Home

Service Manual

1.
2.
3.
4. C2 Cl POWERED FRONT CYLINDER CYLINDER AND REAR PLATFORMS C5 DISE MBA MB3 CYLINDER HOLDING HOLDING VALVE WERING VAL VE WERING MANIFOLD ORIFI ANIFOLD ORIFICE FRONT C4 REAR BLOCK 0 104 BLOCK 0 104 _ PLATFORM PLATFORM HPD XI LION i 1 YLINDER YLINDER PTIONAL OUTRIGGER E AN LEX o Hi Ze 42 YLINDERS T A MBS POWERED BM 1 4 RA aua R3 2H 13 3 MANIFOLD ca C10 C11 C12 RELIEF HOLDING UT VE HOLDING BLOCK 2 PIGHT y PE VALVE VALVE VALVE RON RON REAR REAR 1 L V6 527 27 ITRIGGER LITRIGGER ITRIGGER AUT FRONT REAR YLINDER YLINDER YLINDER CYLINDER ncm lt SN pgETRACI retract RAK VALVE SET LA fee PLATFORM PLATFORM L N VAL VE MANIFOLD A a VALV VALV A LI BLOCK i E ES ES He Hu ne I c ol 5 va XTEN XTEN gt MB7 NTROLLE PL
5. A o 700 7 e e x ELECTRICAL INVERTER WV Q 5 e a H n EAS SHIFT SENSORS DEVICES WIRING COMPARTHENT Hmm 10 a INVERTER T BOX AC R B y y 9 s Q BASE POWER TMR 8A a CONTROL ELI MOTOR CONTR TI TIMER RELAY pe PIN X O2 WHITE MAIN MANIFOLD UPPER CONTROL CABLE OUTRIGGERS m E IN P 3B BLU T p E T Sis IN L 85 VIDLE adds ERES e E BA WHITE RED A FOR MACHINES WITHOUT TIMER RELAY ONLY a 85 VIULET 5 e 85 VIDLET V 02 WHITE e A e WHITERED 98 0h J zw o o aK O A SA MAIN DISCUNNECT SWITCH GROUND INSULATOR JUNCTION
6. View L Parts List Z Z C ye a 4 EI Io IVE ZZ i 7 133227AA N J 57 ELI LIT LESE LL TI LI TI LL TI F 5 H co ED w ce 1 EL a e OUTRIGGER L ia TEN PIN CONNECTOR PLUG _ i e PIN 1 74 BLACK 1 02 WHITE PIN 2 73 BLUE PIN 2 35C WHITE BLACK PIN 3 78 BLACK WHITE PIN 3 70 GREEN BLACK PIN 4 77 BLUE BLACK PIN 4 70A RED BLACK AUTO LEVEL OUTRIGGER SWITCH PIN 5 35D PURPLE WHITE PIN 5 71 ORANGE PIN 9 75 ORANGE BLACK PIN 6 N U PIN 1 79 GREEN Ja PIN 6 72 RED PIN 7 71 ORANGE PIN 7 73 BLUE PIN 2 35D PURPLE WHITE 36 PIN 8 72 RED PIN 8 74 BLACK e PIN 9 75 ORANGE BLACK PIN 10 76 RED BLACK PIN 10 76 RED BLACK
7. 2 3 e DOO Bos DOCG ACOA Si N 9 B BLUE HENTSHR
8. lt 1 Sa l RA ero L uo CI Figure 5 3 Traction Motor Lift Pump Proximity Switch Location 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 2 Disconnect the main battery disconnect plug 3 Unplug the connector for the electrical wiring to the proximity switch you want to replace 4 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 To install the new proximity switch turn the switch in until it bottoms out 6 Tighten the lock nut down while holding the proximity switch in it s adjusted position 7 Reconnect the connector for the electrical wiring to the proximity switch 8 Reconnect the main battery disconnect plug WARNING Make sure the correct proximity switch is adjus
9. eir an LI FAM 1 nu 1 3 CABTIRE RUN UP SCISSORS TO le 1 18 T L 1 yon 1 Se us POWERDECK MANIFOLD Fen ee G 2 1 e _ L m WORKLIGHT WORKLIGHT pe L OL HI LO 7 He A a A La 1 TE REN OUTRIGGER NAN PONER RELAY 1 3 6 al 3 E m Na g A 2 Ne ZEN m macron m gen m m II s jiel acl H 9 2 2 5 tol E loi so Za E E EM D m 3 D d NU a la m Mai 4H 324 SkviacK a m 1187020 tor l 103 HI p BACK VIEW H an LO A g A 3 a z My i BE 1 oo oW I 1 W w m d HAUT 4 FAULT LI M4 7 PS2 10 Lit 10A BROWN TO PLATE 7 EE CNT CN2 Rev For CNt2 ki M F2 oL PLATORM Bower CNS Motor Control 8448 1 1 UX POWER LIMITS jor Dela Me E sms 1943 E 8 E ki CIRCUIT CARD TA ida dd NEV SHIH UPIDOWN SELECTOR 185 H 10F REDWHITE 2840 OF REDWHTE 05 RED 5B
10. NT IU XE EXE 8 UPIDOWN SELECTOR RED 10FREDWHITE 10F REDWHITE 13 ORANGE 5 RED 9 TACHO CIRCUIT CARD TA LA oo j an ooma LARGE PUNP CHK SMALL PUMP CHK EMERGENCY STOP SBRED 04 WHITEBLACK OUTRIGGER PENDANT
11. BACK VIEW DRNEENABLE OUTRGGER A MS TO PRESSURE SWITCH AT LFT CYLINDERS pou m E 77 Mie Jurrosaae ur ensue 4 RELAY REY RELA x 4 bas fe fr fs SKYACK 115 1 PW 1 14BLACKWATE m PN2 CQ NATE ga 4 a S 5 aS 1 CN22 OR LIMIT SWITCHES DU MN VOUT AN 1 01 BLACK 0 BLAUE 2 89 892 4 TO CHARGER CUTOUT su 9
12. SKYJACK 18 3 9 Main Manifold Harness Wiring Diagram i BLACK 23 m Be 23 STEERING DIRECTIONAL VALVE 02 FROM BUTT SPLICE 1 Q0 24 STEERING DIRECTIONAL VALVE 02 FROM BUTT SPLICE 1 MAIN MANIFOLD 32A GEARBOX DIRECTIONAL VALVE 02 FROM BUTT SPLICE 1 MAIN MANIFOLD BAT GREY t O 02 ME BUTT SPLICE 1 BUTT SPLICE 3 M NR N BASE CONTROLS EMERGENCY STOP PB 5B RED 04 WHITE BLACK Print View This Page Parts List ss TILT SWITCH PIN 1 10C PIN2 28 PIN 3 02 FROM BUTT SPLICE 4 PIN 4 N U H H 2A 2B PRESSURE SWITCH MAIN MANIFOLD NAI 13 LOWERING VALVE 02 FROM BUTT SPLICE MAIN MANIFOLD OYE NI c 02 FROM BUTT SPLICE 4 BRAKE MANIFO
13. i 2 1 7150 3 OUTRIGGER BOAR N21 OR MANIFOLD ourmccen ZE REY fa 1 N20 OR CONTROL PRESSURE SWITCH X AT LIFT CYLINDERS urrewae ie fe 22 OR UMIT SWITCHES ls lele lelea fe 1 BACK VIEW 3 1 BOR ae pi
14. 11449 SKYJACK Page 21 DC Electric Scissor Llfts Compact Series 155147 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 A2 5 second pause 3 Half second flashes followed by half second pauses indicate the second digit 4 A5 second pause Hepeat 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 1 2 2 2 2 1 8 3 FAULT HWFS STALLED 60402AB 5 5 7 1 6 6 7 5 1 7 7 7 7 1 7 8 1 8 Z 5 2 8 5 2 2 5 SKYJACK Page 22 DC Electric Scissor Lifts Compact Series 6 Q 155147 Section 5 Procedures Service and Maintenance 5 4 3 Auto Leveling Outrigger Error Code Breakdown RELEASE OUTRIGGER DEMAND Check inputs on P2 pins 5 amp
15. MOVAAYILIVA 9 m kh n l re 9 2 Ate klik 8r AGILIVE AGFILIVE AYLLY AUSLLVH AGILIVE voor T A918 A968 A9 8 Ag 9 50 vi 84 9 98 2928 msa 10 215 SAVT3U 110112 H3OHUVHO 11 8 2 2597 SH3OBVHO AGILIVE TFOVLTOA TFOVLTIOA OWA OLL OWA OLL iG 05 4 7 20 PT BUHMMOVIE gt L GIONTIOS1OVHI3H 36 pi 4 m an L 8 ium C H3OSIHIPO 20 m MOVIE bl uva e 525 GIONJIOSON3DG 4 x 20 Z XOVIBAITE 2 L Na 5 yon GIONTIOS1OVMI3H i e an BE wou 20 z ana GIONTIOSON3DG gy i 4 a 9LHF 92 MOWTE GIY LON Mi GIONTIOSIOVMISH 096 YIODILLNO 3 20 a Ts jy pi 3 7 20 XOVIB AONVHO s L NI N a QIONTTOS LOVYIFY pi l 998 1391 JDDIBLNO 3 1 20 SONVU m 1NOHJ ML NYO 2 ge o Spi 20 E L lt LHOIT Geng
16. View Parts List L wT Oe Few ko 1 pTO fe 3 POS KEY SWITCH pon BASEJOFFIPLFT OO 0 2 FUNCTION SELECTOR TS SU SS WARNING n es Fell LIFTIOFFIDRVE ALARM LIGHT EMERGENCY elle A STOP j si X 4 HORN SWITCH JOYSTICK CONTROL WITH ENABLE amp RELAYS 28 NI c i WARNING ALARM BUZZER CONTROL CIRCUIT BOARD DC Electric Full Size Rough Terrain Model 8831E amp 8841E 155154 OYE L SKYJACK Page 13 Section 3 System Component Identification and Schematics Service and Maintenance 3 6 Outrigger Control Box Wiring Diagram
17. PIN BLAGK 10 PIN 2 WHTE 654 AW PIN 3 GREEN 62 PIN 4 RED 61 ou 2 EFO g 8 la l Dosa ASA at t 9 RIVE PROX YELLOW HEAT SHRINK PIN1 10REDIBLACK van YELOWHEATSHANK IN 2 02 BLUE BLACK IN3 NU IN 4 33 ORANGE W 5 2
18. ua WWW S ill LI L6 p tm A EQ gt 5u Z N gt o 2 gt I tu z I d LLI i lt x m 9 m a O m x m ed z 5 amp 5 Q we Or LLI m zm 2 gt T d ox 3 eo Li lt 1 lt lt DI lt x lt DI Li EZ 2 2 a go T gt L gt 2 o gt 2 E mo ape r x gt e I Qouz Z TI nana lt O 51 m 5 2 a gt 2222 ETS 2 m ZZZZ a agge gt o Tm a oze N t c d lt Lr a E O or B E A ETI m c c ogee cc NE I 633i amp z ZE Li 5 lt
19. 7 4 1 8 Down Circuit Inoperative from ak l l a a a a kon e kk kk e a a kk a ra n 8 4 1 9 Down Circuit Inoperative from T 9 4 1 10 Platform Does Not Steer Left Or F TE een ki on it kk as kt po ki ka 9 Y a tp iya a EA pom kola e ak 10 ioi AE Ko air ie oi ati pe tapi 10 4 1 13 Forward And Reverse Drive Inoperative Machines without 4 10 4 1 14 Forward And Reverse Drive Inoperative Machines with outriggers 11 8 or RM RR 12 cui TT RD HIER 12 4 1 17 Forward And Reverse Slow Speed 2 kebek kadans 13 didi LSU m 13 4 1 19 Lift Traction Shift Circuit Inoperative e Ht 14 4 1 20 Powered Extension Deck OE NG kb ik a na 14 4 1 21 All Outriggers Inoperative Auto level and 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
20. 20 20 ves ISNI 1 2 LOVYIFHE MOOTUZINI ISNA YOL VOL Y 4 Y EN 4 vee 20 M 7 y T 6 T4 se 86 86 86 7 sa FEN 7 a ana dif EUM eee 013 205 als 615 6 20 VM K 12 HOLIMS HOLIMS JTI8VN3 9 MO3G H3MOd 20 20 ta 12 aN31X3 134 Zeb GIONTIOS 42 2 JOVUL3H zza 20 4 x Fa zo 201 gt 7 oe n TG TV 7 VZL ji 891 01 E e 21 TIVWS 81 407 915 218 920 4 20 20 va vel vel K 901 NOLLdO WHOdLV Td 20 20 501 01 60 ISNA voi 4 zu3dnnr u3a nr 4 gt 4 801 ON 821 vel vel Lnoinoanua 21 a N3HM 6010 44 gt NadO ATIVWHON 201 n ri 4 L 61110110 JAYA 1 26 26 ena Luar a6 Ban pi TOL 80 1 00 9 1 n N 3010 z 4 001 AA I Di 01 vol T ou 221 ISNI VOI Ki ude 66 ta 20 le 201 KFDDWINOON 60 60 84 ea Si T P t E 6 14
21. 27 a TOUT We EF TOU wc REVERSE RELAY DEVICES ET su mm qd A an AUX REVERSE RELAY UFTRELEF ER FORWARD RELAY a i ER DE cus 1 ka el PS2 10 BIUE i 10 BLACK ri 171 TM ped tof nd m oe n in pou 05 A ini 4444 44449 ois Hol lo a gso 5 GATO PONER Upper Control E HO ss
22. TIT CHARGER M50070AB DC Electric Full Size Rough Terrain SKYJACK Page 15 Model 8831E amp 8841E 155154 Q Notes SKYJACK Page 16 DC Electric Full Size Rough Terrain Models 8831E amp 8841E 6 Q 155154 View This Page Parts List 3 8 Hydraulic Schematic
23. tS E 4 4 4 0084 20 20 vol 378 8 Ta 20 vol 7 H2S9 18OVOL AVIHTIVNJ gy L 4 20 20 59 NOILISOd 1 NI NMOHS SH3D51HLNO zx ps 7 NOUS ava 5019 1437 1441 AVTIH 78 ea 9 Ta 20 jg 7 19 29 59 7 wa l say l 1951 2951 991 951 mi ari ver 435072 NIdO n SIHOLIMS LINIT an 55 HH 20 33 4 88 2 801 wer 01 60 vor ves eu 211 20 HOLMS 03945 HOMS Pi pi 198 vlzHe Z0 MOOWAINI 20 ves Cond vU iu 1 4 MEL Um i 02 HOT 2472 ou e gt 4 Z0 aionzios 20 20 1 12 60 86 86 86 86 1 NILA 74 als 615 kai Ta EN te 12 iis ANG LOVYLIY go 4 43H 4E Hy 2 GIONJIOS MOTO YAMOd 20 hH E va W r3 zo w 82200 201 gt 4 e P Vs 20 TIVAS 891 O 21 22200 NIXA 4 915 LIS 81 Ta a M wi vert vel 20
24. 0000 FROM 20A GROUND CIRCUIT BREAKER E TO CHARGER 5 il E TO CHARGER 119365 1 DC Electric Full Size Rough Terrain SKYJACK Page 21 Models 8831E amp 8841E 155154 View Parts List Print This Page 3 13 Electrical Schematic ANSI CSA 5 8 8 S ay 5 Lo x y n F 1 i No o gt 1 x j sz 200 GIONFIOS ANFLE 661 YA 20 Viro 8 a 1 GIONTIOS 1OVHI3H yo V 3 ase 14571 4 7 20 MOVIE bl 525 z z0a QIONTFTOS Je YIDOIMLNO 20 2 XOVI8AnT8 L NI 19 GIONTIOS LOVULFH ve n 988 you U399IuLDO H d 20 eZ HH 228 rezoa GIONTIOS 161 TFDDIHLNO 4 4 20 92 a L NO Vi cfs 15 GIONTIOS LOVHIIY gg 988 you A H 20 22 22 4NOU4 18 rl GIONFTOS YFDDIHLNO 20 GL MOVTE JONVHO 52 L NO 1 QIONTTOS 10VHL3H m a
25. PIN9 YELLOW 24 PING GREEN 29 PIN 7 BROWN 59 PIN 6 BLACK 02 PIN5 BLACK 02 PIN4 BLUE 120 PIN 3 ORANGE B PIN 2 WHITE ORANGE A PIN 1 RED 120 DC Electric Scissor Lifts SKYJACK Page 3 Compact Series e o Service and Maintenance kn 5 1 2 Controller Wiring Diagram 24__ 12C_ SKYJACK Page 4 ESL e 02_ Section 5 Procedures RLY2 3 GRN O GRN PIN 8 _YEL___PIN 9 L JA i T c D Gk 711 RED Ul R UT cc RIVE MODE 6 STEER POWER O LEFT STEER RIGHT STEER RLY1 BLK BRN VIO ANALOG SPEED BRN 4 x 59 BRN 7 BLU m O 2D BLU PIN 4 T 6 RED BLU A NABLE GRIP V
26. 20 FUSE F15 6 3A FUSE F16 1 WHT BLK WHT VIO RED BLK RED WHT 29 WHT BLK ORG BLK GRN BLK WHT RED 86 Pt il ezoa 52 HOSN3S LAN of 2 91 20 20 ri 22 8 21 JH 26 GIONFIOS Dvd 98 06 21 7 OF HE HOSNJS NOLLOVHL Hi 20 20 ve ve 21 DIVYAMINO 99 105 HINO b 20 GEHE 52 21 7 HOSN3S 14 1 ES 20 20 ZE ki 28 01 4 HOLIMSALINIXObd 157 26 9 20 20 N3dO ATIVWYON QIONFTOS 1dIHS 16 HOLIMS 20 VZEHE vee 60 80 131 os VRE vee m GIONTTOS ONIOTOH XOBYVID 20 8r gt gt gt m 81 A 12 GIONTIOS 14 814 2t FINI 20 vee 15 4 MOILSAOP YIIZ 20 20 20 J 321 7 azi AVTIU HOSN3SNOLLOVHL S ta m 01 OL FIGI bi N3dO m 7 Ron vee 801 801 HOLIMS ALINIXOdld v a Ld VoL voL vol 20 SWHOZSHOLSISJH 20 ez 2 5 HOVES AVIBY 5 03305 1 20 2
27. L LL lt cw a c 1 E la 2 tu O z diem Q I uzzzz w 4 1 ZUZI I 3 z gt lt e M a 2 ej H lt lt lt lt 2 Z Z a A a gt SEREEN xx eo a 4450 TSE 2 ZOGGOG u QOIS i a O Wood TISE gt M J anan gt 00 A gt 022222 2 en H Lu m gt lt i em lt m 2222 gt F 2222 55 a Vw v ou zi a 2 1 x lt lt z ou 2 lt E a I d a a on 4 sasa lt I O 9 lt O I 5 59 2 O r it ar 5999 ui 5 2555 m gu Su v D Og 222205550 a gt d Q 2222228 2 Zi gu a x 5 L 2 lt EL 2 ZO ma a 22222222 B cil Zz Og Laat c cs 6 ab 2 zzz aj I GO Qo Wi rE rororomro M 7 D Q c 22222222 HB a E
28. S9A OUTRIGGER ENABLE SWITCH ge D 2 PIN 1 35D PURPLE WHITE LM PIN 13 79 GREEN OL1 PIN 14 N U PIN 2 35C x 3 WHITE BLACK BLUE WHITE GREEN WHITE OUTRIGGER LIGHT PIN 15 N U PIN 3 350 PURPLE WHITE 70 RED WHITE 02 WHITE E ou E H m D TT BLUE WHITE N U m EGAL GREEN WHITE N U OUTRIGGER CONTROL CABLE M129300AB2 SKYJACK Page 14 DC Electric Full Size Rough Terrain Models 8831E amp 8841E 6 155154 Service and Maintenance Section 3 System Component Identification and Schematics 3 7 Electrical Inverter Wiring Diagram View Parts List
29. 20 D 6r or or VT NOLLdO uH ee u3awvoNuviOu 8 17 20 vaz NOLLOND TIY VES ve pn UMS Vez H B IHSVII Ove VE et 4 24 D 20 22 YIDWAP Wuviv SWHO 061 962 NOL NN ve 9 esu e 4 E 20 862 862 ygzg YEZ vez zag 9 HOLlVdvO 40470 GL H3d338 20 m e 91 62 EL al 04 as H313WOHOVI 121 NODAIS IAS YOLIINNOD AVM Z1 LP 31 YOLIINNOD AVM LI L M m 00 21 407 4 ve VA eL K ATIVAHON HOLMS 19 20 20 09 VV a 91 407 HOLIMS FUNSSIYd 65 emm ve Lr 82 82 2 77 16 15 14 3 2 lt 4 49 4 VIO GAN WHT BAN BLU ORG GAN BLK BLK RED BAN 99 RB A7 R6 A5 Ra VIOWHT WHT VIO WHT RED GAN BLK BLU BLK BLU WHT BLK WHT WHT GRN RED BLK WHT BRN VIO WHT RED WHT WHT BLK ORG BLK 8OI93NNOO AVM 01 59
30. BE AWARE of crushing hazards Keep all body parts inside platform guardrail DO NOT lower the platform unless the area below is FA clear of personnel obstructions ENSURE that there are no personnel or obstructions in the path of travel including blind spots BE AWARE of blind spots when operating the aerial platform 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 DO NOT use the aerial platform without guardrails locking pins and the entry gate chain bar in place DC Electric Full Size SKYJACK Page 11 Rough Terrain 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 distrib uted 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 an other object to steady the platform DO NOT place materials on the guardrails or ma terials that exceed the confines of the guardrails unless approved by Skyjack IN WARNING Entering and exiting the a
31. PISH 170 5 L d 801 902 Voz voz voz zo 7 7 Sed OL LI 04 XOVT8 NSHHO 02 TT Itt Qed 64 me 64 62 a ras Bene 318VN3H3O9IMIQO 6 096 Q310VH L3H ose 086 065 NI NMOHS 5 w H3MOd 66i 01 1 p E ANOU 1431 ves 1497 81 ose 31HWN33HO NOH 1HOIH NMOQ INOHJ1HOlM 261 d v99 51 961 9 9 s 22 4991 1437 Q 1337 91 bed v89 ai 4 8991 318VN3IdIl 99 N3dO 38070 ATIVWYON SIHOLIMS LINITNMOG 1 624 N N 4001012 HOIH Byes 6 Bese set 1497 161 trwa 8 4 061 LL NMOG LNOYSLHOI 621 94 4 v NMOGANOUJ1431 821 94 4 v 197 221 4 sav 921 4 821 Lbd 24 4 1 14 4 AVIFH HAMOd 4 NIV 20 20 36 aza v 82d NO LON 8236 AVIBYFTAVSI 22 4 20 20 60 56 36 Y 108
32. 49 9 8 LI L 2 2 mum lolz SE s LEPEP s kalis assi S ey 5 5 55 SaS B8 99 a a gt EIE 55556 aL 9 4 00 00 ave MOT 9 lt 555555 ve 035010 Em E 29 i g EIS 4 HOLIMS 3UfISS3Hd 19 20 20 254 09 4 L 91 HOLMS 55 3vuH 69 e Prog 06 ve az 82 88 P P ezoa 92 YOSNIS LAN 0 2 Via mo 91 AVIFYFNWA 16 lt gt 20 20 ZE 02 Z 7 ma Hed FYAB 99 ta 06 21 T ae Yosz l DIVYA 98 Zz ve 2 GIONTIOS 59 a p HOZE AVTIH HOSNJS 447 z z a 4 HOLMS ALIWIXOHd 147 tS 20 al N3dO GIONTIOS 1 6 19 HOLMS ALIMIXOHd 20 vee He vee 60 60 LAI ad 08 gt gt szoa YEE vee GONJIOS L 20 8r pi ezoa 1 4 eau GIONTIOS 1 6 147 Le m vee y z a MOUSAON HOE HOLMS ALINIXOHd INYA 9r sn at AVIFYYOSNIS NOULIYUL 9 za 4 2 po HOEE OUvMUOJ N3dO Tou ve 801 801 HOLIMS
33. 17 5 93 Tachometer Board Fin HeIBIBIIDR korid p apt kalm lak pk af n compa e isk m kap a oka bn ok ke bi uM eua ki be afe a 19 5 3 4 Tachometer Generator Testing nennen nennen nnns naar nns n nnn nens 20 Outrigger Option 5 4 1 Outrigger Mechanical Limit Switch Wiring nnnm nnn nnns 21 5 4 2 Auto Leveling Outrigger Setting and Error 22 5 4 3 Auto Leveling Outrigger Error Code 23 5 4 4 Hand Held Calibration Diagnostic Tool Key 24 545 Outrigger Control Module FET OU AAS aea decina po Ret Ma d dd da EE ART Ir UR AUR EUM E E FREU ka lis kk 25 5 4 6 Auto Leveling Outrigger Control Module Pin Reference 28 Load Sensing System CE 5 5 1 Control Module Pin Reference sas dx Und UE ves 29 3 52 LED Error Codes Quick Reference eee oswa aa ik kit a a ki a a pk ni a a e pan kk pera dos oi k 30 5 5 3 LED Error Codes Code Breakdown LIST s k saaa bani ak l n l pi nt ka a ok pan a a Ba 31 5 5 4 Control Module Load Calibration Code Messages 8 33 5 5 5 Control Module Load Calibration 0400 37 sop Curve aroun Codos 4
34. 16 4 1 24 All Outriggers Inoperative Auto Level Only B Led Power Indicator Light at Outrigger Control Module OCM 1 17 4 1 25 Left Front Outrigger Inoperative 18 4 1 26 Right Front Outrigger Inoperative 18 4 1 27 Right Rear Outriggers Inoperative 18 4 1 28 Left Rear Outriggers Inoperative 19 4 1 29 Individual Outrigger Functions Inoperative auto level 19 PETI cR 19 4 1 31 Auto All Up Inoperative Retract e kk is kk n a pe m pk ki e a ik 20 Hydraulic System 4 2 1 All Controls tn ki a t ak lak m ii pdi le ie e ap kk id kk ba n bi a kiba kan pop bu lala kisa isk ao kiba 21 VI koko kat kon a ka ip lots m mmm 21 4 2 3 Brake Will Not Release bo kr tie p v bn kak k popi na daki 21 CR gl ti a pi aa E a n a ak kn e a ea pe a pa ta eke me am pa ee 21 4 2 5 Work Platform Does Not Lift pit a piy ek kb kl iben a p apik ak SM 21 VOTE PWAN LANS SIONI risi on kap d a tk ai a ak o Md bad ak kk a QUK cM kk a n a ki kk 21 Fuli Size Rough Terrain Series SKYJACK Page 1 Models 8831E amp 8841E 155154 Table of Contents Continued Hr
35. 3SV8 E SLIWIT030 ON 8 50 20 dau 20 YZ x pete ca 80 YAW W3IH3ANI 20 20 B3LH3ANI 00 TANI RE vos 423NNOOSIG NIVW 2 bla 8 AHILIVA 9 e ep os ek e SSS SF ISNI AbzLIVa AtALIVA AbzALIVA AtALIVA AGIFILIVE AH3LLVE AgALLVE AtALIVA voor T A918 A9 28 9 8 A998 4 vi 9 59 9 98 4948 A988 H 10 1 213 8 SAVTFG 100100 AYFLIVE e Lu21 SH3OHVHO AYALIV 298 2 3OVLTOA INIT 39VLTOA OWA OLL OWA OLL SKYJACK Page 22 Section 4 TROUBLESHOOTING INFORMATION Table of Contents a AET EN oe kre l ERROR ECCE 3 Electrical System KO 4 4 1 2 All Controls Inoperanve From Platform kado s Aba 5 4 1 3 Base Controls 5 4 1 4 Up Circuit Inoperative From Platform Machines without outriggers 44 5 4 1 5 Up 6 4 1 6 Up Circuit Inoperative from Platform or Base Controls with Outriggers Retracted lift operates correctly with Outriggers 6 4 1 7 Up Circuit Inoperative from Platform or Base Controls with Outriggers Extended
36. Diagnostic sequence dependant on LED flash code No Last Caldate Load Not Calibrated Height Not Calibration An EZcal is required Waiting For Neutral Drive Lift Inputs Faulty Up Down Select Inputs Active Together EMS Inputs Faulty Check inputs on P2 pins 1 2 3 4 5 6 7 8 3 4 Short To Supply P3 4 Short To Supply P3 6 Short To Supply 46 Disconnect plug If fault clears there is a problem with the wiring from P3 4 or P3 6 to the rest of the vehicle Armguard Active Elevation Switch Shifted Elevation Switch Stuck 22 lf the 23 flash code is triggered by armguard it will occur once then clean This is not a true fault but just an indica tion 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 3 4 Short To OV P3 6 Short To OV Disconnect plug 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 5 zero pressure and 4 5V maximum pressure and should vary as the platform load amp position varies Waiting For B on P2 12 B Supply Too Low P4 1 Or P5 1 Short To OV Check that the battery voltage is not too low Verify battery voltage on P2 12 Disconnect plug P4
37. HOLOVINOO NIVW 5 Em zw 282 HOLVOIONI AVI 91 FOUVHI G3W 1HM NHO YOLOVINOO 91 m 22 0001 YOLOW HIS bi 5 301 1 00 8 2 8 YOL 814 ZWOG OIALLHAM L Le 00 NOIEWIOU 86 86 001 vez vez vee piza ISNI 2 la 20 20 ae 00 001 SLIAFT ON LINOUID Voz ol 358 goi indinooanre 5 00 09 i ae ve VUA MSS3ud ON 0 0 a p ve zo 20 vi vi zo DaN SaNa YOL L 38010 o woo ner T HOLIMS e 40 2 2 8 ga YE NOILISOd 23 NOISN3IX3 HOLIMS dOLS HOLIMS AZ 187 3199 257 dois HOLIMS AI 6 AONFOYFWI TIQVNI FSYA LLTI TIQ WHO4LV 1d 4HO S v8 H31HSANI 20 20 5 55 48 85 NOldO g H31HSANI 00 Fer Pole ISNI LOINNOOSIO NIVW He SKYJACK Page 20 View This Page Parts List 3 12 Electrical System Wiring Diagram ANSI CSA UG 2 ReD HORN 49 GREEN BEEPER 220 LACK
38. Schedule P Schedule Schedule Maintenance nspections Base assemby LL as Ladder Outriggers If Equipped Labels Limit Switches 2 3 d 3 a gt Battery Tray Battery Battery Connectors gt Fuse Box PIP w lt a 5 A 5 a 9 d 5 rt gt UJ gt gt Electrical Panel Manifolds Base Control Switches gt anual unction Tests gt p 1 8 gt Emergency Lowering Rod est Battery Connectors D 2 9 2 5 Test Base Emergency Stop A B Test Off Platform Base Switch AB Test Lower Neutral Raise Switch TexEmegenyloweme AB Platform Control Console Test Platform Emergency stop J Test Enable Trioger Swt A8 Test Platform Raising Lowering AB I Test Lowering Warning CE AE KOT i _ k t 8 Test Elevated Drive Speed as T kon 1 184AA Hydraulic Tank Hydraulic Oil Battery Charger v 5 9 3 a e 3 lt Lanyard Attachment Anchors AC Outlet on Platform Platform Control Console Powered Extension Control Console If E
39. 982 HOLOWNOLLOVHUI 12 2 0 LINIBIO voz 02 20 2 00 20 vaz 182 HOLVH3N3O 61 21 m a HOLVOIONI 2 l L 1 20 20 82 EdvI 179019 319 079 HOIOVINOO 21 00 Gok 2 WO HOLVOIONI FOUVHI AH3LLVB 20 82 DE AVIFG LIL 9 20 1 0019 NYO BOLOVINODJ 81 I 001 22 Po E 3505 315 7 7 1 gt 813 001 L vec 301 8b 301 00 8 8 NO 21 35 4 4 20 20 ae 001 WOR E oanez 00 nog Me apo P ae 7 yaya ae MS 5384 ON yo gt 0 dg met sL pei 935072 435072 L 0 woo Aer 50 HOLMS LIMIT zo NOLLISOd FIAI 423 NOISN3DGI HOLIMS 4018 157 3109 257 4018 HOLIMS ADL AONJOHSMS WHO4 LV 1d 440 35 V8 ve 8 E 45 88 vec MOVTANITYI vez e
40. Check for continuity Replace if defective 2 Loose or broken wire 02 from outrigger board to pin P2 11 on the outrigger control module 1 Check for continuity Replace if defective 3 Defective outrigger control module 1 Replace SKYJACK Page 16 Full Size Rough Terrain Series Models 8831E amp 8841E 6 Q 155154 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 24 Outriggers Inoperative Auto Level Only 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 PROBABLE CAUSE REMEDY Batteries Disconnected 1 Reconnect batteries LED is off No functions 2 Defective Sevcon 2 Replace Sevcon 2 Flash Fault 1 1 Lift or Drive Selected Before First Power Up and then Select Power up Function 1 Sevcon Shorted 1 Replace Sevcon 2 Drive Motor Shorted 2 Replace Drive Motor Procedure Fault 1 Contactor welded 1 Replace Contactor 1 Contactor not shifted 1 Clean Contactor Replace if defective 2 Defective Sevcon 2 Replace Sevcon 1 Loose or broken wire 59 from 1 Check continuity Replace if l upper control box to Pin 14 on defective No Drive Sevcon and Lift 2 Open or defective Base Speed 2 Check Relay Replace if Relay 59ACR defective Low Battery 1 Batteries have dropped below 1 Rec
41. 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 amp 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 amp 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 upd
42. Test between pin 6 and wire 02 48 volt input from line contactor Test between Pin 6 and wire 02 with Key Switch on Tilt switch input 24 volts full speed volts 50 full speed Test between pin 7 and wire 02 Forward Up input from joystick 24 volts drive forward or lift up selected Test between pin 8 and wire 02 Not used Pin 10 Not used Pin 11 Pin 12 Pin 13 Pin 14 Pin 15 Pin 16 Pin 17 Reverse direction input from joystick 24 volts reverse selected Test between pin 11 and wire 02 opeed 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 volts forward Test between 12 and wire 02 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 Accelerator input 3 8 to 4 2 volts with joystick in neutral and key switch on 3 5 volts slow speed volts fast speed Test between pin 14 and wire 02 Forward contactor output Brings B to forward drive contactor Test between pin 15 and wire 10A Drive Lift Select volts drive 24 volts lift Test between pin 16 and wire 02 Reverse contactor output Brings B to reverse drive contactor Test between pin 17 and wire 10A DC Electric Scissor Llfts Compac
43. if the fault clears there is a wiring fault from P4 1 to the rest of the vehicle DC Electric Scissor Lifts SKYJACK Page 31 Compact Series 155147 6 Q Service and Maintenance Section 5 Procedures 5 5 3 LED Error Codes Code Breakdown Chart Continued 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 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 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 Fault Bad HWFS Fault Bad Slave Analogs Fault Bad Strain Monitors Fault Bad Slave Micro Fault HWFS Stalledi 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 6 Q 155147 Section 5 Procedures Service and Maintenance 5 5 4 Control
44. 1491 Vim FDDIHLNO 4 1 20 4 4NOH4 lt lt 028 155154 119365 201 20 20 3LIHM 20 SWHO 055 FISH GNnOHO 20 Models 8831E amp 8841 Stt L ad gol 902 voz voz voz 20 TATION bel Sed 04 oz 04 Ta i Ged 64 Tann 62 64 HS 6 ISE 1 1 SE XOVIB ALIHM ose ose NI NMOHS SH3O9IHLDO H3MOd iti 01 ose 3UHWAIa Ose H3DOUINO ves ase 1331 1441 bed vs9 5957 ISE 3LIHWNIJ99 ISE ANOU3 vag 01 1NOHJ1HOIH 681 5 24 99 NMOG 861 2 2 029 vz 1 0 49 E 1597 veg 01 8957 1457 L L Ld 89 DC Electric Fuli Size Rough Terrain TIAVNILIM 961 829 69 N3dO THH 0350710 NMOG YFD9 B LNO SOU 6 382 100109 INYA HOIH 3aIuu3 0 LTL vel 01 vot 1431 EEL 1 82 NMOGHUV3HIHOIlH ZEL td 22 N
45. 9241 67 38 SJRT 9250 9250 DC Electric Full Size SKYJACK Page 7 Rough Terrain Q 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 Lbf ft max Cartridge max 5 42 to 6 78 SAE Plugs Lbf ft max 4 to 5 48 to 60 Torque 2 5 6 Lbfft max 3 300 33 90 Newton meter Nm Pound force foot Ibf ft Pound force inch Ibf in SKYJACK Page 8 DC Electric Full Size Q Rough Terrain Charts 3 1 3 2 Section 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS Table of Contents Parts List 3 3 3 4 3 4 aa e it pe ete ae f ot et ten e ko n e in n kin 3 KONN KAN sa ak wal ka kab 4 Farts MEET pei a on 5 n a pte ee es n eee ee ees 7 3 RAN MN c NR E n ola kk kok a n tein a n aaa fon T apa ko a IINE 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 25 Platform Control Console Wiring
46. 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 24 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 26 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 S AN OO AN DC Electric Fuli Size Rough Terrain Models 8831E 8 8841E 155154 Service Maintenance Section 3 System Component Identification and Schematics 3 4 Relay Function Chart SUPPLY B Common E CONTROL 65 Gb GROUND B 0 4 870 pi 108589 1
47. Battery negative Pin 2 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 volts forward Test between pin 2 and wire 02 Pin 3 Tachometer generator input Pin 4 Direction signal to Pin 2 of controller volts forward 15 volts reverse Test between pin 4 and wire 02 Pin5 Tachometer generator input Pin 6 Steer enable Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14 Pin 15 Pin 16 Battery Negative Lift mode selected 24 volts when lift selected Test between Pin 8 and wire 02 Drive mode selected 24 volts when drive selected Test between Pin 9 and wire 02 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 Spike suppression for 24 volt B Not used Spike suppression Not used Not used Not used DC Electric Scissor LIfts Compact Series 155147 SKYJACK Page 19 Service and Maintenance 5 3 4 Tachometer Generator Testing Procedure 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 Mark the location of the wires attach
48. DOW kl Bar be p be kin kitap e ke dni apa bu 22 DOWN GIF MODERN aaa a doua a kak oki e fa aa a e kk Ut 22 4 2 9 Powered Extension Platform Will Not Extend Or 0 1 44 1 22 4 2 10 Work Platform Does Not Shift Between Lift And 0 1 22 4 2 11 Outrigger IDGDS b ks ap ok kl Dub ak tot ka ek sann ka ik ki ab bk m ka ine ae a 23 SKYJACK Page 2 Full Size Rough Terrain Series Models 8831E amp 8841E 6 Q 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 num ber represents the probable cause The following line noted by
49. 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 DRIVE SEVCON TACHOMETER CARD TACHOMETER GENERATOR RELAY Inverter Timer Cut out HOURMETER LED BLOCK Red Trouble light SEVCON CONVERTOR lt lt DC Electric Full Size Rough Terrain Models 8831E amp 8841E 155154 Service and Maintenance Section 3 System Component Identification and Schematics 3 8 Hydraulic Manifold Components and Port Identifications View Parts List TO 52 PRESSURE TO 4H 23A SWITCH GEARBOX mE RIGHT STEER 4H 24A TRACTION VALVE LEFT w CO GEARBOX Wis gt lt VALVE GAUGE 4H 33A EM LIFT 9 GEARBOX VALVE 4 5 VALVE LIFT CHECK R2 VALVE GEARBOX 2H 13 1 RELIEF VALVE VALVE G LOWERING No T SYSTEM LIFT GAUGE G XN LOWERING O5 2H 30 ORIFICE BRAKE RELEASE Gus SMALL PUMP LARGE PUMP CHECK CHECK VALVE VALVE 2 140 LIFT O6 2H 21A TO VALVE DUMP DUMP PUMP TO RETURN SMALL FILTER PUMP M10307AA DC Electric Full Size Rough
50. Models 8831E amp 8841E 6 Q 155154 Section 5 PROCEDURES Table of Contents Service and Maintenance PI EN AN A JO EY pee E BE EY AE ON 3 e at a kt aki kk ak a f ees DEP 3 Platform AM l ko it op tk n te ali el kak en an ki n a so A eki ko eli 3 e RINT m tem 4 Base 3251 System Pressure ACSI 5 5 2 2 Gearbox Relief Pressure 5 2205 BUO SUIT FS cc 2 bank 5 ENKONI M REOR ME TNR Tp 6 5 2 5 Proximity Switch Replacement and Adjustment Fi 5 2 6 Proximity Switch Test PLOGE OU NB cus daret phano as ons kat vive de k s pt a d named ii kob kd ob kl a n nal k n e kb UE 8 5 2 7 Wheel Bolt Nut Inspection and ede IRE deeds ka 9 5 2 8 Wheel Reinstallation and Torquing Procedure 9 AA ANN RUD ENN dp pip bak al 10 Sevcon Calibration 5 3 1 Sevcontroller Adjustment and 444420080 12 38202 Controler Fin etai ka e A a Gua a ol a ok e pp pp a n a
51. Positive Signal to Angle Transducer Negative Signal to Pressure Transducer P4 8 902 White 0 Negative Signal to Angle Transducer P4 9 1910 Black Positive Signal to Pressure Transducer 189AA Compact Series 155147 6 Q SKYJACK Page 29 Service and Maintenance Section 5 Procedures 5 5 2 LED Error Codes Quick Reference Chart IN GROUND MODE 7 8 6 3 2 3 4 5 6 3 4 5 6 4 7 1 7 2 P3 4 SHORT SUPPLY 60405 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 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 oince 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 6 Q 155147 Section 5 Procedures Service and Maintenance 5 5 3 LED Error Codes Code Breakdown Chart
52. 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 SKYJACK Page 19 Models 8831E amp 8841E 155154 6 Q Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 1 31 Auto Up Inoperative Retract 1 Loose or broken wire 350 from outrigger enable switch S9A to auto mode outrigger switch 524 Check continuity Replace if defective 2 Defective auto mode outrigger switch 524 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 Check for power at P2 10 If no voltage present ch
53. 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 DC Electric Scissor LIfts SKYJACK Page 27 Compact Series 155147 6 Q Service and Maintenance Section 5 Procedures 5 4 6 Auto Leveling Outrigger Control Module Pin Reference Chart 2 PIO 296 006 OSC AOE aoe 066 NOG U AMOR LED GP106 Control Module 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 70B Red White 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 2 Main Power Input 78 Black White Output used to extend the LEFT REAR outrigger Output used to extend the RIGHT RE
54. functions should not operate Select and hold off platform base key switch to AA base position Attempt to raise or lower the platform Result Platform raising and lowering functions should operate Test Lower Neutral Raise Switch 1 Select hold off platform base key A base position and switch to 1 raise the platform with lower neutral raise switch Result Platform should rise Select and hold off platform base key l base position and wl lower the platform with lower neutral raise switch Result Platform should lower switch to DC Electric Full Size Rough Terrain 27 Function Tests Section 1 Scheduled Maintenance Enable Trigger Switch M Lift Off Drive Switch gt Lift Drive Steer Ny j lt amp 2 amp Operation Light S Test Emergency Lowering 1 2 Raise the platform 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 On hydraulic electrical compartment pull out and hold emergency lowering valve to fully lower the platform Result The platform should lower To restore normal operation depress and turn holding valve manual override knobs clockwise Rocker Switch Lift Drive Steer Controller Ba
55. inspection receives a fail tag and remove the aerial platform from service e f 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 DC Electric Full Size Rough Terrain SKYJACK Page 15 YO Service and Maintenance Inspections Section 1 Scheduled Maintenance Table 1 1 Owner s Annual Inspection Record Model Serial Number Inspection Date Recording Year Owner s Skyjack Name Inc Skyjack Inc 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 Q Rough Terrain Section 1 Scheduled Maintenance Service and Maintenance Inspections SICYTACIC Table 1 2 MAINTENANCE AND I NSPECTI CHECKLIST Serial Number Model Hourmeter Reading Name Printed Date Time LLL 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 I NSPECTI ON FREQUENCY Inspection Schedule pay 55 L FREQUENTLY FAIL L ANNUALLY A B C REPAIRED 1 BI ANNUALLY Bi annuallyt A B C D
56. 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 raise
57. 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 Reset circuit breaker Replace if defective 17 Loose or broken wire 3A from converter to circuit breaker 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 55 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 57 Check continuity Replace if defective SKYJACK Page 4 Full Size Rough Terrain Series Models 8831E amp 8841E 6 Q 15515
58. Diagram RES 13 3 6 Outrigger Control Box Wiring DISAAT n ian pk oer een 14 3 7 Electrical Inverter ci MEE mU EEUU TM 15 3 8 repre CRT 17 3 9 Main Manifold Harness ANN RE T 18 3 10 eu Syst m Wiring Diagram CE L ki m UU e 19 3 11 SU PII E T RETI FE LE so EE issn Hin E EE e 20 3 12 Electrical System Wiring Diagram nennen nemen nnn rn nennen nnns nnns anna 21 912 Electrical Schematic ANSIOSA rtt t nc o cR ka otl rd i dw in 22 DC Electric Full Size Rough Terrain SKYJACK Page 1 Model 8831E amp 8841E 155154 YO SKYJACK Page 2 DC Electric Full Size Rough Terrain Models 8831E amp 8841E 6 Q 155154 Service and Maintenance Section 3 System Component Identification and Schematics 3 1 Electrical Symbol Chart 1 ANGLE WIRE CROSSING HOURMETER KEY SWITCH ini TRANSDUCER WIRES JOINED Q9 LIGHT FOOT SWITCH _ PRESSURE TRANSDUCER HYDRAULIC LIMIT SWITCH 4 BATTERY VALVE COIL TOGGLE SWITCH ur PROPORTIONAL LIMIT SWITCH GROUND HYDRAULIC 2__N O HELD VALVE COIL CLOSED LIMIT SWITCH ELECTRIC FUSE MOTOR 01 N C CIRCUIT LIMIT SWITCH BREAKER N C HELD OPEN ERE EMERGENCY CAM OPERATED 2 CONTROLLED INDICATOR STOP BUTTON RECTIFIER
59. 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 amp logged data ACCESS LEVEL Select this menu amp 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 1 NOTE this menu provides for set ups which are needed to configure the 1 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 OCM 1 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 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 Hi
60. Low Battery Cut out ELEVATED CURRENT Amps Max Current When Elevated BRAKE Seconds d Brake Personality Timer Seconds All aerial platforms will use default settings unless specified NOTE Skyjack does recommend exceeding the default settings AN 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 6 Q 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 O Diagnostic Procedure IN 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
61. PROXIMITY CAPACITOR AAA RESISTOR 1 SINGLE POLE S POTENTIOMETER on LEVEL SENSOR THROWN SINGLE POLE DOUBLE POLE DOUBLE POLE DOUBLE THROW SINGLE THROW DOUBLE THROW NPN RELAY i RELAY RELAY TRANSISTOR 0 ge TRIPLE POLE PRESSURE DOUBLE THROW DIODE G9 TRANSISTOR VACUUM RELAY SWITCH TEMPERATURE SWITCH DC Electric Full Size Rough Terrain SKYJACK Page 3 Model 8831E amp 8841E 155154 6 Q Section 3 System Component Identification and Schematics Service and Maintenance 3 2 Hydraulic Symbol Chart VARIABLE LINE CROSSING DISPLACEMENT SHUTTLE VALV 4500 VELOCITY FUSE PUMP HYDRAULIC CUSHION AK RELIEF VALVE CYLINDER DOUBLE ACTING CYLINDER ACCUMULATOR SINGLE ACTING LINE JOINED HAND PUMP GAS CHARGED CYLINDER HYDRAULIC PRESSURE DOUBLE ACTING FILTER WITH REDUCING 2 19 douse BYPASS VALVE RODDED SPRING APPLIED HYDRAULIC RELEASED BRAKE ELECTRIC Pol MOTION MOTOR FIXED ORIFICE CONTROL VALVE ADJUSTABLE FLOW DIVIDER BRAKE ENGINE FLOW CONTROL COMBINER CYLINDER PUMP BALANCE VALVE ACTUATOR BI DIRECTIONAL HYDRAULIC MOTOR THREE POSITION FOUR WAY OIL COOLER VALVE COIL PROPORTIONAL FIXED DISPLACEMENT COUNTER 9 ROTARY SERIES TWO POSITION THREE POSITION PARALLEL TWO WAY FOUR WAY HYDRAULIC NORMALLY TWO POSITION ET CLOSED CENTER MOTOR CLOSED THREE WAY OPEN PORT TWO POSITION THREE POSITION THREE POSITION TWO WAY TWO POSITION FOUR
62. Use ladder to dismount from platform 6 On battery roll out tray ensure battery connectors are properly connected 7 Onbase control console pull out 6 emergency Stop button A beeping sound should be audible and light should come on DC Electric Full Size Rough Terrain Section 1 Scheduled Maintenance Function Tests Emergency Lowering Valve Off Platform Base Key Switch Platform Lower Neutral Raise Switch Emergency Stop Button WARNING 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 1 Push in base e emergency stop button and attempt to raise or lower the platform Result Platform raising and lowering functions should not operate 2 Turn key clockwise to activate base 9 emergency stop button 2 Pull out base W emergency stop button Test Off Platform Base Switch AN WARNING 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 Holding Valve Manual Override Knob Select off platform base key switch to A platform position Attempt to raise or lower the platform Result Platform raising and lowering
63. VALVE Check Large pump 104567 1 VALVE Check Brake 104567 1 VALVE Check Lift 104567 1 VALVE Check 104567 1 VALVE Check 104115 1 VALVE Check Left front outrigger 104115 1 VALVE Check Right front outrigger 104115 1 VALVE Check Right rear outrigger 104115 1 VALVE Check Left rear outrigger 109568 1 FILTER Return 104254 1 ELEMENT Filter 110652 1 PUMP Hand 108803 1 MANIFOLD BLOCK Main 113494 1 MANIFOLD BLOCK Lowering 130443 1 MANIFOLD BLOCK Holding valve 106688 1 MANIFOLD BLOCK Holding valve 107382 1 MANIFOLD BLOCK Powered platform 119748 1 MANIFOLD BLOCK Lift 116586 1 MANIFOLD BLOCK Quick brake 111970 1 MANIFOLD BLOCK Outrigger 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 SKYJACK Page 5 Model 8831E amp 8841E 155154 6 Q Section 3 System Component Identification and Schematics Service and Maintenance 3 3 Hydraulic Schematic Parts List Continued Skyjack 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 Parts list continued from the previous page VALVE Manual lowering VALVE Controlled lowering VALVE
64. WAY FOUR WAY NORMALLY THREE WAY CLOSED CENTER PROPORTIONAL OPEN CLOSED PORT PRESSURE S VARIABLE MAIN LINES Solid PILOT LINES Dashed DISPLACEMENT TRANSDUCER HYDRAULIC MOTOR QUICK DISCONNECT SKYJACK Page 4 DC Electric Full Size Rough Terrain Models 8831E amp 8841E 6 Q 155154 Service and Maintenance Section 3 System Component Identification and Schematics 3 3 Hydraulic Schematic Parts List Skyjack Ko n 114218 120481 120481 120756 116725 123853 119999 700669 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 130440 122420 122420 104534 104534 106557 106557 120349 1 CYLINDER Lift 120349 1 CYLINDER Lift 120275 1 CYLINDER Extension platform Front 120275 1 CYLINDER Extension platform Rear 120412 1 CYLINDER Disc brake 120405 1 CYLINDER Steer 132694 1 CYLINDER Outrigger Left front 132694 1 CYLINDER Outrigger Right front 132694 1 CYLINDER Outrigger Right rear 132694 1 CYLINDER Outrigger Left rear 104567 1 VALVE Check Small pump 104567 1
65. 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 Service and Maintenance Inspections Battery Charger Sight Gauge Battery Chargers Ensure chargers are secure and shows no visible damage SKYJACK Page 21 Service and Maintenance Inspections Platform Control Console E 1 1 6 Platform Assembly WARNING Ensure that you maintain three points of contact to mount dismount platform Use the ladder of aerial platform to access platform Close the gate Ensure there are no loose or missing paris 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 AC Outlet on Platform Ensure outlet has no visible damage and free from dirt or obstructions SKYJACK Page 22 Section 1 Scheduled Maintenance Platform Railing Platform Assembly Platform Control Console Ensure all switches and controller are returned to neutra
66. 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 702 Replace if defective 5 Defective fuse F7 Replace fuse 6 Open or defective diode 012 1 or D12A Check diode Replace if defective 7 Open or defective diode D12C Check diode Replace if defective 8 Brake not releasing 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 amp 8841 6 Q 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 defec
67. at outrigger board to valve coil 4H 72 retract or wire 76 from pin 10 to 4H 76 extend Check continuity Replace if defective 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 2 Defective right outrigger switch 522 at platform Check switch Replace if defective Loose or broken wire 73 from outrigger control console to pin 3 on connector 20 at outrigger board retract or from wire 77 to pin 4 extend Check continuity Replace if defective Open diode D73 retract or D77 extend on outrigger board Check diode Replace if defective 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 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 6 Q 155154 Section 4 Troubleshooting Information Fuli Size Rough Terrain Series Models 8831E 8 8841E Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 28 Left Rear Outriggers Inoperative Manually 1 Defective left rear outrigger switch 523 at platform
68. damage Fuse Box Ensure fuse box is properly secured and there is no visible damage DC Electric Full Size Rough Terrain SKYJACK Page 19 Service and Maintenance Inspections Section 1 Scheduled Maintenance Electrical Panel Hydraulic Pump Motor Main Manifold Base Control Switches Assembly Brake Manifold 1 1 4 Hydraulic Electrical Compartment Base Control Switches Ensure all compartment latches are secure Ensure there are no signs of visible and in proper working order damage and all switches are in their e Electrical Panel neutral positions Ensure panel is properly secured and e Emergency Lowering Access Rod there is no visible damage Ensure is properly secured and there Ensure there are no loose wires or 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 15 no visible damage DC Electric Full Size Rough Terrain Section 1 Scheduled Maintenance 1 1 5 Battery Charger Hydraulic Compartment Ensure all compartment latches are secure and in proper working order Hydraulic Tank Ensure hydraulic filler cap is secure Ensure tank shows no visible damage and no evidence of hydraulic leakage e Hydraulic Ensure platform is fully lowered
69. 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 Thedisplay 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 39 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 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 0 0 0 0 Select the ESCAPE from the menu once 14 The display will show
70. fully lowered Check that the platform is fully lowered then press the ENTER button to confirm The display will show Calibrate Loaded Empty Asking for confirmation that the platform is empty Check that the platform is empty By using the Up Down buttons enter the Yes followed by pressing the ENTER button SKYJACK Page 38 DC Electric Scissor Lifts Compact Series 6 Q 155147 Section 5 Procedures Service and Maintenance 23 24 25 26 27 28 29 30 The display will show Calibrate Load Please Lift Waiting for the lift switch to be activated 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 When the system detects the lift switch closed the display will show Calibrate Load Lift Empty After a delay the system will stop the platform lifting and will take height 8 pressure measurements the display will show MEASURING 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 When the platform reaches full height release the lift switch The display will briefly show TOTAL DATA 04 to indicate the number of measurements taken Th
71. 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 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 10096 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 SKYJACK Page 15 Compact Series 155147 6 Q Service and Maintenance Table 5 2 Sevcontrol Test Sequence Drive Controller Test Sequence Sequence Test Display pot Forward Switch 2 Reverse Switch 0 23 TachometerInput 4 Elevated Position 0 02 5 KET 7 Actual Direction Tachometer Output First Errortat
72. 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 14 or for calibrator Revision 10 see Table 5 1B When the calibrator is unplugged the Sevcontrol will memorize the new parameters settings Diagnostic LED CUNTRUL WIRING SKI a o UH ODF a o n mn SELECT EM Pa Figure 5 7 Sevcon Calibrator Figure 5 8 Traction Controller SKYJACK Page 12 DC Electric Scissor Lifts Compact Series 6 Q 155147 Section 5 Procedures Service and Maintenance Table 5 1A Sevcontrol Adjustable Parameters Software Revision O7 Amps Maximum Controller Current ACCEL Seconds Acceleration Delay DECEL Seconds Deceleration Delay CREEP 4 10 of Max Speed 2 Maximum Controller Current MAX 96 i 5 5 100 of Max Possible Maximum Allowe
73. 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 1 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 amp 8841E 155154 6 Q 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 Depress manual override knob and rotate clockwise
74. level function used to minimize the effect of vehicle vibrations on the tilt measurement Displays the tilt in the X orientation at which the auto level function will complete Displays the tilt in the Y orientation at which the auto level function will complete 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 lf machine is tilted to 1 0 in the X and Y orientations the auto level function will attempt to level the X orientation 0 8 0 5 lt 1 0 but will not attempt to level the Y orientation 0 7 0 5 gt 1 0 RANGE 0 0 to 1 0 default 0 3 SKYJACK Page 26 DC Electric Scissor Lifts Compact Series 6 Q 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 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 4 places left side right side
75. level sur face 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 SKYJACK Page 10 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 lin NS scaffolding or other devices mounted increase its size or work height It is prohibited DO exert side forces on aerial platform while elevated DO NOT use the aerial platform as a crane It is prohibited DO NOT sit stand or climb on the guardrails It is prohibited DO NOT climb on scissor arm assembly It is prohibited BE AWARE of overhead obstructions or other possible hazards around the aerial platform when driving or lifting DO NOT raise the platform while the aerial platform is on a truck fork lift or other device or vehicle
76. missing parts tie rod end studs are locked and Check each wheel for damage and cracked there is no visible damage welds Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 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 Q 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 1 1 9 Manuals Ensure there are no loose or missing Ensure a copy of operating manual and other parts and there is no visible damage important documents are enclosed in manual storage box e Drive Motor 9 Ensure there are no loose missing Check to be sure manual storage box is parts and there is no visible damage present and in good condition Ensure all bolts are properly tightened Ensure manuals are legible and in good e Ladder condition Ensure there are no loose or missing return manuals to the manual parts and there is no visible damage storage box after use e Outriggers Ensure there are no loose or missing parts and there is no visible damage DC Electric Full Size SKYJACK Page 25 Rough Terrain Q Function Tests Section 1 Scheduled Maintenance Battery Connectors Emergen
77. pi NOLIdO Q3H3MOa 20 20 ro tss ISN YOL so gor gzi Su WM ve vel zi TAOID INYO HIH z 21 7 4 VOI 1 a 26 26 gt on 42 25 101 7 l a 4 6 Sora 301 80 did YOLVOIONI pou pi 4 a L n gt 1NIWJAOW 20 20 201 201 H3O9IMInO 01 221 221 ISNI 6 4 4 84 86 20 20 w NS INVA L6 4 E GEL HE C ME 3AWAONITIOH 96 3 20 gou ISN voL TERE 86 a e eh ant at mi e amp AVTIH NMOG 76 ta z a oun HOLIMS AVISHNMOG 6 E ETT xot 36 3Sf14 VOL 182309 L 4 GIONFTOS 26 20 VIZ HZ viZ viz viz 60 Rem 801 ey 301 d pa 209 82 82 YO 06 H or zoa VIZ 891 aa AE 68 FDDIdLNO ON pam 301 ISNI VOI L GIONTIOS 88 Ta UE souls JO opi FDIMLNO ON ve Vel Vu gt ve he 64 L8 a 4 AVTIH HOLIMS ve viza ve 37 5391 5002 99 L gt 20 20 20 zo 98 4 gt tava Y a ve be vel 2
78. prevent unauthorized use of the aerial platform WEAR all the protective clothing and personal safety devices issued to you or called for by job conditions DO wear loose clothing dangling neckties scarves rings wristwatches or other jewelry while operating this aerial platform AVOID entanglement with ropes cords or hoses AVOID falling Stay within the boundaries of the guardrails DO NOT raise the aerial plat form in windy or gusty condi tions 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 abso lutely 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 el evated After elevation the drive function must not be ac tivated Elevated driving must only be done on a firm
79. 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 596 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 2596 Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened Set up elevation switch
80. to manufacturers specifications and calibrate load Code 20 Height gt 0 This message occurs if the platform height is not 096 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 and 4 OV at all times Check DIAGNOSTICS SENSORS to see the output A reading of OV 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 6 Q 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
81. 0 149 X ORIFIC 0 031 L EXTRA TANK MB 1 MAIN MANIFOLO PORTS 2 PI P2 PLIMP PLIMP 671 IN 0 184 IN 48 48V MOTOR DTEIS M50045AA DC Electric Full Size Rough Terrain SKYJACK Page 17 Models 8831E amp 8841E 155154 Q 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 24 BLUE BLACK PIN 6 14D BLACK PIN 7 21 BROWN RED PIN 32A WHITE RED PIN 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 FIVE PIN CONNECTOR PLUG PIN 05 RED PIN2 04 WHITE BLACK PIN 3 10E RED WHITE PIN 4 13 ORANGE TO N O CONTACT BLOCK PINS 14E BLACK RED THREE PIN CONNECTOR PLUG PIN 1 10C RED YELLOW PIN 2 28 GREEN PIN 3 02 WHITE TO BUTT SPLICE 3
82. 0 YFOOILLNO M NS H3MOd LON 151 t azAv13a 2 J3ATVA 26 JAWA DNIGTOH 96 35 4 vor GIONTIOS NMOG S6 20 m EL EL 26 HOLIMS 6 ISN voi 95 EL viz 60 80 301 rara 82 01072705 26 20 gt 4 art 891 89 68 91 3875 vot 88 2 BFIDWNN 4 L BFIDWAP 4 m 4 4 L 20 SOULS JO FD9IdLNO ON 27 VEL pig oh 48 4 AVT3H HOLIMS ve viza We 3H 5338 8221 98 L 20 0 3LIHM 20 20 221 58 va va vel 2500 3815 vot GIONTIOS143 8 ta SEDE yowa ania sa 4 P 25 1437 1e vel viz vol 20 52 52 z VIE z 52 4 6 zg V L Vel viZ 69 ves GIONTIOS1H9IH 28 e LU vg ve 5 ve 7 ve vez NHOH 62
83. 0 ves 20 L A 61 3SU3A3H HOLMS ALIWNIXOBd INYA 9 66 SWHOIB LYOLSISFY 20 36 gover AVTIH dWNd TIVWS 66 20 20 vel 222 969 ki 20 65 d Ta z 22 22 865 68 68 YOVTE IONVEO TTTOGLNOI 46 187 210001 LAVI 9 ri AVTIY MOOTH31NI SE 20 20 12 I 36 4 9 ve d 89 891 891 891 VIL qug 9 91 MOWTA FLIHM 91 94 SE eg 3515 vor 9573 voi Ta Tu 8 7 Fet sum 4 62 20 le I 91 91 amg 54 4 NNN 20 00 2612 NH9 1HM 1549 281 281 HOLOVINOD 3SH3A3H 82 42 1 8 a 001 92 eo Bt 8 20 982 to 282 082 J 14H97 HOLIMS FNGOASONAN 65 52 ri 4 001 3912 NUB LHM H3d338 39i 39i 982 19 001 982 YOLOVLNOD EZ J 20
84. 08589 108589 108589 126469 108589 108589 108589 108589 108589 108589 108589 108589 108589 108589 108589 108589 NORMALLY CLOSED OPEN CONTACT Skyjack e Rm II Il ll Il ll TI NORMALLY 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 HELAY 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 amp 8841E 155154 SKYJACK Page 7 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 SKYJACK Page 8 Section 3 System Co
85. 1 DC Electric Scissor Llfts SKYJACK Page 1 Compact Series 155147 6 Q Notes SKYJACK Page 2 DC Electric Scissor Lifts Series 6 Q 155147 Section 5 Procedures Service and Maintenance gt RR THY General The following information is provided to assist you in the use and application of servicing and maintenance pro cedures 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 sup port is provided Platform 5 1 1 Controller Wiring BOTTOM VIEW BOTTOM VIEW 2 3 4 Not Ct NOt 8 T 6 5 to NC2 C2 MI YELLOW 24 gi pe STEER LEFT PIN 8 GREEN 29 e STEER RIGHT 3 PING BROWN AA 59 l A BAN amp SPEED 3 PING BLACK 02 VO 6 ENABLE OUTPUT 3 PINS BLACK 02 7 NEGATIVE 3 PIN4 BLUE 120 BLUE MAIN INPUT POWER 3 PINS ORANGE REVERSEDOWN 3 PIN2 WHITE ORANGE A 5 2 FORWARDJUP L 3 RED 120 RED ENABLE INPUT POWER 1234501609 00000000 0
86. 2 8 to outrigger board CN22 pin 16 Check continuity Replace if defective Defective lift enable relay 65 Check relay Replace if defective Defective lift disable relay 17ACR Check relay Replace if defective Open diode D65 on outrigger board Check diode Replace if defective Loose or broken wire 10C or 02 from outrigger board to relay 10CCR ANSI CSA only Check continuity Replace if defective Defective relay 10CCR ANSI CSA only Check relay Replace if defective Loose or broken wire 28E from outrigger control module to relay 10CCR ANSI CSA only Check continuity Replace if defective Loose or broken wire 28 from relay 10CCR to pin 7 on Sevcon ANSI CSA only Check continuity Replace if defective Loose or broken wire 28E from overload control module CM1 to pin 7 on Sevcon CE only Check continuity Replace if defective 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 9 from platform control box to main circuit board at CN1 Check continuity Replace if defective 3 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
87. 200 ISN voL te QIONTTOS 1431 E TM m ra OVIIN A YO Fa 1 NS 25 1331 g gt ver ISN VOL zum 4 we a GIONTIOS1HOlM pom B HMMOVTE 4 32i 14 THI 18 4 gt mi 4 4 52 gay val var VIZ VES LLLA 11 ENRON 108 20 va vo M ve ve 6 ver IH NYOH 6 D 6 6r 6 8 NOLLdO 8 173 325 09 va vaz t mi AOU EASY VE Hg Be 007 2 40 an Mg ve 4 vez gt a SWHO 091 962 NOUONNITIY yg cay soa zavo ZISH HOLOVdvO 9 4 4 mi 4 20 20 62 862 aez yeza YOZ zog B ETE ve 20 262 316NV LIV FANSSTdld Lid 7 O62d8 a ii a Fa 9 m 8 8 85 5 3 8 8 8 8 2 8 2 8 9 y 2 3 9 yo 8 d m m FE E m 4 N m m N a a A b a a a a amp a amp a pe TOULNOI LOU FAIBANODAIS 5 AVM OL _ HOLOSNNOD AVM 1 iP 1 HOLOSNNOO AVM 41 89 vo S 8 n Loon onya Om S E E E AE e e on
88. 4 Section 4 Troubleshooting Information Service and Maintenance Electrical System 25 Open or defective platform emergency stop switch 57 Close switch Replace if defective 26 Loose or broken wire 7A from platform emergency stop switch 57 to platform base platform selector switch 8 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 59 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 58 to base platform base enable swi
89. 5 lt d CY 01 BLACK 5 a cn Fi El 3 IT a Oe LEFT ONT OUTRIGGER L 2 10 LE 1 FRONT OUTAGSER q EE IN 1 BLACK t0 PIN 2 WHITE 664 LIT I LII k 4 mo GEN Ln mi E FIGHT REAR OUTRIGGER CONTROL MODULE OUTRIGGERS 1002 PIN 3 GREEN 64 PIN 4 RED 63 LEFT REAR OUTRIGGER 0 P4 PIN BLAGK 0 PIN2 WHTE 684 qA a 108CR BIN3 GREEN 10 PIN4 RED 69 tr amp mp d b Tt Refer to IA Be Note for AGA EE Rated H 9 D 51 Tm qm q i TRACTION MOTOR ai A i 3 DA a ACH 1 1 WHITE 2 BLACK UMP PROX BLUE HEAT SHRINK IN 1 10 RED a IN 2 02 BLU pou PIN3 320RANGEBLACK BLIJE HEATSHRINK N4 NU Note 1 for EE Rated machines the auxiliary contact relay is mounted to the contactor plate between the Line and Directional Contactors O O Wi lt 4 O 1808 0182 To Tach card and Controller STEER PUMP MOTOR PUMP MOTOR DISCONNECT
90. 5658 115658 115658 gt JJ 1 1 IL IL IIl ll l CABLE ASSEMBLY CABLE ASSEMBLY 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 amp 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 Scissor arm Model 8841 Electrical panel LIMIT SWITCH Outrigger Right front extend LIMIT SWITCH Outrigger Right rear extend LIMIT SWITCH Outrigger Left rear extend Parts list continued on the following page DC Electric Full Size Roug
91. 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 Check input on P2 pin 10 auto level or auto retract has been requested but the platform is elevated NOT FULLY LEVEL 2 1 outrigger legs all down touching the ground but the platform is not fully level OUTRIGGERS NOT HOME 2 2 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 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 STARTUP These are not true faults unless they do not clear the start up tests should only occur for a short time OUTRIGGERS MANUALLY CONTROLLED This is nota 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 FAULT P2 6 FAULTY FAULT P2 8 STUCK ON FAULT P2 8 ALWAYS ON 4 FAULT 2 8 ALWAYS OFF 5 These are internal faults If the fault persists after the power has been reset the outrigger control module may need to be replaced 60412AB DC Electric Scissor Lifts SKYJACK Page 23 Compact Series 155147 6 Q Service and Maintenance Section 5 Procedures 5 4 4 Hand Held Calibrat
92. ABTRE RUN UP SCISSORS TO ARTI POWERDECK MANIFOLD TOF 2 Li WORKLIGHT WORKLIGHT oe w 1 4 279 TO OUTRIGGER MAN POWER RELAY LA on Al H 423 OUTRIGGER MOVEMENT INDICATOR RELAY m mco rue m E ton E D Saso RUF Er E 4471 E E E E 2 4 5 AA 2 TOF dou Ww x _ SEO AHIA el 5 DOWN RELAY SKYJABK Ww x ds TER CRI n 4478 m AUX DOWN RELAY BACK VIEW
93. ALINIXOUd v mn a 24 vor von vor 1 SWHOZSYOLSISFY Zt W cis 382 i Fee 65 HOV6S AVISH TVNOISQ33dS 1 z hee z E A MB LYOLSISFH Or ta wove 3Su3A3H ATE TINS ko z 1 ver Vel 865 32 k 20 86 20 20 22 869 869 68 69 XOVISHONVUO 69 25009 QuVMMOJ z 20 09 5370001 280309 9 wan L AVISHGHVMHOd 96 lite 7 SE a m 36 4 YOL 4 4 4 L re 091 091 mi m W XOVIBALUHM 24009 94 AVIFY 5 2 1 a ETT 3505 YOL 891 891 us a ISN voL 54 oe a p t 8 aj s um n 6z 7 20 X YOLOVINOD 82 D 22 m gt a 001 8 81 9 T zw E 1 O88 082 13010 yo LHON HOLIMS 4 14 68 ai zor 3912 Q3W LHM NHB LHM 434338 YOLOVINOD Z 130 sm HOLOWNOLOVHL IZ H3wv3uH voz 02 7 5 a 182 YOLVYINFO HILINOHOWL 6 n I 20 vez AVT3H HOLVOIONI eum ONINEWM 20 M gr 317022 EdVO Z 0019 72 X18 m8
94. AR 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 71 Orange Output used to retract the LEFT FRONT outrigger 35C White Black Power input for outriggers 8 SKYJACK Page 28 DC Electric Scissor Lifts Series 6 Q 155147 Section 5 Procedures Service and Maintenance Load Sensing System CE 5 5 1 Control Module Pin Reference Chart DC Electric Scissor Lifts a DWE W NJ pen 5 32 D4 E KS pum ues FS pce An AN a g 77 4 g 6 QU Ji Qc V TN EN VON d 2 Van AN AN TN y ON Q 575 4 6 1 KE AT 9 ZAN YAN ZAN Y AN YEN AN E 2 W V KO W 1 ON 2 am i NE N ED SO CONTROL MODULE Q e d J WIRE AND Not used P2 5 0 00 2 P2 6 Ntused Jo 2 P2 Blue 7 Reverse Direction Input 02 5 P2 9 fNotusd 000000 000 0 00 2 P8 6 60E Green White Output to Relays 60ECR1 60ECR2 60 1 000 0 00 2 Varied Input from Pressure Transducer Varied Input from Angle Transducer P4 6 910 Black
95. ATFORM PLATFORM N QUICK WERING VALVE VALVE H BRAK 2 7 cvg CV10 BLOCK Da Asi VI 2 VAL MANUAL CONTROLLE LOWERING LOWER VALVE VALVE 9 4H 7 AH 72 4H 73 RIGHT RIGHT C7 FRON FRON REAR REAR STEER GEARBOX lt IITRIGGER TRIGGER TRIGGER TRIGGER CYLINDER CYLINDER RETRACT RETRACT RETRACT RETRACT PS2 BS VALVE VALVE VALVE KAL YE PRESSLIRE LLL EXTRA PRESSURE SNITCH m PORTS 2 BOOPSI 4 DISCONNECT DISCONNECT ox 1 P 1 P 1 1 05 TL A IWER NE NE NE NE 0 087 i 75 4 76 2 AH 77 LEFT RIGHT ao RIGHT RIGHT STEER 7 4H 33A 2 17 FRON REAR VALVE VALVE A TRIGGER ITRIGGER ITRIGGER TRIGGER m Sesa m GEARBOX HOLDING XTEND EXTEND XTEND VAL VE gt 6 gt gt H VALVE VALVE VALVE VALVE VALVE 2H 30 eae w 4 1 rt 4H 32A MB8 OUTRIGGER lt AH 244A CHECK ELK 1 VALVE STEER 2H 14D 2H 44 VALVE CHECK VALVE LIF G ARB VAL VE 7 VAL VE _ VALVE _ Y 7 2H 21A 2H 13 1 m Q SYSTEM LOWERING E Hy VAL VE RI 2 SYSTEM GEARBOX CHECK VALVE A X Ser TE RELIE VALVE WERING VAL VE VALVE SUME IFICE 500 lt 1 VALVE
96. Check switch Replace if defective 2 Loose or broken wire 74 from outrigger control console to pin 5 on connector 20 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 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 24 Check switch
97. DJUSTER Figure 5 1 Brake Adjustment Reinstall clevis pin back into the clevis actuating lever Remove plastic plug located on the end of the caliper shaft See Figure 5 2 11 12 13 14 Section 5 Procedures ARM FULL CKWISE M n ud BRAKE ADJUSTER Figure 5 2 Removal Replacement 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 Replace plastic plug back into the end of the caliper shaft Pull out black knob to reset brake circuit Wheel blocks battery disconnect plug Operate drive several times to seat pads to brake disc SKYJACK Page 6 DC Electric Scissor Lifts Series 155147 Section 5 Procedures Service and Maintenance 5 2 5 Proximity Switch Replacement and Adjustment Procedure PRI PIN 10 BROWN 1 4 PIN 2 02 BLUE BLUE HEATSRIIK 3 PIN 3 33 BLACK PIN 4 PR w _ SA 9 mcm R2 IN YELLOW HEATSHRINK A N U IN 4 32 BLACK PRI E 2 TURNS
98. Diagrams Service and Maintenance Floor Loading Pressure Locally Concentrated Pressure LCP Overall Uniform Pressure OUP Foot Print Area Length x Width Base Area Length x Width Weight of Aerial Platform Capacity Weight of Aerial Platform Capacity LCP 0 4 OUP Foot Print Area Base Area E Length WAY MA AKAAAA WA Width NA VA A A A AN AN Length EE r pui gt 7 4 a g S lt sa T A 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 SKYJACK Page 5 Rough Terrain Q Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 4a Tire Specifi
99. I RED Ge BLK AT MOT 09 PIN 5 NC 2 URG_W SIN 3 OSW SPD A___WHT ORG___PIN 2 DC Electric Scissor Lifts Series 155147 Section 5 Procedures Service and Maintenance Base 5 2 1 1 10 11 System Relief Pressure Adjustment Locate the System Pressure Quick Disconnect Port on the Main Manifold Refer to Section 3 Hydraulic Manifold And Port Identification for location Install a Calibrated 3000 PSI Gauge to the System Pressure Quick Disconnect Port Remove the Platform Control Box from the Guardrail and disconnect from the Main Control Cable Locate the Main Control Cable Plug in the Hydraulic Electric side of cabinet Disconnect the Main Cable and connect the Platform Control Box into the Plug At the Main Manifold loosen the Locknut on the System Relief Valve R1 Refer to Section 3 Hydraulic Manifold And Port Identification for location Select Drive with the Lift Off Drive Select Switch on the Platform Control Box Engaged Steer Right and hold 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 Release Steer Switch and tighten the Locknut Remove the gauge from the System Pressure Test Port 5 2 2 Gearbox Relief Pressure Adjustment 1 Locate the Gearbox Quick Disconnect Port on
100. INK YELLOW HEATSHRIK PIN 3 32 ORANGE BLACK 4 DRIVE PROX YELLOW HEAT SHRI PIN 1 10 RED BLACK PIN 2 02 BLUE BLACK PIN 3 NIU PIN 4 33 ORANGE Note 1 for EE Rated machines the auxiliary contact relay is mounted to the contactor plate between the Line and Directional Contactors Q O 05 0 OL 9 1080R 182 0181 8 To Tach card and Controller STEER PUMP MOTOR mn PUMP MOTOR 0000001 FROM 20A GROUND CIRCUIT BREAKER TO CHARGER TO CHARGER A c ki SKYIAGK lef 16586 PI ABLACKWHTE a fe hele fe PN2 0WHTE i PIN 1 01 BLACK 2 TO CHARGER CUTOUT PIN2 1ABACKWHTE Efe 01 BLACK Hepe oe Tt 5 E le j d d LLL 52 e 2 LEFT FRONT
101. LD MAIN MANIFOLD 39A GEARBOX DIRECTIONAL VALVE 2 FROM BUTT SPLICE 1 BASE CONTROLS MAIN MANIFOLD UP DOWN SELECTOR 10F REDMHITE TEE BLACK 13 ORANGE pA lO ME BLACK RED SE 2 BUTT SPLICE 2 BUTT SPLICE 4 ZON 2 un 44 GEARBOX VALVE 2 FROM BUTT SPLICE 02 MAIN MANIFOLD 30 BRAKE VALVE 2 FROM BUTT SPLICE 02 MAIN MANIFOLD 14D LIFT VALVE 2 FROM BUTT SPLICE 14D p MAIN MANIFOLD 21A DUMP VALVE 02 FROM BUTT SPLICE gt 02 MAIN MANIFOLD 511858 2 X 25 7 F 7 02 25 QUICK BRAKE VALVE M50045AA DC Electric Full Size Rough Terrain Models 8831E amp 8841E 155154 View This Page Parts List 3 10 Electrical System Wiring Diagram LHT 2 HOR 3 GREEN SEER CONTROL MODULE LOAD SENSING m P 090 996 PUA 009 4 3 E m n din PRESSURE TRANSDUCER Coca nan I q An ANGLE TRANSDUCER n 1 3 C
102. MODELS SJ8831E SJ8841E L i lt Service Manua DC Electric Full Size Rough Terrain KEEP amp CLEAR m rs Part No 155154AB February 2014 Skyjack Service Center 3451 Swenson Ave St Charles Illinois 60174 USA Phone 630 262 0005 Toll Free 1 800 275 9522 Fax 630 262 0006 Email service dskyjack com Parts North America Toll Free 1 800 965 4626 Toll Free Fax 1 888 782 4825 E mail parts dskyjack com Skyjack Australia Pty Ltd 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel 61 0 28786 3200 Fax 61 0 28786 3222 Parts amp Service Europe Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry Shropshire SY10 8NN UK Phone 44 1691 676 235 Fax 44 1691 676 238 E mail infoldskyjackeurope co uk Skyjack Brasil Alameda Jupiter 710 Loteamento American Park Empresarial Indaiatuba SP Brasil 13347 6523 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 SKYJACK Page 3 Rough Terrain Q Service and Maintenance Operator s Responsibility for Maintenance The Safety Alert Symbol ide
103. MOG INOHJIHOIH LEL Etd 91 4a v NMOG INOH31431 061 84 1437 621 Std 821 97 va 221 v 910531491 9 89 TE f Dm 100 AVTIY H3MOd pa NIV BFD9IBLNO 20 56 20 uovzr 929 NO LON 60 s 318VSIG 157 8FDDIBLNO 20 20 ay 1t z00 GION310S ugoomuno 821 20 Wie ee o 4 4 3 JOOHd u3oomuno Ta 4 0 LI vo zuOvOL AV TSH 2 20 VOI M 259 AVTIFL 021 4 4 4 431 3210 20 20 9 NOLLISOd Q319VH L3H NI NMOHS 50439910110 gt 219 lis AVI TINI g 4 JAYA bFDDIBLNO 20 20 19 W d 901 J 921 J 91 ANOU ANOU Hv3H 4431 4H918 4431 19 29 9 9 01 sog 1987 2957 991 29571 E 435070 NIdO ATVWHON SSHOLIMS dN 39918100 89d NO LON 49901 4 20 20 201 L 82 eu 20 801 821 ori 201 60 vol ves elt an TWNOIS 334 HOLIMS HOLIMS 12 01 um FIGI p zo
104. Module Load Calibration Code Messages 8 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 FO4 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 OV 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 Ifthe 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 th
105. OUTRIGGER LA 41 2 EJ PINT PIN2 WHITE 65A ou 9 as PIN GREEN 62 PINA RED w 10 245004 RIGHT FRONT OUTRIGGER 4 ui PIN t BLACK 10 PIN2 WHITE 66A ocmi PIN3 GREEN 63 PIN 4 RED 62 X CONTROL MODULE OUTRIGGERS ie GA u cron 002 TD PIN3 GREEN 64 PINA RED 63 A 6 LEFT REAR OUTRIGGER y 1 CHE 0 P4 P2 Pi PIN 1 BLACK 10 PIN2 WHITE 68A zi ro ro 108CR PN3 GREEN 10 PN4 RED 6 an Refer to o ID wo J 6 Note 1 for on Y EE 3 D CY 1 Q oP 0 T TRACTION MOTOR uo N A 3 md 9 4 TACH Tt WHITE T2 BLACK PUMP PROX BLUE HEAT SHRINK PIN 1 10 RED PIN 2 02 BLUE a a a DC Electric Full Size Rough Terrain 155154 SKYJACK Page 19 View Parts List Print This Page 3 11 Electrical Schematic CE D5 155154
106. RED 14E BLACK RED OEE B i LARGE PUMP CHK SMALL PUMP CHK Lo StL si di EMERGENOYSTOPPB SBRED 04 WHITE BLACK OUTRIGGER PENDANT w 7 TIITTIIITI 443 s 4 0 OUTRIGGER BOAI
107. RR 17 Using 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 Checkfor 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 Ib 23 Repeat steps 5 to 22 for the other hub assembly 24 Lower the aerial platform DC Electric Scissor LIfts SKYJACK Page 11 Compact Series 155147 6 Q Service and Maintenance Section 5 Procedures Sevcon Calibration 5 3 1 Sevcontroller Adjustment and Diagnostics MAN WARNING All machine functions remain operational while calibrator is plugged in Adjustment Procedure The following procedure is relevant for the drive control ler except where otherwise noted The controller is pre set to factory specifications but may be read
108. SKYJACK Page 3 Rough Terrain Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 2a Maximum Platform Capacities Evenly Distributed CE First Extension Second Extension Number of co Number of Number of Occupants Occupants Occupants Capacity Two Extension Platforms Two Extension Platforms 150AA NOTE Occupants and materials are not to exceed rated load Capacities listed are for standard machines equipped with 76 tires Refer to capacity label at sides of platform for additional information and for models equipped with options BEAUFORT Wind Speed SCALE m s mph 3 4 5 4 12 5 19 4 11 5 17 75 5 12 0 Papers and thin branches move flags wave 5 4 8 0 194 288 17 75 26 25 120 18 Dust is raised paper whirls up and small branches sway Ground Conditions 80 108 28 8 38 9 26 25 35 5 18 24 25 Shrubs with leaves start swaying Wave crests are apparent in ponds or swamps 108 139 389 500 35 5 455 24 5 31 Tree branches move Power lines whistle It is difficult to open an umbrella 139 172 500 619 45 5 655 31 385 W nole trees sway It is difficult to walk against the 60338AC SKYJACK Page 4 DC Electric Full Size Q Rough Terrain Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 2b Maximum Platform Capacities Evenly Distributed ANSI CSA First Extension Second Extension Number of Capaci Num
109. TER button The display will show GROUP CODE By using the Up Down buttons enter the Group Code then by using Left Right buttons select the Curve from the menu The display will show X2 CURVE By using the Up Down buttons enter the Curve Code followed by pressing the ESCAPE button The display will show Machine Defaults By using Left Right buttons select the Tilt Setups from the menu and press the ENTER button The display will show Tilt Setups Calibrate Level Select the Tilt Setups Calibrate Level from the menu and press the ENTER button The display will show Calibrate Level Yes Enter No ESC Select the Yes from the menu by press the ENTER button The display will show Calibrate Level Tilt 0 0 0 0 Select the ESCAPE from the menu once The display will show Tilt Setups Calibrate Level Select the ESCAPE from the menu once again The display will show Setups Tilt Setups By using Left Right buttons select the Load Setups from the menu and press the ENTER button The display will show Load Setups Calibrate Load Select the Load Setups Calibrate Load from the menu and press the ENTER button 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 The display will show Calibrate Load Platform Down Asking for confirmation that the platform is
110. Terrain SKYJACK Page 11 Model 8831E amp 8841E 155154 6 Q Section 3 System Component Identification and Schematics Service and Maintenance 3 9 Outrigger Manifold and Auto Reset Manifold Components and Port Identifications View BERGE Parts List TO MAIN MANIFOLD TO TANK AUTO RESET MANIFOLD HP2 HAND PUMP V6 AUTO RESET VALVE 4H 74 OUTRIGGER LEFT REAR wan RETRACT 2H 17A OUTRIGGER OUTRIGGER MANIFOLD petal HOLDING LEFT FRONT 4H 72 RETRACT VALVE OUTRIGGER AL RIGHT FRONT RETRACT AL 2 NN AL wa 4 RIGHT REAR 6 AD OUTRIGGER RETRACT ON 07 ou LEFT REAR EXTEND HL g 4H 75 OUTRIGGER ef A LEFT FRONT E Sak a gt gt EXTEND 4H 76 OUTRIGGER TO AH 77 RIGHT OUTRIGGER OUTRIGGER FRONT CYLINDERS RIGHT REAR EXTEND EXTEND 10283AA SKYJACK Page 12 DC Electric Full Size Rough Terrain Models 8831E amp 8841E 6 155154 Service Maintenance Section 3 System Component Identification and Schematics 3 5 Platform Control Console Wiring Diagram BATTERY METER
111. 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 SKYJACK Page 3 Models 8831E amp 8841E 155154 6 Q 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
112. aerial platform is parked on a firm NOTE level surface Chock or block the wheels to Use only recommended wheel bearing keep the aerial platform from rolling forward or grease NLGI National Lubricating Grease backward Institute Grade 72 or equivalent Fully lower the platform NOTE The bearings must be packed before Using a suitable lifting device or outriggers installing if equipped lift the end of the aerial platform with the steer axle 13 Install replacement inner bearing in the race and then seat the new grease seal Flip hub over and A CAUTION install replacement outer bearing Use a suitably rated support stand to 14 Install hub on the spindle support aerial platform while performing the following operations 15 Install replacement washer and replacement castle flanged nut Hand tighten the castle flanged Turn emergency main power disconnect switch nut until it touches the washer Turn hub by hand to off position to ensure smooth running No resistance should be felt at this time Remove wheel assembly 16 Take a torque wrench and set it at 30 ft Ib and Hemove dust cap item 1 to access internal components of hub assembly SKYJACK Page 10 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
113. age 18 DC Electric Full Size Rough Terrain Section 1 Scheduled Maintenance Service and Maintenance Inspections Batteries Battery Tray 1 1 3 Battery Compartment Battery Tray Ensuretray 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 AN WARNING Explosion hazard Keep flames and sparks away Do not smoke near bat teries AN WARNING Battery acid is extremely cor rosive Wear proper eye and facial protection as well as appropriate protective clothing If contact occurs immediately flush with cold water and seek medical attention Fuse Box Check battery case for damage Clean battery terminals and cable ends thoroughly with a terminal cleaning tool or wire brush Ensure all battery connections are tight If applicable check battery fluid level If plates are not covered by at least 13 mm of solution add distilled or demineralized water Replace battery if damaged or incapable of holding a lasting charge JIN 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
114. ated 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 44 1691 676 238 Include the model and serial number for each applicable aerial platform DC Electric Full Size SKYJACK Page 7 Rough Terrain Q Service and Maintenance Operator s Responsibility for Maintenance Scope of this Manua
115. ber of Capacit Number of Occupants pacity Occupants pac ty Occupants Capacity No Extension 2500 Ib Platform 1134 kg Not Available i 2000 Ib One Extension 2 Not Available Platform 907 Two Extension 1700 Ib 500 Ib 2 Platforms 771 ka 227 kq 227 kq i 1700 Ib No Extension B Not Available Platform 771 kg i 1500 Ib One Extension 5 2 Not Available Platform 680 kg Two Extension 1500 Ib 2 2 Platforms 680 kg 227 kg NOTE 60279AD ANSI 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 SKYJACK Page 5 Rough Terrain Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 3a Floor Loading Pressure CE Total Total Aerial Platform Load 8831E Outrigger Pads 8841E Outrigger Pads 151AC CE min Total aerial plattorm weight with no options max Aerial platform weight all options me 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 struc
116. 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 N WARNING Failure to perform each procedure as pre sented and scheduled may cause death serious injury or substantial damage NOTE Preventive maintenance is the easiest and least expensive type of maintenance e 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 e Repair any damaged or malfunction components before operating aerial platform e Keep records on all 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 A Frequently Annually Bi annually A B C D e Make copies of the maintenance and inspection checklist to be used for each inspection e Check the schedule on the checklist for the type of inspection to be performed e Place a check in the appropriate box after each inspection procedure is completed e Use the maintenance and inspection checklist and step by step procedures in section 5 to perform these inspections e
117. cation Operate Drive slowly while observing gauge It should read a minimum of 800 PSI lf pressure needs to be increased turn black knurled portion clockwise lf pressure need to be decreased turn counter clockwise Once 800 PSI is obtained brake pressure adjustment is complete DC Electric Scissor Lifts Compact Series 155147 SKYJACK Page 5 Service and Maintenance 5 2 4 Brake Adjustment 1 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 counter clockwise 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 al ACTUATUR ARM HERE LKWISE PO ia 10 1 2 O BRAKE A
118. cations 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 Backspace Fill Rating Pi Rim Size 10 16 5 121 mm 6F 10 CARLISLE US LOADER 34 Foam 6F 10 16 5 OTR OUTRIGGER 10 121 mm Non Marking 3 4 152 Usage S tandard O ptional N A Not Available Backspace Rim Backspace Diagram Inboard Outboard SECTION A A DC Electric Full Size SKYJACK Page 9 Rough Terrain 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 Backspace Fill Type Ply Rating 46A 10 16 5 CARLISLE US LOADER Air 10 16 5 OTR OUTRIGGER 76A Non Ma
119. ch 0 2 First Error Latch Value Flash Code Section 5 Procedures Controller Joystick Input Forward Switch Reverse Switch Tachometer Input Pump Traction Switch Actual Direction Tachometer Output Lift Transmission Position Sense Traction Transmission Position Sense NOTE CL Switch Closed OP Switch Open SKYJACK Page 16 60287 DC Electric Scissor Lifts Series 155147 Section 5 Procedures 5 3 2 Diagnostic LED Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Service and Maintenance Traction Controller Pin Reference Pins are identified from left to right Pin 1 thru Pin 17 ADJ SKT CONTROL WIRING SKT ud B n m D BD aN o Brake relay control Brings B to brake relay 25CR Test between pin 1 and wire 10A Direction signal from pin 4 of tachometer card Determines direction volts forward 15 volts reverse Test between pin 4 and wire 02 Not used High Drive Cut out 24 volts high drive enabled volts high drive disabled Test between pin 4 and wire 02 with platform fully lowered 24 volt input from line contactor
120. ck 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 SKYJACK Page 11 Models 8831E amp 8841E 155154 YO Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 26 27 28 29 30 31 Loose or broken wire 28 from relay 10CCR to pin 7 Sevcon ANSI CSA only Check continuity Replace if defective Loose or broken wire 28 from overload control module 1 to pin 7 on Sevcon CE only Check continuity Replace if defective Overload sensing system problem CE Only Refer to Load Sensing Manual available on line Brake not releasing See brake not releasing troubleshooting in this section Lift Traction circuit not shifting See Lift Traction Circuit inoperative Sevcon problem See Sevcon troubleshooting 4 1 15 Forward Drive Inoperative 1 2 3 10 11 12 13 14 Loose or broken wire 16 on lift off drive switch S9 Check continuity Replace if defective Defective fuse F6 Replac
121. ck 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 SKYJACK Page 15 Models 8831E amp 8841E 155154 YO Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 10 Loose or broken wire 17A from pin 1 orwire 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 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 Looseorbroken 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 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 1
122. clean the wire terminals before attaching the jumper clip gt Before starting the calibration you must put a jumper across the base speed resistor See Figure for location of the resistor Jumper gt 42 yo TA t yo 1 wi i Figure 5 10 Main Circuit Board 4 Connect the Easy Cal tool to the P1 connector on the CONTROL MODULE 5 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 SKYJACK Page 37 Compact Series 155147 6 Q Service and Maintenance Section 5 Procedures 6 10 11 12 13 14 15 16 17 18 19 20 21 22 The display will show Access Level Code By using the Up Down buttons enter the Access Level Code xxxx followed by pressing the ENTER button The display will show Access Level 2 By using Left Right buttons select the Setups from the menu and press the ENTER button The display will show Machine Defaults Select the Machine Defaults from the menu and press the ENTER button The display will show Defaults 0 Custom By using Left Right buttons select the X Group Code from the menu and press the EN
123. cy Lowering Platform Lower Neutral 1 2 Function Tests Function tests are designed to discover any malfunctions before aerial platform is put into service The operator must understand and follow step by step instructions to test all aerial platform functions N WARNING Never use a malfunctioning aerial platform If malfunctions are discovered aerial platform must be tagged and placed out of service Repairs to aerial platform may only be made by a qualified service technician After repairs are completed operator must perform a pre operation inspection and a series of function tests again before putting aerial platform into service Prior to performing function tests be sure to read and understand Section 2 10 Start Operation of the operating manual 1 2 1 Test Battery Connectors 1 In battery roll out tray disconnect battery connectors Result Aerial platform functions should not operate SKYJACK Page 26 Off Platform Base Emergency Stop Valve Key Switch Raise Switch Button 1 2 2 Base Control Console WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform 1 Use the ladder of aerial platform to access platform 2 Close the gate 3 platform control console pull out i emergency stop button 4 Insert key into base off platform key switch and select IER base position 5
124. d 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 SKYJACK Page 35 Compact Series 155147 6 Q Service 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 l
125. d Speed Speed ELEVA 5 25 of Max Speed 15 Elevated Cutback Speed TILT 7 5 75 Yo of Max Speed 50 Tilted Cutback Speed CONSTANT SPEED CONTROL 150 Counts 30 Proportional Gain Do Not Adjust CONSTANT SPEED CONTROL 1 100 Counis 20 Integral Gain Do Not Adjust BATTERY Volts Low Battery Cut out Not Used BRAKE Seconds Brake Personality Timer 60285AB NOTE Skyjack does NOT recommend exceeding the default settings Before making adjustments 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 SKYJACK Page 13 Compact Series 155147 6 Q Service and Maintenance Section 5 Procedures Table 5 1B Sevcontrol Adjustable Parameters Software Revision 10 Parameter Default 8841E Settings Modified Amps Maximum Controller Current ACCEL 2 1 3 Seconds 1 1 Acceleration Delay DECEL 3 0 1 3 Seconds 0 1 0 1 Deceleration Delay CREEP 4 10 Yo of Speed 2 2 Maximum Controller Current MAX 96 5 5 100 Yo of Max Maximum Allowed Speed Possible Speed ELEVA 5 25 of Max Speed 15 Elevated Cutback Speed TILT 7 5 75 of Max Speed 50 50 Tilted Cutback Speed CONSTANT SPEED CONTROL Counts Proportional Gain Do Not Adjust CONSTANT SPEED CONTROL Counts Integral Gain Do Not Adjust BATTERY Volts
126. de 7 AE 7 ww gt sumar mestre w 4 166 SKYJACK Page 42 DC Electric Scissor Lifts Compact Series 6 Q 155147 SKYGACK Reliable lift solutions by people who care www skyjack com
127. diode D26 or D26A Check diode Replace if defective Loose or broken wire 27 on switch S17 or wire 727A on switch 19 Check continuity Replace if defective 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 Defective coil 4H 27 or 4H 27A Check coil Replace if defective Open or defective diode 027 or D27A Check diode Replace if defective 4 1 21 Outriggers Inoperative Auto level and manual IN 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 No power at wire 10A on connector CN14 on outrigger board f 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 f no power is present check the close couple connection to main circuit board Replace if defective 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 to relay 9ECR Che
128. e ANSIOSA TNNT IIIS 7 Egg 9 2 40 Tire Specifications ANSI CSA od ne tent ai a ak VOY en a a e 10 25 ROUGON ot ei ki it pat kl a E n ak kk a a kk n ke or AD a e e See be ik ba ii del 11 20 12 DC Electric Full Size SKYJACK Page 1 Rough Terrain YO Service Maintenance Section 2 Maintenance Tables and Diagrams Table 2 1a Specifications and Features CE DC Electric Full Size Rough Terrain 8841 5411 6033 kq Overall width 2 2 m Gradeablility 30 Tires 6 Foam filled Tires Optional 1 x 10 16 46 Foam filled Non marking 31 x 10 16 5 Hydraulic Oil Type ATF Dexron Ill 149AA 31 x 10 16 5 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 79 Q o Table 2 16 Specifications and Features ANSI CSA Rough Terrain E Series 883 I E 68 x 133 5 1 73 m x 3 39 m Working Elevated 11 28 m 47 0 Platform Elevated 9 5 m 41 Platform Lowered 1 5 m Full Normal Drive 2 6 mph Elevated Drive 0 45 mph Lift Rated Load 71 sec Lower Rated Load 60 sec 5151 kg Platform Size 4 2 km h 0 72 km h 60125AF ANSI Weights are approximate refer to serial nameplate for specific weight DC Electric Full Size
129. e 7 ii ak kb al ak kl a T DNE ak ak kk e a a K ke n MNT 7 kk ek tosis ki a pan pak tan cia e ERI bk e ke ke rate so RID l 7 AE GE M a kit l 8 MIT ae ae pl cer 9 ESE TE pet t bk be ek kk kil kk ten at a pk id ER kf ees ok lk ve bed 9 RT PI ka pk kan pa a TIPP 10 Maintenance and Inspection Schedule 13 Owner s Annual Inspection BEBO La sense POUR 13 KOPI OU alaplas kaa kak kk ks kk ka RIDE REM kk pa ke TORO kl ORE ERI SRL e Ek kk UR EP ta R D KE pa A DAN 13 13 Hydraulic System amp Component Maintenance and 14 dial LINE TET TTE TO Tm OT TOT Tm 14 Service and Maintenance NOE m dei 15 zi qo TET TREE 15 Viggo eio pu sioe NT D TER 15 PENN ciis ei m TERR NS 15 Schedule Maintenance Inspections 1 1 Scheduled Maintenance 18 ES EAE AA EEEE 26 Tables Tal MWE e Aana I RECO ER 16 1 2 Maintenance and Inspection 17 DC Electric Full Size SKYJACK Page 5 Rough Terrain YO Notes SKYJACK Page 6 DC Electric Full Size
130. e display will show Calibrate Load Please Lower IMPORTANT lf the lower switch is released earlier than full lower position the calibration will have to be aborted and repeated from the beginning 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 amp 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 0926 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 DC Electric Scissor Llfts SKYJACK Page 39 Compact Series 155147 6 Q Service and Main
131. e fuse Open or defective diode D16 1 Check diode Replace if defective Defective relay 21CR2 Check relay Replace if defective Loose or broken wire 16B from main circuit board at CN5 to pin 8 on Sevcon ANSI CSA only Check continuity Replace if defective Bad contacts in contactor C16E Replace contactor Loose or broken wire 16E from pin 15 on Sevcon to contactor C16E Check continuity Replace if defective Loose or broken wire 02 from main circuit board to forward relay GOECRS or auxiliary forward relay 60CR3 CE only Check continuity Replace if defective Defective forward relay 6 or auxiliary forward relay 60CR3 CE only Check relay Replace if defective Loose or broken wire 60E from control module CM1 at pin P3 6 to forward relay CE only Check continuity Replace if defective 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 Loose or broken wire 16B from main circuit board at CN5 to forward relay GOECR3 CE only Check continuity Replace if defective Loose or broken wire 16C from forward relay GOECRS to auxiliary forward relay 60CR3 CE only Check continuity Replace if defective Loose or broken wire 160 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
132. e 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 OV 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 DC Electric Scissor Lifts SKYJACK Page 33 Compact Series 155147 6 Q Service 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 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
133. eck 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 1 Check continuity Replace if defective SKYJACK Page 20 Full Size Rough Terrain Series Models 8831E amp 8841E 6 Q 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 Brakerelease 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
134. ed 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 Thesample should be analyzed by a qualified lubrication specialist to determine if it is suitable for continued use 10 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 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 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 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 All hydraulic connections must be kept tight A loose connectio
135. ed 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 Remove the four 5 16 18 x 1 1 2 bolts securing the tachometer generator mounting plate to the rear of the motor Remove the coupler half from the tachometer generator and attach generator to a drill with a 1000 RPM rating Attach a voltmeter to the terminals on the rear of the tachometer generator and set the meter for D C voltage Section 5 Procedures 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 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 oteps 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 GEAR BOX DRIVE MOTOR COUPLER HALF TACHOMETER GENERATOR MOUNTING PLATE COUPLER HALF TACHOMETER GENERATOR Figure 5 10 Traction Generator SKYJACK Page 20 DC Electric Scissor Lifts Series 6 Q 155147 Service and Maintenance lagram D tch Wiring it Sw Outrigger Mechanical L Section 5 Procedures Outrigger Option 5 4 1
136. ence until there is no change in torque values If possible drive the machine prior to checking torques Check torque values after 8 hours of operation and then at weekly intervals DC Electric Scissor Llfts Compact Series 155147 SKYJACK Page 9 Service and Maintenance Section 5 Procedures 5 2 9 Front Axle Hub Procedure 7 For front axle hub components refer to your aerial platform s parts manual Pull cotter 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 hub over and then remove and discard inner bearing cone item 8 and grease seal item 10 9 9 Remove and discard both inner and outer bearing cups items 6 amp 8 from hub 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 amp 8 into hub Figure 5 6 Front Axle Hub 12 Pack replacement inner and outer bearings by either pressing wheel bearing grease into each NOTE roller by hand or using a bearing packer and Keep work area clean and visibly free from grease gun Ensure that grease is forced into all contamination at all times surfaces of the bearing Ensure
137. erial platform should only be done using the three points of contact Use only equipped access openings e 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 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 N 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 SKYJACK Page 12 DC Electric Full Size Rough Terrain Operator s Responsibility for Maintenance Service and Maintenance Maintenance and Inspection Schedule The actual operating envi
138. errain Series SKYJACK Page 13 Models 8831E amp 8841E 155154 6 Q Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 6 7 8 9 Loose or broken wire 25 02 on coil 2H 25 Check continuity Replace if defective Defective coil 2H 25 Check coil Replace if defective Open or defective diode 030 Check diode Replace if defective Loose or broken wire 2A from pin 1 on Sevcon to relay 25 Check continuity Replace if defective 4 1 19 Lift Traction Shift Circuit Inoperative 1 2 3 4 8 9 Defective proximity switch PR1 or PR2 Refer to proximity switch test procedure Section 5 Open or defective diode D44 Check diode Replace if defective Loose or broken wire 44 or 02 on coil 2H 44 Check continuity Replace if defective Defective coil 2H 44 Check coil Replace if defective Defective traction sensor relay 33CR or lift sensor relay 32CR Check relay Replace if defective Loose or broken wire 32A or 02 on coil 4H 32A Check continuity Replace if defective Defective coil 4H 33A Check coil Replace if defective Loose or broken wire 33A or 02 on coil 4H 33A Check continuity Replace if defective Defective coil 4H 33A Check coil Replace if defective 10 Open or defective diode D33A or D32A 11 Check diode Replace if defective Loose or broken wire 32 from lift sensor relay 32CR to pi
139. gh 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 Llfts SKYJACK Page 25 Compact Series 155147 6 Q Service and Maintenance Section 5 Procedures DIAGNOSTIC OUTPUTS MENU OPTIONS LAMP P2 7 STABLE P2 8 TILT P2 9 LRe P4 1 RRe P4 2 RFe P4 3 LFe P4 4 LRr P4 5 RRr P4 6 RFr P4 7 LFr P4 8 P4 9 MON Displays state of outrigger control box light Displays state of stable all legs touching the ground output Displays state of tilt Displays state of left rear outrigger extend valve Displays state of right rear outrigger extend valve Displays state of right front outrigger extend valve Displays state of left front outrigger extend valve Displays state of left rear outrigger retract valve Displays state of right rear outrigger retract valve Displays state of right front outrigger retract valve Displays state of left front outrigger retract valve Displays the voltage to the outrigger valve can only be seen when operating in auto level or retract DIAGNOSTIC LOG MENU OPTIONS MAX BATTERY OCM1 version EZcal version D
140. h LS67 Check continuity Replace if defective 6 Defective outrigger limit switch 1567 Check switch Replace if defective 7 Loose or broken wire 67 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 SKYJACK Page 7 Models 8831E amp 8841E 155154 YO Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Loose or broken wire 66A from outrigger limit switch 1566 to outrigger control module at pin P2 3 Check continuity Replace if defective Loose or broken wire 10 from outrigger board to outrigger limit switch 1565 Check continuity Replace if defective Defective outrigger limit switch 1565 Check switch Replace if defective Loose or broken wire 65A from outrigger limit switch LS65 to outrigger control module at pin P2 4 Check continuity Replace if defective Check for power on wire 65 at outrigger control module at pin P2 8 f no voltage present proceed to outrigger control module troubleshooting Loose or broken wire 65 from outrigger control module at pin P
141. h Terrain Model 8831E amp 8841E 155154 SKYJACK Page 9 YO 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 Section 3 System Component Identification and Schematics 4 4 4 4 4 4 4 4 4 4 4 4 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Service and Maintenance 3 4 Electrical Parts List Continued Skyjack Parts list continued from the previous page 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
142. harge Batteries 7 Flash Fault Voltage 13 Volts 8 Flash Fault 1 Sevcon Overheating 1 Letunit cool down 1 Loose or broken wire from Pin 1 Check continuity Replace if 2 on Sevcon to Pin 4 on defective Tachometer Board 2 Loose or broken wire from Pin Check continuity Replace if 12 on Sevcon to Pin 2 on defective Tachometer Board 3 Loose or broken wire 1 or Check continuity Replace if T2 from Tachometer Generator defective to Main Circuit Board 1 Generator Check 20 8 Volts Thermal Cutback defective 1000 RPM Replace if defective 2 Tachometer Generator Wires Switch wires at Generator Heversed 3 Defective Tachometer Board Check Tachometer Board for inputs and outputs Replace if defective Tilt Condition 1 Tilt Condition with Platform 1 Lower Platform and Reposition with Platform Elevated has disabled Sevcon to a firm Level Surface Elevated for Lift and Drive Tachometer Fault Incorrectly set Proximity Switch 1 Refer to Proximity Switch Transmission Adjustment Procedure Section Gear Mesh 5 Page 11 Failure 2 Defective Proximity Switch 2 Refer to Proximity Switch Test Procedure Section 5 Page 12 1 Loose or broken wire to Pin 5 1 Check for 24 Volts between Pin Low or Open on Sevcon 5 and wire 02 key ki 2 Loose or broken wire to Pin 6 2 Check for 48 Volts between Pin on Sevcon 6 and wire 02 60311AA Fuli S
143. 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 2 Activate and hold d enable trigger switch 3 Drive aerial platform Dit 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 1 Push horn pushbutton been checked Result Horn should sound Test Horn 1 4 Drive aerial platform forward Test brake again by releasing 5 4 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 SKYJACK Page 31 Rough Terrain Q Notes SKYJACK Page 32 DC Electric Full Size Rough Terrain Section 2 MAINTENANCE TABLES AND DIAGRAMS List of Tables 21a NO and ANE ANE CE 2 2 16 Specifications and Features 5 5 3 2 2a Maximum Platform Capacities Evenly Distributed 4 2 2b Maximum Platform Capacities Evenly Distributed 5 Io dtt pomi ctp 6 2 3b Floor Loading Pressur
144. hout 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 DC Electric Full Size SKYJACK Page 9 Rough Terrain Q Service 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 pre e cautions 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 job site TURN the emergency main power disconnect switch off when leaving the aerial platform unat tended Remove the key to
145. ief 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 remov
146. ion Diagnostic Key Functions IN 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 ru ED lt gt A prim za 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 C J Outrigger Settings SJIIIB 6 a 4 5 c pe po fo po fon SKYJACK Page 24 DC Electric Scissor Lifts Compact Series 6 Q 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 D 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
147. isplays maximum recorded battery supply voltage Displays part number and software version of GP106 Displays software version of EZcal ACCESS LEVEL MENU OPTIONS CODE xxxx ACCESS LEVEL 3 allows viewing only ACCESS LEVEL 2 allows setup OCM1 ADJUSTMENTS MENU OPTIONS factory set not adjustable Xtilt TRIP Ytilt TRIP TILT ENTRY TILT EXIT Xlevel TRIP Ylevel TRIP Displays the tilt trip point in the X orientation Displays the tilt trip point in the Y orientation Displays the tilt delay time Displays the tilt delay time Displays the tilt trip point in the X orientation during the auto level function 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 amp 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 TILT MODE TILT FILTER Xlevel TARGET Ylevel TARGET tilt SLACK positioned on level ground see Appendix Four 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 Displays the filter applied to the tilt measurements during the auto
148. ize Rough Terrain Series SKYJACK Page 17 Models 8831E amp 8841E 155154 6 Q Service and Maintenance Electrical System Continued 4 1 25 Left Front Outrigger Inoperative Manually 1 2 Defective left front outrigger switch 520 at platform Check switch Replace if defective Loose or broken wire 71 from outrigger control console to pin 6 on connector 20 at outrigger board retract or from wire 75 to pin 7 extend Check continuity Replace if defective Open diode D71 retract or D75 extend on outrigger board Check diode Replace if defective 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 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 L 2 Defective right front outrigger switch 521 at platform Check switch Replace if defective Loose or broken wire 72 from outrigger control console to pin 8 on connector 20 at outrigger board retract or from wire 76 to pin 9 extend Check continuity Replace if defective Open diode D72 retract or D76 extend on outrigger board Check diode Replace if defective Loose or broken wire 72 from pin 9 on connector CN21
149. justed 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 param eters 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 measure ment 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 control ler joystick 1 Locate Sevcon inside Electrical Hydraulic Cabinet on the right side of the machine Controller Adjustment Socket 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 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 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
150. k continuity Replace if defective Loose or broken wire 13 from main circuit board at CN8 to down enable relay 60ECR1 CE only Check continuity Replace if defective Loose or broken wire 13A from down enable relay 60ECR1 to auxiliary down enable relay 60CH1 CE only Check continuity Replace if defective Loose or broken wire 13B or 02 from auxiliary down enable relay 60CR1 to down 2H 13B 1 and holding valve coil 2H 13B 2 and 2H 13B 3 CE only Check continuity Replace if defective Defective down coil 2H 13B 1 or holding valve coil 2H 13B 2 and 2H 13B 3 CE only Check coil Replace if defective Lift Traction circuit not shifting See lift traction circuit inoperative Sevcon problem See Sevcon troubleshooting Overload sensing system problem CE Only Refer to Load Sensing Manual available on line 4 1 9 Down Circuit Inoperative from Base 1 2 Lift Lower switch 56 defective Check continuity Replace if defective 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 defecti
151. l 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 wit
152. l and are 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 Use the ladder to dismount from platform DC Electric Full Size Rough Terrain Section 1 Scheduled Maintenance Slider Lift Cylinder 1 1 7 Lifting Mechanism Scissor Guards Ensure there are no loose or missing parts and there is no visible damage Sliders Ensure sliders are secure and there is no visible damage Ensure sliders path of travel are free from dirt and obstructions 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 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 Service and Maintenance Inspections Scissor Assembly Maintenance Support Limit Switch Scissor Bumper Scissor Bumpers Ensure bumpers are secure and shows no sign of visib
153. le 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 all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Raise the platform until there is adequate clearance to swing up the maintenance support into storage bracket Fully lower the platform 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 e Axles Ensure axles are properly secured Base Weldment there are no loose or missing parts all Ensure there are no visible cracks in fittings and hoses are properly tightened welds or structure and there are no signs and there is no evidence of hydraulic of deformation leakage Wheel Tire Assembly Steer Cylinder Assembly The aerial platform is either equipped with Ensuresteer cylinder assembly is properly foam filled tires Tire and or wheel failure could secured there are no loose or missing result in an aerial platform tipover Component parts all fittings and hoses are properly damage may also result if problems are not tightened and there is no evidence of discovered and repaired in a timely fashion hydraulic leakage Tie Rod Ensure there are no loose or
154. 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 e engine compartment electrical panel e engine wiring harness e hydraulic electrical wiring harnesses Hydraulic Maintaining the hydraulic components is essential to good performance and service life of the aerial platform Platform Control Console Platform Assembly Perform a visual inspection around the following areas e hydraulic tank filter fittings hoses emergency power unit if equipped and base surfaces engine compartment fittings hoses main pump and filter e all hydraulic cylinders e all hydraulic manifolds e the underside of the base e ground area under the aerial platform e 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 e broken or missing actuator arm e missing fasteners loose wiring SKYJACK P
155. mponent Identification and Schematics 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 Service and Maintenance 3 4 Electrical Parts List Skyjack f ow n Parts list continued from the previous page RELAY 24 Volt RELAY 24 Volt RELAY 24 Volt RELAY 24 Volt RELAY 24 Volt Reverse CE RELAY 24 Volt Forward CE RELAY 24 VOIt 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 Auxiliary down CE Auxiliary reverse CE Auxiliary forward CE Down CE An 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 ou
156. n 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 451 lift position Activate and hold d enable trigger switch Push controller handle and raise the platform to an approximate height of 0 5 meter Result Platform should rise Pull controller handle and lower the platform fully Result Platform should lower DC Electric Full Size Rough Terrain 29 Function Tests gt Lift Drive Steer Ny Enable Trigger Switch ZAN 122 gt lt Operation Light S Lift Off Drive Switch Test Lowering Warning 1 Raise the platform until approximately 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 2 Helease controller handle ensure area around scissor is clear then continue lowering the platform Test Steering 1 1 Select lift off drive switch to drive position 2 Activate and hold d enable trigger switch 3 Press rocker switch on top of controller handle to 48 gt left and 9 12 right Result Steer wheels should turn left and right SKYJACK Page 30 Section 1 Scheduled Maintenance Rocke
157. n 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 516 or 518 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 516 or S18 to in out switch 517 or 519 Check continuity Replace if defective SKYJACK Page 14 Full Size Rough Terrain Series Models 8831E amp 8841 6 Q 155154 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 8 9 10 11 12 13 14 15 Loose or broken wire 18A from terminal block to small pump relay 18ACR Check continuity Replace if defective Loose or broken wire 26 on switch S17 or wire 726A on switch 19 Check continuity Replace if defective 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 Defective coil 4H 26 or 4H 26A Check coil Replace if defective Open or defective
158. n 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 Keep connections tight SKYJACK Page 14 DC Electric Full Size Rough Terrain Section 1 Scheduled Maintenance Service and Maintenance Inspections About this Section This section contains the maintenance and inspection schedule that is to be performed Heferences 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
159. n wire 10 from outrigger board to outrigger limit switch 1564 Check continuity Replace if defective 3 Defective outrigger limit switch 1564 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 1563 Check continuity Replace if defective 6 Defective outrigger limit switch 1563 Check continuity Replace if defective SKYJACK Page 6 Full Size Rough Terrain Series Models 8831E amp 8841E 6 Q 155154 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 7 8 9 10 11 12 13 14 15 20 Loose or broken wire 63 from outrigger limit switch LS63 to outrigger board Check continuity Replace if defective Loose or broken wire 63 from outrigger board to outrigger limit switch 1562 Check continuity Replace if defective Defective Limit switch LS62 Check switch Replace if defective Loose or broken wire 62 from outrigger limit switch LS62 to outrigger board Check continuity Replace if defective Loose or broken wire 62 from outrigger board to outrigger limit switch LS61 Check continuity Replace if defective Defective outrigger limit switch LS61 Check switch Replace if defective Loose or broken wire 61 from outrigger limit switch LS61 to out
160. nd 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 hazaras 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 paris 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 DC Electric Full Size Rough Terrain SKYJACK Page 13 YO Service Maintenance Operator s Responsibility for Maintenance Hydraulic System amp Component Maintenance and Repair The following points should be kept in mind when working on the hydraulic system or any component 1 Any structure has limits of strength durability To prevent failure of structural parts of hydraulic components rel
161. ntifies important safety messages on aerial platforms safety This Safety Alert Symbol means attention signs in manuals or elsewhere When you see this symbol be alert to the possibility of Become alert Your safety is involved personal injury or death Follow the instructions in the safety message DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices IMPORTANT IMPORTANT indicates a procedure essential for safe operation and which If not followed may result in a malfunction or damage to the aerial platform SKYJACK Page 4 DC Electric Full Size Q Rough Terrain Section 1 SCHEDULE MAINTENANCE Table of Contents Operator s Responsibility for Maintenance cn E A a et at pa ake E e nat D e ei ee 7 ik 7 Samer nore Come ined et TIT TIT IMMERHIN 7 kit pg ets a a eso E MER AMI ol E a ice ee beeen 7 EAN aa aka k ie ANA AE L e ei eee nee eer nen ea
162. 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 amp 8841E 6 Q 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 2 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 6 to reverse relay G0ECR2 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 60 2 CE only Check continuity Replace if defective 10 Loose or broken wire 15 from main circuit board at CN5 to reverse relay GOECR2 CE only Check continuity Replace if defective 11 Loose or broken wire 15A from reverse relay 60 2 to auxiliary reverse relay 60 2 CE only Check continui
163. owered 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 amp RIGHT to select the flashing digits Press UP amp 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 6 Q 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
164. 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 amp 8841E 6 Q 155154 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 10 11 20 21 22 Defective fuse F4 Replace fuse 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 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 Loose or broken wire 02 from main circuit board to down enable relay 60 1 or auxiliary down enable relay 60CR1 CE only Check continuity Replace if defective Defective down enable relay 60ECR1 or auxiliary down enable relay 60CR1 CE only Check relay Replace if defective 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 Loose or broken wire 60 from control module CM1 at pin P3 4 to auxiliary down enable relay 60CR1 CE only Chec
165. quipped Lift Mechanism Scissor Guards If Equipped Maintenance Support Scissor Assembly A B Lift Cylinder s A B A Perform Visual and Daily Maintenance Inspections amp 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 T 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 SKYJACK Page 17 Rough Terrain Q Service and Maintenance Inspections Section 1 Scheduled Maintenance 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 IN WARNING To avoid injury do not operate an aerial platform until all malfunctions have been corrected IN WARNING To avoid possible injury ensure aerial platform power is off during your visual and daily
166. r Switch Lift Drive Steer Controller Base Off Platform Key Switch Emergency Stop Button Test Driving 1 Ensure path of intended motion is clear Activate and hold A enable trigger switch Slowly move controller handle in 1 hall 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 Slowly move controller handle ah 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 y Lift Drive Steer Controller e 2 Operation Light Lift Off Drive Switch Base Off Platform Key Switch Emergency Stop Button e Test Brakes e Test Elevated Drive Speed WARNING WARNING Brakes will engage instantly when you Be aware of overhead obstructions release the controller handle causing or other possible hazards around the aerial platform to stop immediately aerial platform when lifting 1 Ensure path of intended motion is clear 1 Ensure path of intended motion is clear 2 Raise the platform until approximately a
167. 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 amp 8841E 6 Q 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 75 76 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 SKYJACK Page 23 Models 8831E amp 8841E 155154 6 Q Notes SKYJACK Page 24 Fuli Size Rough Terrain Series
168. rigger board Check continuity Replace if defective Open diode D61 or D65 on outrigger board Check diode Replace if defective Loose or broken wire 10C or 02 from outrigger board to relay 10CCR ANSI CSA only Check continuity Replace if defective Defective relay 10CCR ANSI CSA only Check relay Replace if defective Loose or broken wire 28E from outrigger control module to relay 10CCR ANSI CSA only Check continuity Replace if defective Loose or broken wire 28 from relay 10CCR to pin 7 on Sevcon ANSI CSA only Check continuity Replace if defective Loose or broken wire 28E from overload control module CM1 to pin 7 Sevcon CE only Check continuity Replace if defective 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 2 1 Check continuity Replace if defective 5 Loose or broken wire 10 from outrigger board to outrigger limit switc
169. rking 10 16 5 CARLISLE US LOADER Foam Rim Size 4 10 121 mm 4 10 121 mm 434 10 121 mm 10 16 5 OTR OUTRIGGER Non Marking 3 4 121 60615AA ANSI Factory preset 20 Check pressures regularly as tires can lose pressure over time and over different ambient temperatures even under normal conditions t Usage S tandard Or O ptional N A Not Available Backspace Rim Backspace Diagram Inboard Outboard SECTION SKYJACK Page 10 DC Electric Full Size Rough Terrain Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 5 Rough Terrain Scissor Fluids AXLE OIL Capacity Capacity Liters US Gallons 1 24 0 634 Gear 80W 90 GL5 Dana Front Rear Chevron Gear Lubricant Delo ESI 80W 90 Caltex Gear Lubricant ESI 80W 90 Cushman Rear 1 0 264 Gear ESI 80 90 Caltex RPM Borate 80W 90 Texaco Star Gear Lubricant 80W 90 CENTER DRIVE OIL Axle Type Oil Type Recommended Equivalent Oil Capacity Capacity Center Drive Type Liters US Gallons Recommended Equivalent Gear Oil BOW 90 GL5 HYDRAULIC OIL Capacity Capacity Model a Liters US Gallons SJRT 68XX 86 88 22 95 SJRT 7127 SJRT 7135 7135 80 48 21 26 EM EM 8243 _ 8850 8831 ATF Dexron Ill SJRT 8841 8841 75 71 i RT 8831E RT 8841E
170. ronment of the work platform governs the use of the maintenance schedule The inspection points covered in Table 1 2 Maintenance and Inspection 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 Itis the responsibility of the owner to arrange quarterly and annual inspections of the aerial platform Table 1 1 Owner s Annual Inspection 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 MN WARNING Any unit that is damaged or not operat ing properly must be immediately tagged and removed from service until proper repairs are completed Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this aerial platform All maintenance a
171. se Off Platform Key Switch Emergency Stop Button 1 2 3 Platform Control Console 1 On battery roll out tray ensure battery connectors are properly connected On base control console ensure base i emergency stop button is pulled out Select off platform base key switch to SA platform position WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform Use the ladder of aerial platform to access platform Close the gate Insert key into base off platform key switch and select a platform position On platform control console pull out e emergency stop button SKYJACK Page 28 DC Electric Full Size Rough Terrain Section 1 Scheduled Maintenance Function Tests gt Lift Drive Steer Ny Enable Trigger Switch ZAN 122 Operation Light Lift Off Drive Switch e Test Platform Emergency Stop 1 Push in 6 emergency stop button and attempt to activate any platform function Result All selected platform functions should not operate Test Enable Trigger Switch 1 Pull out 6 emergency stop button 2 Without activating Cx enable trigger switch attempt to activate any platform function Result All platform functions should not operate Rocker Switch Lift Drive Steer Controller Base Off Platform Key Switch Emergency Stop Butto
172. t Series 155147 SKYJACK Page 17 Service and Maintenance Section 5 Procedures Table 5 3 Traction Controller Flash Fault Pin References Number of Flashes Lu ft y eet ft ft S ps pe fet LL gl pete pet X gt 2 c jum tc 60288 SKYJACK Page 18 DC Electric Scissor Lifts Compact Series 6 Q 155147 Section 5 Procedures Service and Maintenance 5 3 3 Tachometer Board Pin Reference nndppHmvsETRS 1171 c 901 999 QZ AR oM ol oFo Figure 5 9 Tachometer Board Term A 48 volt input from relay C10D 12 Term B 24 volt input from wire 10B Test between terminal B and wire 02 Term C 24 volt output to drive steer and line contactors Fused from terminal B Test between terminal C and wire O2 Pin 1
173. tch 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 59 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 8 Replace fuse Full Size Rough Terrain Series SKYJACK Page 5 Models 8831E amp 8841E 155154 6 Q Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 7 8 8 9 10 11 12 13 14 15 16 17 18 19 Open defective diode D9 1 or D9 2 Check diode Replace if defective Loose or broken wire 14 from platform control box to main circuit board at CN1 Check continuity Replace if defective Open or defective diode D14 Check diode Replace if defec
174. ted If the switch you are adjusting does not match the selected mode you will damage the component DC Electric Scissor Llfts SKYJACK Page 7 Compact Series 155147 6 Q Service and Maintenance Section 5 Procedures 5 2 6 Proximity Switch Test Procedure NOTE 00 NOT USE A METER PROXIMITY SWITCHES ARE NORMALLY CLUSED WHEN NOT SENSING METAL TUBE SWITCH penn pi NS BLACK CONTRO BLUE 5 USING THE TIP OF A SCREWDRIVER OTHER PIECE OF METAL SLOWLY WAVE IN FRONT OF THE PROXIMITY SWITCH WITH SCREWDRIVER 1 8 AWAY FROM SWITCH TH TEST LIGHT SHOULO GLOW WHEN METAL IS IN FRONT OF SWITCH TEST LIGHT SHOULD NUT GLOW SCREWORIVER 3 CONNECT THE BLACK WIRE TO THE LEAD OF A TEST LIGHT BLACK 2 CONNECT ROWN WIRE TO THE POSITIV POST JATTERY BLUE BROWN NNECT BLUE WIRE 1 HE NEGATIVE 4 CONNECT THE OTHER LIGHT TU THE NEGATIVE POST OF THE BATTERY _ Figure 5 4 Proximity Switch SKYJACK Page 8 DC Electric Scissor Lifts Compact Series 6 Q 155147 Section 5 Procedures Service and Maintenance 5 2 7 Wheel Bolt Nut Inspec
175. tenance 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 to YES then press ENTER SKYJACK Page 40 DC Electric Scissor Lifts Compact Series 6 Q 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 Code Code 167 RT DC Electric Scissor Llfts SKYJACK Page 41 Compact Series 155147 6 Q 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 Code Co
176. 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 6 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 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 lo
177. tion and Torquing Procedure It is necessary to check the torque on all wheel nuts and wheel bolts at pre delivery after 8 hours of op eration and at weekly intervals using the following procedure 1 2 Confirm that each wheel fastener is torqued to 140 5 ft lb All fasteners must be torqued using the tightening sequence shown below Figure 5 5 Wheel Fastener Tightening Sequence Again confirm that each wheel fastener is torqued to the specified tolerance Re torque as necessary until all fasteners are properly torqued 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 1 Inspect wheel fastener threads for damage of defects Replace if defective Clean the mounting surfaces ofthe hub and wheel rim of debris rust excess paint etc Mount wheel on the hub centering mounting holes on the wheel studs or bolt holes Use appropriate lifting device as required Install wheel nuts or wheel bolts and tighten to center the rim Torque nuts or bolts to approximately 50 ft Ib using the tightening sequence in procedure 5 2 7 Torque again to 100 ft lb using the same sequence Torque again to 140 ft Ib using the same sequence Repeat the tightening sequence to confirm that none have changed from 140 ft Ib If any are found below 140 ft Ib repeat complete sequ
178. tive 6 Defective fuse F7 Replace fuse 7 Open or defective diode D12 1 or 12 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 L S64 Check switch Replace if defective 11 Loose or broken wire 64 from outrigger limit switch 1564 to outrigger board Check continuity Replace if defective 12 Loose or broken wire 64 from outrigger board to outrigger limit switch 1563 Check continuity Replace if defective 13 Defective outrigger limit switch L S63 Check continuity Replace if defective 14 Loose or broken wire 63 from outrigger limit switch 1563 to outrigger board Check continuity Replace if defective 15 Loose or broken wire 63 from outrigger board to outrigger limit switch 1562 Check continuity Replace if defective 16 Defective Limit switch L S62 Check switch Replace if defective 17 Loose or broken wire 62 from outrigger limit switch 1562 to outrigger board Check continuity Replace if defective 18 Loose or broken wire 62 from outrigger board to outrigger limit switch 1561 Check continuity Replace if defective 19 Defective outrigger limit switch 1561 Check switch Replace if defective 20 Loose or broken wire 61 from outrigger limit switch LS61 to outrigger board Che
179. tive Defective fuse F9 Replace fuse Loose or broken wire 14C from main circuit board at CN8 to end of stroke limit switch LS4 Check continuity Replace if defective Open or defective end of stroke limit switch LS4 Check switch Replace if defective Loose or broken wire 14D from end of stroke limit switch LS4 to main circuit board at CN8 Check continuity Replace if defective Loose or broken wire 14D or 02 from main circuit board at CN3 to up coil 2H 14D Check continuity Replace if defective Open or defective diode D14D or D14D 1 Check diode Replace if defective Defective coil 2H 14D Check coil Replace if defective Loose or broken wire 14C from main circuit board at CN8 to overload control module CM1 CE Only Check continuity Replace if defective Lift Traction circuit not shifting See Lift Traction Circuit inoperative Sevcon problem See Sevcon troubleshooting Overload sensing system problem CE Only Refer to Load Sensing Manual available online 4 1 5 Up Circuit Inoperative From Base 1 2 Lift Lower switch 56 defective Check continuity Replace if defective 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 1 lift operates correctly with outriggers extended Outriggers not fully retracted Fully retract outrigger cylinders 2 Loose or broke
180. 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 13 2 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 Manuallowering valve V1 and lift cylinder holding valve 2H 13 2 and 2 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
181. trigger retract Hytos 12 Volt Left front outrigger extend COIL 12 Volt Right front outrigger extend Hytos COIL 12 Volt Right rear outrigger extend Hytos 12 Volt Left rear outrigger extend TRANSDUCER Angle CE BATTERY 6 Amp Trojan U 2500 BATTERY CHARGE INDICATOR CHARGER Battery CHARGER Battery BEEPER Platform control console XL 600 9 28 VDC 24 Volt Pump 24 Volt Main 24 Volt Reverse CONTACTOR 24 Volt Forward CIRCUIT BREAKER Ground 20 amp Parts list continued on the following page DC Electric Fuli Size Rough Terrain Models 8831E 8 8841E 155154 Service Maintenance Section 3 System Component Identification and Schematics 3 4 Electrical Parts List Continued Skyjack Parts list continued from the previous page 117325 CIRCUIT BREAKER 48 Volt 15 amp 117326 CIRCUIT BREAKER 24 Volt 20 amp 130224 CABINET LIGHT 130224 CABINET LIGHT 119373 CABLE ASSEMBLY Platform control console 120370 CABLE ASSEMBLY Scissor arm Model 8831 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 11
182. ture 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 Total Aerial Platform Total Aerial Platform Load Weight Ib kg Ib kg psi kPa psf kg m 2 60614AA ANSI min Total aerial platform weight with no options max Aerial platform weight all options LCP Locally Concentrated Pressure is measure of how hard the aerial platform presses on the areas 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 SKYJACK Page 7 Rough Terrain Section 2 Maintenance Tables and
183. ty Replace if defective 12 Loose or broken wire 15B from auxiliary reverse relay 6 2 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 155 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 T
184. ve diode 18 Check diode Replace if defective Full Size Rough Terrain Series SKYJACK Page 9 Models 8831E amp 8841E 155154 YO Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 1 11 No Steer Right 2 3 Loose or broken wire 23 from platform control box to main circuit board at CN1 Check continuity Replace if defective Open or defective diode D23 Check diode Replace if defective Defective fuse F1 Replace fuse Loose or broken wire 23 or 02 on coil 4H 23 Check continuity Replace if defective Defective coil 4H 23 Check coil Replace if defective Defective steer switch Check switch Replace if defective 4 1 12 No Steer Left 1 2 3 Loose or broken wire 24 from platform control box to main circuit board at CN1 Check continuity Replace if defective Open or defective diode D24 Check diode Replace if defective Defective fuse F2 Replace fuse Loose or broken wire 24 or 02 on coil 4H 24 Check continuity Replace if defective Defective coil 4H 24 Check coil Replace if defective 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

Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents