Maintenance and Parts Manual

Transcription

MODELS SJ 8831E SJ 8841E
Maintenance and Parts Manual
DC Electric Full-Size Rough Terrain
Part No. 119153AO September 2010
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: [email protected]
Parts (North America)
Toll Free: 1-800-965-4626
Toll Free Fax: 1-888-782-4825
Parts & Service (Europe) Unit 1 Maes Y Clawdd, Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK
Phone: +44-1691-676-235
Fax: +44-1691-676-238
Skyjack Asia Pacific Singapore
Phone: +65-6449-3710
Fax: +65-6449-7690
1
Table of Contents
Section - Paragraph
Page No.
Section 1 - About Your Aerial Platform
Aerial Platform Definition..................................................................................................................... 1
Purpose of Equipment........................................................................................................................ 1
Use of Equipment............................................................................................................................... 1
Manual................................................................................................................................................. 1
Operator.............................................................................................................................................. 1
Scope of this Manual.......................................................................................................................... 2
Operator Safety Reminders................................................................................................................ 3
Electrocution Hazard.......................................................................................................................... 3
Safety Precautions.............................................................................................................................. 4
Section 2 - List of Tables
Table of Contents................................................................................................................................ 1
Section 3 - System Component Identification and Schematics - Operation
Section 4 - Troubleshooting Information - Operation
Section 5 - Maintenance and Service - Operation
S
E
C
T
I
O
N
Section 6 - Parts Lists - Operation
I
N
D
E
X
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3
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The Safety Alert Symbol identifies important
safety messages on machines, safety signs
in manuals or elsewhere. When you see this
symbol, be alert to the possibility of personal
injury or death. Follow the instructions in the
safety message.
This Safety Alert Symbol means attention!
Become alert! Your safety is involved.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
CAUTION indicates a potentionally 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(s) essential for safe operation and which,
if not followed, may result in a malfunction or damage to the machine.
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SKYJACK Inc. 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 Rough Terrain - E Series (Models 8831E & 8841E) aerial platforms are designed to transport and
raise personnel, tools and materials to overhead work areas.
Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving MUST be on a flat, level,
compacted surface.
ManualS
Operating Manual
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.
Maintenance & Parts
The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.
All information in this manual should be READ and UNDERSTOOD before any attempt is made to service the
machine. The updated copy of the manuals are found on the company’s website: www.skyjack.com.
Operator
The operator MUST read and completely understand both this operating manual and the safety panel label located on the platform and ALL other warnings in this manual and on the aerial platform. Compare the labels on
the aerial platform with the labels found within this manual. If any labels are damaged or missing, replace them
immediately.
Optional Accessories
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under “Standard and Optional Features” in Section 1 of the Operating Manual.
Operating instructions for these options (if equipped) are located in Section 2 of the Operating Manual.
For options not listed under “Standard and Optional Features”, contact the SKYJACK Service Department at
North America:
( : 800 275-9522
7 : 630 262-0006
Europe:
( : 44 1691-676-235
7 : 44 1691-676-239
Include the model and serial number for each applicable machine.
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Scope of this Manual
a. This manual applies to the ANSI/SIA, CSA and CE versions of the E - Series Rough Terrain aerial platform
models listed on Table 2-1a and Table 2-1b.
- Equipment identified with “ANSI” meets the ANSI SIA-A92.6-1999 standard.
- Equipment identified with “CSA” meets the CSA B354.2-01 standard.
- Equipment identified with “CE” meets the requirements for the European countries, i.e., Machinery
Directive 89/392/EEC, 98/37/EC and EMC Directive 89/336/EEC and the corresponding EN standards.
b. CSA (Canada) and CE (Europe)
Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this aerial platform.
c. ANSI/SIA (United States)
Operators are required by the current ANSI/SIA A92.6 standards to read and understand their RESPONSIBILITIES
in the Manual of Responsibilities before they use or operate this aerial platform.
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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 accident. Therefore, proper usage of this aerial
platform is mandatory. The following pages of this manual should be read and understood completely before
operating the aerial platform.
Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety
devices to protect your eyes, ears, hands, feet and body.
Any modifications from the original design are strictly forbidden without written permission from SKYJACK Inc.
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 THE MACHINE AS A GROUND FOR WELDING.
DO NOT OPERATE THE MACHINE DURING LIGHTNING OR STORMS.
DANGER
Avoid Power Lines
Minimum Safe Approach Distance
ANSI/SIA A92.6-1999 &
CSA B354.2-01 Requirements
Voltage Range
Minimum Safe Approach Distance
(Phase to Phase)
Feet
Meters
0 to 300V
Avoid Contact
Over 300V to 50KV
10
3.05
Over 50KV to 200KV
15
4.60
Over 200KV to 350KV
20
6.10
Over 350KV to 500KV
25
7.62
Over 500KV to 750KV
35
10.67
Over 750KV to 1000KV
45
13.72
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!
60023AC
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Safety Precautions
Know and understand the safety precautions before going on to next section.
WARNING
Failure to heed the following safety precautions could result in tip over, falling,
crushing, or other hazards leading to
death or serious injury.
• KNOW all national, state/provincial and local
rules which apply to your MACHINE and JOBSITE.
• TURN the main power disconnect switch OFF
when leaving the machine unattended. Remove
the key to 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 NOT wear loose clothing,
dangling neckties, scarves,
rings, wristwatches or other
jewelry while operating this lift.
• AVOID entanglement
ropes, cords or hoses.
with
• AVOID falling. Stay within the
boundaries of the guardrails.
• DO NOT raise the aerial platform in windy or gusty conditions.
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• DO NOT increase the lateral
surface area of the platform.
Increasing the area exposed to
the wind will decrease machine
stability.
• DO NOT drive or elevate the
aerial platform if it is not on a
firm level surface. Do not drive
elevated near depressions
or holes of any type, loading
docks, debris, drop-offs and
surfaces that may affect the stability of the aerial platform.
• If operation in areas with
holes or drop-offs is absolutely necessary, elevated
driving shall not be allowed.
Position the machine horizontally only with the platform fully
lowered. After ensuring that
all 4 wheels or outriggers (if
equipped) have contact with
level firm surface, the aerial
platform can be elevated. After elevation, the drive function
must not be activated.
• Elevated driving must only
be done on a firm level surface.
• DO NOT ascend or descend
a grade when elevated. When
fully lowered, ascending or descending, only grades up to
rated maximum listed in Table
2-1a and Table 2-1b are permissible.
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Safety Precautions (Continued)
• DO NOT operate on surfaces not capable of
holding the weight of the aerial platform including
the rated load, e.g. covers, drains, and trenches.
• DO NOT operate an aerial platform that has ladders, scaffolding or other devices mounted
on it to increase its size or work
height. It is prohibited.
• DO NOT raise the aerial platform while the machine is on a
truck, fork lift or other device or
vehicle.
• BE AWARE of crushing hazards. Keep all body parts inside platform guardrail.
• DO NOT exert side forces on
aerial platform while elevated.
• DO NOT lower the platform
unless the area below is clear
of personnel and obstructions.
• DO NOT use the aerial platform
as a crane. It is prohibited.
• ENSURE that there are no personnel or obstructions in the path of travel, including blind spots.
• DO NOT sit, stand or climb on
the guardrails. It is prohibited.
• BE AWARE of blind spots when operating the
aerial platform.
• DO NOT climb on scissor arm
assembly. It is prohibited.
• STUNT driving and horseplay are prohibited.
• ENSURE ALL tires are in good condition and lug
nuts are properly tightened.
• DO NOT alter or disable limit switches or other
safety devices.
• BE AWARE of overhead obstructions or other possible
hazards around the aerial platform when driving or lifting.
• DO NOT use the aerial platform without guardrails, locking pins and the entry gate/chain/bar in
place.
• DO NOT exceed the rated capacity of the aerial
platform. Do make sure the load is evenly distributed on the platform.
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Safety Precautions (Continued)
• DO NOT overload the platform, the lift relief
valve does not protect against overloading when
the platform is elevated. (Machines without load
sensing)
• DO NOT attempt to free a snagged platform with
lower controls until personnel are removed from
the platform.
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.
• DO NOT position the aerial platform against another object to steady the platform.
WARNING
Entering and exiting the aerial platform
should only be done using the three
points of contact system.
• Use only equipped access openings and ladders.
• 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 machine 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.
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 ap
proved by the manufacturer.
• has safety devices which have been altered or disabled.
Failure to avoid these hazards could result in death or serious injury.
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Table of Contents
Table 2-1a. Specifications and Features - ANSI/CSA..................................................................................................2
Table 2-1b. Specifications and Features - CE.............................................................................................................3
Table 2-2.
Owner’s Annual Inspection Record..........................................................................................................4
Table 2-3a. Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA.............................................................6
Table 2-3b. Maximum Platform Capacities (Evenly Distributed) - CE.........................................................................7
Table 2-4.
Maintenance and Inspection Schedule....................................................................................................8
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Height
Table 2-1a. Specifications and Features - ANSI/CSA
Model
8831E
8841E
Weight*
10,455 lbs.
11,355 lbs.
Width
87.0”
Length
137.5”
Platform Size
68” x 133.5”
Elevated Working
37.0’
47.0’
Elevated Platform
31.0’
41’
Stowed Platform
59.0”
69.0”
Full***
Drive
Tires
Standard
30 x 10-16.5 #6 Air filled
30 x 10-16.5 #6 Air filled
#6 or #7 Foam filled
Normal #6 Air filled Drive (Max)
2.6 mph
Elevated Low Drive (Max)
.45 mph
Speed
Optional
Lift (Rated Load)
46 sec.
71 sec.
Lower (Rated Load)
48 sec.
60 sec.
Gradeability
30%
60125AE-ANSI
* Weights are approximate; refer to serial nameplate for specific weight. Values shown are for standard 2WD machines on air
tires with a manual extension platform (Mid Size RT’s) and no extension platforms (Full Size RT’s)
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Height
Table 2-1b. Specifications and Features - CE
Model
8831E
8841E
Weight*
4,898 kg
5,306 kg
Width
2.21m
Length
3.5 m
Platform Size
1.73 x 3.39 m
Elevated Working
11.28 m
14.3 m
Elevated Platform
9.4 m
12.5 m
Stowed Platform
1.50 m
1.75 m
7.9 m
Speed
Tires
Drive
Standard
30 x 10-16.5 #6 Air filled
30 x 10-16.5 #6 Air filled
Optional
#6 or #7 Foam filled
Normal Drive (Max)
4.2 km/h
Elevated Low Drive (Max)
0.8 km/h
Lift (Rated Load)
46 sec.
71 sec.
Lower (Rated Load)
48 sec.
60 sec.
Gradeability
30%
60125AE-CE
* Weights are approximate; refer to serial nameplate for specific weight. Values shown are for standard 2WD machines on air
tires with a manual extension platform Mid Size RT’s and no extension platforms Full Size RT’s.
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Table 2-2. Owner’s Annual Inspection Record
Model Number: ____________________________
Serial Number: ____________________________
Recording Date
Recording Year #
1
2
3
4
5
6
7
8
9
Owner’s Name
Inspected By
60141AB
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 13 months.
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Table 2-3a. Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA
Total
8841E
8831E
MODEL
First Extension
Capacity
Number of
Occupants
No Extension
Platform
2500 lb.
6
One Extension
Platform
2000 lb.
6
500 lb.
2
Two Extension
Platforms
1700 lb.
6
500 lb.
2
No Extension
Platform
1700 lb.
5
One Extension
Platform
1500 lb.
5
500 lb.
2
Two Extension
Platforms
1500 lb.
5
500 lb.
2
Capacity
Second Extension
Number of
Occupants
Capacity
Number of
Occupants
Not Available
Not Available
500 lb.
2
Not Available
Not Available
500 lb.
2
60279AC-ANSI
NOTE:
Occupants AND materials are not to exceed rated load.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
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Table 2-3b. Maximum Platform Capacities (Evenly Distributed) - CE
Total
8841E
8831E
MODEL
First Extension
Capacity
Number of
Occupants
No Extension
Platform
1134 kg
6
One Extension
Platform
908 kg
5
227 kg
2
Two Extension
Platforms
681 kg
4
227 kg
2
No Extension
Platform
681 kg
4
One Extension
Platform
681 kg
4
227 kg
2
Two Extension
Platforms
681 kg
4
227 kg
2
Capacity
Second Extension
Number of
Occupants
Capacity
Number of
Occupants
Not Available
Not Available
227 kg
2
Not Available
Not Available
227 kg
2
60279AC-CE
NOTE:
Occupants AND materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
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General Maintenance
Before attempting any repair work, disconnect the battery by turning the main power disconnect switch to
the “OFF” position. Preventative maintenance is the easiest and least expensive type of maintenance.
Table 2-4. Maintenance and Inspection Schedule
WARNING
Use original or equivalent to the original parts and components for the aerial platform.
Daily
Weekly
Monthly
3 Months
6 Months
12 Months*
Mechanical
Structural damage/welds
A
A
A
B &E
B &E
B&E
Tires/wheels & fasteners
A, B & C
A, B & C
A, B & C
Guides/rollers & slider pads
A, B & I
A, B & I
A, B & I
Railings & railing lock pins
A&C
A&C
A&C
Entry gates
B&C
B&C
B&C
Bolts and fasteners
C
C
C
Maintenance support
B
B
B
Parking brake
Rust
Wheel bearings & king pins
A
A, B & E
Axle gear oil**
Steering cylinder & tie rod
A
A
A, B & E
A, B & E
F
F
A, B & E
A, B & E
Electrical
Battery fluid level
A
A
A
Control switches
A&B
A&B
A&B
Cords & wiring
Battery terminals
Terminals & plugs
Receptacle
Limit switches
A
A
A
A&C
A&C
A&C
C
C
C
A&B
A&B
A&B
B
B
B
Hydraulic
Hydraulic oil level
Hydraulic hoses/fittings
H
H
H
C
A, L & C
A, L & C
G
G
A&B
A&B
A&B
A&L
Lift/lowering speeds
Cylinders
Emergency lowering
B
Lift capacity
D
B
B
D
D
Hydraulic oil filter
F
F
Miscellaneous
Labels and manual
Lanyard attachments
A, J & K
A, J & K
A&C
A&C
Check for applicable service bulletins
A, J & K
A&C
A
A
Notes
A. Visually inspect.
B. Check operation.
C. Check tightness.
D. Check relief valve setting. Refer to serial number nameplate.
E. Lubricate.
F. Replace.
G. Refer to Table 2-1a and Table 2-1b, “Specifications and
Features.”
H. Check oil level.
I. Ensure there is no metal to metal contact with slider, slider side or running
surface. Check for free movement of surface. Also check for free
movement of the slider pin
J. Replace if missing or illegible.
K. Proper manual must be in box.
L. Check for Leaks.
* Record inspection date and signature.
** Gear Oil Requirements: Axle:
ESSO GX 85W-140
Center Drive:
ESSO GX 85W-140
60280AE-PM
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AN
Section 3
System Component Identification
And Schematics
Table Of Contents
Symbols & Charts
Figure 3.1-1.
Figure 3.1-2.
Figure 3.1-3.
Figure 3.1-4.
Relay Function Chart................................................................................................................. 2
Tilt Switch Usage Chart............................................................................................................. 3
Electrical Symbol Chart............................................................................................................. 4
Hydraulic Symbol Chart............................................................................................................ 5
Hydraulic System
Figure 3.2-1.
Figure 3.2-2.
Figure 3.2-3.
Figure 3.2-4.
Hydraulic Schematic Parts List................................................................................................. 7
Hydraulic Schematic ................................................................................................................ 9
Hydraulic Manifold Component And Port Identification......................................................... 10
Outrigger Manifold And Auto Reset Manifold Port Identification............................................ 10
Battery Charger Schematics
Figure 3.3-1. Battery Charger Schematic - MAC BA1001............................................................................ 11
Figure 3.3-2. Battery Charger Schematic - Bycan #4825U......................................................................... 12
Electrical Diagrams And Schematics
Figure 3.4-1.
Figure 3.4-2.
Figure 3.4-3.
Figure 3.5-1.
Figure 3.6-1.
Electrical Schematic And Diagram Parts List......................................................................... 13
Electrical Inverter Wiring Diagram.......................................................................................... 18
Control Box Diagram - ANSI/CSA & CE Equipped with All Options...................................... 19
Electrical Panel Diagram (ANSI/CSA & CE) - All Options...................................................... 21
Electrical Schematic Diagram (ANSI/CSA & CE) - All Options.............................................. 22
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SECTION 3, Page 1
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Figure 3.1-1. Relay Function Chart
SUPPLY (B+) (Common)
CONTROL (B+)
GROUND (B-)
NORMALLY
CLOSED
CONTACT
RELAY NO.
NORMALLY
OPEN
CONTACT
RELAY FUNCTION
10ACR
Outrigger power
10BCR
Brake
12ECR
Joystick Enable
17ACR
Outrigger lift disable
28CR
Tilt
39CR
LWS, Limit Switch
41CR
LWS Time Delay
42CR
LWS Latching
59CCR
Speed signal
61CR-1
Drive enable
61CR-2
Lift enable
65CR
Lift enable
60066AA
SECTION 3, Page 2
119153
Figure 3.1-2. Tilt Switch Usage Chart
ANSI, CSA & CE Models
Tilt switch
Model
Serial Numbers
(X Axis° x Y Axis°)
117880
(2.5° x 4.5°)
8831E
Current production
X
8841E
Current production
X
M600733AA
NOTE: Ensure the platform is
parked on a flat level surface
before performing any adjustments or repairs to the tilt
switch assembly.
M10281AA
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SECTION 3, Page 3
Figure 3.1-3. Electrical Symbol Chart
ANGLE
TRANSDUCER
WIRE CROSSING
HOURMETER
KEY SWITCH
WIRES JOINED
LIGHT
FOOT SWITCH
PRESSURE
TRANSDUCER
BATTERY
HYDRAULIC
VALVE COIL
TOGGLE SWITCH
LIMIT SWITCH
N.O.
GROUND
PROPORTIONAL
HYDRAULIC
VALVE COIL
PUSH BUTTON
LIMIT SWITCH
N.O. HELD
CLOSED
FUSE
ELECTRIC
MOTOR
ROTARY SWITCH
LIMIT SWITCH
N.C.
CIRCUIT
BREAKER
HORN
LIMIT SWITCH
LIMIT SWITCH
N.C. HELD OPEN
BATTERY
CHARGE
INDICATOR
EMERGENCY
STOP BUTTON
CAM OPERATED
LIMIT SWITCH
SILICON
CONTROLLED
RECTIFIER
CAPACITOR
RESISTOR
TILT SWITCH
PROXIMITY
SWITCH
POTENTIOMETER
LEVEL SENSOR
SINGLE POLE
SINGLE THROWN
RELAY
PNP
TRANSISTOR
SINGLE POLE
DOUBLE THROW
RELAY
DOUBLE POLE
SINGLE THROW
RELAY
DOUBLE POLE
DOUBLE THROW
RELAY
NPN
TRANSISTOR
TRIPLE POLE
DOUBLE THROW
RELAY
DIODE
TRANSISTOR
PRESSURE/
VACUUM
SWITCH
TEMPERATURE
SWITCH
SECTION 3, Page 4
119153
Figure 3.1-4. Hydraulic Symbol Chart
LINE CROSSING
VARIABLE
DISPLACEMENT
PUMP
SHUTTLE VALV
VELOCITY FUSE
LINE JOINED
HAND PUMP
ACCUMULATOR,
GAS CHARGED
SINGLE ACTING
CYLINDER
HYDRAULIC
TANK
RELIEF VALVE
CUSHION
CYLINDER
DOUBLE ACTING
CYLINDER
HYDRAULIC
FILTER WITH
BYPASS
PRESSURE
REDUCING
VALVE
PRESSURE
SWITCH
ELECTRIC
MOTOR
FIXED ORIFICE
MOTION
CONTROL VALVE
SPRING APPLIED
HYDRAULIC
RELEASED
BRAKE
ENGINE
ADJUSTABLE
FLOW CONTROL
FLOW DIVIDER
COMBINER
BRAKE
CYLINDER
FIXED
DISPLACEMENT
PUMP
CHECK VALVE
COUNTER
BALANCE VALVE
ROTARY
ACTUATOR
THREE POSITION
FOUR WAY
PROPORTIONAL
OIL COOLER
VALVE COIL
SERIES
PARALLEL
HYDRAULIC
MOTOR
TWO POSITION
TWO WAY
NORMALLY
CLOSED
TWO POSITION
TWO WAY
NORMALLY
OPEN
TWO POSITION
THREE WAY
THREE POSITION
FOUR WAY
CLOSED CENTER
CLOSED PORT
PRESSURE
TRANSDUCER
MAIN LINES Solid
PILOT LINES Dashed
SERVO
119153
TWO POSITION
THREE WAY
DOUBLE ACTING
DOUBLE
RODDED
BI DIRECTIONAL
HYDRAULIC
MOTOR
THREE POSITION
FOUR WAY
CLOSED CENTER
OPEN PORT
THREE POSITION
FOUR WAY
PROPORTIONAL
VARIABLE
DISPLACEMENT
HYDRAULIC MOTOR
QUICK
DISCONNECT
SECTION 3, Page 5
Figure 3.2-1. Hydraulic Schematic Parts List
Index
No.
Skyjack
Part No.
Qty.
Description
C1
109953
1
C2
109953
1
C3
120275
1
C4
120275
1
C5
112448
1
C7
112498
1
C9-C12 132694
1
CYLINDER, Lift
CYLINDER, Lift
CYLINDER, Front extension platform
Use Part # 118090 for Machines with Serial # 36839 (8831)
or 41670 (8841) and below.
CYLINDER, Rear extension platform
Use Part # 118090 for Machines with Serial # 36839 (8831)
or 41670 (8841) and below.
CYLINDER, Disc brake
CYLINDER, Steer
CYLINDER, Outrigger
Order the following as per Serial Breakdown below:
CV1
104567
1
CV2
104567
1
CV3
104567
1
CV4
104567
1
CV5
104567
1
CV6
104567
1
CV7
104115
1
CV8
104115
1
CV9
104115
1
CV10
104115
1
F1
109568
1
104254
1
HP2
110652
1
M1
109311
1
M2
113875
1
MB1
108804
1
106688
1
MB3
MB4
106688
1
MB5
107382
1
MB6
119748
1
MB7
116586
1
MB8
111970
1
MC1
110434
1
O1
114218
1
O2
120481
1
O3
120481
1
O4
120756
1
O5
116725
1
O6
123853
1
OC1
114284
1
P1
119999
1
P2
700669
1
P3
113173
1
PS1
102863
1
VALVE, Check
VALVE, Check
VALVE, Check
VALVE, Check
VALVE, Check
VALVE, Check
VALVE, Check
VALVE, Check
VALVE, Check
VALVE, Check
FILTER
• ELEMENT, Filter
PUMP, Hand
MOTOR, Center drive hydraulic
MOTOR W/FLOW CONTROL, Hyd. generated
MANIFOLD, Main
MANIFOLD, Holding valve
MANIFOLD, Holding valve
MANIFOLD, Powered platform
MANIFOLD, Lift
MANIFOLD, Quick brake
MANIFOLD, Outrigger
MOTION CONTROL ASSEMBLY
ORIFICE, Controller lowering .70
ORIFICE, Lowering .104
ORIFICE, Emergency lowering .067
ORIFICE, Dump Valve 0.031
OIL COOLER ASSEMBLY, Hydraulic generator option
PUMP, (Gearbox)
PUMP, (Hydraulic tray)
PUMP, Hydraulic 1.2gpm powered extension platform
PRESSURE, Switch
1. 126091 - Serial No. 37315 to 37406 (8831E), or 42703 to 43044 (8841E)
2. 120309 - Serial No. 36840 to 37314 (8831E), or 41671 to 42702 (8841E)
3. 115646 - Serial No. 36839 (8831E), or 41670 (8841E), & Below
Parts list continued on the following page.
119153
SECTION 3, Page 7
Figure 3.2-1. Hydraulic Schematic Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
PS2
701194
1
Parts list continued from the previous page.
PRESSURE SWITCH (800 PSI)
PT1
(Ref.)
-
TRANSDUCER, Pressure
(For components refer to Load Sensing Supplement manual, Section 3)
QD1
QD2
R1
R2
R3
R4
V1
V2
V6
2H-13-1
2H-13-2
2H-13-3
2H-14D
2H-17A
2H-21A
2H-25
2H-30
2H-44
4H-23A
4H-24A
4H-26
4H-26A
4H-27
4H-27A
4H-32A
4H-33A
4H-71
4H-72
4H-73
4H-74
4H-75
4H-76
4H-77
4H-78
122420
122420
104534
104534
106557
106557
107271
113556
113752
104412
107269
107269
104412
103655
114365
117189
104412
104412
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
SECTION 3, Page 8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
QUICK DISCONNECT, System pressure
QUICK DISCONNECT, System pressure
VALVE, System relief
VALVE, Gearbox relief (500 PSI)
VALVE, Relief
VALVE, Relief
VALVE, Manual lowering
VALVE, Controlled lowering
VALVE, Auto reset
VALVE, Lowering
VALVE, Holding
VALVE, Holding
VALVE, Lift
VALVE, Outrigger holding
VALVE, System Dump
VALVE, Quick brake
VALVE, Brake release
VALVE, Gearbox
VALVE, Right steer (Vickers)
VALVE, Right steer (Hytos)
VALVE, Left steer (Vickers)
VALVE, Left steer (Hytos)
VALVE, Front platform extend (Vickers)
VALVE, Front platform extend (Hytos)
VALVE, Rear platform extend (Vickers)
VALVE, Rear platform extend (Hytos)
VALVE, Front platform retract (Vickers)
VALVE, Front platform retract (Hytos)
VALVE, Rear platform retract (Vickers)
VALVE, Rear platform retract (Hytos)
VALVE, Traction gearbox (Vickers)
VALVE, Traction gearbox (Hytos)
VALVE, Lift gearbox (Vickers)
VALVE, Lift gearbox (Hytos)
VALVE, Left front outrigger retract (Vickers)
VALVE, Left front outrigger retract (Hytos)
VALVE, Right front outrigger retract (Vickers)
VALVE, Right front outrigger retract (Hytos)
VALVE, Right rear outrigger retract (Vickers)
VALVE, Right rear outrigger retract (Hytos)
VALVE, Left rear outrigger retract (Vickers)
VALVE, Left rear outrigger retract (Hytos)
VALVE, Left front outrigger extend (Vickers)
VALVE, Left front outrigger extend (Hytos)
VALVE, Right front outrigger extend (Vickers)
VALVE, Right front outrigger extend (Hytos)
VALVE, Right rear outrigger extend (Vickers)
VALVE, Right rear outrigger extend (Hytos)
VALVE, Left rear outrigger extend (Vickers)
VALVE, Left rear outrigger extend (Hytos)
119153
Figure 3.2-2. Hydraulic Schematic
A
B
C
D
E
F
G
H
V
W
X
Y
Z
M50045AA
119153
SECTION 3, Page 9
Figure 3.2-3. Hydraulic Manifold Component And Port Identification
PS2
PRESSURE
SWITCH
TO
GEARBOX
4H-32A
TRACTION
GEARBOX
VALVE
CV5
LIFT
CHECK
VALVE
2H-13-1
VALVE
LOWERING
LIFT GAUGE
4H-23A
RIGHT
STEER 4H-24A
VALVE
LEFT
STEER
VALVE
R1
SYSTEM
RELIEF
VALVE
TO
TANK
AUTO
RESET
MANIFOLD
4H-33A
LIFT
GEARBOX
VALVE
CV4
LIFT
CHECK
VALVE
R2
GEARBOX
RELIEF
VALVE
2H-44
GEARBOX
HOLDING
VALVE
CV4
SYSTEM
CHECK
VALVE
EMERGENCY
LOWERING
LIFT
O5
ORIFICE
2H-30
BRAKE
RELEASE
VALVE
2H-21A
SYSTEM
DUMP
VALVE
O6
DUMP
ORIFICE
TO
LARGE
PUMP
2H-25
QUICK
BRAKE
VALVE
V6
AUTO
RESET
VALVE
4H-71
OUTRIGGER
LEFT FRONT
RETRACT
4H-72
OUTRIGGER
RIGHT FRONT
RETRACT
OUTRIGGER
MANIFOLD
4H-74
OUTRIGGER
LEFT REAR
RETRACT
4H-73
OUTRIGGER
RIGHT REAR
RETRACT
TO
SMALL
PUMP
2H-17A
OUTRIGGER
HOLDING
VALVE
4H-78
OUTRIGGER
LEFT REAR
EXTEND
4H-75
OUTRIGGER
LEFT FRONT
EXTEND
TO
RETURN
FILTER
4H-76
OUTRIGGER
RIGHT
4H-77
FRONT
OUTRIGGER
EXTEND
RIGHT REAR
EXTEND
M10307AA
SECTION 3, Page 10
HP2
HAND
PUMP
CV2
SMALL
PUMP
CHECK
VALVE
CV1
LARGE PUMP
CHECK VALVE
2H-14D
LIFT
VALVE
TO
BRAKE
TO MAIN
MANIFOLD
TO
STEER
GEARBOX
GAUGE
CV3
BRAKE
CHECK
VALVE
Figure 3.2-4. Outrigger Manifold And Auto Reset Manifold Component And Port Identification
TO
OUTRIGGER
CYLINDERS
10283AA
119153
Figure 3.3-1. Battery Charger Schematic - MAC BA1001
9
7
5
11
6
8
2
1
11
4
3
10
M1115AA_1
Index
No.
Skyjack
Part No.
Qty.
A
(Ref.)
-
BATTERY CHARGER ASSEMBLY (MAC #BA1001)
1
2
3
4
5
6
7
8
9
10
11
108554
700689
108556
708976
103364
708974
708975
108558
700688
110857
700691
108564
700692
115315
1
1
2
1
1
1
1
1
1
1
1
1
1
2
• AMMETER, 0-30
• RECTIFIER ASSEMBLY
• • DIODE, 70 Amp
• CORD ASSEMBLY, D.C.
• • PLUG, 50 Amp gray
• CAPACITOR, 10MFD 440 VDC
• CONTROL CIRCUIT, 48 VDC 120V VAC
• FUSE HOLDER, A.C.
• • FUSE, 25 Amp A.C.
• STOP SWITCH, N.O.
• TRANSFORMER, 48 VDC 23 Amp 120 VAC/60Hz
• CONTROL TRANSFORMER
• VARISTOR
• RELAY, 120 VAC/30 Amp
Description
119153
SECTION 3, Page 11
Figure 3.3-2. Battery Charger Schematic - Bycan #4825U
1
9
2
3
7
5
10
15
8
13
14
16
12
12
4
6
11
M1115AA_2
Index
No.
Skyjack
Part No.
Qty.
A
122367
-
CHARGER ASSEMBLY, Battery (2440U, 50/60 Hz)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
121570
121564
121536
121569
121538
129258
121540
121541
121542
121543
121565
121545
121546
121566
121567
115391
1
1
1
1
2
1
1
1
2
1
1
2
1
1
1
1
VARISTOR
TRANSFORMER
CAPACITOR
RESISTOR 10K OHM, 3W
RECTIFIER
DIODE
FUSE, LINK
SOCKET, AC Cord
RELAY, 24V DC
AMMETER, 50A DC
CONTROLLER ASSEMBLY
RELAY, 240 V
CIRCUIT BREAKER, AC
FAN, Cooling
CORD, DC Battery
PLUG, Charger cutout
SECTION 3, Page 12
Description
119153
Figure 3.4-1. Electrical Schematic And Diagram Parts List
Index
No.
Skyjack
Part No.
Qty.
AT1
130440
1
B1
106552
8
BC1
103240
1
BC-1 120075-AE
2
120075-AN
2
BC-2 120075-AE
2
120075-AN
2
BP-28B 103057
1
BP29
103056
1
BP-29C 117967
1
C10B-1 119168
1
124823
1
C10B-2 119169
1
124824
1
C15A
119170
1
124825
1
C16A
119170
1
124825
1
C10D-1 119168
1
124823
1
C10D-2 119169
1
124824
1
C15C
119170
1
124825
1
C16E
119170
1
124825
1
CB1
117326
1
CB2
117325
2
CB3
117326
1
CL-1
119358
1
CL-2
119358
1
CRD1
119373
1
CRD2
120370
1
120074
1
CRD3
120069
1
DCM1
116757
1
DCM2
700668
1
123355
1
DPM1
118815
1
DXX
102921
AR
F1
120658
1
F2
120658
1
F3
120658
1
F4
120658
1
F5
120658
1
AN
Description
TRANSDUCER, Angle (CE)
BATTERY, 6 Amp (Trojan U-2500)
BATTERY CHARGE INDICATOR
CHARGER, Battery (MAC BA 1045)
BEEPER
BEEPER
BEEPER, XL - 600 9 - 28 VDC (CE)
CONTACTOR, Pump
CONTACTOR, Steer (24V)(EE Rated) CONTACTOR, Line
CONTACTOR, Line (24V)(EE Rated) CONTACTOR, Reverse
CONTACTOR, Reverse (24V)(EE Rated) CONTACTOR, Forward
CONTACTOR, Forward (24V)(EE Rated) CONTACTOR, Pump (24V)
CONTACTOR, Pump (24V)(EE Rated)
CONTACTOR, Main (24V)
CONTACTOR, Main (24V)(EE Rated)
CONTACTOR, Reverse (24V)
CONTACTOR, Reverse (24V)(EE Rated)
CONTACTOR, Forward (24V)
CONTACTOR, Forward (24V)(EE Rated)
CIRCUIT BREAKER, (20 amp) ground
CIRCUIT BREAKER, (15 amp) (48V) CIRCUIT BREAKER, (20 amp) (24V)
CABINET LIGHT
CABINET LIGHT
CABLE ASSEMBLY, Control box
CABLE ASSEMBLY, Scissor arm (Model 8831)
CABLE ASSEMBLY, Scissor arm (Model 8841)
CABLE ASSEMBLY, Electrical panel
TRACTION MOTOR
MOTOR, 48 Volt
MOTOR, 48 Volt (EE Rated)
MODULE, Power delay
DIODE
FUSE, Right steer
FUSE, Left steer
FUSE, Dump
FUSE, Lowering
FUSE, Reverse
119153
SECTION 3, Page 13
Figure 3.4-1. Electrical Schematic And Diagram Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
F16
700776
1
F17
114866
1
F18
119469
1
FL22
103743
1
FL22A
104535
1
H1
102860
1
INV1
124755
1
124756
1
JS1
126024
1
LCR-1 119156
1
LCR-2
119156
1
LS3
119375
1
LS4
115658
1
LS5
119296
1
LS5
119375
1
LS61
115658
1
LS62
115658
1
LS63
115658
1
LS64
115658
1
LS65
LS66
LS67
LS68
PR1
PR2
PS2
OL1
PT1
RL-22A
S4
S5
S6
115658
115658
115658
115658
116758
116758
701194
133133
134432
108102
120628
115573
102853
1
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 3, Page 14
AN
Description
FUSE, 6.3 Amp
FUSE, 1 Amp tilt switch
FUSE, 200 Amp
FLASHER
LIGHT, Flashing
HORN (on scissors)
INVERTER, 1500W 120V @ 60HZ
INVERTER, 1500W 110/220V @ 50HZ
DRIVE/STEER CONTROLLER
Use part #119371 for machines prior to S/N 37314 (8831E) or 42701
(8841E).
CONTROL RELAY (inside charger)
CONTROL RELAY (inside charger)
LIMIT SWITCH, Drive cut-out limit
LIMIT SWITCH, End of stroke
LIMIT SWITCH, High speed cut-out (ANSI/SIA and CSA)
LIMIT SWITCH, High speed cut-out (CE)
LIMIT SWITCH, Outrigger left/front
Use part #115652 for machines with S/N 37314 (8831E) or 42702 (8841E) &
below.
LIMIT SWITCH, Outrigger right/front
below.
LIMIT SWITCH, Outrigger right/rear
below.
LIMIT SWITCH, Outrigger left/rear
below.
LIMIT SWITCH, Outrigger left/front
LIMIT SWITCH, Outrigger left/rear
PROXIMITY SWITCH, Drive
PROXIMITY SWITCH, LIFT
SWITCH, Pressure
LIGHT, Indicator 12 Volt amber
TRANSDUCER, Pressure 3000 psi (CE)
BEACON, Rotating amber 24 Volt (CE)
SWITCH, Emergency stop key
SWITCH, Platform/base/selector
SWITCH, Toggle up/down
119153
Index
No.
Skyjack
Part No.
Qty.
Description
S7
S8
S9
S9A
F6
F7
F8
F9
F10
F10-2
F11
F12
F13
F14 F15 S11
S12
S16
S17
S18
S19
S20
S21
S22
S23
S24
SV1
TC1
TG1
TMR-8A
TS1
TT1
WL1
X1
10ACR
10ACR1
10ACR2
10BCR
10CCR
12CCR
12ECR
BUTTON, Emergency stop (control box)
SWITCH, Base/off/platform (control box)
SWITCH, Lift/off/drive
SWITCH, Outrigger Enable
FUSE, Forward
FUSE, Drive
FUSE, Pump
FUSE, Lift
FUSE, 10Amp
FUSE, Power deck option
FUSE, Fault
FUSE, 400 Amp main power
FUSE, Center tap 10 Amp
FUSE, 50Amp, Charger Harness & Inverter Option
FUSE, 20 Amp
HORN, (control box)
SWITCH, Lift/Drive Enable (control box)
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, Toggle left/front
SWITCH, Toggle right/front
SWITCH, Toggle right/rear
SWITCH, Toggle left/rear
SWITCH, Auto-Level Outrigger(CE)
DRIVE SEVCON
TACHOMETER CARD
TACHOMETER GENERATOR
RELAY, Inverter Timer Cut-out
SWITCH, TILT
HOURMETER
LIGHT WARNING (Trouble)
SEVCON CONVERTOR
RELAY, Outrigger power
RELAY, Outrigger power (CE)
RELAY, Outrigger safety (CE)
RELAY, Auxiliary Contact (Part of C10B-2 for non EE Rated)
RELAY, Auxiliary Contact (EE Rated)
RELAY, 24 Volt (outrigger movement indicator relay) (CE)
RELAY, Steer switch relay
RELAY, Joystick enable
102769
103082
116382
102853
120658
120658
120658
120658
120658
120658
120658
119364
120658
120302
119172
103057
103280
102853
102853
102853
102853
102853
102853
120853
102853
102853
119167
119171
700227
132494
117880
103336
102671
801347
108589
108589
108589
(Ref.)
118944
108589
126469
108589
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AN
119153
SECTION 3, Page 15
Index
No.
Skyjack
Part No.
Qty.
Description
17ACR 108589
1
18ACR 108589
1
21CR-1 108589
1
21CR-2 108589
1
25CR
108589
1
28CR
108589
1
30CR
108589
1
32CR
108589
1
33CR
108589
1
59ACR 108589
1
60CR1
108589
1
60CR2
108589
1
60CR3
108589
1
60ECR1 108589
1
60ECR2 108589
1
60ECR3 108589
1
61CR
108589
1
61CR-1 108589
1
61CR-2 108589
1
65CR
108589
1
OCM1
132804 1
2H-13-1 105610
1
2H-13-2 104493
1
2H-13-3 104493
1
2H-13B-1 105610
1
2H-13B-2 104493
1
2H-13B-3 104493
1
2H-14D 105610
1
2H-17A 103605
1
2H-21A 105610
1
2H-25
103605
1
2H-30
105610
1
2H-44
105610
1
4H-23
107439
1
128320
1
4H-24
107439
1
128320
1
RELAY, Outrigger lift disable
RELAY, Small pump
RELAY, Power deck interlock
RELAY, Pump interlock
RELAY, Quick brake
RELAY, Tilt
RELAY, Brake
RELAY, Lift sensor
RELAY, Traction sensor
RELAY, Speed signal
RELAY, 24 Volt (auxiliary down relay) (CE)
RELAY, 24 Volt (auxiliary reverse relay) (CE)
RELAY, 24 Volt (auxiliary forward relay) (CE)
RELAY, 24 Volt (down relay) (CE)
RELAY, 24 Volt (reverse relay) (CE)
RELAY, 24 Volt (forward relay) (CE)
RELAY, Drive enable (CE)
RELAY, Drive enable
RELAY, Lift enable
RELAY, Lift enable
MODULE, Outrigger Auto-Levelling Controller
COIL, Lowering
COIL, Holding
COIL, Holding
COIL, Lowering
COIL, Holding
COIL, Holding
COIL, Lift
COIL, Outrigger holding
COIL, System dump
COIL, Quick brake
COIL, Brake release
COIL, Gearbox holding
COIL, Right steer (Vickers)
COIL, Right steer (Hytos)
COIL, Left steer (Vickers)
COIL, Left steer (Hytos)
SECTION 3, Page 16
AN
119153
Index
No.
Skyjack
Part No.
Qty.
Description
4H-26
4H-26A
4H-27
4H-27A
4H-32A
4H-33A
4H-71
4H-72
4H-73
4H-74
4H-75
4H-76
4H-77
4H-78
COIL, Platform extend (Vickers)
COIL, Platform extend (Hytos)
COIL, Platform extend (Vickers)
COIL, Platform extend (Hytos)
COIL, Platform retract (Vickers)
COIL, Platform retract (Hytos)
COIL, Platform retract (Vickers)
COIL, Platform retract (Hytos)
COIL, Traction gearbox (Vickers)
COIL, Traction gearbox (Hytos)
COIL, Lift gearbox (Vickers)
COIL, Lift gearbox (Hytos)
COIL, Left front outrigger retract (Vickers)
COIL, Left front outrigger retract (Hytos)
COIL, Right front outrigger retract (Vickers)
COIL, Right front outrigger retract (Hytos)
COIL, Right rear outrigger retract (Vickers)
COIL, Right rear outrigger retract (Hytos)
COIL, Left rear outrigger retract (Vickers)
COIL, Left rear outrigger retract (Hytos)
COIL, Left front outrigger extend (Vickers)
COIL, Left front outrigger extend (Hytos)
COIL, Right front outrigger extend (Vickers)
COIL, Right front outrigger extend (Hytos)
COIL, Right rear outrigger extend (Vickers)
COIL, Right rear outrigger extend (Hytos)
COIL, Left rear outrigger extend (Vickers)
COIL, Left rear outrigger extend (Hytos)
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
107439
128320
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
119153
SECTION 3, Page 17
Figure 3.4-2. Electrical Inverter Wiring Diagram
M50070AB
SECTION 3, Page 18
119153
Figure 3.4-3a. Control Box Diagram - ANSI/CSA & CE Equipped With All Options
(Refer to Serial No. Reference Chart)
Serial Breakdown Reference Chart
Model
8831E
8841E
Serial Number
37314 & Below
42701 & Below
AN
Refer to following page(s) to locate serial
no. and respective diagram.
Figure 3.4-3b.
60522AA
M50087AA
119153
SECTION 3, Page 19
Figure 3.4-3b. Control Box Diagram - ANSI/CSA & CE Equipped With All Options
(Refer to Serial No. Reference Chart)
Model
8831E
8841E
Serial Number
37315 & Above
42702 & Above
AN
Refer to following page(s) to locate
serial no. and respective diagram.
Figure 3.4-3a.
60523AA
M50087AC
SECTION 3, Page 20
119153
Figure 3.5-1 Electrical Panel Diagram (ANSI/CSA/CE) (Shown with All Options)
A
B
C
D
E
F
G
H
V
W
X
Y
Z
M10070AA
119153
SECTION 3, Page 21
A
B
Figure 3.6-1a. Electrical Schematic (ANSI, CSA & CE) (Shown With All Options)
(Refer to Serial No. Breakdown Chart)
C
D
E
F
G
H
Model
8831E
8841E
Serial Number
37314 & Below
42701 & Below
V
60522AA
Figure 3.6-1b
W
X
Y
Z
M50030AA-A
SECTION 3, Page 22
119153
A
B
Figure 3.6-1b. Electrical Schematic (ANSI, CSA & CE) (Shown With All Options)
(Refer to Serial No. Breakdown Chart)
C
D
E
F
G
H
Model
8831E
8841E
Serial Number
37315 & Above
42702 & Above
V
60523AA
Figure 3.6-1a.
W
X
Y
Z
M50030AC-CD
119153
SECTION 3, Page 23
Section 4
Troubleshooting Information
Table Of Contents
Introduction......................................................................................................................................................... 2
Electrical System
4.1-1. All Controls Inoperative......................................................................................................................... 3
4.1-2. All Controls Inoperative From Platform................................................................................................. 4
4.1-3. Base Controls Inoperative.................................................................................................................... 4
4.1-4. Up Circuit Inoperative from Platform.................................................................................................... 4
4.1-5. Up Circuit Inoperative from Base.......................................................................................................... 5
4.1-6. Down Circuit Inoperative....................................................................................................................... 5
4.1-7. Platform Does Not Steer Left or Right.................................................................................................. 5
4.1-8. No Steer Right....................................................................................................................................... 6
4.1-9. No Steer Left......................................................................................................................................... 6
4.1-10. Forward and Reverse Drive Inoperative............................................................................................... 6
4.1-11. Forward Drive Inoperative..................................................................................................................... 7
4.1-12. Reverse Drive Inoperative..................................................................................................................... 7
4.1-13. Forward and Reverse Slow Speed Only.............................................................................................. 7
4.1-14. Brake Not Releasing............................................................................................................................. 7
4.1-15. Lift/Traction Shift Circuit Inoperative..................................................................................................... 8
4.1-16. Power Extension Deck Inoperative....................................................................................................... 8
4.1-17. Outrigger Circuit Inoperative................................................................................................................ 9
Sevcon Electrical System Flash Codes............................................................................................................ 10
Hydraulic System
4.2-1. All Controls Inoperative....................................................................................................................... 11
4.2-2. All Systems Sluggish ......................................................................................................................... 11
4.2-3. Brake Will Not Release ...................................................................................................................... 11
4.2-4. No Steer Left or Right......................................................................................................................... 11
4.2-5. Brakes Will Not Release and No Steering.......................................................................................... 11
4.2-6. Work Platform Does Not Lift.............................................................................................................. 11
4.2-7. Work Platform Lifts Slowly.................................................................................................................. 12
4.2-8. Platform Drifts Down........................................................................................................................... 12
4.2-9. Drifts Circuit Inoperative...................................................................................................................... 12
4.2-10. Powered Extension Platform will Not Extend or Retract.................................................................... 12
4.2-11. Work Platform Does Not Shift Between Lift and Drive........................................................................ 12
4.2-12. Outrigger Inoperative.......................................................................................................................... 13
119153
SECTION 4, Page 1
4
Troubleshooting Information - Introduction
The following pages contain a Table of Troubleshooting information for locating and correcting most service
trouble which can develop. Careful inspection and accurate analysis of the systems listed in the Table of Troubleshooting Information will localize the trouble more quickly than any other method. This manual cannot cover all
possible troubles and deficiencies that may occur. If a specific trouble is not listed, isolate the major component
in which the trouble occurs, isolate whether the problem is electrical or hydraulic, and then isolate and correct
the specific problem.
The content of this section is separated into “probable cause” and “remedy”. The information preceded by a
number represents the “probable cause”. The following line, noted by a dash and a greater indentation represents
the “remedy” to the “probable cause” directly above it. See example below for clarification.
1. Probable Cause
-Remedy
SECTION 4, Page 2
119153
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).
9. Loose or broken wire #01A from Battery Charger Relay (LCR1) to Battery Charger Relay (LCR2).
10. Loose or broken wire #03 from Battery Charger Relay (LCR2) to Converter.
11. Defective Converter.
-Check for 24 volts between wire #3A and #B-, 48 volts between #03 and #B-.
12. Defective Contactor (C10B-2).
-Check contactor. Replace if defective.
13. Loose or broken wire #10B from Contactor (C10B-2) to Motor Control Plug (CN5).
-Reset circuit breaker. Replace if defective.
15. Loose or broken wire #B- from Circuit Breaker (CB1) to Converter.
-Reset circuit breaker. Replace if defective.
17. Loose or broken wire #3A from Converter to Circuit Breaker (CB3).
18. Loose or broken wire #3B from Circuit Breaker (CB3) to (optional) Pressure Switch (PS1).
19. Loose or broken wire #4 from Pressure Switch (PS1) (optional) to Base Emergency Stop Switch (S4).
20. Open or defective Base Emergency Stop Switch (S4).
-Close switch. Replace if defective.
21. Loose or broken wire #21A or #02 on Coil (2H-21A).
22. Defective Coil (2H-21A).
-Check coil. Replace if defective.
23. Defective Fuse (F3).
-Replace fuse.
24. Defective Base Selector Platform/Base Switch (S5) (ANSI/SIA and CSA only).
-Check switch. Replace if defective.
25. Loose or broken wire #4A from Base Emergency Stop Switch (S4) to Base Selector Platform/Base Switch
(S5)(ANSI/SIA and CSA only).
119153
SECTION 4, Page 3
26. Defective Sevcon.
-See Sevcon troubleshooting Sec. 5, Page 10.
4.1-2. All Controls Inoperative From Platform
1. Loose or broken wire #07 from Base Control Box to Emergency Stop Switch (S7) in Platform Control Box.
2. Open or defective Platform Emergency Stop Switch (S7).
3. Loose or broken wire #07A from Platform Emergency Stop Switch (S7) to Key Switch (S8).
4. Open or defective Key Switch (S8).
5. Loose or broken wire #08 from Key Switch (S8) to Lift/Off/Drive Switch (S9).
6. Open or defective Lift/Off/Drive Switch (S9).
7. Open or defective Gate Limit Switch (LS1) or (LS2) (optional).
-Close gate. Check limit switch adjustment. Replace if defective.
8. Loose or broken wire #05, #05A or #07 on Gate Limit Switches (optional).
4.1-3. Base Controls Inoperative
1. Open or defective Base Selector Platform/Base Switch (S5)(ANSI/SIA and CSA only).
-Select Base. Replace if defective.
2. Loose or broken wire #10E from Key Switch (S8) to Base Control Box.
3. Defective Lift/Lower Switch (S6) at Base Controls.
-Check Switch. Replace if defective.
4. Open or defective Diode (D10E-1).
-Check Diode. Replace if defective.
5. Open Key Switch (S8).
-Select Base Controls.
4.1-4. Up Circuit Inoperative From Platform
-Select Lift. Replace if defective.
-Replace fuse.
3. Open or defective Diode (D9C).
-Check diode. Replace if defective.
4. Defective Delayed Power Module.
-Check for 24 volts between wire #09 and #02. Replace if defective.
5. Open or defective Diode (D9C-1, D9-1 OR D9-2).
-Replace fuse.
7. Defective Contactor (C10B-1).
-Check contactor. Replace if defective.
8. Open or defective Diode (D14).
SECTION 4, Page 4
119153
-Replace fuse.
10. Open or defective End of Stroke Limit Switch (LS4).
11. Loose or broken wire #14D or #02 on Coil (2H-14D).
12. Open or defective Diode (D14D-1).
13. Defective Coil (2H-14D).
14. Lift/Traction Circuit not shifting.
-See Lift/Traction Circuit inoperative Sec. 4, Page 7.
15. Sevcon Problem.
16. Outrigger not properly set. (Optional).
-See Outrigger Circuit troubleshooting Sec.4,Page 8
4.1-5. Up Circuit Inoperative From Base
1. Lift/Lower Switch (S6) defective.
2. Open or defective Diode (D14E or D14E-1).
4.1-6. Down Circuit Inoperative
1. Loose or broken wire #13 or #02 on Coil (2H-13-1, 2H-13-2 or 2H-13-3).
2. Defective Coil (2H-13-1, 2H-13-2 or 2H-13-3).
3. Loose or broken wire #13 on Lift/Off/Drive Switch (S9) (Upper controls only).
4. Lift/Lower Switch (S6) defective (Base controls only).
5. Loose or broken wire #13 on Lift/Lower Switch (S6) (Base control only).
4.1-7. Platform Does Not Steer Left Or Right
1. Defective Relay (18ACR).
2. Loose or broken wire #12C from Lift/Off/Drive Switch (S09) to Steer Switch.
3. Defective Steer Toggle Switch.
4. Open or defective Diode (D18A).
119153
SECTION 4, Page 5
4.1-8. No Steer Right
1. Loose or broken wire #23 from Steer Switch to Terminal Block Inside Platform Control Box.
-Replace fuse.
4. Loose or broken wire #23 or #02 on Coil (4H-23).
5. Defective Coil (4H-23).
6. Defective Steer Switch.
4.1-9. No Steer Left
1. Loose or broken wire #24 from Steer Switch to Terminal Block Inside Platform Control Box.
-Replace fuse.
6. Defective Steer Switch.
4.1-10. Forward And Reverse Drive Inoperative
-Select drive. Check switch. Replace if defective.
2. Loose or broken wire #12C on Lift/Off/Drive Switch (S9).
3. Defective Delayed Power Module.
-Check for 24 volts between wire #12 and #02. Replace if defective.
4. Open or defective Diode (D12C).
-Replace fuse.
6. Open or defective Diode (D12-2).
7. Brake not releasing.
-See Brake Not Releasing troubleshooting Sec. 4, Page 6.
8. Lift/Traction Circuit not shifting.
-See Lift/Traction Circuit inoperative Sec. 4, Page 7.
9. Sevcon problem.
10. Outriggers not retracted (optional).
-See Outrigger Circuit troubleshooting Sec. 4, Page, 8.
SECTION 4, Page 6
119153
4.1-11. Forward Drive Inoperative
1. Loose or broken wire #16 on Lift/Off/Drive Switch (S9).
-Replace fuse.
3. Bad contacts in Contactor (C16A).
-Replace Contactor.
4. Loose or broken wire #16A from Pin #15 on Sevcon to Contactor (C16A).
4.1-12. Reverse Drive Inoperative
1. Loose or broken wire #15 on Lift/Off/Drive Switch (S9).
-Replace fuse.
3. Bad contacts in Contactor (C15A).
-Replace contactor.
4. Loose or broken wire #15A from Pin #17 on Sevcon to Contactor (C15A).
4.1-13. Forward And Reverse Slow Speed Only
1. High Drive Cut Out Limit Switch (LS5) open or defective.
2. Loose or broken wire #10A from Pin #4 on Sevcon to High Drive Cut Out Limit Switch (LS5).
3. Open or defective Tilt Switch (TS1).
-Check tilt switch. Replace if defective.
4. Loose or broken wire #28 from Pin #7 on Sevcon to Tilt Switch (TS1).
4.1-14. Brake Not Releasing
1. Open or defective Brake Relay (30CR) or Quick Brake Relay (25CR).
2. Loose or broken wire #2A or #2B on Brake Pressure Switch (PS2).
3. Open or defective Brake Pressure Switch (PS2).
-Check for continuity between wire #2A and #2B on Brake Pressure Switch (PS2). Replace if defective.
9. Loose or broken wire #2A from Pin #1 on Sevcon to Relay (25CR).
119153
SECTION 4, Page 7
4.1-15. Lift/Traction Shift Circuit Inoperative
1. Defective Proximity Switch (PR1 or PR2).
-Refer to Proximity Switch Test Procedure Sec. 5, Page 17.
5. Traction Sensor Relay (33CR) or Lift Sensor Relay (32CR) defective.
-Check Relay. Replace if defective.
10. Open or defective Diode (D33A or D32A).
11. Loose or broken wire #32 from Lift Sensor Relay (32CR) to Pin #8 on Tachometer Board.
12. Loose or broken wire #33 from Traction Sensor Relay (33CR) to Pin #9 on Tachometer Board.
4.1-16. Power Extension Deck Inoperative
1. Open or defective Pump Interlock Relay (21CR).
-Replace fuse.
3. Loose or broken wire #9B from Terminal Block to Enable Switch (S16 or S18).
4. Open or defective Enable Switch (S16 or S18).
-Close switch. Check switch. Replace if defective.
5. Loose or broken wire #9B from Enable Switch (S16 or S18) to In/Out Switch (S17 or S19).
6. Loose or broken wire #18A from Terminal Block to Small Pump Relay (18ACR).
7. Loose or broken wire #26 on Switch (S17) or wire #26A on Switch (S19).
8. Loose or broken wire #26 or #02 on Coil (4H-26) or wire #26A or #02 on Coil (4H-26A).
9. Defective Coil (4H-26) or (4H-26A).
-Check Coil. Replace if defective.
10. Open or defective Diode (D26) or (D26A).
11. Loose or broken wire #27 on Switch (S17) or wire #27A on Switch (S19).
12. Loose or broken wire #27 or #02 on Coil (4H-27) or wire #27A or #02 on Coil (4H-27A).
SECTION 4, Page 8
119153
13. Defective Coil (4H-27) or (4H-27A).
14. Open or defective Diode (D27) or (D27A).
4.1-17. Outrigger Circuit Inoperative (Optional)
1. Open or defective Outrigger Enable Relay (10ACR).
2. Loose or broken wire #09 to Outrigger Enable Relay (19CR).
3. Loose or broken wire #09A to Outrigger Toggle Switches (S20,S21,S22 or S23).
4. Open or defective Outrigger Toggle Switches (S20, S21, S22 or S23).
7. Loose or broken wire #71, #72, #73, #74, #75, #76,#77, #78 or #02 on Outrigger Coils.
8. Defective Coil (4H-71, 4H-72, 4H-73, 4H-74, 4H-75, 4H-76, 4H-77 or 4H-78).
9. Open or defective Limit Switch (LS61, LS62, LS63 or LS64).
-Make sure Outriggers are fully retracted. Check switch. Replace if defective.
10. Open or defective Lift Enable Relay (61CR-2).
12. Open or defective Lift Enable Relay (65CR).
-Check Relay. Replace if defective.
14. Open or defective Drive Enable Relay (61CR-1).
119153
SECTION 4, Page 9
Troubleshooting Information - Sevcon Electrical System Flash Codes
NOTE: A Steady Light on Sevcon Means System is Ready to Operate.
FLASH CODE
TROUBLE
LED is off
No functions
2 Flash Fault
3 Flash Fault
4 Flash Fault
Procedure
Fault
5 Flash Fault
6 Flash Fault
No Drive
and Lift
7 Flash Fault
Low Battery
Voltage
8 Flash Fault
Thermal
Cutback
10 Flash Fault
11 Flash Fault
Tachometer
Fault
12 Flash Fault
Tilt Condition
with Platform
Elevated.
13 Flash Fault
Transmission
Gear Mesh
Failure
14 Flash Fault
Low or Open
Voltage to
Sevcon
PROBABLE CAUSE
1. Batteries Disconnected.
1. Lift or Drive Selected Before
Power up.
1. Sevcon Shorted.
2. Drive Motor Shorted.
1. Contactor welded.
REMEDY
1. Reconnect batteries.
2. Replace Sevcon.
1. First Power Up and then Select
Function.
1. Replace Sevcon.
2. Replace Drive Motor.
1. Replace Contactor.
1. Contactor not shifted.
1. Clean Contactor. Replace if
defective.
2. Replace Sevcon.
1. Check continuity. Replace if
defective.
1. Loose or broken wire #59 from
upper control box to Pin #14 on
Sevcon.
2. Open or defective Base Speed
Relay (59ACR).
2. Check Relay. Replace if
defective.
1. Batteries have dropped below
13 Volts.
1. Sevcon Overheating.
1. Recharge Batteries.
1. Loose or broken wire from Pin
#2 on Sevcon to Pin #4 on
Tachometer Board.
2. Loose or broken wire from Pin
#12 on Sevcon to Pin #2 on
Tachometer Board.
3. Loose or broken wire #T1 or
#T2 from Tachometer Generator
to Main Circuit Board.
1. Tachometer Generator
defective.
2. Tachometer Generator Wires
Reversed.
3. Defective Tachometer Board.
defective.
1. Tilt Condition with Platform
Elevated has disabled Sevcon
for Lift and Drive.
1. Incorrectly set Proximity Switch.
2. Defective Proximity Switch.
1. Loose or broken wire to Pin #5
on Sevcon.
2. Loose or broken wire to Pin #6
on Sevcon.
1. Let unit cool down.
defective.
defective.
1. Check output 20.8 Volts per
1000 RPM. Replace if defective.
2. Switch wires at Generator.
3. Check Tachometer Board for
inputs and outputs. Replace if
defective.
1. Lower Platform and Reposition
to a firm Level Surface.
1. Refer to Proximity Switch
Adjustment Procedure (Section
5, Page 11)
2. Refer to Proximity Switch Test
Procedure (Section 5, Page 12)
1. Check for 24 Volts between Pin
#5 and wire #02.
2. Check for 48 Volts between Pin
#6 and wire #02.
60311AA
SECTION 4, Page 10
119153
Troubleshooting Information - 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 Sec. 5, Page 2 for recommendations.)
2. System Relief Valve (R1) setting to low or valve is defective.
-Check Serial Number Plate for correct pressure setting. Replace valve if defective.
4.2-3. Brake Will Not Release
1. Brake Release Valve (2H-30) stuck.
-Check valve. Replace if defective
2. Quick Brake Valve (2H-25) stuck.
3. Hand pump (HP-2) bypassing oil.
-Check seals for valve. Replace if defective.
4.2-4. No Steer Left Or Right
1. Stuck or defective Steer Valve (4H-23A) or (4H-24A).
-Check valve. Replace if defective
2. Steer Cylinder (C7) leaking internally.
-Check cylinder. Replace if defective.
3. Gearbox Valve (2H-44) stuck open.
-Check valve and reinstall. Replace if defective
4.2-5. Brakes Will Not Release And No Steering
1. Defective Small Pump (P2).
-Check pump. Replace if defective.
4.2-6. 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.
3. Manual Lowering Valve (V1) stuck open.
4. Brake Release Valve (2H-30) stuck or open.
5. Lift Gearbox Valve (4H-33A) not shifting.
-Clean valve and reinstall. Replace if defective.
7. Defective Large Pump (P1).
-Check pump. Repair or replace if defective.
119153
SECTION 4, Page 11
4.2-7. Work Platform Lifts Slowly
1. Contaminated System Dump Valve (2H-21A).
2. Contaminated Brake Release Valve (2H-30).
3. Contaminated Lowering Valve (2H-13-1) or Manual Lowering Valve (V1).
4. Controlled Lowering Valve (V2) stuck.
5. Lift Cylinder Holding Valve (2H-13-2) or (2H-13-3) Manual Override open, contaminated or defective.
-Depress Manual Override Knob and rotate clockwise to close valve. Clean valve and reinstall. Replace
if defective.
6. System Relief Valve (R1) set to low.
-Check Serial Number Plate for correct pressure setting. Replace valve if defective.
7. Worn Hydraulic Pump (P1).
-Check pump performance. Repair or replace if defective.
4.2-8. Platform Drifts Down
1. Main Lowering Valve (2H-13-1) and Lift Cylinder Holding Valves (2H-13-2) or (2H-13-3) Manual Override
open, contaminated or defective.
-Depress manual override knob and rotate clockwise to close valve. Clean valve and reinstall. Replace
if defective.
2. Manual Lowering Valve (V1) and Lift Cylinder Holding Valve (2H-13-2) and (2H-13-3) stuck open, contaminated
or defective.
-Push valve plunger in. Clean valve and reinstall. Replace if defective.
3. Leaking Cylinder Packing.
-Replace packing.
4.2-9. Down Circuit Inoperative
1. Lowering Valve (2H-13-1) not shifting or defective.
2. Lift Cylinder Holding Valves (2H-13-2) or (2H-13-3) not shifting.
-Clean valves and reinstall. Replace if defective.
3. Lowering Orifice (02 or 03) plugged.
-Remove contamination and reinstall.
4.2-10. 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.
2. Platform Extension Cylinder (C3) or (C4) packing bad.
-Replace packing.
4.2-11. 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.
2. Gearbox Valve (4H-44) not shifting.
-Check valve and reinstall. Replace if defective.
SECTION 4, Page 12
119153
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.
4.2-12. Outrigger Inoperative
1. Outrigger Holding Valve (2H-17A) not shifting.
2. Outrigger Valve (4H-71, 4H-72, 4H-73, 4H-74, 4H-75, 4H-76, 4H-77 or 4H-78) not shifting.
-Depress manual override on each valve. If outriggers extend and retract, clean valves and reassemble.
Replace if defective.
3. Outrigger Check Valve (CV-7, CV-8, CV-9 or CV-10) not shifting.
119153
SECTION 4, Page 13
SECTION 5
MAINTENANCE AND SERVICE
Table Of Contents
Description
Page No.
Operators Responsibility For Maintenance......................................................................................... 2
Maintenance And Inspection Schedule............................................................................................... 2
Owners Annual Inspection Record...................................................................................................... 2
General Maintenance Hints................................................................................................................. 2
Hydraulic System And Component Maintenance And Repair............................................................ 3
General Specifications......................................................................................................................... 4
Torque Specifications........................................................................................................................... 5
Tire Specifications................................................................................................................................ 5
System Gearbox and Brake Pressure Adjustments............................................................................ 6
Brake Adjustment Procedure............................................................................................................... 7
Proximity Switch Replacement and Adjustment Procedure............................................................... 8
Proximity Switch Test Procedure......................................................................................................... 9
Sevcontroller Adjustment and Diagnostics....................................................................................... 11
Tachometer Board Pin Reference...................................................................................................... 18
Tachometer Generator Testing Procedure........................................................................................ 19
List Of Tables
Table 5-1. General Specifications.........................................................................Section 5,.Page 4
Table 5-2. Torque Specifications..........................................................................Section 5,.Page 5
Table 5-3. Tire Specifications................................................................................Section 5,.Page 5
Table 5-4A.Sevcontrol Adjustable Parameters......................................................Section 5,.Page 12
Table 5-4B.Sevcontrol Adjustable Parameters......................................................Section 5,.Page 13
Table 5-5. Sevcontrol Test Sequence...................................................................Section 5,.Page 15
Table 5-6. Traction Controller Flash Fault Pin References...................................Section 5,.Page 17
5
119153
SECTION 5, Page 1
Operator’s Responsibility For
Maintenance
Maintenance And Inspection
Schedule
Death or injury can result if the work platform is not kept
in good working order. Inspection and maintenance
should be performed by competent personnel who
are familiar with mechanical procedures.
The actual operating environment of the work platform
governs the use of the maintenance schedule. The
inspection points covered in the Maintenance and
Inspection Schedule (Section 2, Table 2-3.) indicates
the areas of the work platform to be maintained or
inspected and at what intervals the maintenance and
inspections are to be performed.
The operator should be assured that the work platform
has been properly maintained and inspected before
using it.
Even if the operator is not directly responsible for the
maintenance of this work platform, the operator should
perform ALL the daily inspections in the Maintenance
and Inspection Schedule (Table 2-3.) found in Section
2 of this manual.
Note
Replace all worn, damaged or missing parts or labels
discovered during this inspection.
Owner’s Annual Inspection Record
It is the responsibility of the owner to arrange daily,
weekly, monthly and annual inspections of the work
platform. The Owner’s Annual Inspection Record
(Table 2-1. in Section 2) is to be used for recording
the date of inspection, owner’s name and the person
responsible for the inspection of this work platform.
General Maintenance Hints
Danger
Crushing Hazard
DO NOT reach through scissors assembly without the
safety bar properly positioned. Failure to avoid this
hazard will result in death or serious injury!
SECTION 5, Page 2
•
Properly position maintenance bar if the scissor
assembly is raised.
•
Before attempting any repair work, disconnect
the battery ground (-) lead.
•
Preventive maintenance is the easiest and least
expensive type of maintenance.
119153
Hydraulic System And Component
Maintenance And Repair
7.
The following points should be kept in mind when working on the hydraulic system or any component:
1.
Any structure has limits of strength and durability.
To prevent failure of structural parts of hydraulic
components, relief valves which limit pressure to
safe operating values are included in the hydraulic circuits.
2.
Tolerance of working parts in the hydraulic system are very close. Even small amounts of dirt
or foreign material 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.
3.
Samples of hydraulic oil should be drawn from
the reservoir every six months. These samples
should be about two quarts and should be taken
while the oil is warmed through normal operation
of the system. If possible, the sample should be
analyzed by a qualified lubrication specialist to
determine whether it is suitable for further use.
The intervals between oil changes depend on
operating conditions and on the care used in
keeping the oil clean.
4.
5.
6.
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.
DO NOT use synthetic or fire resistant oils in this
work platform. Use ATF Dexron III (ESSO) or
equivalent hydraulic oil. For conditions causing
oil temperatures below -31°F (-35°C) and above
122°F (50°C) consult Skyjack, Inc.
119153
8.
9.
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 filler opening. The use of cloth to strain the
oil should be avoided to prevent lint from getting
into the system.
When removing any hydraulic component, be
sure to cap and tag all hydraulic lines involved.
Also, plug the ports of the removed components.
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.
10. 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.
11. 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.
12. All hydraulic connections must be kept tight. A
loose connection in a pressure line will permit
the oil to leak out or air to be drawn into the
system. Air in the system can cause damage
to the components and noisy or erratic system
operation.
MAINTENANCE. Three simple maintenance procedures have the greatest effect on hydraulic system
performance, efficiency and life. Yet, the very simplicity
of them may be reasons they are so often overlooked.
What are they? Simply these:
1.
Change filters regularly.
2.
Maintain a sufficient quantity of clean hydraulic oil
of the proper type and viscosity in the hydraulic
reservoir.
3.
Keep all connections tight.
SECTION 5, Page 3
Table 5-1. General Specifications
Model
8831E
8841E
Electrical System
48 Volts DC
Batteries
6V, 250AH
Lift Relief
Refer to Serial Number Nameplate
System Relief
Return Filter
20 Micron
Hydraulic Tank
Capacity
20.5 Gallons
(77.6 Liters)
Hydraulic System Capacity
22.0 Gallons
(83.3 Liters)
Hydraulic Pump (ci/rev)
.671 (Lift)
.194 (Shift)
DC Motor (Steer/Brake)
3.7 HP
(2.76 kW)
DC Motor (Traction)
14 HP
(10.4 kW)
High Travel Speed
(Level Compacted Surface)
2.6 mph
(4.2 km/h)
High Travel Speed
(Retracted platform & Steep Incline)
1.55 mph
(2.5 km/h)
Elevated Platform
Drive Speed
.45 mph
(.8 km/h)
High Speed Drive Cut Out Height
10’
(3.05 m)
Lift Time (Seconds)
46
71
Lower Time (Seconds)
48
60
Gradability
25%
Inside Turning Radius
124”
(3.15 m)
Outside Turning Radius
224”
(5.69 m)
Tires
Refer to Table 5-3
Ground Clearance
8”
(0.203 m)
Tire Contact
Pressure (Max)
60031AA
SECTION 5, Page 4
119153
Table 5-2. Torque Specifications
Directional valve mounting bolts
Wheel mounting bolts
28-32 lbf.in
2.16 – 3.61 Nm
135-145 lbf.ft
183.06-196.62 Nm
Cartridge
Size
Torque
Lbf.ft (max)
Lbf.in (max)
Nm (max)
08
38
58
10
12
16
20
20
20
25
35
50
240
240
240
300
420
600
27.12
27.12
27.12
33.90
47.46
67.80
Coils
Size
Torque
All coils
Lbf.ft (max)
4 to 5
Lbf.in (max)
48 to 60
Nm (max)
5.42 to 6.78
SAE Plugs
Size
Torque
Lbf.ft (max)
Lbf.in (max)
Nm (max)
2
4
5
6
8
10
12
16
3
10
15
15
25
25
30
35
36
120
180
180
300
300
360
420
4.07
13.56
20.34
20.34
33.90
33.90
40.68
47.46
Newton-meter = Nm
Pound-force foot = lbf.ft
Pound-force inch = lbf.in
60284AA
Table 5-3. Tire Specifications
WARNING
Air Pressure Can Affect Stability. Temperature Changes Can Affect Air Pressure. It Is Important To Check Tire Pressures Prior To
Use On A Daily Basis In The Operating Conditions Experienced By End User. If The Measured PSI Reading Is Less Than The
Specification And Tolerance, Re-inflate To The Proper Specification Within The Tolerance Range Specified. Tires Shall Also Not
Be Subject To Over-Inflation Above The Recommended Specification And Tolerance Range.
Tire*
Size
Fill Type
Ply Rating
Fill Specification
Pressure
Psi (kPa)
Listed Sidewall
Maximum
Factory
#6
30-10-16.5 NHS
8
50 (344.7)*
65 (448.2)
#6
32.3-10-16.5 HD Stabilizer
10
70 (482.6)*
75 (517.1)
#6
30-10-16.5 OTR Outrigger
10
70 (482.6)*
75 (517.1)
50 (344.7)*
Not Available
#7
31-15.5-15 NHS
#8
31-13.5-15 NHS
Air
8
Consult Skyjack Inc.
#6
31-10-16.5 “Carlisle”
10
#6
31-10-16.5 “Carlisle”
10
#6F
30-10-16.5 NHS
#7F
31-15.5-15 NHS
#8F
31-13.5-15 NHS
*
**
***
Solid
Urethane
75 (517.1)*
Not Available
***
8
**
8
**
Consult Skyjack Inc.
Factory preset @ 20°C, Check pressures regularly as tires can lose pressure over time and over different ambient temperatures
even under normal conditions.
Urethane used for filling #6F and #7F tires MUST be 50-55 durometer.
Urethane used for filling #6 “Carlisle” tires MUST be 32 durometer.
60035AB
119153
SECTION 5, Page 5
System, Gearbox and Brake Pressure Adjustments
All adjustments must be made with a Calibrated Gauge.
Refer to the Serial Number Plate located on the rear of the machine for System and Lift Pressure values.
System Relief Pressure Adjustment
1.
Locate the System Pressure Quick Disconnect Port on the Main Manifold. Refer to Section 3 “Hydraulic
Manifold And Port Identification” for location.
2. Install a Calibrated 3000 PSI Gauge to the System Pressure Quick Disconnect Port.
3. Remove the Platform Control Box from the Guardrail and disconnect from the Main Control Cable.
4. Locate the Main Control Cable Plug in the Hydraulic/ Electric side of cabinet.
5. Disconnect the Main Cable and connect the Platform Control Box into the Plug.
6. At the Main Manifold, loosen the Locknut on the System Relief Valve R1. Refer to Section 3 “Hydraulic
7. Select Drive with the Lift/Off/Drive Select Switch on the Platform Control Box.
8. Engaged Steer Right and hold.
9. Observe reading on Gauge. Adjust the R1 System Relief Value listed on the Serial Number Plate. Turning
the stem on the Relief Valve clockwise increases pressure. Turning the stem counterclockwise decreases
pressure.
10. Release Steer Switch and tighten the Locknut.
11. Remove the gauge from the System Pressure Test Port.
Gearbox Relief Pressure Adjustment
1.
2.
3.
4.
5.
6.
7.
8.
Locate the Gearbox Quick Disconnect Port on the Main Manifold. Refer to Section 3 “Hydraulic Manifold
And Port Identification” for location.
Install a Calibrated 1000 PSI Gauge to the Gearbox Quick Disconnect Port.
At the Main Manifold, loosen the Locknut on the Gearbox Relief Valve R2. Refer to Section 3 “Hydraulic
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.
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.
Brake Pressure Adjustment
1.
2.
3.
4.
5.
6.
7.
8.
Locate Pressure Switch (PS2) on Main Manifold. Refer to Section 3 “Hydraulic Manifold And Port Identification” for location.
Disconnect spade connectors for pressure switch wires.
Turn the black knurled portion of the pressure switch body counter-clockwise until movement stops.
Turn the black knurled portion of the pressure switch clockwise for only four full revolutions and reconnect spade connectors.
Install 3000 PSI Gauge to quick coupler on main manifold. Refer to Section 3 “Hydraulic Manifold And
Port Identification” for location.
Operate Drive slowly while observing gauge. It should read a minimum of 800 PSI.
If pressure needs to be increased, turn black knurled portion clockwise. If pressure need to be decreased turn counter-clockwise.
Once 800 PSI is obtained, brake pressure adjustment is complete.
SECTION 5, Page 6
119153
Brake Adjustment Procedure
1.
2.
3.
4.
5.
6.
7.
8.
Place machine on level surface and block wheels
to prevent rolling in either direction.
Unplug battery , disconnect plug.
Locate brake manifold in hydraulic/electric side
cabinet.
Depress black knob.
Grasp the red plunger and rapidly depress until
plunger can no longer be depressed and the
brake is fully released.
Inspect caliper and brake pads for binding. Pads
should move freely on the pins.
Remove pin from brake cylinder clevis and brake
actuating lever. Rotate actuating lever counterclockwise to the end of it’s stroke.
Adjust brake cylinder clevis to obtain 1/2”
between the center of the holes of the actuating
lever and brake cylinder clevis. See Figure 5-1.
Tighten jamb nut on brake cylinder rod against
clevis. Note: It is important that the brake cylinder
reaches it’s maximum stroke before the caliper
to prevent damage to the caliper.
9.
Reinstall clevis pin back into the clevis
actuating lever.
10. Remove plastic plug located on the end of the
caliper shaft. See Figure 5-2.
Figure 5-2. Plug Removal and Replacement
11. Using a 1/4” Allen wrench, turn brake adjuster
counter-clockwise until it bottoms out. Turn Allen
wrench 1/2 turn clockwise to set adjustment.
12. Replace plastic plug back into the end of the
caliper shaft.
13. Pull out black knob to reset brake circuit.
14. Remove Wheel blocks. Reconnect battery,
disconnect plug. Operate drive several times to
seat pads to brake disc.
Figure 5-1. Brake Adjustment
119153
SECTION 5, Page 7
Proximity Switch Replacement And Adjustment Procedure
Figure 5-3. Traction Motor/Lift Pump Proximity Switch Location
1. 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.
5. To install the new proximity switch turn the switch in until it bottoms out. 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.
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 adjusted.
If the switch you are adjusting does not match the selected mode you will damage the component.
SECTION 5, Page 8
119153
Proximity Switch Test Procedure
Figure 5-4. Proximity Switch
119153
SECTION 5, Page 9
Sevcontroller Adjustment And Diagnostics
Sevcon Calibration Tool
WARNING
All machine functions remain operational while calibrator is plugged in.
ADJUSTMENT PROCEDURE:
The following procedure is relevant for the drive controller, except where otherwise noted. The
controller is preset to factory specifications but may be readjusted.
A hand-held calibrator (Figure 5-5, Skyjack part #701051) can be plugged into the controller adjustment socket
and used to digitally view or reset the parameters. The current value of these parameters will be shown on an
LCD display. Additionally, the calibrator can perform certain measurements that can be useful for diagnostic
purposes.
The calibrator has a bar display, operated by the SELECT button, showing the parameters/ measurement selected
and an LCD display showing values that, provided they are parameters, may be adjusted using the +/- buttons.
This unit can also be used to perform certain tests on the control wiring and controller (joystick).
1.
2.
Locate Sevcon inside Electrical/Hydraulic Cabinet on the right side of the machine.
Locate controller adjustment socket, as shown in Figure 5-6, 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.
3.
4.
5.
No LED segments on the bar display will be lit and the minutes/seconds count is displayed. The hours
count is displayed by pressing the (-) button and the 1000’s of hours count is displayed by pressing the
(+) button as described later in this section. Pressing the select button reverts the calibrator to its normal
operation and the IMax LED will be lit.
When the desired parameters has been selected, on the left side of the calibrator, it may be adjusted by
pressing the + or - button on the right side of the calibrator. See Table 5-4A. (For calibrator Revision .07)
or Table 5-4B. (for calibrator Revision .10) for adjustable parameters and ranges.
When the calibrator is unplugged the Sevcontrol will ‘memorize’ the new parameters settings.
Figure 5-5. Sevcon Calibrator
119153
SECTION 5, Page 11
Sevcontroller Adjustment And Diagnostics (Continued)
Diagnostic LED
Controller
Adjustment
Socket
Figure 5-6. Traction Controller
Table 5-4A. Sevcontrol Adjustable Parameters (Software Revision .07)
SEQ. NO.
PARAMETER
MIN.
MAX.
UNITS
DEFAULT
1
IMAX
Maximum Controller Current
50
600
Amps
400
2
ACCEL
Acceleration Delay
1
3
Seconds
1
3
DECEL
Deceleration Delay
0.1
3
Seconds
0.1
4
CREEP
0
10
% of Max. Speed
2
5
MAX
Maximum Allowed Speed
5
100
% of Max. Possible Speed
80
6
ELEVA
Elevated Cutback Speed
5
25
% of Max. Speed
15
7
TILT
Tilted Cutback Speed
5
75
% of Max. Speed
50
8
CONSTANT SPEED CONTROL
Proportional Gain (Do Not Adjust)
0
150
Counts
30
9
Integral Gain (Do Not Adjust)
1
100
Counts
20
10
BATTERY
Low Battery Cut-out
25
40
Volts
25
Seconds
0.5
11
Not Used
12
Not Used
13
BRAKE
Brake Personality Timer
0
3
60285AA
NOTE: Skyjack does NOT recommend exceeding the default settings.
WARNING
Before making any adjustments, you must determine the revision of your software. When the calibrator is
plugged in, turn the power on and push and hold down the “-” button for 5 seconds.
SECTION 5, Page 12
119153
Table 5-4B. Sevcontrol Adjustable Parameters (Software Revision .10)
SEQ. NO.
PARAMETER
MIN.
MAX.
UNITS
DEFAULT
1
IMAX
50
600
Amps
400
2
ACCEL
Acceleration Delay
1.0
3.0
Seconds
1.0
3
DECEL
Deceleration Delay
0.1
3.0
Seconds
0.1
4
CREEP
0
10
% of Max. Speed
2
5
MAX
Maximum Allowed Speed
5
100
% of Max. Possible Speed
80
6
ELEVA
Elevated Cutback Speed
5
25
% of Max. Speed
15
7
TILT
Tilted Cutback Speed
5
75
% of Max. Speed
50
8
Proportional Gain (Do Not Adjust)
0
150
Counts
30
9
Integral Gain (Do Not Adjust)
1
100
Counts
20
10
BATTERY
Low Battery Cut-out
25
40
Volts
25
11
Not Used
12
Not Used
13
ELEVATED CURRENT
Max. Current When Elevated
50
400
Amps
230
14
BRAKE
Brake Personality Timer
0.0
3.0
Seconds
0.5
60286AA
NOTE: Skyjack does NOT recommend exceeding the default settings.
WARNING
Before making any adjustments, you must determine the revision of your software. When the
calibrator is plugged in, turn the power on and push and hold down the “-” button for 5 seconds.
119153
SECTION 5, Page 13
Sevcon Calibration Tool (Continued)
HOURS COUNTER:
The hours counter records pulsing hours, and is displayed when the calibrator is first plugged in. Once the
SELECT button is pressed, the calibrator reverts to normal operation.
Initially a minute/seconds count is displayed. By pressing the (-) button, hours are displayed
and by pressing the (+) button 1000’s of hours are displayed.
Releasing the buttons reverts back to the minute/seconds display. The decimal point blinks every second during
drive. The counter will record up to 65,500 hours before rolling back to 0.
DIAGNOSTIC PROCEDURE:
WARNING
All machine functions remain operational while calibrator is plugged in.
The last five segments on the bar display are as follows.
BATT
Displays the current battery voltage. Pressing the (+) button displays the highest voltage, for the machine, that the Sevcontrol has recorded.
MOTOR V.
Displays the motor voltage as the machine is being driven.
MOTOR AMP Displays the motor current as the machine is being driven.
TEMP
Displays the temperature of the MOSFET heat sink in °C. Pressing the (+) button displays the highest temperature recorded and pressing the (-) button displays the lowest temperature recorded.
TEST
This invokes the diagnostic test routines to check machine switches, joystick,
control wiring etc.
With the calibrator connected and the platform powered up, as described in the adjustment procedure. Use the
SELECT button to select the test segment. If the SELECT button is pressed at any time during the test, the test
will be terminated and the minute/seconds count will be displayed.
The first test displayed, on the drive Sevcontrol, is the joystick input. This displays the input as 0-100% as joystick
is moved from min. to max.
Pressing the (+) and (-) buttons step through the tests as shown in Table 5-5. After the final test, the sequence
will loop back to the joystick input test, then test 1.
SECTION 5, Page 14
119153
Table 5-5. Sevcontrol Test Sequence
Drive Controller Test Sequence
Sequence
No.
Test
1
2
3
4
5
6
Controller (Joystick) Input
Forward Switch
Reverse Switch
Tachometer Input
Elevated Position
Tilt Switch
Pump/Traction Switch
7
8
9
10
Actual Direction, Tachometer Output
Lift Transmission Position Sense
Traction Transmission Position Sense
First Error Latch
Display
0 to 100%
CL/OP
CL/OP
0 to 100%
CL=Collapsed OP=Lifted
CL=Level OP=Tilt
CL=Pump Mode OP=Traction
Mode
CL= Reverse OP=Forward
CL = Engaged OP = Disengaged
CL = Engaged OP = Disengaged
Value= Flash Code
NOTE: CL=Switch Closed
OP=Switch Open
60287AB
119153
SECTION 5, Page 15
Traction Controller Pin Reference
Pins are identified from left to right
Pin #1 thru Pin #17
Diagnostic LED
Figure 5-7. Traction Controller
Pin 1- Brake relay control.
Brings B- to brake relay (25CR).
Test between pin 1 and wire #10A.
Pin 11- Reverse direction input from joystick
24 volts = reverse selected.
Test between pin 11 and wire #02.
Pin 2- Direction signal from pin 4 of tachometer
card. Determines direction.
0 volts = forward.
15 volts = reverse.
Pin 12- Speed signal from pin 2 on tachometer
card.
7.5 volts with joystick in neutral.
7.5 volts to 15 volts = reverse.
7.5 volts to 0 volts = forward.
Pin 3- Not used.
Pin 4- High Drive Cut-out.
24 volts high drive enabled.
0 volts high drive disabled.
Test between pin 4 and wire #02 with platform fully lowered.
Pin 5- 24 volt input from line contactor.
Pin 6- 48 volt input from line contactor.
Test between Pin 6 and wire #02 with Key
Switch on.
Pin 7- Tilt switch input.
24 volts = full speed
0 volts = 50% full speed.
Pin 8- Forward/Up input from joystick.
24 volts = drive forward or lift up selected.
Pin 9- Not used
Pin 10- Not used
SECTION 5, Page 16
Pin 13- Speed sensing enable.
Determines lift or drive mode.
2 volts = drive. Speed sensing enabled.
4 volts = lift. Speed sensing disabled.
Anything above 2.52 volts = Lift
Pin 14- Accelerator input.
3.8 to 4.2 volts with joystick in neutral and
key switch on.
3.5 volts = slow speed.
0 volts = fast speed.
Pin 15- Forward contactor output.
Brings B- to forward drive contactor.
Pin 16- Drive/Lift Select.
0 volts = drive
24 volts = lift
Pin 17- Reverse contactor output.
Brings B- to reverse drive contactor.
119153
Table 5-6. Traction Controller Flash Fault Pin References
Number of Flashes
2
3
4
5
6
7
8
10
11
X
X
12
13
14
1
2
3
4
5
X
Pin Reference Number
6
X
X
7
8
X
X
X
X
X
9
10
11
12
X
13
X
14
X
15
16
17
X
X
X
X
X
X
X
60288AA
119153
SECTION 5, Page 17
Tachometer Board Pin Reference
Pins are identified from right to left
Figure 5-8. Tachometer Board
Term A- 48 volt input from relay 10ACR-2.
Pin 6-
Steer enable
Term B- 24 volt input from wire #10A.
Test between terminal B and wire 02.
Pin 7-
Pin 8-
not used
Lift mode selected.
24 volts when lift selected.
Test between Pin 8 and wire 02.
Pin 9-
Drive mode selected.
24 volts when drive selected.
Test between Pin 9 and wire 02.
Term C- 24 volt output to drive, steer and line contactors. Fused from terminal B.
Test between terminal C and wire 02.
Pin 1- Battery negative
Pin 2- Speed signal to Pin 12 of controller.
7.5 volts with key switch on and platform
selected.
7.5 volts to 15 volts = reverse
7.5 volts to 0 volts = forward
Pin 3-
Tachometer generator input.
Pin 4-
Direction signal to Pin 2 of controller.
0 volts = forward
15 volts = reverse
Pin 5-
Tachometer generator input.
Pin 10- Speed sensing enable. To Pin 13 on controller.
Drive mode = 2 volts = speed sensing
enabled.
Lift mode = 4 volts = speed sensing
disabled.
Pin 11- Spike suppression for 24 volt B+.
Pin 12- Not used
Pin 13- Spike suppression B-.
Pin 14- Not used`
Pin 15- Not used
Pin 16- Not used
SECTION 5, Page 18
119153
Tachometer Generator Testing Procedure
1.
Locate tachometer generator on back of drive motor. Remove rubber boot from the rear of the tachometer
generator.
2.
Mark the location of the wires attached to the generator and remove wires. NOTE: Wires must be
reattached to the same terminals as they were removed from or the Sevcon controller will not function
when reassembled.
3.
Remove the four 5/16-18 x 1-1/2” bolts securing the tachometer generator mounting plate to the rear of
the motor.
NOTE: Do not attempt to remove the tachometer generator from mounting plate until it has been determined
to be defective.
4.
Remove the coupler half from the tachometer generator and attach generator to a drill with a 1000-RPM
rating.
5.
Attach a voltmeter to the terminals on the rear of the tachometer generator and set the meter for D.C.
voltage.
6.
Energize drill and read voltage on meter. At 1000-RPM voltmeter should indicate (20.8) volts. If reading
is lower the tachometer generator is defective.
7.
Put the drill in reverse and energize drill, read voltage on meter. At 1000-RPM voltmeter should read (-20.8)
volts. If reading is lower the tachometer generator is defective.
Note
Steps #6 and #7, the voltage should be a smooth incline to proper voltage.
If voltage is erratic it may affect the performance of the machine.
1.
2.
3.
4.
5.
GEAR BOX
DRIVE MOTOR
COUPLER HALF
TACHOMETER GENERATOR MOUNTING PLATE
COUPLER HALF
1
2
3
4
5
6
Figure 5-9. Traction Motor/Tach Generator
119153
SECTION 5, Page 19
SECTION 6
PARTS MANUAL
GENERAL
The information contained in this section is designed
to aid the user in locating and identifying replacement
parts. Component parts of various assemblies and
sub-assemblies comprising the work platform are
illustrated and accompanied by a descriptive parts list.
Exploded drawings are used to show relative location of
component parts in disassembly order. If a part cannot
be found in this section, order by work platform model
number and serial number, giving a complete description
of the part.
PARTS ORDERING INFORMATION
When ordering replacement parts, the complete part
number and description should be used to ensure
proper identification and delivery of the desired item.
This complete identification should also be used when
requesting equipment information.
METHOD OF LISTING
Parts are listed in order according to the reference
number shown in the illustration, followed by a full
description based upon the “NOUN FIRST” method.
That is, the noun name of the part is listed first, then
the modifying description information which serves to
specifically identify the item. For example: PIN, Clevis.
Assemblies or groups are shown at the beginning of a
parts list and are identified with the letter references A, B,
C, etc. Individual parts in these lists have corresponding
letters after their description to identify which assembly or
group it is used in. Individual parts without identifying
letters are used in all the assemblies or group shown at
the beginning of the parts list. Descriptions preceded
with an (•) indicates a serviceable component or
attaching hardware for the higher level assembly.
QUANTITIES (Units per Assy.)
The quantities of each part that are required to complete
the assembly. If quantity is (AR), it is understood that
the quantity may vary when machine is equipped with
certain options. Order quantity as needed.
HARDWARE
Standard screws, washers, nuts, etc. are not identified
by a reference number. These parts are known as
COMMON HARDWARE items and appear indented
under the major items with which they are used. They
should be ordered separately as listed, since they are
not component parts of the pieces they attach to.
HOW TO ORDER REPAIR PARTS
1. Address all orders to your local SKYJACK dealer.
2. Specify model and serial number of the work
platform (found on the serial number plate).
3. List the quantity needed.
4. List the length needed (if bulk item).
5. List the part number and description as shown in
this manual for each item.
6. Show billing and shipping address and name of
individual if possible.
7. Suggest best routing.
CUSTOMER___________________________________________________________________
DEALER______________________________________________________________________
MODEL NUMBER ______________________________________________________________
SERIAL NUMBER ______________________________________________________________
DATE PURCHASED ____________________________________________________________
Use Only Skyjack Authorized Replacement Parts!
119153
SECTION 6, Page 1
6
AN
List Of Illustrations
Description
Page No.
Platform And Related Parts
Figure 6.1-1. Main Platform And Railings......................................................................................................... 4
Figure 6.1-2. 4 Ft. Roll-out Extension Platform Assembly................................................................................ 8
Figure 6.1-3. 4 Ft. Powered Extension Platform Assembly............................................................................ 10
Figure 6.1-4. Hydraulic Hose Connections - Single Powered Extension Platform........................................ 14
Figure 6.1-5. Hydraulic Hose Connections - Double Extension Platform...................................................... 15
Figure 6.1-6. Powered Extension Platform - Cylinder Assembly................................................................... 16
Figure 6.1-7. Powered Extension Platform - Electrical Panel......................................................................... 18
Figure 6.1-8. Powered Extension Platform - Control Box Assembly............................................................. 21
Figure 6.1-9. Control Box Assembly............................................................................................................... 22
Figure 6.1-10. Drive/Steer Controller Assembly . ............................................................................................ 30
Figure 6.1-11. AC Outlet On Platform............................................................................................................... 32
Figure 6.1-12. Air Hose To Platform Option..................................................................................................... 33
Scissor And Related Parts
Figure 6.2-1. Scissor Arm Assembly (31’ Models)......................................................................................... 34
Figure 6.2-2. Scissor Arm Assembly (41’ Models)......................................................................................... 38
Figure 6.2-3. Hydraulic Hose Connections- Scissors.................................................................................... 42
Figure 6.2-4. Lift Cylinder Assembly............................................................................................................... 44
Figure 6.2-5. Lift Cylinder Manifold Assembly............................................................................................... 48
Base And Related Parts
Figure 6.3-1. Base, Axles And Wheels........................................................................................................... 50
Figure 6.3-2. Electrical Components - Base.................................................................................................. 54
Figure 6.3-3. Hydraulic Hose Connections - Base......................................................................................... 58
Figure 6.3-4. Front Drive Axle Assembly - 4-Wheel Drive Machines.............................................................. 60
Figure 6.3-5. Front Idle Axle Assembly - 2 Wheel Drive Machines................................................................ 64
Figure 6.3-6. Steer Cylinder Assembly . ........................................................................................................ 66
Figure 6.3-7. Pump, Gear Box And Drive Motor Assembly........................................................................... 68
Figure 6.3-8. Gearbox Assembly.................................................................................................................... 70
Figure 6.3-9. Disc Brake Assembly................................................................................................................ 72
Figure 6.3-10. Disc Brake Cylinder Assembly . ............................................................................................... 74
Figure 6.3-11. Rear Drive Axle Assembly......................................................................................................... 76
Figure 6.3-12. Battery Roll-out Tray Assembly............................................................................................... 78
SECTION 6, Page 2
119153
AN
List Of Illustrations
Description
Page No.
Hydraulic Cabinet Assembly
Figure 6.4-1. Hydraulic Oil Tank/Charger Cabinet Assembly........................................................................ 82
Figure 6.4-2. Hydraulic Oil Tank Assembly.................................................................................................... 84
Figure 6.4-3. Hydraulic Hose Connections - Hydraulic Electric/Tray .......................................................... 86
Figure 6.4-4. Battery Charger Assembly........................................................................................................ 88
Hydraulic/Electric Cabinet Assembly
Figure 6.5-1. Hydraulic/Electric Cabinet Assembly........................................................................................ 96
Figure 6.5-2. Auto Reset Brake Manifold Assembly..................................................................................... 101
Figure 6.5-3. Main Manifold Assembly......................................................................................................... 102
Electrical Panel Assembly
Figure 6.6-1. Base Control/Electrical Panel Assembly................................................................................. 104
Figure 6.6-2. Sevcon Battery Cable Layout ................................................................................................ 106
Figure 6.6-3. Panel Layout............................................................................................................................ 108
Figure 6.6-4. Proximity And Tachometer Harness........................................................................................ 110
Figure 6.6-5. Control Cable Harnesses........................................................................................................ 111
Figure 6.6-6. Devices Connector Layout A.................................................................................................. 112
Figure 6.6-7. Devices Connector Layout B.................................................................................................. 114
Special Option
Figure 6.7-1. Hydraulic Outrigger Option - Leg Assembly........................................................................... 116
Figure 6.7-2 Hydraulic Outrigger Option - Hydraulic Hose Connections................................................... 122
Figure 6.7-3. Hydraulic Outrigger Option - Cylinder Assembly................................................................... 124
Figure 6.7-4. Hydraulic Outrigger Option - Manifold Assembly................................................................... 128
Figure 6.7-5. Hydraulic Outrigger Option - Control Box Assembly............................................................. 129
Figure 6.7-6. 1500W DC Inverter.................................................................................................................. 130
Figure 6.7-7. Scissor Guard Option............................................................................................................. 132
Figure 6.7-8. Lanyard Attachment D-Ring Option........................................................................................ 136
Figure 6.7-9. Work Light Option................................................................................................................... 137
Labels And Nameplates
Figure 6.8-1. Labels Kit................................................................................................................................. 139
Figure 6.8-2. Labels And Nameplates.......................................................................................................... 140
Figure 6.8-3. Labels - Outrigger................................................................................................................... 144
119153
SECTION 6, Page 3
AN
Figure 6.1-1. Main Platform And Railings
37
36
34
4
20
21
16
35
17
14
18
15
22
13
23
11
25
12
6
24
26
27
8
7
10
28
29
30
5
4
31
2
9
3
32 33
30
1
M1003AD
SECTION 6, Page 4
119153
Figure 6.1-1. Main Platform And Railings
Index
No.
Skyjack
Part No.
Qty.
A
B
C
(Ref.)
(Ref.)
(Ref.)
1
107623
1
104625
16
103978
16
2
117289
2
3
117290
2
117291
2
103873
4
104606
4
4
117277
4
103856
12
104000
12
103983
12
103632
12
5
103107
2
6
105310
2
7
105312
2
8
105307
2
9
109377
2
10
100702
AR
11
110693
2
103632
4
12
107615
2
13
115531
AR
14
107621
1
111808
1
15
106915
2
103865
4
103984
4
16
101778
AR
Description
Machines with front extension platform.
Machines with rear extension platform.
Machines with hinged end rails.
WELDMENT, Main platform
• SCREW, Set 3/8”-16 x 5/8” lg.
• NUT, Hex 3/8”-16
WELDMENT, Hinged bottom gate
WELDMENT, Hinged top gate (Half gate)
WELDMENT, Hinged top gate (Full gate)
• BOLT, Hex-hd 3/8”-16 x 2-1/2” lg.
• NUT, Lock 3/8”-16
HINGE, Spring return (Stanley 3-1/2” #2060R)
• BOLT, Hex-hd 1/4”-20 x 3/4” lg.
• WASHER, Lock 1/4”
• NUT, Jam 1/4”-20
• SCREW, Self-tapping 1/4”-14 x 3/4” lg.
SPRING, Compression
PIN, Roll 1/8” x 1-1/4” lg.
GUIDE, Spring
PLATE, Latch release
PIN, Latch 5/8” x 4-3/16” lg.
CAP, Tube end
STOP, Latch
• SCREW, Self-tapping 1/4”-14 x 3/4” lg.
RAILING, Lower front RH/lower rear LH
LABEL, Warning falling hazard
RAILING, Upper rear LH, B
RAILING, Upper rear LH, A & C
RAILING, Gate top (Half gate)
• BOLT, Hex-hd 5/16”-18 x 2” lg.
• NUT, Lock 5/16”-18
CLAMP, Entry railing
119153
SECTION 6, Page 5
Figure 6.1-1. Main Platform And Railings (Continued)
Index
No.
Skyjack
Part No.
Qty.
AN
Description
17
107617
2
18
104183
2
20
107621
1
111840
1
21
111845
AR
22
111842
AR
23
107621
1
111808
1
24
132814
1
132816
1
103865
2
103984
2
103996
2
124547
1
134355
1
115649
1
25
108791
1
26
107621
1
111840
1
27
100509
AR
28
105807
AR
29
107614
8
30
(Ref.)
-
31
120143
1
32
119943
1
33
119945
4
34
121017
AR
35
121016
AR
36
121015
AR
37
117279
AR
125010
AR
RAILING, Lower front LH/lower rear RH
PAD, Entry insulation 27” lg. (Half gate)
RAILING, Upper rear RH, B
RAILING, Upper rear RH, A & C
RAILING, Hinged upper end, C
RAILING, Hinged lower end, C
RAILING, Upper front RH, A & B
RAILING, Upper front RH, C
ASSEMBLY, Control box mount
• WELDMENT, Control box mount
• BOLT, Hex head (5/16-18 x 2” lg.)
• NUT, Lock (5/16-18)
• WASHER, Flat (5/16”)
• PIN, Quick release assy. small loop
• SCREW, Machine flat head (1/4”-20 x 3/4”)
• NUT, Hex nylon lock (1/4”-20 Grade 5)
CLIP, Cable (stick-on)
RAILING, Upper front LH, A & B
RAILING, Upper front LH, C
PIN, Locking 3/8”
CABLE, Lanyard 6” lg.
PLATE, Railing retainer
RING KIT, Safety
(For components, Refer to Figure 6.7-8)
Extension, Gate (CE)
PLATE, Gate clamp (CE)
RIVET, Pop Wide Head (CE)
RAILING, Bottom Left, D
RAILING, Bottom Right, D
RAILING, Top, D
GATE, Full (Left swinging) D
GATE, Full (Right swinging) D
119153
SECTION 6, Page 7
AN
Figure 6.1-2. 4 Ft. Roll-out Extension Platform Assembly
24
9
L
8
7
6
5
10
4
3
21
22
20
19
14
17
18
11
12
14
23
2
1
17
15
14
13
16
M10033AA_1
SECTION 6, Page 8
119153
Figure 6.1-2. 4 Ft. Roll-out Extension Platform Assembly
Index
No.
Skyjack
Part No.
Qty.
AN
Description
1
107639
1
105829
2
100141
2
2
106432
2
3
117200
1
4
115531
AR
5
117199
1
6
115015
2
7
112467
2
8
130229
1
103632
4
9
115014
1
10
115016
2
11
117198
1
12
(Ref.)
1
13
102237
2
14
110425
8
15
111136
2
16
114998
2
17
105673
AR
101954
AR
18
107057
4
19
112736
1
20
112389
1
21
100509
AR
22
105807
AR
23
(Ref.)
-
24
115543
2
L
(Ref.)
-
WELDMENT, Extension platform
• PIN, Roller 3/4” x 2-3/8” lg.
• ROLLER, Rear
U-BOLT, 1/4”-20 x 3/4”ID
RAILING, Pivoting front
LABEL, Falling hazard
RAILING, Side RH
TUBE, Push bar lower RH
PLUNGER, Quick release pull ring
PLATE, Safety label
• BOLT, Self tapping 1/4” - 14 x 3/4” lg.
WELDMENT, Push bar upper
TUBE, Push bar lower LH
RAILING, Side LH
(For Components, Refer to Figure 6.1-1)
PIN, Roller 3/4” x 3-11/32” lg.
PAD, Deck slider 1” dia. x 11/32” thk.
ROLLER, Extension platform
PAD, Extension stop
PAD, Slider 1-1/2” dia. x1/2”thk.
PAD, Slider 1-1/2” dia. x 3/8” thk.
PAD, Platform slide 3/8” x 1-3/4 x 4” lg.
STOP, Extension platform (welded to platform deck)
PIN, Quick release
PIN, Locking 3/8”
CABLE, Lanyard 6”
RING KIT, Safety
LABEL, No step
LABEL, Info/Warning
NOTE: Quantities shown are for a single extension platform.
119153
SECTION 6, Page 9
AN
Figure 6.1-3. 4 Ft. Powered Extension Platform Assembly
6
7
4
30
32
L
2
16
17
26
14
27
3
13
31
15
12
19
1
5
28
21
11
9
10
18
25
20
21
23
24
22
8
9
29
M10035AC
SECTION 6, Page 10
119153
AN
Figure 6.1-3. 4 Ft. Powered Extension Platform Assembly
Index
No.
Skyjack
Part No.
1
107639
105829
100141
2
130229
103632
3
117198
4
117199
5
(Ref.)
101632
103472
103999
111290
6
(Ref.)
103860
103995
104000
103980
7
117188
103856
104000
8
(Ref.)
103845
103404
100397
9
(Ref.)
10
(Ref.)
11
108366
12
111136
13
110425
14
(Ref.)
15
101954
16
100509
17
105807
18
106446
19
102237
Qty.
1
2
2
1
AR
1
1
1
-
2
2
2
1
1
-
2
2
2
2
1
4
6
1
-
2
2
2
1
-
1
-
1
2
8
1
-
AR
AR
AR
1
2
Description
WELDMENT, Extension platform
• PIN, Roller 3/4” x 2-3/8” lg.
• ROLLER, Rear
PLATE, Info/warning mount
• BOLT, Self tapping 1/4” - 14 x 3/4” lg.
RAILING, Extension platform side LH
RAILING, Extension platform side RH
PLATE, Valve and panel mounting
(For Components, Refer to Figures 6.1-7)
• BOLT, Hex-hd 3/8”-16 x 3/4” lg.
• WASHER, Flat 3/8”
• BLOCK, Manifold
BOX ASSEMBLY, Powered ext. platform control
• BOLT, Hex-hd 1/4”-20 x .75” lg.
• WASHER, Flat
• NUT, Hex-hd 1/4”-20
PLATE, Control box mounting
• BOLT, Hex-hd 1/4”-20 x 3/4” lg.
PANEL ASSEMBLY, Powered platform electrical
• BOLT, Hex-hd 5/16”-18 x 1/2
• NUT, Hex 5/16”-18
VALVE AND MANIFOLD ASSEMBLY
(For Components, Refer to Figures 6.1-4 & 6.1-5)
CYLINDER ASSEMBLY, Powered extension platform
WELDMENT, Cylinder front support
ROLLER, Extension platform
PAD, Deck slider 1” dia. x 11/32” thk.
PAD, Slider 1-1/2” dia. x 3/8” thk.
PIN, Locking 3/8”
CABLE, Lanyard 6” lg.
RING, Retaining
PIN, Roller 3/4” x 3-11/32” lg.
NOTE: Quantities shown are for a single extension platform.
119153
SECTION 6, Page 11
Figure 6.1-3. 4 Ft. Powered Extension Platform Assembly (Continued)
Index
No.
Skyjack
Part No.
Qty.
20
113304
2
21
113305
2
22
113331
1
23
113334
1
24
115544
1
25
113360
1
104002
1
26
113164
1
27
107057
4
28
105673
2
30
115531
AR
31
(Ref.)
-
32
117200
1
L
(Ref.)
-
AN
Description
WASHER, Isolator 3/4” x 2”
ISOLATOR, Cylinder rod
ADAPTER, Cylinder rod
WELDMENT, Cylinder rod mount
SPACER, 3/4” x 1 x 3/4” lg.
BOLT, Hex-hd 3/4” x 16 x 1-1/2” lg.
WASHER, Lock 3/4”
CLAMP, Cable
PAD, Platform slide 3/8” x 1-3/4” x 4” lg.
BUMPER, Extension platform
LABEL, Falling hazard
RING KIT, Safety
RAILING, Pivoting front
LABEL, Info/Warning
119153
SECTION 6, Page 13
Figure 6.1-4. Hydraulic Hose Connections - Powered Extension Platform
(Machines With Front Extension Platform)
5
3
7
4
8
2
6
9
1
5
10
M1046AB
Index
No.
Skyjack
Part No.
Qty.
1
(Ref.)
1
-
2
107382
1
3
103614
1
107439
2
103920
AR
128798
1
128317
1
128320
2
103920
AR
104345
AR
104409
AR
4
103069
3
5
114578
3
6
104134
1
7
106516
1
8
124355
2
124354
2
9
103070
1
10
102665
1
SECTION 6, Page 14
Description
BLOCK, Valve manifold
VALVE ASS’Y, “Vickers” (Early models - replace with Hytos below)
• COIL, 24 Volt Spool Valve
• BOLT, Socket head #10-24 x 2” grade 5
VALVE ASS’Y, “Hytos” (Later models & Vickers replacement)
• VALVE, Directional spool
• • COIL, 24 Volt Spool Valve
• CONNECTOR, Gray
• CONNECTOR, Black
FITTING, Connector #6orb-#6
FITTING, Elbow 90° #6orb-#6
HOSE ASSEMBLY, Cylinder retract 93” lg
HOSE ASSEMBLY, Cylinder extend 27” lg.
HOSE ASSEMBLY, Powered Extension Supply and Return (Model 8831)
Use Part #123038 for Machines with Serial #37120 and Below.
FITTING, O-Ring #6-#8 (in manifold at base)
FITTING, O-Ring Elbow #8-#6 (in manifold at base)
Use Part #103070 for Machines with Serial #37120 (8831)
or #42302 (8841) and below.
119153
Figure 6.1-5. Hydraulic Hose Connections - Powered Extension Platform
(Machines With Front And Rear Extension Platforms)
Rear 8831
Front 8841
Front 8831
Rear 8841
3
5
2
6
10
4
1
1
7
3
9
11
5
8
12
Index
No.
Skyjack
Part No.
Qty.
1
(Ref.)
2
-
2
107382
2
3
103614
1
107439
2
103920
AR
128798
1
128317
1
128320
2
103920
AR
104345
AR
104409
AR
4
103069
2
5
114578
6
6
110447
1
7
102490
1
8
124355
2
124354
2
9
104134
1
10
106516
1
11
104660
2
12
103070
1
13
102665
1
13
M1027AB
Description
BLOCK, Valve manifold
VALVE ASS’Y, “Vickers” (Early models - replace with Hytos below)
• COIL, 24 Volt Spool Valve
VALVE ASS’Y, “Hytos” (Later models & Vickers replacement)
• VALVE, Directional spool
• • COIL, 24 Volt Spool Valve
• CONNECTOR, Gray
FITTING, Connector #6orb - #6
FITTING, Elbow 90° #6orb - #6
HOSE ASSEMBLY, Cylinder Retract 56” lg.
HOSE ASSEMBLY, Cylinder Extend 16” lg.
HOSE ASSEMBLY, Cylinder Retract 93” lg.
HOSE ASSEMBLY, Cylinder Extend 27” lg.
FITTING, Tee #6orb-#6-#6
FITTING, O-Ring #6-#8 (in manifold at base)
FITTING, O-Ring Elbow #8-#6 (in manifold at base)
Use Part #103070 for Machines with Serial #37120 (8831
or #42302 (8841) and below.
119153
SECTION 6, Page 15
Figure 6.1-6A. Powered Extension Platform Cylinder Assembly
(Model 8831E with Serial No. 36839 and Below) (Model 8841E with Serial No. 41670 and Below)
9
8
2
7
6
11
5
4
1
10
3
12
M118090AB
Index
No.
Skyjack
Part No.
Qty.
A
118090
-
CYLINDER ASSEMBLY, 5 Ft. Extension platform
1
2
*3
*4
*5
*6
*7
*8
9
10
11
12
119418
119407
110976
103825
106452
106449
108798
103828
118089
117942
103830
116069
1
1
1
1
1
1
1
1
1
1
1
1
• WELDMENT, Cylinder barrel
• GLAND, Cylinder end
• O-RING, Piston
• SEAL, Piston
• RING, Piston wear
• WIPER, Rod
• SEAL, Rod
• O-RING, Gland
• ROD, Piston
• PISTON
• NUT, Lock 5/8”-11 grade C
• SPACER, Limit
*
107396
AR
SECTION 6, Page 16
Description
KIT, Seal Repair
* Part of Seal Repair Kit
119153
Figure 6.1-6B. Powered Extension Platform Cylinder Assembly
(Model 8831E with Serial No. 36840 and Above) (Model 8841E with Serial No. 41671 and Above)
9
8
2
7
6
1
11
5
12
4
10
3
M1007AA
Index
No.
Skyjack
Part No.
Qty.
A
120275
-
CYLINDER ASSEMBLY, Extension platform
1
2
*3
*4
*5
*6
*7
*8
9
10
11
12
120271
120254
110976
103825
106452
106449
108798
120436
118089
117942
103830
116069
1
1
1
1
1
1
1
1
1
1
1
1
• GLAND, Cylinder end
• O-RING, Piston
• SEAL, Piston
• WIPER, Rod
• SEAL, Rod
• O-RING, Gland
• ROD, Piston
• PISTON
• SPACER, Stop Tube
*
107396
AR
Description
KIT, Seal Repair
119153
SECTION 6, Page 17
Figure 6.1-7A. Powered Extension Platform Electrical Panel
(Model 8831 with Serial No. 36901 and Below) (Model 8841E with Serial No. 41892 and Below)
1
3
7
5
6
8
3
2
4
9
M117362AA
Index
No.
1
2
3
4
5
6
7
8
9
Skyjack
Part No.
Qty.
103012
103955
103985
117362
100397
(Ref.)
104345
104409
115817
103257
(Ref.)
104345
104409
115817
103257
(Ref.)
107711
103257
(Ref.)
107711
103257
102921
103036
(Ref.)
103257
119130
119895
116399
1
2
2
1
2
1
1
1
2
20” lg.
2
2
2
2
20” lg.
1
1
180” lg.
1
1
180” lg.
AR
AR
1
20” lg.
1
1
1
SECTION 6, Page 18
Description
BLOCK, Terminal
• BOLT, Machine #6-32 x 3/4” lg.
• NUT, Machine #6-32
PANEL, Powered platform electrical
• NUT, Hex-hd 5/16-18
CORD ASS’Y, Valve manifold (Machines with single extension platform)
• CONNECTOR, Gray
• DIODE, Flyback 1 amp 400 PIV
• CORD, 18/3
CORD ASS’Y, Valve manifold (Machines with two extension platforms)
• CONNECTOR, Gray
• DIODE, Flyback 1 amp 400 PIV
• CORD, 18/3
CORD ASSEMBLY, Front platform control box
• CONNECTOR ASSEMBLY, 5 Pole female
• CORD, 18/3
CORD ASSEMBLY, Rear platform control box
• CONNECTOR ASSEMBLY, 5 Pole female
• CORD, 18/3
DIODE, 6 Amp
CONNECTOR, Strain relief
CORD ASSEMBLY, Electrical panel
• CORD, 18/3
• KIT, 4 pole receptacle connector
• CONNECTOR, 3 pole P.C. Board
BRACKET, Power Deck Panel and Valve
119153
Figure 6.1-7B. Powered Extension Platform Electrical Panel
(Model 8831 with Serial No. 36902 and Above) (Model 8841 with Serial No. 41893 and Above)
2
1
6
3
4
5
M1020AA
Index
No.
Skyjack
Part No.
Qty.
A
B
(Ref.)
(Ref.)
-
-
1
120844
1
2
122178
1
122179
1
119900
1
103257
AR
107711
AR
103568
1
103570
1
3
120658
1
4
122189
1
122190
1
119896
AR
119825
AR
111354
AR
5
122192
1
124353
1
119897
1
119895
1
103257
588”
103257
756”
6
122186
1
Description
SINGLE POWERED EXTENSION PLATFORM
DOUBLE POWERED EXTENSION PLATFORMS (Shown)
BOARD, Power Deck PC
HARNESS, Power Deck Control box, A
HARNESS, Power Deck Control box, B
• PLUG, 8 Pin PC Board Connector
• CABLE, Cabtire 18/3 (180” long)
• CONNECTOR, Cabtire 5 Pin Female
• • HOUSING, Base
• • INSERT, Female
FUSE, 10A
HARNESS, Power Deck Directional Valves, A
HARNESS, Power Deck Directional Valves, B
• CONNECTOR, Solenoid
• PROTECTOR, 3/8” Wire
HARNESS, Power Deck To Main Panel (Model 8831)
HARNESS, Power Deck To Main Panel (Model 8841)
• CABLE, Cabtire 18/3 (Model 8831)
• CABLE, Cabtire 18/3 (Model 8841)
BRACKET, Power Deck PC Board and Valve
119153
SECTION 6, Page 19
Figure 6.1-8. Powered Extension Platform Control Box Assembly
5
6
8
9
6
7
7
1
2
3
4
M1006AA
Index
No.
Skyjack
Part No.
Qty.
A
115592
-
1
2
3
4
5
6
7
8
9
115539
103041
106401
107712
103567
103569
108328
102853
111181
115594
114377
1
1
AR
1
1
1
1
2
2
1
1
Description
CONTROL BOX ASSEMBLY, Powered ext. platform
• BOX, Control
• STRAIN RELIEF, Straight 1/2”
• CORD, Coiled 18/3
• CONNECTOR ASSEMBLY, 5 pole male
• • INSERT, Male
• LABEL, Platform extend/retract
• SWITCH, Toggle
• GUARD, Toggle switch
• LABEL, Enable
• PLUG, Plastic 1/2”
119153
SECTION 6, Page 21
Figure 6.1-9A. Control Box Assembly
3
20
L
19
12
L
11
L
16
14
1
8
L
2
L
5
23
L
17
10
9
25
L
L
7
6
13
22
4
15
18
24
21
M1040AA
SECTION 6, Page 22
119153
Figure 6.1-9A. Control Box Assembly
Index
No.
Skyjack
Part No.
Qty.
Description
A
119367
-
B
119374
1
119344
1
112327
10
2
119345
1
3
(Ref.)
1
-
103957
4
112249
4
4
119369
1
119898
1
103100
1
103225
2
103141
1
5
103082
1
6
102769
1
100149
2
7
119368
1
119895
1
8
103240
1
9
119396
1
119899
1
102671
1
10
103057
1
11
103202
1
12
102771
1
13
119370
1
119903
1
14
116382
1
15
119366
1
114678
4
106099
4
16
111181
1
17
114377
1
18
102956
1
19
100509
1
20
105807
1
CONTROL BOX ASSEMBLY
CONTROL BOX ASSEMBLY WITH HORN
• WELDMENT, Control box, 1 hole
• • BOLT, Hex-hd #8-18 x 1/2” lg.
• COVER, Control box bottom
• CONTROLLER ASSEMBLY, Drive/steer
(For components, refer to Figure 6-1-10A)
• • SCREW, Machine #8-32 x 1/2” lg.
• • WASHER, Lock #8
• HARNESS ASSEMBLY, Key switch, emergency stop
• • CONNECTOR, 6 pole P. C. Board
• • BASE, Contact
• • BLOCK, N. C. Contact
• • BLOCK, N.O. Contact
• HEAD, Base/off/platform key select switch
• HEAD, Emergency stop switch
• • WASHER
• HARNESS ASSEMBLY, Battery meter
• • BATTERY CHARGER INDICATOR
• HARNESS ASSEMBLY, Warning light, beeper
• • CONNECTOR, 7 pole P.C. Board
• • BLOCK & BASE, Warning light
• • BEEPER
• LENS
• BULB
• HARNESS ASSEMBLY, Lift/off/drive
• • SWITCH, Toggle lift/off/drive
• BOARD, Control circuit
• • SCREW, Machine #6-32 x 1/2” lg
• • WASHER, Lock #6
• GUARD, Toggle
• PLUG, 1/2” hole (located on top of control box)
• PLUG, 7/8” hole (located on side of control box)
• PIN, Locking
• CHAIN, Lanyard 6” lg.
119153
SECTION 6, Page 23
Figure 6.1-9A. Control Box Assembly (Continued)
Index
No.
Skyjack
Part No.
Qty.
21
119373
1
119907
1
103041
1
119359
1
114469
1
102887
44”lg.
22
119397
1
119894
1
103100
1
103141
1
23
102851
1
24
(Ref.)
1
-
25
(Ref.)
1
108854
1
103100
1
103141
1
L
(Ref.)
1
-
AN
Description
Parts list continued from the previous page
• CABLE ASSEMBLY, Control box 16 pole
• • CONNECTOR, P.C. Board 15 pole
• • CONNECTOR, Strain relief
• • HOUSING, 16 pole
• • PLUG, 16 pole male
• • CABLE, 16/15
• SWITCH ASSEMBLY, Horn push-button
• HEAD, Push-button switch
• CABLE ASSEMBLY, Scissor control
• SWITCH ASSEMBLY, Enable push-button
• • HEAD, Green Push-button switch
• LABEL, Control Box
119153
SECTION 6, Page 25
Figure 6.1-9B. Control Box Assembly
4
30
25
5
6
26
A
31
B
L
14
26
15
34
27
11
35
28
29
1
L
L
8
32
13
24 17
9
16
23
32
8
12
10
2
22
7
18
19
C
3
D
32
1
20
21
33
M10268AB
SECTION 6, Page 26
119153
Figure 6.1-9B. Control Box Assembly
Index
No.
Skyjack
Part No.
Qty.
A
B
C
D
130249
130250
119374
123619
-
-
-
-
1
130196
126446
2
130197
119345
3
112327
4
(Ref.)
5
103957
6
112249
7
119369
119898
103100
103225
103141
8
103082
104466
106398
9
102769
10
119368
119895
11
122093
12
119396
119899
102671
13
103057
14
103202
15
102771
16
119370
119903
17
116382
18
119366
19
114678
20
106099
21
119373
119907
103041
119359
114469
102887
1
1
1
1
10
1
-
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
44”
Description
CONTROL BOX ASSEMBLY (With Key)
CONTROL BOX ASSEMBLY (Without Key)
CONTROL BOX ASSEMBLY (With Key) (Older Generation)
CONTROL BOX ASSEMBLY (Without Key) (Older Generation)
• WELDMENT, Control box, 1 hole, A & B
• WELDMENT, Control box, 1 hole, C & D
• COVER, Control box bottom, A & B
• COVER, Control box bottom, C & D
• BOLT, Hex-hd #8-18 x 1/2” lg.
• CONTROLLER ASSEMBLY, Drive/steer
(For components, refer to Figure 6.1-10B)
• SCREW, Machine #8-32 x 1/2” lg.
• WASHER, Lock #8
• HARNESS ASSEMBLY, Base/off/platform switch, emergency stop
• • BLOCK, N. C. 1 Contact
• • BLOCK, N.O. 2 Contact
• HEAD, Base/off/platform key select switch, A
• • KEY, #455
• HEAD, Base/off/platform selector switch, B
• HEAD, Emergency stop switch
• HARNESS ASSEMBLY, Battery meter
• • BATTERY CHARGER INDICATOR
• HARNESS ASSEMBLY, Warning light, beeper
• • BLOCK & BASE, Warning light
• • BEEPER
• LENS
• BULB
• HARNESS ASSEMBLY, Lift/off/drive
• • SWITCH, Toggle lift/off/drive
• BOARD, Control circuit
• SCREW, Machine #6-32 x 1/2” lg
• WASHER, Lock #6
• CABLE ASSEMBLY, Control box 16 pole
• • CONNECTOR, Strain relief
• • HOUSING, 16 pole
• • PLUG, 16 pole male
• • CABLE, 16/15
Parts list continued on following page.
119153
SECTION 6, Page 27
Figure 6.1-9B. Control Box Assembly (Continued)
Index
No.
Skyjack
Part No.
Qty.
AN
Description
Parts list continued from previous page.
22
119397
1
119894
1
103100
1
103141
1
23
102851
1
24
111181
1
25
126447
1
26
104185
3
27
104694
2
28
104003
2
29
103962
2
30
103917
1
31
103987
1
32
100149
1
33
(Ref.)
1
-
34
100509
1
35
105807
1
L
(Ref.)
-
• HARNESS ASSEMBLY, Horn push-button
• HEAD, Horn Push-button switch
• GUARD, Toggle
• GUARD, Control Box
• WASHER, Lock #10 NOM
• WASHER, Flat #10 S.A.E.
• NUT, Machine #10 - 32 Grade B
• BOLT, Machine #10 - 32 x 1/2”
• BOLT, Socket #10 - 24 x 1”
• NUT, Machine #10 - 24
• WASHER
CABLE ASSEMBLY, Scissor control
PIN, Locking
LANYARD, Retaining Pin
LABEL, Control Box
119153
SECTION 6, Page 29
Figure 6.1-10A. Drive/Steer Controller Assembly
1
2
4
3
4
5
6
8
14
13
10
7
11
9
12
M1022AA
Index
No.
Skyjack
Part No.
Qty.
A
119371
-
CONTROLLER ASSEMBLY, Drive/steer
1
2
3
4
5
6
7
8
9
10
11
12
13
14
105735
105734
105733
105738
105737
105736
105378
106729
106730
106725
106726
119142
106731
110982
1
1
2
2
1
1
1
1
1
1
1
1
1
1
• CAP, Elastic
• ACTUATOR, Rocker
• SWITCH, Directional
• KNOB HALF
• SPRING, Compression
• SLIDE LOCK
• HANDLE EXTENSION
• HOUSING
• SPRING, Handle return
• RATCHET
• BUSHING, Spring
• CIRCUIT BOARD
• SCREW, Hollow
• GASKET, Housing
SECTION 6, Page 30
Description
119153
Figure 6.1-10B. Drive/Steer Controller Assembly
1
2
4
3
M10269AB
Index
No.
Skyjack
Part No.
Qty.
1
2
3
4
127063
126469
126488
126489
-
2
1
9
Description
CONTROLLER ASSEMBLY, Drive/steer
• RELAY, DPDT 24V
• CONNECTOR, 9-Pin PCB
• PINS, PCB connector crimp
119153
SECTION 6, Page 31
AN
Figure 6.1-11. AC Outlet On Platform
L
5
L
1
8
3
2
6
L
6
3
2
7
4
4
7
M11090AF
Index
No.
Skyjack
Part No.
Qty.
A
B
C
D
113257
113256
117548
117549
-
-
-
-
M11090AG
Description
110V AC OUTLET ON PLATFORM - Model 8831 (ANSI/SIA and CSA)
110V AC OUTLET ON PLATFORM - Model 8841 (ANSI/SIA and CSA)
220V AC OUTLET ON PLATFORM - Model 8831 (CE)
220V AC OUTLET ON PLATFORM - Model 8841 (CE)
1
131999
1
BOX, G.F.C.I. Receptacle A & B
132042
2
• RIVET, Pop (1/4” Dia.)
2
109698
1
RECEPTACLE, 125V G.F.I. A & B
3
109699
1
PLATE, Weatherproof cover, A & B
4
104208
1
PLUG, 3-Prong male (15A/125V) A & B
5
103035
1
ELBOW, Strain relief (90°)
6
105269
1
CABTIRE (14/3 x 600” lg.) A
105269
1
CABTIRE (14/3 x 720” lg.) B
117542
1
CABTIRE (14/3 x 600” lg.) C
117542
1
CABTIRE (14/3 x 720” lg.) D
7
103024
1
CLIP, Cord
8
136328
1
BOX, Outlet with fitting
134140
2
• RIVET, Open end dome (1/4” Dia.)
L
(Ref.)
-
LABEL, AC outlet
(For components, refer to Figure 6.8-2)
SECTION 6, Page 32
119153
Figure 6.1-12. Air Hose To Platform Option
2
1
2
M1017AA
Index
No.
Skyjack
Part No.
Qty.
A
B
116374
124177
-
-
1
2
(Ref.)
107882
107883
107884
107884
109050
107886
102891
102893
107887
1
1
1
840” lg.
720” lg.
2
2
AR
AR
2
Description
AIR HOSE TO PLATFORM (Model 8841)
AIR HOSE TO PLATFORM (Model 8831)
HOSE ASSEMBLY, Air to platform
• FITTING, Female disconnect
• FITTING, Male disconnect
• HOSE, Air 1/2” Dia. A
• HOSE, Air 1/2” Dia. B
• FITTING, Hose barb
• CLAMP, Hose
STRAP, Tie 7” lg.
STRAP, Tie 10-1/2” lg.
LABEL, Connect air here
119153
SECTION 6, Page 33
AM
Figure 6.2-1. Scissor Arm Assembly (Model 8831E)
21
36 37 20
16
36 37 31
1
30
2
32
28
29
27
26
25
40
3
4
33
34
5 35
6
7
23
37
8
13 39
24
36
22
21
36 37 20
11
15 14
38
19
18
12
10
16
9
17
M1010AA
SECTION 6, Page 34
119153
Index
No.
Skyjack
Part No.
Qty.
AM
Description
A
110057
1
110395
1
2
110361
1
3
110347
1
4
110377
1
5
100071
AR
6
110410
7
(Ref.)
1
-
103887
1
103404
1
7
110363
1
8
110328
1
9
102236
12
103887
20
103404
20
101632
32
103999
32
10
110408
6
11
101564
18
12
117840
6
13
111135
8
14
105395
4
15
131952
16
16
114043
4
103997
4
103972
4
17
112440
1
103865
1
103984
1
18
(Ref.)
1
-
19
(Ref.)
1
-
20
110418
4
21
101689
3
103907
16
103468
16
103470
16
103471
16
22
101523
8
25
103997
4
24
115532
4
25
(Ref.)
2
-
26
111172
1
103256
1
119825
2
ASSEMBLY, 3 Arm Scissor
ARM ASSEMBLY, 3rd Inner
ARM ASSEMBLY, 3rd Outer
ARM ASSEMBLY, 2nd Outer
ARM ASSEMBLY, 2nd Inner
BUSHING, End pin 1-1/4” x 2” lg.
PIN, End 1-1/4”
• PIN, End 1-1/4” (limit switch cam)
• BOLT, Hex-hd 5/16”-18 x 3/4” lg.
ARM ASSEMBLY, 1st Inner
ARM ASSEMBLY, 1st Outer
PLATE, Center pin retainer
• BOLT, Hex-hd 5/16”-18 x 1” lg.
• BOLT, Hex-hd 3/8”-16 x 3/4” lg.
PIN, Center 1-3/4” x 9-1/2” lg.
BUSHING, Center pin 1-3/4” x 1-1/2” lg.
BEARING, Thrust (not shown)
BUMPER, Scissor arm 2-1/2” x 1-1/16” thk. (arm)
BUMPER, Scissor arm 2-1/2” x 1-1/2” thk. (base)
SPACER, Bumper
BAR, Centering
• WASHER, Flat 1-1/4”
• PIN, Cotter 1/4” x 2 1/2” lg.
WELDMENT, Centering bar pivot/lowering valve
• BOLT, Adjusting 5/16”-18 x 2” lg.
• NUT, Lock 5/16”-18
VALVE AND VALVE BLOCK ASSEMBLY
BEEPER, LIGHT AND HORN ASSEMBLY
PIN, Centering bar pivot
WELDMENT, Centering bar pivot
• BOLT, Hex-hd 1/2”-13 x 11/2” lg.
• NUT, Hex 1/2”-13
BUSHING, Centering arm 1-1/4” x 3/4” lg.
WASHER, Flat 1-1/4”
PIN, Cotter 1/4”
CYLINDER ASSEMBLY, Lift
CORD ASSEMBLY, Holding valve (Not shown)
• CABLE, 18/2 x 321” lg.
• CONNECTOR, Solenoid
119153
SECTION 6, Page 35
AN
Figure 6.2-1. Scissor Arm Assembly (Model 8831E) (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
27
111954
102780
111534
103855
104000
28
111137
29
110409
30
111225
101949
105549
101950
103701
117148
117553
101581
31
110413
32
124761
103078
124445
103962
104694
104185
104003
124763
33
(Ref.)
34
(Ref.)
104698
104003
35
124642
36
103887
37
103404
38
103938
39
103937
40
133130
112449
104000
103995
103980
LATCH ASSEMBLY, Safety bar
• LATCH, Safety bar
• KNOB, Latch
• BOLT, Hex-hd 1/4”-20
NUT, Jam 2-1/8”
PIN, Lift cylinder pivot
SLIDER ASSEMBLY
• PIN, 3/8” diameter x 1.25” lg.
• WELDMENT, Slider
• PAD, Teflon 3/8” x 3-1/2” x 5-1/2” lg.
• PAD, Teflon 3/8” x 1-1/4” x 5-1/2” lg.
• KIT, Slider bushing
• • BUSHING, 1” x 1-1/8” x 3/8” lg.
• • BUSHING, 1” x 1-1/8” x 1-1/4” lg.
PIN, Slider
CLAMP ASSEMBLY (Ontario Hydro)
• CLAMP, Double G10
• CLAMP, Double
• SCREW, Machine #10 - 32 x .5
• WASHER, Flat #10 S.A.E
• NUT, Machine #10 -32 grade B
• LABEL, Ontario Hydro
CAM, Limit Switch
SWITCHES, Limit
SPACER, 1/4”
BOLT, Hex-hd 5/16”-18 x 3/4” lg.
WASHER, Lock 5/16” lg.
BOLT, Socket 3/8”-16 grade 5 x 1 1/2” lg.
BOLT, Socket 3/8”-16 grade 5 x 3/4” lg.
• COVER, Limit Switch
• • SCREW, Hex head machine 1/4”-20 x 1”
• • WASHER, Lock 1/4”
• • WASHER, Flat 1/4”
• • NUT, Hex Hd 1/4”-20 Grd. 5
1
1
1
1
1
4
4
8
32
8
8
16
8
1
2
4
1
2
9
9
9
9
9
1
-
-
1
-
2
2
AR
AR
AR
AR
AR
1
2
2
4
2
NOTE: The following components were used on earlier models:
PROTECTION, Adhesive Cable 72” lg. (Not Shown)
CLIP, Adhesive Cord (Not shown)
BRACKET, Horn mounting (Earlier Models)
-
-
-
104127
108791
106977
AR
9
1
119153
SECTION 6, Page 37
23
AM
22 38 39
18
38 39 33
32
1
2
3
4
34
30
31
29
27
42
5
28
6
35
36
7 37
7
8 38 39
9
15 41
26
25
10
24
23
38 39 22
40 17 16
21
20
SECTION 6, Page 38
13
18
11
14
12
19
M1009AA
119153
Index
No.
A
Skyjack
Part No.
Qty.
110059
1
110361
2
110389
3
110381
4
110359
5
110347
6
110377
7
100071
8
110410
(Ref.)
9
110363
10
110328
11
102236
103887
103404
103473
103999
12
110408
13
101564
14
117840
15
111135
16
105395
103936
17
131952
18
114043
19
112440
103865
103984
20
(Ref.)
21
(Ref.)
22
110418
23
101689
103907
103468
103470
103471
24
101523
25
103997
26
115532
27
(Ref.)
1
1
1
1
1
1
AR
11
1
-
1
1
16
16
16
32
32
8
48
8
12
4
12
16
4
1
1
1
1
-
1
-
4
AR
16
16
16
16
8
4
4
2
-
AM
Description
ASSEMBLY, 4 Arm Scissor
• ARM ASSEMBLY, 4th Outer
• ARM ASSEMBLY, 4th Inner
• ARM ASSEMBLY, 3rd Inner
• ARM ASSEMBLY, 3rd Outer
• ARM ASSEMBLY, 2nd Outer
• ARM ASSEMBLY, 2nd Inner
BUSHING, End pin 1-1/4” x 2” lg.
• PIN, End 1-1/4”
• PIN, End 1-1/4” (limit switch cam)
• ARM ASSEMBLY, 1st Inner
• ARM ASSEMBLY, 1st Outer
• PLATE, Center pin retainer
• • BOLT, Hex-hd 5/16”-18 x 1” lg.
• • BOLT, Hex-hd 3/8”-16 x 1” lg.
• PIN, Center 1-3/4” x 9-1/2” lg.
• BUSHING, Center pin 1-3/4” x 1-1/2” lg.
• BEARING, Thrust
BUMPER, Scissor arm 2-1/2” x 1-1/16” thk. (arm)
BUMPER, Scissor arm 2-1/2” x 1-1/2” thk. (base)
• BOLT, Soc-hd 3/8”-16 x 1” lg.
• SPACER, Bumper 2-1/2” dia.
BAR, Centering 34-3/4” lg.
WELDMENT, Centering bar pivot/lowering valve
• BOLT, Adjusting 5/16”-18 x 2” lg.
• NUT, Lock 5/16”-18
VALVE AND VALVE BLOCK ASSEMBLY
BEEPER/LIGHT AND HORN ASSEMBLY
PIN, Centering bar pivot
WELDMENT, Centering bar pivot
• BOLT, Hex-hd 1/2”-13 x 1-3/4” lg.
• NUT, Hex 1/2”-13
BUSHING, Centering arm 1-1/4” x 3/4” lg.
WASHER, Flat 1-1/4”
PIN, Cotter 1/4” x 2-1/2” lg.
119153
SECTION 6, Page 39
AN
Figure 6.2-2. Scissor Arm Assembly (Model 8841E) (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
28
111172
103256
119825
29
111954
102780
111534
103855
104000
30
111137
31
110409
32
111225
101949
105549
101950
103701
117148
117553
101581
33
110413
34
124762
103078
124445
103962
104694
104185
104003
124763
35
(Ref.)
36
(Ref.)
37
124642
38
103887
39
103404
40
103938
41
103937
42
133130
112449
104000
103995
103980
CORD ASSEMBLY, Holding valve
• CABLE, 18/2 x 321” lg.
• CONNECTOR W/DIODE, Black
LATCH ASSEMBLY, Safety bar
• LATCH, Safety bar
• KNOB, Latch
• BOLT, Hex-hd 1/4”-20 x .50” lg.
NUT, Jam 1-1/2”-12
PIN, Lift cylinder pivot
SLIDER ASSEMBLY
• PIN, 3/8” diameter x 1.25” lg.
• WELDMENT, Slider
• PAD, Teflon 3/8” x 3-1/2” x 5-1/2” lg.
• PAD, Teflon 3/8” x 1-1/4” x 5-1/2” lg.
• KIT, Slider bushing
• • BUSHING, 1” x 1-1/8” x 3/8” lg.
• • BUSHING, 1” x 1-1/8” x 1-1/4” lg.
PIN, Slider
CLAMP ASSEMBLY (Ontario Hydro)
• CLAMP, Double G10
• CLAMP, Double
• SCREW, Machine #10 - 32 x .5
• NUT, Machine #10 -32 grade B
• LABEL, Ontario Hydro
CAM, Limit Switch
SWITCH ASSEMBLY, Limit
SPACER, 1/4”
BOLT, Hex-hd 5/16”-18 x 3/4” lg.
WASHER, Lock 5/16” lg.
BOLT, Socket 3/8”-16 grade 5 x 1 1/2” lg.
BOLT, Socket 3/8”-16 grade 5 x 3/4” lg.
• COVER, Limit Switch
• • SCREW, Hex head machine 1/4”-20 x 1”
• • NUT, Hex Hd 1/4”-20 Grd. 5
1
1
2
1
1
1
1
1
4
4
8
32
8
8
16
8
1
2
8
1
2
11
11
11
11
11
1
-
-
-
-
AR
AR
AR
AR
AR
1
2
2
4
2
-
104127
AR
-
108791
9
-
106977
1
NOTE: The following components were used on earlier models:
PROTECTION, Adhesive Cable 72” lg. (Not Shown)
CLIP, Adhesive Cord (Not shown)
BRACKET, Horn mounting (Earlier Models)
119153
SECTION 6, Page 41
Figure 6.2-3. Hydraulic Hose Connections- Scissors
1
6
5
4
2
2
3
7
10
9
8
11
13
12
14
11
M1003AA
SECTION 6, Page 42
119153
Figure 6.2-3. Hydraulic Hose Connections - Scissors
Index
No.
Skyjack
Part No.
1
(Ref.)
2
114578
3
125430
103746
104637
4
104437
5
103090
6
110592
7
114582
8
114227
9
113556
119085
10
113494
11
114583
12
113496
13
114218
14
110473
Qty.
2
-
4
1
8
8
2
2
2
1
1
1
AR
1
2
1
1
1
Description
BLOCK, Lift manifold
• BOLT, Socket 5/16”-18
PLUG, Soc-hd #6
CONDUIT, Convoluted 1-1/4” x 28” lg.
HOSE ASSEMBLY, Lift cylinder 30” lg.
HOSE ASSEMBLY, Lift manifold to lowering valve manifold 149” lg.
VALVE ASSEMBLY, Lowering
• KIT, Seal repair
BLOCK, Lowering valve manifold
SPACER, Orifice
ORIFICE, .070 Diameter
HOSE ASSEMBLY, Lowering valve manifold to main manifold 60” lg.
119153
SECTION 6, Page 43
Figure 6.2-4A. Lift Cylinder Assembly
AN
2
7
11
8
9
10
12
11
6
5
13
4
3
1
M109953AA
SECTION 6, Page 44
119153
Figure 6.2-4A. Lift Cylinder Assembly
Index
No.
Skyjack
Part No.
Qty.
A
109953
-
AN
Description
1
109227
1
2
109232
1
*3
109246
1
*4
109244
1
*5
109247
1
6
109225
1
*7
109248
2
*8
109245
1
9
102856
1
10
102027
2
11
109249
4
12
109250
2
13
(Ref.)
-
• WELDMENT, Cylinder rod
• WIPER, Rod
• SEAL, Rod
• RING, Rod wear
• GLAND, Front end
• O-RING, Front gland
• PLUG, Soc-hd 3/8”-24
• FITTING, Grease 1/8 NPT
• RING, Retaining
• BEARING, Spherical
BLOCK, Lift cylinder manifold
*
112165
AR
KIT, Seal repair
* Part of Seal Repair Kit, 112165.
119153
SECTION 6, Page 45
Figure 6.2-4B. Lift Cylinder Assembly
AN
2
7
11
8
9
10
12
11
5
6
13
4
3
1
M1002AA
SECTION 6, Page 46
119153
Figure 6.2-4B. Lift Cylinder Assembly
Index
No.
Skyjack
Part No.
Qty.
AN
Description
A
120349
-
1
120348
1
2
109232
1
*3
109246
1
*4
109244
1
*5
109247
1
6
120317
1
*7
109248
2
8
120446
1
9
102856
1
10
102027
2
11
109249
AR
12
109250
2
13
(Ref.)
-
• WELDMENT, Cylinder rod
• WIPER, Rod
• SEAL, Rod
• RING, Rod wear
• PLUG, Soc-hd 3/8”-24
• RING, Retaining
BLOCK, Lift cylinder manifold
*
112165
AR
KIT, Seal repair
* Part of Seal Repair Kit, 112165.
119153
SECTION 6, Page 47
Figure 6.2-5. Lift Cylinder Manifold Assembly
7
3
AN
4
8
9
10
2
1
5
6
Note: Additional components for CE machines equipped with
Load Sensing System, refer to Load Sensing Supplement Manual.
SECTION 6, Page 48
M11218AA
119153
Figure 6.2-5. Lift Cylinder Manifold Assembly
Index
No.
Skyjack
Part No.
Qty.
1
2
3
4
5
6
7
8
9
10
106688
111316
108052
106557
107269
114578
103403
120481
104493
103931
104637
103996
1
1
1
1
1
1
1
1
1
4
4
4
AN
Description
BLOCK, Manifold with plugs
• BLOCK, Manifold
• PLUG, Expander
VALVE, Relief
VALVE, Holding valve (N.C.)
FITTING, Hydraulic elbow
SEAL, O-ring
ORIFICE, One way (0.104” Dia.)
COIL, 24V
BOLT, Socket (5/16”-18 x 2” Grade 5)
WASHER, Lock (5/16” high collar 0.09)
WASHER, Flat (5/16”)
119153
SECTION 6, Page 49
Figure 6.3-1. Base, Axles And Wheels
14
13
15
11
10
9
12
13
8
3
7
16
6
5
4
3
1
16
2
M11143AA
SECTION 6, Page 50
119153
Figure 6.3-1. Base, Axles And Wheels
Index
No.
Skyjack
Part No.
1
(Ref.)
(Ref.)
123855
126286
123856
2
(Ref.)
116801
3
129399
129397
129398
129387
112654
130035
130031
130030
124982
124984
124981
124673
124980
124983
124979
124673
132975
132974
124981
124673
111612
106201
112654
111613
106201
112654
112738
104085
111518
4
116801
5
(Ref.)
103907
103470
103468
6
(Ref.)
Qty.
1
-
1
-
8
8
8
16
-
16
1
2
2
1
1
1
2
2
2
2
2
2
2
2
1
1
2
2
1
1
4
1
1
4
1
1
4
1
1
16
1
-
4
4
4
1
-
AL
Description
AXLE ASSEMBLY, Front idle (2wd)
AXLE ASSEMBLY, Front drive (4wd)
• BOLT, Hex-hd 1/2”-13 x 2-3/4” grade 8
• WASHER, Lock 1/2” heavy duty
• NUT, Hex-hd 1/2”-13 grade 8
BOLT, Wheel 5/8”-18 (For front idle axle)
NUT, Wheel 5/8”-18 (For front drive axle)
WHEEL ASSEMBLY, #6 “Carlisle” 10 ply Air Filled
RIM/TIRE ASSEMBLY, LH #6 Air 4.75” backspace 75 psi
RIM/TIRE ASSEMBLY, RH #6 Air 4.75” backspace 75 psi
• TIRE, #6 Air 10 ply 75 psi
• RIM, #6 4.75 (16.5x8.25x8)
WHEEL ASSEMBLY, #6 “Carlisle” 10 ply Foam Filled
RIM/TIRE ASSEMBLY, LH #6 Foam 4.75” backspace
RIM/TIRE ASSEMBLY, RH #6 Foam 4.75” backspace
RIM/TIRE ASSEMBLY, #6 LH “OTR” Air filled Non-marking 4.75” backspace
RIM/TIRE ASSEMBLY, #6 RH “OTR” Air filled Non-marking 4.75” backspace
• TIRE, #6 “OTR” Stabilizer non-marking
• RIM, #6 “OTR”
RIM/TIRE ASSEMBLY, #6 “OTR” 10 ply Air Filled (Model 8841)
RIM/TIRE ASSEMBLY, #6 “OTR” 10 ply Air Filled (Model 8841)
• TIRE, #6 10 ply “OTR” Stabilizer
• RIM, #6 OTR
RIM/TIRE ASSEMBLY, LH #6 “OTR” Foam Filled Non-marking (Model 8841)
RIM/TIRE ASSEMBLY, RH #6 “OTR” Foam Filled Non-marking (Model 8841)
• TIRE, #6 “OTR” Stabilizer non-marking
• RIM, #6 “OTR” 4.75” backspace
RIM/TIRE ASSEMBLY, #6 “IronMan SKS” 8 ply Air filled 4.75” backspace
• TIRE, #6 8 ply (30x10x16.5) 50 psi
• RIM, #6 8.25 x 16.5 - 8 bolt
RIM/TIRE ASSEMBLY, #6 “IronMan SKS” 8 ply Foam Filled 4.75” backspace
• TIRE, #6 8 ply (30x10x16.5)
• RIM, #6 8.25 x 16.5 - 8 bolt
RIM/TIRE ASSEMBLY, #7 “McCreary” 8 ply Foam Filled 5.313” backspace
• TIRE, #7 8 ply (31x15.5x15)
• RIM, #7 12 x 15 - 8 bolt
NUT, Wheel 5/8-18 (For rear drive axle)
GEAR BOX AND DC DRIVE MOTOR ASSEMBLY
• BOLT, Hex-hd 1/2”-13 x 1-1/2” lg.
DISC BRAKE ASSEMBLY
119153
SECTION 6, Page 51
AO
Figure 6.3-1. Base, Axles And Wheels (Continued)
Index
No.
Skyjack
Part No.
Qty.
7
(Ref.)
1
-
123855
8
126286
8
123856
8
8
124342
1
132477
1
108767
1
119920
2
103964
2
124160
2
9
(Ref.)
1
10
117317
1
123547
1
117320
1
123806
1
11
(Ref.)
1
-
12
(Ref.)
1
-
13
151977
2
151979
2
103473
8
103472
16
103999
8
103978
8
14
(Ref.)
1
-
103473
8
103472
16
103999
8
103978
8
15
(Ref.)
4
-
16
123760
1
123752
2
101632
1
103999
1
Description
AXLE ASSEMBLY, Rear drive
• BOLT, Hex-hd 1/2”-13 x 2-3/4” grade 8
• WASHER, Lock 1/2” heavy duty
• NUT, Hex-hd 1/2”-13 grade 8
KIT, Emergency Lowering Access Bar
• BAR ASSEMBLY, Emergency Lowering Access (ANSI/CSA)
• BAR ASSEMBLY, Emergency Lowering Access (CE)
• CLIP, Spring
• BOLT, Machine #10-32 x 1/4”
• PIN, Locking BATTERY ROLL-OUT TRAY ASSEMBLY
WELDMENT, Base
WELDMENT, Base (w/Scissor Guard option)
Use Part # 117318 for Machines with Serial # 37007 (8831) or
42123 (8841) and below.
WELDMENT, Base (w/Outrigger option)
WELDMENT, Base (w/Scissor Guard & Outrigger option)
Use Part # 117319 for Machines with Serial # 37007 (8831) or
42123 (8841) and below.
SWITCH, End-of-stroke limit
HYDRAULIC/ELECTRIC CABINET ASSEMBLY
LADDER (Model 8831E)
LADDER (Model 8841E)
• BOLT, Hex-hd 3/8”-16 x 1” lg.
• NUT, Hex 3/8”-16
HYDRAULIC OIL TANK/CHARGER CABINET ASSEMBLY
• BOLT, Hex-hd 3/8”-16 x 1” lg.
• NUT, Hex 3/8”-16
LEG, Outrigger (Machines with Outrigger Option)
STRAP, Static Assembly (EE Rated)
• STRAP, Static
• BOLT, 3/8”-16 x .75
• WASHER, 3/8” Lock
119153
SECTION 6, Page 53
Figure 6.3-2. Electrical Components - Base
15
14
8
13
16
12
21 11
7
20
7
3
4
5
8
9
10
6
10
9
2
19
1
17
18
M1062AD
SECTION 6, Page 54
119153
Figure 6.3-2. Electrical Components - Base
Index
No.
Skyjack
Part No.
1
105600
2
119567
3
119566
4
120765
5
120767
6
(Ref.)
7
120071
103256
119894
119293
120658
8
119571
117493
117494
106746
9
(Ref.)
10
120100
103256
116992
116990
103367
11
120394
120395
12
119568
13
(Ref.)
14
123184
124880
117493
119829
117494
102871
103206
102700
105787
124879
15
119570
106746
117493
117494
Qty.
12
1
1
1
1
1
-
1
1
1
1
1
1
1
2
498”
2
-
1
144”
2
4
30”
8
8
6
8
-
-
-
1
1
2
4
2
96”
96”
200”
-
48”
1
2
Description
BATTERY, Boot Red (Traction Motor)
CABLE ASSEMBLY, Battery (S2)
CABLE ASSEMBLY, Battery (S1)
CABLE ASSEMBLY, Battery (A2)
CABLE ASSEMBLY, Battery (A1)
CABLE ASSEMBLY, Tach generator And Proximity
HARNESS ASSEMBLY, Center tap
• CABLE, 18/2 x 264” lg.
• CONNECTOR, P C Board 2 pole
• HOLDER, Fuse w/cover
• FUSE, 10 amp
CABLE ASSEMBLY, Disconnect to Panel
• CONNECTOR
• CONTACT
• CABLE, Welding #1
CONNECTOR ASSEMBLY, Battery
HARNESS, Charger Cut-out
• CABLE, 18/2 Cabtire
• PLUG, Male 2 Pole Housing
• PIN, Female Wire
• HEATSHRINK, 1/4”
BOOT, Battery Black
BOOT, Battery Red
CABLE ASSEMBLY, Battery
BATTERY, 6 Volt
DUAL CHARGER ADAPTER (4’) (EE rated)
DUAL CHARGER ADAPTER (8’) (Optional For EE rated)
• CONNECTORS, Battery
• HANDLE, Battery disconnect
• CONTACTS, I/O
• PARALLEL SPLICE
• CONNECTOR, Battery
• WIRE, Black 10 AWG, (Used on 4’ Cable)
• WIRE, Red 10 AWG, (Used on 4’ Cable)
• CABLE, 10/2 SOW, (Used on 8’ Cable)
CONNECTOR ASSEMBLY, Battery
• CABLE, Welding #1
• CONNECTOR
• CONTACTS
119153
SECTION 6, Page 55
Figure 6.3-2. Electrical Components - Base (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
16
119569
1
17
(Ref.)
1
-
18
(Ref.)
1
-
19
103092
AR
20
124176
4”
21
103404
16
CABLE ASSEMBLY, Battery
SWITCH ASSEMBLY, Proximity
MOTOR And TACHOMETER GENERATOR ASSEMBLY
PROTECTOR, Wire 1”
Used on Machines with Serial #42303 (8841) and 37123 (8831) & Below.
PROTECTOR, 1 1/4” Wire
WASHER, 5/16” Lock
119153
SECTION 6, Page 57
Figure 6.3-3. Hydraulic Hose Connections - Base
12
8
13
9
10
3
14
11
15
16
17
18
19
20
21
4
7
6
3
5
22
2
SECTION 6, Page 58
1
M1062AD
119153
Figure 6.3-3. Hydraulic Hose Connections - Base
Index
No.
Skyjack
Part No.
Qty.
1
(Ref.)
1
-
2
114583
1
3
(Ref.)
1
-
4
114388
1
5
119854
1
6
110473
1
7
120057
1
8
114402
1
9
102659
1
10
108799
1
11
114325
1
12
109418
2
13
114578
2
14
(Ref.)
1
-
15
120056
1
16
110475
1
17
114233
1
18
114234
1
19
114326
2
20
102854
1
21
116800
2
22
(Ref.)
1
AN
Description
DISC BRAKE ASSEMBLY
PUMP, MANIFOLDS, GEAR BOX AND DRIVE MOTOR ASSEMBLY
HOSE ASSEMBLY, Brake 1/2” x 32”
HOSE, Large pump to small pump 3/4” x 65”
HOSE ASSEMBLY, Pump pressure 1/2” x 60”
HOSE, Tank to manifold 1” x 120”
CLAMP
HOSE, Barb
FITTING, Pump suction
HOSE ASSEMBLY, Steer 1/4” x 140”
CYLINDER ASSEMBLY, Steer
(For components, refer to Figures 6.3-6)
HOSE, Drive suction to pump 1-1/4” x 24”
HOSE ASSEMBLY, Tank 1/2” x 122”
HOSE ASSEMBLY, Gearbox to manifold 1/4” x 100”
HOSE ASSEMBLY, Gearbox to manifold 1/4” x 95”
CLAMP, Hose (1.58”)
CLAMP, #12
FITTING, Special gear box
COVER, Hydraulic tank
(For components, refer to Figure 6.4-2.)
119153
SECTION 6, Page 59
Figure 6.3-4. Front Drive Axle Assembly - 4 Wheel Drive Machines
26
1
44
42
34
2
43
42
3
41
40
39
4
5
6
35
7
54 53
48
46
47
28
17
52
29
30
27
50
51
37
38
49
8
36
45
31
32
26
33
34
9
10
25
24
22
12
23
21
20
13
15
18
11
19
17
14
16
M1028AC
SECTION 6, Page 60
119153
AN
Figure 6.3-4. Front Drive Axle Assembly - 4 Wheel Drive Machines
Index
No.
Skyjack
Part No.
Qty.
Description
A
115602
-
1
120845
1
2
120191
1
3
122071
1
4
103264
1
5
102028
4
6
(Ref.)
1
-
7
102030
1
B
115728
1
8
108394
1
9
113888
1
10
113891
12
11
113908
1
12
115371
1
13
113909
AR
14
113910
8
15
117130
1
16
113879
1
17
113880
1
18
113881
AR
19
113882
1
20
113901
AR
21
708440
2
22
110070
1
-
23
115303
1
-
24
113900
2
25
113897
2
26
115373
1
$
1
113792
1
113793
1
27
108392
AR
28
113899
2
29
113898
2
30
113896
2
31
113895
2
32
108388
2
33
105817
2
MODIFIED AXLE ASSEMBLY, Front drive (5.13 ratio)
• AXLE ASSEMBLY, Front drive (DANA #070BA502-14)
• • COVER, Carrier
• • PLUG, Carrier cover
• • BOLT, Drive gear
• • DIFFERENTIAL ASSEMBLY
• • • GEAR SET, Internal differential
• • • KIT, Disc and plate
• • • BOLT, Differential case
• • DRIVE GEAR AND PINION SET
• • SLINGER, Inner pinion
• • BEARING ASSEMBLY, Inner pinion
• • KIT, Pinion adjusting shim
• • SLINGER, inner pinion bearing
• • KIT, Spindle bearing and seal
• • SLINGER
• • AXLE SHAFT ASSEMBLY, LH (37” lg.)
(Includes item #35)
• • AXLE SHAFT ASSEMBLY, RH (47” lg.)
(Includes item #35)
• • JOINT, Universal drive
• • CAP, Lower king pin
• • TIE ROD ASSEMBLY
• • • TIE ROD
• • • END, Tie rod RH
• • • END, Tie rod LH
• • KIT, King pin seal and bearing
• • CAP, Upper king pin
• • GASKET, Upper king pin
• • SPRING, upper king pin
• • RETAINER, Spring
• • BUSHING, upper king pin
• • PIN, Upper king
• WELDMENT, Steering arm Support (Must use Castle Nut #120191)
• NUT, Tie Rod Castle Hex
Both part numbers 120845 & 120191 MUST be ordered for Machines
with Serial numbers 36602 (8831) or 41283 (8841) & Below
• PIN, Cotter 1/8 X 2”
• WASHER, Bronze 1” x 2” x 1/8” thk.
• SPACER, 3/4” x 1” x 7/16” thk.
• CYLINDER ASSEMBLY, Steer (For components, refer to Figure 6.3-6)
• WELDMENT, Steering arm
119153
SECTION 6, Page 61
Figure 6.3-4. Front Drive Axle Assembly - 4 Wheel Drive Machines (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
• • KNUCKLE, Steering LH (shown)
• • KNUCKLE, Steering RH (opposite)
• • SPINDLE ASSEMBLY
• • SEAL, Wheel hub
• • BEARING ASSEMBLY, Inner hub
• • HUB, Wheel
• • • STUD, Wheel 5/8-18 RH
• • CAP, Hub
• • GEAR, Drive
• • • RING, Snap
• • SPACER, Drive gear
• • NUT, Bearing retaining
• • WASHER, Retaining nut lock
• • BEARING ASSEMBLY, Outer hub
• • NUT, Pinion
• • WASHER, Pinion nut
• • YOKE ASSEMBLY, End
• • SEAL, Pinion
• • BEARING ASSEMBLY, Outer pinion
• • SEAL AND GUIDE ASSEMBLY
• • KIT, Differential bearing shim
• • BEARING ASSEMBLY, Differential
• • HOUSING W/BEARING CAPS, Front drive axle
• • PLUG, Vent
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
113732
113733
113902
108393
108390
113903
111719
113907
119179
134763
119180
113904
113905
108391
113886
113885
113887
113884
113883
113893
113890
113889
$
113892
1
1
2
2
2
2
16
2
2
2
2
4
2
2
1
1
1
1
1
1
AR
2
1
1
119153
SECTION 6, Page 63
Figure 6.3-5. Front Idle Axle Assembly - 2 Wheel Drive Machines
26
24
25
27
23
1
2
22
3
21
5
4
20
19
18
7
6
16
15
8
14
9
SECTION 6, Page 64
17
10
11
12
13
M1004AB
119153
Figure 6.3-5. Front Idle Axle Assembly - 2 Wheel Drive Machines
Index
No.
Skyjack
Part No.
Qty.
A
120345
-
1
108487
2
100249
3
101801
4
102230
103887
103996
5
102027
6
111755
7
107908
8
103220
9
103085
10
104351
11
102646
12
102978
13
103009
14
103198
15
102905
16
102979
17
103004
18
120414
19
100309
20
103264
21
102229
103845
103996
22
101995
23
111756
24
113432
25
102028
26
113489
103990
104002
100252
27
(Ref.)
1
8
2
2
2
2
2
1
2
2
2
2
2
2
2
16
2
2
2
2
2
2
2
2
2
1
1
2
2
2
2
2
2
1
-
Description
AXLE ASSEMBLY, Front idle
• WELDMENT, Front idle axle
• BUSHING, 1”ID x 3/4” lg.
• BEARING, Thrust
• PIN, Spindle
• • BOLT, Hex-hd 5/16-18 x 3/4” lg.
• NIPPLE, Grease
• WELDMENT, Spindle arm LH
• HUB ASSEMBLY, Front wheel
• • CAP, Dust
• • PIN, Cotter 3/16” x 1-1/2” lg.
• • NUT, Castle 1”-14
• • WASHER, Flat
• • BEARING, Outer cup
• • BEARING, Outer cone
• • BOLT, Wheel
• • HUB, Front wheel
• • BEARING, Inner cup
• • BEARING, Inner cone
• • SEAL, Grease
• BUSHING
• WASHER, Bronze 1” x 2” x 1/8” thk.
• PIN, Tie bar
• • BOLT-HEX HEAD 5/16-18 GRADE 5*0.50
• WELDMENT, Tie bar
• WELDMENT, Spindle arm RH
SLEEVE, Cylinder mounting bolt
SPACER, Steer cylinder
BOLT, Hex-hd 3/4-10 x 3-1/4” lg. grade 8
WASHER, Flat 3/4”
WASHER, Lock 3/4”
NUT, Jam 3/4”-10
CYLINDER ASSEMBLY, Steer
119153
SECTION 6, Page 65
Figure 6.3-6A. Steer Cylinder Assembly
(Model 8831E with Serial Number 36839 and Below) (Model 8841E with Serial Number 41670 and Below)
3
4
5
2
1
13
13
12
14
14
13
12
13
11
7
10
6
9
8
M112498AA
Index
No.
Skyjack
Part No.
Qty.
A
112498
-
CYLINDER ASSEMBLY, Steer (2WD/4WD)
1
*2
*3
4
*5
6
*7
*8
9
10
11
12
13
14
113347
113350
107934
112496
113349
104111
103829
107935
112497
103830
112494
102025
104114
103513
1
1
1
1
1
1
1
1
1
1
1
2
2
2
• ROD, Steering
• SEAL, Steering rod
• O-RING, Gland
• WIPER, Rod
• SPACER
• O-RING, Piston
• SEAL, Piston
• PISTON, Cylinder
• NUT, Lock 5/8-11 grade C
• RING, Retaining
• FITTING, Grease
*
113443
AR
SECTION 6, Page 66
Description
KIT, Seal Repair
* Part of Seal Repair Kit.
119153
Figure 6.3-6B. Steer Cylinder Assembly
(Model 8831E with Serial Number 36840 and Above) (Model 8841E with Serial Number 41671 and Above)
3
4
5
2
1
13
13
12
14 15
15 6
13
12
13
11
7
10
9
8
M120405AE
Index
No.
Skyjack
Part No.
Qty.
A
120405
-
1
*2
*3
4
*5
6
*7
*8
9
10
11
12
13
14
15
113347
113350
120438
120401
113349
103513
110976
107935
120633
103830
120404
102025
104114
104350
132565
1
1
1
1
1
2
1
1
1
1
1
2
AR
1
2
*
121108
1
Description
CYLINDER ASSEMBLY, Steer (2WD/4WD)
• ROD, Steering
• SEAL, Steering rod
• O-RING, Gland
• WIPER, Rod
• FITTING, Grease
• O-RING, Piston
• SEAL, Piston
• PISTON, Cylinder
• RING, Retaining
• FITTING, Grease 1/4”-28 90 deg
• CAP, Grease fitting
KIT, Seal Repair
* Part of Seal Repair Kit.
119153
SECTION 6, Page 67
Figure 6.3-7. Pump, Gear Box And Drive Motor Assembly
7
8
6
5
9
10
4
11
3
2
1
15
12
16
14
13
14
20
19
14
18
17
M1066AA
SECTION 6, Page 68
119153
Figure 6.3-7. Pump, Gear Box And Drive Motor Assembly
Index
No.
Skyjack
Part No.
Qty.
1
120110
1
117074
1
103864
4
103404
4
103880
2
103979
2
700227
1
700487
1
117071
1
114271
1
103256
1
2
700081
1
3
116757
1
103899
4
103998
4
4
(Ref.)
2
-
5
(Ref.)
1
-
100844
4
100352
4
111577
4
6
120228
1
120221
1
120224
4
120222
1
120223
1
7
120002
1
8
119750
1
119751
4
106099
4
9
119999
1
10
120001
1
11
120000
1
116796
4
116218
6
12
128793
-
13
128789
1
14
128791
AR
15
128792
1
16
128790
1
17
112709
18
103099
1
19
116179
1
20
103084
1
Description
TACH GENERATOR ASSEMBLY
• HOUSING, Tach generator
• BOLT, Hex-hd 5/16-18 x 1” lg.
• BOLT, Hex-hd 3/8”-24 x 3/4” lg.
• NUT, Hex-hd 3/8”-24
• GENERATOR, Tachometer
• COUPLING, Rubber
• COLLAR, Generator
• CAP, Vinyl
• CABLE, 18/2 36” lg.
• COUPLER, Motor generator
MOTOR, Electric drive
• BOLT, Hex-hd 5/8”-11 x 1-1/2” lg.
SENSORS, Proximity (pump/drive)
GEAR BOX ASSEMBLY
• BOLT, Hex-hd 5/8”-11 x 2-3/4” lg.
• NUT, Lock 5/8”-11
• KIT, Pump adapter
• • PLATE, Pump adapter
• • BOLT, Soc-hd M8 x 60 mm
• • COUPLING, Pump adapter
• • SEAL, O-ring
SEAL, Pump To Pressure Manifold O-Ring
BLOCK, Manifold pressure
• BOLT, Hex-hd m6 x 45mm
• WASHER, Lock #6
PUMP, Hydraulic gear
SEAL, Pump To Suction Manifold O-Ring
BLOCK, Suction Junction
• BOLT, Soc-hd M8 x 60 mm
• WASHER, Lock M8
DRIVE SHAFT ASSEMBLY, Rear
• YOKE, Rear drive shaft
• KIT, Universal joint
• SHAFT, Rear drive
• FLANGE, Drive shaft yoke
CAP, 2WD Dust
YOKE, (4WD) Front drive
SHAFT, (4WD) Front drive
U-BOLT KIT, (4WD) Front drive shaft
Used on Machines with Serial #42303 (8841)
and 37123 (8831) & Below.
119153
SECTION 6, Page 69
Figure 6.3-8. Gearbox Assembly
22
23
24
25
26
27
21
20 19
28
18
29
17
16
20
15
30
14
18
13
31
12
32
11
33
10
34
9
35
8
36
4
3
2
1
38 7
6
5
37
M120234AA
SECTION 6, Page 70
119153
Figure 6.3-8. Gearbox Assembly
Index
No.
Skyjack
Part No.
Qty.
A
120234
1
1
122918
1
2
122920
2
3
122921
1
*4
122922
1
*5
122923
1
6
122944
1
7
122945
4
8
122951
1
9
122950
1
10
122948
1
11
122946
1
12
122929
1
13
122940
1
14
122932
1
15
122937
1
16
122936
1
17
122931
1
*18
122926
2
19
122938
1
20
122935
3
21
122939
1
22
122933
5
23
122930
1
24
122942
1
25
122943
1
*26
122953
2
27
122941
1
28
122927
1
29
122934
1
30
122928
1
*31
122925
1
32
122924
1
33
122949
1
34
122947
1
*35
122954
2
36
122952
2
37
122919
1
38
116802
6.5
*
122955
-
Description
GEAR BOX ASSEMBLY
• HOUSING, Half
• PIN, Parallel 8m6X28
• PLUG, Socket Pipe
• RING, A20X24X1.5 Sealing
• VENT, Dipstick
• Plate, Label
• PIN, 3X6 Round Head Groved Aluminium
• GEAR, 65X3.5 Helical
• SHAFT, Output
• BEARING, NJ2208E Roller
• SHAFT, Pinion
• GEAR, 24X2 Helical
• COLLAR, Shift
• RING, Inner
• COUPLING, Pump
• BOLT, Omnifit Lock on
• PLATE, End
• RING, A45X65X8 Shaft Sealing
• BEARING, 6009 Ball
• RING, 45X1.75 Retaining
• CAGE, Needle
• GUIDE, Shift Collar
• FORK, Shift
• PIN, 6X40 Spring Type Straight
• O-RING, 25X3
• BAR, Shift
• SHAFT, Drive
• O-RING 75X3
• FLANGE, Motor
• BEARING, NJ208E Roller
• GEAR, 65X3.5 Helical
• RING, D80X100X10 Shaft Sealing
• HOUSING, Flange Side Half
OIL, Gearbox (Litres)
KIT, Gearbox Seal
* Part Of Seal Repair Kit
119153
SECTION 6, Page 71
Figure 6.3-9. Disc Brake Assembly
10
12
11
8
9
4
5
6
3
7
2
13
1
2
M120572AA
SECTION 6, Page 72
119153
Figure 6.3-9. Disc Brake Assembly
Index
No.
Skyjack
Part No.
Qty.
A
120572
-
1
(Ref.)
2
109579
3
109599
4
109598
5
109600
6
109601
7
109580
103907
103470
103468
8
109602
120996
120997
120998
103909
103470
115347
9
110529
103872
104636
103977
10
115912
100845
100352
111577
103907
107949
11
111117
103872
104636
103977
12
111961
13
(Ref.)
1
-
2
1
1
1
1
1
2
2
2
1
AR
1
1
3
3
1
1
4
4
4
1
2
4
2
2
2
1
4
4
8
2
-
-
Description
ASSEMBLY, Disk Brake
ASSEMBLY, Disc Brake Cylinder
SPACER, Cylinder Mounting
CLEVIS, Rod End 1/2-20
NUT, Jam 1/2-20
PIN, Clevis
PIN, Cotter
BRACKET, Brake Cylinder
• BOLT, Hex-hd 1/2-13 X 1-1/2” Lg.
ASSEMBLY, Disc Brake Caliper
• KIT, Disc Pad Thin
• • PAD, Brake, Actuated
• • PAD, Brake, Non actuated
• BOLT, Hex-hd 1/2”-13 X 1-1/4” Lg.
• LEVER, Brake Actuator
DISC, 11” Diameter Brake
• BOLT, Hex-hd 3/8”-16 X 2-1/4” Lg.
• NUT, Hex 7/16”-14
SUPPORT, Disc Brake Tube
• BOLT, Hex-hd 5/8”-11 X 3-1/2” Lg. Grade 8
• NUT, Lock 5/8”-11 (Special)
• BOLT, Hex-hd 1/2”-13 X 1-1/2” Lg.
• NUT, Jam 1/2”-13
WELDMENT, Brake Skid
• BOLT, Hex-hd 3/8”-16 X 2-1/4” Lg.
• NUT, Hex 7/16”-14
PAD, Brake Support
FLANGE, Drive Shaft Yoke
119153
SECTION 6, Page 73
Figure 6.3-10A. Disc Brake Cylinder Assembly
(Model 8831E with Serial Number 36839 and Below) (Model 8841E with Serial Number 41670 and Below)
6
9
7
11
8
1
13
14
12
5
10
4
2
3
M112448AC
Index
No.
Skyjack
Part No.
Qty.
A
112448
-
CYLINDER ASSEMBLY, Disc brake
1
2
*3
*4
5
*6
*7
8
9
10
11
12
13
14
109575
109571
106583
109597
109572
116364
109596
111803
109574
109573
109642
109603
109604
109579
1
1
1
1
1
1
1
1
1
1
1
1
1
2
• WIPER, Brake rod
• ROD, Brake cylinder
• SEAL, Piston
• O-RING, Piston
• NUT, Hex 7/16-20
• PISTON
• SPACER, Stroke limit
• WASHER, Rod spacer
• SPRING, Inner
• SPRING, Outer
• SPACER, Mounting
*
112274
AR
SECTION 6, Page 74
Description
KIT, Seal repair
119153
Figure 6.3-10B. Disc Brake Cylinder Assembly
(Model 8831E with Serial Number 36840 and Above) (Model 8841E with Serial Number 41671 and Above)
7
8
9
10
11
12
6
1
5
2
3
4
M120412AF
Index
No.
Skyjack
Part No.
Qty.
A
120412
-
CYLINDER ASSEMBLY, Disc brake
1
*2
3
4
5
6
*7
8
*9
10
11
12
120631
109597
120409
109573
109604
109603
116364
120630
120632
111803
120411
109579
1
1
1
1
1
1
1
1
1
1
1
2
• ROD, Brake cylinder
• WIPER, Brake rod
• SPACER, Stroke limit
• SPRING, Outer
• SPRING, Inner
• SEAL, Piston
• PISTON
• O-RING, Piston
• NUT, Hex 7/16-20
SPACER, Mounting
*
112274
AR
Description
Kit, Seal Repair
119153
SECTION 6, Page 75
AM
Figure 6.3-11. Rear Drive Axle Assembly
9
18
19
10
11
17
12
15
13
16
20
15
21
14
6
22
23
24
25
8
8
26
7
27
6
5
3
4
1
2
M1029AA
SECTION 6, Page 76
119153
Figure 6.3-11. Rear Drive Axle Assembly
Index
No.
-
-
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Skyjack
Part No.
Qty.
115821
115729
113888
108394
113926
117130
113880
113881
113882
$
$
$
113886
113885
113914
113884
113913
113883
113920
113921
109137
109137
113925
113924
113919
113916
113918
113915
113917
113889
113912
-
-
1
1
1
1
1
AR
1
1
2
4
1
1
1
1
1
1
4
2
1
1
16
16
16
2
2
2
2
2
AR
AM
Description
MODIFIED AXLE ASSEMBLY, Rear drive (5.13 ratio)
• AXLE ASSEMBLY, Rear drive (DANA #070AF512-51A)
• • PLUG, Cover carrier
• • COVER, Carrier
• • DIFFERENTIAL ASSEMBLY, (Detroit Locker)
• • DRIVE GEAR AND PINION ASSEMBLY
• • BEARING ASSEMBLY, Inner pinion (Includes item 4)
• • KIT, Pinion adjusting shim
• • SLINGER, Inner pinion
• • HOUSING W/BEARING CAPS, Rear drive axle
• • • CAP, Differential bearing
• • • BOLT, Differential bearing cap
• • NUT, Pinion
• • WASHER, Pinion nut
• • YOKE ASSEMBLY, End
• • SEAL, Pinion
• • SLINGER, Inner pinion bearing
• • BEARING ASSEMBLY, Outer pinion
• • NUT, Spindle
• • WASHER, Spindle
• • SHAFT, Flanged axle LH (shown)
• • SHAFT, Flanged axle RH (opposite)
• • NUT, Stud
• • ADAPTER, Stud nut
• • STUD, Axle hub
• • BEARING ASSEMBLY, Outer wheel
• • HUB, Wheel
• • BEARING ASSEMBLY, Inner wheel
• • SEAL, Hub
• • BEARING ASSEMBLY, Differential
• • KIT, Differential shim
119153
SECTION 6, Page 77
Figure 6.3-12. Battery Roll-out Tray Assembly
8
19
3
21
26
13
1
5
10 9
6
16
2
14
25
18
12
11
30
15
17
28
29
27
7
4
20
22
24 23
M1074AA
SECTION 6, Page 78
119153
Figure 6.3-12. Battery Roll-out Tray Assembly
Index
No.
Skyjack
Part No.
1
115220
102780
2
119746
3
115404
4
111351
116621
5
103232
6
103055
7
(Ref.)
102781
103864
111534
103855
104000
8
117276
9
119815
119364
103068
120112
123780
123779
10
119915
11
119967
12
109694
13
119827
14
(Ref.)
15
119974
16
109123
17
(Ref.)
18
117261
123819
19
117262
123821
20
117260
123818
21
117263
123820
Qty.
1
1
1
1
4
AR
2
2
1
1
3
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
-
1
1
1
-
1
1
2
2
1
1
2
2
Description
WELDMENT, Battery roll-out tray
• LATCH, Battery tray
WELDMENT, Battery box
GUARD, Battery tray
ROLLER, Battery tray
• SHIM, 7/8” x 1-3/16 x 1/16” thk
PIN, Clevis 1/2” x 1-3/4” lg.
PIN, Hitch Clip 1/8” x 2-1/4” lg.
LATCH ASSEMBLY, Front cover
• LATCH, Front cover (blue spring)
• • BOLT, Hex-hd 5/16”-18 x 1-1/2” lg.
• KNOB, Latch
• • BOLT, Hex-hd 1/4”-20 x 1/2” lg.
COVER, Battery tray
BOX, Fuse holder
• FUSE, 400 amp (main power)
• INSULATOR, Fuse
• CABLE, Fuse
• STRAIN RELIEF MODIFICATION (EE Rated)
• REDUCER, Bushing (EE Rated)
LABEL, Fuse
LABEL, Battery disconnect
GROMMET, Rubber
PLATE, Battery disconnect
CONNECTOR ASSEMBLY
LABEL, Lock out here
HOLDER, Cable
HANDLE, Battery disconnect
PLYWOOD, 3/8” x 10-1/8 x 28-1/2”
PLYWOOD, 3/8” x 10-1/8 x 28-1/2” (EE Rated)
PLYWOOD, 3/8” x 9-1/2 x 28-1/2”
PLYWOOD, 1/4” x 13-1/4” x 28-1/2” (EE Rated)
PLYWOOD, 3/8” x 24-1/4” x 28-1/2”
PLYWOOD, 3/8” x 24-1/4” x 28-1/2 (EE Rated)
PLYWOOD, 1/4” x 10-1/2 x 24-1/4”
PLYWOOD, 1/4” x 10-1/2 x 24-1/4” (EE Rated)
119153
SECTION 6, Page 79
Figure 6.3-12. Battery Roll-out Tray Assembly (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
22
106552
8
23
(Ref.)
6
-
24
(Ref.)
-
-
25
116494
2
26
123367
1
122834
1
122998
1
122999
1
122835
AR
122836
AR
27
112307
1
103886
2
28
112308
1
103886
2
29
116133
1
116136
1
116135
3
112378
1
30
116132
1
116136
1
116135
1
112378
1
BATTERY, 6 Volt (Trojan U-2500)
CABLES, Battery
BOOTS, Battery
BUMPER, Vibrations
CARRIER ASSEMBLY, Hose (18 links)
• BRACKETS, Carrier Assembly Mounting (2 Pieces)
• • BRACKET, Carrier Assembly Mounting (Male)
• • BRACKET, Carrier Assembly Mounting (Female)
• SEPARATOR, E-Chain
• LINK, Hose carrier
Use CARRIER ASSEMBLY #111395 (17 links) or 113852 (18 Links) for
Machines with Serial #36959 (8831) or 42098 (8841) and below.
• Uses Brackets #113853
• Uses SEPARATOR #114199
• Uses LINK #113860
LATCH, LH Engine
• BOLT, Hex-hd 5/16-18 x 1-1/2” lg.
LATCH, RH Engine
• BOLT, Hex-hd 5/16-18 x 1-1/2” lg.
HANDLE, LH
• SCREW, Shoulder 1/4” x 3/8”
• WASHER, Brass 17/64” ID x 15/32” OD
HANDLE, RH
• WASHER, Brass 17/64” ID x 15/32” OD
119153
SECTION 6, Page 81
Figure 6.4-1. Hydraulic Oil Tank/Charger Cabinet Assembly
2
4
5
3
1
6
8
9
7
M1077AA
SECTION 6, Page 82
119153
Figure 6.4-1. Hydraulic Oil Tank/Charger Cabinet Assembly
Index
No.
Skyjack
Part No.
1
120242
120252
109779
2
108464
103628
101541
111944
3
108463
103628
101541
111944
4
116052
124296
5
(Ref.)
101632
103472
103999
103978
6
(Ref.)
7
103090
8
120253
9
120199
Qty.
1
1
1
1
AR
1
AR
1
AR
1
AR
AR
1
1
-
2
2
2
2
-
-
AR
2
1
Description
WELDMENT, Hydraulic oil tank cabinet (Machines w/o scissor guards)
WELDMENT, Hydraulic oil tank cabinet (Machines with scissor guards)
WELDMENT, Hydraulic oil tank cabinet (EE Rated)
DOOR, Oil tank access
• SEAL, Door (102” total)
• HANDLE W/LOCK, Recessed
• • KEY, Door #CH501
DOOR, Battery charger access
• SEAL, Door (88” total)
• HANDLE W/LOCK, Recessed
• • KEY, Door #CH501
CABLE, Door stop (18”)
CABLE, Door stop (13.25”)
TANK ASSEMBLY, Hydraulic oil
• BOLT, Hex-hd 3/8”-16 x 3/4” lg.
• NUT, Hex 3/8”-16
CHARGER ASSEMBLY, Battery
CONDUIT, Convoluted (edge protection) 57” lg.
SUPPORT, Battery charger
COVER, Charger (splash guard)
119153
SECTION 6, Page 83
Figure 6.4-2. Hydraulic Oil Tank Assembly
Earlier Models
7
8
6
9
5
10
11 12
3
4
2
1
14
13
M1067AA
Later Models
8
6 15
9
12
11
3
4
1
2
10
13
M11077AA
SECTION 6, Page 84
119153
AN
Figure 6.4-2. Hydraulic Oil Tank Assembly
Index
No.
Skyjack
Part No.
Qty.
A
B
132083
116753
-
-
1
132180
1
114337
1
2
119309
80 L
3
103236
1
4
124311
2
5
113118
1
6
132127
1
102694
1
103959
6
7
114331
1
103964
14
8
112187
1
9
109568
1
104254
1
103857
2
104000
2
103980
2
123022
1
123021
1
123020
1
122973
1
121571
1
122969
3
122968
1
10
110517
1
11
102918
1
12
103320
1
13
117701
1
103339
1
14
(Ref.)
-
15
132128
1
Description
TANK ASSEMBLY, Hydraulic Oil (Later Models)
TANK ASSEMBLY, Hydraulic Oil (Earlier Models)
• WELDMENT, Hydraulic oil tank, A
• WELDMENT, Hydraulic oil tank, B
• OIL, Hydraulic (Liters)
• GAUGE ASSEMBLY, Oil level temp
• INSERT, Threaded (Not Needed If Ordering Gauge Assembly)
• NECK, Side filler, B
• CAP, Filler Assembly w/ Vent, A
• CAP W/GASKET, Filler/breather, B
• COVER , Hydraulic tank, B
• FITTING, 3/4” Hose barb
• FILTER ASSEMBLY, Return
• • ELEMENT, Filter
• • BOLT, Hex-hd 1/4”-20 x 1” lg.
• • NUT, Hex 1/4”-20
• • SEAL, Filter Assembly
• • COVER, Filter Assembly
• • SPRING, Filter Assembly
• • CASTING, Aluminum
• • SCREW, Set
• • BOLT, Washer Combined
• • CASING, Filter
• FITTING, Elbow 90° 1/2P-#6
• HOSE, Tank 1” x 10” lg.
• CLAMP, #16 Gear
• PLUG, Drain Plug 3/4” NPT, A
• PLUG, Drain Plug 3/4” NPT, B
LABELS
(Refer to Figure 6.8-2)
• SCREEN, Filler Neck (Inside), A
119153
SECTION 6, Page 85
AN
Figure 6.4-3. Hydraulic Hose Connections - Hydraulic Electric/Tray
6
7
8
5
10
9
4
11
12
3
2
2
13 14 15
16
2
18
17
1
M120034AD_1
SECTION 6, Page 86
119153
Figure 6.4-3. Hydraulic Hose Connections - Hydraulic Electric/Tray
Index
No.
Skyjack
Part No.
1
(Ref.)
2
(Ref.)
3
110498
4
(Ref.)
5
120038
6
103069
7
119748
8
107271
9
120036
10
120141
11
(Ref.)
12
102854
13
114402
14
108478
15
103002
16
146119
17
120504
18
104402
Qty.
1
-
1
-
1
1
-
1
2
1
1
1
1
1
-
1
1
1
1
1
1
1
AN
Description
MOTOR/PUMP ASSEMBLY, Hydraulic
BASE HOSE ASSEMBLIES, Hydraulic
FITTING, Reducing Connector #6-#8
MANIFOLD ASSEMBLY, Auto reset brake
HOSE ASSEMBLY, Auto reset brake to main manifold
MANIFOLD, Emergency lowering
VALVE, Emergency lowering
HOSE ASSEMBLY, Emergency lowering block to hydraulic tank
HOSE ASSEMBLY, Emergency lowering block to main manifold
MANIFOLD ASSEMBLY, Main
CLAMP, #12
CLAMP, Hose
FITTING, Brass (1/2 NPT-3/4 Barb)
FITTING, Swivel connector (#8-#8)
FITTING, Hose barb elbow to SAE straight thread
HOSE ASSEMBLY, Small pump to main manifold
FITTING, Connector #6-#8
119153
SECTION 6, Page 87
Figure 6.4-4A. Battery Charger Assembly - Mac #BA1001
9
6
7
11
4
13
14
12
5
3
1
2
8
10
15
M1086AA
SECTION 6, Page 88
119153
Figure 6.4-4A. Battery Charger Assembly - Mac #BA1001
Index
No.
Skyjack
Part No.
Qty.
Description
A
117393
-
CHARGER ASSEMBLY, Battery (MAC #BA1001) (North American)
48VDC, 25A, 120VAC, 60 Hz
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
• AMMETER, 0-30
• CAPACITOR, 10MFD 440VAC,
• CORD ASSEMBLY, D.C.
• • PLUG, 50 Amp gray
• DIODE, 70 Amp
• FUSE HOLDER, A.C.
• • FUSE, 25 Amp A.C.
• RELAY, 120 VAC/30 Amp,
• RECTIFIER ASSEMBLY,
• STRAIN RELIEF
• TRIAC
• TRANSFORMER, 48 VDC 23 Amp 120 VAC/60Hz,
• CONTROL TRANSFORMER
• TRANSFORMER, Control
• VARISTOR
• CONTROL CIRCUIT, 48VDC 120V VAC,
• STOP SWITCH, N.O.
CABLE ASSEMBLY, Charger A.C.,
• PLUG, 15A Male
• RECEPTACLE, 20 Amp Female
• CABLE, 14/3
• LANYARD, 6” lg.
108554
708974
708976
103364
108556
108558
700688
115315
700689
700690
108562
700691
108564
111907
700692
708975
110857
700530
700635
700597
105269
105807
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
8”
1
119153
SECTION 6, Page 89
Figure 6.4-4B. Battery Charger Assembly (Motor Appliance #BA1045 and #BA961)
14
11
1
4
13
16
10
3
6
7
12
18
8
2
5
9
M120075AA
SECTION 6, Page 90
119153
Figure 6.4-4B. Battery Charger Assembly (Motor Appliance #BA1045 and #BA961)
Index
No.
Skyjack
Part No.
Qty.
A
120075-AA
2
B
120075-AE
2
C
120075-AN
2
1
119157
2
2
119143
2
3
119151
1
119183
1
4
119160
1
5
119152
1
103206
1
6
117177
1
7
117178
1
8
119162
2
9
119161
1
10
119148
1
119150
2
119185
1
119186
2
11
119155
1
12
119156
1
13
119149
1
14
119145
1
119184
1
15
119144
1
16
119159
1
17
119187
1
119146
1
18
120790
1
120791
1
120789
1
119188
1
Description
CHARGER ASSEMBLY, Battery (BA1045) (ANSI/SIA , CSA and CE)
(Machine Serial Number 98283227 and Above)
CHARGER ASSEMBLY, Battery (BA1045) (CE)
(Machine Serial Number 98176386 thru 98176391)
(Machine Serial Number 98186812 thru 98186829)
CHARGER ASSEMBLY, Battery (BA961) (ANSI/SIA AND CSA)
(Machine Serial Number 98.....)
• CAPACITOR ASSEMBLY, 400V, A & B
• CIRCUIT BREAKER, 10 Amp
• CONTROL CIRCUIT, 48V21A, A & B
• CONTROL CIRCUIT, 48V17A, C
• CONTROL, AC2/48V, A & B
• CORD ASSEMBLY, DC
• • PLUG, 50 Amp (red)
• FUSE, 80 Amp DC, A & B
• HOLDER, Fuse, A & B
• INSULATOR, Relay
• PLATE, Mounting
• RECTIFIER ASSEMBLY, A & B
• • SCR, 35 Amp
• RECTIFIER ASSEMBLY, C
• • SCR, 20 Amp
• RELAY, 24VDC 30A, A & B
• RELAY, 120VAC, A & B
• SHUNT ASSEMBLY
• TRANSFORMER, Main 48V20A, 120/240V, 50/60Hz, A & B
• TRANSFORMER, Main 48V17A, 120/240V, 50/60Hz, C
• VARISTOR ASSEMBLY
• TRANSFORMER, Control 230V16A, A & B
• SOCKET, AC Cord (C19,C20), A & B
• SOCKET, AC Cord (C13, C14), C
• CORD, 220V AC (C19.C20) (Europe)
• CORD, 110/220V AC (C19, C20) (U.K.)
• CORD, 120V AC (C19,C20) (North America)
• CORD, 120/220V AC (C13, C14)
119153
SECTION 6, Page 91
Figure 6.4-4C. Battery Charger Assembly - Bycan 4825U
18
12
15
9
14
3
4
5
1
16
13
8
7
11
6
2
17
10
M1079AC
SECTION 6, Page 92
119153
Figure 6.4-4C. Battery Charger Assembly - Bycan 4825U
Index
No.
Skyjack
Part No.
Qty.
A
122367
-
CHARGER ASSEMBLY, Battery
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
121534
121564
121536
121537
121538
121539
121540
121541
121542
121543
121565
121545
121546
121566
115391
121567
120789
120790
120791
120820
120821
123764
1
1
1
1
2
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
• HOUSING, Charger
• TRANSFORMER
• CAPACITOR
• HEATSINK
• RECTIFIER
• BLOCK, TERMINAL
• FUSE, LINK
• SOCKET, AC Cord
• RELAY, 24V DC
• AMMETER, 50A DC
• CONTROLLER ASSEMBLY
• RELAY, 240 V
• CIRCUIT BREAKER, AC
• FAN, Cooling
• PLUG, Charger cutout
CORD, DC Battery
CORD, AC 120V
CORD, AC 220V
CORD, AC No Plug
CORD, AC 120V (U.K.)
CORD, AC 220V (U.K.)
CLIP, Single G6 #10 screw
Description
119153
SECTION 6, Page 93
Figure 6.4-4D. Battery Charger Assembly
13
14
12
18 19
1
16
20 21
17
15
2
3
11
4
9
5
8
22
6
7
10
M10734AA
SECTION 6, Page 94
119153
Figure 6.4-4D. Battery Charger Assembly
Index
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Skyjack
Part No.
Qty.
129685
130096
130092
127155
130091
127164
130093
129688
127171
127154
130097
127158
130089
127156
130094
103206
115391
130090
103856
103995
104000
103980
120789
120790
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
1
1
Description
CHARGER, 48 V DC
• CONTROL BOARD, Main
• BOARD, Main PC (2)
• FUSE, Internal
• BOARD, Main PC (1)
• SCREWS, Front and Rear Plates
• PLATE, Front
• LABEL, Front Plate
• RELAY, Power ON
• • RELAY, Interlock
• GASKET, Front or Rear Plate
• STRAIN RELIEF, Rear Plate
• CABLE, Output
• CABLE, Interlock
• PLATE, Rear
CONNECTOR, Battery Red 50 Amp
PLUG, Charger Cutout
AC Inlet
BOLT, 1/4” - 20 x 3/4 Grade 5
WASHER, 1/4” Flat
WASHER, 1/4” Lock
NUT, 1/4”-20 Grade B
CORD, Charger Cord 120V
CORD, Charger Cord 220V (CE)
119153
SECTION 6, Page 95
Figure 6.5-1. Hydraulic/Electric Cabinet Assembly
24
25
3
26
4
5
6
2
1
5
27
7
32
8
9 10
11
12
23
13
14
15
16
17
18
20
19
21
22
30
29
31
28
M10036AB
SECTION 6, Page 96
119153
Figure 6.5-1. Hydraulic/Electric Cabinet Assembly
Index
No.
Skyjack
Part No.
Qty.
Description
1
119976
1
119986
1
124408
1
2
114377
1
3
102657
108328
1
120094
10
4
102451
1
5
111181
2
6
102853
1
7
115573
1
8
(Ref.)
1
-
103855
2
104000
2
103995
2
9
120628
1
10
111814
1
11
116052
2
124296
2
12
117880
1
114866
1
13
120031
1
103855
2
104000
2
14
(Ref.)
1
-
116107
4
103404
4
103996
4
15
120039
1
16
(Ref.)
1
-
103887
2
103404
2
103996
2
17
700224
1
700669
1
106052
1
700668
1
109174
1
109175
8
WELDMENT, Hydraulic/electric cabinet
(For machines without Scissor Guard Option)
(For machines with Scissor Guard Option)
(For EE Rated machines)
PLUG, 1/2” (CE)
LABEL, Platform up/down (ANSI/SIA and CSA)
LABEL, Platform up/off/down (CE)
BOLT, Machine #10-32 x 5/8” lg.
LABEL, Plat/base Select
GUARD, Toggle
SWITCH, Toggle up/down
SWITCH, Toggle platform/base select (ANSI/SIA AND CSA)
BLOCK, Emergency lowering valve manifold
• BOLT, Hex-hd 1/4”-20 x 1/2” lg.
KEY SWITCH, Emergency stop
LABEL, Emergency stop
CABLE, Door stop (18”)
CABLE, Door stop (13.25”)
TILT SWITCH ASSEMBLY, 2.5° x 4.5°
• FUSE, 1 amp
BRACKET, Tilt switch
• BOLT, Hex-hd 1/4”-20 x 1/2” lg.
• STUD, 5/16”-18 x 1-1/2” lg.
SPACER, Manifold mounting
MANIFOLD ASSEMBLY, Brake
• BOLT, Hex-hd 5/16”-18 x 3/4” lg.
PUMP/MOTOR ASSEMBLY, Hydraulic
• PUMP, Hydraulic
• COUPLING
• MOTOR, 48 Volt
• • BRUSH (Set of 8)
• • SPRING, Brush
119153
SECTION 6, Page 97
Figure 6.5-1. Hydraulic/Electric Cabinet Assembly (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
103887
4
103996
8
103404
4
700523
4
123145
1
700669
1
123355
1
18
108462
1
124418
1
101541
1
103628
AR
19
108461
1
124420
1
101541
1
103628
AR
20
117618
1
112601
1
124541
1
103472
1
103999
1
111921
1
21
119358
2
120093
3
22
119894
2
23
(Ref.)
1
103864
4
103404
4
102034
4
24
123219
1
25
123220
1
26
123217
1
27
123218
1
28
117293
1
29
117363
1
30
(Ref.)
-
-
31
130224
1
130240
1
127178
1
32
132792
AR
132793
AR
• BOLT, Hex-hd 5/16-18 x 3/4” lg.
• BUSHING, Rubber
PUMP/MOTOR ASSEMBLY, Hydraulic (EE Rated)
• PUMP, Hydraulic
• MOTOR, 48 Volt
DOOR, Electrical panel access
DOOR, Electrical panel access (EE Rated)
• HANDLE, Latch
• SEAL, Foam (88” total)
DOOR, Hydraulic component access
DOOR, Hydraulic component access (EE Rated)
• HANDLE, Latch
• SEAL, Foam (102” total)
INSULATOR, Ground
NUT, Metal flanged lock 3/8” - 16
SCREW, Set 3/8” -16 UNC x 1 1/2”
Order Both The Flanged Nut & Set Screw for Machines with
Serial #’s 42303 (8841E), 37123 (8831E) and Below.
WASHER, Flat 3/8”
WASHER, Lock 3/8”
BOLT, Hex-hd 3/8”-16 x 1/2”
LIGHT, Work (with auto shut off)
CONNECTOR , 2 Pin PCB
PANEL ASSEMBLY, Base control/electrical
(For components, refer to Figure 6.6-1.)
• BOLT, Hex-hd 5/16”-18 x 1” lg.
• NUT, Hex 5/16”-18
COVER, Gasket
GASKET, SJ-800E
COVER, Gasket
GASKET, W/O P.D. & OUTR.
BOX, Manual
PLATE, Manual box mount
LABEL, Manual Box
LIGHT ASSEMBLY, Cabinet
• LIGHT BULB, 24V
• LENS
CLAMP, Cable Bundle (7/8”)
CLAMP, Cable Bundle (1 3/8”)
119153
SECTION 6, Page 99
Figure 6.5-2. Auto Reset Brake Manifold Assembly
8
3
2
1
7
4
5
6
M1018AA
Index
No.
Skyjack
Part No.
Qty.
A
(Ref.)
MANIFOLD ASSEMBLY, Auto reset brake
1
2
3
4
5
6
7
8
116586
110554
102659
117189
103605
110652
113752
103070
1
1
1
1
1
1
1
1
• BLOCK, Manifold, Auto reset brake
• FITTING, Run tee #8orb-#8-#8
• FITTING, Connector #8orb-#8
• VALVE, N.O. (Brake)
• COIL, 24 Volt
• PUMP, Cavity hand
• VALVE, Auto reset
Description
119153
SECTION 6, Page 101
Figure 6.5-3. Main Manifold Assembly
14
21
31
20
19
23 30
18
12
17
14
30 22
24
15
5 16
25
14
26
13
27
14
8
10 5
12
3
2
5
1
9
31
11
7
5
4
6
14
29
5
28
M10307AB
SECTION 6, Page 102
119153
Figure 6.5-3. Main Manifold Assembly
Index
No.
Skyjack
Part No.
Qty.
A
118804
-
1
118803
1
2
104567
1
3
104567
1
4
123853
1
5
105610
5
6
114365
1
7
104412
1
8
114578
1
9
104412
1
10
104412
1
11
112366
1
12
122420
2
122428
1
122385
1
114521
1
13
104534
2
14
115320
9
15
120756
1
16
104412
1
17
104567
2
18
104567
1
19
106554
1
20
701194
1
21
103069
4
22
103614
1
107439
2
103920
4
128798
1
128317
1
128320
2
103920
4
23
103614
1
107439
2
103920
4
128798
1
128317
1
128320
2
103920
4
24
104567
1
25
104567
1
26
116725
1
27
103070
1
28
112187
1
29
102659
2
30
(Ref.)
-
104345
1
104409
1
31
103069
2
Description
• BLOCK, Main manifold
• VALVE, Check (small pump)
• VALVE, Check (large pump)
• ORIFICE, Dump Valve
• COIL, 24 Volt
• VALVE, #10 N.O. (system dump)
• VALVE, #8 N.C. (lift)
• FITTING, Elbow 90°
• VALVE, #8 N.C. (brake release)
• VALVE, #8 N.C. (gearbox holding)
• FITTING, Elbow 90° #12orb-#8
• ASSEMBLY, Quick Disconnect (Pressure)
Order Entire Assembly for Machines with Serial # 36924 (8831),
41960 (8841) and below.
• • FITTING, #6-#6
• • COUPLER, Quick
• • CAP, Dust
• VALVE, Relief (system/gearbox)
• PLUG, Manifold #8orb
• ORIFICE, Lowering
• VALVE, #8 N.C. (lowering)
• VALVE, Check (lift)
• VALVE, Check (brake)
• FITTING, Swivel
• PRESSURE SWITCH, Brake
VALVE ASS’Y, Vickers 24 Volt (replace with Hytos) (Gearbox shift)
• COIL, 24V
VALVE ASS’Y Hytos 24 Volt (replacement for Vickers)
• VALVE ASSEMBLY, Directional 24V spool
• • COIL, 24V Spool valve
VALVE ASS’Y, Vickers 24 Volt (replace with Hytos) (Steer)
• COIL, 24V
• VALVE, Check (Lift)
• VALVE, Check (System)
• ORIFICE, .067 diameter (Emergency lowering)
• FITTING, Hose barb #12orb-3/4
CONNECTORS, Electrical valve
• CONNECTOR, Gray
FITTING, Straight (If Equipped with Outrigger Option)
119153
SECTION 6, Page 103
Figure 6.6-1. Base Control/Electrical Panel Assembly
1
2
22
3
23 21
4
20 19
18
5
6
7
10
8
9 20
11
12
14
16
13
15
17
M10067AA
SECTION 6, Page 104
119153
Figure 6.6-1. Base Control/Electrical Panel Assembly
Index
No.
Skyjack
Part No.
Qty.
1
119972
1
103887
3
103984
3
2
(Ref.)
1
-
3
(Ref.)
1
-
4
(Ref.)
1
-
5
(Ref.)
-
6
103336
1
7
117326
2
8
117325
1
9
801347
1
103964
4
10
118815
1
11
119168
1
124823
1
12
119469
1
13
119169
1
124824
1
14
119170
1
124825
1
15
118944
1
16
120136
1
103014
1
119507
2
17
120137
1
120133
2
119544
2
18
120020
1
19
119167
1
123140
1
20
(Ref.)
-
21
119171
1
700776
1
119172
1
22
133759
1
23
119166
1
AN
Description
PANEL, Base control electrical
• BOLT, Hex-hd 5/16”-18 x 3/4” lg.
• NUT, Lock 5/16”-18
BOARD, Main control
FLASHER, Flashing Light
(For components, refer to Figures 6.6-6 & 6.6-7)
BOARD, Outriggers
LABELS
HOURMETER
CIRCUIT BREAKER, 20 Amp
CIRCUIT BREAKER, 15 Amp
CONVERTOR, Sevcon
MODULE, Power delay
CONTACTOR, Steer (24V)
CONTACTOR, Steer (24V) (EE Rated)
FUSE, Contactor 200 Amp
CONTACTOR, Line (24V)
CONTACTOR, Line (24V) (EE Rated)
CONTACTOR, Forward/reverse (24V)
CONTACTOR, Forward/reverse (24V) (EE Rated)
RELAY, 24V (EE Rated)
WELDMENT, Contactor bracket
GROMMET, 7/8” Rubber
RECEPTACLE, 1/4” turn stud
COVER, Contactor Clear
• STUD, 1/4” turn
• RETAINER, Stud
PLATE, Heatsink
CONTROLLER, MOS-90
CONTROLLER, Traction (EE Rated)
CABLE ASSEMBLIES
TACHOMETER BOARD ASSEMBLY
• FUSE, 6.3 amp
• FUSE, 20 amp
BOARD ASSEMBLY, Moisture protection P.C.B.
PLATE, Tach card P.C.B. Mounting
119153
SECTION 6, Page 105
Figure 6.6-2. Sevcon Battery Cable Layout
3
2
1
14
13
12
4
5
6
15
17
18 19
11
16
20
8
9
10
7
M1073AB
SECTION 6, Page 106
119153
Figure 6.6-2. Sevcon Battery Cable Layout
Index
No.
Skyjack
Part No.
1
(Ref.)
2
(Ref.)
3
(Ref.)
4
120116
5
120117
6
120118
7
124512
103206
103754
124514
124515
124516
8
120119
9
(Ref.)
10
122567
11
(Ref.)
12
(Ref.)
13
105601
105600
14
122566
15
124521
16
103068
17
120302
18
119815
19
119915
20
103024
Qty.
-
-
-
-
-
1
1
1
1
2
AR
AR
1
1
1
-
-
1
1
-
1
-
1
1
1
1
1
1
1
1
1
Description
TRACTION MOTOR AND CABLE ASSEMBLIES
CONTACTORS
(For components, refer to Figure 6-6-1)
CONTROLLER
CABLE ASSEMBLY, Controller to Directional Contactor
CABLE ASSEMBLY, Controller to Directional Contactor
CABLE ASSEMBLY, Controller to Line Contactor
HARNESS ASSEMBLY, Charger
• CONNECTOR, Red 50 Amp Battery
• HEATSHRINK, 1/2” Clear
• CABTIRE, 10/4 SOW
• TERMINAL, 6 GA x 1/4”
• TERMINAL, 6 GA x 3/8”
CABLE ASSEMBLY, Controller to Insulator
INSULATOR
CABLE ASSEMBLY, Insulator to Pump
DISCONNECT ASSEMBLY
PUMP AND MOTOR ASSEMBLY
BOOT, Black Battery
BOOT, Red Battery
CABLE ASSEMBLY, Pump to Contactor
CABLE ASSEMBLY, Fuse to Contactor
INSULATOR, Fuse
FUSE, 50 AMP
BOX, Fuse
LABEL, Fuse
CLIP, Single G8
119153
SECTION 6, Page 107
Figure 6.6-3. Panel Layout
5
4
6
3
7
8
2
9
1
10
11
12
13
10
14
15
16
17
10
8
18
19
4
20
MLP-1076AA
SECTION 6, Page 108
119153
Figure 6.6-3. Panel Layout
Index
No.
Skyjack
Part No.
Qty.
1
119722
1
2
102921
AR
3
(Ref.)
1
-
4
108589
9
5
(Ref.)
2
-
6
(Ref.)
1
-
7
(Ref.)
1
-
8
(Ref.)
1
-
9
120658
AR
10
120045
1
119906
1
119897
1
119895
1
104345
2
104409
2
119131
1
11
(Ref.)
-
12
120099
1
119897
1
13
(Ref.)
-
14
(Ref.)
1
-
15
118815
1
119897
1
103962
2
16
119724
1
17
120147
1
125257
119907
1
18
(Ref.)
1
-
19
(Ref.)
1
-
20
120298
1
119908
1
107711
1
103568
1
103570
1
Description
BOARD, Main control
DIODE
HARNESS ASSEMBLY, Devices
(For Components, Refer to Figure 6-41)
RELAY, 24 V
LIGHT, Work
HARNESS, Center Tap
HARNESS, Power Deck
HARNESS ASSEMBLY, Proximity/Tach
FUSE, 10 Amp
HARNESS ASSEMBLY, Main manifold, Tilt And Base Control
• CONNECTOR, P. C. Board 14-pin
• CONNECTOR, P.C. Board 5-pin
• CONNECTOR, Solenoid (gray)
• CONNECTOR, Solenoid (black)
• KIT, 4 Pole plug Tilt switch
HARNESS, Overload/Aux. Power (Reserved For Future Use)
HARNESS, Power
HARNESS, Platform Limits (Reserved For Future Use)
HARNESS ASSEMBLY, Control Cable
CABLE ASSEMBLY, Power module
• CONNECTOR, P.C. Board
• • BOLT, Machine #10-32 x 1/2” lg.
BOARD, P.C. Outriggers (option)
HARNESS ASSEMBLY, Electrical panel
HARNESS ASSEMBLY, Electrical panel (EE-Rated)
HARNESS ASSEMBLY, Outrigger manifold
CABLE ASSEMBLY, Outrigger Control Box
HARNESS ASSEMBLY, Outrigger limit switch
• CONNECTOR ASSEMBLY, 5 pole female
• • INSERT, Female
119153
SECTION 6, Page 109
Figure 6.6-4. Proximity And Tachometer Harness
10
9
5
8
7
PUMP PROXY
PIN 1 - 10 BROWN
PIN 2 - 02 BLUE
PIN 3 - 32 BLACK
PIN 4 - N/U
6
4
3
DRIVE PROXY
PIN 1 - 10 BROWN
PIN 2 - 02 BLUE
PIN 3 - N/U
PIN 4 - 33 BLACK
2
11
1
ML1F-1063AA
Index
No.
Skyjack
Part No.
1
(Ref.)
2
(Ref.)
3
116758
4
119130
5
120337
6
119131
7
120355
120356
8
102888
9
119894
10
119898
11
120748
SECTION 6, Page 110
Qty.
-
-
-
-
2
2
1
2
1.5”
1.5”
96”
1
1
28”
Description
GENERATOR ASSEMBLY
GEARBOX ASSEMBLY
SWITCH, Proximity (pump/drive)
KIT, 4 Pole Receptacle
HARNESS, Proximity/Tachometer
• KIT, 4 Pole Plug
• HEATSHRINK, 3/16” Yellow
• HEATSHRINK, 3/16” Blue
• CABLE, 16/10
• CONNECTOR, PC Board 2 Pin
• CONNECTOR, PC Board 6 pole
• PROTECTION, 1/2” Cable
119153
Figure 6.6-5. Control Cable Harnesses
1
2
8
9
7
6
5
4
3
10
11
ML1F-1070AA
Index
No.
1
2
3
4
5
6
7
8
9
10
11
Skyjack
Part No.
Qty.
120370
120074
102887
102887
119360
114467
120644
119359
114469
120069
102887
120065
120644
114467
119907
1
1
648”
768”
1
1
2
1
1
1
42”
1
1
1
1
Description
CABLE ASSEMBLY, Scissor control (Model 8831)
CABLE ASSEMBLY, Scissor control (Model 8841)
• CABLE, 16/15 (Model 8831)
• CABLE, 16/15 (Model 8841)
• HOUSING, 16 Pole Female
• INSERT, 16 Pole Female
• CONNECTOR, Strain Relief
• HOUSING, 16 Pole Male
• PLUG, 16 Pole Male
HARNESS, Panel Control
• CABLE, 16/15
• COUPLING, Base
• CONNECTOR, Strain Relief
• INSERT, 16 Pole Female
• CONNECTOR, PC Board
119153
SECTION 6, Page 111
Figure 6.6-6. Devices Connector Layout A
12
11
AN
10
9
13
8
14
15
3
2
17
16
2
4
5
6
18
1
7
ML1F-1069AC
SECTION 6, Page 112
119153
Figure 6.6-6. Devices Connector Layout A
Index
No.
Skyjack
Part No.
1
108102
2
120102
3
(Ref.)
103743
132793
103111
4
121838
121477
121533
103111
103743
5
103056
6
103255
7
121058
8
119905
9
110416
10
(Ref.)
119296
104698
104003
11
100967
12
119375
13
(Ref.)
14
115658
15
110428
16
110429
103958
110853
17
123180
123177
123178
120094
104003
104694
104185
18
123137
123133
120094
104003
104694
104185
123134
100648
Qty.
1
1
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
-
1
-
-
1
1
1
2
2
1
1
1
4
4
4
4
1
1
4
4
4
4
1
1
Description
BEACON, Rotating Amber (Optional)
BEEPER/LIGHT ASSEMBLY
• LIGHT ASSEMBLY
• • FLASHER, 12-24 Volt
• • CLAMP, Flasher
• • BULB, 24 Volt
• LIGHT ASSEMBLY, Flashing amber
• • LIGHT, Beacon
• • • LENS, Amber
• • • BULB, 24 Volt
• • FLASHER, 12-24 Volt (Located @ Panel)
• BEEPER, 7.5 - 16 Volt
• CABLE, 18/4 x 144” lg.
HORN, 24V
PIN, Limit Switch And Scissor End
SWITCH ASSEMBLY, Limit
• SWITCH, Limit (high speed cut-out)
CAM, Limit Switch
SWITCH, Limit (26 Ft. drive cut-out) (Optional)
SLIDER ASSEMBLY, Scissor
(For Components, Refer to Figure 6.2-1 & 6.2-2)
SWITCH, End-of-stroke limit
PLATE, Limit switch mounting
PLATE, Limit locking (top)
• BOLT, Machines 8-32 x .75” lg.
• BOLT, Flat-hd 1/4”-20 5/8” lg.
COVER Assembly, EE Rated flashing light
• COVER, Flashing Light
• BRACKET, Flashing Light
• BOLT, Machine #10-32 x 5/8”
• NUT, #10-32
• WASHER, #10 Flat
• WASHER, #10 Lock
COVER Assembly, EE Rated Rotating Beacon
• COVER, Rotating Beacon,
• BOLT, #10 - 32 x 5/8”
• NUT, #10 - 32 Grade B
• WASHER, Lock # 10 Nom
• BRACKET, Rotating Beacon,
• GROMMET
119153
SECTION 6, Page 113
Figure 6.6-7. Devices Connector Layout B
9
10
2
11
10
1
8
12
5
3
4
6
6
5
7
2
5
6
5
M11418AA
SECTION 6, Page 114
119153
Figure 6.6-7. Devices Connector Layout B
Index
No.
Skyjack
Part No.
Qty.
A
B
133826
133845
-
-
1
2
3
4
5
6
7
8
9
10
11
12
132295
103978
103472
103999
104694
121477
108102
103056
104003
104698
104185
129196
121058
103980
104000
103995
103856
114594
119752
126608
103255
120098
119905
120083
105359
114595
1
2
2
2
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
144”
1
1
2
1
1
Description
ASSEMBLY, Horn/light/beeper
ASSEMBLY, Horn/Rotating light/beeper
PLATE, Horn / light mount
• NUT, Hex Hd 3/8”-16 Gr. 5
• WASHER, Flat #10, A
LIGHT, Beacon 24V, A
BEACON, Rotating Amber 24 V, B
BEEPER, 7.5 - 16 VDC
• NUT, Hex Hd #10-32, A
• SCREW, Rnd Hd Machine #10-32 x 3/4”, A
• WASHER, Lock #10, A
• BOLT. Flat head SHCS #4-40 x 1/2”
HORN, 24 Volt
• NUT, Hex 1/4”-20
• BOLT, Hex Hd 1/4”-20 x 3/4” Gr. 5
TERMINAL, Male 18GA Pink
TERMINAL, 22 - 16GA #10 red ring
ASSEMBLY, Cabtire Beeper 18/4
• CABTIRE 18/4
CIRCUIT BREAKER, H. Meter, Volt Con. Ass’y
CONNECTOR, 13 Pin PC Board
SWITCH, Limit Ass’y
TERMINAL, Female 14-16GA Ins. Blue
TERMINAL, Female 18GA Pink
119153
SECTION 6, Page 115
Figure 6.7-1A. Hydraulic Outrigger Option - Leg Assembly
(Model 8831E with Serial No. 37314 and Below)(Model 8841E with Serial No. 42702 and Below)
7
8
4
9
11
10
12
13
6
5
4
3
14
2
1
15
ML1F-1014AB
SECTION 6, Page 116
119153
Figure 6.7-1A. Hydraulic Outrigger Option - Leg Assembly
(Model 8831E with Serial No. 37314 and Below)(Model 8841E with Serial No. 42702 and Below)
Index
No.
Skyjack
Part No.
1
118497
118496
118499
118500
2
106705
3
(Ref.)
101297
103999
4
118478
5
115656
116072
6
115652
103859
104000
7
102355
103855
103995
8
103091
9
113584
10
107712
11
116827
12
115658
13
116826
103962
103958
104694
104185
112249
14
118387
15
103909
103470
Qty.
2
2
2
2
4
4
-
12
12
8
2
2
4
8
16
4
16
16
4
4
4
-
4
4
4
16
8
16
16
8
4
4
4
Description
WELDMENT, Outrigger leg, LH rear
WELDMENT, Outrigger leg, RH rear
WELDMENT, Outrigger leg, RH front
WELDMENT, Outrigger leg, LH front
LABEL, Do not alter
CYLINDER ASSEMBLY, Outrigger
• BOLT, Hex-hd 3/8”-16 x 1-1/4” lg.
BUSHING, Limit switch mount
MOUNT, Limit switch LH (Lower)
MOUNT, Limit switch RH (Lower)
SWITCH, Limit
• BOLT, Hex-hd 1/4”-20 x 1-1/2” lg.
COVER, Outrigger hose
• BOLT, Hex-hd 1/4”-20 x 1/2” lg.
CABLE PROTECTION, 5/8” x 24” lg.
HEATSHRINK, 1/2” x 8”
CONNECTOR ASSEMBLY, 5 Pole male
(Replaces round connector by also ordering (1) connector #107711.)
MOUNT, Limit switch (Upper)
SWITCH, Limit (inside outrigger cross tube)
COVER, Limit switch (Upper)
• BOLT, Machine #8-32 x 1.2” lg.
• WASHER, Flat #10
• WASHER, Lock #10
• WASHER, Lock #8
SPACER, Outrigger
BOLT, Outrigger leg stop
119153
SECTION 6, Page 117
Figure 6.7-1B. Hydraulic Outrigger Option - Leg Assembly
(Model 8831E with Serial No. 37315 to 37406, & Model 8841E with Serial No. 42703 to 43044)
22
7
13
17
12
16
23
8
24
4
18
11
9
10
12
25
15
13
14
19 20
3
2
4
21
16
1
5
ML1F-1014AD
SECTION 6, Page 118
119153
Figure 6.7-1B. Hydraulic Outrigger Option - Leg Assembly
(Model 8831E with Serial No. 37315 to 37406, & Model 8841E with Serial No. 42703 to 43044
Index
No.
Skyjack
Part No.
1
118497
118496
118499
118500
2
106705
3
(Ref.)
101297
103999
4
118387
5
103909
103470
6
116826
103962
104694
104185
7
102355
103855
103995
8
103091
9
113584
10
107712
103567
103569
11
116827
103859
104000
103995
12
115658
13
124353
14
125233
15
112495
16
112601
17
124972
18
124356
19
103998
20
103472
21
124338
22
126499
23
112249
24
103986
25
104000
Qty.
Description
2
2
2
2
4
4
-
12
12
4
4
4
4
16
16
16
4
16
16
4
4
4
1
1
4
AR
AR
AR
4
1
1
2
2
1
1
1
1
1
4
8
2
2
WELDMENT, Outrigger leg, LH rear
WELDMENT, Outrigger leg, RH rear
WELDMENT, Outrigger leg, RH front
WELDMENT, Outrigger leg, LH front
LABEL, Do not alter
• BOLT, Hex-hd 3/8”-16 x 1-1/4” lg.
SPACER, Outrigger
BOLT, Outrigger leg stop
COVER, Limit switch (Upper)
• WASHER, Flat #10
• WASHER, Lock #10
COVER, Outrigger hose
• BOLT, Hex-hd 1/4”-20 x 1/2” lg.
CABLE PROTECTION, 5/8” x 24” lg.
HEATSHRINK, 1/2” x 8”
CONNECTOR ASSEMBLY, 5 Pole male
• HOUSING, Base
• INSERT, Male
MOUNT, Limit switch (Upper)
BOLT, Hex-hd 1/4”-20 x 1-1/2” lg.
WASHER, Lock 1/4”
WASHER, Flat 1/4”
SWITCH, Limit (inside outrigger cross tube)
BRACKET, Limit switch
ROD ASSEMBLY
BOLT, Hex head 1/4” - 20 x 3/8”
NUT, Hex head flange 3/8” - 16
CAP, Nut
SPRING, Compression
NUT, Hex head 3/8” - 16
WASHER, Flat 3/8”
CLIP, Plastic
SCREW, Machine 8 - 32 x 7/8”
WASHER, Lock #8
NUT, Hex 8 - 32
WASHER, Lock 1/4”
119153
SECTION 6, Page 119
Figure 6.7-1C. Hydraulic Outrigger Option - Leg Assembly
AO
9
6
13
10
12
11
14 15
16 25
17
18
19
20 21
22
17
12
26
15
25
24
23
1
13
4
27
L
28
8
5
29
30
3
7
6
2
31
M132697AD
SECTION 6, Page 120
119153
Figure 6.7-1C. Hydraulic Outrigger Option - Leg Assembly
Index
No.
Skyjack
Part No.
Qty.
A
B
C
D
130858
130856
132695
132697
1
1
1
1
AO
Description
ASSEMBLY, Outrigger leg (Front LH)
ASSEMBLY, Outrigger leg (Front RH)
ASSEMBLY, Outrigger leg (Rear LH)
ASSEMBLY, Outrigger leg (Rear RH)
1
130857
1
130855
1
124196
1
124200
1
•
•
•
•
WELDMENT, Outrigger leg (Front LH) A
WELDMENT, Outrigger leg (Front RH) B
WELDMENT, Outrigger leg (Rear LH) C
WELDMENT, Outrigger leg (Rear RH) D
2
(Ref.)
-
3
101297
3
4
103999
3
5
124338
1
6
112601
1
7
103472
1
8
103978
2
9
124972
1
10
124356
1
11
127003
1
12
115658
2
13
126499
4
14
124335
1
15
104000
4
16
103855
2
17
112249
4
18
103986
2
19
102355
1
103856
4
104000
4
103995
4
20
103091
24”
21
113584
8”
22
107712
1
103567
1
132790
1
132110
1
23
118478
1
24
116827
1
25
103995
4
26
103859
2
27
116826
1
116193
2
28
118387
1
29
103470
1
30
103909
1
L
(Ref.)
-
• CYLINDER ASSEMBLY, Outrigger
• • BOLT, Hex head (3/8”-16 x 1-1/4” lg.)
• • WASHER, Lock (3/8”)
• CLIP, Plastic
• NUT, Hex head flange (3/8” - 16)
• NUT, Hex head (3/8” - 16)
• CAP, Nut
• SPRING, Compression
• ROD, Actuator
• SWITCH, Limit
• SCREW, Machine (#8 - 32 x 7/8”)
• BRACKET, Limit switch
• WASHER, Lock (1/4”)
• BOLT, Hex head (1/4” - 20 x 1/2”)
• WASHER, Lock (#8)
• NUT, Hex (8 - 32)
• COVER, Outrigger hose
• • BOLT, Hex head (1/4”-20 x 3/4” lg.)
• • WASHER, Lock (1/4”)
• • WASHER, Flat (1/4”)
• CABLE PROTECTION (5/8” x 24” lg.)
• HEATSHRINK (1/2” x 8”)
• CONNECTOR ASSEMBLY, 5 Pole male
• • HOUSING w/ Strain relief connector
• • • HOUSING
• • • CONNECTOR, Strain relief
• BUSHING, Limit switch mount
• MOUNT, Limit switch
• BOLT, Hex head (1/4”-20 x 1-1/2” lg.)
• COVER, Limit switch
• • BOLT, Hex washer head (#10 - 32 x 1/2”)
• SPACER, Outrigger
• WASHER, Lock (1/2”)
• BOLT, Outrigger leg stop
LABELS
NOTE: The following quantities are per one outrigger assembly
119153
SECTION 6, Page 121
Figure 6.7-2. Hydraulic Outrigger Option - Hydraulic Hose Connections
Left Front
Outrigger
15
3
15
Right Front
Outrigger
3
6
2
4
4
2
12
13
To Main
Manifold
7
Lower
Ports
5
Upper
Ports
1
14
11
8
2
Left Rear
Outrigger
9
3
10
4
SECTION 6, Page 122
15
Upper Port (Retract)
3
15
4
2
Right Rear
Outrigger
ML1F-1015AA
119153
Figure 6.7-2. Hydraulic Outrigger Option - Hydraulic Hose Connections
Index
No.
Skyjack
Part No.
Qty.
1
(Ref.)
1
-
2
(Ref.)
4
-
3
103069
8
4
130843
8
5
102554
2
6
112062
1
7
112063
1
8
112064
1
9
112065
1
10
112066
1
11
112067
1
12
112068
1
13
112069
1
14
118216
1
15
102085
10
Description
MANIFOLD ASSEMBLY, Outrigger
HOSE ASSEMBLY, Outrigger cylinder
(Order P/N 106330 for machines with Serial No. 37406 (8831E),
43044 (8841E), and Below)
HOSE ASSEMBLY, Main manifold to outrigger manifold
TUBE ASSEMBLY, Left front retract
TUBE ASSEMBLY, Right front retract
TUBE ASSEMBLY, Left rear retract
TUBE ASSEMBLY, Right rear retract
TUBE ASSEMBLY, Left rear extend
TUBE ASSEMBLY, Right rear extend
TUBE ASSEMBLY, Right front extend
TUBE ASSEMBLY, Left front extend
COVER, Outrigger manifold
CLAMP, Double tube 3/8”
119153
SECTION 6, Page 123
Figure 6.7-3A. Hydraulic Outrigger Option - Cylinder Assembly
15
11
14
8
6
2
5
10
9
1
12
7
8
4
3
13
ML1F-1076AA
Index
No.
Skyjack
Part No.
Qty.
Description
A
115646
-
1
2
*3
*4
*5
*6
*7
*8
*9
10
11
12
13
14
15
115645
118416
106229
106228
106223
106227
106466
106220
106225
106461
106230
106460
102027
118468
118469
104115
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
• HOUSING, Cylinder
• ROD, Cylinder
• WIPER, Rod
• SEAL, Rod
• RING, Rod wear
• O-RING, Piston
• SEAL, Piston
• PISTON
• NUT, Lock 1-1/4”-12 grade C
• GLAND, Front head
• COLLAR, Limit switch activator
• • SCREW, Cup point set 1/4”-30 x 5/16” lg.
VALVE, Pilot check (not part of cylinder)
*
104355
AR
SECTION 6, Page 124
KIT, Seal repair
119153
Figure 6.7-3B. Hydraulic Outrigger Option - Cylinder Assembly
(Model 8831E with Serial No. 36840 To 37314) (Model 8841E with Serial No. 41671 To 42702)
15
11
14
8
6
5
10
9
1
2
12
4
7
8
3
13
ML1F-1016AA
Index
No.
Skyjack
Part No.
Qty.
Description
A
120389
-
1
2
*3
*4
*5
*6
*7
*8
*9
10
11
12
13
14
15
120386
120641
106229
106228
120445
106227
120642
106220
106225
120640
106230
120387
102027
118468
118469
104115
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
• ROD, Cylinder
• WIPER, Rod
• SEAL, Rod
• RING, Rod wear
• O-RING, Piston
• SEAL, Piston
• PISTON
• COLLAR, Limit switch activator
• • SCREW, Cup point set 1/4”-30 x 5/16” lg.
*
104355
AR
KIT, Seal Repair
119153
SECTION 6, Page 125
Figure 6.7-3C. Hydraulic Outrigger Option - Cylinder Assembly
(Model 8831E with Serial No. 37315 to 37406) (Model 8841E with Serial No. 42703 to 43044)
15
11
8
6
5
10
9
1
12
4
7
2
14
8
3
13
ML1F-1016AA
Index
No.
Skyjack
Part No.
Qty.
A
1
2
*3
*4
*5
*6
*7
*8
*9
10
11
12
13
14
15
126091
126087
126498
106229
106228
120445
106227
120642
106220
106225
120640
106230
120387
102027
126279
104115
-
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
*
104355
AR
SECTION 6, Page 126
Description
• ROD, Cylinder
• WIPER, Rod
• SEAL, Rod
• RING, Rod wear
• O-RING, Piston
• SEAL, Piston
• PISTON
• RING, Retaining
KIT, Seal Repair
119153
Figure 6.7-3D. Hydraulic Outrigger Option - Cylinder Assembly
AO
2
3
4
8
13
5
1
12
6
7
9
4
11
10
14
17
15
16
M10373AB
Index
No.
Skyjack
Part No.
Qty.
A
132694
-
OUTRIGGER CYLINDER ASSEMBLY
1
2
3
*4
5
*6
*7
8
9
*10
*11
*12
*13
14
15
16
17
152132
104115
103069
106220
120640
120642
106225
106230
120387
106229
106228
120445
106227
126999
102027
132565
132690
126279
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
• WELDMENT, Outrigger Cylinder Barrel
• VALVE, Pilot Check (not part of cylinder)
• FITTING, O-Ring
• RING, Piston Wear
• PISTON
• O-RING, Piston
• SEAL, Piston
• NUT, Lock 1 1/4”-12 grade C
• GLAND, Front Head
• WIPER, Rod
• SEAL, Rod
• O-RING, Front Gland
• RING, Rod Wear
• ROD ASSEMBLY, Outrigger Cylinder
• CAP, Rubber Grease
• SPACER, Cylinder Tube
• RING, Retaining 2.5”
*
104355
AR
Description
KIT, Seal repair
119153
SECTION 6, Page 127
Figure 6.7-4. Hydraulic Outrigger Option - Manifold Assembly
3
9
5
7
8
2
6
4
1
ML1F-1017AB
Index
No.
A
1
2
3
4
5
6
7
8
9
Skyjack
Part No.
Qty.
(Ref.)
111970
103069
103614
107439
103920
128798
128317
128320
103920
104437
103073
113801
103613
103655
120295
119902
104345
104409
102888
-
1
9
1
2
4
1
1
2
4
2
1
1
1
1
1
1
4
4
96”
SECTION 6, Page 128
Description
MANIFOLD ASSEMBLY, Outrigger
• BLOCK, Outrigger manifold
VALVE ASS’Y, Vickers 24 Volt (replace with Hytos)
• COIL, 24V
• PLUG, Soc-hd #8orb
• FITTING, Elbow 90° #6orb-#6,
• PLUG, Cavity,
• COIL, 24 Volt
• VALVE, N.C. (outrigger holding),
• HARNESS ASSEMBLY, Outrigger manifold
• • CONNECTOR, Gray
• • CONNECTOR, Black
• • CORD, 16/10
119153
Figure 6.7-5. Hydraulic Outrigger Option - Control Box Assembly
4
5
6
3
2
1
8
7
MS3F-1023AB
Index
No.
A
1
2
3
4
5
6
7
8
Skyjack
Part No.
Qty.
120266
119440
120270
115276
120277
120268
120269
119439
102853
111181
114377
119443
121664
122044
122043
102888
102888
103041
119901
119902
1
1
1
1
1
1
1
1
4
4
2
1
1
1
1
672”
840”
1
1
1
Description
OUTRIGGER CONTROL BOX ASSEMBLY
• WELDMENT, Control box
• SCREW, Retainer
• WASHER, Flat 1-1/4”
• LANYARD
• SCREW, Wing
• SCREW, Receptacle
• WELDMENT, Control box bottom
• SWITCH, Toggle
• GUARD, Toggle
• PLUG, 1/2”
• LABEL, Outrigger
• BOARD W/CONNECTOR, 10-pin
CABLE ASSEMBLY, Control box outrigger (8831E)
CABLE ASSEMBLY, Control box outrigger (8841E)
• CABLE, 16/10 (8831E)
• CABLE, 16/10 (8841E)
• CONNECTOR, Strain relief
119153
SECTION 6, Page 129
Figure 6.7-6. 1500 Watt DC Inverter
2
3
4
3
1
9
5
4
6
5
7
5
7
8
20
18
17
19
14
10
12
16
15
13
12
11
SECTION 6, Page 130
M10521AB
119153
Figure 6.7-6. 1500 Watt DC Inverter
Index
No.
Skyjack
Part No.
Qty.
1
124755
1
124756
1
2
123748
1
3
103856
8
4
103995
AR
5
104000
AR
6
124171
1
7
103980
AR
8
124098
1
9
103889
2
10
(Ref.)
-
11
124895
1
12
(Ref.)
-
13
124089
1
14
105359
3
15
105360
3
16
103041
1
17
124149
1
18
(Ref.)
-
19
132494
1
20
103955
1
106099
1
Description
INVERTER, 1500 Watt 120V @ 60hz
INVERTER, 1500 Watt 110/220V @ 50hz
COVER, Inverter,
BOLT, Hex head 1/4”-20 grade 5 x 0.75”
WASHER, Flat 1/4” SAE
WASHER, Lock 1/4” nom x 0.06
SUPPORT, Assembly inverter 800
NUT, Hex 1/4”-20 grade B
SUPPORT, Inverter
BOLT, Hex head 1/4”-20 grade 5 x 5.00
CONTACTORS AND ELECTRICAL PANEL
CABLE ASSEMBLY, Welding #2ga 3/8” - 142” (-,-)
BATTERY CABLES AND FUSE BOX
CABLE ASSEMBLY, Welding #2ga 1/4” - 144” (+,+)
TERMINAL, Female 14-16ga insulated blue
TERMINAL, Male14-16ga x 1/4” full insulation
CONNECTOR, Strain relief (blue)
WIRE ASSEMBLY, Remote Switch, B
AC OUTLET ASSEMBLY
RELAY, Timer 24V Cut-Off
BOLT, Machine #6-32 x 3/4”
WASHER, Lock #6
119153
SECTION 6, Page 131
Figure 6.7-7. Scissor Guard Option
8
6
5
13
12
2
9
4
10
1
3
7
11
14
ML2F-1004AB
SECTION 6, Page 132
119153
Figure 6.7-7. Scissor Guard Option
Index
No.
Skyjack
Part No.
Qty.
Description
1
116506
1
116525
1
103883
4
103984
4
103996
4
2
116528
1
116530
1
103883
4
103984
4
103996
4
3
116527
1
116525
1
103883
4
103984
4
103996
4
4
116529
1
116530
1
103883
4
103984
4
103996
4
103871
4
103596
4
103978
8
5
116562
1
116548
1
116546
1
116547
1
101632
8
103999
8
103472
8
6
116566
1
116542
1
116565
1
116541
1
101632
8
103999
8
103472
8
7
116535
4
116536
4
8
100702
20
9
116434
2
FRAME, RH Front side scissor guard
• MESH, RH Front scissor
• BOLT, Hex-hd 5/16-18 Gr. 5
• NUT, Lock Hex 5/16”-18 Gr. B
FRAME, RH Rear side scissor guard
• MESH, RH Rear scissor
• BOLT, Hex-hd 5/16-18 Gr. 5
FRAME, LH Front side scissor guard
• MESH, LH Front scissor
• BOLT, Hex-hd 5/16-18 Gr. 5
FRAME, LH Rear side scissor guard
• MESH, LH Rear scissor
• BOLT, Hex-hd 5/16-18 Gr. 5
Use the following hardware on side guards for Machines with
Serial number 37007 (8831) or 42123 (8841) and below.
• BOLT, Hex hd 3/8”-16 x 1-3/4”
• BOLT, Hex hd 3/8”-16 x 2”
• NUT, Hex 3/8”-16
FRAME, Front scissor guard, (Model 8831)
FRAME, Front scissor guard, (Model 8841)
• MESH, Front top, (Model 8841)
• MESH, Front elbow
• BOLT, Hex-hd 3/8”-16 x 3/4” lg.
FRAME, Rear scissor guard, (Model 8831)
FRAME, Rear scissor guard, (Model 8841)
• MESH, Rear, (Model 8831)
• MESH, Rear, (Model 8841)
• BOLT, Hex-hd 3/8”-16 x 3/4” lg.
FRAME, Corner, (Machines without Outriggers)
• MESH, Rear
CAP, Tube end
BUMPER
Use Part # 116438 for Machines with Serial #37007 (8831) or
42123 (8841) and below.
Part list continued on the next page.
119153
SECTION 6, Page 133
Figure 6.7-7. Scissor Guard Option (Continued)
Index
No.
Skyjack
Part No.
Qty.
10
118313
2
118322
1
130024
2
130083
2
129898
4
103472
4
103999
4
130884
4
11
118312
2
118315
1
130024
2
130083
2
129898
4
103472
4
103999
4
130884
4
12
116828
AR
116829
AR
119969
1
119968
1
13
(Ref.)
1
14
129841
4
Description
Part list continued from the previous page.
FRAME, Scissor guard center, (Model 8831)
• MESH, Center
• BOLT, Hex-hd M10-1.5 x 65mm
• NUT, Knurled Insert M10-1.5
• WASHER, Lock M10
FRAME, Scissor guard center, (Model 8841)
• MESH, Center
• NUT, Knurled Insert M10-1.5
• WASHER, Lock M10
FRAME, Scissor guard, (Model 8831 with one or no extension)
FRAME, Scissor guard, (Model 8841 with one or no extension)
• MESH, Front/rear (Model 8831)
• MESH, Front/rear (Model 8841)
BAR ASSEMBLY, Emergency Lowering Access
PLATE, Scissor guard spacing plate
119153
SECTION 6, Page 135
Figure 6.7-8. Safety D-ring Assembly
Extension Deck
Extension
Deck
Optional Location
LocationFor
For
Safety D-Rings
D-Rings
ac inesWithout
it o t
Machines
Extension
Platform
Extension
Platform
Platform
Platform
acMachines
ines itWithout
o t
Optional Location For
Optional
For
Extension
Platform
Extension
Platform
Safety D-Rings
D-Rings
Extension Deck
Extension
Deck
Optional Location
Optional
Location For
For
Safety D-Rings
D-Rings
1
2
3
4
5
M10983AA
Index
No.
Skyjack
Part No.
Qty.
A
125584
-
SAFETY D-RING KIT
1
2
3
4
5
103473
113122
114989
103472
104606
2
1
1
2
2
• BOLT, Hex Head 3/8”-16 x 1” Gr. 5
• BRACKET, Safety Ring
• D-RING, Safety
• NUT, Hex Nylon Lock 3/8”-16 Gr. 5
SECTION 6, Page 136
Description
119153
Figure 6.7-9. Work Light Option
AN
1
2
3
4
5
6
M137979AB
Index
No.
Skyjack
Part No.
Qty.
-
137979
-
ASSEMBLY, Work light
1
2
3
4
5
6
141732
141701
138050
103861
104000
103995
1
1
1
2
2
2
• BULB, 150 Watt halogen, 78 mm
• WORK LIGHT, Dual 250 Watt halogen
• BRACKET, Work light
• BOLT, Hex head (0.25-20 x 2 grade 5)
• WASHER, Lock (0.25)
• WASHER, Flat (0.25)
Description
119153
SECTION 6, Page 137
Figure 6.8-1. Label Kit
AN
Label Kits
The following label kit is for models SJ 8831E and 8841E. The kit contains labels that are common to both
machines.
It excludes:
•
•
•
•
•
•
•
•
serial numbers
nameplates
registrations
stripes
tapes
platform capacities
model designations
all special options
Supply model number, country and language when ordering complete machine labels.
Items with * are part of the label kit.
LABEL KIT:
Model SJ 8831E & 8841E: 129968
TM
119153
SECTION 6, Page 139
Figure 6.8-2. Labels And Nameplates (Old Skyjack Logo)
1B
AO
33
35
1A
12
32
13
34
27
6
2
51
28
11
54
5
30
31
44
21 22 49 20
7
10 52
39
24
46
60
61
38
18
25
26
8
62
37
9
63
17
50
19
47
48
55
56
64
54
15
36
14
57
58
53 43 42 41 40
3
4
59
M10003AB_1
SECTION 6, Page 140
119153
Figure 6.8-2. Labels And Nameplates (Old Skyjack Logo)
Index
No.
Skyjack
Part No.
Qty.
-
(Ref)
-
1A
146526
1
*1B
118277
1
*2
106691
2
*3
106760
2
*4
106761
1
*5
109985
1
*6
108666
2
*7
108946
2
*8
102632
1
9
146525
1
*10
11
12
*13
*14
*15
*16
*17
*18
*19
*20
*21
*22
*23
24
*
*25
26
27
129772
102961
103110
103125
106406
106703
106705
111604
111605
106704
111814
119974
700473
119967
110333
123628
117131
114224
111265
120341
(Ref.)
129806
116097
129807
116094
129823
(Ref.)
130369
132775
130362
107800
130367
130363
130376
130378
132833
134807
2
1
2
1
2
2
1
1
1
1
1
1
1
1
2
1
AR
AR
AR
AR
4
4
4
4
4
4
2
2
4
2
2
2
2
2
2
4
1
AO
Description
(To order a complete label kit, refer to Figure 6.8-1)
LABEL, Danger/Warning Info
(Order Part # 128742 for Machines with Serial #’s 40000127 and Below)
LABEL, Danger/warning (Earlier models)
LABEL, Operator checklist
LABEL, Keep (on scissor arm)
LABEL, Clear (on scissor arm)
LABEL, Annual inspection
LABEL, Replacement parts
LABEL, SKYJACK (small) (21-1/2” wide)
LABEL, SKYJACK (medium) (26” wide)
LABEL, On/Off slab (compliance) (ANSI/SIA & CSA)
Order Part # 108664 for Machines w/Serial # 36945 (8831), 41978 (8841) and below
125476 for Machines w/Serial # 36946 to 36951 (8831), 41979 to 42028 (8841)
129999 for Machines w/Serial # 36952 to 40000127 (8831 & 8841)
LABEL, On/Off slab (CE)
LABEL, Use hydraulic oil
STRIPE, Red/blue/red 96” lg.
STRIPE, White/blue 163” lg.
LABEL, Maintenance support
LABEL, Orifice warning (on lift cylinder)
LABEL, Do not alter (limit switches)
LABEL, Manual brake procedure (in hydraulic/electric cabinet)
LABEL, Emergency lowering
LABEL, Operator warning (on control box)
LABEL, Emergency stop (on control box)
LABEL, Lock-out here
LABEL, Check water daily
LABEL, Emergency battery disconnect and fuse
LABEL, Connect AC Here (@ Cabinet & Platform)
LABEL, Manual box
MANUAL, Operating booklet
MANUAL, Responsibilities
LABEL, 800 Series
LABEL, “E”
LABEL, Model designation
• SJ 8831
• SJ 8831F
• SJ 8841
• SJ 8841F
• “E”
LABEL, Platform capacities
• 2500 lbs. (Model 8831E - CE)
• 2500 lbs. (Model 8831E - ANSI/CSA)
• 2500 lbs (Model 8831FE)
• 2000 lbs. (Model 8831FE - CE)
• 1500 lbs. (Model 8841FE - CE)
• 2000 lbs. (Model 8841FE - CE/CSA with #6F IronMan, & #6F Carlisle Tires)
• 2000 lbs. (Model 8841FE - CE)
• 2000 lbs. (Model 8841FE - ANSI/CSA)
• 1700 lbs. (Model 8841E - with Non-marking foam filled tires)
• 1500 lbs. (Model 8841E - CE)
119153
SECTION 6, Page 141
Figure 6.8-2. Labels And Nameplates (Old Skyjack Logo) (Continued)
Index
No.
Skyjack
Part No.
Qty.
AL
Description
*28
106693
1
*29
110333
1
30
(Ref.)
AR
31
102975
AR
*32
102631
1
33
112906
AR
*34
115982
2
*35
115531
AR
36
115604
AR
*37
102599
1
*38
116648
1
*39
115326
1
123488
1
*40
120090
1
*41
120089
1
*42
117387
2
*43
117389
1
44
120124
1
*45
102657
1
*46
702005
1
*47
102657
1
*48
102451
1
*49
119915
1
*50
115594
1
*51
124362
2
*52
114378
1
*53
120816
1
*54
124465
1
55
(Ref.)
-
*56
114588
2
*57
104589
2
*58
115719
1
59
123274
2
*60
124080
1
*61
119909
1
*62
105352
1
*63
118212
1
64
125024
4
126928
4
133035
4
134409
4
LABEL, Danger, filled tires
LABEL, Connect 110V AC supply here (Machines with AC Outlet on Platform)
NAMEPLATE, Serial number (Consult factory)
STRIPE, Warning 648” roll)
LABEL, SKYJACK (large) (36” wide) (Machines with extension platform)
TAPE, Caution
LABEL, (Warning) (Full torque)
LABEL, Warning (falling hazard)
LABEL, CE
LABEL, Lift/off/drive (located on control box)
LABEL, Lift/drive (joystick) (located on control box)
LABEL, Operation
LABEL, Operation (Machines equipped with Lift/Drive Enable Switch)
LABEL, 48V
LABEL, 24V
LABEL, Power circuit breaker symbol
LABEL, Ground circuit breaker symbol
LABEL, Warning 120V separate circuit (Located on battery tray for EE)
LABEL, Up/off/down
LABEL, Do not release brake (located in hydraulic cabinet)
LABEL, Platform Up/down (base control)
LABEL, Platform/base select (base control)
LABEL, Fuse symbol
LABEL, Enable (located on control box)
LABEL, Warning do not wear jewelry
LABEL, Hydraulic oil
LABEL, Main Board
LABEL, Side force/outdoor
LABELS, EE Rated
• LABEL, FM Approved
• LABEL, EE Rated
• LABEL, Connect Charger Here (EE Rated) (Front of Battery Rollout)
• LABEL, A.C. Connection In Hazardous Area (@ Cabinet & Platform)
LABEL, Joystick trigger enable (located on control box)
LABEL, Trouble alarm (located on control box)
LABEL, Horn (located on control box)
LABEL, Base/Off/Platform (located on control box)
LABEL, Tire Pressure - 70 psi (Equipped with Air Filled Tires only)
LABEL, Tire Pressure - 75 psi (Equipped with Air Filled Tires only)
LABEL, Wheel Load (Equipped with Foam Filled Tires only)
LABEL, Wheel Load (Equipped with Foam Filled Tires only)
*Included in the label kit
NOTE: Supply Model Number, Serial Number, Country and
Language when ordering complete machine labels.
119153
SECTION 6, Page 143
Figure 6.8-3. Labels - Outrigger
2
1
M11523AB
SECTION 6, Page 144
119153
Figure 6.8-3. Labels - Outrigger
Index
No.
Skyjack
Part No.
Qty.
1
2
119866
106705
4
4
Description
LABEL, Danger! Hand/foot pinch
LABEL, Do not alter
NOTE: Supply Model Number, Serial Number, Country and
Language when ordering complete machine labels.
119153
SECTION 6, Page 145
Reliable lift solutions by people who care.
www.skyjack.com

Maintenance and Parts Manual

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