platform Control
Console
Section 1 - Scheduled Maintenance
Platform
Railing
Platform
Assembly
1.1-6 Platform Assembly
WARNING
Ensure that you maintain three points of
contact to mount/dismount platform.
1. Use the ladder of aerial platform to access
platform.
2. Close the gate.
-- Ensure there are no loose or missing
parts and there is no visible damage.
-- Ensure all fasteners are securely in
place.
-- Ensure all railings are properly positioned
and secured.
-- Ensure gate is in good working order.
• Lanyard Attachment Anchors
-- Ensure attachment rings are secure and
have no visible damage.
• Platform Control Console
-- Ensure all switches and controller are
returned to neutral and are properly
secured.
-- Ensure there are no loose or missing
parts and there is no visible damage.
• Powered Extension Control Console
(If Equipped)
-- Ensure all switches are returned to
neutral and are properly secured.
-- Ensure there are no loose or missing
parts and there is no visible damage.
WARNING
Ensure that you maintain three points of
contact to mount/dismount platform.
3. Use the ladder to dismount from platform.
• AC Outlet on Platform
-- Ensure outlet has no visible damage and
free from dirt or obstructions.
SKYJACK, Page 22
DC Electric Full-Size
Rough Terrain
Section 1 - Scheduled Maintenance
Slider
Service and Maintenance Inspections
Scissor Assembly
Maintenance
Support
Lift Cylinder
Limit Switch
Scissor Bumper
1.1-7 Lifting Mechanism
• Scissor Guards
-- Ensure there are no loose or missing
parts and there is no visible damage.
• Scissor Bumpers
-- Ensure bumpers are secure and shows
no sign of visible damage.
• Sliders
-- Ensure sliders are secure and there is no
visible damage.
• Lift Cylinder(s)
-- Ensure each lift cylinder is properly
secured, there are no loose or missing
parts and there is no evidence of
damage.
-- Ensure sliders’ path of travel are free from
-- Ensure all fittings and hoses are properly
dirt and obstructions.
1. Raise the platform until there is adequate
clearance to swing down the maintenance
support.
• Maintenance Support
-- Ensure maintenance support is properly
secured and shows no visible damage.
tightened and there is no evidence of
hydraulic leakage.
2. Raise the platform until there is adequate
clearance to swing up the maintenance
support into storage bracket.
3. Fully lower the platform.
• Scissor Assembly
-- Ensure scissor assembly shows no visible
damage and no signs of deformation in
weldments.
-- Ensure all pins are properly secured.
-- Ensure cables and wires are properly
routed and shows no signs of wear and/
or physical damage.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 23
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Ladder
Base
Weldment
Wheel/Tire
Assembly
Tie Rod
Drive Axle
Steer Cylinder
Assembly
1.1-8 Base
• Base Weldment
-- Ensure there are no visible cracks in
welds or structure and there are no signs
of deformation.
• Axles
-- Ensure axles are properly secured,
there are no loose or missing parts, all
fittings and hoses are properly tightened
and there is no evidence of hydraulic
leakage.
• Wheel/Tire Assembly
The aerial platform is either equipped with
foam-filled tires. Tire and/or wheel failure could
result in an aerial platform tipover. Component
damage may also result if problems are not
discovered and repaired in a timely fashion.
• 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 leakage.
--
Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
--
Check each wheel for damage and cracked
welds.
• Tie Rod
-- Ensure there are no loose or missing
parts, tie rod end studs are locked and
there is no visible damage.
--
Check each lug nut for proper torque to
ensure none are loose.
Refer to Table 2.4 for wheel/tire specifications.
SKYJACK, Page 24
DC Electric Full-Size
Rough Terrain
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Ladder
Base
Weldment
Wheel/Tire
Assembly
Tie Rod
Drive Axle
Steer Cylinder
Assembly
• Disc Brake
-- Ensure there are no loose or missing
parts and there is no visible damage.
• Drive Motor
-- Ensure there are no loose or missing
parts and there is no visible damage.
-- Ensure all bolts are properly tightened.
• Ladder
-- Ensure there are no loose or missing
parts and there is no visible damage.
1.1-9 Manuals
Ensure a copy of operating manual, and other
important documents are enclosed in manual
storage box.
-- Check to be sure manual storage box is
present and in good condition.
-- Ensure manuals are legible and in good
condition.
-- Always return manuals to the manual
storage box after use.
• Outriggers
-- Ensure there are no loose or missing
parts and there is no visible damage.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 25
Function Tests
Section 1 - Scheduled Maintenance
Battery Connectors
Emergency Lowering
Valve
Off/Platform/Base
Key Switch
Platform Lower/Neutral/
Raise Switch
TM
Emergency Stop
Button
1.2 Function Tests
1.2-2 Base Control Console
Function tests are designed to discover any malfunctions
before aerial platform is put into service. The operator
must understand and follow step-by-step instructions
to test all aerial platform functions.
WARNING
Ensure that you maintain three points of
contact when using the ladder to mount/
dismount platform.
WARNING
1.
Use the ladder of aerial platform to access
platform.
2.
Close the gate.
3.
After repairs are completed, operator must perform a
pre-operation inspection and a series of function tests
again before putting aerial platform into service.
On platform control console, pull out “
emergency stop button.
4.
Insert key into base/off/platform key switch and
Prior to performing function tests, be sure to read
and understand Section 2.10 - Start Operation of the
operating manual.
5.
Use the ladder to dismount from platform.
6.
On battery roll-out tray, ensure battery connectors
are properly connected.
7.
On base control console, pull out “ ” emergency
stop button. A beeping sound should be audible
and light should come on.
Never use a malfunctioning aerial
platform. If malfunctions are discovered,
aerial platform must be tagged and
placed out of service. Repairs to aerial
platform may only be made by a qualified
service technician.
select “
1.2-1 Test Battery Connectors
1.
In battery roll-out tray, disconnect battery
connectors.
Result: Aerial platform functions should not
operate.
”
” base position.
•
SKYJACK, Page 26
DC Electric Full-Size
Rough Terrain
Section 1 - Scheduled Maintenance
Function Tests
Holding Valve Manual
Override Knob
Emergency Lowering
Valve
Off/Platform/Base
Key Switch
Platform Lower/Neutral/
Raise Switch
TM
Emergency Stop
Button
WARNING
2. Select off/platform/base key switch to “ ”
platform position. Attempt to raise or lower
the platform.
Result: Platform raising and lowering
functions should not operate.
If beeping sound is not audible and light
does not come on, aerial platform must
be tagged and placed out of service.
• Test Base Emergency Stop
3. Select and hold off/platform/base key
” emergency stop
1. Push in base “
button and attempt to raise or lower the
platform.
Result: Platform raising and lowering
functions should not operate.
switch to “
” base position. Attempt
to raise or lower the platform.
Result: Platform raising and lowering
functions should operate.
• Test Lower/Neutral/Raise Switch
2. Turn key clockwise to activate base “
emergency stop button.
2. Pull out base “
button.
”
1. Select and hold off/platform/base key
switch to “
” emergency stop
• Test Off/Platform/Base Switch
WARNING
DC Electric Full-Size
Rough Terrain
” raise the platform with lower/neutral/
“
raise switch.
Result: Platform should rise.
2. Select and hold off/platform/base key
switch to “
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
1. Select off/platform/base key switch
“ ” off position. Attempt to raise or lower
the platform.
Result: Platform raising and lowering
functions should not operate.
” base position and
•
” base position and
“
” lower the platform with lower/
neutral/raise switch.
Result: Platform should lower.
SKYJACK, Page 27
Function Tests
Section 1 - Scheduled Maintenance
Rocker Switch
Lift/Drive/Steer
Enable Trigger Switch
Lift/Drive/Steer Controller
Operation Light
Lift/Off/Drive Switch
Base/Off/Platform
Key Switch
Horn
Emergency Stop
Button
• Test Emergency Lowering
1. Raise the platform.
2. Locate holding valve manual override
knob at the base of each lift cylinder.
Depress and turn counterclockwise.
If necessary, use emergency lowering
access rod that is located on the base of
the aerial platform.
1.2-3 Platform Control Console
1.
On battery roll-out tray, ensure battery connectors
are properly connected.
2.
On base control console, ensure base “
emergency stop button is pulled out.
”
3.
Select off/platform/base key switch to “
platform position.
”
3. On hydraulic/electrical compartment, pull
out and hold emergency lowering valve to
fully lower the platform.
Result: The platform should lower.
4. To restore normal operation, depress and
turn holding valve manual override knobs
clockwise.
WARNING
Ensure that you maintain three points of
contact when using the ladder to mount/
dismount platform.
4.
Use the ladder of aerial platform to access
platform.
5.
Close the gate.
6.
Insert key into base/off/platform key switch and
select “
7.
SKYJACK, Page 28
” platform position.
On platform control console, pull out “
emergency stop button.
”
DC Electric Full-Size
Rough Terrain
Section 1 - Scheduled Maintenance
Lift/Drive/Steer
Enable Trigger Switch
Function Tests
Rocker Switch
Lift/Drive/Steer Controller
Operation Light
Lift/Off/Drive Switch
Horn
Base/Off/Platform
Key Switch
Emergency Stop
Button
• Test Platform Emergency Stop
” emergency stop button
1. Push in “
and attempt to activate any platform
function.
Result: All selected platform functions
should not operate.
• Test Enable Trigger Switch
1. Pull out “
• Test Platform Raising/Lowering
WARNING
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
1. Select lift/off/drive switch to “
position.
” lift
” emergency stop button.
2. Without activating “ ” enable trigger
switch, attempt to activate any platform
function.
Result: All platform functions should not
operate.
2. Activate and hold “
switch.
” enable trigger
3. Push controller handle and raise the
platform to an approximate height of
0.5 meter.
Result: Platform should rise.
4. Pull controller handle and lower the
platform fully.
Result: Platform should lower.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 29
Function Tests
Section 1 - Scheduled Maintenance
Rocker Switch
Lift/Drive/Steer
Enable Trigger Switch
Lift/Drive/Steer Controller
Operation Light
Lift/Off/Drive Switch
Base/Off/Platform
Key Switch
Horn
Emergency Stop
Button
• Test Lowering Warning
• Test Driving
1. Raise the platform until approximately a
height of 3 to 4 meters is reached them
attempt to fully lower the platform.
Result: Platform should stop lowering at
a height of 2.5 meters high and an alarm
should sound.
1. Ensure path of intended motion is clear.
2. Activate and hold “
switch.
3. Slowly move controller handle in
2. Release controller handle, ensure area
around scissor is clear, then continue
lowering the platform.
• Test Steering
1. Select lift/off/drive switch to “
position.
2. Activate and hold “
switch.
” enable trigger
handle to “
” left and “
”
right.
Result: Steer wheels should turn left and
right.
SKYJACK, Page 30
“ ” forward direction until aerial platform
begins to move, and then return handle to
center position.
Result: Aerial platform should move in
forward direction, and then come to a
stop.
” drive
3. Press rocker switch on top of controller
”enable trigger
4. Slowly move controller handle in “ ”
reverse direction until aerial platform begins
to move, and then return handle to center
position.
Result: Aerial platform should move in
reverse direction, and then come to a
stop.
DC Electric Full-Size
Rough Terrain
Section 1 - Scheduled Maintenance
Function Tests
Rocker Switch
Lift/Drive/Steer
Enable Trigger Switch
Lift/Drive/Steer Controller
Operation Light
Lift/Off/Drive Switch
Base/Off/Platform
Key Switch
Horn
Emergency Stop
Button
• Test Brakes
• Test Elevated Drive Speed
WARNING
WARNING
Brakes will engage instantly when you
release the controller handle, causing
aerial platform to stop immediately.
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
1. Ensure path of intended motion is clear.
1. Ensure path of intended motion is clear.
2. Activate and hold “
switch.
” enable trigger
3. Drive aerial platform “ ” forward. Test
brake by releasing controller handle.
Result: Aerial platform should come to
a stop. If aerial platform pulls to one side
while stopping, do not operate aerial
platform until brake adjustments have
been checked.
4. Drive aerial platform “
2. Raise the platform until approximately a
height of 2 meters is reached and attempt
to drive forward or reverse.
Result: Aerial platform should move slower
than when it is in stowed position.
• Test Horn
” horn pushbutton.
1. Push “
Result: Horn should sound.
” forward. Test
brake again by releasing “ ” enable
trigger switch only.
Result: Aerial platform should come to an
instant and abrupt stop. If aerial platform
does not stop immediately, or if aerial
platform pulls to one side while stopping,
do not operate aerial platform until brake
adjustments have been checked.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 31
Notes
SKYJACK, Page 32
DC Electric Full-Size
Rough Terrain
Section 2
maintenance tables and diagrams
List of Tables
2.1a Specifications and Features (CE)......................................................................................................................2
2.1b Specifications and Features (ANSI/CSA)...........................................................................................................3
2.2a Maximum Platform Capacities (Evenly Distributed - CE)..................................................................................4
2.2b Maximum Platform Capacities (Evenly Distributed - ANSI/CSA).......................................................................5
2.3a Floor Loading Pressure (CE).............................................................................................................................6
2.3b Floor Loading Pressure (ANSI/CSA)..................................................................................................................7
2.4a Tire Specifications (CE)......................................................................................................................................9
2.4b Tire Specifications (ANSI/CSA)........................................................................................................................10
2.5 Rough Terrain Scissor Fluids...........................................................................................................................11
2.6 Torque Specifications.......................................................................................................................................12
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 1
2
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.1a Specifications and Features (CE)
MODEL
Weight
*
DC Electric Full-Size
Rough Terrain
8831E
8841E
5411 kg
6033 kg
Overall width
2.2 m
Overall length
3.7 m
1,73 m x 3,5 m
Platform Size (inside)
Height
Working Height
11.6 m
14.5 m
Platform Elevated Height
9.6 m
12.5 m
Stowed Platform Height
1.5 m
1.8 m
Full
Drive Height
Standard Operating Times
Lift Time (Rated Load)
46 s
71 s
Lower Time (Rated Load)
48 s
60 s
Normal Drive Speed
4.8 km/h
4.8 km/h
Elevated Drive Speed
0.34 km/h
0.34 km/h
Chassis
Gradeablility
30%
Tires
(#6 Foam-filled)
31 x 10-16.5
Tires (Optional)
(#6 Foam-filled - Non-marking)
31 x 10-16.5
Hydraulic Oil
Type
Tank Capacity (Liters)
ATF Dexron III
75.71
149AA
* Weights are approximate; refer to serial nameplate for specific weight.
SKYJACK, Page 2
DC Electric Full-Size
Rough Terrain
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.1b Specifications and Features (ANSI/CSA)
Rough Terrain E-Series
Model
8831E
Width*
10,455 lb.
4742 kg
11,355 lb.
5151 kg
Width
87.0”
2.21 m
87.0”
2.21 m
Length
137.5”
3.5 m
137.5”
3.5 m
Platform Size
Height
8841E
68” x 133.5” (1.73 m x 3.39 m)
Working Elevated
37.0’
11.28 m
47.0’
14.3 m
Platform Elevated
31.0’
9.5 m
41’
12.5 m
Platform Lowered
59.0”
1.5 m
69.0”
1.75 m
Full
Tires
Speed
Drive
Normal Drive
2.6 mph
4.2 km/h
2.6 mph
4.2 km/h
Elevated Drive
0.45 mph
0.72 km/h
0.45 mph
0.72 km/h
Lift (Rated Load)
46 sec.
71 sec.
Lower (Rated Load)
48 sec.
60 sec.
Standard
30 x 10-16.5 #6 Air-filled
Optional
#6F or #7F
Gradeability
30%
60125AF-ANSI
*
Weights are approximate; refer to serial nameplate for specific weight.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 3
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.2a Maximum Platform Capacities (Evenly Distributed - CE)
Total
Second Extension
Capacity
Number of
Occupants
Capacity
Number of
Occupants
Capacity
Number of
Occupants
8831E
First Extension
Two Extension
Platforms
908 kg
6
227 kg
2
227 kg
2
8841E
MODEL
Two Extension
Platforms
681 kg
5
227 kg
2
227 kg
2
150AA
NOTE:
Occupants and materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires.
Refer to capacity label at sides of platform for additional information and for models equipped with
options.
Wind Speed
BEAUFORT
SCALE
m/s
km/h
ft/s
mph
3
3.4 – 5.4
12.5 – 19.4
11.5 – 17.75
5 – 12.0
Papers and thin branches move, flags wave
4
5.4 – 8.0
19.4 – 28.8
17.75 – 26.25
12.0 – 18
Dust is raised, paper whirls up, and small
branches sway.
5
8.0 – 10.8
28.8 – 38.9
26.25 – 35.5
18 – 24.25
Shrubs with leaves start swaying. Wave crests are
apparent in ponds or swamps.
6
10.8 – 13.9
38.9 – 50.0
35.5 – 45.5
24.5 – 31
Tree branches move. Power lines whistle. It is
difficult to open an umbrella.
7
13.9 – 17.2
50.0 – 61.9
45.5 – 65.5
31 – 38.5
Whole trees sway. It is difficult to walk against the
wind.
Ground Conditions
60338AC
SKYJACK, Page 4
DC Electric Full-Size
Rough Terrain
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.2b Maximum Platform Capacities (Evenly Distributed - ANSI/CSA)
Total
MODEL
8841E
8831E
No Extension
Platform
Capacity
2500 lb.
1134 kg
One Extension
Platform
2000 lb.
Two Extension
Platforms
1700 lb.
No Extension
Platform
1700 lb.
One Extension
Platform
1500 lb.
Two Extension
Platforms
1500 lb.
907 kg
771 kg
771 kg
680 kg
680 kg
First Extension
Number of
Occupants
Capacity
Number of
Occupants
6
500 lb.
227 kg
5
Number of
Occupants
500 lb.
227 kg
Not Available
2
2
5
5
Capacity
Not Available
6
6
Second Extension
500 lb.
2
227 kg
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
Not Available
500 lb.
227 kg
2
60279AD-ANSI
NOTE:
Occupants and materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 5
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.3a Floor Loading Pressure (CE)
WHEEL
LCP **
OUP **
kg
kg
kPa
kg/m2
min*
5536
2164
1254
719
max*
6788
2645
1399
882
min*
5831
2282
451
690
max*
6788
2645
525
804
min*
6119
2410
1312
795
max*
7145
2800
1455
928
min*
6415
2528
496
759
max*
7145
2800
553
846
MODEL
8831E
8831E
Outrigger Pads
8841E
8841E
Outrigger Pads
Total Aerial Platform Load
Total Aerial
Platform Weight
151AC-CE
*
min - Total aerial platform weight with no options
max - Aerial platform weight + all options
**
LCP - Locally Concentrated Pressure is a measure of how hard the aerial
platform presses on the areas in direct contact with the floor. The floor
covering (tile, carpet, etc.) must be able to withstand more than the
indicated values above.
OUP - Overall Uniform Pressure is a measure of the average load the
aerial platform imparts on the whole surface directly underneath it. The
structure of the operating surface (beams, etc.) must be able to withstand
more than the indicated values above.
NOTE:
The LCP or OUP that an individual surface can withstand varies from
structure to structure and is generally determined by the engineer or
architect for that particular structure.
SKYJACK, Page 6
DC Electric Full-Size
Rough Terrain
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.3b Floor Loading Pressure (ANSI/CSA)
MODEL
8831E
8831E
Outrigger Pads
8841E
8841E
Outrigger Pads
Total Aerial Platform Load
Total Aerial Platform
Weight
WHEEL
LCP **
OUP **
lb.
kg
lb.
kg
psi
kPa
psf
kg/m2
min*
10455
4742
4182
1897
114.4
788.8
160.8
785.1
max*
14135
6412
5654
2565
127.3
877.7
217.5
1061.9
min*
11325
5137
4530
2055
57.7
397.8
168.8
824.2
max*
15050
6827
6020
2731
76.7
528.8
224.3
1095.1
min*
11355
5151
4542
2060
118.0
813.6
174.7
852.9
max*
14835
6729
5934
2692
129.3
891.5
228.2
1114.3
min*
12225
5545
4890
2218
62.3
429.5
182.2
889.5
max*
15825
7178
6330
2871
80.6
556.0
235.8
1151.5
60614AA-ANSI
*
**
min - Total aerial platform weight with no options
max - Aerial platform weight + all options
LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the areas in direct
contact with the floor. The floor covering (tile, carpet, etc.) must be able to withstand more that the indicated values
above.
OUP - Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the whole
surface directly underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more
than the indicated values above.
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally
determined by the engineer or architect for that particular structure.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 7
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Floor Loading Pressure
Locally Concentrated Pressure (LCP):
Overall Uniform Pressure (OUP):
Foot Print Area = Length x Width
= πr2
Base Area = Length x Width
LCP = 0.4 x
Weight of Aerial Platform + Capacity
Foot Print Area
OUP =
Weight of Aerial Platform + Capacity
Base Area
Length
Width
Width
Length
Width
Diameter
Length
WARNING
Intermixing tires of different types or using tires of types other than those originally supplied with
this equipment can adversely affect stability. Therefore, replace tires only with the exact original
Skyjack-approved type. Failure to operate with matched approved tires in good condition may
result in death or serious injury.
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 5
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.4a Tire Specifications (CE)
WARNING
Tires should be checked by end user on a daily basis. Do not intermix tires of different types on
one aerial platform. Use only tires of type originally supplied.
Tire Specification
Tire Size
Fill Type
#6F
#6F
10-16.5
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
(Non-Marking)
Ply Rating
Backspace
Rim Size
10
Foam
10
121 mm
4 ¾"
121 mm
4 ¾"
Usage*
Pressure (Factory)
(kPa)
8831E
8841E
N/A
S
S
N/A
O
O
152AA
*
Usage: (S)tandard Or (O)ptional
(N/A) Not Available
Backspace
Rim Backspace Diagram
Inboard
Outboard
SECTION A-A
DC Electric Full-Size
Rough Terrain
A
A
SKYJACK, Page 9
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.4b Tire Specifications (ANSI/CSA)
WARNING
Air pressure can affect stability. Temperature changes can affect air pressure. It is important to
visually inspect all tires for proper tire inflation prior to use. Tires should be checked by end user
on a daily basis. Tire inflation pressures must be checked weekly with a calibrated gauge. If the
measured pressure is less than the specification, reinflate to the pressure specified below. Tires
must not be inflated above the recommended specification. Do not intermix tires of different types
on one aerial platform. Use only tires of type originally supplied.
Tire Specification
Tire Size
Fill Type
#6A
10-16.5
CARLISLE US LOADER
#6A
10-16.5 OTR OUTRIGGER
(Non-Marking)
#6F
10-16.5
CARLISLE US LOADER
#6F
10-16.5 OTR OUTRIGGER
(Non-Marking)
Ply Rating
10
Usage†
Backspace
Rim Size
4 ¾"
Pressure (Factory)
(kPa)
121 mm
(517.1)*
Air
10
10
Foam
10
8831E
8841E
S
S
O
O
N/A
O
O
N/A
O
O
75*
4 ¾"
75*
121 mm
(517.1)*
4 ¾"
121 mm
4 ¾"
121 mm
60615AA-ANSI
*
Factory preset @ 20°C, Check pressures regularly as tires can lose pressure over time and over different ambient temperatures even under normal
conditions.
†
Usage: (S)tandard Or (O)ptional
(N/A) Not Available
Backspace
Rim Backspace Diagram
Inboard
Outboard
SECTION A-A
SKYJACK, Page 10
A
A
DC Electric Full-Size
Rough Terrain
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.5 Rough Terrain Scissor Fluids
AXLE OIL
Axle Type
Cushman
Front
Dana
Front / Rear
Cushman
Rear
Capacity
(Liters)
Capacity
(US Gallons)
Oil Type
Recommended Equivalent Oil
2.4
0.634
Gear Oil, 80W-90 GL5
-
Gear Oil, ESI 80W-90
Chevron Gear Lubricant Delo ESI 80W-90,
Caltex Gear Lubricant ESI 80W-90,
Caltex RPM Borate EP 80W-90,
Texaco Star Gear Lubricant 80W-90
1
0.264
CENTER DRIVE OIL
Center Drive Type
Capacity
(Liters)
Capacity
(US Gallons)
Oil Type
Recommended Equivalent Oil
Center Drive
1
0.26
Gear Oil, 80W-90 GL5
-
HYDRAULIC OIL
Model
SJRT-68XX
Capacity
(Liters)
86.88
Capacity
(US Gallons)
22.95
80.48
21.26
Oil Type
SJRT-7127
SJRT-7135
SJRT-8243
SJRT-8850
SJRT-8831
SJRT-8841
SJRT-8831E
ATF Dexron III
75.71
20
67.38
17.8
SJRT-8841E
SJRT-9241
SJRT-9250
DC Electric Full-Size
Rough Terrain
SKYJACK, Page 7
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.6 Torque Specifications
Directional valve mounting bolts
Wheel mounting bolts
Center drive sprocket mounting bolts
Hydraulic drive motor mounting bolts
Positive battery post cable/fuse nut
Torque
Lbf.ft (max)
Lbf.in (max)
Nm (max)
08
28-32 lbf.in
135-145 lbf.ft
110-115 lbf.ft (242 LOCTITE)
120 lbf.ft (242 LOCTITE)
90 lb-in
Cartridge
Size
58
38
20
240
27.12
10
25
300
33.90
3.16 - 3.61 Nm
183 – 196 Nm
149 – 156 Nm
162 Nm
10.2 Nm
12
35
420
47.46
16
50
600
67.80
Coils
Size
All coils
4 to 5
48 to 60
5.42 to 6.78
SAE Plugs
Torque
Lbf.ft (max)
Lbf.in (max)
Nm (max)
Torque
2
Lbf.ft (max)
3
Lbf.in (max)
36
Nm (max)
4.07
Newton-meter = Nm
4
10
120
13.56
5
6
Size
15
180
20.34
Pound-force foot = lbf.ft
8
10
12
16
25
30
35
300
360
420
33.90
40.68
47.46
Pound-force inch = lbf.in
60022AC
SKYJACK, Page 8
DC Electric Full-Size
Rough Terrain
Section 3
System component identification and schematics
Table of Contents
Charts
3.1 Electrical Symbol Chart...................................................................................................................................3
3.2 Hydraulic Symbol Chart...................................................................................................................................4
Parts List
3.3 Hydraulic Schematic Parts List........................................................................................................................5
3.4 Relay Function Chart.......................................................................................................................................7
3.4 Electrical Parts List...........................................................................................................................................8
Diagrams and Schematics
3.8 Hydraulic Manifold Components and Port Identifications............................................................................11
3.9 Outrigger Manifold and Auto Reset Manifold Components and Port Identifications...................................12
3.5 Platform Control Console Wiring Diagram....................................................................................................13
3.6 Outrigger Control Box Wiring Diagram.........................................................................................................14
3.7 Electrical Inverter Wiring Diagram.................................................................................................................15
3.8 Hydraulic Schematic......................................................................................................................................17
3.9 Main Manifold Harness Wiring Diagram........................................................................................................18
3.10 Electrical System Wiring Diagram (CE).........................................................................................................19
3.11 Electrical Schematic (CE)..............................................................................................................................20
3.12 Electrical System Wiring Diagram (ANSI/CSA).............................................................................................21
3.13 Electrical Schematic (ANSI/CSA)..................................................................................................................22
DC Electric Full-Size Rough Terrain
Model 8831E & 8841E
155154
SKYJACK, Page 1
3
SKYJACK, Page 2
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
Service and Maintenance
Section 3 - System Component Identification and Schematics
3.1 Electrical Symbol Chart
ANGLE
TRANSDUCER
WIRE CROSSING
HOURMETER
KEY SWITCH
WIRES JOINED
LIGHT
FOOT SWITCH
PRESSURE
TRANSDUCER
BATTERY
HYDRAULIC
VALVE COIL
TOGGLE SWITCH
LIMIT SWITCH
N.O.
GROUND
PROPORTIONAL
HYDRAULIC
VALVE COIL
PUSH BUTTON
LIMIT SWITCH
N.O. HELD
CLOSED
FUSE
ELECTRIC
MOTOR
ROTARY SWITCH
LIMIT SWITCH
N.C.
CIRCUIT
BREAKER
HORN
LIMIT SWITCH
LIMIT SWITCH
N.C. HELD OPEN
BATTERY
CHARGE
INDICATOR
EMERGENCY
STOP BUTTON
CAM OPERATED
LIMIT SWITCH
SILICON
CONTROLLED
RECTIFIER
CAPACITOR
RESISTOR
TILT SWITCH
PROXIMITY
SWITCH
POTENTIOMETER
LEVEL SENSOR
SINGLE POLE
SINGLE THROWN
RELAY
PNP
TRANSISTOR
SINGLE POLE
DOUBLE THROW
RELAY
DOUBLE POLE
SINGLE THROW
RELAY
DOUBLE POLE
DOUBLE THROW
RELAY
NPN
TRANSISTOR
TRIPLE POLE
DOUBLE THROW
RELAY
DIODE
TRANSISTOR
PRESSURE/
VACUUM
SWITCH
TEMPERATURE
SWITCH
DC Electric Full-Size Rough Terrain
Model 8831E & 8841E
155154
SKYJACK, Page 3
Section 3 - System Component Identification and Schematics
Service and Maintenance
3.2 Hydraulic Symbol Chart
LINE CROSSING
VARIABLE
DISPLACEMENT
PUMP
SHUTTLE VALV
VELOCITY FUSE
LINE JOINED
HAND PUMP
ACCUMULATOR,
GAS CHARGED
SINGLE ACTING
CYLINDER
HYDRAULIC
TANK
RELIEF VALVE
CUSHION
CYLINDER
DOUBLE ACTING
CYLINDER
HYDRAULIC
FILTER WITH
BYPASS
PRESSURE
REDUCING
VALVE
PRESSURE
SWITCH
ELECTRIC
MOTOR
FIXED ORIFICE
MOTION
CONTROL VALVE
SPRING APPLIED
HYDRAULIC
RELEASED
BRAKE
ENGINE
ADJUSTABLE
FLOW CONTROL
FLOW DIVIDER
COMBINER
BRAKE
CYLINDER
FIXED
DISPLACEMENT
PUMP
CHECK VALVE
COUNTER
BALANCE VALVE
ROTARY
ACTUATOR
THREE POSITION
FOUR WAY
PROPORTIONAL
OIL COOLER
VALVE COIL
SERIES
PARALLEL
HYDRAULIC
MOTOR
TWO POSITION
TWO WAY
NORMALLY
CLOSED
TWO POSITION
TWO WAY
NORMALLY
OPEN
TWO POSITION
THREE WAY
THREE POSITION
FOUR WAY
CLOSED CENTER
CLOSED PORT
PRESSURE
TRANSDUCER
MAIN LINES Solid
PILOT LINES Dashed
SERVO
SKYJACK, Page 4
TWO POSITION
THREE WAY
DOUBLE ACTING
DOUBLE
RODDED
BI DIRECTIONAL
HYDRAULIC
MOTOR
THREE POSITION
FOUR WAY
CLOSED CENTER
OPEN PORT
THREE POSITION
FOUR WAY
PROPORTIONAL
VARIABLE
DISPLACEMENT
HYDRAULIC MOTOR
QUICK
DISCONNECT
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
Service and Maintenance
Section 3 - System Component Identification and Schematics
3.3 Hydraulic Schematic Parts List
Index
No.
Skyjack
Part No.
Qty.
C1
C2
C3
C4
C5
C7
C9
C10
C11
C12
CV1
CV2
CV3
CV4
CV5
CV6
CV7
CV8
CV9
CV10
F1
HP2
MB1
MB2
MB3
MB4
MB5
MB6
MB7
MB8
O1
O2
O3
O4
O5
O6
P1
P2
PT1
QD1
QD2
R1
R2
R3
R4
120349
120349
120275
120275
120412
120405
132694
132694
132694
132694
104567
104567
104567
104567
104567
104567
104115
104115
104115
104115
109568
104254
110652
108803
113494
130443
106688
107382
119748
116586
111970
114218
120481
120481
120756
116725
123853
119999
700669
130440
122420
122420
104534
104534
106557
106557
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
CYLINDER, Lift
CYLINDER, Lift
CYLINDER, Extension platform (Front)
CYLINDER, Extension platform (Rear)
CYLINDER, Disc brake
CYLINDER, Steer
CYLINDER, Outrigger (Left front)
CYLINDER, Outrigger (Right front)
CYLINDER, Outrigger (Right rear)
CYLINDER, Outrigger (Left rear)
VALVE, Check (Small pump)
VALVE, Check (Large pump)
VALVE, Check (Brake)
VALVE, Check (Lift)
VALVE, Check
VALVE, Check
VALVE, Check (Left front outrigger)
VALVE, Check (Right front outrigger)
VALVE, Check (Right rear outrigger)
VALVE, Check (Left rear outrigger)
FILTER, Return
• ELEMENT, Filter
PUMP, Hand
MANIFOLD BLOCK (Main)
MANIFOLD BLOCK (Lowering)
MANIFOLD BLOCK (Holding valve)
MANIFOLD BLOCK (Holding valve)
MANIFOLD BLOCK (Powered platform)
MANIFOLD BLOCK (Lift)
MANIFOLD BLOCK (Quick brake)
MANIFOLD BLOCK (Outrigger)
ORIFICE, Controller lowering (0.70”)
ORIFICE, Lowering (0.104”) (Lift cylinder)
ORIFICE, Lowering (0.104”) (Lift cylinder)
ORIFICE, Lowering (0.149”)
ORIFICE, Emergency lowering (0.067”)
ORIFICE, Dump valve (0.031”)
PUMP (Gearbox)
PUMP (Hydraulic tray)
TRANSDUCER, Pressure (CE)
QUICK DISCONNECT (System pressure)
QUICK DISCONNECT (System pressure)
VALVE, Relief (System)
VALVE, Relief (Gearbox)
VALVE, Relief (Holding valve)
VALVE, Relief (Holding valve)
Parts list continued on the following page.
DC Electric Full-Size Rough Terrain
Model 8831E & 8841E
155154
SKYJACK, Page 5
Section 3 - System Component Identification and Schematics
Service and Maintenance
3.3 Hydraulic Schematic Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
V1
V2
V6
2H-13-1
2H-13-2
2H-13-3
2H-14D
2H-17A
2H-21A
2H-25
2H-30
2H-44
4H-23A
4H-24A
4H-26
4H-26A
4H-27
4H-27A
4H-32A
4H-33A
4H-71
4H-72
4H-73
4H-74
4H-75
4H-76
4H-77
4H-78
VALVE, Manual lowering
VALVE, Controlled lowering
VALVE, Auto reset
VALVE, Lowering
VALVE, Holding
VALVE, Holding
VALVE, Lift
VALVE, Outrigger holding
VALVE, System dump
VALVE, Quick brake
VALVE, Brake release
VALVE, Gearbox holding
VALVE, “Hytos” (Right steer) (includes 4H-24A)
VALVE, “Hytos” (Left steer) (includes 4H-23A)
VALVE, “Hytos” (Front platform extend) (includes 4H-27)
VALVE, “Hytos” (Rear platform extend) (includes 4H-27A)
VALVE, “Hytos” (Front platform retract) (includes 4H-26)
VALVE, “Hytos” (Rear platform retract) (includes 4H-26A)
VALVE, “Hytos” (Traction gearbox) (includes 4H-33A)
VALVE, “Hytos” (Lift gearbox) (includes 4H-32A)
VALVE, “Hytos” (Left front outrigger retract) (includes 4H-75)
VALVE, “Hytos” (Right front outrigger retract) (includes 4H-76)
VALVE, “Hytos” (Right rear outrigger retract) (includes 4H-77)
VALVE, “Hytos” (Left rear outrigger retract) (includes 4H-78)
VALVE, “Hytos” (Left front outrigger extend) (includes 4H-71)
VALVE, “Hytos” (Right front outrigger extend) (includes 4H-72)
VALVE, “Hytos” (Right rear outrigger extend) (includes 4H-73)
VALVE, “Hytos” (Left rear outrigger extend) (includes 4H-74)
107271
113556
113752
104412
107269
107269
104412
103655
114365
117189
104412
104412
153334
153334
153334
153334
153334
153334
153334
153334
128318
128318
128318
128318
128318
128318
128318
128318
SKYJACK, Page 6
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
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
Service and Maintenance
Section 3 - System Component Identification and Schematics
3.4 Relay Function Chart
SUPPLY (B+) (Common)
CONTROL (B+)
GROUND (B-)
NORMALLY
CLOSED
CONTACT
Index
No.
Skyjack
Part No.
Qty.
9ECR
10ACR1
10ACR2
10CCR
12CCR
12ECR
17ACR
18ACR
21CR-1
21CR-2
25CR
28ACR
28CR
30CR
32CR
33CR
59ACR
108589
108589
108589
108589
126469
108589
108589
108589
108589
108589
108589
108589
108589
108589
108589
108589
108589
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
NORMALLY
OPEN
CONTACT
Description
RELAY, 24 Volt (Outrigger power)
RELAY, 24 Volt (Outrigger enable) (CE)
RELAY, 24 Volt (Outrigger safety) (CE)
RELAY, 24 Volt (outrigger movement indicator) (CE)
RELAY, 24 Volt (Steer switch)
RELAY, 24 Volt (Joystick enable)
RELAY, 24 Volt (Outrigger lift disable)
RELAY, 24 Volt (Small pump)
RELAY, 24 Volt (Power deck interlock)
RELAY, 24 Volt (Pump interlock)
RELAY, 24 Volt (Quick brake)
RELAY, 24 Volt (Warning indicator)
RELAY, 24 Volt (Tilt)
RELAY, 24 Volt (Brake)
RELAY, 24 Volt (Lift sensor)
RELAY, 24 Volt (Traction sensor)
RELAY, 24 Volt (Speed signal)
Parts list continued on the following page.
DC Electric Full-Size Rough Terrain
Model 8831E & 8841E
155154
SKYJACK, Page 7
Section 3 - System Component Identification and Schematics
Service and Maintenance
3.4 Electrical Parts List
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
60CR1
60CR2
60CR3
60ECR1
60ECR2
60ECR3
61CR
65CR
OCM1
2H-13B-1
2H-13B-2
2H-13B-3
2H-14D
2H-17A
2H-21A
2H-25
2H-30
2H-44
4H-23
4H-24
4H-26
4H-26A
4H-27
4H-27A
4H-32A
4H-33A
4H-71
4H-72
4H-73
4H-74
4H-75
4H-76
4H-77
4H-78
AT1
B1
BC1
BC-1
BC-2
BP-28B
BP-29C
C10D-1
C10D-2
C15C
C16E
CB1
RELAY, 24 Volt (Auxiliary down) (CE)
RELAY, 24 Volt (Auxiliary reverse) (CE)
RELAY, 24 Volt (Auxiliary forward) (CE)
RELAY, 24 Volt (Down) (CE)
RELAY, 24 Volt (Reverse) (CE)
RELAY, 24 Volt (Forward) (CE)
RELAY, 24 VOlt (Outrigger drive enable) (CE)
RELAY, 24 Volt (Outrigger lift enable)
MODULE, Outrigger auto-levelling controller
COIL, 24 Volt (Lowering)
COIL, 24 Volt (Holding)
COIL, 24 Volt (Holding)
COIL, 24 Volt (Lifting)
COIL, 24 Volt (Outrigger holding)
COIL, 24 Volt (System dump)
COIL, 24 Volt (Quick brake)
COIL, 24 Volt (Brake)
COIL, 24 Volt (Gearbox holding)
COIL, 24 Volt (Right steer) (Hytos)
COIL, 24 Volt (Left steer) (Hytos)
COIL, 24 Volt (Platform extend) (Hytos)
COIL, 24 Volt (Platform extend) (Hytos)
COIL, 24 Volt (Platform retract) (Hytos)
COIL, 24 Volt (Platform retract) (Hytos)
COIL, 24 Volt (Drive shift) (Hytos)
COIL, 24 Volt (Lift shift) (Hytos)
COIL, 12 Volt (Left front outrigger retract) (Hytos)
COIL, 12 Volt (Right front outrigger retract) (Hytos)
COIL, 12 Volt (Right rear outrigger retract) (Hytos)
COIL, 12 Volt (Left rear outrigger retract) (Hytos)
COIL, 12 Volt (Left front outrigger extend) (Hytos)
COIL, 12 Volt (Right front outrigger extend) (Hytos)
COIL, 12 Volt (Right rear outrigger extend) (Hytos)
COIL, 12 Volt (Left rear outrigger extend) (Hytos)
TRANSDUCER, Angle (CE)
BATTERY, 6 Amp (Trojan U-2500)
BATTERY CHARGE INDICATOR
CHARGER, Battery
CHARGER, Battery
BEEPER (Platform control console)
BEEPER (XL - 600, 9 - 28 VDC) (CE)
CONTACTOR, 24 Volt (Pump)
CONTACTOR, 24 Volt (Main)
CONTACTOR, 24 Volt (Reverse)
CONTACTOR, 24 Volt (Forward)
CIRCUIT BREAKER, Ground (20 amp)
108589
108589
108589
108589
108589
108589
108589
108589
132804 105610
104493
104493
105610
103605
105610
103605
105610
105610
153335
153335
153335
153335
153335
153335
153335
153335
128321
128321
128321
128321
128321
128321
128321
128321
130440
106552
122093
129685
129685
103057
117967
119168
119169
119170
119170
117326
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
SKYJACK, Page 8
Parts list continued on the following page.
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
Service and Maintenance
Section 3 - System Component Identification and Schematics
3.4 Electrical Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
CB2
CB3
CL-1
CL-2
CRD1
CRD2
CRD3
DCM1
DCM2
DPM1
DXX
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F10-2
F11
F12
F13
F14 F15 F16
F18
FL22
FL22A
H1
INV1
JS1
LCR-1 LCR-2
LS5
LS61
LS62
LS63
LS64
LS65
LS66
LS67
LS68
CIRCUIT BREAKER, 48 Volt (15 amp)
CIRCUIT BREAKER, 24 Volt (20 amp)
CABINET LIGHT
CABINET LIGHT
CABLE ASSEMBLY (Platform control console)
CABLE ASSEMBLY (Scissor arm) (Model 8831)
CABLE ASSEMBLY (Scissor arm) (Model 8841)
CABLE ASSEMBLY (Electrical panel)
TRACTION MOTOR
MOTOR, 48 Volt
MODULE, Power delay
DIODE
FUSE, Right steer (10 Amp)
FUSE, Left steer (10 Amp)
FUSE, Dump (10 Amp)
FUSE, Lowering (10 Amp)
FUSE, Reverse (10 Amp)
FUSE, Forward (10 Amp)
FUSE, Drive (10 Amp)
FUSE, Pump (10 Amp)
FUSE, Lift (10 Amp)
FUSE (10Amp)
FUSE, Power deck option (10 Amp)
FUSE, Fault (10 Amp)
FUSE, Main power (400 Amp)
FUSE, Center tap (10 Amp)
FUSE, Charger harness & inverter (50 Amp)
FUSE (20 Amp)
FUSE (6.3 Amp)
FUSE (200 Amp)
FLASHER
LIGHT, Flashing (24 Volt)
HORN, Low tone (24 Volt)
INVERTER, 1500W 110/220V @ 50HZ
DRIVE/STEER CONTROLLER
CONTROL RELAY (inside charger)
CONTROL RELAY (inside charger)
LIMIT SWITCH, High speed cut-out (CE)
LIMIT SWITCH, Outrigger (Left front retract)
LIMIT SWITCH, Outrigger (Right front retract)
LIMIT SWITCH, Outrigger (Right rear retract)
LIMIT SWITCH, Outrigger (Left rear retract)
LIMIT SWITCH, Outrigger (Left front extend)
LIMIT SWITCH, Outrigger (Right front extend)
LIMIT SWITCH, Outrigger (Right rear extend)
LIMIT SWITCH, Outrigger (Left rear extend)
117325
117326
130224
130224
119373
120370
120074
120069
116757
700668
118815
102921
120658
120658
120658
120658
120658
120658
120658
120658
120658
120658
120658
120658
119364
120658
120302
119172
700776
119469
103743
121477
146649
124756
127063
127154
127154
119375
115658
115658
115658
115658
115658
115658
115658
115658
2
1
1
1
1
1
1
1
1
1
1
AR
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Parts list continued on the following page.
DC Electric Full-Size Rough Terrain
Model 8831E & 8841E
155154
SKYJACK, Page 9
Section 3 - System Component Identification and Schematics
Service and Maintenance
3.4 Electrical Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
PR1
PR2
PS2
OL1
PT1
RL-22A
RST4
S4
S5
S6
S7
S8
S9
S9A
S11
S16
S17
S18
S19
S20
S21
S22
S23
S24
SV1
TC1
TG1
TMR-8A
TT1
WL1
X1
SWITCH, Proximity (Drive)
SWITCH, Proximity (Lift)
SWITCH, Pressure (Brake)
LIGHT, Indicator amber (12 Volt)
TRANSDUCER, Pressure (CE)
BEACON, Rotating amber (24 Volt) (CE)
RESISTOR (330 Ohm - 2 watt)
N.C. CONTACT (Emergency stop) (Base controls)
N.C. CONTACT (Off/Platform/Base) (Base controls)
N.O. CONTACT (Off/Platform/Base) (Base controls)
N.O. CONTACT (Up/Down) (Base controls)
N.C. CONTACT (Emergency stop) (Platform control console)
N.O. CONTACT (Base/off/platform) (Platform control console)
SWITCH, Lift/Off/Drive
SWITCH, Enable (Outrigger)
N.O. CONTACT (Horn) (Platform control console)
SWITCH, Power deck enable (Single deck)
SWITCH, Power deck extend/retract (Single deck)
SWITCH, Power deck enable (Double deck)
SWITCH, Power deck extend/retract (Double deck)
SWITCH, Left front outrigger (Extend/Retract) (Platform control console)
SWITCH, Right front outrigger (Extend/Retract) (Platform control console)
SWITCH, Right rear outrigger (Extend/Retract) (Platform control console)
SWITCH, Left rear outrigger (Extend/Retract) (Platform control console)
SWITCH, Auto-level outrigger (CE)
DRIVE SEVCON
TACHOMETER CARD
TACHOMETER GENERATOR
RELAY, Inverter Timer Cut-out
HOURMETER
LED BLOCK, Red (Trouble light)
SEVCON CONVERTOR
116758
116758
701194
133133
130440
108102
146004
147053
147053
147054
147054
147053
147054
116382
102853
147054
102853
102853
102853
102853
102853
102853
120853
102853
102853
119167
119171
700227
132494
103336
147061
801347
SKYJACK, Page 10
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
Service and Maintenance
Section 3 - System Component Identification and Schematics
3.8 Hydraulic Manifold Components and Port Identifications
PS2
PRESSURE
SWITCH
TO
GEARBOX
TO
STEER
4H-32A
TRACTION
GEARBOX
VALVE
GEARBOX
GAUGE
CV3
BRAKE
CHECK
VALVE
CV5
LIFT
CHECK
VALVE
2H-13-1
VALVE
LOWERING
LIFT GAUGE
4H-23A
RIGHT
STEER 4H-24A
VALVE
LEFT
STEER
VALVE
R1
SYSTEM
RELIEF
VALVE
4H-33A
LIFT
GEARBOX
VALVE
CV4
LIFT
CHECK
VALVE
R2
GEARBOX
RELIEF
VALVE
2H-44
GEARBOX
HOLDING
VALVE
CV4
SYSTEM
CHECK
VALVE
EMERGENCY
LOWERING
LIFT
O5
ORIFICE
2H-30
BRAKE
RELEASE
VALVE
CV2
SMALL
PUMP
CHECK
VALVE
CV1
LARGE PUMP
CHECK VALVE
2H-14D
LIFT
VALVE
2H-21A
SYSTEM
DUMP
VALVE
O6
DUMP
ORIFICE
TO
LARGE
PUMP
TO
SMALL
PUMP
TO
RETURN
FILTER
M10307AA
DC Electric Full-Size Rough Terrain
Model 8831E & 8841E
155154
SKYJACK, Page 11
Section 3 - System Component Identification and Schematics
Service and Maintenance
3.9 Outrigger Manifold and Auto Reset Manifold Components and Port Identifications
TO
BRAKE
TO MAIN
MANIFOLD
TO
TANK
AUTO
RESET
MANIFOLD
HP2
HAND
PUMP
2H-25
QUICK
BRAKE
VALVE
V6
AUTO
RESET
VALVE
4H-71
OUTRIGGER
LEFT FRONT
RETRACT
4H-72
OUTRIGGER
RIGHT FRONT
RETRACT
OUTRIGGER
MANIFOLD
4H-74
OUTRIGGER
LEFT REAR
RETRACT
4H-73
OUTRIGGER
RIGHT REAR
RETRACT
2H-17A
OUTRIGGER
HOLDING
VALVE
4H-78
OUTRIGGER
LEFT REAR
EXTEND
4H-75
OUTRIGGER
LEFT FRONT
EXTEND
4H-76
OUTRIGGER
RIGHT
4H-77
FRONT
OUTRIGGER
EXTEND
RIGHT REAR
EXTEND
TO
OUTRIGGER
CYLINDERS
10283AA
SKYJACK, Page 12
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
Service and Maintenance
Section 3 - System Component Identification and Schematics
3.5 Platform Control Console Wiring Diagram
7A
08
28A
10E
02
3 POS / KEY SWITCH
BASE/OFF/PLFT
28D
14
02
28B
0
A
LED-1
9
12
28B
49
JOYSTICK CONTROL
WITH ENABLE & RELAYS
WARNING
ALARM LIGHT
11
09
16
8
B
4
5
6
EMERGENCY
STOP
15
2
08
1
FUNCTION SELECTOR
LIFT/OFF/DRIVE
3
07
12
7A
13
28B
X2
7A
X1
BATTERY METER
08
CN4
02
28B
HORN SWITCH
WARNING
ALARM BUZZER
CN6 CN5
CN1
CN2
CN3
CN7
CONTROL CIRCUIT BOARD
DC Electric Full-Size Rough Terrain
Model 8831E & 8841E
155154
SKYJACK, Page 13
Section 3 - System Component Identification and Schematics
Service and Maintenance
3.6 Outrigger Control Box Wiring Diagram
ZZ
70
35D
79
3
2
1
S24
AUTO-LEVEL OUTRIGGER SWITCH
PIN 1 - 79 GREEN
PIN 2 - 35D PURPLE/WHITE
PIN 3 - 70 GREEN/BLACK
133227AA
3
1
35D
35C
35D
S9A
OUTRIGGER ENABLE SWITCH
PIN 1 - 35D PURPLE/WHITE
PIN 2 - 35C x 3 (WHITE/BLACK,
BLUE/WHITE & GREEN/WHITE)
PIN 3 - 35D PURPLE/WHITE
2
35D
TEN PIN CONNECTOR PLUG
PIN 1 - 74 BLACK
PIN 2 - 73 BLUE
PIN 3 - 78 BLACK/WHITE
PIN 4 - 77 BLUE/BLACK
PIN 5 - 35D PURPLE/WHITE
PIN 6 - N/U
PIN 7 - 71 ORANGE
PIN 8 - 72 RED
PIN 9 - 75 ORANGE/BLACK
PIN 10 - 76 RED/BLACK
35D
70A
02
OL1
OUTRIGGER LIGHT
70A RED/WHITE
02 WHITE
BLUE/WHITE (N/U)
GREEN/WHITE (N/U)
TO OUTRIGGER
ELECTRICAL PANEL
PIN 1 - 02 WHITE
PIN 2 - 35C WHITE/BLACK
PIN 3 - 70 GREEN/BLACK
PIN 4 - 70A RED/BLACK
PIN 5 - 71 ORANGE
PIN 6 - 72 RED
PIN 7 - 73 BLUE
PIN 8 - 74 BLACK
PIN 9 - 75 ORANGE/BLACK
PIN 10 - 76 RED/BLACK
PIN 11 - 77 BLUE/BLACK
PIN 12 - 78 BLACK/WHITE
PIN 13 - 79 GREEN
PIN 14 - N/U
PIN 15 - N/U
OUTRIGGER CONTROL CABLE
M129300AB2
SKYJACK, Page 14
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
Service and Maintenance
Section 3 - System Component Identification and Schematics
3.7 Electrical Inverter Wiring Diagram
M50070AB
DC Electric Full-Size Rough Terrain
Model 8831E & 8841E
155154
SKYJACK, Page 15
Notes
SKYJACK, Page 16
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
A
B
C
3.8 Hydraulic Schematic
D
E
F
G
H
V
W
X
Y
Z
M50045AA
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
SKYJACK, Page 17
A
FOURTEEN PIN
CONNECTOR PLUG
PIN 1 - 02 WHITE - (TO BUTT SPLICE #1)
PIN 2 - 02 WHITE - (TO BUTT SPLICE #2)
PIN 3 - 23 BLACK/WHITE
PIN 4 - 2B PURPLE
PIN 5 - 24 BLUE/BLACK
PIN 6 - 14D BLACK
PIN 7 - 21A BROWN/RED
PIN 8 - 32A WHITE/RED
PIN 9 - 13 ORANGE - (TO MAIN MAINIFOLD)
PIN 10 - 30 BROWN
PIN 11 - 44 BLUE/RED
PIN 12 - 2A BLUE
PIN 13 - 25 ORANGE/GREEN
PIN 14 - 33A - ORANGE/BLACK
B
C
3.9 Main Manifold Harness Wiring Diagram
D
E
FIVE PIN
CONNECTOR PLUG
PIN 1 - 05 RED
PIN 2 - 04 WHITE/BLACK
PIN 3 - 10E RED/WHITE
PIN 4 - 13 ORANGE - (TO N.O. CONTACT BLOCK)
PIN 5 - 14E BLACK/RED
G
H
V
5B
BASE CONTROLS
EMERGENCY STOP PB
5B RED
04 WHITE/BLACK
GREY
THREE PIN
CONNECTOR PLUG
PIN 1 - 10C RED/YELLOW
PIN 2 - 28 GREEN
PIN 3 - 02 WHITE - (TO BUTT SPLICE #3)
23
24
02
02
23 - STEERING DIRECTIONAL VALVE
02 - FROM BUTT SPLICE #1
MAIN MANIFOLD
1 2 3
32A
33A
02
02
BUTT SPLICE #1
BUTT SPLICE #3
33A - GEARBOX DIRECTIONAL VALVE
02 - FROM BUTT SPLICE #1
MAIN MANIFOLD
04
10F
13
BASE CONTROLS
UP/DOWN SELECTOR
10 F RED/WHITE
13 ORANGE
14E BLACK/RED
BLACK
10F
5B
10F
14E 05
10E
W
TILT SWITCH
PIN 1 - 10C
PIN 2 - 28
PIN 3 - 02 FROM BUTT SPLICE #4
PIN 4 - N/U
BASE CONTROLS
KEY SWITCH
10E RED/WHITE
10 F RED/WHITE
05 RED
5B RED
4
3
DEUTSCH
GREY
BLACK
24 - STEERING DIRECTIONAL VALVE
02 - FROM BUTT SPLICE #1
MAIN MANIFOLD
32A - GEARBOX DIRECTIONAL VALVE
02 - FROM BUTT SPLICE #1
MAIN MANIFOLD
1 2 3 4 5
1 2 3 4 5 6 7 8 9 10 11 12 13 14
F
1
2
X
BUTT SPLICE #4
BUTT SPLICE #2
25
02
44
02
2A, 2B - PRESSURE SWITCH
MAIN MANIFOLD
44 - GEARBOX VALVE
02 - FROM BUTT SPLICE
#2
MAIN MANIFOLD
25 - QUICK BRAKE VALVE
02 - FROM BUTT SPLICE #4
BRAKE MANIFOLD
2A
2B
02
13
30
02
14D
02
21A
Y
14D - LIFT VALVE
02 - FROM BUTT SPLICE
#2
MAIN MANIFOLD
21A - DUMP VALVE
02 - FROM BUTT SPLICE
#2
MAIN MANIFOLD
Z
02
13
02
30 - BRAKE VALVE
02 - FROM BUTT SPLICE
#2
MAIN MANIFOLD
13 - LOWERING VALVE
02 - FROM BUTT SPLICE
#3
MAIN MANIFOLD
M50045AA
SKYJACK, Page 18
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
3.10 Electrical System Wiring Diagram
A
B
C
D
E
F
G
H
LIGHT 22 - RED
HORN 49 - GREEN
BEEPER 29C - BLACK
CM1
CONTROL MODULE (LOAD SENSING)
NEG. 02 - WHITE
8
9
4
5
6
5
6
1
2
3
1
2
3
10 11 12
4
8
9
3
4
5
6
2
1
2
3
1
7
PT1
PRESSURE TRANSDUCER
SJ# 134432
3000 PSI XDDYY
WARRANTY VOID IF
TAMPERED
7
4
AT1
ANGLE TRANSDUCER
D15-1
D29A
D2C
D12A
D16-1
Lift
F11
35C
28
13A
60CR3
AUX. FORWARD RELAY
RED/BLACK (18)
WHITE/BLACK (16)
N/U
15
14
7
6
13
12
5
4
(7) RED
(14) BLACK
11
10
3
2
(13) ORANGE
9
1
(02) WHITE
(10E) BLUE/WHITE
LIFT RELIEF
G
(15) BLUE
GEARBOX
PS2
HY
D
13B
60
2B
2A
TO PLATFORM
LIMIT SWITCHES
CN17 Tach
2H-13-1
LIFT
XX
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
15B
SEV
SEV
59B
16E
09
15C
10E
21A
02
S6
UP/DOWN SELECTOR
10 F RED/WHITE
13 ORANGE
14E BLACK/RED
05
14E
CXDA-XAN
LARGE PUMP CHK
SMALL PUMP CHK
10F
5B
10F
10F
04
13
02
T2
T1
OUTRIGGER BOARD PLUGS
DIRECTLY INTO MAIN BOARD
CN1
10C
28
02
17A
59A
10
14A
09
10A
10B
12B
02
02
14C
10C
07
24
23
10E
13
49
18
59
15
28A
16
14
12C
9C
02
02
D2
3B
3B
CN10
CN4
CN17
OUTRIGGER BOARD PLUGS
DIRECTLY INTO MAIN BOARD
3
S21
3B
3B
02
02
TT1
CN21
DRIVE ENABLE
RELAY
61CR-1
OUTRIGGER
POWER RELAY
10ACR
CN20 O.R. CONTROL
9E
78
73
77
74
71
75
72
76
17A
02
78
73
77
74
71
75
72
76
17A
02
78
73
77
74
71
75
72
76
CN21 O.R. MANIFOLD
TO PRESSURE SWITCH
AT LIFT CYLINDERS
X1
ZZ
48 V
ZZ
120090-0
ZZ
117387-0
ZZ
24 V
BACK VIEW
01
S20
120089-0
117387-0
ZZ
00000
117389-0
1
10
9E
78
73
77
74
71
75
72
76
74
73
78
77
35D
35D
71
72
75
76
CN20
LIFT ENABLE
RELAY
61CR-2
LIFT DISABLE
RELAY
17ACR
LIFT ENABLE
RELAY
65CR
- V-IN +
- V-OUT +
15
20
20
CB2
CB3
CB1
8A
HOURS
CN1
PIN 1 - 1A BLACK/WHITE
PIN 2 - 03 WHITE
8
9
5
6
7
8
9
3
1
2
3
10 11 12
4
5
6
2
1
2
3
1
10D
10D
1
A2
1
A2
15C
S2
00
16E
X
00
00
PIN 2 - WHITE (66A)
PIN 4 - RED (62)
C10D-1
PIN 2 - WHITE (67A)
PIN 4 - RED (63)
C10D-2
C16E
10BCR
(Refer to
Note #1 for
EE-Rated)
PIN 2 - WHITE (68A)
PIN 4 - RED (64)
4
C16E
C15C
F18
C10D-1
C15C
100A
S1
TRACTION MOTOR
A1
4
T1
+
1
1
TACH
T1 - WHITE
T2 - BLACK
A1
T2
S1
48+
+
1
B+
S2
S1
1
A2
A2
C10D-2
B+
1
1
P2
10D
10D
1
P4
3A
3
2C
PIN 2 - WHITE (65A)
PIN 4 - RED (61)
6
7
4
S2
LEFT FRONT OUTRIGGER:
PIN 1 - BLACK (10)
PIN 3 - GREEN (62)
RIGHT FRONT OUTRIGGER:
PIN 1 - BLACK (10)
PIN 3 - GREEN (63)
RIGHT REAR OUTRIGGER:
PIN 1 - BLACK (10)
PIN 3 - GREEN (64)
LEFT REAR OUTRIGGER:
PIN 1 - BLACK (10)
PIN 3 - GREEN (10)
48+
OCM1
CONTROL MODULE (OUTRIGGERS)
35D
48+
1
35D
02
00
79
2
35C
70A
OL1
00
70
35D
2
3
35D
35C
S9
2H-25
1
3
35D
PIN 1 - 01 BLACK
PIN 2 - 1A BLACK/WHITE
TO CHARGER CUTOUT
01 - BLACK
03 - WHITE
61
62
62
63
63
64
64
10
10
10
10
10
---65
00
CN22 O.R. LIMIT SWITCHES
S24
116586
25
02
OUTRIGGER BOARD
35D
48+
77
02
76
CN3
35D
1
2
3B
75
02
02
23
2B
24
14D
21A
32A
13
30
44
2A
25
33A
73
3
3A
3
72
02
71
35D
10
18
35D
1
2
1
2
17A
59A
10
14A
09
10A
10B
12B
02
02
14C
10C
3
35D
2
78
5B
17A
59A
10
14A
09
10A
10B
12B
02
02
14C
10C
A2
1
35D
35D
CN13
S22
74
A1
00
B+
S23
1
B+
1
S4
EMERGENCY STOP PB
5B RED
04 WHITE/BLACK
OUTRIGGER PENDANT
A
SKYJACK # 116757-0
1
S
Advanced D.C. Motors Inc.
B+
203-06-4002
B-
72 V
M
W
13
2H-21A
CXDA-XAN
13
02
10A
10D
48+
28E
16D
2A
SEV
C.
CONNECTION FOR HARNESS TO LIFT
CYLINDER HOLDING VALVES
S5
KEY SWITCH
10E RED/WHITE
10 F RED/WHITE
05 RED
5B RED
14D
02
2H-14D
IN
DUMP
30
02
F OR C E
SV1 DRIVE SEVCON
PIN REFERENCE NUMBERS
2H-30
HY
D
X XX
02
02
T2
T1
CN5
44
02
2H-44
HY
D
X XX
NC
BLACK
BLUE BLACK/WHITE
BRAKE
BROWN
LS5
HY
D
T
60E
02
XX
10C
28
02
CN4 Tilt
T2
T1
12C
9D
02
09
12
CN13
Outriggers Option
CN12
9D
10A
10B
2C
2A
15
16B
59B
32
33
05
5A
5A
07
CN2
16C
GREEN/BLACK (28A)
ORANGE/BLACK (59)
05
5A
5A
07
CN5 Motor Control
F9
NO
Pump
F7 F8
CN1 Upper Control
CN7
04
10
3B
18
Drive
60ECR3
FORWARD RELAY
RA
9D
12
02
12C
9
CN11
CN12
Power
Delay
17A
59A
10
14A
09
10A
10B
12B
02
02
14C
10C
3B
3B
CN10 POWER
CN3
F5 F6
12C
9D
02
09
12
Main Manifold
Rev For
CN2
Base
Control
BLUE/BLACK (24)
60CR2
AUX. REVERSE RELAY
(12C) GREEN
(9C) GREEN/WHITE
F OR C E
02
02
23
2B
24
14D
21A
32A
13
30
44
2A
25
33A
04
10
3B
18
05
5A
5A
07
CN7
CN11
PLATFORM
O.L.
AUX POWER LIMITS
09
10A
10B
2C
2A
15
16B
59B
32
33
2B
02
02
T2
T1
DUMP
LEFT
LOWER
F1 F2 F3 F4
05
04
10E
13
14E
RIGHT
10 - BLUE
10 - BLACK
10A - BLACK/WHITE
18B - BROWN
BLACK/WHITE (23)
15A
16B
60
02
8
16
X XX
D13
D14D
RED/WHITE (49)
XX
D16-2
D17A-1
BACK VIEW
60ECR2
REVERSE RELAY
X XX
D13-1
D8A
D29B
D14E-1
118760-0
60CR1
AUX. DOWN RELAY
FEMALE
15
XX
D29A
D14E
22A
8A
29
12A
49
10
D14
Spare
D21A
D59A
Spare
D14A
FAULT
02
D2
52 2W
D17A
13A
60
02
60E
02
RA
B- SPIKE SUPPRESSION
D14D-1
D30
D12
D12-1
07
24
23
10E
13
49
18
59
15
28A
16
14
12C
9C
02
02
02
10
10
33
32
SPIKE
A
B
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
00
SEV
T1
SEV
T2
2C
02
32
33
SEV
SPIKE
48+
10B
10D
D18A
D23
D10E-1
4H-24
4H-33A
F OR C E
TACHO CIRCUIT CARD
D24
D9C-1
4H-32A
RA
DPM1
D9-1
4H-23
60ECR1
DOWN RELAY
F OR C E
2H-17A
TC1 TACH CARD
PIN REFERENCE NUMBERS
D44
D32A
D9-2
D02-11
D02-10
D02-9
D02-8
D02-7
D02-6
D02-5
D02-4
D02-3
D02-2
D02-1
13
60E
02
RA
24 VOLT SPIKE SUPPRESSION
05
04
10E
13
14E
9B
18A
02
D33A
17A
02
CN8
22
SPARE FUSES
22A
DEVICES
SHIFT SENSORS
CN6
10A
14C
02
02
02
02
02
F10
POWERDECK
CN9
9ECR
OUTRIGGER MAIN POWER RELAY
10CCR
OUTRIGGER MOVEMENT INDICATOR RELAY
10C
02
15A
FLASHER
10
12
22A
8A
29
12A
49
14D
10A
14C
02
02
02
02
10
10
33
32
9B
18A
02
CN8
60C
15B
DEVICES
3B
9E
02
16C
100
B-
100
B-
100
B-
CN16
SHIFT SENSORS
CN6
02
16D
100
B-
100
100A
100
B-
9B
18A
02
74
78
28
10C
02
13
13A
60E
02
13A
13B
60
02
15
15A
60E
02
15A
15B
60
02
16B
16C
60E
02
16C
16D
60
PUMP
RELAY
18CR
C.
BRAKE
RELAY
30CR
PUMP
INTERLOCK
21CR2
C.
POWER
DECK
RELAY
21CR1
02
SPEED
RELAY
59CR
WORK LIGHT
CN15
POWERDECK
CN9
4H-74
BRAKE
RELAY
25CR
33A
02
24V TAP
CN14
PUMP
SENSOR
32CR
02
71
02
4H-71
TRACTION
SENSOR
33CR
32A
75
4H-78
02
3B
9E
35C
02
WORK LIGHT
TILT
RELAY
28CR
IN
02
4H-72
WORKLIGHT
CL-2
IN
WORKLIGHT
CL-1
CN16
C.
72
02
4H-75
76
4H-76
CN15
IN
24V TAP
CN14
02
02
02
02
TO B- BATTERY TERMINAL
100A
100
TO CENTER TAP FUSE F13
18/3 CABTIRE RUN UP SCISSORS TO
POWERDECK MANIFOLD
4H-73
V
24
23
73
77
4H-77
100
B-
100
B-
SKYJACK
#130440AB
S/N XXXXXX
BLUE
BLUE HEATSHRINK
YELLO
W
YELLOW HEATSHRINK
PUMP PROX - BLUE HEAT SHRINK
PIN 1 - 10 RED
PIN 2 - O2 BLUE
PIN 3 - 32 ORANGE/BLACK
PIN 4 - N/U
DRIVE PROX - YELLOW HEAT SHRINK
PIN 1 - 10 RED/BLACK
PIN 2 - O2 BLUE/BLACK
PIN 3 - N/U
PIN 4 - 33 ORANGE
Y
Note #1: for EE-Rated machines, the auxiliary contact relay is mounted to the contactor plate between the Line and Directional Contactors.
+
+
100A
48+
48+
C16A
10BCR
C10B-2
C10B-1
To Tach card and Controller
F14
STEER PUMP MOTOR
DCM2
50A
6
6
+
-
4
PUMP MOTOR
4
+
FOR DISCONNECT USE ONLY
MAIN DISCONNECT
Z
FROM 20A GROUND CIRCUIT BREAKER
00
TO CHARGER
BATTERY
CONNECTOR
TO CHARGER
BATTERY
CONNECTOR
M133585AC1
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
SKYJACK, Page 19
SKYJACK, Page 20
02
02
02
RETRACT
SOLENOID
EXTEND
SOLENOID
RETRACT
SOLENOID
DO2-25
DO2-24
DO2-23
DO2-22
4H-27A
4H-26A
4H-27
4H-26
D27A
18A
D26A
D27
D26
EXT
26
S17
35D
S16
RET
EXT
RET
27A
26A
27
EXTEND/
RETRACT
SWITCH
S19
EXTEND/
RETRACT
SWITCH
FRONT
LEFT
35D
REAR
LEFT
35D
35D
FRONT
RIGHT 35D
S23
S22
S21
S20
DN
UP
DN
UP
DN
UP
DN
UP
78
74
77
BLACK/WHITE
BLACK
BLUE/BLACK
BLUE
RED/BLACK
76
73
RED
ORANGE/BLACK
75
72
ORANGE
71
WHITE
78
74
77
73
76
72
75
71
02
70A
RED/WHITE
70A
02
70
79
GREEN/BLACK
GREEN
70
79
35C
WHITE/BLACK
35C
59A
BB
3B
35C
10ACR2
9ECR (NOT ON PCB)
02
9E
10A
9E
D17A
9G
02
10A
9B
10ACR1
21CR-1
09
02
09
02
10A
FF
09
EE
12
09
D12-1
D9-1
10
10
TILT OVERRIDE/
HIGH DRIVE CUTOUT
10
CC
10
D78
64
63
RIGHT
FRONT
LS62
21
D77
D76
D75
62
D74
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT
REAR
LS63
D73
61
17A
D72
LEFT
FRONT
LS61
D17A
D71
DRIVE CUTOUT
JUMPER 8
NO OUTRIGGER
JUMPER 3
16B D17A-1 17A
18A
12
10
OUTRIGGER UP LIMIT SWITCHES
NORMALLY OPEN HELD CLOSED
LEFT
REAR
LS64
13
17A
AA
12A
10C
D65
10C
LL
13
17A
14A
14A
DD
10C
24
23
17ACR
12A
10CCR
F4
13
02
65
02
14C
14B
65CR
12B
LDR- 4
10A FUSE
D12A
02
13
60C
NO OUTRIGGER
JUMPER 4
14C
D61
14C
KK
12B
60ECR1
D14D-1
14D
13A
60
02
02
61
10B
GG
10B
13B
02
21A
H1
F3
23
02
21A
LDR- 3
LS68
LS66
66A
68A
02
LS67
LS65
65A
RST4
330 OHMS
70A
70B
LEFT FRONT
10
RIGHT REAR
10
67A
LDR- 21
SPEED SIGNAL
59A
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT FRONT
10
LEFT REAR
10
02
LDR- 1
23
RL-22A
FL-22
LDR- 19 POWER
DECK INTERLOCK
21
F1
22A
22
CAP2
BP-29C
10A FUSE
10A FUSE
FLASHER
60CR1
14D
49
FL-22A
29
29C
OUTRIGGER DOWN LIMIT SWITCHES
NORMALLY CLOSED HELD OPEN
10B
12B
61CR
NO OUTRIGGER
JUMPER 2
13
60E
D14D
12B
HH
16B
24
LDR- 2
10A FUSE
F2
END OF STROKE
JUMPER 7
24
ALL FUNCTION
LIGHT JUMPER 9
22A
RST2
150 OHMS
30
25
2H-30
2H-25
D02-4
D02-3
D02-7
2H-21A
02
D02-2
02
02
02
02
02
4H-73
4H-77
4H-74
4H-78
02
02
4H-76
02
02
4H-75
4H-72
02
02
02
02
02
02
02
02
02
II
JJ
02
02
02
02
02
02
02
02
4H-71
02 = P2-11
70B = P2-7
70 = P2-5
79 = P2-6
35C = P4-9
10 = P2-12
65A = P2-4
66A = P2-3
67A = P2-2
68A = P2-1
65 = P2-8
N/U = P2-9
10A = P2-10
78 = P4-1
77 = P4-2
76 = P4-3
75 = P4-4
74 = P4-5
73 = P4-6
72 = P4-7
71 = P4-8
OCM1
2H-17A
LDR- 20
PUMP INTERLOCK
21
LDR- 18
SMALL PUMP
18A
13
13
02
2H-13B-3
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
2H-13B-2
D02-1
21A D02-10
14D D02-6
2H-14D
24
4H-24
4H-23
23 D02-11
TT
TT1
2H-13B-1
8A
02
02
02
02
CM1 - CONTROL MODULE
10 WAY CONNECTOR
D02-8
32A D02-5
2H-44
44
4H-32A
00
RST3
RST1
33A D02-9
2E
4H-33A
B-
B-
LDR- 11
10A FUSE
F11
CL-2
CL-1
CB1
02
02
02
02
9
23
PROXIMITY SWITCH
PROXIMITY SWITCH
LEFT REAR DOWN
RIGHT REAR DOWN
RIGHT FRONT DOWN
LEFT FRONT DOWN
POWER
OUTRIGGER ENABLE
AUTO RETRACT
AUTO LEVEL
OUTRIGGER LIGHT
GROUND
136
137
138
139
140
141
142
143
144
153
152
151
150
149
148
147
146
L/R OUTRIGGER
EXTEND SOLENOID
L/R OUTRIGGER
RETRACT SOLENOID
R/R OUTRIGGER
EXTEND SOLENOID
R/R OUTRIGGER
RETRACT SOLENOID
R/F OUTRIGGER
EXTEND SOLENOID
R/F OUTRIGGER
RETRACT SOLENOID
L/F OUTRIGGER
EXTEND SOLENOID
L/F OUTRIGGER
RETRACT SOLENOID
LIFT ENABLE
145
TILT
RIGHT REAR DOWN
133
RIGHT FRONT DOWN
129
130
135
LEFT FRONT DOWN
128
134
LEFT REAR UP
127
LEFT REAR DOWN
RIGHT REAR UP
126
TILT OVERRIDE/
HIGH DRIVE CUTOUT
RIGHT FRONT UP
125
132
LEFT FRONT UP
124
131
OUTRIGGER MAIN
POWER RELAY
OUTRIGGER LIFT
DISABLE RELAY
OUTRIGGER
HOLDING SOLENOID
OUTRIGGER
PROOF RELAY
OUTRIGGER
ENABLE RELAY
OUTRIGGER LIFT
ENABLE RELAY
OUTRIGGER DRIVE
ENABLE RELAY
POWER DECK
INTERLOCK RELAY
OUTRIGGER MOVEMENT
INDICATOR RELAY
HOLDING VALVE
HOLDING VALVE
DOWN SOLENOID
AUX. DOWN RELAY
DOWN RELAY
DUMP SOLENOID
UP SOLENOID
LEFT SOLENOID
RIGHT SOLENOID
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
98
97
96
95
94
93
92
91
90
89
88
87
86
85
84
83
82
HOURMETER
HORN
81
80
FLASHING LIGHT
ROTATING AMBER
BEACON OPTION
79
CAPACITO R
78
0.47uF
BEEPER
BRAKE PRESSURE SWITCH
BRAKE RELAY
BRAKE SOLENOID
QUICK BRAKE RELAY
QUICK BRAKE SOLENOID
LIFT SENSOR RELAY
LIFT
DRIVE SHIFT SOLENOID
GEARBOX HOLDING
SOLENOID
LIFT SHIFT SOLENOID
DRIVE
TRACTION SENSOR RELAY
RESISTOR 52 OHMS
SPEED SIGNAL RELAY
RESISTOR 1.8K OHMS
SMALL PUMP RELAY
AUX. FORWARD RELAY
FORWARD RELAY
PUMP INTERLOCK RELAY
AUX. REVERSE RELAY
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
REVERSE RELAY
CABINET LIGHT
REVERSE CONTACTOR
29
28
CABINET LIGHT
27
26
25
24
FORWARD CONTACTOR
TRACTION MOTOR
22
20A CIRCUIT
21
BREAKER
TACHOMETER GENERATOR
MAIN CONTACTOR
TILT RELAY
20
19
18
17
16
STEER PUMP MOTOR
PUMP CONTACTOR
15
CONVERTER
48VDC INPUT
24VDC OUTPUT
INVERTER
OPTION TIMER
14
13
12
11
10
G
REAR
RIGHT
LEVEL
ALL UP
OL1
OUTRIGGER
LIGHT
02
35D
S24
35C
35C
9B
21
10
10
10
AUTO
MODE
10A FUSE
21
12
NC
NO
16
BLUE/WHITE
GREEN/WHITE
9B
LDR- 10
21
D14A
F7
10A FUSE
10A
18B
35C
35C
9B
F10
14A
02
12
LDR- 7
15
35C
10A
FUSE
F10-2
12
9D
LS5
LDR- 9
60
D24
D23
NO OUTRIGGER
JUMPER 1
8A
22A
ALL FUNCTION
ALARM JUMPER 4
29B
29B
15B
00
00
00
00
00
00
MAIN DISCONNECT
F
S9A
OUTRIGGER
ENABLE
ENABLE
SWITCH
S18
ENABLE
SWITCH
9D
18B
TRIPPED
WHEN
RAISED
16
02
D9C-1
LDR- 8
10A FUSE
13
60E
28
14A
18A
18A
D8A
22A
8A
AT1 ANGLE
TRANSDUCER
COM
COM
BATTERY PACK
INVERTER
OPTION
7
8
6
5
E
EXTEND
SOLENOID
9C
12C
09
28E
GREEN/WHITE
10E D10E-1
F8
21A
10E
9C
12C
GREEN
12C
09
02
DPM1
DELAYED
POWER
MODULE
09
13
9C
10B
60
D9-2
8A
14A
60
POWERED PLATFORM OPTION
12C
13
60E
10B
F9
D21A
10A FUSE
14C
02
D9C
08
13
ORANGE
13
28
21A
14A
60E
S6
UP/DOWN
SWITCH
13
14E
P3-1
16B
P2-12
15
10F
10E
2
14A
1
P2-7
D14E
3
P2-8
14E
4
D14 14A
9
P2-10
14
5
18A
13
D18A
14
14C
BLACK
7
P2-2
60C
14
VIO
8
TABS
10A
P-
16D
28E
100
100
M
DCM2
X1
00
B-
D
12CCR STEER
SWITCH RELAY
GRN/WHT
6
P2-4
D14E-1
WHT/VIO
11
P3-6
02
10
P3-4
WHITE
WHT/BLK
12
P2-3
02
GRN/BLK
17
P2-11
02
WHT/RED
1
12C
ORG/BLK
2
21A
BRN
3
900
8A
VIO/WHT
4
P3-3
60A
24
18A
RED/WHT
5
P4-9
8A
RED
P4-2
910
21A
RED/BLK
P4-7
12
910A
D59A
WHT/BRN
13
60B
PT1 PRESSURE
TRANSDUCER
16
D29A
WHT/GRN
14
D13-1
15
902
29A
VIO
9
P4-8
59A
D13
BLK
8
P4-3
13
BLK
7
D29B
VIO/WHT
6
TACHOMETER CARD
17
15
BLK/WHT
P4-6
29C
29A D15-1
29B
GRN
J1 - 17 WAY CONNECTOR
00
10B
1
BLUE/BLACK
15
ORG
11
P3-2
29A D29A-1
BLU/WHT
10
TC1 -
BLU
SEVCON DRIVE
BRN
A
SV1 -
A
WHT
C
S
02
LDR- 15
LIFT SENSOR
32
BLU/BLK
B
B+
02
02
32A
32A
33A
F16
B-
T2
02
32CR
D32A
D33A
33A
02
LDR- 14
TRACTION SENSOR
33
32
09
44
44
33CR
02
02
F15
6.3A FUSE
M
T1
30
2C
44
12
33
18ACR
2
17 WAY CONNECTOR
09
D30
D2C
D44
2C
18A
20A FUSE
59A
29A
PS2
BRAKE
PRESSURE
SWITCH
NORMALLY
CLOSED
2A
21A
2B
18A
2C
48+
10D
S1
A2
T2
B+
R1
D16-2
2B
21A
2A
10A
59B
DR-1
DCM1
FIELD
ARMATURE
M
G
TG1
10D
WHT/RED
C10D-1
20A CIRCUIT
BREAKER
48V
24V
7
16
2B
09
18A
16D
2C
S2
A1
T1
2C
GRN
LDR- 12
POWER ON
02
3A
03
R2
3
24
2A
LDR- 17
QUICK BRAKE
12
30CR
LDR- 16
BRAKE
12
30
2A
12
25CR
25
12
12
32
02
10
60CR3
02
16D
3B
CB3
8
24
12
10B
02
60
60CR2
15B
S1
S1
10D
WHT/RED
C16E
S2
15C
10D
WHT/GRN
WHT/RED
C15C
B+
A2
16E
WHT/BRN
B+
S2
100A
10A FUSE
F13
3B
WHT
5
23
D12
02
33
PR2 LIFT
PROXIMITY SWITCH
NORMALLY OPEN
21
10
10A
60ECR3
16C
02
48+
15C
100
02
R3
4
BLACK/WHITE
02
59A
60E
16B
60
15B
16E
F18
3B
TMR-8A
100A FUSE
A2
8A
WHT/VIO
6
23
59B
59B
59
59ACR
CAP1 1000uF
CAPACITOR
21CR-2
02
16B
2E
21
16A
PR1 DRIVE
PROXIMITY SWITCH
NORMALLY OPEN
12
D16-1
60ECR2
02
15A
48+
WHT/VIO
10D
00
WHT/RED
BLU/BLK
C10D-2
48+
48+
WHT/VIO
01
B1 6V
BATTERY
R6
23
10
16
12
16
60E
15
100
CB2
15A CIRCUIT
BREAKER
48+
B2 6V
BATTERY
R7
49
10
LDR- 6
10A FUSE
F6
15
LDR- 5
02
02
3B
B3 6V
BATTERY
WHT/RED
R8
49
28E
F5
10A FUSE
LDR- 13
TILT
28CR
100
NO PRES SW
JUMPER 6
B4 6V
BATTERY
R4
RED/WHITE
CRD3
59
ORANGE/BLACK
59
CRD2
16
WHITE/BLACK
16
CRD1
15
18
BLUE
RED/BLACK
15
18
28
28
28A
04
24V
WHT/BLK
49
02
02
04
03
R5
GRN/BLK
02
LEFT
00
RST 4
2.7K OHMS
28B
10F
5B
1A
ORG/BLK
P3-5
12E
14
16
13
02
BLUE/WHITE
05
85
B5 6V
BATTERY
RED/WHT
9
RIGHT
A
B
15
BP-28B
BEEPER
WL1
TROUBLE LIGHT
28B
02
02
28A
10E
GREEN/BLACK
28A
10E
5A
NO DECK LIMITS
JUMPER 5
LS2 GATE
LIMIT SWITCH
NORMALLY
CLOSED
INV1
B6 6V
BATTERY
RED/BLK
10
12E
S11
HORN
SWITCH
02
02
02
S9
LIFT/OFF/DRIVE
SWITCH
28B
CAP4 0.47uF
CAPACITOR
28A
02
07
RED
07
B7 6V
BATTERY
BLK
08
02
28D
FORWARD
REVERSE
28ACR
V
CAP3 220uF
CAPACITOR
28A
BCI
BATTERY CHARGE
INDICATOR
7A
S4
EMERGENCY
STOP KEY
B8 6V
BATTERY
BATTERY CHARGER
CUTOUT RELAYS
4
3
48V BATTERY
CHARGERS
1
2
C
D12C
02
28C
28A
WARNING
INDICATOR RELAY
12ECR JOYSTICK
ENABLE RELAY
12E
12D
59
59
D18
28C
7A
S5
IDLE/PLTF/BASE ENABLE
LS1 MANUAL
KEY SWITCH
EXTENSION DECK (IN IDLE POSITION)
LIMIT SWITCH
NORMALLY CLOSED
1A
LCR-2
B
12D
D8
D10E-1
BASE
OFF
PLTF
S7
EMERGENCY
STOP
01
BC-2
A
ENABLE
JS1
CONTROLLER
10E
08
S8
BASE/OFF/PLATFORM
KEY SWITCH
F14
50A
FUSE
F12
400A
FUSE
LCR-1
110 VAC
LINE VOLTAGE
48+
48+
BC-1
110 VAC
LINE VOLTAGE
3.11 Electrical Schematic (CE)
H
V
W
X
Y
Z
M133585AC
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
3.12 Electrical System Wiring Diagram (ANSI/CSA)
A
B
C
D
E
F
G
H
LIGHT 22 - RED
HORN 49 - GREEN
BEEPER 29C - BLACK
35C
3B
9ECR
OUTRIGGER MAIN POWER RELAY
60C
4H-23
10CCR
OUTRIGGER MOVEMENT INDICATOR RELAY
10C
118760-0
10
12
22A
8A
29
12A
49
14D
10A
14C
02
02
FLASHER
D14E-1
D16-2
D17A-1
D2C
D14D
D15-1
D29A
D12A
CN8
FEMALE
10A
14C
02
02
02
RED/WHITE (49)
16
8
(12C) GREEN
BLACK/WHITE (23)
15
14
7
6
(10E) BLUE/WHITE
13
12
5
4
(7) RED
(14) BLACK
11
10
3
2
(13) ORANGE
9
1
(02) WHITE
BLUE/BLACK (24)
GREEN/BLACK (28A)
Spare
D13
22A
8A
29
12A
49
10
D14E
ORANGE/BLACK (59)
D16-1
RED/BLACK (18)
WHITE/BLACK (16)
(9C) GREEN/WHITE
LIFT RELIEF
G
(15) BLUE
HY
D
T
XX
N/U
FAULT
GEARBOX
PS2
HY
D
NC
X XX
XX
BLACK
BROWN
CN17 Tach
2H-13-1
CN5
LIFT
XX
F OR C E
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
15B
SEV
SEV
59B
16E
09
15C
10E
21A
02
S6
UP/DOWN SELECTOR
10 F RED/WHITE
13 ORANGE
14E BLACK/RED
05
14E
13
2H-21A
CXDA-XAN
CXDA-XAN
LARGE PUMP CHK
SMALL PUMP CHK
13
02
10A
10D
48+
28E
16D
2A
SEV
CONNECTION FOR HARNESS TO LIFT
CYLINDER HOLDING VALVES
C.
DUMP
IN
SV1 DRIVE SEVCON
PIN REFERENCE NUMBERS
S5
KEY SWITCH
10E RED/WHITE
10 F RED/WHITE
05 RED
5B RED
14D
02
2H-14D
HY
D
X XX
CN12
30
02
HY
D
X XX
T2
T1
LS5
NO
BLUE BLACK/WHITE
05
5A
5A
07
CN4 Tilt
BRAKE
XX
17A
59A
10
14A
09
10A
10B
12B
02
02
14C
10C
10C
28
02
CN13
Outriggers Option
2B
2A
TO PLATFORM
LIMIT SWITCHES
02
02
T2
T1
05
5A
5A
07
CN2
10 - BLUE
10A - BROWN
F11
CN5 Motor Control
F9
12C
9D
02
09
12
05
04
10E
13
14E
Lift
Pump
F7 F8
CN1 Upper Control
CN7
04
10
3B
18
Drive
RA
9D
12
02
12C
9
CN11
CN12
Power
Delay
9D
10A
10B
2C
2A
15
16B
59B
32
33
3B
3B
CN10 POWER
CN3
F5 F6
12C
9D
02
09
12
Main Manifold
Rev For
CN2
Base
Control
44
02
2H-44
2H-30
F OR C E
02
02
23
2B
24
14D
21A
32A
13
30
44
2A
25
33A
04
10
3B
18
05
5A
5A
07
CN7
CN11
PLATFORM
O.L.
AUX POWER LIMITS
09
10A
10B
2C
2A
15
16B
59B
32
33
2B
02
02
T2
T1
DUMP
LEFT
LOWER
F1 F2 F3 F4
02
D2
RIGHT
07
24
23
10E
13
49
18
59
15
28A
16
14
12C
9C
02
02
02
10
10
33
32
52 2W
D14
D13-1
D8A
D29B
RA
B- SPIKE SUPPRESSION
D14A
D29A
F OR C E
TACHO CIRCUIT CARD
D17A
D21A
D59A
RA
DPM1
D12
D12-1
05
04
10E
13
14E
9B
18A
02
SPIKE
A
B
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
00
SEV
T1
SEV
T2
2C
02
32
33
SEV
SPIKE
48+
10B
10D
TC1 TACH CARD
PIN REFERENCE NUMBERS
D10E-1
D14D-1
D30
F OR C E
2H-17A
D9C-1
D18A
D23
C.
24 VOLT SPIKE SUPPRESSION
D9-1
D24
RA
17A
02
D9-2
D02-11
D02-10
D02-9
D02-8
D02-7
D02-6
D02-5
D02-4
D02-3
D02-2
D02-1
D44
Spare
D32A
D33A
22
SPARE FUSES
22A
SHIFT SENSORS
CN6
IN
02
02
BACK VIEW
X XX
100
B-
100
B-
100
B-
02
02
10
10
33
32
9B
18A
02
CN8
C.
74
DEVICES
DEVICES
POWERDECK
CN9
4H-33A
CN16
SHIFT SENSORS
CN6
F10
IN
02
78
4H-32A
WORK LIGHT
CN15
POWERDECK
CN9
4H-24
02
28
9E
02
33A
02
24V TAP
CN14
4H-74
V
02
02
71
4H-71
28
10C
PUMP
RELAY
18CR
BRAKE
RELAY
30CR
PUMP
INTERLOCK
21CR2
32A
02
3B
9E
35C
02
POWER
DECK
RELAY
21CR1
SPEED
RELAY
59CR
BRAKE
RELAY
25CR
PUMP
SENSOR
32CR
TRACTION
SENSOR
33CR
TILT
RELAY
28CR
C.
100
B-
WORKLIGHT
CL-2
IN
100
100A
100
B-
9B
18A
02
WORKLIGHT
CL-1
CN16
WORK LIGHT
02
75
4H-78
CN15
02
72
02
4H-75
4H-72
24
02
76
24V TAP
CN14
4H-76
02
02
TO B- BATTERY TERMINAL
100A
100
TO CENTER TAP FUSE F13
18/3 CABTIRE RUN UP SCISSORS TO
POWERDECK MANIFOLD
4H-73
23
73
77
4H-77
100
B-
100
B-
NEG. 02 - WHITE
10F
5B
10F
10F
T2
T1
17A
59A
10
14A
09
10A
10B
12B
02
02
14C
10C
02
D2
3B
3B
07
24
23
10E
13
49
18
59
15
28A
16
14
12C
9C
02
OUTRIGGER BOARD PLUGS
DIRECTLY INTO MAIN BOARD
CN1
CN4
CN17
3
3B
3B
02
02
S21
TT1
CN21
DRIVE ENABLE
RELAY
61CR-1
OUTRIGGER
POWER RELAY
10ACR
CN20 O.R. CONTROL
9E
78
73
77
74
71
75
72
76
17A
02
78
73
77
74
71
75
72
76
17A
02
78
73
77
74
71
75
72
76
CN21 O.R. MANIFOLD
TO PRESSURE SWITCH
AT LIFT CYLINDERS
X1
ZZ
48 V
ZZ
120090-0
ZZ
117387-0
ZZ
24 V
BACK VIEW
01
S20
120089-0
117387-0
ZZ
00000
117389-0
1
10
CN1
9E
78
73
77
74
71
75
72
76
74
73
78
77
35D
35D
71
72
75
76
CN20
LIFT ENABLE
RELAY
61CR-2
LIFT DISABLE
RELAY
17ACR
LIFT ENABLE
RELAY
65CR
- V-IN +
- V-OUT +
15
20
20
CB2
CB3
CB1
8A
HOURS
PIN 1 - 1A BLACK/WHITE
PIN 2 - 03 WHITE
9
10 11 12
4
5
6
7
8
9
3
1
2
3
4
5
6
2
1
2
3
1
15C
10D
00
10D
10D
1
A2
1
A2
16E
S2
10D
00
00
C10D-1
PIN 2 - WHITE (67A)
PIN 4 - RED (63)
C10D-2
C16E
10BCR
(Refer to
Note #1 for
EE-Rated)
PIN 2 - WHITE (68A)
PIN 4 - RED (64)
4
C16E
C15C
C10D-1
X
C15C
100A
S1
TRACTION MOTOR
A1
4
T1
+
1
1
TACH
T1 - WHITE
T2 - BLACK
A1
T2
S1
48+
+
1
B+
S2
S1
1
A2
A2
B+
1
F18
C10D-2
1
P2
2C
PIN 2 - WHITE (66A)
PIN 4 - RED (62)
1
P4
3A
3
PIN 2 - WHITE (65A)
PIN 4 - RED (61)
48+
8
S2
LEFT FRONT OUTRIGGER:
PIN 1 - BLACK (10)
PIN 3 - GREEN (62)
RIGHT FRONT OUTRIGGER:
PIN 1 - BLACK (10)
PIN 3 - GREEN (63)
RIGHT REAR OUTRIGGER:
PIN 1 - BLACK (10)
PIN 3 - GREEN (64)
LEFT REAR OUTRIGGER:
PIN 1 - BLACK (10)
PIN 3 - GREEN (10)
6
7
35D
48+
1
35D
02
OCM1
CONTROL MODULE (OUTRIGGERS)
00
79
2
35C
70A
OL1
00
70
35D
2
3
35D
35C
S9
2H-25
1
3
35D
PIN 1 - 01 BLACK
PIN 2 - 1A BLACK/WHITE
TO CHARGER CUTOUT
01 - BLACK
03 - WHITE
61
62
62
63
63
64
64
10
10
10
10
10
---65
00
CN22 O.R. LIMIT SWITCHES
S24
116586
25
02
35D
48+
76
OUTRIGGER BOARD
02
75
2
CN10
OUTRIGGER BOARD PLUGS
DIRECTLY INTO MAIN BOARD
77
3B
3
CN3
35D
1
3A
35D
02
02
23
2B
24
14D
21A
32A
13
30
44
2A
25
33A
73
3
02
2
72
10C
28
02
35D
1
2
71
10
18
3
1
5B
17A
59A
10
14A
09
10A
10B
12B
02
02
14C
10C
2
78
35D
1
35D
35D
CN13
S22
17A
59A
10
14A
09
10A
10B
12B
02
02
14C
10C
A2
A1
1
B+
00
B+
S23
74
1
S4
EMERGENCY STOP PB
5B RED
04 WHITE/BLACK
OUTRIGGER PENDANT
A
Advanced D.C. Motors Inc.
S
SKYJACK # 116757-0
1
B+
203-06-4002
B-
72 V
M
W
04
13
02
BLUE
BLUE HEATSHRINK
YELLO
W
YELLOW HEATSHRINK
PUMP PROX - BLUE HEAT SHRINK
PIN 1 - 10 RED
PIN 2 - O2 BLUE
PIN 3 - 32 ORANGE/BLACK
PIN 4 - N/U
DRIVE PROX - YELLOW HEAT SHRINK
PIN 1 - 10 RED/BLACK
PIN 2 - O2 BLUE/BLACK
PIN 3 - N/U
PIN 4 - 33 ORANGE
Y
Note #1: for EE-Rated machines, the auxiliary contact relay is mounted to the contactor plate between the Line and Directional Contactors.
+
+
100A
48+
48+
C16A
10BCR
C10B-2
C10B-1
To Tach card and Controller
F14
STEER PUMP MOTOR
DCM2
50A
6
6
+
-
4
PUMP MOTOR
4
+
FOR DISCONNECT USE ONLY
MAIN DISCONNECT
Z
FROM 20A GROUND CIRCUIT BREAKER
00
TO CHARGER
BATTERY
CONNECTOR
TO CHARGER
BATTERY
CONNECTOR
M119365AM1
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
SKYJACK, Page 21
SKYJACK, Page 22
02
02
02
02
RETRACT
SOLENOID
EXTEND
SOLENOID
RETRACT
SOLENOID
4H-27A
4H-26A
4H-27
4H-26
D27A
D26A
D27
D26
EXT
26
S17
35D
S16
RET
EXT
RET
27A
26A
27
35D
35D
FRONT
RIGHT 35D
REAR
LEFT
LEVEL
ALL UP
S23
S22
S21
S20
DN
UP
DN
UP
DN
UP
DN
UP
78
74
77
BLACK/WHITE
BLACK
BLUE/BLACK
BLUE
RED/BLACK
76
73
RED
ORANGE/BLACK
75
72
ORANGE
71
WHITE
78
74
77
73
76
72
75
71
02
70A
RED/WHITE
70A
02
70
79
GREEN/BLACK
GREEN
70
79
35C
WHITE/BLACK
35C
21
59A
BB
3B
10ACR2
35C
9E
10A
21
9ECR (NOT ON PCB)
02
D14A
F7
9G
02
10A
9B
21
12
10ACR1
21CR-1
10A FUSE
9E
D17A
14A
02
12
09
02
09
02
10A
FF
09
EE
12
09
D12-1
D9-1
10
10
10
CC
10
LS64
64
D78
LEFT
REAR
LS63
63
LS62
RIGHT
FRONT
21
D77
D76
D75
62
D74
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT
REAR
D73
61
17A
D72
LEFT
FRONT
LS61
D17A
D71
DRIVE CUTOUT
JUMPER 8
NO OUTRIGGER
JUMPER 3
16B D17A-1 17A
18A
12
OUTRIGGER UP LIMIT SWITCHES
NORMALLY OPEN HELD CLOSED
13
10
17A
AA
12A
10C
D65
10C
LL
17A
14A
14A
DD
24
23
17ACR
02
65
14B
65CR
10CCR
(NOT ON PCB)
02
28E
02
12B
02
28
D12A
TS1
10C
12A
28
10C
TS1 NOT PRESENT
W/ OUTRIGGER OPT.
NO OUTRIGGER
JUMPER 1
D24
D23
14C
14C
D61
14C
KK
12B
13
LDR- 4
10A FUSE
F4
D14D-1
14D
02
61
10B
GG
21A
H1
F3
23
02
F1
21A
LDR- 3
LS68
LS66
66A
68A
02
LS67
LS65
65A
RST4
330 OHMS
70A
70B
LEFT FRONT
10
RIGHT REAR
10
67A
LDR- 21
SPEED SIGNAL
59A
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT FRONT
10
LEFT REAR
10
02
LDR- 1
23
RL-22A
FL-22
LDR- 19 POWER
DECK INTERLOCK
21
22
22A
10A FUSE
10A FUSE
FLASHER
10B
14D
49
22A
FL-22A
OUTRIGGER DOWN LIMIT SWITCHES
NORMALLY CLOSED HELD OPEN
10B
12B
61CR
NO OUTRIGGER
JUMPER 2
13
D14D
12B
HH
16B
24
LDR- 2
10A FUSE
F2
END OF STROKE
JUMPER 7
24
ALL FUNCTION
LIGHT JUMPER 9
29B
30
25
2H-30
2H-25
D02-7
13
13
2H-13-3
2H-13-2
2H-13-1
2H-21A
02
D02-2
D02-1
21A D02-10
14D D02-6
2H-14D
24
4H-24
4H-23
23 D02-11
TT
TT1
D02-4
D02-3
02
02 = P2-11
70B = P2-7
70 = P2-5
79 = P2-6
35C = P4-9
10 = P2-12
65A = P2-4
66A = P2-3
67A = P2-2
68A = P2-1
65 = P2-8
28E = P2-9
10A = P2-10
78 = P4-1
77 = P4-2
76 = P4-3
75 = P4-4
74 = P4-5
73 = P4-6
72 = P4-7
71 = P4-8
OCM1
D02-25
D02-24
4H-78
D02-23
4H-74
D02-22
4H-77
D02-21
4H-73
D02-20
4H-76
D02-19
4H-72
D02-18
4H-75
4H-71
D02-17
2H-17A
LDR- 20
PUMP INTERLOCK
21
LDR- 18
SMALL PUMP
18A
8A
02
02
02
02
D02-8
32A D02-5
2H-44
44
4H-32A
00
RST3
RST1
33A D02-9
2E
4H-33A
B-
B-
LDR- 11
10A FUSE
F11
CL-2
CL-1
CB1
00
00
00
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
II
JJ
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
9
STEER PUMP MOTOR
23
PROXIMITY SWITCH
PROXIMITY SWITCH
81
RIGHT REAR DOWN
RIGHT FRONT DOWN
LEFT FRONT DOWN
POWER
OUTRIGGER ENABLE
AUTO RETRACT
AUTO LEVEL
OUTRIGGER LIGHT
GROUND
139
140
141
142
143
144
145
146
155
154
153
152
151
150
149
148
L/R OUTRIGGER
EXTEND SOLENOID
L/R OUTRIGGER
RETRACT SOLENOID
R/R OUTRIGGER
EXTEND SOLENOID
R/R OUTRIGGER
RETRACT SOLENOID
R/F OUTRIGGER
EXTEND SOLENOID
R/F OUTRIGGER
RETRACT SOLENOID
L/F OUTRIGGER
EXTEND SOLENOID
L/F OUTRIGGER
RETRACT SOLENOID
LEFT REAR DOWN
138
147
LIFT ENABLE
137
RIGHT REAR DOWN
132
TILT
RIGHT FRONT DOWN
131
136
LEFT FRONT DOWN
130
LEFT REAR DOWN
LEFT REAR UP
129
TILT OVERRIDE/
HIGH DRIVE CUTOUT
RIGHT REAR UP
128
135
RIGHT FRONT UP
127
133
LEFT FRONT UP
126
134
OUTRIGGER MAIN
POWER RELAY
OUTRIGGER LIFT
DISABLE RELAY
OUTRIGGER
HOLDING SOLENOID
OUTRIGGER
PROOF RELAY
OUTRIGGER
ENABLE RELAY
OUTRIGGER LIFT
ENABLE RELAY
OUTRIGGER DRIVE
ENABLE RELAY
OUTRIGGER MOVEMENT
INDICATOR RELAY
POWER DECK
INTERLOCK RELAY
TILT SWITCH
HOLDING VALVE
HOLDING VALVE
DOWN SOLENOID
DUMP SOLENOID
UP SOLENOID
LEFT SOLENOID
RIGHT SOLENOID
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
98
97
96
95
94
93
92
91
90
89
88
87
86
85
84
83
82
HOURMETER
HORN
80
FLASHING LIGHT
ROTATING AMBER
BEACON OPTION
79
CAPACITO R
78
0.47uF
BEEPER
BRAKE PRESSURE SWITCH
BRAKE RELAY
BRAKE SOLENOID
QUICK BRAKE RELAY
QUICK BRAKE SOLENOID
LIFT SENSOR RELAY
LIFT
DRIVE SHIFT SOLENOID
GEARBOX HOLDING
SOLENOID
LIFT SHIFT SOLENOID
DRIVE
TRACTION SENSOR RELAY
RESISTOR 52 OHMS
SPEED SIGNAL RELAY
RESISTOR 1.8K OHMS
SMALL PUMP RELAY
PUMP INTERLOCK RELAY
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
CABINET LIGHT
REVERSE CONTACTOR
28
CABINET LIGHT
27
26
25
24
FORWARD CONTACTOR
TRACTION MOTOR
22
20A CIRCUIT
21
BREAKER
TACHOMETER GENERATOR
MAIN CONTACTOR
20
19
18
17
TILT RELAY
PUMP CONTACTOR
16
15
CONVERTER
48VDC INPUT
24VDC OUTPUT
14
13
12
11
10
G
REAR
RIGHT
S24
OL1
OUTRIGGER
LIGHT
02
35D
FRONT
LEFT
35D
AUTO
MODE
35C
35C
9B
12
9D
10
15
BLUE/WHITE
GREEN/WHITE
F10
10A FUSE
LDR- 10
9B
9D
NO
TILT OVERRIDE/
HIGH DRIVE CUTOUT L.S.
NORMALLY OPEN
HELD CLOSED WHEN LOWERED
LS5
10A
13
35C
35C
9B
D9C-1
LDR- 7
LDR- 8
10A FUSE
14
35C
10A
FUSE
F10-2
9C
12C
09
LDR- 9
13
14A
8A
22A
22A
ALL FUNCTION
ALARM JUMPER 4
CAP2
00
00
MAIN DISCONNECT
INVERTER
OPTION TIMER
F
S9A
OUTRIGGER
ENABLE
ENABLE
SWITCH
S18
S19
EXTEND/
RETRACT
SWITCH
ENABLE
SWITCH
EXTEND/
RETRACT
SWITCH
GREEN/WHITE
10E D10E-1
F8
8A
14A
18A
18A
D8A
D13-1
8A
29
29
BP-29
10 WAY CONNECTOR
RST2
150 OHMS
29B
15
00
COM
COM
02
BATTERY PACK
INVERTER
OPTION
7
8
6
5
4
E
DO2-25
DO2-24
DO2-23
DO2-22
9C
12C
GREEN
12C
09
02
DPM1
DELAYED
POWER
MODULE
2
9C
10B
F9
D21A
10A FUSE
16
EXTEND
SOLENOID
18A
12C
13
21A
21A
14A
17
POWERED PLATFORM OPTION
08
13
ORANGE
13
S6
UP/DOWN
SWITCH
09
1
D9-2
3
10B
4
16B
9
28
8
TABS
10A
P-
16B
28E
100
100
M
X1
00
B-
BATTERY CHARGER
CUTOUT RELAYS
D
14E
VIO
5
13
10F
GRN/BLK
7
14A
GRN/WHT
6
D14E
WHT/VIO
14E
WHT/RED
11
D14 14A
10
14
WHT/BLK
BLACK
ORG/BLK
12
14
VIO/WHT
12CCR STEER
SWITCH RELAY
RED/WHT
1
D14E-1
RED
5
02
BRN
2
WHITE
RED/BLK
3
18A
WHT/BRN
4
D18A
WHT/GRN
9
21A
VIO
7
8A
BLK
8
02
18A
VIO/WHT
6
02
8A
BLK/WHT
11
21A
BLK
13
D59A
D29A
GRN
12
12C
29A
ORG
14
59A
BLU/WHT
10
J1 - 17 WAY CONNECTOR
16
13
D13
BLU
TACHOMETER CARD
17
D29B
BRN
TC1 -
WHT
29B
A
BLU/BLK
A
29A D29A-1
S
15
24
15
B+
1
BLUE/BLACK
29A D15-1
B-
F16
B
59A
29A
M
00
02
LDR- 15
LIFT SENSOR
32
2
17 WAY CONNECTOR
T2
02
02
02
32A
32A
33A
10B
F15
6.3A FUSE
C
SEVCON DRIVE
T1
30
2C
32CR
D32A
D33A
LDR- 14
TRACTION SENSOR
33
32
09
44
44
33A
02
20A FUSE
SV1 -
09
D30
D2C
44
33CR
02
02
48+
10D
S1
A2
T2
24V
48V
DCM2
3
D16-2
PS2
BRAKE
PRESSURE
SWITCH
NORMALLY
CLOSED
2A
2B
21A
D44
12
33
18ACR
DR-1
DCM1
FIELD
ARMATURE
M
G
TG1
B+
R1
16
2B
21A
2A
18A
2C
18A
20A CIRCUIT
BREAKER
10D
WHT/RED
C10D-1
02
R2
24
2A
2B
09
10A
2C
2C
S2
A1
T1
2C
GRN
LDR- 12
POWER ON
03
3A
B1 6V
BATTERY
8
24
LDR- 16
BRAKE
12
LDR- 17
QUICK BRAKE
12
12
2A
30CR
25
30
12
25CR
12
12
32
02
10
10A
59B
S1
15C
10D
WHT/GRN
WHT/RED
C15C
B+
S1
10D
WHT/RED
C16E
S2
S2
3B
CB3
WHT
7
23
12
10B
28
18A
16B
15
15C
A2
16E
WHT/BRN
B+
A2
100A
10A FUSE
F13
3B
WHT/VIO
5
BLACK/WHITE
D12
02
33
PR2 LIFT
PROXIMITY SWITCH
NORMALLY OPEN
21
10
PR1 DRIVE
PROXIMITY SWITCH
NORMALLY OPEN
02
59A
59ACR
59B
59B
59
16B
48+
16E
F18
100
100A FUSE
3B
TMR-8A
R3
4
23
02
16B
CAP1 1000uF
CAPACITOR
21CR-2
2E
21
16A
48+
WHT/VIO
10D
00
WHT/RED
BLU/BLK
C10D-2
48+
48+
WHT/VIO
01
WHT/RED
6
23
10
12
D16-1
15
100
CB2
15A CIRCUIT
BREAKER
48+
B2 6V
BATTERY
R6
49
10
LDR- 6
16
02
3B
B3 6V
BATTERY
R7
49
F6
10A FUSE
15
LDR- 5
10A FUSE
F5
28CR
LDR- 13
TILT
02
100
NO PRES SW
JUMPER 6
B4 6V
BATTERY
R5
R4
RED/WHITE
CRD3
59
ORANGE/BLACK
59
CRD2
16
WHITE/BLACK
16
CRD1
15
18
BLUE
RED/BLACK
15
18
28
28
28A
04
24V
WHT/BLK
49
02
04
03
ORG/BLK
GRN/BLK
9
LEFT
RST 4
2.7K OHMS
02
10F
5B
02
1A
10
12E
14
16
13
00
28B
BLUE/WHITE
05
85
B5 6V
BATTERY
RED/WHT
R8
RIGHT
A
B
15
02
WL1
TROUBLE LIGHT
BP-28B
BEEPER
02
02
28A
10E
GREEN/BLACK
28A
10E
5A
NO DECK LIMITS
JUMPER 5
LS2 GATE
LIMIT SWITCH
NORMALLY
CLOSED
8A
INV1
B6 6V
BATTERY
BLK
12E
S11
HORN
SWITCH
02
02
02
S9
LIFT/OFF/DRIVE
SWITCH
28B
28B
CAP4 0.47uF
CAPACITOR
28A
02
07
RED
07
B7 6V
BATTERY
RED/BLK
08
02
28D
FORWARD
REVERSE
28ACR
V
CAP3 220uF
CAPACITOR
28A
BCI
BATTERY CHARGE
INDICATOR
7A
S4
EMERGENCY
STOP KEY
B8 6V
BATTERY
48V BATTERY
CHARGERS
1
3
2
C
D9C
02
28C
28A
WARNING
INDICATOR RELAY
12ECR JOYSTICK
ENABLE RELAY
12E
12D
59
59
D18
28C
7A
S5
IDLE/PLTF/BASE ENABLE
LS1 MANUAL
SWITCH
EXTENSION DECK (IN IDLE POSITION)
LIMIT SWITCH
NORMALLY CLOSED
1A
LCR-2
B
D12C
12D
D8
D10E-1
BASE
OFF
PLTF
S7
EMERGENCY
STOP
01
BC-2
A
ENABLE
JS1
CONTROLLER
10E
08
S8
BASE/OFF/PLATFORM
KEY SWITCH
F14
50A
FUSE
F12
400A
FUSE
LCR-1
110 VAC
LINE VOLTAGE
48+
48+
BC-1
110 VAC
LINE VOLTAGE
3.13 Electrical Schematic (ANSI/CSA)
H
V
W
X
Y
Z
M119365AM
DC Electric Full-Size Rough Terrain
Models 8831E & 8841E
155154
Section 4
Troubleshooting Information
Table of Contents
Introduction...................................................................................................................................................................3
Electrical System
4.1-1. All Controls Inoperative....................................................................................................................................4
4.1-2. All Controls Inoperative From Platform...........................................................................................................5
4.1-3. Base Controls Inoperative...............................................................................................................................5
4.1-4. Up Circuit Inoperative From Platform (Machines without outriggers)............................................................5
4.1-5. Up Circuit Inoperative From Base...................................................................................................................6
4.1-6 Up Circuit Inoperative from Platform or Base Controls with Outriggers Retracted
(lift operates correctly with outriggers extended)............................................................................................6
4.1-7 Up Circuit Inoperative from Platform or Base Controls with Outriggers Extended........................................7
4.1-8 Down Circuit Inoperative from Platform..........................................................................................................8
4.1-9. Down Circuit Inoperative from Base................................................................................................................9
4.1-10. Platform Does Not Steer Left Or Right............................................................................................................9
4.1-11. No Steer Right................................................................................................................................................10
4.1-12. No Steer Left..................................................................................................................................................10
4.1-13. Forward And Reverse Drive Inoperative (Machines without outriggers)......................................................10
4.1-14. Forward And Reverse Drive Inoperative (Machines with outriggers)...........................................................11
4.1-15. Forward Drive Inoperative..............................................................................................................................12
4.1-16. Reverse Drive Inoperative..............................................................................................................................12
4.1-17. Forward And Reverse Slow Speed Only.......................................................................................................13
4.1-18. Brake Not Releasing......................................................................................................................................13
4.1-19. Lift/Traction Shift Circuit Inoperative..............................................................................................................14
4.1-20. Powered Extension Deck Inoperative............................................................................................................14
4.1-21 All Outriggers Inoperative (Auto-level and manual)......................................................................................15
4.1-22 All Outriggers Inoperative (Auto-level and manual from platform controls).................................................16
4.1-23 All Outriggers Inoperative (Auto-level)
A: Led Power Indicator Light at Outrigger Control Module (OCM1) Not on Constant.................................16
4.1-24 All Outriggers Inoperative (Auto Level Only)
B: Led Power Indicator Light at Outrigger Control Module (OCM1) Flashing..............................................17
4.1-25 Left Front Outrigger Inoperative Manually.....................................................................................................18
4.1-26 Right Front Outrigger Inoperative Manually..................................................................................................18
4.1-27 Right Rear Outriggers Inoperative Manually.................................................................................................18
4.1-28 Left Rear Outriggers Inoperative Manually....................................................................................................19
4.1-29 Individual Outrigger Functions Inoperative (auto-level) ...............................................................................19
4.1-30 Auto-level Inoperative....................................................................................................................................19
4.1-31 Auto All Up Inoperative (Retract)...................................................................................................................20
Hydraulic System
4.2-1. All Controls Inoperative..................................................................................................................................21
4.2-2. All Systems Sluggish.....................................................................................................................................21
4.2-3. Brake Will Not Release..................................................................................................................................21
4.2-4. No Steer Left Or Right....................................................................................................................................21
4.2-5. Work Platform Does Not Lift..........................................................................................................................21
4.2-6. Work Platform Lifts Slowly.............................................................................................................................21
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 1
4
Table of Contents (Continued)
4.2-7. Platform Drifts Down......................................................................................................................................22
4.2-8. Down Circuit Inoperative...............................................................................................................................22
4.2-9. Powered Extension Platform Will Not Extend Or Retract..............................................................................22
4.2-10. Work Platform Does Not Shift Between Lift And Drive..................................................................................22
4.2-11. Outrigger Inoperative.....................................................................................................................................23
SKYJACK, Page 2
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Introduction
The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble
which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information
will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and
deficiencies that may occur.
If a specific trouble is not listed, isolate the major component in which the trouble
occurs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem.
The content of this section is separated into “probable cause” and “remedy.” The information preceded by a 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
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 3
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System
4.1-1. All Controls Inoperative
1. Batteries disconnected or discharged.
-- Connect batteries or recharge.
2. Battery charger plugged into an outside source.
-- Disconnect charger cord.
3. Dirty or loose battery terminals.
-- Clean and tighten terminals.
4. Main battery cables open or defective.
-- Check continuity. Replace if defective.
5. Main fuse F12 defective.
-- Replace fuse.
6. Defective battery charger relay LCR1 or LCR2.
-- Check relay. Replace if defective.
7. Defective or tripped circuit breaker CB2.
-- Reset circuit breaker. Replace if defective.
8. Loose or broken wire #01 from battery charger relay LCR1 to circuit breaker CB2.
-- Check continuity. Replace if defective.
9. Loose or broken wire #01A from battery charger relay LCR1 to battery charger relay LCR2.
-- Check continuity. Replace if defective.
10. Loose or broken wire #03 from battery charger relay LCR2 to converter.
-- Check continuity. Replace if defective.
11. Defective converter.
-- Check for 24 volts between wire #3A and #00, 48 volts between #03 and #00.
12. Defective contactor C10D-2.
-- Check contactor. Replace if defective.
13. Loose or broken wire #10D from contactor C10D-2 to motor control plug CN5.
-- Check continuity. Replace if defective.
14. Defective or tripped circuit breaker CB1.
-- Reset circuit breaker. Replace if defective.
15. Loose or broken wire #00 from circuit breaker CB1 to converter.
-- Check continuity. Replace if defective.
16. Defective or tripped circuit breaker CB3.
-- Reset circuit breaker. Replace if defective.
17. Loose or broken wire #3A from converter to circuit breaker CB3.
-- Check continuity. Replace if defective.
18. Loose or broken wire #3B from circuit breaker CB3 to (optional) pressure switch PS1.
-- Check continuity. Replace if defective.
19. Loose or broken wire #4 from (optional) pressure switch PS1 to base emergency stop switch S4.
-- Check continuity. Replace if defective.
20. Open or defective base emergency stop switch S4.
-- Close switch. Replace if defective.
21. Loose or broken wire #5B from base emergency stop switch S4 to base platform/base enable switch
S5.
-- Check continuity. Replace if defective.
22. Defective base platform/base enable switch S5.
-- Check switch. Replace if defective.
23. Loose or broken wire #5 from base platform/base enable switch S5 to main circuit board at CN2.
-- Check continuity. Replace if defective.
24. Loose or broken wire #7 from main circuit board at CN1 to platform emergency stop switch S7.
-- Check continuity. Replace if defective.
SKYJACK, Page 4
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System
25. Open or defective platform emergency stop switch S7.
-- Close switch. Replace if defective.
26. Loose or broken wire #7A from platform emergency stop switch S7 to platform base/platform selector
switch S8.
-- Check continuity. Replace if defective.
27. Open or defective platform base/platform selector switch S8.
-- Close switch. Replace if defective.
28. Defective Sevcon.
-- See Sevcon troubleshooting Section 5.
4.1-2. All Controls Inoperative From Platform
1. Open or defective platform base/platform selector switch S8.
-- Select Platform with switch. Replace if defective.
2. Loose or broken wire #08 from platform base/platform selector switch S8 to lift/off/drive switch S9.
-- Check continuity. Replace if defective.
3. Open or defective lift/off/drive switch S9.
-- Close switch. Replace if defective.
4. Loose or broken wire #12D from diodes D9C and D12C to Joystick enable switch.
-- Check continuity. Replace if defective.
5. Defective Joystick Controller JS1.
-- Check Joystick. Replace if defective.
4.1-3. Base Controls Inoperative
1. Open or defective base platform/base enable switch S5.
-- Select Base with switch. Replace if defective.
2. Open or defective platform base/platform selector switch S8.
-- Select Base with switch. Replace if defective.
3. Loose or broken wire #10E from platform base/platform selector switch S8 to base platform/base enable
switch S5.
-- Check continuity. Replace if defective.
4. Loose or broken wire #10F from base platform/base enable switch S5 to lift/lower switch S6 at base
controls.
-- Check continuity. Replace if defective.
5. Defective lift/lower switch S6 at base controls.
-- Check switch. Replace if defective.
4.1-4. Up Circuit Inoperative From Platform (Machines without outriggers)
1. Open or defective lift/off/drive switch S9.
-- Select Lift. Replace if defective.
2. Loose or broken wire #9C from platform control box to main circuit board at CN1.
-- Check continuity. Replace if defective.
3. Open or defective diode D9C-1.
-- Check diode. Replace if defective.
4. Loose or broken wire #9D from main circuit board at CN12 to delayed power module.
-- Check continuity. Replace if defective.
5. Defective delayed power module.
-- Check for 24 volts between wire #09 and #02. Replace if defective.
6. Defective fuse F8.
-- Replace fuse.
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 5
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
7. Open or defective diode D9-1 or D9-2.
-- Check diode. Replace if defective.
8. Loose or broken wire #14 from platform control box to main circuit board at CN1.
-- Check continuity. Replace if defective.
8. Open or defective diode D14.
-- Check diode. Replace if defective.
9. Defective fuse F9.
-- Replace fuse.
10. Loose or broken wire #14C from main circuit board at CN8 to end of stroke limit switch LS4.
-- Check continuity. Replace if defective.
11. Open or defective end of stroke limit switch LS4.
-- Check switch. Replace if defective.
12. Loose or broken wire #14D from end of stroke limit switch LS4 to main circuit board at CN8.
-- Check continuity. Replace if defective.
13. Loose or broken wire #14D or #02 from main circuit board at CN3 to up coil 2H-14D.
-- Check continuity. Replace if defective.
14. Open or defective diode D14D or D14D-1.
-- Check diode. Replace if defective.
15. Defective coil 2H-14D.
-- Check coil. Replace if defective.
16. Loose or broken wire #14C from main circuit board at CN8 to overload control module
CM1. (CE Only)
-- Check continuity. Replace if defective.
17. Lift/Traction circuit not shifting.
-- See Lift/Traction Circuit inoperative.
18. Sevcon problem.
-- See Sevcon troubleshooting.
19. Overload sensing system problem. (CE Only)
-- Refer to Load Sensing Manual available online.
4.1-5. Up Circuit Inoperative From Base
1. Lift/Lower switch S6 defective.
-- Check continuity. Replace if defective.
2. Open or defective diode D14E or D14E-1.
-- Check diode. Replace if defective.
4.1-6 Up Circuit Inoperative from Platform or Base Controls with Outriggers Retracted
(lift operates correctly with outriggers extended)
1. Outriggers not fully retracted.
-- Fully retract outrigger cylinders.
2. Loose or broken wire #10 from outrigger board to outrigger limit switch LS64.
-- Check continuity. Replace if defective.
3. Defective outrigger limit switch LS64.
-- Check switch. Replace if defective.
4. Loose or broken wire #64 from outrigger limit switch LS64 to outrigger board.
-- Check continuity. Replace if defective.
5. Loose or broken wire #64 from outrigger board to outrigger limit switch LS63.
-- Check continuity. Replace if defective.
6. Defective outrigger limit switch LS63.
-- Check continuity. Replace if defective.
SKYJACK, Page 6
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
7. Loose or broken wire #63 from outrigger limit switch LS63 to outrigger board.
-- Check continuity. Replace if defective.
8. Loose or broken wire #63 from outrigger board to outrigger limit switch LS62.
-- Check continuity. Replace if defective.
9. Defective Limit switch LS62.
-- Check switch. Replace if defective.
10. Loose or broken wire #62 from outrigger limit switch LS62 to outrigger board.
-- Check continuity. Replace if defective.
11. Loose or broken wire #62 from outrigger board to outrigger limit switch LS61.
-- Check continuity. Replace if defective.
12. Defective outrigger limit switch LS61.
-- Check switch. Replace if defective.
13. Loose or broken wire #61 from outrigger limit switch LS61 to outrigger board .
-- Check continuity. Replace if defective.
14. Open diode D61 or D65 on outrigger board.
-- Check diode. Replace if defective.
15. Loose or broken wire #10C or #02 from outrigger board to relay 10CCR. (ANSI/CSA only)
-- Check continuity. Replace if defective.
16. Defective relay 10CCR. (ANSI/CSA only)
-- Check relay. Replace if defective.
17. Loose or broken wire #28E from outrigger control module to relay 10CCR. (ANSI/CSA only)
-- Check continuity. Replace if defective.
18. Loose or broken wire #28 from relay 10CCR to pin #7 on Sevcon. (ANSI/CSA only)
-- Check continuity. Replace if defective.
19. Loose or broken wire #28E from overload control module CM1 to pin #7 on Sevcon. (CE only)
-- Check continuity. Replace if defective.
20. Overload sensing system problem. (CE Only)
-- Refer to Load Sensing Manual available on line.
4.1-7 Up Circuit Inoperative from Platform or Base Controls with Outriggers Extended
1. Outriggers not extended enough.
-- Extend outriggers to take weight off tires (refer to operator section).
2. Loose or broken wire #10 from outrigger board to outrigger limit switch LS68.
-- Check continuity. Replace if defective.
3. Defective outrigger limit switch LS68.
-- Check switch. Replace if defective.
4. Loose or broken wire #68A from outrigger limit switch LS68 to outrigger control module at pin P2-1.
-- Check continuity. Replace if defective.
5. Loose or broken wire #10 from outrigger board to outrigger limit switch LS67.
-- Check continuity. Replace if defective.
6. Defective outrigger limit switch LS67.
-- Check switch. Replace if defective.
7. Loose or broken wire #67A from outrigger limit switch LS67 to outrigger control module at pin P2-2.
-- Check continuity. Replace if defective.
8. Loose or broken wire #10 from outrigger board to outrigger limit switch LS66.
-- Check continuity. Replace if defective.
9. Defective outrigger limit switch LS66.
-- Check switch. Replace if defective.
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 7
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
10. Loose or broken wire #66A from outrigger limit switch LS66 to outrigger control module at pin P2-3.
-- Check continuity. Replace if defective.
11. Loose or broken wire #10 from outrigger board to outrigger limit switch LS65.
-- Check continuity. Replace if defective.
12. Defective outrigger limit switch LS65.
-- Check switch. Replace if defective.
13. Loose or broken wire #65A from outrigger limit switch LS65 to outrigger control module at pin P2-4.
-- Check continuity. Replace if defective.
14. Check for power on wire #65 at outrigger control module at pin P2-8.
-- If no voltage present, proceed to outrigger control module troubleshooting.
15. Loose or broken wire #65 from outrigger control module at pin P2-8 to outrigger board CN22 pin
#16.
-- Check continuity. Replace if defective.
16. Defective lift enable relay 65CR.
-- Check relay. Replace if defective.
17. Defective lift disable relay 17ACR.
-- Check relay. Replace if defective.
18. Open diode D65 on outrigger board.
-- Check diode. Replace if defective.
19. Loose or broken wire #10C or #02 from outrigger board to relay 10CCR. (ANSI/CSA only)
-- Check continuity. Replace if defective.
20. Defective relay 10CCR. (ANSI/CSA only)
-- Check relay. Replace if defective.
21. Loose or broken wire #28E from outrigger control module to relay 10CCR. (ANSI/CSA only)
-- Check continuity. Replace if defective.
22. Loose or broken wire #28 from relay 10CCR to pin #7 on Sevcon. (ANSI/CSA only)
-- Check continuity. Replace if defective.
23. Loose or broken wire #28E from overload control module CM1 to pin #7 on Sevcon. (CE only)
-- Check continuity. Replace if defective.
24. Overload sensing system problem. (CE Only)
-- Refer to Load Sensing Manual available on line.
4.1-8 Down Circuit Inoperative from Platform
1. Open or defective lift/off/drive switch S9.
-- Select Lift. Replace if defective.
2. Loose or broken wire #9C from platform control box to main circuit board at CN1.
-- Check continuity. Replace if defective.
3. Open or defective diode D9C-1.
-- Check diode. Replace if defective.
4. Loose or broken wire #9D from main circuit board at CN12 to delayed power module.
-- Check continuity. Replace if defective.
5. Defective delayed power module.
-- Check for 24 volts between wire #09 and #02. Replace if defective.
6. Defective fuse F8.
-- Replace fuse.
7. Open or defective diode D9-1 or D9-2.
-- Check diode. Replace if defective.
8. Loose or broken wire #13 from platform control box to main circuit board at CN1.
-- Check continuity. Replace if defective.
SKYJACK, Page 8
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
9. Defective fuse F4.
-- Replace fuse.
10. Loose or broken wire #13 or #02 from main circuit board at CN3 to down coil 2H-13-1, and holding
valve coil 2H-13-2 and 2H-13-3. (ANSI/CSA only)
-- Check continuity. Replace if defective.
11. Defective Down coil 2H-13-1, or holding valve coil 2H-13-2 and 2H-13-3. (ANSI/CSA only)
-- Check coil. Replace if defective.
12. Loose or broken wire #02 from main circuit board to down enable relay 60ECR1 or auxiliary down
enable relay 60CR1. (CE only)
-- Check continuity. Replace if defective.
13. Defective down enable relay 60ECR1 or auxiliary down enable relay 60CR1. (CE only)
-- Check relay. Replace if defective.
14. Loose or broken wire #60E from control module CM1 at pin #P3-6 to down enable relay 60ECR1.
(CE only)
-- Check continuity. Replace if defective.
15. Loose or broken wire #60 from control module CM1 at pin #P3-4 to auxiliary down enable relay 60CR1.
(CE only)
-- Check continuity. Replace if defective.
16. Loose or broken wire #13 from main circuit board at CN8 to down enable relay 60ECR1. (CE only)
-- Check continuity. Replace if defective.
17. Loose or broken wire #13A from down enable relay 60ECR1 to auxiliary down enable relay 60CR1.
(CE only)
-- Check continuity. Replace if defective.
18. Loose or broken wire #13B or #02 from auxiliary down enable relay 60CR1 to down coil 2H-13B-1,
and holding valve coil 2H-13B-2 and 2H-13B-3. (CE only)
-- Check continuity. Replace if defective.
19. Defective down coil 2H-13B-1, or holding valve coil 2H-13B-2 and 2H-13B-3. (CE only)
-- Check coil. Replace if defective.
20. Lift/Traction circuit not shifting.
-- See lift/traction circuit inoperative.
21. Sevcon problem.
-- See Sevcon troubleshooting.
22. Overload sensing system problem. (CE Only)
-- Refer to Load Sensing Manual available on line.
4.1-9. Down Circuit Inoperative from Base
1. Lift/Lower switch S6 defective.
-- Check continuity. Replace if defective.
2. Loose or broken wire #13 on lift/lower switch S6 to main circuit board at CN2.
-- Check continuity. Replace if defective.
4.1-10. Platform Does Not Steer Left Or Right
1. Defective relay 18ACR.
-- Check relay. Replace if defective.
2. Loose or broken wire #12C from lift/off/drive switch S9 to steer enable relay 12CCR.
-- Check continuity. Replace if defective.
3. Defective steer toggle switch.
-- Check switch. Replace if defective.
4. Open or defective diode D18A.
-- Check diode. Replace if defective.
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 9
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
4.1-11. No Steer Right
1. Loose or broken wire #23 from platform control box to main circuit board at CN1.
-- Check continuity. Replace if defective.
2. Open or defective diode D23.
-- Check diode. Replace if defective.
3. Defective fuse F1.
-- Replace fuse.
4. Loose or broken wire #23 or #02 on coil 4H-23.
-- Check continuity. Replace if defective.
5. Defective coil 4H-23.
-- Check coil. Replace if defective.
6. Defective steer switch.
-- Check switch. Replace if defective.
4.1-12. No Steer Left
1. Loose or broken wire #24 from platform control box to main circuit board at CN1.
-- Check continuity. Replace if defective.
2. Open or defective diode D24.
-- Check diode. Replace if defective.
3. Defective fuse F2.
-- Replace fuse.
4. Loose or broken wire #24 or #02 on coil 4H-24.
-- Check continuity. Replace if defective.
5. Defective coil 4H-24.
-- Check coil. Replace if defective.
6. Defective steer switch.
-- Check switch. Replace if defective.
4.1-13. Forward And Reverse Drive Inoperative (Machines without outriggers)
1. Open or defective lift/off/drive switch S9.
-- Select Lift. Replace if defective.
2. Loose or broken wire #12C from platform control box to main circuit board at CN1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #12C from main circuit board at CN12 to delayed power module.
-- Check continuity. Replace if defective.
4. Defective delayed power module.
-- Check for 24 volts between wire #09 and #02. Replace if defective.
5. Defective fuse F7.
-- Replace fuse.
6. Open or defective diode D12-1 or D12A.
-- Check diode. Replace if defective.
7. Open or defective diode D12C.
-- Check diode. Replace if defective.
8. Brake not releasing.
-- See brake not releasing troubleshooting in this section.
8. Lift/Traction circuit not shifting.
-- See lift/traction circuit inoperative.
9. Sevcon problem.
-- See Sevcon troubleshooting.
SKYJACK, Page 10
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
4.1-14. Forward And Reverse Drive Inoperative (Machines with outriggers)
1. Outriggers not fully retracted
-- Fully retract outrigger cylinders
2. Open or defective lift/off/drive switch S9.
-- Select Lift. Replace if defective.
3. Loose or broken wire #12C from platform control box to main circuit board at CN1.
-- Check continuity. Replace if defective.
4. Loose or broken wire #12C from main circuit board at CN12 to delayed power module.
-- Check continuity. Replace if defective.
5. Defective delayed power module.
-- Check for 24 volts between wire #09 and #02. Replace if defective.
6. Defective fuse F7.
-- Replace fuse.
7. Open or defective diode D12-1 or D12A.
-- Check diode. Replace if defective.
8. Open or defective diode D12C.
-- Check diode. Replace if defective.
9. Loose or broken wire #10 from outrigger board to outrigger limit switch LS64.
-- Check continuity. Replace if defective.
10. Defective outrigger limit switch LS64.
-- Check switch. Replace if defective.
11. Loose or broken wire #64 from outrigger limit switch LS64 to outrigger board.
-- Check continuity. Replace if defective.
12. Loose or broken wire #64 from outrigger board to outrigger limit switch LS63.
-- Check continuity. Replace if defective.
13. Defective outrigger limit switch LS63.
-- Check continuity. Replace if defective.
14. Loose or broken wire #63 from outrigger limit switch LS63 to outrigger board.
-- Check continuity. Replace if defective.
15. Loose or broken wire #63 from outrigger board to outrigger limit switch LS62.
-- Check continuity. Replace if defective.
16. Defective Limit switch LS62.
-- Check switch. Replace if defective.
17. Loose or broken wire #62 from outrigger limit switch LS62 to outrigger board.
-- Check continuity. Replace if defective.
18. Loose or broken wire #62 from outrigger board to outrigger limit switch LS61.
-- Check continuity. Replace if defective.
19. Defective outrigger limit switch LS61.
-- Check switch. Replace if defective.
20. Loose or broken wire #61 from outrigger limit switch LS61 to outrigger board.
-- Check continuity. Replace if defective.
21. Open diode D61 or D65 on outrigger board.
-- Check diode. Replace if defective.
22. Loose or broken wire #10C or #02 from outrigger board to relay 10CCR. (ANSI/CSA only)
-- Check continuity. Replace if defective.
24. Defective relay 10CCR. (ANSI/CSA only)
-- Check relay. Replace if defective.
25. Loose or broken wire #28E from outrigger control module to relay 10CCR. (ANSI/CSA only)
-- Check continuity. Replace if defective.
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 11
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
26. Loose or broken wire #28 from relay 10CCR to pin #7 on Sevcon. (ANSI/CSA only)
-- Check continuity. Replace if defective.
27. Loose or broken wire #28E from overload control module CM1 to pin #7 on Sevcon. (CE only)
-- Check continuity. Replace if defective.
28. Overload sensing system problem. (CE Only)
-- Refer to Load Sensing Manual available on line.
29. Brake not releasing.
-- See brake not releasing troubleshooting in this section.
30. Lift/Traction circuit not shifting.
-- See Lift/Traction Circuit inoperative.
31. Sevcon problem.
-- See Sevcon troubleshooting.
4.1-15. Forward Drive Inoperative
1. Loose or broken wire #16 on lift/off/drive switch S9.
-- Check continuity. Replace if defective.
2. Defective fuse F6.
-- Replace fuse.
3. Open or defective diode D16-1.
-- Check diode. Replace if defective.
4. Defective relay 21CR2.
-- Check relay. Replace if defective.
5. Loose or broken wire #16B from main circuit board at CN5 to pin #8 on Sevcon. (ANSI/CSA only)
-- Check continuity. Replace if defective.
6. Bad contacts in contactor C16E.
-- Replace contactor.
7. Loose or broken wire #16E from pin #15 on Sevcon to contactor C16E.
-- Check continuity. Replace if defective.
8. Loose or broken wire #02 from main circuit board to forward relay 60ECR3 or auxiliary forward relay
60CR3. (CE only)
-- Check continuity. Replace if defective.
9. Defective forward relay 60ECR3 or auxiliary forward relay 60CR3. (CE only)
-- Check relay. Replace if defective.
10. Loose or broken wire #60E from control module CM1 at pin #P3-6 to forward relay
60ECR3. (CE only)
-- Check continuity. Replace if defective.
11. Loose or broken wire #60 from control module CM1 at pin #P3-4 to auxiliary forward relay 60CR3.
(CE only)
-- Check continuity. Replace if defective.
12. Loose or broken wire #16B from main circuit board at CN5 to forward relay 60ECR3. (CE only)
-- Check continuity. Replace if defective.
13. Loose or broken wire #16C from forward relay 60ECR3 to auxiliary forward relay 60CR3. (CE only)
-- Check continuity. Replace if defective.
14. Loose or broken wire #16D from auxiliary forward relay 60CR3 to pin #8 on Sevcon. (CE only)
-- Check continuity. Replace if defective.
4.1-16. Reverse Drive Inoperative
1. Loose or broken wire #15 on lift/off/drive switch S9.
-- Check continuity. Replace if defective.
SKYJACK, Page 12
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
2. Defective fuse F5.
-- Replace fuse.
3. Loose or broken wire #15 from main circuit board at CN5 to pin #11 on Sevcon. (ANSI/CSA only)
-- Check continuity. Replace if defective.
4. Bad contacts in contactor C15C.
-- Replace contactor.
5. Loose or broken wire #15C from pin #17 on Sevcon to contactor C15C.
-- Check continuity. Replace if defective.
6. Loose or broken wire #02 from main circuit board to reverse relay 60ECR2 or auxiliary reverse relay
60CR2. (CE only)
-- Check continuity. Replace if defective.
7. Defective reverse relay 60ECR2 or auxiliary reverse relay 60CR2. (CE only)
-- Check relay. Replace if defective.
8. Loose or broken wire #60E from control module CM1 at pin #P3-6 to reverse relay 60ECR2.
(CE only)
-- Check continuity. Replace if defective.
9. Loose or broken wire #60 from control module CM1 at pin #P3-4 to auxiliary reverse relay 60CR2.
(CE only)
-- Check continuity. Replace if defective.
10. Loose or broken wire #15 from main circuit board at CN5 to reverse relay 60ECR2. (CE only)
-- Check continuity. Replace if defective.
11. Loose or broken wire #15A from reverse relay 60ECR2 to auxiliary reverse relay 60CR2. (CE only)
-- Check continuity. Replace if defective.
12. Loose or broken wire #15B from auxiliary reverse relay 60CR2 to pin #11 on Sevcon. (CE only)
-- Check continuity. Replace if defective.
4.1-17. Forward And Reverse Slow Speed Only
1. Loose or broken wire #10 from main circuit board at CN8 to high drive cut out limit switch LS5.
-- Check continuity. Replace if defective.
2. High drive cut out limit switch LS5 out of adjustment, open or defective.
-- Adjust switch. Check switch. Replace if defective.
3. Loose or broken wire #10A from high drive cut out limit switch LS5 to main circuit board at CN8.
-- Check continuity. Replace if defective.
4. Loose or broken wire #10A from main circuit board at CN5 to pin #4 on Sevcon.
-- Check continuity. Replace if defective.
5. Loose or broken wire #28 (ANSI/CSA), or #28E (CE) at pin #7 on Sevcon.
-- Check for 24 volts at pin #7. If no voltage present see Sevcon troubleshooting.
4.1-18. Brake Not Releasing
1. Open or defective brake relay 30CR or quick brake relay 25CR.
-- Check relay. Replace if defective.
2. Loose or broken wire #2A or #2B on Brake pressure switch PS2.
-- Check continuity. Replace if defective.
3. Open or defective brake pressure switch PS2.
-- Check for continuity between wire #2A and #2B on Brake pressure switch (PS2). Replace if
defective.
4. Loose or broken wire #30 or #02 on coil 2H-30.
-- Check continuity. Replace if defective.
5. Defective coil 2H-30.
-- Check coil. Replace if defective.
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 13
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
6. Loose or broken wire #25 or #02 on coil 2H-25.
-- Check continuity. Replace if defective.
7. Defective coil 2H-25.
-- Check coil. Replace if defective.
8. Open or defective diode D30.
-- Check diode. Replace if defective.
9. Loose or broken wire #2A from pin #1 on Sevcon to relay 25CR.
-- Check continuity. Replace if defective.
4.1-19. Lift/Traction Shift Circuit Inoperative
1. Defective proximity switch PR1 or PR2.
-- Refer to proximity switch test procedure Section 5.
2. Open or defective diode D44.
-- Check diode. Replace if defective.
3. Loose or broken wire #44 or #02 on coil 2H-44.
-- Check continuity. Replace if defective.
4. Defective coil 2H-44.
-- Check coil. Replace if defective.
5. Defective traction sensor relay 33CR, or lift sensor relay 32CR.
-- Check relay. Replace if defective.
6. Loose or broken wire #32A or #02 on coil 4H-32A.
-- Check continuity. Replace if defective.
7. Defective coil 4H-33A.
-- Check coil. Replace if defective.
8. Loose or broken wire #33A or #02 on coil 4H-33A.
-- Check continuity. Replace if defective.
9. Defective coil 4H-33A.
-- Check coil. Replace if defective.
10. Open or defective diode D33A or D32A.
-- Check diode. Replace if defective.
11. Loose or broken wire #32 from lift sensor relay 32CR to pin #8 on tachometer board.
-- Check continuity. Replace if defective.
12. Loose or broken wire #33 from traction sensor relay 33CR to pin #9 on tachometer board.
-- Check continuity. Replace if defective.
4.1-20. Powered Extension Deck Inoperative
1. Open or defective pump interlock relay 21CR-1.
-- Check relay. Replace if defective.
2. Defective fuse F10.
-- Replace fuse.
3. Defective fuse F10-2.
-- Replace fuse.
4. Loose or broken wire #9B from terminal block to enable switch S16 or S18.
-- Check continuity. Replace if defective.
5. Open or defective enable switch S16 or S18.
-- Close switch. Check switch. Replace if defective.
6. Loose or broken wire #9B from enable switch S16 or S18 to in/out switch S17 or S19.
-- Check continuity. Replace if defective.
SKYJACK, Page 14
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
7. Loose or broken wire #18A from terminal block to small pump relay 18ACR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #26 on switch S17 or wire #26A on switch S19.
-- Check continuity. Replace if defective.
9. Loose or broken wire #26 or #02 on coil 4H-26 or wire #26A or #02 on coil 4H-26A.
-- Check continuity. Replace if defective.
10. Defective coil 4H-26 or 4H-26A.
-- Check coil. Replace if defective.
11. Open or defective diode D26 or D26A.
-- Check diode. Replace if defective.
12. Loose or broken wire #27 on switch S17 or wire #27A on switch S19.
-- Check continuity. Replace if defective.
13. Loose or broken wire #27 or #02 on coil 4H-27 or wire #27A or #02 on coil 4H-27A.
-- Check continuity. Replace if defective.
14. Defective coil 4H-27 or 4H-27A.
-- Check coil. Replace if defective.
15. Open or defective diode D27 or D27A.
-- Check diode. Replace if defective.
4.1-21 All Outriggers Inoperative (Auto-level and manual)
WARNING
Scissors lift must be below high speed limit switch for outriggers to function.
NOTE
For the outriggers to function the upper control console must be in
the lift position.
1. No power at wire #10A on connector CN14 on outrigger board.
-- If no power is present check the close couple connection to main circuit board. Replace if
defective.
2. No power at wire #9 on connector CN14 on outrigger board.
-- If no power is present check the close couple connection to main circuit board. Replace if
defective.
3. Defective relay 10ACR1 or 10ACR2 on outrigger board.
-- Check relays. Replace if defective.
4. Loose or broken wire #9E from outrigger board to relay 9ECR.
-- Check for continuity. Replace if defective.
5. Loose or broken wire #02 from main circuit board to relay 9ECR.
-- Check continuity. Replace if defective.
6. Defective relay 9ECR.
-- Check relay. Replace if defective.
7. Loose or broken wire #3B from circuit breaker CB3 to relay 9ECR.
-- Check for continuity. Replace if defective.
8. Loose or broken wire #35C from relay 9ECR to outrigger circuit board.
-- Check continuity. Replace if defective.
9. Open diode D17A or D17A-1 on outrigger board.
-- Check diode. Replace if defective.
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 15
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
10. Loose or broken wire #17A from pin #1 or wire #02 from pin #2 on connector CN21 on outrigger board
to outrigger holding valve coil 2H-17A.
-- Check for continuity. Replace if defective.
11. Defective outrigger holding valve coil 2H-17A.
-- Check coil. Replace if defective.
4.1-22 All Outriggers Inoperative (Auto-level and manual from platform controls)
1. Loose or broken wire #35C from connector CN20 on outrigger board through outrigger cables and
plugs to the outrigger enable switch S9A in the control console.
-- Check for continuity. Replace if defective.
2. Loose or broken wire #35D from outrigger enable switch S9A to pin #5 on the outrigger control console
plug.
-- Check for continuity. Replace if defective.
3. Defective outrigger enable switch S9A.
-- Check switch. Replace if defective.
4.1-23 All Outriggers Inoperative (Auto-level)
A: Led Power Indicator Light at Outrigger Control Module (OCM1) Not on Constant
1. Loose or broken wire #10 from outrigger board to pin P2-12 on the outrigger control module OCM1.
-- Check for continuity. Replace if defective.
2. Loose or broken wire #02 from outrigger board to pin P2-11 on the outrigger control module OCM1.
-- Check for continuity. Replace if defective.
3. Defective outrigger control module OCM1.
-- Replace.
SKYJACK, Page 16
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
4.1-24 All Outriggers Inoperative (Auto Level Only)
B: Led Power Indicator Light at Outrigger Control Module (OCM1) Flashing
NOTE: A Steady Light on Sevcon Means System is Ready to Operate.
FLASH CODE
TROUBLE
LED is off
No functions
2 Flash Fault
3 Flash Fault
4 Flash Fault
Procedure
Fault
5 Flash Fault
6 Flash Fault
No Drive
and Lift
7 Flash Fault
Low Battery
Voltage
8 Flash Fault
10 Flash Fault
Thermal
Cutback
11 Flash Fault
Tachometer
Fault
12 Flash Fault
Tilt Condition
with Platform
Elevated.
13 Flash Fault
Transmission
Gear Mesh
Failure
14 Flash Fault
Low or Open
Voltage to
Sevcon
PROBABLE CAUSE
1. Batteries Disconnected.
2. Defective Sevcon.
1. Lift or Drive Selected Before
Power up.
1. Sevcon Shorted.
2. Drive Motor Shorted.
1. Contactor welded.
REMEDY
1. Reconnect batteries.
2. Replace Sevcon.
1. First Power Up and then Select
Function.
1. Replace Sevcon.
2. Replace Drive Motor.
1. Replace Contactor.
1. Contactor not shifted.
1. Clean Contactor. Replace if
defective.
2. Replace Sevcon.
1. Check continuity. Replace if
defective.
2. Defective Sevcon.
1. Loose or broken wire #59 from
upper control box to Pin #14 on
Sevcon.
2. Open or defective Base Speed
Relay (59ACR).
2. Check Relay. Replace if
defective.
1. Batteries have dropped below
13 Volts.
1. Sevcon Overheating.
1. Recharge Batteries.
1. Loose or broken wire from Pin
#2 on Sevcon to Pin #4 on
Tachometer Board.
2. Loose or broken wire from Pin
#12 on Sevcon to Pin #2 on
Tachometer Board.
3. Loose or broken wire #T1 or
#T2 from Tachometer Generator
to Main Circuit Board.
1. Tachometer Generator
defective.
2. Tachometer Generator Wires
Reversed.
3. Defective Tachometer Board.
1. Check continuity. Replace if
defective.
1. Tilt Condition with Platform
Elevated has disabled Sevcon
for Lift and Drive.
1. Incorrectly set Proximity Switch.
2. Defective Proximity Switch.
1. Loose or broken wire to Pin #5
on Sevcon.
2. Loose or broken wire to Pin #6
on Sevcon.
1. Let unit cool down.
2. Check continuity. Replace if
defective.
3. Check continuity. Replace if
defective.
1. Check output 20.8 Volts per
1000 RPM. Replace if defective.
2. Switch wires at Generator.
3. Check Tachometer Board for
inputs and outputs. Replace if
defective.
1. Lower Platform and Reposition
to a firm Level Surface.
1. Refer to Proximity Switch
Adjustment Procedure (Section
5, Page 11)
2. Refer to Proximity Switch Test
Procedure (Section 5, Page 12)
1. Check for 24 Volts between Pin
#5 and wire #02.
2. Check for 48 Volts between Pin
#6 and wire #02.
60311AA
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 17
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
4.1-25 Left Front Outrigger Inoperative Manually
1. Defective left front outrigger switch S20 at platform.
-- Check switch. Replace if defective.
2. Loose or broken wire #71 from outrigger control console to pin #6 on connector CN20 at outrigger
board (retract), or from wire #75 to pin #7 (extend).
-- Check continuity. Replace if defective.
3. Open diode D71 (retract) or D75 (extend) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #71 from pin #7 on connector CN21 at outrigger board to valve coil 4H-71 (retract)
, or wire #75 from pin #8 to 4H-75 (extend).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-71 (retract) or 4H-75 (extend) to pin #2 on connector
CN21 at the outrigger board.
-- Check continuity. Replace if defective.
4.1-26 Right Front Outrigger Inoperative Manually
1. Defective right front outrigger switch S21 at platform.
-- Check switch. Replace if defective.
2. Loose or broken wire #72 from outrigger control console to pin #8 on connector CN20 at outrigger
board (retract), or from wire #76 to pin #9 (extend).
-- Check continuity. Replace if defective.
3. Open diode D72 (retract) or D76 (extend) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #72 from pin #9 on connector CN21 at outrigger board to valve coil 4H-72
(retract), or wire #76 from pin #10 to 4H-76 (extend).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-72 (retract) or 4H-76 (extend) to pin #2 on connector
CN21 at the outrigger board.
-- Check continuity. Replace if defective.
4.1-27 Right Rear Outriggers Inoperative Manually
1. Defective right rear outrigger switch S22 at platform.
-- Check switch. Replace if defective.
2. Loose or broken wire #73 from outrigger control console to pin #3 on connector CN20 at outrigger
board (retract), or from wire #77 to pin #4 (extend).
-- Check continuity. Replace if defective.
3. Open diode D73 (retract) or D77 (extend) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #73 from pin #4 on connector CN21 at outrigger board to valve coil 4H-73
(retract), or wire #77 from pin #4 to 4H-77 (extend).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-73 (retract) or 4H-77 (extend) to pin #2 on connector
CN21 at the outrigger board.
-- Check continuity. Replace if defective.
SKYJACK, Page 18
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
4.1-28 Left Rear Outriggers Inoperative Manually
1. Defective left rear outrigger switch S23 at platform.
-- Check switch. Replace if defective.
2. Loose or broken wire #74 from outrigger control console to pin #5 on connector CN20 at outrigger
board (retract), or from wire #78 to pin #2 (extend).
-- Check continuity. Replace if defective.
3. Open diode D74 (retract) or D78 (extend) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #74 from pin #6 on connector CN21 at outrigger board to valve coil 4H-74
(retract), or wire #78 from pin #3 to 4H-78 (extend).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-74 (retract) or 4H-78 (extend) to pin #2 on connector
CN21 at the outrigger board.
-- Check continuity. Replace if defective.
4.1-29 Individual Outrigger Functions Inoperative (auto-level)
1. Loose or broken wire #71- #75 (depending on function not working) at pins 1-8 of outrigger control
module plug P4.
-- Check connections of outrigger functions not working (refer to Section 5 for pin reference
chart). Replace if defective.
2. No output from outrigger control module OCM1 at pins 1-8 of outrigger control module plug P4.
-- Turn off power to reset the outrigger control module. Turn power back on and retest. If problem
persists, replace outrigger control module.
4.1-30 Auto-level Inoperative
1. Loose or broken wire #35D from outrigger enable switch S9A to auto mode outrigger switch S24.
-- Check continuity. Replace if defective.
2. Defective auto mode outrigger switch S24.
-- Check switch. Replace if defective.
3. Loose or broken wire #10 at pin #P2-12 on outrigger control module OCM1.
-- Check for power at P2-12. If no voltage present, check continuity of wire. Replace if
defective.
4. Loose or broken wire #10A at pin #P2-10 on outrigger control module OCM1.
-- Check for power at P2-10. If no voltage present, check continuity of wire. Replace if
defective.
5. Loose or broken wire #02 at pin #P2-11 on outrigger control module OCM1.
-- Check for ground at P2-11. If no ground present, check continuity of wire. Replace if
defective.
6. Loose or broken wire #70 from auto mode outrigger switch S24 to pin #P2-5 on outrigger control
module OCM1.
-- Check continuity. Replace if defective.
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 19
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
4.1-31 Auto All Up Inoperative (Retract)
1. Loose or broken wire #35D from outrigger enable switch S9A to auto mode outrigger switch S24.
-- Check continuity. Replace if defective.
2. Defective auto mode outrigger switch S24.
-- Check switch. Replace if defective.
3. Loose or broken wire #10 at pin #P2-12 on outrigger control module OCM1.
-- Check for power at P2-12. If no voltage present, check continuity of wire. Replace if
defective.
4. Loose or broken wire #10A at pin #P2-12 on outrigger control module OCM1.
-- Check for power at P2-10. If no voltage present, check continuity of wire. Replace if
defective.
5. Loose or broken wire #02 at pin #P2-11 on outrigger control module OCM1.
-- Check for ground at P2-11. If no ground present, check continuity of wire. Replace if
defective.
6. Loose or broken wire #79 from auto mode outrigger switch S24 to pin #P2-6 on outrigger control
module OCM1.
-- Check continuity. Replace if defective.
SKYJACK, Page 20
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Hydraulic System
4.2-1. All Controls Inoperative
1. Defective system dump valve 2H-21A.
-- Check valve. Replace if defective.
4.2-2. All Systems Sluggish
1. Systems contaminated.
-- Thoroughly flush Hydraulic System and add new hydraulic oil. (Refer to Section 5 for
recommendations.)
2. System relief valve R1 setting to low or valve is defective.
-- Check serial number plate for correct pressure setting. Replace valve if defective.
4.2-3. Brake Will Not Release
1. Brake release valve 2H-30 stuck.
-- Check valve. Replace if defective
2. Quick brake valve 2H-25 stuck.
-- Check valve. Replace if defective.
3. Hand pump HP-2 bypassing oil.
-- Check seals for valve. Replace if defective.
4. Auto reset valve V6 stuck in closed position.
-- Check valve. Replace if defective
4.2-4. No Steer Left Or Right
1. Stuck or defective steer valve 4H-23 or 4H-24.
-- Check valve. Replace if defective
2. Steer cylinder C7 leaking internally.
-- Check cylinder. Replace if defective.
4.2-5. Work Platform Does Not Lift
1. Lift valve 2H-14D not shifting or contaminated.
-- Clean valve and reinstall.
2. Lowering valve 2H-13-1 stuck open.
-- Check valve. Replace if defective.
3. Manual lowering valve V1 stuck open.
-- Check valve. Replace if defective.
4. Brake release valve 2H-30 stuck or open.
-- Check valve. Replace if defective.
5. Lift gearbox valve 4H-33A not shifting.
-- Clean valve and reinstall. Replace if defective.
6. Gearbox valve 2H-44 stuck open.
-- Check valve. Replace if defective.
7. Defective large pump P1.
-- Check pump. Repair or replace if defective.
4.2-6. Work Platform Lifts Slowly
1. Contaminated system dump valve 2H-21A.
-- Clean valve and reinstall. Replace if defective.
2. Contaminated brake release valve 2H-30.
-- Clean valve and reinstall. Replace if defective.
3. Contaminated lowering valve 2H-13-1 or manual lowering valve V1.
-- Clean valve and reinstall. Replace if defective.
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 21
Service and Maintenance
Section 4 - Troubleshooting Information
Hydraulic System
4. Controlled lowering valve V2 stuck.
-- Clean valve and reinstall. Replace if defective.
5. Contaminated or defective lift cylinder holding valve 2H-13-2 or 2H-13-3 (ANSI/CSA), or manual override
open 2H-13B-2 or 2H-13B-3 (CE).
-- Depress manual override knob and rotate clockwise to close valve. Clean valve and reinstall.
Replace if defective.
6. System relief valve R1 set to low.
-- Check serial number plate for correct pressure setting. Replace valve if defective.
7. Worn hydraulic pump P1.
-- Check pump performance. Repair or replace if defective.
4.2-7. Platform Drifts Down
1. Main lowering valve 2H-13-1 (ANSI/CSA) or 2H-13B-1 (CE), and lift cylinder holding valves 2H-132 or 2H-13-3 (ANSI/CSA), or manual override 2H-13B-2 or 2H-13B-3 (CE) open, contaminated or
defective.
-- Depress manual override knob and rotate clockwise to close valve. Clean valve and reinstall.
Replace if defective.
2. Manual lowering valve V1 and lift cylinder holding valve 2H-13-2 and 2H-13-3 (ANSI/CSA), or 2H-13B-2
or 2H-13B-3 (CE) Stuck open, contaminated or defective.
-- Push valve plunger in. Clean valve and reinstall. Replace if defective.
3. Leaking cylinder packing.
-- Replace packing.
4.2-8. Down Circuit Inoperative
1. Lowering valve 2H-13-1 (ANSI/CSA) or 2H-13B-1 (CE) not shifting or defective.
-- Clean valve and reinstall. Replace if defective.
2. Lift cylinder holding valves 2H-13-2 or 2H-13-3 (ANSI/CSA), or 2H-13B-2 or 2H-13B-3 (CE) not
shifting.
-- Clean valves and reinstall. Replace if defective.
3. Plugged lowering orifice 02 or 03.
-- Remove contamination and reinstall.
4.2-9. Powered Extension Platform Will Not Extend Or Retract
1. Powered platform valve 4H-26 or 4H-27, or 4H-26A or 4H-27A not shifting or stuck.
-- Clean valve and reinstall. Replace if defective.
2. Platform extension cylinder C3 or C4 packing bad.
-- Replace packing.
4.2-10. Work Platform Does Not Shift Between Lift And Drive.
1. Lift gearbox valve 4H-33A, or traction gearbox valve 4H-32A not shifting or is sticking.
-- Clean valve and reinstall. Replace if defective.
2. Gearbox valve 4H-44 not shifting.
-- Check valve and reinstall. Replace if defective.
3. Gearbox relief valve R2 set to low.
-- Setting should be 500 psi.
4. Gearbox shift cylinder leaking internally.
-- Check cylinder. Repair or replace if defective.
SKYJACK, Page 22
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 4 - Troubleshooting Information
Service and Maintenance
Hydraulic System (Continued)
4.2-11. Outrigger Inoperative
1. Outrigger holding valve 2H-17A not shifting.
-- Check valve and reinstall. Replace if defective.
2. Outrigger valve 4H-71, 4H-72, 4H-73, 4H-74, 4H-75, 4H-76, 4H-77 or 4H-78 not shifting.
-- Depress manual override on each valve. If outriggers extend and retract, clean valves and
reassemble. Replace if defective.
3. Outrigger check valve CV-7, CV-8, CV-9 or CV-10 not shifting.
-- Check valve and reinstall. Replace if defective.
4. Gearbox valve 2H-44 stuck open.
-- Check valve and reinstall. Replace if defective.
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
SKYJACK, Page 23
Notes
SKYJACK, Page 24
Full-Size Rough Terrain Series
Models 8831E & 8841E
155154
Section 5
Procedures
Table of Contents
Service and Maintenance
General..........................................................................................................................................................................3
Safety and Workmanship..............................................................................................................................................3
Platform
5.1-1 PQ Controller Wiring..........................................................................................................................................3
5.1-2 PQ Controller Wiring Diagram...........................................................................................................................4
Base
5.2-1
5.2-2
5.2-3
5.2-4
5.2-5
5.2-6
5.2-7
5.2-8
5.2-9
System Relief Pressure Adjustment...................................................................................................................5
Gearbox Relief Pressure Adjustment.................................................................................................................5
Brake Pressure Adjustment................................................................................................................................5
Brake Adjustment...............................................................................................................................................6
Proximity Switch Replacement and Adjustment Procedure..............................................................................7
Proximity Switch Test Procedure........................................................................................................................8
Wheel Bolt/Nut Inspection and Torquing Procedure.........................................................................................9
Wheel Reinstallation and Torquing Procedure..................................................................................................9
Front Axle Hub Procedure................................................................................................................................10
Sevcon Calibration Tool
5.3-1
5.3-2
5.3-3
5.3-4
Sevcontroller Adjustment and Diagnostics......................................................................................................12
Traction Controller Pin Reference....................................................................................................................17
Tachometer Board Pin Reference....................................................................................................................19
Tachometer Generator Testing Procedure.......................................................................................................20
Outrigger Option
5.4-1
5.4-2
5.4-3
5.4-4
5.4-5
5.4-6
Outrigger Mechanical Limit Switch Wiring Diagram........................................................................................21
Auto-Leveling Outrigger Setting and Error Codes...........................................................................................22
Auto-Leveling Outrigger Error Code Breakdown.............................................................................................23
Hand Held Calibration/Diagnostic Tool Key Functions....................................................................................24
Outrigger Control Module Instructions............................................................................................................25
Auto-Leveling Outrigger Control Module Pin Reference Chart.......................................................................28
Load Sensing System - CE
5.5-1
5.5-2
5.5-3
5.5-4
5.5-5
5.5-6
Control Module Pin Reference Chart...............................................................................................................29
LED Error Codes - Quick Reference Chart......................................................................................................30
LED Error Codes - Code Breakdown Chart.....................................................................................................31
Control Module Load Calibration - Code Messages & Definitions..................................................................33
Control Module Load Calibration Procedure...................................................................................................37
Curve/Group Codes Chart...............................................................................................................................41
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 1
5
Notes
SKYJACK, Page 2
DC Electric Scissor Lifts
Compact Series
155147
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.
Platform
5.1-1 PQ Controller Wiring
1
BOTTOM VIEW
2 3
4
8
7
5
6
R1
-
BOTTOM VIEW
NC1 C1 NO1
+
NC2 C2 NO2
PIN 9 YELLOW (24)
YEL
STEER LEFT
PIN 8 GREEN (23)
GRN
STEER RIGHT
PIN 6 BROWN (59)
BRN
SPEED
PIN 6 BLACK (02)
VIO
ENABLE OUTPUT
PIN 5 BLACK (02)
NEGATIVE
BLUE
MAIN INPUT POWER
PIN 3 ORANGE (B)
REVERSE/DOWN
PIN 2 WHITE/ORANGE (A)
FORWARD/UP
RED
ENABLE INPUT POWER
PIN 4 BLUE (12D)
PIN 1 RED (12C)
1 2 3 4 5 6 7 8 9
PIN 9
PIN 8
PIN 7
PIN 6
PIN 5
PIN 4
PIN 3
PIN 2
PIN 1
YELLOW (24)
GREEN (23)
BROWN (59)
BLACK (02)
BLACK (02)
BLUE (12D)
ORANGE (B)
WHITE/ORANGE (A)
RED (12C)
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 3
Service and Maintenance
Section 5 - Procedures
5.1-2 PQ Controller Wiring Diagram
SKYJACK, Page 4
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Base
5.2-1 System Relief Pressure Adjustment
1. Locate the System Pressure Quick Disconnect
Port on the Main Manifold. Refer to Section 3
“Hydraulic Manifold And Port Identification” for
location.
2. Install a Calibrated 3000 PSI Gauge to the System
Pressure Quick Disconnect Port.
3. Remove the Platform Control Box from the
Guardrail and disconnect from the Main Control
Cable.
4. Locate the Main Control Cable Plug in the
Hydraulic/ Electric side of cabinet.
5. Disconnect the Main Cable and connect the
Platform Control Box into the Plug.
6. At the Main Manifold, loosen the Locknut on
the System Relief Valve R1. Refer to Section 3
“Hydraulic Manifold And Port Identification” for
location.
7. Select Drive with the Lift/Off/Drive Select Switch
on the Platform Control Box.
8. Engaged Steer Right and hold.
9. Observe reading on Gauge. Adjust the R1
System Relief Value listed on the Serial Number
Plate. Turning the stem on the Relief Valve
clockwise increases pressure. Turning the stem
counterclockwise decreases pressure.
10. Release Steer Switch and tighten the Locknut.
11. Remove the gauge from the System Pressure Test
Port.
5.2-2 Gearbox Relief Pressure Adjustment
1.
2.
3.
4.
5.
Service and Maintenance
6.
7.
8.
Observe reading on gauge. Adjust Gearbox Relief
Valve (R2) to obtain 500 PSI. Turning the stem
on the Relief Valve clockwise increases pressure.
Turning the stem counterclockwise decreases the
pressure.
Reconnect wiring to the Proximity Switches and
tighten the Locknut on the Relief Valve.
Remove the gauge form the Gearbox Pressure
Test Port.
5.2-3 Brake Pressure Adjustment
1.
2.
3.
4.
5.
6.
7.
8.
Locate Pressure Switch (PS2) on Main Manifold.
Refer to Section 3 “Hydraulic Manifold And Port
Identification” for location.
Disconnect spade connectors for pressure switch
wires.
Turn the black knurled portion of the pressure
switch body counter-clockwise until movement
stops.
Turn the black knurled portion of the pressure
switch clockwise for only four full revolutions and
reconnect spade connectors.
Install 3000 PSI Gauge to quick coupler on main
manifold. Refer to Section 3 “Hydraulic Manifold
And Port Identification” for location.
Operate Drive slowly while observing gauge. It
should read a minimum of 800 PSI.
If pressure needs to be increased, turn black
knurled portion clockwise. If pressure need to
be decreased turn counter-clockwise.
Once 800 PSI is obtained, brake pressure
adjustment is complete.
Locate the Gearbox Quick Disconnect Port on
the Main Manifold. Refer to Section 3 “Hydraulic
Manifold And Port Identification” for location.
Install a Calibrated 1000 PSI Gauge to the
Gearbox Quick Disconnect Port.
At the Main Manifold, loosen the Locknut on
the Gearbox Relief Valve R2. Refer to Section 3
“Hydraulic Manifold And Port Identification” for
location.
Disconnect the shift sensors plug (CN6) located
near the top left corner of the main control board.
Refer to Section 3.
Select Platform Controls. The Small Pump (P2)
will start operating.
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 5
Service and Maintenance
Section 5 - Procedures
5.2-4 Brake Adjustment
1.
2.
3.
4.
5.
6.
7.
8.
Place machine on level surface and block wheels
to prevent rolling in either direction.
Unplug battery , disconnect plug.
Locate brake manifold in hydraulic/electric side
cabinet.
Depress black knob.
Grasp the red plunger and rapidly depress until
plunger can no longer be depressed and the
brake is fully released.
Inspect caliper and brake pads for binding. Pads
should move freely on the pins.
Remove pin from brake cylinder clevis and brake
actuating lever. Rotate actuating lever counterclockwise to the end of it’s stroke.
Adjust brake cylinder clevis to obtain 1/2” between
the center of the holes of the actuating lever and
brake cylinder clevis. See Figure 5-1. Tighten
jamb nut on brake cylinder rod against clevis.
Note: It is important that the brake cylinder
reaches it’s maximum stroke before the caliper
to prevent damage to the caliper.
Figure 5-2. Plug Removal and Replacement
11. Using a 1/4” Allen wrench, turn brake adjuster
counter-clockwise until it bottoms out. Turn Allen
wrench 1/2 turn clockwise to set adjustment.
12. Replace plastic plug back into the end of the
caliper shaft.
13. Pull out black knob to reset brake circuit.
14. Remove Wheel blocks. Reconnect battery,
disconnect plug. Operate drive several times to
seat pads to brake disc.
Figure 5-1. Brake Adjustment
9.
Reinstall clevis pin back into the clevis actuating
lever.
10. Remove plastic plug located on the end of the
caliper shaft. See Figure 5-2.
SKYJACK, Page 6
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
5.2-5 Proximity Switch Replacement and Adjustment Procedure
Figure 5-3. Traction Motor/Lift Pump Proximity Switch Location
1.
2.
3.
4.
To replace a proximity switch. First select either: lift mode to replace the PR2 proximity switch or traction mode
to replace the PR1 proximity switch.
Disconnect the main battery disconnect plug.
Unplug the connector for the electrical wiring to the proximity switch you want to replace.
Back off the lock nut and remove the proximity switch from the gearbox.
NOTE
There should be threads of the proximity switch showing when it bottoms out. Then back off the switch
two full turns. This insures the switch is set at the proper distance from it’s sensing surface of 2mm.
5.
6.
7.
8.
To install the new proximity switch turn the switch in until it bottoms out.
Tighten the lock nut down while holding the proximity switch in it’s adjusted position.
Reconnect the connector for the electrical wiring to the proximity switch.
Reconnect the main battery disconnect plug.
WARNING
Make sure the correct proximity switch is adjusted. If the switch you are adjusting does not match
the selected mode you will damage the component.
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 7
Service and Maintenance
Section 5 - Procedures
5.2-6 Proximity Switch Test Procedure
Figure 5-4. Proximity Switch
SKYJACK, Page 8
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
5.2-7 Wheel Bolt/Nut Inspection and
Torquing Procedure
It is necessary to check the torque on all wheel nuts
and wheel bolts at pre-delivery, after 8 hours of operation and at weekly intervals using the following
procedure:
1.
Confirm that each wheel fastener is torqued to
140 ± 5 ft-lb. All fasteners must be torqued using
the tightening sequence shown below.
1
3
1.
Inspect wheel fastener threads for damage of
defects. Replace if defective.
2.
Clean the mounting surfaces of the hub and wheel
rim of debris, rust, excess paint, etc.
3.
Mount wheel on the hub, centering mounting
holes on the wheel studs or bolt holes. Use
appropriate lifting device as required.
4.
Install wheel nuts or wheel bolts and hand tighten
to center the rim.
5.
Torque nuts or bolts to approximately 50 ft-lb using
the tightening sequence in procedure 5.2-7.
6.
Torque again to 100 ft-Ib using the same
sequence.
7.
Torque again to 140 ft-lb using the same
sequence.
8.
Repeat the tightening sequence to confirm that
none have changed from 140 ft-lb. If any are
found below 140 ft-lb, repeat complete sequence
until there is no change in torque values. If
possible, drive the machine prior to checking
torques.
9.
Check torque values after 8 hours of operation
and then at weekly intervals.
4
5
2
Figure 5.5 Wheel Fastener Tightening Sequence
2.
5.2-8 Wheel Reinstallation and Torquing
Procedure
When a wheel/tire assembly has been removed or
replaced, it will be necessary to follow the procedure
below to ensure proper installation:
Again, confirm that each wheel fastener is torqued
to the specified tolerance. Re-torque as necessary
until all fasteners are properly torqued.
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 9
Service and Maintenance
Section 5 - Procedures
5.2-9 Front Axle Hub Procedure
For front axle hub components, refer to your aerial
platform’s parts manual.
7
7.
Pull cotter pin (item 2) out of spindle arm (item 11)
and then remove castle nut (item 3), washer (item
4) and outer bearing cone (item 5). Dispose of
dust cap, cotter pin, castle nut, washer, and outer
bearing cone.
8.
Flip hub over and then remove and discard inner
bearing cone (item 8) and grease seal (item
10).
9.
Remove and discard both inner and outer bearing
cups (items 6 & 8) from hub.
11
5
10
4
9
8
6
3
2
1
10. Remove grease from spindle arm and hub and
look for signs of visible damage. If damage is
found on the hub or on the spindle arm, contact
Service Department immediately using information
found in page 2 for further instructions.
11. Press new bearing cups (items 6 & 8) into hub.
Figure 5.6 Front Axle Hub
NOTE
Keep work area clean and visibly free from
contamination at all times.
12. Pack replacement inner and outer bearings by
either pressing wheel bearing grease into each
roller by hand or using a bearing packer and
grease gun. Ensure that grease is forced into all
surfaces of the bearing.
1.
Ensure aerial platform is parked on a firm,
level surface. Chock or block the wheels to
keep the aerial platform from rolling forward or
backward.
NOTE
Use only recommended wheel bearing
grease - NLGI (National Lubricating Grease
Institute) Grade #2 or equivalent.
2.
Fully lower the platform.
3.
Using a suitable lifting device or outriggers
(if equipped), lift the end of the aerial platform
with the steer axle.
NOTE
The bearings must be packed before
installing.
CAUTION
Use a suitably-rated support stand to
support aerial platform while performing
the following operations.
4.
Turn emergency main power disconnect switch
to “ ” off position.
5.
Remove wheel assembly.
6.
Remove dust cap (item 1) to access internal
components of hub assembly.
SKYJACK, Page 10
13. Install replacement inner bearing in the race and
then seat the new grease seal. Flip hub over and
install replacement outer bearing.
14. Install hub on the spindle.
15. Install replacement washer and replacement
castle flanged nut. Hand tighten the castle flanged
nut until it touches the washer. Turn hub by hand
to ensure smooth running. No resistance should
be felt at this time.
16. Take a torque wrench and set it at 30 ft-lb, and
while continuously rotating hub, tighten castle
flanged nut. While hub is being turned and nut
tightened, resistance will increase.
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
17. Using an open-ended wrench, loosen castle
flanged nut a 1/4 turn while turning the wheel hub.
It should turn easily. The nut should not come
completely loose.
18. Using a torque wrench set to 15 ft-lb, tighten
castle flanged nut. Turn wheel hub and check for
smooth turning.
19. Check for alignment of the castle flanged nut with
one of the cross holes in spindle arm. If required,
loosen nut to align with nearest hole. Use an
open-ended wrench to be able to see the cross
holes. The nut should not be turned more than
15 degrees. Secure with new cotter pin. Check
again for smooth turning of wheel hub. The wheel
hub should turn but with slight resistance.
20. Grab the top and bottom of the hub and check
for play. There should be no evidence of play.
21. Install dust cap back on hub assembly.
22. Install wheel assembly. Torque nuts or bolts to
140 ft-lb.
23. Repeat steps 5 to 22 for the other hub
assembly.
24. Lower the aerial platform.
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 11
Service and Maintenance
Section 5 - Procedures
Sevcon Calibration Tool
2.
5.3-1 Sevcontroller Adjustment and
Diagnostics
Locate controller adjustment socket, as shown
in Figure 5-8, and connect hand-held calibrator.
Power up the Platform by selecting platform
controls using key switch at the Platform Control
Box.
WARNING
WARNING
All machine functions remain operational
while calibrator is plugged in.
Before making any adjustments, you must
determine the revision of your calibrator.
When the calibrator is plugged in, turn
the power on and push and hold down
the “-” button for 5 seconds.
Adjustment Procedure
The following procedure is relevant for the drive controller, except where otherwise noted. The controller is preset to factory specifications but may be readjusted.
A hand-held calibrator (Figure 5-7, Skyjack part
#701051) can be plugged into the controller adjustment
socket and used to digitally view or reset the parameters. The current value of these parameters will be
shown on an LCD display. Additionally, the calibrator
can perform certain measurements that can be useful
for diagnostic purposes.
The calibrator has a bar display, operated by the
SELECT button, showing the parameters/ measurement selected and an LCD display showing values
that, provided they are parameters, may be adjusted
using the +/- buttons. This unit can also be used to
perform certain tests on the control wiring and controller (joystick).
1.
Locate Sevcon inside Electrical/Hydraulic Cabinet
on the right side of the machine.
3.
4.
5.
No LED segments on the bar display will be lit
and the minutes/seconds count is displayed.
The hours count is displayed by pressing the (-)
button and the 1000’s of hours count is displayed
by pressing the (+) button as described later in
this section. Pressing the select button reverts the
calibrator to its normal operation and the IMax
LED will be lit.
When the desired parameters has been selected,
on the left side of the calibrator, it may be adjusted
by pressing the + or - button on the right side of
the calibrator. (For calibrator Revision .07,
see Table 5-1A) or (for calibrator Revision .10,
see Table 5-1B).
When the calibrator is unplugged the Sevcontrol
will ‘memorize’ the new parameters settings.
Controller
Adjustment Socket
Figure 5-7. Sevcon Calibrator
SKYJACK, Page 12
Diagnostic LED
Figure 5-8. Traction Controller
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
Table 5-1A. Sevcontrol Adjustable Parameters (Software Revision .07)
Sequence No.
1
2
3
4
5
6
7
8
9
10
Parameter
IMAX
Maximum Controller Current
ACCEL
Acceleration Delay
DECEL
Deceleration Delay
CREEP
Maximum Controller Current
MAX
Maximum Allowed Speed
ELEVA
Elevated Cutback Speed
TILT
Tilted Cutback Speed
CONSTANT SPEED CONTROL
Proportional Gain (Do Not Adjust)
CONSTANT SPEED CONTROL
Integral Gain (Do Not Adjust)
BATTERY
Low Battery Cut-out
Min.
Max.
Units
Default
50
600
Amps
400
1
3
Seconds
1
0.1
3
Seconds
0.1
0
10
% of Max. Speed
2
5
100
% of Max. Possible
Speed
80
5
25
% of Max. Speed
15
5
75
% of Max. Speed
50
0
150
Counts
30
1
100
Counts
20
25
40
Volts
25
3
Seconds
0.5
11
Not Used
12
Not Used
13
BRAKE
Brake Personality Timer
0
60285AB
NOTE: Skyjack does NOT recommend exceeding the default settings.
WARNING
Before making any adjustments, you must determine the revision of your software. When
the calibrator is plugged in, turn the power on and push and hold down the “-” button for
5 seconds.
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 13
Service and Maintenance
Section 5 - Procedures
Table 5-1B. Sevcontrol Adjustable Parameters (Software Revision .10)
Sequence No.
1
2
3
4
5
6
7
8
9
10
Parameter
IMAX
Maximum Controller Current
ACCEL
Acceleration Delay
DECEL
Deceleration Delay
CREEP
Maximum Controller Current
MAX
Maximum Allowed Speed
ELEVA
Elevated Cutback Speed
TILT
Tilted Cutback Speed
CONSTANT SPEED CONTROL
Proportional Gain (Do Not Adjust)
CONSTANT SPEED CONTROL
Integral Gain (Do Not Adjust)
BATTERY
Low Battery Cut-out
Min.
Max.
Units
Default
Settings*
8841E
Modified
50
600
Amps
400
400
1
3
Seconds
1
1
0.1
3
Seconds
0.1
0.1
0
10
% of Max. Speed
2
2
5
100
% of Max.
Possible Speed
80
80
5
25
% of Max. Speed
15
8
5
75
% of Max. Speed
50
50
0
150
Counts
30
30
1
100
Counts
20
20
25
40
Volts
25
25
11
Not Used
12
Not Used
13
14
ELEVATED CURRENT
Max. Current When Elevated
BRAKE
Brake Personality Timer
50
400
Amps
230
230
0
3
Seconds
0.5
0.5
60286AB
* All aerial platforms will use default settings, unless specified.
NOTE: Skyjack does NOT recommend exceeding the default settings.
WARNING
Before making any adjustments, you must determine the revision of your software. When
the calibrator is plugged in, turn the power on and push and hold down the “-” button for
5 seconds.
SKYJACK, Page 14
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
Hour Counter
The hours counter records pulsing hours, and is displayed when the calibrator is first plugged in. Once the SELECT
button is pressed, the calibrator reverts to normal operation.
Initially a minute/seconds count is displayed. By pressing the (-) button, hours are displayed
and by pressing the (+) button 1000’s of hours are displayed.
Releasing the buttons reverts back to the minute/seconds display. The decimal point blinks every second during
drive. The counter will record up to 65,500 hours before rolling back to 0.
Diagnostic Procedure
WARNING
All machine functions remain operational while calibrator is plugged in.
The last five segments on the bar display are as follows.
BATT
Displays the current battery voltage. Pressing the (+) button displays the highest voltage, for the machine, that the Sevcontrol has recorded.
MOTOR V.
Displays the motor voltage as the machine is being driven.
MOTOR AMP Displays the motor current as the machine is being driven.
TEMP
Displays the temperature of the MOSFET heat sink in °C. Pressing the (+) button displays the highest temperature recorded and pressing the (-) button displays the lowest temperature recorded.
TEST
This invokes the diagnostic test routines to check machine switches, joystick,
control wiring etc.
With the calibrator connected and the platform powered up, as described in the adjustment procedure. Use the
SELECT button to select the test segment. If the SELECT button is pressed at any time during the test, the test will
be terminated and the minute/seconds count will be displayed.
The first test displayed, on the drive Sevcontrol, is the joystick input. This displays the input as 0-100% as joystick
is moved from min. to max.
Pressing the (+) and (-) buttons step through the tests as shown in Table 5-2. After the final test, the sequence will
loop back to the joystick input test, then test 1.
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 15
Service and Maintenance
Section 5 - Procedures
Table 5-2. Sevcontrol Test Sequence
Drive Controller Test Sequence
Sequence No.
Test
Display
-
Controller (Joystick) Input
0 to 100%
1
Forward Switch
CL/OP
2
Reverse Switch
CL/OP
3
Tachometer Input
0 to 100%
4
Elevated Position
CL=Collapsed OP=Lifted
5
Tilt Switch
CL=Level OP=Tilt
6
Pump/Traction Switch
CL=Pump Mode OP=Traction Mode
7
Actual Direction, Tachometer Output
CL= Reverse OP=Forward
8
Lift Transmission Position Sense
CL = Engaged OP = Disengaged
9
Traction Transmission Position Sense
CL = Engaged OP = Disengaged
10
First Error Latch
Value= Flash Code
NOTE: CL=Switch Closed, OP=Switch Open
60287AC
SKYJACK, Page 16
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
5.3-2 Traction Controller Pin Reference
Diagnostic LED
Pins are identified from left to right
Pin #1 thru Pin #17
Pin 11- Reverse direction input from joystick
24 volts = reverse selected.
Test between pin 11 and wire #02.
Pin 12- Speed signal from pin 2 on tachometer card.
7.5 volts with joystick in neutral.
7.5 volts to 15 volts = reverse.
7.5 volts to 0 volts = forward.
Test between pin 12 and wire #02.
Pin 1- Brake relay control.
Brings B- to brake relay (25CR).
Test between pin 1 and wire #10A.
Pin 2- Direction signal from pin 4 of tachometer card. Determines direction.
0 volts = forward.
15 volts = reverse.
Test between pin 4 and wire #02.
Pin 3- Not used.
Pin 4- High Drive Cut-out.
24 volts high drive enabled.
0 volts high drive disabled.
Test between pin 4 and wire #02 with platform fully lowered.
Pin 5- 24 volt input from line contactor.
Test between pin 6 and wire #02.
Pin 6- 48 volt input from line contactor.
Test between Pin 6 and wire #02 with Key Switch on.
Pin 7- Pin 13- Speed sensing enable.
Determines lift or drive mode.
2 volts = drive. Speed sensing enabled.
4 volts = lift. Speed sensing disabled.
Anything above 2.52 volts = Lift
Test between pin 13 and wire #02.
Pin 14- Accelerator input.
3.8 to 4.2 volts with joystick in neutral and
key switch on.
3.5 volts = slow speed.
0 volts = fast speed.
Test between pin 14 and wire #02.
Pin 15- Forward contactor output.
Brings B- to forward drive contactor.
Test between pin 15 and wire #10A.
Pin 16- Drive/Lift Select.
0 volts = drive
24 volts = lift
Test between pin 16 and wire #02.
Pin 17- Reverse contactor output.
Brings B- to reverse drive contactor.
Test between pin 17 and wire #10A.
Tilt switch input.
24 volts = full speed
0 volts = 50% full speed.
Test between pin 7 and wire #02.
Pin 8- Forward/Up input from joystick.
24 volts = drive forward or lift up selected.
Test between pin 8 and wire #02.
Pin 9- Not used
Pin 10- Not used
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 17
Service and Maintenance
Section 5 - Procedures
Table 5-3. Traction Controller Flash Fault Pin References
Number of Flashes
2
3
4
5
6
7
8
10
11
X
X
12
13
14
1
2
3
4
5
X
Pin Reference Number
6
X
X
7
8
X
X
X
X
X
9
10
11
12
X
13
X
14
X
15
16
X
X
X
X
17
X
X
X
60288AA
SKYJACK, Page 18
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
5.3-3 Tachometer Board Pin Reference
Service and Maintenance
Pin 7- Battery Negative
Pin 8- Lift mode selected.
24 volts when lift selected.
Test between Pin 8 and wire 02.
Pin 9- Drive mode selected.
24 volts when drive selected.
Test between Pin 9 and wire 02.
Figure 5-9. Tachometer Board
Pin 10- Speed sensing enable. To Pin 13 on controller.
Drive mode = 2 volts
= speed sensing enabled.
Lift mode = 4 volts
= speed sensing disabled.
Test between pin 10 and wire #02.
Term A-48 volt input from relay C10D-12.
Pin 11- Spike suppression for 24 volt B+.
Term B-24 volt input from wire #10B.
Test between terminal B and wire 02.
Pin 12- Not used
Term C-24 volt output to drive, steer and line contactors. Fused from terminal B.
Test between terminal C and wire 02.
Pin 1- Battery negative
Pin 2-
Pin 13- Spike suppression B-.
Pin 14- Not used`
Pin 15- Not used
Pin 16- Not used
Speed signal to Pin 12 of controller.
7.5 volts with key switch on and platform
selected.
7.5 volts to 15 volts = reverse
7.5 volts to 0 volts = forward
Test between pin 2 and wire #02.
Pin 3- Tachometer generator input.
Pin 4-
Direction signal to Pin 2 of controller.
0 volts = forward
15 volts = reverse
Test between pin 4 and wire #02.
Pin 5- Tachometer generator input.
Pin 6- Steer enable
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 19
Service and Maintenance
Section 5 - Procedures
5.3-4 Tachometer Generator Testing
Procedure
1.
2.
Locate tachometer generator on back of drive
motor. Remove rubber boot from the rear of the
tachometer generator.
NOTE
Wires must be reattached to the same
terminals as they were removed from or
the Sevcon controller will not function
when reassembled.
6.
Energize drill and read voltage on meter. At
1000-RPM voltmeter should indicate (20.8) volts.
If reading is lower the tachometer generator is
defective.
7.
Put the drill in reverse and energize drill, read
voltage on meter. At 1000-RPM voltmeter
should read (-20.8) volts. If reading is lower the
tachometer generator is defective.
Note
Steps #6 and #7, the voltage should be a
smooth incline to proper voltage. If voltage
is erratic it may affect the performance of
the machine.
Mark the location of the wires attached to the
generator and remove wires.
NOTE
Do not attempt to remove the tachometer
generator from mounting plate until it has
been determined to be defective.
3.
Remove the four 5/16-18 x 1-1/2” bolts securing
the tachometer generator mounting plate to the
rear of the motor.
4.
Remove the coupler half from the tachometer
generator and attach generator to a drill with a
1000-RPM rating.
5.
Attach a voltmeter to the terminals on the rear of
the tachometer generator and set the meter for
D.C. voltage.
1.
2.
3.
4.
5.
6.
GEAR BOX
DRIVE MOTOR
COUPLER HALF
TACHOMETER GENERATOR MOUNTING
PLATE
COUPLER HALF
TACHOMETER GENERATOR
1
2
3
4
5
6
Figure 5-10. Traction Generator
SKYJACK, Page 20
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
Outrigger Option
5.4-1 Outrigger Mechanical Limit Switch Wiring Diagram
O.R. UP SWITCH (NO) - BLUE & BROWN
O.R. UP SWITCH (NO) - BLUE & BROWN
BACK VIEW - MALE
3
2
4
1
BACK VIEW - MALE
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
BACK VIEW - FEMALE
LEFT FRONT OUTRIGGER
3 PIN 1 - BLACK (10A)
PIN 2 - BLACK / WHITE (65A)
PIN 3 - BLUE (62)
4 PIN 4 - BROWN (61)
2
1
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
LEFT FRONT OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE)
2
4
1
RIGHT FRONT OUTRIGGER
PIN 1 - BLACK (10A)
PIN 2 - WHITE (66A) BACK VIEW - FEMALE
PIN 3 - GREEN (63)
2
3
PIN 4 - RED (62)
1
4
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
RIGHT FRONT OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE)
LEFT FRONT
SIXTEEN PIN CONNECTOR PLUG
OUTRIGGER PCB ON ELECTRICAL PANEL
PIN 1 - 61 RED
PIN 2 - 62 GREEN
PIN 3 - 62 RED
PIN 4 - 63 GREEN
PIN 5 - 63 RED
PIN 6 - 64 GREEN
PIN 7 - 64 RED
PIN 8 - 10 GREEN
3
PIN 9 - 10 BLACK (2)
PIN 10 - 10 BLACK (2)
PIN 11 - 10 BLACK (2)
PIN 12 - 10 BLACK (2)
PIN 13 - (N/U)
PIN 14 - (N/U)
PIN 15 - (N/U)
PIN 16 - 65 GREEN / BLACK
RIGHT FRONT
RIGHT REAR
LEFT REAR
TO CONTROL MODULE
PIN 1 - 65 GREEN / BLACK
PIN 2 - 65A WHITE
PIN 3 - 66A WHITE
PIN 4 - 67A WHITE
PIN 5 - 68A WHITE
PIN 6 - (N/U)
O.R. UP SWITCH (NO) - BLUE & BROWN
O.R. UP SWITCH (NO) - BLUE & BROWN
BACK VIEW - MALE
3
2
4
1
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
BACK VIEW - FEMALE
2
1
LEFT REAR OUTRIGGER
3 PIN 1 - BLACK (10A)
PIN 2 - WHITE (68A)
PIN 3 - GREEN (01)
4 PIN 4 - RED (64)
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
LEFT REAR OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE)
BACK VIEW - MALE
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
3
2
4
1
RIGHT REAR OUTRIGGER
PIN 1 - BLACK (10A)
PIN 2 - WHITE (67A) BACK VIEW - FEMALE
PIN 3 - GREEN (64)
2
3
PIN 4 - RED (63)
1
4
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
RIGHT REAR OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE)
M11449AC
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 21
Service and Maintenance
Section 5 - Procedures
5.4-2 Auto-Leveling Outrigger Setting and Error Codes
Reading the Codes:
In order to read the fault codes, a sequence of pauses and flashes can be seen on the LED mounted on the outrigger
control module. The codes are continuously displayed by the LED until the fault is cleared, the outrigger control
module is reset and no longer detects the fault, or idle timeout becomes active.
The sequence is as follows:
1. Half second flashes followed by half second pauses indicate the first digit.
2. A 2.5 second pause.
3. Half second flashes followed by half second pauses indicate the second digit
4. A 5 second pause.
Repeat steps 1-4
Since the outrigger control module only reports one error, only one code can be read from the LED per instance.
If the error is cleared and another error is present, it will then be presented.
LED Error Codes
EVERYTHING OK
ON
VEHICLE TILTED
1/1
OUTRIGGERS CANNOT BE MOVED!
1/2
OUTRIGGERS NOT HOME
2/2
NOT FULLY LEVEL
2/1
RELEASE OUTRIGGER DEMAND!
5/5
CHECK OUTRIGGER SUPPLY (P4-9)
5/2
CANNOT LEVEL : BAD TILT SENSOR
7/1
OUTRIGGERS MANUALLY CONTROLLED!
6/6
TESTING HWFS
7/8
B+ SUPPLY TOO LOW
5/1
STARTUP!
7/7
FAULT: BAD SLAVE MICRO
7/5
FAULT: BAD TILT SENSOR
7/1
FAULT: BAD HWFS
7/2
FAULT: P2-5 FAULTY
8/1
FAULT: P2-6 FAULTY
8/2
FAULT: P2-8 STUCK ON
8/3
FAULT: P2-8 ALWAYS ON
8/4
FAULT: P2-8 ALWAYS OFF
8/5
FAULT: HWFS STALLED!
SKYJACK, Page 22
7/6
60402AB
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
5.4-3 Auto-Leveling Outrigger Error Code Breakdown
RELEASE OUTRIGGER DEMAND!
5/5
Check inputs on P2 pins 5 & 6 - the “auto-level” or “auto-retract” input is active at power-on or
when it is not allowed to carry out the function.
OUTRIGGERS CANNOT BE MOVED!
1/2
Check input on P2 pin 10 – “auto-level” or “auto-retract” has been requested but the platform
is elevated.
NOT FULLY LEVEL
2/1
The outrigger legs are all down (touching the ground) but the platform is not fully level.
OUTRIGGERS NOT HOME
2/2
The outrigger legs are not all down (touching the ground) and also are not all home (fully
retracted).
B+ SUPPLY TOO LOW
CHECK OUTRIGGER SUPPLY (P4-9)
5/1
5/2
Check that the battery voltage is not too low.
VEHICLE TILTED
1/1
These is not a true fault – move the vehicle to level ground!
TESTING HWFS
7/8
STARTUP!
7/7
These are not true faults unless they do not clear – the start-up tests should only occur for a
short time.
OUTRIGGERS MANUALLY CONTROLLED!
6/6
This is not a true fault – the outriggers are being manually operated (one or more outrigger legs
on P4 pins 1-8 is high, when the outrigger control module is not active.
CANNOT LEVEL (BAD TILT SENSOR)
FAULT: BAD TILT SENSOR
FAULT: BAD HWFS
FAULT: BAD SLAVE MICRO
FAULT: HWFS STALLED!
FAULT: P2-5 FAULTY
FAULT: P2-6 FAULTY
FAULT: P2-8 STUCK ON
FAULT: P2-8 ALWAYS ON
FAULT: P2-8 ALWAYS OFF
7/1
7/1
7/2
7/5
7/6
8/1
8/2
8/3
8/4
8/5
These are internal faults. If the fault persists after the power has been reset, the outrigger control
module may need to be replaced.
DC Electric Scissor LIfts
Compact Series
155147
60412AB
SKYJACK, Page 23
Service and Maintenance
Section 5 - Procedures
5.4-4 Hand Held Calibration/Diagnostic Tool Key Functions
WARNING
Only trained and authorized personnel shall be permitted to service an aerial platform.
WARNING
Read all instructions closely before attempting each phase of this procedure.
SYMBOL
KEY FUNCTIONS
ESC/ENTER BUTTONS
To move back and forth between menu and sub-menu
LEFT/RIGHT BUTTONS
Select menus and setting to be adjusted
UP/DOWN BUTTONS
Adjust setting values
Outrigger Settings
SJIIIB
6826E
SJIIIB
6832E
7027
7127
7135
8243
8850
8831
8831E
8841
8841E
9241
9250
ANSI/CSA
4
4
5
4
4
4
4
5
5
5
5
-
5
CE
-
9
-
9
9
-
-
8
8
8
8
8
8
Models
SKYJACK, Page 24
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
5.4-5 Outrigger Control Module Instructions
When EZcal hand-held device is connected to the OCM1 control module, a two line displays shows various menus
and settings. At any time the top line of the display describes the currently selected menu and the bottom line shows
the currently selected item in that menu.
Six buttons on EZcal allow easy navigation through the menus:
 and  change the selected item (the bottom line display)
ENTER enters the selected new menu when available (top line display changes)
 and  adjusts the selected item when available
ESC exits the current menu back to the previous menu
TOP LEVEL MENU OPTIONS
HELP
Select this menu to see a description of current OCM1 status
DIAGNOSTICS Select this menu to see switch input status & logged data
ACCESS LEVEL Select this menu & enter correct code to enable adjustments and calibrations
ADJUSTMENTS Select this menu to see and adjust OCM1 settings
NOTE: this menu provides for adjustments which might be needed for different work activities
SETUPS
Select this menu to carry out initial set-up of the OCM1
NOTE: this menu provides for set-ups which are needed to configure the OCM1 for a particular vehicle
HELP MENU OPTIONS
(help message)
A message displays current OCM1 status, indicating if everything is OK or if there is an error code (see LED Error Codes - Table 5.3)
DIAGNOSTIC MENU OPTIONS
SYSTEM
Select this menu to see general OCM1 system information
SWITCHES
Select this menu to see switch input status
OUTPUTS
Select this menu to see OCM1 output status
LOG
Select this menu to see logged information
DIAGNOSTIC / SYSTEM MENU OPTIONS
OUTRIGGERS
Displays various status during the auto-level function
TILT
Displays vehicle tilt in “X” and “Y” orientations measured by integral sensor
TILTED
Displays whether vehicle is tilted (YES or NO)
BATTERY
Displays battery supply voltage (on P2-12)
DIAGNOSTIC / SWITCHES MENU OPTIONS
LR/P2-1
High when the left rear outrigger is in contact with the ground
RR/P2-2
High when the right rear outrigger is in contact with the ground
RF/P2-3
High when the right front outrigger is in contact with the ground
LF/P2-4
High when the left front outrigger is in contact with the ground
EXTEND/P2-5
High to activate the auto-level function
RETRACT/P2-6 High to activate the auto-retract function
ELEV/P2-10
High when the scissor stack is stowed (“elevated” input indicates that the vehicle is stowed).
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 25
Service and Maintenance
Section 5 - Procedures
DIAGNOSTIC / OUTPUTS MENU OPTIONS
LAMP/P2-7
Displays state of outrigger control box light
STABLE/P2-8
Displays state of stable (all legs touching the ground) output
TILT/P2-9
Displays state of tilt
LRe/P4-1
Displays state of left rear outrigger extend valve
RRe/P4-2
Displays state of right rear outrigger extend valve
RFe/P4-3
Displays state of right front outrigger extend valve
LFe/P4-4
Displays state of left front outrigger extend valve
LRr/P4-5
Displays state of left rear outrigger retract valve
RRr/P4-6
Displays state of right rear outrigger retract valve
RFr/P4-7
Displays state of right front outrigger retract valve
LFr/P4-8
Displays state of left front outrigger retract valve
P4-9 MON
Displays the voltage to the outrigger valve (can only be seen when operating in auto-
level or retract)
DIAGNOSTIC / LOG MENU OPTIONS
MAX.BATTERY Displays maximum recorded battery supply voltage
OCM1 version Displays part number and software version of GP106
EZcal version
Displays software version of EZcal
ACCESS LEVEL MENU OPTIONS
CODE xxxx
“ACCESS LEVEL” 3 (allows viewing only)
“ACCESS LEVEL” 2 (allows setup on OCM1)
ADJUSTMENTS MENU OPTIONS (factory set - not adjustable)
Xtilt TRIP
Displays the tilt trip point in the “X” orientation
Ytilt TRIP
Displays the tilt trip point in the “Y” orientation
TILT ENTRY
Displays the tilt delay time
TILT EXIT
Displays the tilt delay time
Xlevel TRIP
Displays the tilt trip point in the “X” orientation during the auto-level function
Ylevel TRIP
Displays the tilt trip point in the “Y” orientation which applies during the auto-level function
MACHINE SETUP MENU OPTIONS (factory set - not adjustable)
DEFAULTS
Allows all adjustments & machine settings to be set to defaults
WARNING: all GP106 settings will be changed; use with caution!
CALIBRATE LEVEL Allows levelling of the integral tilt sensor of the GP106, when the vehicle is positioned on level ground (see Appendix Four)
TILT MODE
Allows configuration of the GP106 tilt output (P2-9):
1 – output turns on to light lamp when tilted
2 – output turns off to cutout functions when tilted
3 – output turns off to cutout functions when tilted AND elevated
TILT FILTER
Displays the filter applied to the tilt measurements during the auto-level function (used to minimize the effect of vehicle vibrations on the tilt measurement)
Xlevel TARGET
Displays the tilt in the “X” orientation at which the auto-level function will complete.
Ylevel TARGET
Displays the tilt in the “Y” orientation at which the auto-level function will complete.
tilt SLACK
Displays the amount of vehicle tilt exceeding the Xtilt TARGET and/or Ytilt TARGET in which the auto-level function will not attempt to level
EXAMPLE:
Xtilt TARGET=0.3°, Ytilt TARGET=0.7°, tilt SLACK=0.5°
If machine is tilted to 1.0° in the X and Y orientations, the auto-level function will attempt to level the X orientation (0.3+0.5<1.0) but will not attempt to level the Y orientation (0.7+0.5>1.0)
RANGE: 0.0° to 1.0°, default 0.3°
SKYJACK, Page 26
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
IMPORTANT
Each phase must be completed before the next phase can be carried out.
All phases must be completed before the aerial platform can be operated.
Always follow the instructions of the Calibration instrument.
1.
Ensure aerial platform is parked on a firm and level surface.
2.
Elevate the scissors high enough to lay a level accross the base tubes. Ensure there is no debris on the base
and the level sits flat. Do not elevate aerial platform higher than the high speed/tilt override limit switch.
3.
Manually operate the outriggers and level the machine in 4 places: left side, right side, front and rear. All 4
outriggers must be firmly placed and all 4 tires are off the ground.
4.
Double check that the aerial platform is level at all 4 points.
5.
Connect the EZcal tool to the P1 connector on the CONTROL MODULE.
6.
The display will show “Help: Press Enter”.
By using Left/Right buttons, select the “Access Level (3 )” from the menu and press the ENTER button.
7.
The display will show “Access Level: Code (0000)”.
By using the Up/Down buttons, enter the Access Level Code (1 1  2  2) followed by pressing the ENTER
button.
8.
The display will show “Access Level 2”.
By using Left/Right buttons, select the “Setups” from the menu and press the ENTER button.
9.
The display will show “Setups: Change Defaults”.
Select the “Change Defaults” from the menu and press the ENTER button.
10. The display will show “Defaults, 0 = Custom”.
By using Up/Down buttons, select the “Defaults: Code Setting for your Model (For Default Code Refer to Table
5-3)” from the menu and press the ENTER button and followed by ESCAPE button.
11. The display will show “Setups Change Defaults”.
By using Left/Right buttons, select the “Calibrate Level” from the menu and press the ENTER.
12. The display will show “Calibrate Level: Yes: Enter, No: ESC”.
Select the “Yes” from the menu by press the ENTER button.
13. The display will show “Calibrate Level: Tilt 0.0’ , 0.0’”.
Select the “ESCAPE” from the menu once.
14. The display will show “Setups Calibrate Level”.
Select the “ESCAPE” from the menu once again.
15. The Calibration procedure is complete, unplug and remove the EZ-Cal.
16. Close the hydraulic/electric cabinet.
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Compact Series
155147
SKYJACK, Page 27
Service and Maintenance
Section 5 - Procedures
5.4-6 Auto-Leveling Outrigger Control Module Pin Reference Chart
LED
GP106 Control Module
PLUG
P1
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P4
P4
P4
P4
P4
P4
P4
P4
P4
WIRE #
AND
COLOUR
PIN
#
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
68A White
67A Red/White
66A Blue/White
65A Green/White
70 Green/Black
79 Green
70B Red/White
65 Green/Black
28E Green
10A Green
02 White
10 Black
78 Black/White
77 Blue/Black
76 Red/Black
75 Orange/Black
74 Black
73 Blue
72 Red
71 Orange
35C White/Black
SKYJACK, Page 28
WIRE FUNCTION
The Calibration Connection
Input indicating that the LEFT REAR outrigger is in contact with the ground
Input indicating that the RIGHT REAR outrigger is in contact with the ground
Input indicating that the RIGHT FRONT outrigger is in contact with the ground
Input indicating that the LEFT FRONT outrigger is in contact with the ground
Input for AUTO-LEVEL function to extend the outriggers to level the machine
Input for AUTO-RETRACT function to retract the outriggers until the switch is released
Outrigger Light on Outrigger Control Box
STABLE output to indicate that all outriggers are in contact with the ground
TILT output to indicate that the machine is level (ANSI/CSA only)
Tilt override / High Drive Cutout
Negative Input
Main Power Input
Output used to extend the LEFT REAR outrigger
Output used to extend the RIGHT REAR outrigger
Output used to extend the RIGHT FRONT outrigger
Output used to extend the LEFT FRONT outrigger
Output used to retract the LEFT REAR outrigger
Output used to retract the RIGHT REAR outrigger
Output used to retract the RIGHT FRONT outrigger
Output used to retract the LEFT FRONT outrigger
Power input for outriggers
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
Load Sensing System - CE
5.5-1 Control Module Pin Reference Chart
PLUG
PIN #
WIRE # AND
COLOUR
WIRE FUNCTION
P1
Calibration Connection
P2
1
Not used
P2
2
10E Black/White
Input from base controls
P2
3
14C Black
Platform Raise Input
P2
4
13 Orange
Platform Lower Input
P2
5
Not used
P2
6
Not used
P2
7
16 White/Black
Forward Direction Input
P2
8
15 Blue
Reverse Direction Input
P2
9
Not used
P2
10
18B Red/Black
P2
11
02 White
Negative Input
P2
12
10 Red
Main Power Input
P3
1
28E Red
Machine Level Output to pin #7 at the Sevcon- Tilt Switch Output
P3
2
29C Black
Output to Beeper BP29C
P3
3
60C Black/White
Output to Overload Warning Light on Control Box
P3
4
60 Green/Black
Output to Aux. Relays 60CR1, 60CR2, 60CR3
P3
5
02 White
Negative for Flashing Light, Beeper and Horn
P3
6
60E Green/White
Output to Relays 60ECR1, 60ECR2, 60ECR3
P4
1
Not used
P4
2
60A Green
Varied Input from Pressure Transducer
P4
3
60B Green
Varied Input from Angle Transducer
P4
4
Not used
P4
5
Not used
P4
6
910 Black
Positive Signal to Angle Transducer
P4
7
900 White
Negative Signal to Pressure Transducer
P4
8
902 White
Negative Signal to Angle Transducer
P4
9
910A Black
Positive Signal to Pressure Transducer
Elevated Platform Input from LS5 Limit Switch
189AA
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 29
Service and Maintenance
Section 5 - Procedures
5.5-2 LED Error Codes - Quick Reference Chart
HELP Message
EVERYTHING OK
IN GROUND MODE!
OVERLOAD FUNCTIONS DISABLED!
VEHICLE TILTED
VEHICLE OVERLOADED
WAITING FOR B+ ON P2-12
ARMGUARD ACTIVE!
TOO HIGH - DRIVE PREVENTED
TOO HIGH - LIFT UP PREVENTED
TESTING HWFS
IDLE TIMEOUT ACTIVE!
WAITING FOR NEUTRAL
ELEVATION SWITCH SHIFTED?
ELEVATION SWITCH STUCK?
NO LAST CALDATE!
LOAD NOT CALIBRATED
DRIVE/LIFT INPUTS FAULTY!
UP/DOWN SELECT INPUTS ACTIVE TOGETHER
INVALID LOAD - CHECK SENSORS
HEIGHT NOT CALIBRATED
INVALID HEIGHT - CHECK SENSOR
EMS INPUTS FAULTY!
B+ SUPPLY TOO LOW
P4-1 OR P5-1 SHORT TO 0V?
P3-4 SHORT TO SUPPLY!
P3-4 SHORT TO 0V?
P3-4 SHORT TO SUPPLY?
P3-6 SHORT TO 0V?
P3-6 SHORT TO SUPPLY?
FAULT: BAD TILT SENSOR
FAULT: BAD HWFS
FAULT: BAD SLAVE ANALOGS
FAULT: BAD STRAIN MONITORS
FAULT: BAD SLAVE MICRO
FAULT: HWFS STALLED!
STARTUP!
FACTORY OVERRIDE
LED indication
Steady on
Steady on
6/6
1/1
1/2
5/2
1/3
1/4
1/5
7/8
Always off
5/5
2/1
2/2
6/3
6/2
5/6
5/4
6/4
6/1
6/5
5/2
5/1
4/1
4/2
4/3
4/4
4/5
4/6
7/1
7/2
7/3
7/4
7/5
7/6
7/7
6/7
60405AA
Reading the Codes:
In order to read the fault codes, a sequence of pauses and flashes can be seen on the LED mounted on the GP102
module. The codes are continuously displayed by the LED until the fault is cleared, the GP102 reset and no longer
detects the fault, or idle timeout becomes active.
The sequence is as follows:
1. Quarter second flashes followed by quarter second pauses indicate the first digit.
2. A 1.5 second pause.
3. Quarter second flashes followed by quarter second pauses indicate the second digit
4. A 4 second pause. Repeat steps 1-4
Since the GP102 only reports one error, only one code can be read from the LED per instance. If the error is cleared
and another error is present, it will then be presented.
SKYJACK, Page 30
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
5.5-3 LED Error Codes - Code Breakdown Chart
Diagnostic sequence dependant on LED flash code:
No Last Caldate
63
Load Not Calibrated
62
Height Not Calibration
An EZcal is required!
61
Waiting For Neutral
55
Drive/Lift Inputs Faulty!
56
Up/Down Select Inputs Active Together
54
EMS Inputs Faulty!
Check inputs on P2 pins 1,2,3,4,5,6,7,8.
52
P3-4 Short To Supply!
42
P3-4 Short To Supply?
44
P3-6 Short To Supply?
46
Disconnect plug P3. If fault clears there is a problem with the wiring from P3-4 or P3-6 to the rest of the vehicle.
Armguard Active!
23
Elevation Switch Shifted?
21
Elevation Switch Stuck?
22
If the 23 flash code is triggered by armguard, it will occur once then clean. This is not a true fault but just an indication of the reason for the vehicle stop. If the 21 or 22 flash code is triggered by a fault with the elevation switch, it
will not clear. Check that the elevation switch correctly opens/closes when the platform is raised/lowered.
P3-4 Short To 0V?
43
P3-6 Short To 0V?
45
Disconnect plug P3. If fault clears there is a wiring fault from P3-4 or P3-6 to the rest of the vehicle.
Invalid Load - Check Sensors
45
Check the voltage out of the pressure transducer, into P4-2. It should be between 0.5V (zero pressure) and 4.5V
(maximum pressure) and should vary as the platform load & position varies.
Waiting For B+ on P2-12
52
B+ Supply Too Low
51
P4-1 Or P5-1 Short To 0V?
41
Check that the battery voltage is not too low.
Verify battery voltage on P2-12.
Disconnect plug P4 – if the fault clears there is a wiring fault from P4-1 to the rest of the vehicle.
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 31
Service and Maintenance
Section 5 - Procedures
5.5-3 LED Error Codes - Code Breakdown Chart (Continued)
Vehicle Tilted
11
Vehicle Overloaded
12
Too High - Drive Prevented
14
Too High - Lift Up Prevented
15
These are not true faults but an indication that vehicle movement is prevented. Remove excessive load from the
platform. Lower the platform if close to maximum height. Move the vehicle to level ground.
Invalid Height - Check Sensor
65
Check the voltage out of the height transducer, into P4-3. It should be between .4V and 4.6V and should vary as
the platform position varies.
Testing HWFS
78
Start Up!
77
These are not true faults unless they do not clear – the start-up tests should only occur for a short time.
Overload Functions Disabled!
66
Factory Override
67
These are not true faults – the GP102 has been configured to suppress overload functionality.
Idle Timeout Active!
Always Off
Fault: Bad Tilt Sensor
71
Fault: Bad HWFS
72
Fault: Bad Slave Analogs
73
Fault: Bad Strain Monitors
74
Fault: Bad Slave Micro
75
Fault HWFS Stalled!
76
Action a function to clear the idle timeout if it occurred. Ensure the GP102 is correctly mounted – incorrect
mounting can cause the “bad tilt sensor” diagnostic to occur. Otherwise there may be an internal problem with the
GP102.
SKYJACK, Page 32
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
5.5-4 Control Module Load Calibration - Code Messages & Definitions
During calibration the following failure message may appear:
(Refer to 5.5-5 for hand held calibration/diagnostic tool key functions)
Code F01: Check HWFS
This message is given if the GP102 startup tests have not completed.
-- Check HELP message for more information.
Code F02: Not Ground Mode
This message is given if the machine is not in ground mode (P2-2 must be high).
-- Calibration can only be carried out in ground mode.
Code F03: Not Stopped
This message is given if any function switch is closed.
-- Check DIAGNOSTICS / SWITCHES to see which function switch is closed.
Code F04: Tilted
This message is given if the machine is tilted.
-- Calibration must be carried out with the machine level. If the machine is level, use the SETUPS / TILT
SETUPS to set the GP102 level.
Code F05: Bad Height
This message is given if the height sensor output (P4-3) is out of range at the start of calibration.
-- The height sensor output must be 3.7V. Check DIAGNOSTICS / SENSORS to see the output. A reading
of 0V or 5V is probably due to a wiring problem.
Code F06: Check Elev
This message is given if the elevation switch (P2-10) is closed at the start of calibration, when the operator has
confirmed the “PLATFORM DOWN?” question.
-- If the platform is down, check the elevation switch wiring.
Code F08: Check Elev
This message is given if the elevation switch (P2-10) is closed at the end of calibration, when the platform should
be fully raised.
-- This message would occur if the UP switch was accidentally opened near the start of the lift. If the
platform is fully raised, check the elevation switch wiring.
Code F09: Bad Height
This message is given if the height sensor output (P4-3) is out of range at the start of calibration.
-- The height sensor output must be 3.7V. Check DIAGNOSTICS / SENSORS to see the output.
Code F10: Bad Height
This message is given if the height sensor output (P4-3) is out of range at the end of calibration.
-- The height sensor output must be between 0.9V and 4.1V. Check DIAGNOSTICS / SENSORS to see
the output. A reading of 0V or 5V is probably due to a wiring problem.
Code F11: Not Up
This message occurs at the start of calibration if the operator selects a function other than UP.
-- Select the UP function only.
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Compact Series
155147
SKYJACK, Page 33
Service and Maintenance
Section 5 - Procedures
Code F13: Low Height Range
This message occurs at the end of calibration if the height sensor output did not change sufficiently to give a
reasonably accurate platform height estimate.
This message could occur if the UP switch was accidentally opened too early (when the platform is not fully
raised). DIAGNOSTICS / SENSORS can be used to check the height sensor output (P4-3). A difference of at
least 1V is to be expected.
Code F15: Check Elev
This message is given if the elevation switch (P2-10) is closed when the platform has been fully lowered at the
end of calibration.
This message would occur if the DOWN switch was accidentally opened before the platform was fully lowered.
If the platform is fully lowered, check the elevation switch.
Code F16: Low Elev.open
This message is given if the elevation switch (P2-10) opened during lift at a too low height (below 5%).
-- Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where the switch
opened. Set up elevation switch to manufacturers’ specifications and calibrate load.
Code F17: High Elev.open
This message is given if the elevation switch (P2-10) opened during lift at a too high height (above 25%).
-- Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where the switch
opened. Set up elevation switch to manufacturers’ specifications and calibrate load.
Code F18: Low Elev.close
This message is given if the elevation switch (P2-10) closed during lower at a too low height (below 5%).
-- Check CALIBRATIONS / HEIGHT CALS; the “ElevDown” value shows the recorded height where the
switch opened. Set up elevation switch to manufacturers’ specifications and calibrate load.
Code F19: High Elev.close
This message is given if the elevation switch (P2-10) closed during lower at a too high height (above 25%).
-- Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where the switch
opened. Set up elevation switch to manufacturers’ specifications and calibrate load.
Code F20: Height<>0%
This message occurs if the platform height is not 0% after the platform has been fully lowered during either
STATIC lift.
The platform must return to the same height each time it is fully lowered.
-- Check DIAGNOSTICS / SYSTEM to check the height.
Code F28: Bad Height
This message indicates a problem with the height sensor output (P4-3) during calibration.
The height sensor output must be between 1.0V and 4.0V at all times.
-- Check DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring
problem.
Code F42: Low Pressure
This message indicates that the pressure transducer output (P4-2) is too low (0.5V or less) at the beginning of
calibration.
-- Check DIAGNOSTICS / SENSORS to read output.
SKYJACK, Page 34
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
Code F43: High Pressure
This message indicates that the pressure transducer output (P4-2) is too high (4.5V or more) at the beginning
of calibration.
-- Check DIAGNOSTICS / SENSORS to read output.
Code F44: Low Pressure
This message indicates that the pressure transducer output (P4-2) is too low (0.5V or less) at a measurement
point.
-- Check DIAGNOSTICS / SENSORS to read output.
Code F45: High Pressure
This message indicates that the pressure transducer output (P4-2) is too high (4.5V or more) at a measurement
point.
-- Check DIAGNOSTICS / SENSORS to read output.
Code F46: Check Elev
This message indicates that the elevation switch opened more than once during calibration lifting.
Code F47: Check Elev
This message indicates that the elevation switch closed more than once during calibration lower.
Code F48: Bad Pressure
This message indicates that the pressure transducer output (P4-2) is out of range at the beginning of
calibration.
-- Check DIAGNOSTICS / SENSORS to read output.
Code F52: Too Few
This message indicates that not enough measurements were recorded during calibration lifting or lowering.
Code F98: Out of Range
This message indicates that the “fine tune” calibration is unacceptable.
This is probably due to a faulty transducer or faulty/open holding valve(s)/ emergency lowering valve.
During calibration the following information messages may appear:
Platform Down?
This message is prompting for confirmation that the platform is fully lowered. If necessary the DOWN switch
can be activated to lower the platform. Press ENTER to confirm when the platform is fully lowered.
Platform Empty?
This message is prompting for confirmation that the platform is completely empty. Press ENTER to confirm if
the platform is empty.
Platform Loaded?
This message is prompting for confirmation that the platform is loaded to rated load Press ENTER to confirm
if the platform is loaded.
Please Lift
This message is prompting for the platform to be raised. The UP switch should be closed.
Please Lower
This message is prompting for the platform to be lowered. The DOWN switch should be closed.
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 35
Service and Maintenance
Section 5 - Procedures
Lift Empty
This message is displayed while the platform is being raised to the next measurement height, when an EMPTY
platform is being calibrated.
Lift Loaded
This message is displayed while the platform is being raised to the next measurement height, when a LOADED
platform is being calibrated.
Lifting
This message is displayed while the platform is being raised, during HEIGHT-only calibration.
Measuring #
This message is displayed when the platform is stopped during calibration, when the GP102 takes a measurement.
There will be a short delay while the machine is allowed to stabilize after movement is stopped.
Must Go Down!
This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be lowered.
Must Go Up!
This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be raised.
Please Wait
This message indicates that the GP102 is busy; the delay will be short (no more than 5 s).
Lower Empty
This message is displayed while the platform is being lowered to the next measurement height, when an EMPTY
platform is being calibrated.
Lower Loaded
This message is displayed while the platform is being lowered to the next measurement height, when an EMPTY
platform is being calibrated.
Lowering
This message is displayed while the platform is being lowered, during HEIGHT-only calibration.
Total Data:
This message is displayed at the end of each phase, to confirm the number of measurements recorded by the
GP102.
Caldate
This message is prompting for the date to be entered; it is stored to identify when the machine was
calibrated.
The last calibrate date can be viewed in DIAGNOSTICS / LOG. Press LEFT & RIGHT to select the flashing digits.
Press UP & DOWN to change the flashing digits. Press ENTER when the entry is complete. IMPORTANT: The
date 00/00/00 is not allowed!
Finished
This message confirms that calibration is complete and successful.
SKYJACK, Page 36
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
5.5-5 Control Module Load Calibration Procedure
1.
Move the aerial platform to a test area where the platform can be elevated to its maximum working height and
reach.
2.
Ensure the aerial platform is parked on a firm, level surface.
IMPORTANT
Each phase must be completed before the next phase can be carried out.
All phases must be completed before the aerial platform can be operated.
IMPORTANT
Always follow the instructions of the Calibration instrument.
IMPORTANT
Make sure the aerial platform is on BASE mode.
NOTE
To ensure a good and clear contact, clean the wire terminals before attaching the jumper clip.
3.
Before starting the calibration you must put a jumper across the base speed resistor (See Figure for location
of the resistor.)
Jumper
Figure 5-10. Main Circuit Board
4.
Connect the Easy-Cal tool to the P1 connector on the CONTROL MODULE.
5.
The display will show “Help: Press Enter”.
By using Left/Right buttons, select the “Access Level ( ? )” from the menu and press the ENTER button.
Contact Skyjack Service Department at:
(44) 1691-676 236 for your Access Level Code Number.
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 37
Service and Maintenance
Section 5 - Procedures
6.
The display will show “Access Level Code (xxxx)”.
By using the Up/Down buttons, enter the Access Level Code (xxxx) followed by pressing the ENTER
button.
7.
The display will show “Access Level 2”.
By using Left/Right buttons, select the “Setups” from the menu and press the ENTER button.
8.
The display will show “Machine Defaults”.
Select the “Machine Defaults” from the menu and press the ENTER button.
9.
The display will show “Defaults, 0 = Custom”.
By using Left/Right buttons, select the “X = Group Code” from the menu and press the ENTER button.
10. The display will show “X=GROUP CODE”.
By using the Up/Down buttons, enter the “Group Code (?)” then by using Left/Right buttons, select the “Curve”
from the menu.
11. The display will show “X=CURVE”.
By using the Up/Down buttons, enter the “Curve Code (?)” followed by pressing the ESCAPE button.
12. The display will show “Machine Defaults”.
By using Left/Right buttons, select the “Tilt Setups” from the menu and press the ENTER button.
13. The display will show “Tilt Setups: Calibrate Level”.
Select the “Tilt Setups: Calibrate Level” from the menu and press the ENTER button.
14. The display will show “Calibrate Level: Yes: Enter, No: ESC”.
Select the “Yes” from the menu by press the ENTER button.
15. The display will show “Calibrate Level: Tilt 0.0’ , 0.0’”.
Select the “ESCAPE” from the menu once.
16. The display will show “Tilt Setups Calibrate Level”.
Select the “ESCAPE” from the menu once again.
17. The display will show “Setups Tilt Setups”.
By using Left/Right buttons, select the “Load Setups” from the menu and press the ENTER button.
18. The display will show “Load Setups: Calibrate Load”.
Select the “Load Setups: Calibrate Load” from the menu and press the ENTER button.
19. At this point, elevate the aerial platform at full height, check the harness and making sure it is not stretched
tight, then lower down the platform.
20. The display will show “Calibrate Load: Platform Down?”.
Asking for confirmation that the platform is fully lowered?
Check that the platform is fully lowered then press the ENTER button to confirm.
21. The display will show “Calibrate: Loaded Empty? No”.
Asking for confirmation that the platform is empty?
Check that the platform is empty
22. By using the Up/Down buttons, enter the “Yes” followed by pressing the ENTER button.
SKYJACK, Page 38
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
23. The display will show “Calibrate Load: Please Lift......”.
Waiting for the lift switch to be activated.
24. Hold the lift switch and keep holding it until the platform is fully elevated.
IMPORTANT
If the lift switch is released earlier than full-height position, the
calibration will have to be aborted and repeated from the beginning!
25. When the system detects the lift switch closed, the display will show “Calibrate Load: Lift Empty”.
26. After a delay, the system will stop the platform lifting and will take height & pressure measurements; the display
will show “MEASURING # xx” When the measurements have been taken, the platform will resume lifting.
NOTE
The Lifting......stopping.......measuring....lifting process will continue until the platform reaches full height.
27. When the platform reaches full height release the lift switch.
28. The display will briefly show “TOTAL DATA: 04” to indicate the number of measurements taken.
29. The display will show “Calibrate Load: Please Lower......”.
IMPORTANT
If the lower switch is released earlier than full-lower position, the
calibration will have to be aborted and repeated from the beginning!
30. Hold the lower switch and keep holding it until the platform is fully lowered.
31. When the system detects the lower switch closed, the display will show “Calibrate Load: Lower Empty”
32. After a delay, the system will stop the platform lowering and will take height & pressure measurements; the.
display will show “MEASURING #xx”. When the measurements have been taken, the platform will resume
lowering.
NOTE
The lowering......stopping.......measuring....lowering process will
continue until the platform is fully lowered.
33. When the platform is fully lowered (and height 0% is displayed), release the lower switch.
34. The display will show briefly “TOTAL DATA: 04” to indicate the number of measurements taken.
35. The display will show “Calibrate Load: Caldate: mm/dd/yy”.
It is recommended that the current date be entered here to provide easy taking of the data of last
calibration.
The current date must be entered using the LEFT/RIGHT and UP/DOWN buttons.
36. Press ENTER to complete date entry (the system will store it).
37. The display will show “Calibrate Load” option.
38. Press the ESC button to exit the “Calibrate Load” option.
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Compact Series
155147
SKYJACK, Page 39
Service and Maintenance
Section 5 - Procedures
39. Remove the jumper wire and re-connect the black wire #14 to the coil removed earlier.
40. Close the hydraulic/electric tray.
NOTE
Continuing partially complete load calibration.
Once a calibration phase has been successfully completed, it is not required to do it again (unless of course
a change to the vehicle such as a replacement sensor requires that calibration be repeated). This is useful if
the calibration procedure is interrupted – the remaining phases can be completed at a later time.
If a calibration phase has been successfully completed, a “REDO” message is displayed:
REDO DYNAMIC: NO
REDO LOADED: NO
REDO EMPTY: NO
If the phase does not need to be repeated, just press ENTER to move on.
If the phase does need to be repeated, press UP or DOWN to change “NO” to “YES” then press ENTER.
SKYJACK, Page 40
DC Electric Scissor Lifts
Compact Series
155147
Section 5 - Procedures
Service and Maintenance
5.5-6 Curve/Group Codes Chart
NOTE
Chart below is for models built effectively from January 1, 2010
MODEL
Number of Extension Decks
Curve
Code
Group
Code
7127
1 Manual Extension Deck
24
7
7127
1 Powered Extension Deck
25
7
7135
1 Manual Extension Deck
26
7
7135
1 Powered Extension Deck
27
7
8831
None
30
19
8831
1 Manual Extension Deck
31
19
8831
1 Powered Extension Deck
32
19
8831
2 Manual Extension Deck
33
19
8831
2 Powered Extension Deck
34
19
8831E
None
35
20
8831E
1 Manual Extension Deck
36
20
8831E
1 Powered Extension Deck
37
20
8831E
2 Manual Extension Deck
38
20
8831E
2 Powered Extension Deck
39
20
8841
None
40
17
8841
1 Manual Extension Deck
41
17
8841
1 Powered Extension Deck
42
17
8841
2 Manual Extension Deck
43
17
8841
2 Powered Extension Deck
44
17
8841E
None
45
18
8841E
1 Manual Extension Deck
46
18
8841E
1 Powered Extension Deck
47
18
8841E
2 Manual Extension Deck
48
18
8841E
2 Powered Extension Deck
49
18
9250
None
52
10
9250
1 Powered Extension Deck
53
10
9250
2 Powered Extension Deck
54
10
6832RT
1 Manual Extension Deck
56
15
6826RT
1 Manual Extension Deck
57
15
9241
2 Powered Extension Deck
58
15
167AA_RT
DC Electric Scissor LIfts
Compact Series
155147
SKYJACK, Page 41
Service and Maintenance
Section 5 - Procedures
5.5-6 Curve/Group Codes Chart (Continued)
NOTE
Chart below is for models built prior to January 1, 2010
MODEL
Number of Extension Decks
Curve
Code
Group
Code
7127
1 Manual Extension Deck
24
7
7127
1 Powered Extension Deck
25
7
7135
1 Manual Extension Deck
26
7
7135
1 Powered Extension Deck
27
7
8243
1 Manual Extension Deck
28
7
8243
1 Powered Extension Deck
29
7
8831
None
30
9
8831
1 Manual Extension Deck
31
9
8831
1 Powered Extension Deck
32
9
8831
2 Manual Extension Deck
33
9
8831
2 Powered Extension Deck
34
9
8831E
None
35
13
8831E
1 Manual Extension Deck
36
13
8831E
1 Powered Extension Deck
37
13
8831E
2 Manual Extension Deck
38
13
8831E
2 Powered Extension Deck
39
13
8841
None
40
10
8841
1 Manual Extension Deck
41
10
8841
1 Powered Extension Deck
42
10
8841
2 Manual Extension Deck
43
10
8841
2 Powered Extension Deck
44
10
8841E
None
45
14
8841E
1 Manual Extension Deck
46
14
8841E
1 Powered Extension Deck
47
14
8841E
2 Manual Extension Deck
48
14
8841E
2 Powered Extension Deck
49
14
8850
1 Manual Extension Deck
50
7
8850
1 Powered Extension Deck
51
7
9250
None
52
10
9250
1 Powered Extension Deck
53
10
9250
2 Powered Extension Deck
54
10
6832RT
1 Manual Extension Deck
56
15
6826RT
1 Manual Extension Deck
57
15
9241
2 Powered Extension Deck
58
15
166AA
SKYJACK, Page 42
DC Electric Scissor Lifts
Compact Series
155147
Reliable lift solutions by people who care.
www.skyjack.com