Maintenance and Parts Manual
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: service@skyjack.com
Parts (North America)
Toll Free: 1-800-965-4626
Toll Free Fax: 1-888-782-4825
Email: parts@skyjack.com
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
Email: info@skyjackeurope.co.uk
Skyjack Asia Pacific
Singapore
Phone: +65-6449-3710
Fax: +65-6449-7690
Email: skyjack@singnet.com.sg
Table of Contents
Section - Paragraph Page No.
Section 1 - About Your Aerial Platform
Section 3 - System Component Identification and Schematics - Operation
Section 4 - Troubleshooting Information - Operation
Section 5 - Maintenance and Service - Operation
Section 6 - Parts Lists - Operation
I
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S
E
C
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D
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X
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SKYJACK, Page i
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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Section 1 - About Your Aerial platform
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:
Europe:
( : 800 275-9522
7 : 630 262-0006
( : 44 1691-676-235
7 : 44 1691-676-239
Include the model and serial number for each applicable machine.
1
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Section 1 - About Your Aerial platform
SCOpE Of ThIS mANUAl
models listed on Table 2-1a and
- 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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Section 1 - About Your Aerial platform
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
(Phase to Phase)
Minimum Safe Approach Distance
Feet Meters
Avoid Contact 0 to 300V
Over 300V to 50KV
Over 50KV to 200KV
Over 200KV to 350KV
Over 350KV to 500KV
Over 500KV to 750KV
Over 750KV to 1000KV
10
15
20
25
35
45
3.05
4.60
6.10
7.62
10.67
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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Section 1 - About Your Aerial platform
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 JOB-
SITE.
• 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 with ropes, cords or hoses.
•
•
•
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.
• AVOID falling. Stay within the boundaries of the guardrails.
• Elevated driving must only be done on a firm level surface.
• DO NOT raise the aerial platform in windy or gusty conditions.
• DO NOT ascend or descend a grade when elevated. When fully lowered, ascending or de-
scending, o nly grades up to rated maximum listed in Table
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Section 1 - About Your Aerial platform
Safety precautions (Continued)
Know and understand the safety precautions before going on to next section.
• DO NOT operate on surfaces not capable of holding the weight of the aerial platform including the rated load, e.g. covers, drains, and trenches.
• DO NOT vehicle.
raise the aerial platform while the machine is on a truck, fork lift or other device or
• 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.
• BE AWARE of crushing hazards. Keep all body parts inside platform guardrail.
• DO NOT exert side forces on aerial platform while elevated.
• DO NOT use the aerial platform as a crane. It is prohibited.
• DO NOT lower the platform unless the area below is clear of personnel and obstructions.
• 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.
• DO NOT climb on scissor arm assembly. It is prohibited.
• BE AWARE of overhead obstructions or other possible hazards around the aerial platform when driving or lifting.
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•
•
BE AWARE aerial platform.
STUNT place.
of blind spots when operating the
driving and horseplay are prohibited.
• ENSURE All tires are in good condition and lug nuts are properly tightened.
• DO NOT alter or disable limit switches or other safety devices.
• DO NOT use the aerial platform without guardrails, locking pins and the entry gate/chain/bar in
• DO NOT exceed the rated capacity of the aerial platform. Do make sure the load is evenly distributed on the platform.
SKYJACK, Page 5
Section 1 - About Your Aerial platform
• DO NOT attempt to free a snagged platform with lower controls until personnel are removed from the platform.
Safety precautions (Continued)
Know and understand the safety precautions before going on to next section.
• DO NOT overload the platform, the lift relief valve does not protect against overloading when the platform is elevated. (Machines without load sensing)
•
•
•
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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Section 2 - list of Tables
Table of Contents
2
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Section 2 - list of Tables
Table 2-1a. Specifications and features - ANSI/CSA
Model 8831E 8841E
Weight*
Width
Length
Platform Size
Elevated Working
Elevated Platform
10,455 lbs.
37.0’
31.0’
87.0”
137.5”
68” x 133.5”
11,355 lbs.
47.0’
41’
Stowed Platform
Drive
Standard
Optional
Normal #6 Air filled Drive (Max)
Elevated Low Drive (Max)
Lift (Rated Load)
Lower (Rated Load)
Gradeability
59.0” 69.0”
Full***
30 x 10-16.5 #6 Air filled 30 x 10-16.5 #6 Air filled
#6 or #7 Foam filled
2.6 mph
.45 mph
46 sec.
48 sec.
71 sec.
60 sec.
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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Section 2 - list of Tables
Table 2-1b. Specifications and features - CE
Model
Weight*
Width
Length
Platform Size
Elevated Working
Elevated Platform
Stowed Platform
Drive
Standard
Optional
Normal Drive (Max)
Elevated Low Drive (Max)
Lift (Rated Load)
Lower (Rated Load)
Gradeability
8831E 8841E
4,898 kg 5,306 kg
2.21m
3.5 m
1.73 x 3.39 m
11.28 m
9.4 m
1.50 m
14.3 m
12.5 m
1.75 m
7.9 m
30 x 10-16.5 #6 Air filled 30 x 10-16.5 #6 Air filled
#6 or #7 Foam filled
4.2 km/h
0.8 km/h
46 sec.
48 sec.
71 sec.
60 sec.
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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Section 2 - list of Tables
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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Section 2 - list of Tables
Table 2-3a. maximum platform Capacities (Evenly Distributed) - ANSI/CSA
NOTE:
MODEL
No Extension
Platform
One Extension
Platform
Two Extension
Platforms
No Extension
Platform
One Extension
Platform
Two Extension
Platforms
Capacity
2500 lb.
2000 lb.
1700 lb.
1700 lb.
1500 lb.
1500 lb.
Total
Number of
Occupants
6
6
6
5
5
5
First Extension
Capacity
Number of
Occupants
Not Available
Second Extension
Capacity
Number of
Occupants
500 lb.
500 lb.
500 lb.
500 lb.
2 Not Available
2
2
2 500 lb.
Not Available
Not Available
500 lb.
2
2
60279AC-ANSI
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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Section 2 - list of Tables
Table 2-3b. maximum platform Capacities (Evenly Distributed) - CE
NOTE:
MODEL
No Extension
Platform
One Extension
Platform
Two Extension
Platforms
No Extension
Platform
One Extension
Platform
Two Extension
Platforms
Capacity
1134 kg
908 kg
681 kg
681 kg
681 kg
681 kg
Total
Number of
Occupants
6
5
4
4
4
4
First Extension
Capacity
Number of
Occupants
Not Available
Second Extension
Capacity
Number of
Occupants
227 kg
227 kg
227 kg
227 kg
2 Not Available
2
2
2 227 kg
Not Available
Not Available
227 kg
2
2
60279AC-CE
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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Section 2 - list of Tables
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
Parking brake
Tires/wheels & fasteners
Guides/rollers & slider pads
Railings & railing lock pins
Entry gates
Bolts and fasteners
Maintenance support
Rust
Wheel bearings & king pins
Axle gear oil**
Steering cylinder & tie rod
Electrical
Battery fluid level
Control switches
Cords & wiring
Battery terminals
Terminals & plugs
Receptacle
Limit switches
Hydraulic
A, B & E
A
A & B
A
A & C
C
A & B
B
A
B &E
A, B & C
A, B & I
A & C
B & C
C
B
A
A
A & B
A
A & C
C
A & B
B
A
B &E
A, B & C
A, B & I
A & C
B & C
C
B
A
A, B & E
F
A, B & E
A
A & B
A
A & C
C
A & B
B
A
B & E
A, B & C
A, B & I
A & C
B & C
C
B
A
A, B & E
F
A, B & E
Hydraulic oil level
Hydraulic hoses/fittings
Lift/lowering speeds
Cylinders
Emergency lowering
Lift capacity
H
A & L
B
Hydraulic oil filter
Miscellaneous
Labels and manual A, J & K
Lanyard attachments A & C
Check for applicable service bulletins
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.
C
A & B
D
H
A, L & C
G
A & B
B
D
A, J & K
A & C
F
A
H
A, L & C
G
A & B
B
D
F
A, J & K
A & C
A
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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Section 3
System Component Identification
And Schematics
Table Of Contents
Symbols & Charts
AN
Hydraulic System
Battery Charger Schematics
Electrical Diagrams And Schematics
3
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SECTION 3, Page 1
Figure 3.1-1. Relay Function Chart
SUPPLY (B+) (Common)
CONTROL (B+)
GROUND (B-)
NORMALLY
CLOSED
CONTACT
RELAY NO.
10ACR
10BCR
12ECR
17ACR
28CR
39CR
41CR
42CR
59CCR
61CR-1
61CR-2
65CR
RELAY FUNCTION
Outrigger power
Brake
Joystick Enable
Outrigger lift disable
Tilt
LWS, Limit Switch
LWS Time Delay
LWS Latching
Speed signal
Drive enable
Lift enable
Lift enable
NORMALLY
OPEN
CONTACT
SECTION 3, Page 2
60066AA
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Figure 3.1-2. Tilt Switch Usage Chart
Model
8831E
8841E
ANSI, CSA & CE Models
Serial Numbers
Current production
Tilt switch
(X Axis° x Y Axis°)
117880
(2.5° x 4.5°)
X
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.
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M10281AA
SECTION 3, Page 3
WIRE CROSSING
WIRES JOINED
BATTERY
GROUND
FUSE
CIRCUIT
BREAKER
BATTERY
CHARGE
INDICATOR
CAPACITOR
POTENTIOMETER
SINGLE POLE
DOUBLE THROW
RELAY
TRIPLE POLE
DOUBLE THROW
RELAY
TEMPERATURE
SWITCH
SECTION 3, Page 4
Figure 3.1-3. Electrical Symbol Chart
HOURMETER KEY SWITCH
LIGHT
HYDRAULIC
VALVE COIL
PROPORTIONAL
HYDRAULIC
VALVE COIL
ELECTRIC
MOTOR
HORN
EMERGENCY
STOP BUTTON
RESISTOR
LEVEL SENSOR
DOUBLE POLE
SINGLE THROW
RELAY
DIODE
FOOT SWITCH
TOGGLE SWITCH
PUSH BUTTON
ROTARY SWITCH
LIMIT SWITCH
CAM OPERATED
LIMIT SWITCH
TILT SWITCH
SINGLE POLE
SINGLE THROWN
RELAY
DOUBLE POLE
DOUBLE THROW
RELAY
TRANSISTOR
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ANGLE
TRANSDUCER
PRESSURE
TRANSDUCER
LIMIT SWITCH
N.O.
LIMIT SWITCH
N.O. HELD
CLOSED
LIMIT SWITCH
N.C.
LIMIT SWITCH
N.C. HELD OPEN
SILICON
CONTROLLED
RECTIFIER
PROXIMITY
SWITCH
PNP
TRANSISTOR
NPN
TRANSISTOR
PRESSURE/
VACUUM
SWITCH
LINE CROSSING
LINE JOINED
HYDRAULIC
TANK
HYDRAULIC
FILTER WITH
BYPASS
ELECTRIC
MOTOR
ENGINE
FIXED
DISPLACEMENT
PUMP
THREE POSITION
FOUR WAY
PROPORTIONAL
SERIES
PARALLEL
HYDRAULIC
MOTOR
TWO POSITION
TWO WAY
NORMALLY
OPEN
PRESSURE
TRANSDUCER
ADJUSTABLE
FLOW CONTROL
CHECK VALVE
OIL COOLER
TWO POSITION
TWO WAY
NORMALLY
CLOSED
TWO POSITION
THREE WAY
MAIN LINES Solid
SERVO
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QUICK
DISCONNECT
Figure 3.1-4. Hydraulic Symbol Chart
VARIABLE
DISPLACEMENT
PUMP
SHUTTLE VALV
HAND PUMP
ACCUMULATOR,
GAS CHARGED
CUSHION
CYLINDER
RELIEF VALVE
PRESSURE
REDUCING
VALVE
FIXED ORIFICE
PRESSURE
SWITCH
MOTION
CONTROL VALVE
FLOW DIVIDER
COMBINER
COUNTER
BALANCE VALVE
VALVE COIL
TWO POSITION
THREE WAY
THREE POSITION
FOUR WAY
CLOSED CENTER
CLOSED PORT
PILOT LINES Dashed
SECTION 3, Page 5
VELOCITY FUSE
SINGLE ACTING
CYLINDER
DOUBLE ACTING
CYLINDER
DOUBLE ACTING
DOUBLE
RODDED
SPRING APPLIED
HYDRAULIC
RELEASED
BRAKE
BRAKE
CYLINDER
ROTARY
ACTUATOR
BI DIRECTIONAL
HYDRAULIC
MOTOR
THREE POSITION
FOUR WAY
CLOSED CENTER
OPEN PORT
THREE POSITION
FOUR WAY
PROPORTIONAL
VARIABLE
DISPLACEMENT
HYDRAULIC MOTOR
Index
No.
Skyjack
Part No.
C1
C2
C3
C4
109953
109953
120275
120275
C5
C7
112448
112498
C9-C12 132694
CV1
CV2
CV3
CV4
CV5
CV6
CV7
CV8
104567
104567
104567
104567
104567
104567
104115
104115
CV9 104115
CV10 104115
F1 109568
104254
110652
109311
HP2
M1
M2
MB1
MB3
MB4
MB5
MB6
MB7
MB8
MC1 110434
O1
O2
O3
O4
113875
108804
106688
106688
107382
119748
116586
111970
O5
O6
OC1
P1
P2
P3
PS1
114218
120481
120481
120756
116725
123853
114284
119999
700669
113173
102863
Qty.
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
Figure 3.2-1. Hydraulic Schematic Parts List
Description
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:
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
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, Lowering .104
ORIFICE, Lowering .149
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
Parts list continued on the following page.
SJ-800 Series E Battery Powered
119153
SECTION 3, Page 7
Index
No.
Skyjack
Part No.
PS2
PT1
701194
(Ref.)
4H-73
4H-74
4H-75
4H-76
4H-77
4H-78
QD1
QD2
R1
R2
R3
R4
V1
V2
122420
122420
104534
104534
106557
106557
107271
113556
V6 113752
2H-13-1 104412
2H-13-2 107269
2H-13-3 107269
2H-14D 104412
2H-17A 103655
2H-21A 114365
2H-25
2H-30
2H-44
117189
104412
104412
4H-23A 103614
128798
4H-24A 103614
4H-26
128798
103614
128798
4H-26A 103614
4H-27
128798
103614
128798
4H-27A 103614
128798
4H-32A 103614
128798
4H-33A 103614
4H-71
4H-72
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
103614
128798
SECTION 3, Page 8
Figure 3.2-1. Hydraulic Schematic Parts List (Continued)
Qty.
Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
Parts list continued from the previous page.
PRESSURE SWITCH (800 PSI)
TRANSDUCER, Pressure
(For components refer to Load Sensing Supplement manual, Section 3)
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)
SJ-800 Series E Battery Powered
119153
A B C
Figure 3.2-2. Hydraulic Schematic
D E F G H
V
W
X
SJ-800 Series E Battery Powered
119153
Y
Z
M50045AA
SECTION 3, Page 9
Figure 3.2-3. Hydraulic Manifold Component And Port Identification
PS2
PRESSURE
SWITCH
GEARBOX
GAUGE
TO
GEARBOX
TO
STEER
CV3
BRAKE
CHECK
VALVE
CV5
LIFT
CHECK
VALVE
2H-13-1
VALVE
LOWERING
LIFT GAUGE
2H-44
GEARBOX
HOLDING
VALVE
LIFT
2H-30
BRAKE
RELEASE
VALVE
2H-14D
LIFT
VALVE
2H-21A
SYSTEM
DUMP
VALVE
O6
DUMP
ORIFICE
R1
4H-32A
TRACTION
GEARBOX
VALVE
SYSTEM
RELIEF
VALVE
4H-23A
RIGHT
STEER
VALVE
4H-24A
LEFT
STEER
VALVE
4H-33A
LIFT
GEARBOX
VALVE
CV4
LIFT
CHECK
VALVE
R2
GEARBOX
RELIEF
VALVE
CV4
SYSTEM
CHECK
VALVE
EMERGENCY
LOWERING
O5
ORIFICE
CV1
LARGE PUMP
CHECK VALVE
TO
LARGE
PUMP TO
SMALL
PUMP
CV2
SMALL
PUMP
CHECK
VALVE
TO
RETURN
FILTER
M10307AA
SECTION 3, Page 10
Figure 3.2-4. Outrigger Manifold And Auto Reset Manifold Component And Port Identification
TO MAIN
MANIFOLD
TO
BRAKE
TO
TANK
2H-25
QUICK
BRAKE
VALVE
AUTO
RESET
MANIFOLD
HP2
HAND
PUMP
V6
AUTO
RESET
VALVE
OUTRIGGER
MANIFOLD
4H-73
OUTRIGGER
RIGHT REAR
RETRACT
4H-72
OUTRIGGER
RIGHT FRONT
RETRACT
4H-71
OUTRIGGER
LEFT FRONT
RETRACT
4H-74
OUTRIG-
GER
LEFT REAR
RETRACT
2H-17A
OUTRIGGER
HOLDING
VALVE
4H-78
OUTRIGGER
LEFT REAR
EXTEND
4H-75
OUTRIGGER
LEFT FRONT
EXTEND
4H-77
OUTRIGGER
RIGHT REAR
EXTEND
4H-76
OUTRIGGER
RIGHT
FRONT
EXTEND
TO
OUTRIGGER
CYLINDERS
10283AA
SJ-800 Series E Battery Powered
119153
11
6
Figure 3.3-1. Battery Charger Schematic - MAC BA1001
9 5 7
8
2
1 3
11 4 10
Index
No.
A
1
2
3
4
5
6
7
8
9
10
11
Skyjack
Part No.
(Ref.)
108554
700689
108556
708976
103364
708974
708975
108558
700688
110857
700691
108564
700692
115315
Qty.
-
1
1
1
1
1
2
1
1
1
1
1
1
2
1
Description
BATTERY CHARGER ASSEMBLY (MAC #BA1001)
• 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
SJ-800 Series E Battery Powered
119153
M1115AA_1
SECTION 3, Page 11
1
Figure 3.3-2. Battery Charger Schematic - Bycan #4825U
9 2
3
7 5
10 15
8
13
14
16
12
12
4 6
11
M1115AA_2
Index
No.
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Skyjack
Part No.
122367
121570
121564
121536
121569
121538
129258
121540
121541
121542
121543
121565
121545
121546
121566
121567
115391
Qty.
-
1
1
1
1
2
1
1
2
2
1
1
1
1
1
1
1
Description
CHARGER ASSEMBLY, Battery (2440U, 50/60 Hz)
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 SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
Figure 3.4-1. Electrical Schematic And Diagram Parts List
Qty.
Description
AT1
B1
130440
106552
1
8
BC1 103240 1
BC-1 120075-AE 2
120075-AN 2
BC-2 120075-AE 2
120075-AN 2
BP-28B 103057
BP29 103056
BP-29C 117967
C10B-1 119168
124823
C10B-2 119169
124824
C15A 119170
C16A
C10D-1
C10D-2
C15C
DXX
F1
F2
F3
F4
F5
124825
119170
124825
119168
124823
119169
124824
119170
124825
C16E 119170
CB1
CB2
CB3
CL-1
CL-2
124825
117326
117325
117326
119358
119358
CRD1 119373
CRD2 120370
120074
CRD3 120069
DCM1 116757
DCM2 700668
123355
DPM1 118815
102921
120658
120658
120658
120658
120658
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
TRANSDUCER, Angle (CE)
BATTERY, 6 Amp (Trojan U-2500)
BATTERY CHARGE INDICATOR
CHARGER, Battery (MAC BA 1045)
CHARGER, Battery (MAC BA 961)
CHARGER, Battery (MAC BA 1045)
CHARGER, Battery (MAC BA 961)
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
1
1
1
1
1
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
AR DIODE
FUSE, Right steer
FUSE, Left steer
FUSE, Dump
FUSE, Lowering
FUSE, Reverse
Parts list continued on the following page.
SJ-800 Series E Battery Powered
119153
AN
SECTION 3, Page 13
Index
No.
LS3
LS4
LS5
LS5
LS61 115658
LS62
LS63
LS64
Skyjack
Part No.
Figure 3.4-1. Electrical Schematic And Diagram Parts List (Continued)
F16
F17
700776
114866
F18 119469
FL22 103743
FL22A 104535
H1 102860
INV1 124755
JS1
124756
126024
LCR-1 119156
LCR-2 119156
119375
115658
119296
119375
115658
115658
115658
LS65 115658
LS66 115658
LS67 115658
LS68 115658
PR1
PR2
PS2
OL1
S4
S5
S6
116758
116758
701194
133133
PT1 134432
RL-22A 108102
120628
115573
102853
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Parts list continued from the previous page.
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)
AN
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
Use part #115652 for machines with S/N 37314 (8831E) or 42702 (8841E) & below.
LIMIT SWITCH, Outrigger right/rear
Use part #115652 for machines with S/N 37314 (8831E) or 42702 (8841E) & below.
LIMIT SWITCH, Outrigger left/rear
Use part #115652 for machines with S/N 37314 (8831E) or 42702 (8841E) & below.
LIMIT SWITCH, Outrigger left/front
LIMIT SWITCH, Outrigger right/front
LIMIT SWITCH, Outrigger right/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
Parts list continued on the following page.
SECTION 3, Page 14 SJ-800 Series E Battery Powered
119153
Index
No.
S7
S8
S9
S9A
F6
F7
F8
F9
102769
103082
116382
102853
120658
120658
120658
120658
F10 120658
F10-2 120658
F11
F12
120658
119364
F13 120658
F14 120302
F15 119172
S11
S12
S16
S17
S18
103057
103280
102853
102853
102853
102853
102853
102853
120853
102853
S19
S20
S21
S22
S23
S24
SV1
TC1
102853
119167
119171
700227 TG1
TMR-8A 132494
TS1
TT1
WL1
X1
117880
103336
102671
801347
10ACR 108589
10ACR1 108589
10ACR2 108589
10BCR (Ref.)
118944
10CCR 108589
12CCR 126469
12ECR 108589
Skyjack
Part No.
Figure 3.4-1. Electrical Schematic And Diagram Parts List (Continued)
Qty.
Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Parts list continued from the previous page.
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
Parts list continued on the following page.
AN
SJ-800 Series E Battery Powered
119153
SECTION 3, Page 15
Index
No.
Skyjack
Part No.
Figure 3.4-1. Electrical Schematic And Diagram Parts List (Continued)
17ACR 108589
18ACR 108589
21CR-1 108589
21CR-2 108589
25CR 108589
28CR 108589
30CR 108589
32CR 108589
33CR 108589
59ACR 108589
60CR1 108589
60CR2 108589
60CR3 108589
60ECR1 108589
60ECR2 108589
60ECR3 108589
61CR 108589
61CR-1 108589
61CR-2 108589
65CR 108589
OCM1 132804
2H-13-1 105610
2H-13-2 104493
2H-13-3 104493
2H-13B-1 105610
2H-13B-2 104493
2H-13B-3 104493
2H-14D 105610
2H-17A 103605
2H-21A 105610
2H-25 103605
2H-30 105610
2H-44 105610
4H-23 107439
128320
4H-24 107439
128320
Qty.
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
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
1 MODULE, Outrigger Auto-Levelling Controller
1 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)
Description
Parts list continued from the previous page.
Parts list continued on the following page.
AN
SECTION 3, Page 16 SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
Figure 3.4-1. Electrical Schematic And Diagram Parts List (Continued)
Qty.
Description
4H-26 107439
128320
4H-26A 107439
128320
4H-27 107439
128320
4H-27A 107439
128320
4H-32A 107439
128320
4H-33A 107439
128320
4H-71 107439
128320
4H-72 107439
128320
4H-73 107439
128320
4H-74 107439
128320
4H-75 107439
128320
4H-76 107439
128320
4H-77 107439
128320
4H-78 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
Parts list continued from the previous page.
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)
SJ-800 Series E Battery Powered
119153
SECTION 3, Page 17
Figure 3.4-2. Electrical Inverter Wiring Diagram
SECTION 3, Page 18
M50070AB
SJ-800 Series E Battery Powered
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
Serial Number
37314 & Below
8841E 42701 & Below
60522AA
Refer to following page(s) to locate serial no. and respective diagram.
Figure 3.4-3b.
AN
SJ-800 Series E Battery Powered
119153
M50087AA
SECTION 3, Page 19
Figure 3.4-3b. 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
37315 & Above
42702 & Above
60523AA
Refer to following page(s) to locate serial no. and respective diagram.
Figure 3.4-3a.
AN
SECTION 3, Page 20
M50087AC
SJ-800 Series E Battery Powered
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A B C
Figure 3.5-1 Electrical Panel Diagram (ANSI/CSA/CE) (Shown with All Options)
D E F G H
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M10070AA
SECTION 3, Page 21
A
Serial Breakdown Reference Chart
Model
8831E
Serial Number
37314 & Below
8841E 42701 & Below
Refer to following page(s) to locate serial no. and respective diagram.
60522AA
Figure 3.6-1b
B C
Figure 3.6-1a. Electrical Schematic (ANSI, CSA & CE) (Shown With All Options)
(Refer to Serial No. Breakdown Chart)
D E F G H
V
W
X
SECTION 3, Page 22
Y
Z
M50030AA-A
SJ-800 Series E Battery Powered
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A
Serial Breakdown Reference Chart
Model
8831E
Serial Number
37315 & Above
8841E 42702 & Above
Refer to following page(s) to locate serial no. and respective diagram.
60523AA
Figure 3.6-1a.
B C
Figure 3.6-1b. Electrical Schematic (ANSI, CSA & CE) (Shown With All Options)
(Refer to Serial No. Breakdown Chart)
D E F G H
V
W
X
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M50030AC-CD
SECTION 3, Page 23
Section 4
Troubleshooting Information
Table Of Contents
Electrical System
Hydraulic System
4
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SECTION 4, Page 1
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 SJ-800 Series E Battery Powered
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Troubleshooting Information - Electrical System
4.1-1. All Controls Inoperative
1. Batteries disconnected or discharged.
-Connect batteries or recharge.
2. Battery charger plugged into an outside source.
-Disconnect charger cord.
3. Dirty or loose battery terminals.
-Clean and tighten terminals.
4. Main battery cables open or defective.
-Check continuity. Replace if defective.
5. Main Fuse (F12) defective.
-Replace fuse.
6. Defective Battery Charger Relay (LCR1) or (LCR2).
-Check relay. Replace if defective.
7. Defective or tripped Circuit Breaker (CB2).
-Reset Circuit Breaker. Replace if defective.
8. Loose or broken wire #01 from Battery Charger Relay (LCR1) to Circuit Breaker (CB2).
-Check continuity. Replace if defective.
9. Loose or broken wire #01A from Battery Charger Relay (LCR1) to Battery Charger Relay (LCR2).
-Check continuity. Replace if defective.
10. Loose or broken wire #03 from Battery Charger Relay (LCR2) to Converter.
-Check continuity. Replace if defective.
11. Defective Converter.
-Check for 24 volts between wire #3A and #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).
-Check continuity. Replace if defective.
14. Defective or tripped Circuit Breaker (CB1).
-Reset circuit breaker. Replace if defective.
15. Loose or broken wire #B- from Circuit Breaker (CB1) to Converter.
-Check continuity. Replace if defective.
16. Defective or tripped Circuit Breaker (CB3).
-Reset circuit breaker. Replace if defective.
17. Loose or broken wire #3A from Converter to Circuit Breaker (CB3).
-Check continuity. Replace if defective.
18. Loose or broken wire #3B from Circuit Breaker (CB3) to (optional) Pressure Switch (PS1).
-Check continuity. Replace if defective.
19. Loose or broken wire #4 from Pressure Switch (PS1) (optional) to Base Emergency Stop Switch (S4).
-Check continuity. Replace if defective.
20. Open or defective Base Emergency Stop Switch (S4).
-Close switch. Replace if defective.
21. Loose or broken wire #21A or #02 on Coil (2H-21A).
-Check continuity. Replace if defective.
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).
-Check continuity. Replace if defective.
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SECTION 4, Page 3
Troubleshooting Information - Electrical System
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.
-Check continuity. Replace if defective.
2. Open or defective Platform Emergency Stop Switch (S7).
-Close switch. Replace if defective.
3. Loose or broken wire #07A from Platform Emergency Stop Switch (S7) to Key Switch (S8).
-Check continuity. Replace if defective.
4. Open or defective Key Switch (S8).
-Close switch. Replace if defective.
5. Loose or broken wire #08 from Key Switch (S8) to Lift/Off/Drive Switch (S9).
-Check continuity. Replace if defective.
6. Open or defective Lift/Off/Drive Switch (S9).
-Close switch. Replace if defective.
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).
-Check continuity. Replace if defective.
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.
-Check continuity. Replace if defective.
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
1. Open or defective Lift/Off/Drive Switch (S9).
-Select Lift. Replace if defective.
2. Defective Fuse (F8).
-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).
-Check diode. Replace if defective.
6. Defective Fuse (F5).
-Replace fuse.
7. Defective Contactor (C10B-1).
-Check contactor. Replace if defective.
8. Open or defective Diode (D14).
-Check diode. Replace if defective.
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Troubleshooting Information - Electrical System
9. Defective Fuse (F9).
-Replace fuse.
10. Open or defective End of Stroke Limit Switch (LS4).
-Check switch. Replace if defective.
11. Loose or broken wire #14D or #02 on Coil (2H-14D).
-Check continuity. Replace if defective.
12. Open or defective Diode (D14D-1).
-Check diode. Replace if defective.
13. Defective Coil (2H-14D).
-Check coil. Replace if defective.
14. Lift/Traction Circuit not shifting.
-See Lift/Traction Circuit inoperative Sec. 4, Page 7.
15. Sevcon Problem.
-See Sevcon troubleshooting Sec. 4, Page 9.
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.
-Check continuity. Replace if defective.
2. Open or defective Diode (D14E or D14E-1).
-Check diode. Replace if defective.
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).
-Check continuity. Replace if defective.
2. Defective Coil (2H-13-1, 2H-13-2 or 2H-13-3).
-Check coil. Replace if defective.
3. Loose or broken wire #13 on Lift/Off/Drive Switch (S9) (Upper controls only).
-Check continuity. Replace if defective.
4. Lift/Lower Switch (S6) defective (Base controls only).
-Check continuity. Replace if defective.
5. Loose or broken wire #13 on Lift/Lower Switch (S6) (Base control only).
-Check continuity. Replace if defective.
4.1-7. Platform Does Not Steer Left Or Right
1. Defective Relay (18ACR).
-Check relay. Replace if defective.
2. Loose or broken wire #12C from Lift/Off/Drive Switch (S09) to Steer Switch.
-Check continuity. Replace if defective.
3. Defective Steer Toggle Switch.
-Check switch. Replace if defective.
4. Open or defective Diode (D18A).
-Check diode. Replace if defective.
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SECTION 4, Page 5
Troubleshooting Information - Electrical System
4.1-8. No Steer Right
1. Loose or broken wire #23 from Steer Switch to Terminal Block Inside Platform Control Box.
-Check continuity. Replace if defective.
2. Open or defective Diode (D23).
-Check diode. Replace if defective.
3. Defective Fuse (F1).
-Replace fuse.
4. Loose or broken wire #23 or #02 on Coil (4H-23).
-Check continuity. Replace if defective.
5. Defective Coil (4H-23).
-Check coil. Replace if defective.
6. Defective Steer Switch.
-Check switch. Replace if defective.
4.1-9. No Steer Left
1. Loose or broken wire #24 from Steer Switch to Terminal Block Inside Platform Control Box.
-Check continuity. Replace if defective.
2. Open or defective Diode (D24).
-Check diode. Replace if defective.
3. Defective Fuse (F2).
-Replace fuse.
4. Loose or broken wire #24 or #02 on Coil (4H-24).
-Check continuity. Replace if defective.
5. Defective Coil (4H-24).
-Check coil. Replace if defective.
6. Defective Steer Switch.
-Check switch. Replace if defective.
4.1-10. Forward And Reverse Drive Inoperative
1. Open or defective Lift/Off/Drive Switch (S9).
-Select drive. Check switch. Replace if defective.
2. Loose or broken wire #12C on Lift/Off/Drive Switch (S9).
-Check continuity. Replace if defective.
3. Defective Delayed Power Module.
-Check for 24 volts between wire #12 and #02. Replace if defective.
4. Open or defective Diode (D12C).
-Check diode. Replace if defective.
5. Defective Fuse (F7).
-Replace fuse.
6. Open or defective Diode (D12-2).
-Check diode. Replace if defective.
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.
-See Sevcon troubleshooting Sec. 4, Page 9.
10. Outriggers not retracted (optional).
-See Outrigger Circuit troubleshooting Sec. 4, Page, 8.
SECTION 4, Page 6 SJ-800 Series E Battery Powered
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Troubleshooting Information - Electrical System
4.1-11. Forward Drive Inoperative
1. Loose or broken wire #16 on Lift/Off/Drive Switch (S9).
-Check continuity. Replace if defective.
2. Defective Fuse (F6).
-Replace fuse.
3. Bad contacts in Contactor (C16A).
-Replace Contactor.
4. Loose or broken wire #16A from Pin #15 on Sevcon to Contactor (C16A).
-Check continuity. Replace if defective.
4.1-12. Reverse Drive Inoperative
1. Loose or broken wire #15 on Lift/Off/Drive Switch (S9).
-Check continuity. Replace if defective.
2. Defective Fuse (F5).
-Replace fuse.
3. Bad contacts in Contactor (C15A).
-Replace contactor.
4. Loose or broken wire #15A from Pin #17 on Sevcon to Contactor (C15A).
-Check continuity. Replace if defective.
4.1-13. Forward And Reverse Slow Speed Only
1. High Drive Cut Out Limit Switch (LS5) open or defective.
-Check switch. Replace if defective.
2. Loose or broken wire #10A from Pin #4 on Sevcon to High Drive Cut Out Limit Switch (LS5).
-Check continuity. Replace if defective.
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).
-Check continuity. Replace if defective.
4.1-14. Brake Not Releasing
1. Open or defective Brake Relay (30CR) or Quick Brake Relay (25CR).
-Check relay. Replace if defective.
2. Loose or broken wire #2A or #2B on Brake Pressure Switch (PS2).
-Check continuity. Replace if defective.
3. Open or defective Brake Pressure Switch (PS2).
-Check for continuity between wire #2A and #2B on Brake Pressure Switch (PS2). Replace if defective.
4. Loose or broken wire #30 or #02 on Coil (2H-30).
-Check continuity. Replace if defective.
5. Defective Coil (2H-30).
-Check coil. Replace if defective.
6. Loose or broken wire #25 or #02 on Coil (2H-25).
-Check continuity. Replace if defective.
7. Defective Coil (2H-25).
-Check coil. Replace if defective.
8. Open or defective Diode (D30).
-Check diode. Replace if defective.
9. Loose or broken wire #2A from Pin #1 on Sevcon to Relay (25CR).
-Check continuity. Replace if defective.
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SECTION 4, Page 7
Troubleshooting Information - Electrical System
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.
2. Open or defective Diode (D44).
Check diode. Replace if defective.
3. Loose or broken wire #44 or #02 on Coil (2H-44).
Check continuity. Replace if defective.
4. Defective Coil (2H-44).
Check coil. Replace if defective.
5. Traction Sensor Relay (33CR) or Lift Sensor Relay (32CR) defective.
Check Relay. Replace if defective.
6. Loose or broken wire #32A or #02 on Coil (4H-32A).
Check continuity. Replace if defective.
7. Defective Coil (4H-33A).
Check coil. Replace if defective.
8. Loose or broken wire #33A or #02 on Coil (4H-33A).
-Check continuity. Replace if defective.
9. Defective Coil (4H-33A).
Check coil. Replace if defective.
10. Open or defective Diode (D33A or D32A).
Check diode. Replace if defective.
11. Loose or broken wire #32 from Lift Sensor Relay (32CR) to Pin #8 on Tachometer Board.
Check continuity. Replace if defective.
12. Loose or broken wire #33 from Traction Sensor Relay (33CR) to Pin #9 on Tachometer Board.
Check continuity. Replace if defective.
4.1-16. Power Extension Deck Inoperative
1. Open or defective Pump Interlock Relay (21CR).
Check relay. Replace if defective.
2. Defective Fuse (F10).
Replace fuse.
3. Loose or broken wire #9B from Terminal Block to Enable Switch (S16 or S18).
Check continuity. Replace if defective.
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).
Check continuity. Replace if defective.
6. Loose or broken wire #18A from Terminal Block to Small Pump Relay (18ACR).
-Check continuity. Replace if defective.
7. Loose or broken wire #26 on Switch (S17) or wire #26A on Switch (S19).
-Check continuity. Replace if defective.
8. Loose or broken wire #26 or #02 on Coil (4H-26) or wire #26A or #02 on Coil (4H-26A).
-Check continuity. Replace if defective.
9. Defective Coil (4H-26) or (4H-26A).
-Check Coil. Replace if defective.
10. Open or defective Diode (D26) or (D26A).
-Check diode. Replace if defective.
11. Loose or broken wire #27 on Switch (S17) or wire #27A on Switch (S19).
-Check continuity. Replace if defective.
12. Loose or broken wire #27 or #02 on Coil (4H-27) or wire #27A or #02 on Coil (4H-27A).
-Check continuity. Replace if defective.
SECTION 4, Page 8 SJ-800 Series E Battery Powered
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Troubleshooting Information - Electrical System
13. Defective Coil (4H-27) or (4H-27A).
-Check coil. Replace if defective.
14. Open or defective Diode (D27) or (D27A).
-Check diode. Replace if defective.
4.1-17. Outrigger Circuit Inoperative (Optional)
1. Open or defective Outrigger Enable Relay (10ACR).
-Check relay. Replace if defective.
2. Loose or broken wire #09 to Outrigger Enable Relay (19CR).
-Check continuity. Replace if defective.
3. Loose or broken wire #09A to Outrigger Toggle Switches (S20,S21,S22 or S23).
-Check continuity. Replace if defective.
4. Open or defective Outrigger Toggle Switches (S20, S21, S22 or S23).
-Close switch. Replace if defective.
5. Loose or broken wire #17A or #02 on Coil (2H-17A).
-Check continuity. Replace if defective.
6. Defective Coil (2H-17A).
-Check coil. Replace if defective.
7. Loose or broken wire #71, #72, #73, #74, #75, #76,#77, #78 or #02 on Outrigger Coils.
-Check continuity. Replace if defective.
8. Defective Coil (4H-71, 4H-72, 4H-73, 4H-74, 4H-75, 4H-76, 4H-77 or 4H-78).
-Check coil. Replace if defective.
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).
-Check relay. Replace if defective.
11. Open or defective Limit Switch (LS65, LS66, LS67 or LS68).
-Make sure Outriggers are fully retracted. Check switch. Replace if defective.
12. Open or defective Lift Enable Relay (65CR).
-Check Relay. Replace if defective.
13. Open or defective Limit Switch (LS61, LS62, LS63 or LS64).
-Make sure Outriggers are fully retracted. Check switch. Replace if defective.
14. Open or defective Drive Enable Relay (61CR-1).
-Check relay. Replace if defective.
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SECTION 4, Page 9
Troubleshooting Information - Sevcon Electrical System Flash Codes
FLASH CODE
LED is off
2 Flash Fault
3 Flash Fault
4 Flash Fault
5 Flash Fault
6 Flash Fault
7 Flash Fault
8 Flash Fault
10 Flash Fault
11 Flash Fault
12 Flash Fault
13 Flash Fault
14 Flash Fault
NOTE: A Steady Light on Sevcon Means System is Ready to Operate.
TROUBLE
Procedure
Fault
No Drive and Lift
Low Battery
Voltage
Thermal
Cutback
Tachometer
Fault
Tilt Condition with Platform
Elevated.
Transmission
Gear Mesh
Failure
Low or Open
Voltage to
Sevcon
PROBABLE CAUSE
1. Lift or Drive Selected Before
Power up.
1. Sevcon Shorted.
2. Drive Motor Shorted.
1. Contactor welded.
1. Contactor not shifted.
2. Defective Sevcon.
1. Loose or broken wire #59 from upper control box to Pin #14 on
Sevcon.
2. Open or defective Base Speed
Relay (59ACR).
1. Batteries have dropped below
13 Volts.
1. Sevcon Overheating.
1. Loose or broken wire from Pin
#2 on Sevcon to Pin #4 on
Tachometer Board.
2. Loose or broken wire from Pin
#12 on Sevcon to Pin #2 on
Tachometer Board.
3. Loose or broken wire #T1 or
#T2 from Tachometer Generator to Main Circuit Board.
1. Tachometer Generator defective.
2. Tachometer Generator Wires
Reversed.
3. Defective Tachometer Board.
1. 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. Clean Contactor. Replace if defective.
2. Replace Sevcon.
1. Check continuity. Replace if defective.
2. Check Relay. Replace if defective.
1. Recharge Batteries.
2. Check continuity. Replace if
2. Switch wires at Generator. defective. defective. defective. defective.
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. Let unit cool down.
1. Check continuity. Replace if
3. Check continuity. Replace if
1. Check output 20.8 Volts per
1000 RPM. Replace if defective.
3. Check Tachometer Board for inputs and outputs. Replace if
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 SJ-800 Series E Battery Powered
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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.
-Check valve. Replace if defective.
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.
-Check valve. Replace if defective.
3. Manual Lowering Valve (V1) stuck open.
-Check valve. Replace if defective.
4. Brake Release Valve (2H-30) stuck or open.
-Check valve. Replace if defective.
5. Lift Gearbox Valve (4H-33A) not shifting.
-Clean valve and reinstall. Replace if defective.
6. Gearbox Valve (2H-44) stuck open.
-Check valve. Replace if defective.
7. Defective Large Pump (P1).
-Check pump. Repair or replace if defective.
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SECTION 4, Page 11
Troubleshooting Information - Hydraulic System
4.2-7. Work Platform Lifts Slowly
1. Contaminated System Dump Valve (2H-21A).
-Clean valve and reinstall. Replace if defective.
2. Contaminated Brake Release Valve (2H-30).
-Clean valve and reinstall. Replace if defective.
3. Contaminated Lowering Valve (2H-13-1) or Manual Lowering Valve (V1).
-Clean valve and reinstall. Replace if defective.
4. Controlled Lowering Valve (V2) stuck.
-Clean valve and reinstall. Replace if defective.
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.
-Clean valve and reinstall. Replace if 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.
-Clean valve and reinstall. Replace if defective.
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.
-Clean valve and reinstall. Replace if defective.
2. Gearbox Valve (4H-44) not shifting.
-Check valve and reinstall. Replace if defective.
SECTION 4, Page 12 SJ-800 Series E Battery Powered
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Troubleshooting Information - Hydraulic System
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.
-Check valve and reinstall. Replace if defective.
2. Outrigger Valve (4H-71, 4H-72, 4H-73, 4H-74, 4H-75, 4H-76, 4H-77 or 4H-78) not shifting.
-Depress manual override on each valve. If outriggers extend and retract, clean valves and reassemble.
Replace if defective.
3. Outrigger Check Valve (CV-7, CV-8, CV-9 or CV-10) not shifting.
-Check valve and reinstall. Replace if defective.
4. Gearbox Valve (2H-44) stuck open.
-Check valve and reinstall. Replace if defective.
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SECTION 4, Page 13
SECTION 5
MAINTENANCE AND SERVICE
Table Of Contents
Description Page No.
Maintenance And Inspection Schedule .............................................................................................. 2
Owners Annual Inspection Record ..................................................................................................... 2
General Maintenance Hints ................................................................................................................ 2
Tire Specifications ............................................................................................................................... 5
List Of Tables
Table 5-3. Tire Specifications ...............................................................................Section 5, Page 5
5
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SECTION 5, Page 1
Operator’s Responsibility For
Maintenance
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 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
Note
Replace all worn, damaged or missing parts or labels discovered during this inspection.
Maintenance And Inspection
Schedule
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.
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.
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!
General Maintenance Hints
• 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.
SECTION 5, Page 2 SJ-800 Series E Battery Powered
119153
Hydraulic System And Component
Maintenance And Repair
The following points should be kept in mind when working on the hydraulic system or any component:
1. Any structure has limits of strength 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. 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.
5. 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.
6. 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.
7. 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.
8. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved.
Also, plug the ports of the removed components.
9. 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.
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SECTION 5, Page 3
Model
Electrical System
Batteries
Lift Relief
System Relief
Return Filter
Hydraulic Tank
Capacity
Hydraulic System Capacity
Hydraulic Pump (ci/rev)
DC Motor (Steer/Brake)
DC Motor (Traction)
High Travel Speed
(Level Compacted Surface)
High Travel Speed
(Retracted platform & Steep Incline)
Elevated Platform
Drive Speed
High Speed Drive Cut Out Height
Lift Time (Seconds)
Lower Time (Seconds)
Gradability
Inside Turning Radius
Outside Turning Radius
Tires
Ground Clearance
Tire Contact
Pressure (Max)
Table 5-1. General Specifications
8831E
48 Volts DC
46
48
6V, 250AH
Refer to Serial Number Nameplate
Refer to Serial Number Nameplate
20 Micron
20.5 Gallons
(77.6 Liters)
22.0 Gallons
(83.3 Liters)
.671 (Lift)
.194 (Shift)
3.7 HP
(2.76 kW)
14 HP
(10.4 kW)
2.6 mph
(4.2 km/h)
1.55 mph
(2.5 km/h)
.45 mph
(.8 km/h)
10’
(3.05 m)
25%
124”
(3.15 m)
224”
(5.69 m)
Refer to Table 5-3
8”
(0.203 m)
Refer to Serial Number Nameplate
8841E
71
60
60031AA
SECTION 5, Page 4 SJ-800 Series E Battery Powered
119153
Table 5-2. Torque Specifications
Directional valve mounting bolts
Wheel mounting bolts
Torque
Lbf.ft (max)
Lbf.in (max)
Nm (max)
Torque
Lbf.ft (max)
Lbf.in (max)
Nm (max)
08
20
240
27.12
4
10
120
13.56
38
20
240
27.12
Cartridge
28-32 lbf.in
135-145 lbf.ft
Size
58
20
240
27.12
Coils
10
25
300
33.90
Size
All coils
4 to 5
48 to 60
5.42 to 6.78
SAE Plugs
Size
5
15
180
20.34
6
15
180
20.34
Pound-force foot = lbf.ft
8
25
300
33.90
2.16 – 3.61 Nm
183.06-196.62 Nm
12
35
420
47.46
16
50
600
67.80
Torque
Lbf.ft (max)
Lbf.in (max)
Nm (max)
2
3
36
4.07
Newton-meter = Nm
10
25
300
33.90
12
30
360
40.68
16
35
420
47.46
Pound-force inch = lbf.in
60284AA
#6
#6
#7
#8
#6
#6
#6F
#7F
#8F
*
**
***
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.
Size
Tire*
Fill Type Ply Rating
Fill Specification
Pressure
Factory
Psi (kPa)
Listed Sidewall
Maximum
#6 30-10-16.5 NHS 8 50 (344.7)* 65 (448.2)
32.3-10-16.5 HD Stabilizer
30-10-16.5 OTR Outrigger
31-15.5-15 NHS
31-13.5-15 NHS
Air
10
10
8
10
10
8
8
70 (482.6)*
70 (482.6)*
50 (344.7)*
Consult Skyjack Inc.
75 (517.1)*
***
75 (517.1)
75 (517.1)
Not Available
31-10-16.5 “Carlisle”
31-10-16.5 “Carlisle”
30-10-16.5 NHS
31-15.5-15 NHS
Solid
Urethane
**
**
Not Available
31-13.5-15 NHS 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
SJ-800 Series E Battery Powered
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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
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.
Manifold And Port Identification” for location.
7. Select Drive with the Lift/Off/Drive Select Switch on the Platform Control Box.
8. Engaged Steer Right and hold.
9. Observe reading on Gauge. Adjust the R1 System Relief Value listed on the Serial Number Plate. Turning the stem on the Relief Valve clockwise increases pressure. Turning the stem counterclockwise decreases pressure.
10. Release Steer Switch and tighten the Locknut.
11. Remove the gauge from the System Pressure Test Port.
Gearbox Relief Pressure Adjustment
And Port Identification” for location.
2. Install a Calibrated 1000 PSI Gauge to the Gearbox Quick Disconnect Port.
Manifold And Port Identification” for location.
5. Select Platform Controls. The Small Pump (P2) will start operating.
6. Observe reading on gauge. Adjust Gearbox Relief Valve (R2) to obtain 500 PSI. Turning the stem on the
Relief Valve clockwise increases pressure. Turning the stem counterclockwise decreases the pressure.
7. Reconnect wiring to the Proximity Switches and tighten the Locknut on the Relief Valve.
8. Remove the gauge form the Gearbox Pressure Test Port.
Brake Pressure Adjustment
2. Disconnect spade connectors for pressure switch wires.
3. Turn the black knurled portion of the pressure switch body counter-clockwise until movement stops.
4. Turn the black knurled portion of the pressure switch clockwise for only four full revolutions and reconnect spade connectors.
5. Install 3000 PSI Gauge to quick coupler on main manifold. Refer to Section 3 “Hydraulic Manifold And
Port Identification” for location.
6. Operate Drive slowly while observing gauge. It should read a minimum of 800 PSI.
7. If pressure needs to be increased, turn black knurled portion clockwise. If pressure need to be decreased turn counter-clockwise.
8. Once 800 PSI is obtained, brake pressure adjustment is complete.
SECTION 5, Page 6 SJ-800 Series E Battery Powered
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Brake Adjustment Procedure
1. Place machine on level surface and block wheels to prevent rolling in either direction.
2. Unplug battery , disconnect plug.
3. Locate brake manifold in hydraulic/electric side cabinet.
4. Depress black knob.
5. Grasp the red plunger and rapidly depress until plunger can no longer be depressed and the brake is fully released.
6. Inspect caliper and brake pads for binding. Pads should move freely on the pins.
7. Remove pin from brake cylinder clevis and brake actuating lever. Rotate actuating lever counterclockwise to the end of it’s stroke.
8. 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
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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 SJ-800 Series E Battery Powered
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Proximity Switch Test Procedure
SJ-800 Series E Battery Powered
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Figure 5-4. Proximity Switch
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. Locate Sevcon inside Electrical/Hydraulic Cabinet on the right side of the machine.
2. 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. 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.
4. When the desired parameters has been selected, on the left side of the calibrator, it may be adjusted by
or Table 5-4B. (for calibrator Revision .10) for adjustable parameters and ranges.
5. When the calibrator is unplugged the Sevcontrol will ‘memorize’ the new parameters settings.
SJ-800 Series E Battery Powered
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Figure 5-5. Sevcon Calibrator
SECTION 5, Page 11
Sevcontroller Adjustment And Diagnostics (Continued)
Diagnostic LED
Controller
Adjustment
Socket
SEQ. NO.
1
2
3
4
5
6
7
8
9
10
11
Figure 5-6. Traction Controller
Table 5-4A. Sevcontrol Adjustable Parameters (Software Revision .07)
MIN. MAX. UNITS PARAMETER
IMAX
Maximum Controller Current
ACCEL
Acceleration Delay
DECEL
Deceleration Delay
CREEP
Maximum Controller Current
MAX
Maximum Allowed Speed
ELEVA
Elevated Cutback Speed
TILT
Tilted Cutback Speed
CONSTANT SPEED CONTROL
Proportional Gain (Do Not Adjust)
CONSTANT SPEED CONTROL
Integral Gain (Do Not Adjust)
BATTERY
Low Battery Cut-out
50
1
0.1
0
5
5
5
0
1
25
600
3
3
10
100
25
75
150
100
40
Amps
Seconds
Seconds
% of Max. Speed
% of Max. Possible Speed
% of Max. Speed
% of Max. Speed
Counts
Counts
Volts
DEFAULT
400
1
0.1
2
80
15
50
30
20
25
Not Used
12 Not Used
13
BRAKE
Brake Personality Timer
0 3 Seconds 0.5
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 SJ-800 Series E Battery Powered
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Sevcontroller Adjustment And Diagnostics (Continued)
SEQ. NO.
1
2
3
4
5
6
7
8
9
10
11
Table 5-4B. Sevcontrol Adjustable Parameters (Software Revision .10)
MIN. MAX. UNITS PARAMETER
IMAX
Maximum Controller Current
ACCEL
Acceleration Delay
DECEL
Deceleration Delay
CREEP
Maximum Controller Current
MAX
Maximum Allowed Speed
ELEVA
Elevated Cutback Speed
TILT
Tilted Cutback Speed
CONSTANT SPEED CONTROL
Proportional Gain (Do Not Adjust)
CONSTANT SPEED CONTROL
Integral Gain (Do Not Adjust)
BATTERY
Low Battery Cut-out
50
1.0
0.1
0
5
5
5
0
1
25
600
3.0
3.0
10
100
25
75
150
100
40
Amps
Seconds
Seconds
% of Max. Speed
% of Max. Possible Speed
% of Max. Speed
% of Max. Speed
Counts
Counts
Volts
Not Used
DEFAULT
400
1.0
0.1
2
80
15
50
30
20
25
12 Not Used
13
14
ELEVATED CURRENT
Max. Current When Elevated
BRAKE
Brake Personality Timer
50
0.0
400
3.0
Amps
Seconds
230
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.
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SECTION 5, Page 13
Sevcontroller Adjustment And Diagnostics (Continued)
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
TEST
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.
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.
SECTION 5, Page 14 SJ-800 Series E Battery Powered
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Sevcontroller Adjustment And Diagnostics (Continued)
Sequence
No.
4
5
6
-
1
2
3
7
8
9
10
Table 5-5. Sevcontrol Test Sequence
Drive Controller Test Sequence
Test Display
Controller (Joystick) Input
Forward Switch
Reverse Switch
Tachometer Input
Elevated Position
Tilt Switch
Pump/Traction Switch
0 to 100%
CL/OP
CL/OP
0 to 100%
CL=Collapsed OP=Lifted
CL=Level OP=Tilt
CL=Pump Mode OP=Traction
Mode
Actual Direction, Tachometer Output
Lift Transmission Position Sense
CL= Reverse OP=Forward
CL = Engaged OP = Disengaged
Traction Transmission Position Sense CL = Engaged OP = Disengaged
First Error Latch Value= Flash Code
NOTE: CL=Switch Closed
OP=Switch Open
60287AB
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SECTION 5, Page 15
Sevcontroller Adjustment And Diagnostics (Continued)
Traction Controller Pin Reference
Diagnostic LED
Pins are identified from left to right
Pin #1 thru Pin #17
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.
Test between pin 4 and wire #02.
Pin 12- Speed signal from pin 2 on tachometer card.
7.5 volts with joystick in neutral.
7.5 volts to 15 volts = reverse.
7.5 volts to 0 volts = forward.
Test between pin 12 and wire #02.
Pin 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 13- Speed sensing enable.
Determines lift or drive mode.
2 volts = drive. Speed sensing enabled.
4 volts = lift. Speed sensing disabled.
Anything above 2.52 volts = Lift
Test between pin 13 and wire #02.
Pin 5- 24 volt input from line contactor.
Test between pin 6 and wire #02.
Pin 6- 48 volt input from line contactor.
Test between Pin 6 and wire #02 with Key
Switch on.
Pin 14- Accelerator input.
3.8 to 4.2 volts with joystick in neutral and key switch on.
3.5 volts = slow speed.
0 volts = fast speed.
Test between pin 14 and wire #02.
Pin 15- Forward contactor output.
Brings B- to forward drive contactor.
Test between pin 15 and wire #10A.
Pin 7- Tilt switch input.
24 volts = full speed
0 volts = 50% full speed.
Test between pin 7 and wire #02.
Pin 8- Forward/Up input from joystick.
24 volts = drive forward or lift up selected.
Test between pin 8 and wire #02.
Pin 9- Not used
Pin 10- Not used
Pin 16- Drive/Lift Select.
0 volts = drive
24 volts = lift
Test between pin 16 and wire #02.
Pin 17- Reverse contactor output.
Brings B- to reverse drive contactor.
Test between pin 17 and wire #10A.
SECTION 5, Page 16 SJ-800 Series E Battery Powered
119153
10
11
12
13
8
9
14
15
16
17
4
5
2
3
6
7
1
Sevcontroller Adjustment And Diagnostics (Continued)
2
Table 5-6. Traction Controller Flash Fault Pin References
Number of Flashes
3 4 5 6 7 8 10 11 12
X
X
X
X
X
X
X
X
X
X X
X
X
X
X
X
X
13
X
60288AA
X
X
14
SJ-800 Series E Battery Powered
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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.
Term B- 24 volt input from wire #10A.
Test between terminal B and wire 02.
Term C- 24 volt output to drive, steer and line contactors. Fused from terminal B.
Test between terminal C and wire 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
Test between pin 2 and wire #02.
Pin 3- Tachometer generator input.
Pin 4- Direction signal to Pin 2 of controller.
0 volts = forward
15 volts = reverse
Test between pin 4 and wire #02.
Pin 5- Tachometer generator input.
Pin 6- Steer enable
Pin 7- not used
Pin 8- Lift mode selected.
24 volts when lift selected.
Test between Pin 8 and wire 02.
Pin 9- Drive mode selected.
24 volts when drive selected.
Test between Pin 9 and wire 02.
Pin 10- Speed sensing enable. To Pin 13 on controller.
Drive mode = 2 volts = speed sensing enabled.
Lift mode = 4 volts = speed sensing disabled.
Test between pin 10 and wire #02.
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 SJ-800 Series E Battery Powered
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. GEAR BOX
2. DRIVE MOTOR
3. COUPLER HALF
4. TACHOMETER GENERATOR MOUNTING PLATE
5. COUPLER HALF
1
2
3
4
5
Figure 5-9. Traction Motor/Tach Generator
SJ-800 Series E Battery Powered
119153
6
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!
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 1
6
AN
List Of Illustrations
Description Page No.
Platform And Related Parts
Scissor And Related Parts
Base And Related Parts
SECTION 6, Page 2 SJ-800 Series E Battery Powered
119153
AN
List Of Illustrations
Description Page No.
Hydraulic Cabinet Assembly
Hydraulic/Electric Cabinet Assembly
Electrical Panel Assembly
Special Option
Labels And Nameplates
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 3
Figure 6.1-1. Main Platform And Railings
AN
SECTION 6, Page 4
M1003AD
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
(Ref.)
(Ref.)
(Ref.)
105307
109377
100702
110693
103632
107615
115531
107621
111808
106915
103865
103984
101778
107623
104625
103978
117289
117290
117291
103873
104606
117277
103856
104000
103983
103632
103107
105310
105312
Index
No.
A
B
C
Qty.
Figure 6.1-1. Main Platform And Railings
Description
Machines with front extension platform.
Machines with rear extension platform.
Machines with hinged end rails.
1 WELDMENT, Main platform
16 • SCREW, Set 3/8”-16 x 5/8” lg.
16 • NUT, Hex 3/8”-16
2
2
2
4
4
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.
4
• NUT, Lock 3/8”-16
HINGE, Spring return (Stanley 3-1/2” #2060R)
12 • BOLT, Hex-hd 1/4”-20 x 3/4” lg.
12 • WASHER, Lock 1/4”
12 • NUT, Jam 1/4”-20
12 • SCREW, Self-tapping 1/4”-14 x 3/4” lg.
2
2
2
2
2
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.
AR CAP, Tube end
2
4
1
1
2
4
STOP, Latch
• SCREW, Self-tapping 1/4”-14 x 3/4” lg.
2 RAILING, Lower front RH/lower rear LH
AR LABEL, Warning falling hazard
RAILING, Upper rear LH,
RAILING, Upper rear LH,
B
A & C
RAILING, Gate top (Half gate)
• BOLT, Hex-hd 5/16”-18 x 2” lg.
4 • NUT, Lock 5/16”-18
AR CLAMP, Entry railing
Parts list continued on the following page.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 5
Skyjack
Part No.
108791
107621
111840
100509
105807
107614
(Ref.)
120143
119943
119945
121017
121016
121015
117279
125010
107617
104183
107621
111840
111845
111842
107621
111808
132814
132816
103865
103984
103996
124547
134355
115649
Index
No.
Qty.
Figure 6.1-1. Main Platform And Railings (Continued)
Description
Parts list continued from the previous page.
2
2
1
1
AR RAILING, Hinged upper end, C
AR RAILING, Hinged lower end, C
1
1
2
1
1
1
1
1
2
2
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, Upper front RH,
RAILING, Upper front RH,
A & B
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
1
1
• 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
1 RAILING, Upper front LH, C
AR PIN, Locking 3/8”
AR CABLE, Lanyard 6” lg.
8
1
1
-
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) 4
AR RAILING, Bottom Left, D
AR RAILING, Bottom Right, D
AR RAILING, Top, D
AR GATE, Full (Left swinging) D
AR GATE, Full (Right swinging) D
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 7
Figure 6.1-2. 4 Ft. Roll-out Extension Platform Assembly
AN
SECTION 6, Page 8
M10033AA_1
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
102237
110425
111136
114998
105673
101954
107057
112736
112389
100509
105807
(Ref.)
115543
(Ref.)
107639
105829
100141
106432
117200
115531
117199
115015
112467
130229
103632
115014
115016
117198
(Ref.)
Index
No.
Figure 6.1-2. 4 Ft. Roll-out Extension Platform Assembly
Qty.
Description
1
2
2
2
1 RAILING, Pivoting front
AR LABEL, Falling hazard
1
2
2
1
1
2
1
4
1
WELDMENT, Extension platform
• PIN, Roller 3/4” x 2-3/8” lg.
• ROLLER, Rear
U-BOLT, 1/4”-20 x 3/4”ID
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
2
8
2
2
WELDMENT, Main platform
(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
AR PAD, Slider 1-1/2” dia. x1/2”thk.
AR PAD, Slider 1-1/2” dia. x 3/8” thk.
2
-
4
1
PAD, Platform slide 3/8” x 1-3/4 x 4” lg.
STOP, Extension platform (welded to platform deck)
1 PIN, Quick release
AR PIN, Locking 3/8”
AR CABLE, Lanyard 6”
- RING KIT, Safety
(For Components, Refer to Figure 6.7-8)
LABEL, Info/Warning
(For Components, Refer to Figure 6.8-2)
NOTE: Quantities shown are for a single extension platform.
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 9
Figure 6.1-3. 4 Ft. Powered Extension Platform Assembly AN
SECTION 6, Page 10
M10035AC
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
103995
104000
103980
117188
103856
104000
(Ref.)
103845
103404
100397
(Ref.)
(Ref.)
108366
107639
105829
100141
130229
103632
117198
117199
(Ref.)
101632
103472
103999
111290
(Ref.)
103860
111136
110425
(Ref.)
101954
100509
105807
106446
102237
Index
No.
Figure 6.1-3. 4 Ft. Powered Extension Platform Assembly
Qty.
Description
2
2
1
1
1
1
-
2
2
1
-
1
1
-
2
2
2
1
4
6
-
2
2
2
1
2
2
1
WELDMENT, Extension platform
• PIN, Roller 3/4” x 2-3/8” lg.
• ROLLER, Rear
PLATE, Info/warning mount
AR • BOLT, Self tapping 1/4” - 14 x 3/4” lg.
1 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”
• WASHER, Lock 3/8”
• BLOCK, Manifold
BOX ASSEMBLY, Powered ext. platform control
(For Components, Refer to Figure 6.1-8)
• BOLT, Hex-hd 1/4”-20 x .75” lg.
• WASHER, Flat
• WASHER, Lock 1/4”
• NUT, Hex-hd 1/4”-20
PLATE, Control box mounting
• BOLT, Hex-hd 1/4”-20 x 3/4” lg.
• WASHER, Lock 1/4”
PANEL ASSEMBLY, Powered platform electrical
(For Components, Refer to Figures 6.1-7)
• WASHER, Lock 5/16”
• 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
(For Components, Refer to Figures 6.1-6 & 6.1-7)
-
1
2
8
1
-
WELDMENT, Cylinder front support
ROLLER, Extension platform
PAD, Deck slider 1” dia. x 11/32” thk.
WELDMENT, Main platform
(For Components, Refer to Figure 6.1-1)
AR PAD, Slider 1-1/2” dia. x 3/8” thk.
AR PIN, Locking 3/8”
AR CABLE, Lanyard 6” lg.
1
2
RING, Retaining
PIN, Roller 3/4” x 3-11/32” lg.
NOTE: Quantities shown are for a single extension platform.
Parts list continued on the following page.
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 11
Index
No.
113304
113305
113331
113334
115544
113360
104002
113164
107057
105673
115531
(Ref.)
117200
(Ref.)
Skyjack
Part No.
Figure 6.1-3. 4 Ft. Powered Extension Platform Assembly (Continued)
Qty.
Description
Parts list continued from the previous page.
1
-
1
1
1
1
2
2
1
1
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
4
2
PAD, Platform slide 3/8” x 1-3/4” x 4” lg.
BUMPER, Extension platform
AR LABEL, Falling hazard
- RING KIT, Safety
(For Components, Refer to Figure 6.7-8)
RAILING, Pivoting front
LABEL, Info/Warning
(For Components, Refer to Figure 6.8-2)
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 13
3
Figure 6.1-4. Hydraulic Hose Connections - Powered Extension Platform
(Machines With Front Extension Platform)
5
7
4
8
2
6
1
5
9
10
Index
No.
5
6
7
8
9
10
1
2
3
4
Skyjack
Part No.
(Ref.)
107382
103614
107439
103920
128798
128317
128320
103920
104345
104409
103069
114578
104134
106516
124355
124354
103070
102665
Qty.
Description
VALVE ASS’Y, “Hytos” (Later models & Vickers replacement)
• VALVE, Directional spool
2 • • COIL, 24 Volt Spool Valve
AR • BOLT, Socket head #10-24 x 2” grade 5
AR • CONNECTOR, Gray
AR • CONNECTOR, Black
3
3
2
1
1
1
1
2
1
-
1
1
CYLINDER ASSEMBLY, Powered extension platform
(For Components, Refer to Figures 6.1-6)
VALVE ASS’Y, “Vickers” (Early models - replace with Hytos below)
2 • COIL, 24 Volt Spool Valve
AR • BOLT, Socket head #10-24 x 2” grade 5
1
1
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
FITTING, O-Ring Elbow #8-#6 (in manifold at base)
Use Part #103070 for Machines with Serial #37120 (8831)
or #42302 (8841) and below.
(Model 8831)
Use Part #123038 for Machines with Serial #37120 and Below.
HOSE ASSEMBLY, Powered Extension Supply and Return (Model 8841)
Use Part #123675 for Machines with Serial #42302 and Below.
FITTING, O-Ring #6-#8 (in manifold at base)
M1046AB
SECTION 6, Page 14 SJ-800 Series E Battery Powered
119153
Rear 8831
Front 8841
5
Figure 6.1-5. Hydraulic Hose Connections - Powered Extension Platform
(Machines With Front And Rear Extension Platforms)
Front 8831
Rear 8841
3 2
6 10 4
1
1 7
3 11 9
5
8
12
13
M1027AB
Index
No.
5
6
7
8
9
10
11
12
13
1
2
3
4
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
124355
124354
104134
106516
104660
103070
102665
(Ref.)
107382
103614
107439
103920
128798
128317
128320
103920
104345
104409
103069
114578
110447
102490
Qty.
Description
VALVE ASS’Y, “Hytos” (Later models & Vickers replacement)
• VALVE, Directional spool
2 • • COIL, 24 Volt Spool Valve
AR • BOLT, Socket head #10-24 x 2” grade 5
AR • CONNECTOR, Gray
AR • CONNECTOR, Black
2
6
2
1
1
1
1
2
2
1
1
2
-
2
1
CYLINDER ASSEMBLY, Powered extension platform
(For Components, Refer to Figures 6.1-6)
VALVE ASS’Y, “Vickers” (Early models - replace with Hytos below)
2 • COIL, 24 Volt Spool Valve
AR • BOLT, Socket head #10-24 x 2” grade 5
1
1
FITTING, Connector #6orb - #6
FITTING, Elbow 90° #6orb - #6
HOSE ASSEMBLY, Cylinder Retract 56” lg.
HOSE ASSEMBLY, Cylinder Extend 16” lg.
HOSE ASSEMBLY, Powered Extension Supply and Return (Model 8831)
Use Part #123038 for Machines with Serial #37120 and Below.
HOSE ASSEMBLY, Powered Extension Supply and Return (Model 8841)
Use Part #123675 for Machines with Serial #42302 and Below.
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.
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
1
11
5
4
10
3
12
M118090AB
Index
No.
A
1
2
* 3
* 4
* 5
* 6
* 7
* 8
9
10
11
12
*
Skyjack
Part No.
118090
119418
119407
110976
103825
106452
106449
108798
103828
118089
117942
103830
116069
107396
Qty.
Description
-
1
1
1
1
1
1
1
1
1
1
1
1
CYLINDER ASSEMBLY, 5 Ft. Extension platform
• 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
AR KIT, Seal Repair
* Part of Seal Repair Kit
SECTION 6, Page 16 SJ-800 Series E Battery Powered
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
4
10
3
Index
No.
A
1
2
* 3
* 4
* 5
* 6
* 7
* 8
9
10
11
12
*
Skyjack
Part No.
120275
120271
120254
110976
103825
106452
106449
108798
120436
118089
117942
103830
116069
107396
Qty.
Description
-
1
1
1
1
1
1
1
1
1
1
1
1
CYLINDER ASSEMBLY, Extension platform
• 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, Stop Tube
AR KIT, Seal Repair
* Part of Seal Repair Kit
SJ-800 Series E Battery Powered
119153
12
M1007AA
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
6
7
5
3
2
8
4
Index
No.
4
5
6
7
8
9
1
2
3
SECTION 6, Page 18
9
Skyjack
Part No.
Qty.
Description
103012
103955
103985
117362
100397
(Ref.)
104345
104409
2
1
1
1
1
2
2
1
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
• CONNECTOR, Black
115817 2 • DIODE, Flyback 1 amp 400 PIV
103257 20” lg. • CORD, 18/3
(Ref.)
104345
2
2
2
2
CORD ASS’Y, Valve manifold (Machines with two extension platforms)
• CONNECTOR, Gray
• CONNECTOR, Black
• DIODE, Flyback 1 amp 400 PIV
104409
115817
103257 20” lg. • CORD, 18/3
(Ref.)
107711
1
1
CORD ASSEMBLY, Front platform control box
• CONNECTOR ASSEMBLY, 5 Pole female
103257 180” lg. • CORD, 18/3
(Ref.)
107711
1
1
CORD ASSEMBLY, Rear platform control box
• CONNECTOR ASSEMBLY, 5 Pole female
103257 180” lg. • CORD, 18/3
102921
103036
(Ref.)
AR DIODE, 6 Amp
AR CONNECTOR, Strain relief
1 CORD ASSEMBLY, Electrical panel
103257 20” lg. • CORD, 18/3
119130
119895
116399
1
1
1
• KIT, 4 pole receptacle connector
• CONNECTOR, 3 pole P.C. Board
BRACKET, Power Deck Panel and Valve
M117362AA
SJ-800 Series E Battery Powered
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
6
1
3
4
5
M1020AA
Skyjack
Part No.
(Ref.)
(Ref.)
120844
122178
122179
119900
103257
107711
103568
103570
120658
122189
122190
119896
119825
111354
122192
124353
119897
119895
103257
103257
122186
Index
No.
A
B
5
6
1
2
3
4
Qty.
SJ-800 Series E Battery Powered
119153
Description
-
-
SINGLE POWERED EXTENSION PLATFORM
DOUBLE POWERED EXTENSION PLATFORMS (Shown)
1
1
1
1
1
1
BOARD, Power Deck PC
HARNESS, Power Deck Control box, A
HARNESS, Power Deck Control box, B
• PLUG, 8 Pin PC Board Connector
AR • CABLE, Cabtire 18/3 (180” long)
AR • CONNECTOR, Cabtire 5 Pin Female
1
1
• • HOUSING, Base
• • INSERT, Female
FUSE, 10A
HARNESS, Power Deck Directional Valves, A
1 HARNESS, Power Deck Directional Valves, B
AR • PLUG, 4 Pin PC Board Connector
AR • CONNECTOR, Solenoid
AR • PROTECTOR, 3/8” Wire
1
1
1
HARNESS, Power Deck To Main Panel (Model 8831)
HARNESS, Power Deck To Main Panel (Model 8841)
Use Part #122188 for Machines with Serial #42302 and Below.
• PLUG, 5 Pin PC Board Connector
1 • PLUG, 3 Pin PC Board Connector
588” • CABLE, Cabtire 18/3 (Model 8831)
756” • CABLE, Cabtire 18/3 (Model 8841)
1 BRACKET, Power Deck PC Board and Valve
SECTION 6, Page 19
8
5
Figure 6.1-8. Powered Extension Platform Control Box Assembly
6 7
7
6
9
2
1
3
4
M1006AA
Index
No.
A
1
2
3
4
5
6
7
8
9
Skyjack
Part No.
115592
115539
103041
106401
107712
103567
103569
108328
102853
111181
115594
114377
Qty.
Description
- CONTROL BOX ASSEMBLY, Powered ext. platform
2
1
1
1
1
1
2
1
1
• BOX, Control
• STRAIN RELIEF, Straight 1/2”
AR • CORD, Coiled 18/3
1 • CONNECTOR ASSEMBLY, 5 pole male
• • HOUSING, Base
• • INSERT, Male
• LABEL, Platform extend/retract
• SWITCH, Toggle
• GUARD, Toggle switch
• LABEL, Enable
• PLUG, Plastic 1/2”
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 21
Figure 6.1-9A. Control Box Assembly
(Model 8831E with Serial No. 37314 and Below) (Model 8841E with Serial No. 42701 and Below)
SECTION 6, Page 22
M1040AA
SJ-800 Series E Battery Powered
119153
Index
No.
Figure 6.1-9A. Control Box Assembly
(Model 8831E with Serial No. 37314 and Below) (Model 8841E with Serial No. 42701 and Below)
Skyjack
Part No.
Qty.
Description
A
100149
119368
119895
103240
119396
119899
102671
103057
103202
102771
119370
119903
116382
119366
114678
106099
111181
114377
102956
100509
105807
119367
119374
119344
112327
119345
(Ref.)
103957
112249
119369
119898
103100
103225
103141
103082
102769
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
4
1
1
1
1
1
-
4
- CONTROL BOX ASSEMBLY
CONTROL BOX ASSEMBLY WITH HORN
1 • WELDMENT, Control box, 1 hole
10 • • 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
• • CONNECTOR, 3 pole P. C. Board
• • 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
• • CONNECTOR, 11 pole P.C. Board
• • 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.
Parts list continued on the following page.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 23
Index
No.
Figure 6.1-9A. Control Box Assembly (Continued)
(Model 8831E with Serial No. 37314 and Below) (Model 8841E with Serial No. 42701 and Below)
Skyjack
Part No.
Qty.
Description
103100
103141
102851
(Ref.)
(Ref.)
108854
103100
103141
(Ref.)
Parts list continued from the previous page
119373
119907
103041
119359
1
1
1
1
• CABLE ASSEMBLY, Control box 16 pole
• • CONNECTOR, P.C. Board 15 pole
• • CONNECTOR, Strain relief
• • HOUSING, 16 pole
114469 1 • • PLUG, 16 pole male
102887 44”lg. • • CABLE, 16/15
119397
119894
1
1
-
1
1
1
1
1
1
1
1
1
-
• SWITCH ASSEMBLY, Horn push-button
• • CONNECTOR, P.C. Board 2 pole
• • BASE, Contact
• • BLOCK, N.O. Contact
• HEAD, Push-button switch
• CABLE ASSEMBLY, Scissor control
(For Components, Refer to Figure 6.6-5)
• SWITCH ASSEMBLY, Enable push-button
• • HEAD, Green Push-button switch
• • BASE, Contact
• • BLOCK, N.O. Contact
• LABEL, Control Box
(For Components, Refer to Figure 6.8-2)
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 25
Figure 6.1-9B. Control Box Assembly
(Model 8831E with Serial No. 37315 and Above) (Model 8841E with Serial No. 42702 and Above)
SECTION 6, Page 26
M10268AB
SJ-800 Series E Battery Powered
119153
Index
No.
Figure 6.1-9B. Control Box Assembly
(Model 8831E with Serial No. 37315 and Above) (Model 8841E with Serial No. 42702 and Above)
Skyjack
Part No.
Qty.
Description
130249
130250
119374
123619
106398
102769
119368
119895
122093
119396
119899
102671
103057
103202
102771
119370
119903
116382
119366
114678
130196
126446
130197
119345
112327
(Ref.)
103957
112249
119369
119898
103100
103225
103141
103082
104466
106099
119373
119907
103041
119359
114469
102887
-
-
-
-
1
1
1
1
-
4
4
1
1
1
1
1
1
1
1
1
10 • BOLT, Hex-hd #8-18 x 1/2” lg.
1 • CONTROLLER ASSEMBLY, Drive/steer
(For components, refer to Figure 6.1-10B)
1
1
1
1
1
1
1
1
1
1
1
1
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
• SCREW, Machine #8-32 x 1/2” lg.
• WASHER, Lock #8
• HARNESS ASSEMBLY, Base/off/platform switch, emergency stop
• • CONNECTOR, 6 pole P. C. Board
• • BASE, Contact
• • 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,
• HEAD, Emergency stop switch
• HARNESS ASSEMBLY, Battery meter
• • CONNECTOR, 3 pole P. C. Board
• • BATTERY CHARGER INDICATOR
B
• HARNESS ASSEMBLY, Warning light, beeper
• • CONNECTOR, 7 pole P.C. Board
1
1
1
1
1
4
4
1
• • BLOCK & BASE, Warning light
• • BEEPER
• LENS
• BULB
• HARNESS ASSEMBLY, Lift/off/drive
• • CONNECTOR, 11 pole P.C. Board
• • 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, P.C. Board 15 pole
• • CONNECTOR, Strain relief
• • HOUSING, 16 pole
• • PLUG, 16 pole male
44” • • CABLE, 16/15
Parts list continued on following page.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 27
Index
No.
Figure 6.1-9B. Control Box Assembly (Continued)
(Model 8831E with Serial No. 37315 and Above) (Model 8841E with Serial No. 42702 and Above)
Skyjack
Part No.
Qty.
Description
AN
119397
119894
103100
103141
102851
111181
126447
104185
104694
104003
103962
103917
103987
100149
(Ref.)
100509
105807
(Ref.)
1
1
1
-
2
2
2
1
1
1
-
1
1
1
3
1
1
1
1
Parts list continued from previous page.
• HARNESS ASSEMBLY, Horn push-button
• • CONNECTOR, P.C. Board 2 pole
• • BASE, Contact
• • BLOCK, N.O. Contact
• 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
(For Components, Refer to Figure 6.6-5)
LANYARD, Retaining Pin
LABEL, Control Box
(For Components, Refer to Figure 6.8-2)
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 29
Figure 6.1-10A. Drive/Steer Controller Assembly
(Model 8831E with Serial No. 37314 and Below) (Model 8841E with Serial No. 42701 and Below)
1
2
4
5
3
4
6
8
14
13
7
11
9
10
12
M1022AA
Index
No.
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Skyjack
Part No.
119371
105735
105734
105733
105738
105737
105736
105378
106729
106730
106725
106726
119142
106731
110982
Qty.
-
1
1
1
1
1
1
1
1
1
1
1
1
2
2
Description
CONTROLLER ASSEMBLY, Drive/steer
• 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 SJ-800 Series E Battery Powered
119153
Figure 6.1-10B. Drive/Steer Controller Assembly
(Model 8831E with Serial No. 37315 and Above) (Model 8841E with Serial No. 42702 and Above)
1
2
4 3
Index
No.
1
2
3
4
Skyjack
Part No.
127063
126469
126488
126489
Qty.
-
2
1
9
Description
CONTROLLER ASSEMBLY, Drive/steer
• RELAY, DPDT 24V
• CONNECTOR, 9-Pin PCB
• PINS, PCB connector crimp
M10269AB
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 31
Figure 6.1-11. AC Outlet On Platform
L
AN
5
L
1
8
3 2
L
3 2
6
7
4
6
4
7
Index
No.
A
B
C
D
1
2
3
4
5
6
7
8
L
Skyjack
Part No.
113257
113256
117548
117549
131999
132042
109698
109699
104208
103035
105269
105269
117542
117542
103024
136328
134140
(Ref.)
Qty.
-
-
-
-
2
-
1
1
1
1
1
1
1
1
1
2
1
1
M11090AF
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)
M11090AG
BOX, G.F.C.I. Receptacle A & B
• RIVET, Pop (1/4” Dia.)
RECEPTACLE, 125V G.F.I. A & B
PLATE, Weatherproof cover, A & B
PLUG, 3-Prong male (15A/125V) A & B
ELBOW, Strain relief (90°)
CABTIRE (14/3 x 600” lg.) A
CABTIRE (14/3 x 720” lg.) B
CABTIRE (14/3 x 600” lg.) C
CABTIRE (14/3 x 720” lg.) D
CLIP, Cord
BOX, Outlet with fitting
• RIVET, Open end dome (1/4” Dia.)
(For components, refer to Figure 6.8-2)
SECTION 6, Page 32 SJ-800 Series E Battery Powered
119153
Figure 6.1-12. Air Hose To Platform Option
2
1
2
Index
No.
A
B
1
2
Skyjack
Part No.
116374
124177
Qty.
-
-
Description
AIR HOSE TO PLATFORM (Model 8841)
AIR HOSE TO PLATFORM (Model 8831)
(Ref.)
107882
1
1
HOSE ASSEMBLY, Air to platform
• FITTING, Female disconnect
107883 1 • FITTING, Male disconnect
107884 840” lg. • HOSE, Air 1/2” Dia. A
107884 720” lg. • HOSE, Air 1/2” Dia. B
109050
107886
102891
102893
107887
2
2
• FITTING, Hose barb
• CLAMP, Hose
AR STRAP, Tie 7” lg.
AR STRAP, Tie 10-1/2” lg.
2 LABEL, Connect air here
SJ-800 Series E Battery Powered
119153
M1017AA
SECTION 6, Page 33
Figure 6.2-1. Scissor Arm Assembly (Model 8831E)
34
AM
SECTION 6, Page 34
M1010AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
101632
103999
110408
101564
117840
111135
105395
131952
114043
103997
103972
112440
103865
103984
(Ref.)
110057
110395
110361
110347
110377
100071
110410
(Ref.)
103887
103404
110363
110328
102236
103887
103404
(Ref.)
110418
101689
103907
103468
103470
103471
101523
103997
115532
(Ref.)
111172
103256
119825
SJ-800 Series E Battery Powered
119153
Index
No.
Qty.
Figure 6.2-1. Scissor Arm Assembly (Model 8831E)
Description
1
1
1
ASSEMBLY, 3 Arm Scissor
ARM ASSEMBLY, 3rd Inner
ARM ASSEMBLY, 3rd Outer
ARM ASSEMBLY, 2nd Outer
1 ARM ASSEMBLY, 2nd Inner
AR BUSHING, End pin 1-1/4” x 2” lg.
7
1
-
1
1
1
PIN, End 1-1/4”
• PIN, End 1-1/4” (limit switch cam)
(For Components, Refer to Figures 6.6-6 & 6.6-7)
• BOLT, Hex-hd 5/16”-18 x 3/4” lg.
• WASHER, Lock 5/16”
ARM ASSEMBLY, 1st Inner
1 ARM ASSEMBLY, 1st Outer
12 PLATE, Center pin retainer
20 • BOLT, Hex-hd 5/16”-18 x 1” lg.
20 • WASHER, Lock 5/16”
32 • BOLT, Hex-hd 3/8”-16 x 3/4” lg.
32 • WASHER, Lock 3/8”
6 PIN, Center 1-3/4” x 9-1/2” lg.
18 BUSHING, Center pin 1-3/4” x 1-1/2” lg.
6
8
4
4
4
1
BEARING, Thrust (not shown)
BUMPER, Scissor arm 2-1/2” x 1-1/16” thk. (arm)
4 BUMPER, Scissor arm 2-1/2” x 1-1/2” thk. (base)
16 SPACER, Bumper
-
1
1
2
8
4
4
2
1
-
4
3
1
1
1
-
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
(For Components, Refer to Figure 6.2-3)
BEEPER, LIGHT AND HORN ASSEMBLY
(For Components, Refer to Figures 6.6-6 & 6.6-7)
PIN, Centering bar pivot
WELDMENT, Centering bar pivot
16 • BOLT, Hex-hd 1/2”-13 x 11/2” lg.
16 • WASHER, Flat 1/2”
16 • WASHER, Lock 1/2”
16 • 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
(For Components, Refer to Figures 6.2-4)
CORD ASSEMBLY, Holding valve (Not shown)
• CABLE, 18/2 x 321” lg.
• CONNECTOR, Solenoid
Parts list continued on the following page.
AM
SECTION 6, Page 35
Index
No.
-
-
-
Skyjack
Part No.
Figure 6.2-1. Scissor Arm Assembly (Model 8831E) (Continued)
Qty.
Description
124761
103078
124445
103962
104694
104185
104003
124763
(Ref.)
(Ref.)
104698
104003
124642
103887
111954
102780
111534
103855
104000
111137
110409
111225
101949
105549
101950
103701
117148
117553
101581
110413
103404
103938
103937
133130
112449
104000
103995
103980
104127
108791
106977
Parts list continued from the previous page.
1
4
4
8
1
1
1
1
32 • PIN, 3/8” diameter x 1.25” lg.
8
8
16 • PAD, Teflon 3/8” x 1-1/4” x 5-1/2” lg.
8
1
1
-
2
2
9
1
-
-
9
9
9
9
2
4
1
2
LATCH ASSEMBLY, Safety bar
• LATCH, Safety bar
• KNOB, Latch
• BOLT, Hex-hd 1/4”-20
• WASHER, Lock 1/4”
NUT, Jam 2-1/8”
PIN, Lift cylinder pivot
SLIDER ASSEMBLY
• WELDMENT, Slider
• PAD, Teflon 3/8” x 3-1/2” 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
• WASHER, Lock #10 NOM
• NUT, Machine #10 -32 grade B
• LABEL, Ontario Hydro
CAM, Limit Switch
(For Components, Refer to Figures 6.6-6 & 6.6-7)
(For Components, Refer to Figures 6.6-6 & 6.6-7)
2
2
4
2
• BOLT, Machine #10-32 x 3/4” lg.
• NUT, Machine #10-32
AR SPACER, 1/4”
AR BOLT, Hex-hd 5/16”-18 x 3/4” lg.
AR WASHER, Lock 5/16” lg.
AR BOLT, Socket 3/8”-16 grade 5 x 1 1/2” lg.
AR BOLT, Socket 3/8”-16 grade 5 x 3/4” lg.
1 • 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
NOTE: The following components were used on earlier models:
AR PROTECTION, Adhesive Cable 72” lg. (Not Shown)
9
1
CLIP, Adhesive Cord (Not shown)
BRACKET, Horn mounting (Earlier Models)
SJ-800 Series E Battery Powered
119153
AN
SECTION 6, Page 37
Figure 6.2-2. Scissor Arm Assembly (Model 8841E)
AM
SECTION 6, Page 38
M1009AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
110059
103999
110408
101564
117840
111135
105395
103936
131952
114043
112440
103865
103984
(Ref.)
(Ref.)
110361
110389
110381
110359
110347
110377
100071
110410
(Ref.)
110363
110328
102236
103887
103404
103473
110418
101689
103907
103468
103470
103471
101523
103997
115532
(Ref.)
Index
No.
A
Qty.
Figure 6.2-2. Scissor Arm Assembly (Model 8841E)
Description
ASSEMBLY, 4 Arm Scissor
1
1
1
1
• ARM ASSEMBLY, 4th Outer
• ARM ASSEMBLY, 4th Inner
• ARM ASSEMBLY, 3rd Inner
• ARM ASSEMBLY, 3rd Outer
1
1
• ARM ASSEMBLY, 2nd Outer
• ARM ASSEMBLY, 2nd Inner
AR BUSHING, End pin 1-1/4” x 2” lg.
11 • PIN, End 1-1/4”
1
-
1
1
• PIN, End 1-1/4” (limit switch cam)
(For Components, Refer to Figures 6.6-6 & 6.6-7)
• ARM ASSEMBLY, 1st Inner
• ARM ASSEMBLY, 1st Outer
16 • PLATE, Center pin retainer
16 • • BOLT, Hex-hd 5/16”-18 x 1” lg.
16 • • WASHER, Lock 5/16”
32 • • BOLT, Hex-hd 3/8”-16 x 1” lg.
-
1
-
4
1
1
1
1
32 • • WASHER, Lock 3/8”
8 • PIN, Center 1-3/4” x 9-1/2” lg.
48 • BUSHING, Center pin 1-3/4” x 1-1/2” lg.
8 • BEARING, Thrust
12 BUMPER, Scissor arm 2-1/2” x 1-1/16” thk. (arm)
4 BUMPER, Scissor arm 2-1/2” x 1-1/2” thk. (base)
12 • BOLT, Soc-hd 3/8”-16 x 1” lg.
16 • SPACER, Bumper 2-1/2” dia.
4 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
(For Components, Refer to Figure 6.2-3)
BEEPER/LIGHT AND HORN ASSEMBLY
(For Components, Refer to Figures 6.6-6 & 6.6-7)
PIN, Centering bar pivot
AR WELDMENT, Centering bar pivot
8
4
4
2
-
16 • BOLT, Hex-hd 1/2”-13 x 1-3/4” lg.
16 • WASHER, Flat 1/2”
16 • WASHER, Lock 1/2”
16 • 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.
(For Components, Refer to Figure 6.2-4)
Parts list continued on the following page.
SJ-800 Series E Battery Powered
119153
AM
SECTION 6, Page 39
Index
No.
-
-
-
Skyjack
Part No.
Figure 6.2-2. Scissor Arm Assembly (Model 8841E) (Continued)
Qty.
Description
117553
101581
110413
124762
103078
124445
103962
104694
104185
104003
124763
(Ref.)
(Ref.)
124642
111172
103256
119825
111954
102780
111534
103855
104000
111137
110409
111225
101949
105549
101950
103701
117148
103887
103404
103938
103937
133130
112449
104000
103995
103980
104127
108791
106977
Parts list continued from the previous page.
1
1
1
1
1
1
2
1
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.
• WASHER, Lock 1/4”
4
4
NUT, Jam 1-1/2”-12
PIN, Lift cylinder pivot
8 SLIDER ASSEMBLY
32 • PIN, 3/8” diameter x 1.25” lg.
8
8
• WELDMENT, Slider
• PAD, Teflon 3/8” x 3-1/2” x 5-1/2” lg.
16 • PAD, Teflon 3/8” x 1-1/4” x 5-1/2” lg.
8
1
-
-
-
1
2
8
1
• 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
2
CLAMP ASSEMBLY (Ontario Hydro)
• CLAMP, Double G10
11 • CLAMP, Double
11 • SCREW, Machine #10 - 32 x .5
11 • WASHER, Flat #10 S.A.E.
11 • WASHER, Lock #10 NOM
11 • NUT, Machine #10 -32 grade B
• LABEL, Ontario Hydro
(For Components, Refer to Figures 6.6-6 & 6.6-7)
-
(For Components, Refer to Figures 6.6-6 & 6.6-7)
AR
AR BOLT, Hex-hd 5/16”-18 x 3/4” lg.
AR WASHER, Lock 5/16” lg.
AR BOLT, Socket 3/8”-16 grade 5 x 1 1/2” lg.
AR BOLT, Socket 3/8”-16 grade 5 x 3/4” lg.
1
2
2
4
2
• 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
NOTE: The following components were used on earlier models:
AR PROTECTION, Adhesive Cable 72” lg. (Not Shown)
9
1
CLIP, Adhesive Cord (Not shown)
BRACKET, Horn mounting (Earlier Models)
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 41
Figure 6.2-3. Hydraulic Hose Connections- Scissors
SECTION 6, Page 42
M1003AA
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
(Ref.)
114578
125430
103746
104637
104437
103090
110592
114582
114227
113556
119085
113494
114583
113496
114218
110473
Qty.
Figure 6.2-3. Hydraulic Hose Connections - Scissors
Description
2
1
1
1
8
8
2
2
2
-
4
1
CYLINDER ASSEMBLY, Lift
(For Components, Refer to Figures 6.2-4)
FITTING, Elbow 90° #6orb-#6
BLOCK, Lift manifold
• BOLT, Socket 5/16”-18
• WASHER, Lock 5/16”
PLUG, Soc-hd #6
CONDUIT, Convoluted 1-1/4” x 28” lg.
2
1
1
1
HOSE ASSEMBLY, Lift cylinder 30” lg.
FITTING, Elbow 90° #8orb-#6
HOSE ASSEMBLY, Lift manifold to lowering valve manifold 149” lg.
VALVE ASSEMBLY, Lowering
AR • KIT, Seal repair
1 BLOCK, Lowering valve manifold
FITTING, Elbow 90° #8orb-#8
SPACER, Orifice
ORIFICE, .070 Diameter
HOSE ASSEMBLY, Lowering valve manifold to main manifold 60” lg.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 43
Figure 6.2-4A. Lift Cylinder Assembly
(Model 8831E with Serial No. 36839 and Below) (Model 8841E with Serial No. 41670 and Below)
AN
SECTION 6, Page 44
M109953AA
SJ-800 Series E Battery Powered
119153
Figure 6.2-4A. Lift Cylinder Assembly
(Model 8831E with Serial No. 36839 and Below) (Model 8841E with Serial No. 41670 and Below)
Index
No.
Skyjack
Part No.
Qty.
Description
AN
A
109953
109227
109232
109246
109244
109247
109225
109248
109245
102856
102027
109249
109250
(Ref.)
112165
-
1
2
4
2
-
1
1
2
1
1
1
1
1
CYLINDER ASSEMBLY, Lift
• WELDMENT, Cylinder barrel
• WELDMENT, Cylinder rod
• WIPER, Rod
• SEAL, Rod
• RING, Rod wear
• GLAND, Front end
• RING, Piston wear
• O-RING, Front gland
• PLUG, Soc-hd 3/8”-24
• FITTING, Grease 1/8 NPT
• RING, Retaining
• BEARING, Spherical
BLOCK, Lift cylinder manifold
(For components, refer to Figure 6.2-5)
AR KIT, Seal repair
* Part of Seal Repair Kit, 112165.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 45
Figure 6.2-4B. Lift Cylinder Assembly
(Model 8831E with Serial No. 36840 and Above) (Model 8841E with Serial No. 41671 and Above)
AN
SECTION 6, Page 46
M1002AA
SJ-800 Series E Battery Powered
119153
Figure 6.2-4B. Lift Cylinder Assembly
(Model 8831E with Serial No. 36840 and Above) (Model 8841E with Serial No. 41671 and Above)
Index
No.
Skyjack
Part No.
Qty.
Description
AN
120349
120348
109232
109246
109244
109247
120317
109248
120446
102856
102027
109249
109250
(Ref.)
112165
1
1
1
2
-
1
1
1
CYLINDER ASSEMBLY, Lift
• WELDMENT, Cylinder barrel
• WELDMENT, Cylinder rod
• WIPER, Rod
• SEAL, Rod
• RING, Rod wear
• GLAND, Front end
• RING, Piston wear
1
1
• O-RING, Front gland
• PLUG, Soc-hd 3/8”-24
2 • FITTING, Grease 1/8 NPT
AR • RING, Retaining
2
-
• BEARING, Spherical
BLOCK, Lift cylinder manifold
(For components, refer to Figure 6.2-5)
AR KIT, Seal repair
* Part of Seal Repair Kit, 112165.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 47
Figure 6.2-5. Lift Cylinder Manifold Assembly AN
Note: Additional components for CE machines equipped with
Load Sensing System, refer to Load Sensing Supplement Manual.
SECTION 6, Page 48
M11218AA
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
106688
111316
108052
106557
107269
114578
103403
120481
104493
103931
104637
103996
Qty.
Figure 6.2-5. Lift Cylinder Manifold Assembly
Description
1
1
1
1
1
1
1
1
1
4
4
4
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”)
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 49
Figure 6.3-1. Base, Axles And Wheels
SECTION 6, Page 50
M11143AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
(Ref.)
(Ref.)
123855
126286
123856
(Ref.)
116801
129399
129397
129398
129387
112654
130035
112654
111613
106201
112654
112738
104085
111518
116801
(Ref.)
103907
103470
103468
(Ref.)
130031
130030
124982
124984
124981
124673
124980
124983
124979
124673
132975
132974
124981
124673
111612
106201
Index
No.
Qty.
Figure 6.3-1. Base, Axles And Wheels
Description
2
2
1
1
1
1
-
1
-
AXLE ASSEMBLY, Front idle (2wd)
(For Components, Refer to Figure 6.3-5)
AXLE ASSEMBLY, Front drive (4wd)
(For Components, Refer to Figure 6.3-4)
8
8
• BOLT, Hex-hd 1/2”-13 x 2-3/4” grade 8
• WASHER, Lock 1/2” heavy duty
8 • NUT, Hex-hd 1/2”-13 grade 8
16 BOLT, Wheel 5/8”-18 (For front idle axle)
-
(For Components, Refer to Figure 6.3-5)
16
NUT, Wheel 5/8”-18 (For front drive axle)
1 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
1
1
4
1
1
1
2
2
2
2
2
2
2
2
2
2
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
4
1
-
1
-
4
4
1
4
1
1
• 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
4
1
RIM/TIRE ASSEMBLY, #7 “McCreary” 8 ply Foam Filled 5.313” backspace
• TIRE, #7 8 ply (31x15.5x15)
1 • RIM, #7 12 x 15 - 8 bolt
16 NUT, Wheel 5/8-18 (For rear drive axle)
GEAR BOX AND DC DRIVE MOTOR ASSEMBLY
(For Components, Refer to Figure 6.3-7)
• BOLT, Hex-hd 1/2”-13 x 1-1/2” lg.
• WASHER, Lock 1/2”
• WASHER, Flat 1/2”
DISC BRAKE ASSEMBLY
(For Components, Refer to Figure 6.3-9)
Parts list continued on the following page.
AL
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 51
Index
No.
Skyjack
Part No.
117320
123806
(Ref.)
(Ref.)
151977
151979
103473
103472
103999
103978
(Ref.)
(Ref.)
123855
126286
123856
124342
132477
108767
119920
103964
124160
(Ref.)
117317
123547
103473
103472
103999
103978
(Ref.)
123760
123752
101632
103999
Qty.
Figure 6.3-1. Base, Axles And Wheels (Continued)
Description
Parts list continued from the previous page.
1
1
2
2
2
1
8
1
1
1
1
-
8
8
AXLE ASSEMBLY, Rear drive
(For Components, Refer to Figure 6.3-11)
• 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
(For Components, Refer to Figure 6.3-12)
WELDMENT, Base
WELDMENT, Base (w/Scissor Guard option)
Use Part # 117318 for Machines with Serial # 37007 (8831) or
1
-
1
1
1
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
(For Components, Refer to Figures 6.6-6 & 6.6-7)
HYDRAULIC/ELECTRIC CABINET ASSEMBLY
-
2
2
8
(For Components, Refer to Figure 6.5-1)
LADDER (Model 8831E)
LADDER (Model 8841E)
• BOLT, Hex-hd 3/8”-16 x 1” lg.
16 • WASHER, Flat 3/8”
8 • WASHER, Lock 3/8”
• NUT, Hex 3/8”-16
1
2
1
1
8
8
4
-
8
1
-
8
HYDRAULIC OIL TANK/CHARGER CABINET ASSEMBLY
(For Components, Refer to Figure 6.4-2)
• BOLT, Hex-hd 3/8”-16 x 1” lg.
16 • WASHER, Flat 3/8”
• WASHER, Lock 3/8”
• NUT, Hex 3/8”-16
LEG, Outrigger (Machines with Outrigger Option)
(For Components, Refer to Figures 6.7-1)
• STRAP, Static
• BOLT, 3/8”-16 x .75
• WASHER, 3/8” Lock
AO
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 53
Figure 6.3-2. Electrical Components - Base
SECTION 6, Page 54
M1062AD
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
(Ref.)
120100
103256
116992
116990
103367
120394
120395
119568
(Ref.)
123184
124880
117493
119829
117494
102871
103206
102700
105787
124879
119570
106746
117493
117494
105600
119567
119566
120765
120767
(Ref.)
120071
103256
119894
119293
120658
119571
117493
117494
106746
Qty.
Figure 6.3-2. Electrical Components - Base
Description
1
1
1
1
1
1
1
1
-
1
1
1
12 BATTERY, Boot Red (Traction Motor)
1 CABLE ASSEMBLY, Battery (S2)
CABLE ASSEMBLY, Battery (S1)
CABLE ASSEMBLY, Battery (A2)
CABLE ASSEMBLY, Battery (A1)
CABLE ASSEMBLY, Tach generator And Proximity
(For Components, Refer to Figure 6.6-4)
• 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 2
498” • CABLE, Welding #1
2
-
CONNECTOR ASSEMBLY, Battery
(For Components, Refer to Figure 6.6-2)
1 HARNESS, Charger Cut-out
144” • CABLE, 18/2 Cabtire
2
4
30” • HEATSHRINK, 1/4”
8
1
1
-
-
8
6
8
-
• PLUG, Male 2 Pole Housing
• PIN, Female Wire
BOOT, Battery Black
BOOT, Battery Red
CABLE ASSEMBLY, Battery
(For Components, Refer to Figure 6.3-12)
DUAL CHARGER ADAPTER (4’)
DUAL CHARGER ADAPTER (8’)
• CONNECTORS, Battery
(EE rated)
(Optional For EE rated)
2
4
2
• HANDLE, Battery disconnect
• CONTACTS, I/O
• PARALLEL SPLICE
• CONNECTOR, Battery
96” • WIRE, Black 10 AWG, (Used on 4’ Cable)
96” • WIRE, Red 10 AWG, (Used on 4’ Cable)
200” • CABLE, 10/2 SOW, (Used on 8’ Cable)
- CONNECTOR ASSEMBLY, Battery
48” • CABLE, Welding #1
1
2
• CONNECTOR
• CONTACTS
Parts list continued on the following page.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 55
Index
No.
Skyjack
Part No.
119569
(Ref.)
(Ref.)
103092
124176
103404
Figure 6.3-2. Electrical Components - Base (Continued)
Qty.
Description
Parts list continued from the previous page.
1
1
-
1
CABLE ASSEMBLY, Battery
SWITCH ASSEMBLY, Proximity
(For Components, Refer to Figure 6.6-4)
MOTOR And TACHOMETER GENERATOR ASSEMBLY
-
(For Components, Refer to Figure 6.3-7)
AR PROTECTOR, Wire 1”
Used on Machines with Serial #42303 (8841) and 37123 (8831) & Below.
4” PROTECTOR, 1 1/4” Wire
16 WASHER, 5/16” Lock
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 57
Figure 6.3-3. Hydraulic Hose Connections - Base
SECTION 6, Page 58
M1062AD
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
(Ref.)
114583
(Ref.)
114388
119854
110473
120057
114402
102659
108799
114325
109418
114578
(Ref.)
120056
110475
114233
114234
114326
102854
116800
(Ref.)
Qty.
Figure 6.3-3. Hydraulic Hose Connections - Base
Description
1
2
2
1
1
1
1
1
-
1
1
1
1
-
1
1
1
2
1
2
-
1
1
1
1
DISC BRAKE ASSEMBLY
(For components, refer to Figure 6.3-9)
PUMP, MANIFOLDS, GEAR BOX AND DRIVE MOTOR ASSEMBLY
(For components, refer to Figure 6.3-7)
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
FITTING, Connector #8orb-#8
HOSE, Barb
FITTING, Pump suction
HOSE ASSEMBLY, Steer 1/4” x 140”
FITTING, Elbow 90° #6orb-#6
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.)
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 59
Figure 6.3-4. Front Drive Axle Assembly - 4 Wheel Drive Machines
34
SECTION 6, Page 60
M1028AC
SJ-800 Series E Battery Powered
119153
Index
No.
A
Skyjack
Part No.
Figure 6.3-4. Front Drive Axle Assembly - 4 Wheel Drive Machines
Qty.
Description
115303
113900
113897
115373
$
113792
113793
108392
113899
113898
113896
113895
108388
105817
115728
108394
113888
113891
113908
115371
113909
113910
117130
113879
113880
113881
113882
113901
708440
110070
115602
120845
120191
122071
103264
102028
(Ref.)
102030
-
1
1
4
1
1
1
-
1
2
1
1
1
-
1
-
2
MODIFIED AXLE ASSEMBLY, Front drive (5.13 ratio)
• 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)
1
1
• AXLE ASSEMBLY, Front drive (DANA #070BA502-14)
• • COVER, Carrier
1 • • PLUG, Carrier cover
12 • • BOLT, Drive gear
1
1
• • DIFFERENTIAL ASSEMBLY
• • • GEAR SET, Internal differential
AR • • • KIT, Disc and plate
8
1
1
1
• • • BOLT, Differential case
• • DRIVE GEAR AND PINION SET
• • SLINGER, Inner pinion
• • BEARING ASSEMBLY, Inner pinion
AR • • KIT, Pinion adjusting shim
1 • • SLINGER, inner pinion bearing
AR • • KIT, Spindle bearing and seal
2
1
• • SLINGER
• • AXLE SHAFT ASSEMBLY, LH (37” lg.)
(Includes item #35)
• • AXLE SHAFT ASSEMBLY, RH (47” lg.)
2
2
2
2
2
2
(Includes item #35)
• • JOINT, Universal drive
• • CAP, Lower king pin
• • TIE ROD ASSEMBLY
• • • TIE ROD
• • • END, Tie rod RH
1 • • • END, Tie rod LH
AR • • 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
Parts list continued on the following page.
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 61
Index
No.
Figure 6.3-4. Front Drive Axle Assembly - 4 Wheel Drive Machines (Continued)
Skyjack
Part No.
Qty.
Description
113732
113733
113902
108393
108390
113903
111719
113907
119179
134763
119180
113904
113905
108391
113886
113885
113887
113884
113883
113893
113890
113889
$
113892
Parts list continued from the previous page.
2
2
1
1
2
2
2
4
1
1
2
2
• • KNUCKLE, Steering LH (shown)
• • KNUCKLE, Steering RH (opposite)
• • SPINDLE ASSEMBLY
• • SEAL, Wheel hub
2
2
• • BEARING ASSEMBLY, Inner hub
• • HUB, Wheel
16 • • • STUD, Wheel 5/8-18 RH
2 • • CAP, Hub
• • GEAR, Drive
• • • RING, Snap
• • SPACER, Drive gear
• • NUT, Bearing retaining
• • WASHER, Retaining nut lock
• • BEARING ASSEMBLY, Outer hub
• • NUT, Pinion
1
1
1
1
AR • • KIT, Differential bearing shim
2
1
1
• • WASHER, Pinion nut
• • YOKE ASSEMBLY, End
• • SEAL, Pinion
• • BEARING ASSEMBLY, Outer pinion
• • SEAL AND GUIDE ASSEMBLY
• • BEARING ASSEMBLY, Differential
• • HOUSING W/BEARING CAPS, Front drive axle
• • PLUG, Vent
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 63
Figure 6.3-5. Front Idle Axle Assembly - 2 Wheel Drive Machines
SECTION 6, Page 64
M1004AB
SJ-800 Series E Battery Powered
119153
Index
No.
A
Skyjack
Part No.
Figure 6.3-5. Front Idle Axle Assembly - 2 Wheel Drive Machines
Qty.
Description
120345
102905
102979
103004
120414
100309
103264
102229
103845
103996
101995
111756
113432
102028
113489
103990
104002
100252
(Ref.)
108487
100249
101801
102230
103887
103996
102027
111755
107908
103220
103085
104351
102646
102978
103009
103198
-
2
2
2
2
2
1
1
2
2
1
-
2
2
2
2
2
2
2
2
AXLE ASSEMBLY, Front idle
2
2
2
1
1
8
2
2
• 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.
• • WASHER, Flat 5/16”
• NIPPLE, Grease
• WELDMENT, Spindle arm LH
2
2
2
2
• HUB ASSEMBLY, Front wheel
• • CAP, Dust
• • PIN, Cotter 3/16” x 1-1/2” lg.
• • NUT, Castle 1”-14
2
2
• • WASHER, Flat
• • BEARING, Outer cup
2 • • BEARING, Outer cone
16 • • 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
• • WASHER, Flat 5/16”
• 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
(For components, refer to Figures 6.3-6)
SJ-800 Series E Battery Powered
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
10
9
8
7
6
Index
No.
A
1
* 2
* 3
4
* 5
6
* 7
* 8
9
10
11
12
13
14
*
Skyjack
Part No.
112498
113347
113350
107934
112496
113349
104111
103829
107935
112497
103830
112494
102025
104114
103513
113443
SECTION 6, Page 66
M112498AA
Qty.
Description
-
1
1
1
2
2
2
1
1
1
1
1
1
1
1
CYLINDER ASSEMBLY, Steer (2WD/4WD)
• ROD, Steering
• SEAL, Steering rod
• O-RING, Gland
• GLAND, Front end
• WIPER, Rod
• SPACER
• O-RING, Piston
• SEAL, Piston
• PISTON, Cylinder
• NUT, Lock 5/8-11 grade C
• WELDMENT, Cylinder barrel
• BEARING, Spherical
• RING, Retaining
• FITTING, Grease
AR KIT, Seal Repair
* Part of Seal Repair Kit.
SJ-800 Series E Battery Powered
119153
Figure 6.3-6B. Steer Cylinder Assembly
(Model 8831E with Serial Number 36840 and Above) (Model 8841E with Serial Number 41671 and Above)
2
3
4
5
1
15 6
13
13
12
14 15
13
12
13
11
7 10
9
8
M120405AE
Index
No.
A
1
* 2
* 3
4
* 5
6
* 7
* 8
9
10
11
12
13
14
15
Skyjack
Part No.
120405
113347
113350
120438
120401
113349
103513
110976
107935
120633
103830
120404
102025
104114
104350
132565
Qty.
Description
- CYLINDER ASSEMBLY, Steer (2WD/4WD)
1
2
1
1
1
1
1
1
1
1
1
2
• ROD, Steering
• SEAL, Steering rod
• O-RING, Gland
• GLAND, Front end
• WIPER, Rod
• FITTING, Grease
• O-RING, Piston
• SEAL, Piston
• PISTON, Cylinder
• NUT, Lock 5/8”-11 grade C
• WELDMENT, Cylinder barrel
• BEARING, Spherical
AR • RING, Retaining
1
2
• FITTING, Grease 1/4”-28 90 deg
• CAP, Grease fitting
* 121108 1 KIT, Seal Repair
SJ-800 Series E Battery Powered
119153
* Part of Seal Repair Kit.
SECTION 6, Page 67
Figure 6.3-7. Pump, Gear Box And Drive Motor Assembly
SECTION 6, Page 68
M1066AA
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
(Ref.)
100844
100352
111577
120228
120221
120224
120222
120223
120002
119750
119751
106099
119999
120110
117074
103864
103404
103880
103979
700227
700487
117071
114271
103256
700081
116757
103899
103998
(Ref.)
120001
120000
116796
116218
128793
128789
128791
128792
128790
112709
103099
116179
103084
Figure 6.3-7. Pump, Gear Box And Drive Motor Assembly
Qty.
Description
1
4
4
1
4
1
1
1
4
4
1
1
-
1
-
4
1
4
4
2
1
1
1
1
2
2
1
1
1
1
4
4
TACH GENERATOR ASSEMBLY
• HOUSING, Tach generator
• BOLT, Hex-hd 5/16-18 x 1” lg.
• WASHER, Lock 5/16”
• 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.
• WASHER, Lock 5/8”
SENSORS, Proximity (pump/drive)
(For Components, Refer to Figure 6.6-4)
GEAR BOX ASSEMBLY
(For Components, Refer to Figure 6.3-8)
• BOLT, Hex-hd 5/8”-11 x 2-3/4” lg.
• WASHER, Flat 5/8”
• 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
-
1
AR • KIT, Universal joint
1
1
1
1
1
1
1
4
6
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
• 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.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 69
Figure 6.3-8. Gearbox Assembly
SECTION 6, Page 70
M120234AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
120234
122931
122926
122938
122935
122939
122933
122930
122942
122943
122953
122941
122927
122934
122928
122925
122924
122918
122920
122921
122922
122923
122944
122945
122951
122950
122948
122946
122929
122940
122932
122937
122936
122949
122947
122954
122952
122919
116802
122955
Index
No.
A
Qty.
Figure 6.3-8. Gearbox Assembly
Description
1 GEAR BOX ASSEMBLY
1
1
1
1
1
2
1
1
1
5
1
1
1
2
1
3
1
1
1
1
1
1
1
1
1
1
4
1
1
2
1
1
1
1
2
2
• 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
• RING, 75X2.5 Retaining
• CAGE, Needle
• GUIDE, Shift Collar
• FORK, Shift
• PIN, 6X40 Spring Type Straight
• O-RING, 25X3
• BAR, Shift
• RING, 85X3.0 Retaining
• BEARING, 6209 Ball
• SHAFT, Drive
• O-RING 75X3
• FLANGE, Motor
• BEARING, NJ208E Roller
• GEAR, 65X3.5 Helical
• RING, D80X100X10 Shaft Sealing
• BEARING, 6216 Ball
1 • HOUSING, Flange Side Half
6.5 OIL, Gearbox (Litres)
- KIT, Gearbox Seal
* Part Of Seal Repair Kit
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 71
Figure 6.3-9. Disc Brake Assembly
SECTION 6, Page 72
M120572AA
SJ-800 Series E Battery Powered
119153
Index
No.
A
Skyjack
Part No.
120572
103470
115347
110529
103872
104636
103977
115912
100845
100352
111577
103907
107949
111117
103872
104636
103977
111961
(Ref.)
(Ref.)
109579
109599
109598
109600
109601
109580
103907
103470
103468
109602
120996
120997
120998
103909
Qty.
Figure 6.3-9. Disc Brake Assembly
Description
- ASSEMBLY, Disk Brake
2
2
1
4
1
2
4
2
4
8
2
-
-
1
4
4
4
1
3
3
1
1
1
1
1
1
-
2
1
ASSEMBLY, Disc Brake Cylinder
(For components, refer to Figure 6.3-10)
SPACER, Cylinder Mounting
CLEVIS, Rod End 1/2-20
NUT, Jam 1/2-20
PIN, Clevis
PIN, Cotter
BRACKET, Brake Cylinder
2
2
2
1
• BOLT, Hex-hd 1/2-13 X 1-1/2” Lg.
• WASHER, Lock 1/2”
• WASHER, Flat 1/2”
ASSEMBLY, Disc Brake Caliper
AR • KIT, Disc Pad Thin
1 • • PAD, Brake, Actuated
• • PAD, Brake, Non actuated
• BOLT, Hex-hd 1/2”-13 X 1-1/4” Lg.
• WASHER, Lock 1/2”
• LEVER, Brake Actuator
DISC, 11” Diameter Brake
• BOLT, Hex-hd 3/8”-16 X 2-1/4” Lg.
• WASHER, Lock 7/16”
• NUT, Hex 7/16”-14
SUPPORT, Disc Brake Tube
• BOLT, Hex-hd 5/8”-11 X 3-1/2” Lg. Grade 8
• WASHER, Flat 5/8”
• 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.
• WASHER, Lock 7/16”
• NUT, Hex 7/16”-14
PAD, Brake Support
FLANGE, Drive Shaft Yoke
(For components, refer to Figure 6.3-7)
SJ-800 Series E Battery Powered
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
13
1
14
12
5
4 10
2
3
Index
No.
A
1
2
* 3
* 4
5
* 6
* 7
8
9
10
11
12
13
14
*
Skyjack
Part No.
112448
109575
109571
106583
109597
109572
116364
109596
111803
109574
109573
109642
109603
109604
109579
112274
SECTION 6, Page 74
M112448AC
Qty.
-
1
1
1
1
1
2
1
1
1
1
1
1
1
1
CYLINDER ASSEMBLY, Disc brake
• WELDMENT, Cylinder barrel
• GLAND, Front end
• O-RING, Front gland
• 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
AR KIT, Seal repair
* Part of Seal Repair Kit
Description
SJ-800 Series E Battery Powered
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
Index
No.
A
1
* 2
3
4
5
6
* 7
8
* 9
10
11
12
*
Skyjack
Part No.
120412
120631
109597
120409
109573
109604
109603
116364
120630
120632
111803
120411
109579
112274
Qty.
-
1
1
1
1
1
1
1
1
1
1
1
2
CYLINDER ASSEMBLY, Disc brake
• ROD, Brake cylinder
• WIPER, Brake rod
• GLAND, Front end
• SPACER, Stroke limit
• SPRING, Outer
• SPRING, Inner
• SEAL, Piston
• PISTON
• O-RING, Piston
• NUT, Hex 7/16-20
• WELDMENT, Cylinder barrel
SPACER, Mounting
AR Kit, Seal Repair
* Part of Seal Repair Kit
Description
SJ-800 Series E Battery Powered
119153
M120412AF
SECTION 6, Page 75
Figure 6.3-11. Rear Drive Axle Assembly
AM
SECTION 6, Page 76
M1029AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
113913
113883
113920
113921
109137
109137
113925
113924
113919
113916
113918
113915
113917
113889
113912
115821
115729
113888
108394
113926
117130
113880
113881
113882
$
$
$
113886
113885
113914
113884
Index
No.
Qty.
Figure 6.3-11. Rear Drive Axle Assembly
Description
1
1
1
1
1
1
2
4
1
1
-
-
MODIFIED AXLE ASSEMBLY, Rear drive (5.13 ratio)
• AXLE ASSEMBLY, Rear drive (DANA #070AF512-51A)
• • PLUG, Cover carrier
• • COVER, Carrier
1
1
• • DIFFERENTIAL ASSEMBLY, (Detroit Locker)
• • DRIVE GEAR AND PINION ASSEMBLY
1 • • BEARING ASSEMBLY, Inner pinion (Includes item 4)
AR • • 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
1
1
4
2
• • SLINGER, Inner pinion bearing
• • BEARING ASSEMBLY, Outer pinion
• • NUT, Spindle
• • WASHER, Spindle
1
1
• • SHAFT, Flanged axle LH (shown)
• • SHAFT, Flanged axle RH (opposite)
16 • • NUT, Stud
16 • • ADAPTER, Stud nut
2
2
2
2
16 • • STUD, Axle hub
2 • • BEARING ASSEMBLY, Outer wheel
• • HUB, Wheel
• • BEARING ASSEMBLY, Inner wheel
• • SEAL, Hub
• • BEARING ASSEMBLY, Differential
AR • • KIT, Differential shim
AM
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 77
Figure 6.3-12. Battery Roll-out Tray Assembly
SECTION 6, Page 78
M1074AA
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
119364
103068
120112
123780
123779
119915
119967
109694
119827
(Ref.)
119974
109123
(Ref.)
117261
115220
102780
119746
115404
111351
116621
103232
103055
(Ref.)
102781
103864
111534
103855
104000
117276
119815
123819
117262
123821
117260
123818
117263
123820
Qty.
Figure 6.3-12. Battery Roll-out Tray Assembly
Description
1
2
2
1
2
2
1
1
1
-
1
1
1
-
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
3
1
1
1
1
1
WELDMENT, Battery roll-out tray
• LATCH, Battery tray
WELDMENT, Battery box
GUARD, Battery tray
4 ROLLER, Battery tray
AR • SHIM, 7/8” x 1-3/16 x 1/16” thk
2
2
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.
• • WASHER, Lock 1/4”
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
(For Components, Refer to Figure 6.3-2)
HOLDER, Cable
(For Components, Refer to Figure 6.3-2)
PLYWOOD, 3/8” x 10-1/8 x 28-1/2”
PLYWOOD, 3/8” x 10-1/8 x 28-1/2”
PLYWOOD, 3/8” x 9-1/2 x 28-1/2”
PLYWOOD, 3/8” x 24-1/4” x 28-1/2”
PLYWOOD, 3/8” x 24-1/4” x 28-1/2
PLYWOOD, 1/4” x 10-1/2 x 24-1/4”
PLYWOOD, 1/4” x 10-1/2 x 24-1/4”
(EE Rated)
PLYWOOD, 1/4” x 13-1/4” x 28-1/2” (EE Rated)
(EE Rated)
(EE Rated)
Parts list continued on the following page.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 79
Index
No.
Skyjack
Part No.
112307
103886
112308
103886
116133
116136
116135
112378
116132
116136
116135
112378
106552
(Ref.)
(Ref.)
116494
123367
122834
122998
122999
122835
122836
Figure 6.3-12. Battery Roll-out Tray Assembly (Continued)
Qty.
Description
Parts list continued from the previous page.
2
1
1
3
1
2
1
1
1
1
1
1
-
2
1
1
8
6
-
-
BATTERY, 6 Volt (Trojan U-2500)
(For Components, Refer to Figure 6.3-2)
(For Components, Refer to Figure 6.3-2)
CARRIER ASSEMBLY, Hose (18 links)
• BRACKETS, Carrier Assembly Mounting (2 Pieces)
1
1
• • BRACKET, Carrier Assembly Mounting (Male)
• • BRACKET, Carrier Assembly Mounting (Female)
AR • SEPARATOR, E-Chain
AR • 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”
• SCREW, Shoulder 1/4” x 1/4”
• WASHER, Brass 17/64” ID x 15/32” OD
HANDLE, RH
• SCREW, Shoulder 1/4” x 3/8”
• SCREW, Shoulder 1/4” x 1/4”
• WASHER, Brass 17/64” ID x 15/32” OD
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 81
Figure 6.4-1. Hydraulic Oil Tank/Charger Cabinet Assembly
SECTION 6, Page 82
M1077AA
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
120242
120252
109779
108464
103628
101541
111944
108463
103628
101541
111944
116052
124296
(Ref.)
101632
103472
103999
103978
(Ref.)
103090
120253
120199
Figure 6.4-1. Hydraulic Oil Tank/Charger Cabinet Assembly
Qty.
Description
1
1
1
1
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
AR • SEAL, Door (102” total)
1 • HANDLE W/LOCK, Recessed
AR • • KEY, Door #CH501
1 DOOR, Battery charger access
AR • SEAL, Door (88” total)
1 • HANDLE W/LOCK, Recessed
AR • • KEY, Door #CH501
AR CABLE, Door stop (18”)
1 CABLE, Door stop (13.25”)
TANK ASSEMBLY, Hydraulic oil
2
2
-
-
1
-
2
2
(For components, refer to Figure 6.4-2)
• BOLT, Hex-hd 3/8”-16 x 3/4” lg.
• WASHER, Flat 3/8”
• WASHER, Lock 3/8”
• NUT, Hex 3/8”-16
CHARGER ASSEMBLY, Battery
(For components, refer to Figures 6.4-4)
AR CONDUIT, Convoluted (edge protection) 57” lg.
2
1
SUPPORT, Battery charger
COVER, Charger (splash guard)
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 83
Earlier Models
Figure 6.4-2. Hydraulic Oil Tank Assembly
Later Models
M1067AA
SECTION 6, Page 84
M11077AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
132083
116753
103980
123022
123021
123020
122973
121571
122969
122968
110517
102918
103320
117701
103339
(Ref.)
132128
132180
114337
119309
103236
124311
113118
132127
102694
103959
114331
103964
112187
109568
104254
103857
104000
Index
No.
A
B
Qty.
Figure 6.4-2. Hydraulic Oil Tank Assembly
Description
-
-
TANK ASSEMBLY, Hydraulic Oil (Later Models)
TANK ASSEMBLY, Hydraulic Oil (Earlier Models)
1
1
1
1
1
1
1
3
1
1
-
1
2
2
1
1
1
1
1
2
1
1
80 L • OIL, Hydraulic (Liters)
1
2
1
1
1
• WELDMENT, Hydraulic oil tank, A
• WELDMENT, Hydraulic oil tank, B
• GAUGE ASSEMBLY, Oil level temp
• INSERT, Threaded (Not Needed If Ordering Gauge Assembly)
• NECK, Side filler, B
• CAP, Filler Assembly w/ Vent, A
6
1
• CAP W/GASKET, Filler/breather, B
• • SCREW, Machine #10-24 x 1/4” lg.
• COVER , Hydraulic tank, B
14 • • SCREW, Machine #10-32 x 1/4” lg.
• FITTING, 3/4” Hose barb
• FILTER ASSEMBLY, Return
• • ELEMENT, Filter
• • BOLT, Hex-hd 1/4”-20 x 1” lg.
• • WASHER, Lock 1/4”
• • 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,
• PLUG, Drain Plug 3/4” NPT,
LABELS
A
B
• SCREEN, Filler Neck (Inside), A
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 85
Figure 6.4-3. Hydraulic Hose Connections - Hydraulic Electric/Tray
AN
SECTION 6, Page 86
M120034AD_1
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
Figure 6.4-3. Hydraulic Hose Connections - Hydraulic Electric/Tray
Qty.
Description
(Ref.)
(Ref.)
110498
(Ref.)
120038
103069
119748
107271
120036
120141
(Ref.)
102854
114402
108478
103002
146119
120504
104402
1
1
-
1
2
1
1
1
1
1
-
1
1
-
1
-
1
1
1
1
1
1
MOTOR/PUMP ASSEMBLY, Hydraulic
(For components, refer to Figure 6.5-1)
BASE HOSE ASSEMBLIES, Hydraulic
(For components, refer to Figure 6.3-3)
FITTING, Reducing Connector #6-#8
MANIFOLD ASSEMBLY, Auto reset brake
(For components, refer to Figure 6.5-2)
HOSE ASSEMBLY, Auto reset brake to main manifold
FITTING, Connector #6orb-#6
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
(For components, refer to Figure 6.5-3)
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
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 87
SECTION 6, Page 88
Figure 6.4-4A. Battery Charger Assembly - Mac #BA1001
M1086AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
117393
108554
708974
708976
103364
108556
108558
700688
115315
700689
700690
108562
700691
108564
111907
700692
708975
110857
700530
700635
700597
105269
105807
Index
No.
A
Figure 6.4-4A. Battery Charger Assembly - Mac #BA1001
Qty.
Description
- CHARGER ASSEMBLY, Battery (MAC #BA1001) (North American)
48VDC, 25A, 120VAC, 60 Hz
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
• 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,
1
1
1
1
• STOP SWITCH, N.O.
CABLE ASSEMBLY, Charger A.C.,
• PLUG, 15A Male
• RECEPTACLE, 20 Amp Female
8” • CABLE, 14/3
1 • LANYARD, 6” lg.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 89
Figure 6.4-4B. Battery Charger Assembly (Motor Appliance #BA1045 and #BA961)
SECTION 6, Page 90
M120075AA
SJ-800 Series E Battery Powered
119153
Index
No.
Figure 6.4-4B. Battery Charger Assembly (Motor Appliance #BA1045 and #BA961)
Skyjack
Part No.
Qty.
A 120075-AA
B 120075-AE
C 120075-AN 2
2
2
119157
119143
119151
119183
119160
119152
103206
117177
117178
119162
119161
119148
119150
119185
119186
119155
119156
119149
119145
119184
119144
119159
119187
119146
120790
120791
120789
119188
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
2
1
1
1
1
1
2
2
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)
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 91
Figure 6.4-4C. Battery Charger Assembly - Bycan 4825U
SECTION 6, Page 92
M1079AC
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
122367
121534
121564
121536
121537
121538
121539
121540
121541
121542
121543
121565
121545
121546
121566
115391
121567
120789
120790
120791
120820
120821
123764
Index
No.
A
Figure 6.4-4C. Battery Charger Assembly - Bycan 4825U
Qty.
Description
-
1
1
1
1
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
CHARGER ASSEMBLY, Battery
• 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
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 93
Figure 6.4-4D. Battery Charger Assembly
SECTION 6, Page 94
M10734AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
129685
130096
130092
127155
130091
127164
130093
129688
127171
127154
130097
127158
130089
127156
130094
103206
115391
130090
103856
103995
104000
103980
120789
120790
Index
No.
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
4
4
Figure 6.4-4D. Battery Charger Assembly
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)
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 95
SECTION 6, Page 96
Figure 6.5-1. Hydraulic/Electric Cabinet Assembly
M10036AB
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
103855
104000
103995
120628
111814
116052
124296
117880
114866
120031
103855
104000
(Ref.)
116107
103404
119976
119986
124408
114377
102657
108328
120094
102451
111181
102853
115573
(Ref.)
103996
120039
(Ref.)
103887
103404
103996
700224
700669
106052
700668
109174
109175
Qty.
Figure 6.5-1. Hydraulic/Electric Cabinet Assembly
Description
1
1
1
1
8
2
2
2
1
4
1
1
-
1
-
4
4
1
1
2
2
1
2
2
1
2
2
2
1
1
1
1
-
1
1
1
1
WELDMENT, Hydraulic/electric cabinet
(For machines without Scissor Guard Option)
WELDMENT, Hydraulic/electric cabinet
(For machines with Scissor Guard Option)
WELDMENT, Hydraulic/electric cabinet
(For EE Rated machines)
PLUG, 1/2” (CE)
LABEL, Platform up/down (ANSI/SIA and CSA)
1 LABEL, Platform up/off/down (CE)
10 BOLT, Machine #10-32 x 5/8” lg.
1
2
LABEL, Plat/base Select
GUARD, Toggle
SWITCH, Toggle up/down
SWITCH, Toggle platform/base select (ANSI/SIA AND CSA)
BLOCK, Emergency lowering valve manifold
(For Components, Refer to Figure 6.4-3)
• BOLT, Hex-hd 1/4”-20 x 1/2” lg.
• WASHER, Lock 1/4”
• WASHER, Flat 1/4”
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.
• WASHER, Lock 1/4”
MANIFOLD ASSEMBLY, Main
(For Components, Refer to Figure 6.5-3)
• WASHER, Lock 5/16”
• WASHER, Flat 5/16”
SPACER, Manifold mounting
MANIFOLD ASSEMBLY, Brake
(For Components, Refer to Figure 6.4-3)
• BOLT, Hex-hd 5/16”-18 x 3/4” lg.
• WASHER, Lock 5/16”
• WASHER, Flat 5/16”
PUMP/MOTOR ASSEMBLY, Hydraulic
• PUMP, Hydraulic
• COUPLING
• MOTOR, 48 Volt
• • BRUSH (Set of 8)
• • SPRING, Brush
Parts list continued on the following page.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 97
Index
No.
Skyjack
Part No.
112601
124541
103472
103999
111921
119358
120093
119894
(Ref.)
103864
103404
102034
123219
103887
103996
103404
700523
123145
700669
123355
108462
124418
101541
103628
108461
124420
101541
103628
117618
123220
123217
123218
117293
117363
(Ref.)
130224
130240
127178
132792
132793
Figure 6.5-1. Hydraulic/Electric Cabinet Assembly (Continued)
Qty.
Description
4
4
4
2
3
2
1
1
1
1
1
1
1
1
1
-
-
1
1
1
1
Parts list continued from the previous page.
1
1
1
1
4
8
4
4
• BOLT, Hex-hd 5/16-18 x 3/4” lg.
• WASHER, Flat 5/16”
• WASHER, Lock 5/16”
• BUSHING, Rubber
PUMP/MOTOR ASSEMBLY, Hydraulic (EE Rated)
• PUMP, Hydraulic
• MOTOR, 48 Volt
DOOR, Electrical panel access
1
1
DOOR, Electrical panel access (EE Rated)
• HANDLE, Latch
AR • SEAL, Foam (88” total)
1
1
1
DOOR, Hydraulic component access
DOOR, Hydraulic component access (EE Rated)
• HANDLE, Latch
AR • 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)
• BOLT, Machine #8-32 x 1/4” lg.
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.
• WASHER, Lock 5/16”
• 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
(For Components, Refer to Figure 6.8-2)
1
1
• LIGHT BULB, 24V
1 • LENS
AR CLAMP, Cable Bundle (7/8”)
AR CLAMP, Cable Bundle (1 3/8”)
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 99
2
Figure 6.5-2. Auto Reset Brake Manifold Assembly
8
3
1
7
5
4
6
Index
No.
A
1
2
3
4
5
6
7
8
Skyjack
Part No.
(Ref.)
116586
110554
102659
117189
103605
110652
113752
103070
Qty.
1
1
1
1
1
1
1
1
Description
MANIFOLD ASSEMBLY, Auto reset brake
• 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
• FITTING, Connector #8orb-#6
M1018AA
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 101
Figure 6.5-3. Main Manifold Assembly
SECTION 6, Page 102
M10307AB
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
122385
114521
104534
115320
120756
104412
104567
104567
106554
701194
103069
103614
107439
103920
128798
128317
118804
118803
104567
104567
123853
105610
114365
104412
114578
104412
104412
112366
122420
122428
128320
103920
103614
107439
103920
128798
128317
128320
103920
104567
104567
116725
103070
112187
102659
(Ref.)
104345
104409
103069
Index
No.
Qty.
2
4
1
1
1
1
4
1
1
1
2
1
1
1
2
9
2
1
1
1
1
1
1
5
1
1
-
1
1
1
1
1
2
-
4
1
1
1
1
1
4
1
1
2
2
4
1
2
2
Figure 6.5-3. Main Manifold Assembly
Description
MANIFOLD ASSEMBLY, Main
• 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
• FITTING, Connector #6orb-#6
VALVE ASS’Y, Vickers 24 Volt (replace with Hytos) (Gearbox shift)
• COIL, 24V
• BOLT, Socket head #10-24 x 2” grade 5
VALVE ASS’Y Hytos 24 Volt (replacement for Vickers)
• VALVE ASSEMBLY, Directional 24V spool
• • COIL, 24V Spool valve
• BOLT, Socket head #10-24 x 2” grade 5
VALVE ASS’Y, Vickers 24 Volt (replace with Hytos) (Steer)
• COIL, 24V
• BOLT, Socket head #10-24 x 2” grade 5
VALVE ASS’Y Hytos 24 Volt (replacement for Vickers)
• VALVE ASSEMBLY, Directional 24V spool
• • COIL, 24V Spool valve
• BOLT, Socket head #10-24 x 2” grade 5
• VALVE, Check (Lift)
• VALVE, Check (System)
• ORIFICE, .067 diameter (Emergency lowering)
• FITTING, Connector #6orb-#8
• FITTING, Hose barb #12orb-3/4
• FITTING, Connector #6orb-#8
CONNECTORS, Electrical valve
• CONNECTOR, Gray
• CONNECTOR, Black
FITTING,
Straight (If Equipped with Outrigger Option)
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 103
Figure 6.6-1. Base Control/Electrical Panel Assembly
SECTION 6, Page 104
M10067AA
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
118815
119168
124823
119469
119169
124824
119170
124825
118944
120136
103014
119507
120137
120133
119544
120020
119972
103887
103984
(Ref.)
(Ref.)
(Ref.)
(Ref.)
103336
117326
117325
801347
103964
119167
123140
(Ref.)
119171
700776
119172
133759
119166
Qty.
Figure 6.6-1. Base Control/Electrical Panel Assembly
Description
1
2
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
2
1
1
4
-
1
-
-
1
-
1
1
3
3
1
PANEL, Base control electrical
• BOLT, Hex-hd 5/16”-18 x 3/4” lg.
• NUT, Lock 5/16”-18
BOARD, Main control
(For components, refer to Figure 6.6-3)
FLASHER, Flashing Light
(For components, refer to Figures 6.6-6 & 6.6-7)
BOARD, Outriggers
(For components, refer to Figure 6.6-3)
LABELS
(For components, refer to Figure 6.8-3)
HOURMETER
CIRCUIT BREAKER, 20 Amp
CIRCUIT BREAKER, 15 Amp
CONVERTOR, Sevcon
• BOLT, Machine #10-32 x 1/4” lg.
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
(For components, refer to Figure 6.6-2)
TACHOMETER BOARD ASSEMBLY
• FUSE, 6.3 amp
• FUSE, 20 amp
BOARD ASSEMBLY, Moisture protection P.C.B.
PLATE, Tach card P.C.B. Mounting
AN
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 105
Figure 6.6-2. Sevcon Battery Cable Layout
SECTION 6, Page 106
M1073AB
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
(Ref.)
122567
(Ref.)
(Ref.)
105601
105600
122566
124521
103068
120302
119815
119915
103024
(Ref.)
(Ref.)
(Ref.)
120116
120117
120118
124512
103206
103754
124514
124515
124516
120119
Index
No.
Qty.
Figure 6.6-2. Sevcon Battery Cable Layout
Description
1
1
1
1
-
1
1
1
1
1
1
1
-
1
1
1
-
-
1
1
-
-
-
-
-
TRACTION MOTOR AND CABLE ASSEMBLIES
(For components, refer to Figure 6.3-2)
CONTACTORS
(For components, refer to Figure 6-6-1)
(For components, refer to Figure 6.6-1)
CABLE ASSEMBLY, Controller to Directional Contactor
CABLE ASSEMBLY, Controller to Directional Contactor
1
1
CABLE ASSEMBLY, Controller to Line Contactor
HARNESS ASSEMBLY, Charger
2 • CONNECTOR, Red 50 Amp Battery
AR • HEATSHRINK, 1/2” Clear
AR • CABTIRE, 10/4 SOW
1 • TERMINAL, 6 GA x 1/4”
• TERMINAL, 6 GA x 3/8”
CABLE ASSEMBLY, Controller to Insulator
INSULATOR
(For components, refer to Figure 6.5-1)
CABLE ASSEMBLY, Insulator to Pump
DISCONNECT ASSEMBLY
(For components, refer to Figure 6.3-2)
(For components, refer to Figure 6.5-1)
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
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 107
Figure 6.6-3. Panel Layout
10 11 12 13 10 14 15 16 17 10 8
SECTION 6, Page 108
MLP-1076AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
119897
119895
104345
104409
119131
(Ref.)
120099
119897
(Ref.)
(Ref.)
118815
119897
103962
119724
120147
119722
102921
(Ref.)
108589
(Ref.)
(Ref.)
(Ref.)
(Ref.)
120658
120045
119906
125257
119907
(Ref.)
(Ref.)
120298
119908
107711
103568
103570
Index
No.
Qty.
Figure 6.6-3. Panel Layout
Description
1
-
1
-
1
1
1
1
1
1
1
1
-
1
1
2
1
1
-
1
-
1
-
1
9
2
-
1
2
2
1
-
1
1
1
1
1 BOARD, Main control
AR DIODE
1
-
HARNESS ASSEMBLY, Devices
(For Components, Refer to Figure 6-41)
RELAY, 24 V
LIGHT, Work
(For Components, Refer to Figure 6.5-1)
HARNESS, Center Tap
(For Components, Refer to Figure 6.3-2)
HARNESS, Power Deck
(For Components, Refer to Figures 6.1-8 & 6.1-9)
HARNESS ASSEMBLY, Proximity/Tach
-
(For Components, Refer to Figure 6.6-4)
AR FUSE, 10 Amp
HARNESS ASSEMBLY, Main manifold, Tilt And Base Control
• CONNECTOR, P. C. Board 14-pin
• CONNECTOR, P.C. Board 5-pin
• CONNECTOR, P.C. Board 3-pin
• CONNECTOR, Solenoid (gray)
• CONNECTOR, Solenoid (black)
• KIT, 4 Pole plug Tilt switch
HARNESS, Overload/Aux. Power (Reserved For Future Use)
HARNESS, Power
• CONNECTOR, P.C. Board 5-pin
HARNESS, Platform Limits (Reserved For Future Use)
HARNESS ASSEMBLY, Control Cable
(For Components, Refer to Figure 6.6-5)
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)
• CONNECTOR, P.C. Board 15-pin
HARNESS ASSEMBLY, Outrigger manifold
(For Components, Refer to Figure 6.7-4)
CABLE ASSEMBLY, Outrigger Control Box
(For Components, Refer to Figure 6.7-5)
HARNESS ASSEMBLY, Outrigger limit switch
• CONNECTOR, P.C. Board 16-pin
• CONNECTOR ASSEMBLY, 5 pole female
• • HOUSING, Base
• • INSERT, Female
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 109
10 9
Figure 6.6-4. Proximity And Tachometer Harness
8
5
7 6
PUMP PROXY
PIN 1 - 10 BROWN
PIN 2 - 02 BLUE
PIN 3 - 32 BLACK
PIN 4 - N/U
4
DRIVE PROXY
PIN 1 - 10 BROWN
PIN 2 - 02 BLUE
PIN 3 - N/U
PIN 4 - 33 BLACK
11
3
2
1
Index
No.
1
2
3
4
5
6
7
8
9
10
11
Skyjack
Part No.
(Ref.)
(Ref.)
116758
119130
120337
119131
120355
120356
102888
119894
119898
120748
Qty.
Description
2
2
1
2
-
-
-
-
GENERATOR ASSEMBLY
(For Components, Refer to Figure 6.3-7)
GEARBOX ASSEMBLY
(For Components, Refer to Figure 6.3-8)
SWITCH, Proximity (pump/drive)
KIT, 4 Pole Receptacle
HARNESS, Proximity/Tachometer
• KIT, 4 Pole Plug
1.5” • HEATSHRINK, 3/16” Yellow
1.5” • HEATSHRINK, 3/16” Blue
96” • CABLE, 16/10
1
1
• CONNECTOR, PC Board 2 Pin
• CONNECTOR, PC Board 6 pole
28” • PROTECTION, 1/2” Cable
SECTION 6, Page 110
ML1F-1063AA
SJ-800 Series E Battery Powered
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.
120370
120074
102887
102887
119360
114467
120644
119359
114469
120069
102887
120065
120644
114467
119907
Qty.
Description
1
1
CABLE ASSEMBLY, Scissor control (Model 8831)
CABLE ASSEMBLY, Scissor control (Model 8841)
648” • CABLE, 16/15 (Model 8831)
768” • CABLE, 16/15 (Model 8841)
1
1
2
1
• HOUSING, 16 Pole Female
• INSERT, 16 Pole Female
• CONNECTOR, Strain Relief
• HOUSING, 16 Pole Male
1
1
• PLUG, 16 Pole Male
HARNESS, Panel Control
42” • CABLE, 16/15
1
1
1
1
• COUPLING, Base
• CONNECTOR, Strain Relief
• INSERT, 16 Pole Female
• CONNECTOR, PC Board
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 111
Figure 6.6-6. Devices Connector Layout A
AN
SECTION 6, Page 112
ML1F-1069AC
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
(Ref.)
119296
104698
104003
100967
119375
(Ref.)
115658
110428
110429
103958
110853
123180
123177
123178
108102
120102
(Ref.)
103743
132793
103111
121838
121477
121533
103111
103743
103056
103255
121058
119905
110416
120094
104003
104694
104185
123137
123133
120094
104003
104694
104185
123134
100648
Qty.
2
1
1
1
1
1
1
2
-
1
-
-
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
1
1
1
4
4
4
4
4
4
4
4
1
1
Figure 6.6-6. Devices Connector Layout A
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
• CONNECTOR, 13 pole P.C. Board
PIN, Limit Switch And Scissor End
SWITCH ASSEMBLY, Limit
• SWITCH, Limit (high speed cut-out)
• BOLT, Machine #10-32 x 3/4” lg.
• NUT, Machine #10-32
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, Flat #10 S.A.E.
• WASHER, Lock # 10 Nom
• BRACKET, Rotating Beacon,
• GROMMET
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 113
Figure 6.6-7. Devices Connector Layout B
SECTION 6, Page 114
M11418AA
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
133826
133845
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
Index
No.
A
B
Qty.
-
-
Figure 6.6-7. Devices Connector Layout B
ASSEMBLY, Horn/light/beeper
Description
ASSEMBLY, Horn/Rotating light/beeper
1
2
2
2
1
1
1
1
1
1
1
1
1
2
2
2
PLATE, Horn / light mount
• NUT, Hex Hd 3/8”-16 Gr. 5
• WASHER, Flat 3/8”
• WASHER, Lock 3/8”
• 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
• WASHER, Lock 1/4”
• WASHER, Flat 1/4”
2
1
1
1
• 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
144” • CABTIRE 18/4
1 CIRCUIT BREAKER, H. Meter, Volt Con. Ass’y
CONNECTOR, 13 Pin PC Board 1
2
1
1
SWITCH, Limit Ass’y
TERMINAL, Female 14-16GA Ins. Blue
TERMINAL, Female 18GA Pink
SJ-800 Series E Battery Powered
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)
SECTION 6, Page 116
ML1F-1014AB
SJ-800 Series E Battery Powered
119153
Index
No.
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)
Skyjack
Part No.
Qty.
Description
103855
103995
103091
113584
107712
116827
115658
116826
103962
103958
104694
104185
112249
118387
103909
103470
118497
118496
118499
118500
106705
(Ref.)
101297
103999
118478
115656
116072
115652
103859
104000
102355
2
2
2
2
WELDMENT, Outrigger leg, LH rear
WELDMENT, Outrigger leg, RH rear
WELDMENT, Outrigger leg, RH front
WELDMENT, Outrigger leg, LH front
4
4
LABEL, Do not alter
CYLINDER ASSEMBLY, Outrigger
-
(For Components, Refer to Figures 6.7-3)
12
• BOLT, Hex-hd 3/8”-16 x 1-1/4” lg.
2
2
4
8
12 • WASHER, Lock 3/8”
8 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.
16 • WASHER, Lock 1/4”
4 COVER, Outrigger hose
16 • BOLT, Hex-hd 1/4”-20 x 1/2” lg.
16 • WASHER, Flat 1/4”
4
4
4
-
4
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.)
4
4
MOUNT, Limit switch (Upper)
SWITCH, Limit (inside outrigger cross tube)
COVER, Limit switch (Upper)
16 • BOLT, Machine #10-32 x 1/2” lg.
8 • BOLT, Machine #8-32 x 1.2” lg.
16 • WASHER, Flat #10
16 • WASHER, Lock #10
8
4
4
4
• WASHER, Lock #8
SPACER, Outrigger
BOLT, Outrigger leg stop
• WASHER, Lock 1/2”
SJ-800 Series E Battery Powered
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)
SECTION 6, Page 118
ML1F-1014AD
SJ-800 Series E Battery Powered
119153
Index
No.
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
Skyjack
Part No.
Qty.
Description
102355
103855
103995
103091
113584
107712
103567
103569
116827
103859
104000
103995
115658
124353
125233
112495
112601
124972
124356
103998
103472
124338
126499
112249
103986
104000
118497
118496
118499
118500
106705
(Ref.)
101297
103999
118387
103909
103470
116826
103962
104694
104185
1
1
4
8
2
2
2
1
1
1
4
1
1
2
2
2
2
2
WELDMENT, Outrigger leg, LH rear
WELDMENT, Outrigger leg, RH rear
WELDMENT, Outrigger leg, RH front
WELDMENT, Outrigger leg, LH front
4
4
LABEL, Do not alter
CYLINDER ASSEMBLY, Outrigger
-
(For Components, Refer to Figures 6.7-3)
12 • BOLT, Hex-hd 3/8”-16 x 1-1/4” lg.
12 • WASHER, Lock 3/8”
4
4
4
4
SPACER, Outrigger
BOLT, Outrigger leg stop
• WASHER, Lock 1/2”
COVER, Limit switch (Upper)
16 • BOLT, Machine #10-32 x 1/2” lg.
16 • WASHER, Flat #10
16 • WASHER, Lock #10
4 COVER, Outrigger hose
16 • BOLT, Hex-hd 1/4”-20 x 1/2” lg.
16 • WASHER, Flat 1/4”
4 CABLE PROTECTION, 5/8” x 24” lg.
HEATSHRINK, 1/2” x 8” 4
4
1
1
CONNECTOR ASSEMBLY, 5 Pole male
• HOUSING, Base
• INSERT, Male
MOUNT, Limit switch (Upper) 4
AR BOLT, Hex-hd 1/4”-20 x 1-1/2” lg.
AR WASHER, Lock 1/4”
AR 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”
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 119
Figure 6.7-1C. Hydraulic Outrigger Option - Leg Assembly
(Model 8831E with Serial No. 37407 and Above) (Model 8841E with Serial No. 43045 and Above)
AO
SECTION 6, Page 120
M132697AD
SJ-800 Series E Battery Powered
119153
Figure 6.7-1C. Hydraulic Outrigger Option - Leg Assembly
(Model 8831E with Serial No. 37407 and Above) (Model 8841E with Serial No. 43045 and Above)
Index
No.
Skyjack
Part No.
Qty.
Description
A
B
C
130858
130856
132695
132697
1
1
1
1
ASSEMBLY, Outrigger leg (Front LH)
ASSEMBLY, Outrigger leg (Front RH)
ASSEMBLY, Outrigger leg (Rear LH)
ASSEMBLY, Outrigger leg (Rear RH)
130857
130855
124196
124200
1
1
1
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
NOTE: The following quantities are per one outrigger assembly
SJ-800 Series E Battery Powered
119153
112249
103986
102355
103856
104000
103995
103091
113584
107712
103567
132790
132110
118478
116827
103995
103859
(Ref.)
101297
103999
124338
112601
103472
103978
124972
124356
127003
115658
126499
124335
104000
103855
116826
116193
118387
103470
103909
(Ref.)
1
-
1
2
1
1
4
1
4
2
1
1
1
2
1
1
1
2
3
3
-
1
1
4
2
1
1
1
1
• CYLINDER ASSEMBLY, Outrigger
(For components, refer to Figure 6.7-3)
• • BOLT, Hex head (3/8”-16 x 1-1/4” lg.)
• • WASHER, Lock (3/8”)
• CLIP, Plastic
• NUT, Hex head flange (3/8” - 16)
• WASHER, Flat (3/8”)
• 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”)
4
2
1
4
• WASHER, Lock (#8)
• NUT, Hex (8 - 32)
• COVER, Outrigger hose
• • BOLT, Hex head (1/4”-20 x 3/4” lg.)
4
4
• • WASHER, Lock (1/4”)
• • WASHER, Flat (1/4”)
24” • CABLE PROTECTION (5/8” x 24” lg.)
8” • 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
• WASHER, Flat (1/4”)
• 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
(For components, refer to Figure 6.8-2)
AO
SECTION 6, Page 121
Left Front
Outrigger
Figure 6.7-2. Hydraulic Outrigger Option - Hydraulic Hose Connections
Right Front
Outrigger
To Main
Manifold
Lower
Ports
Upper
Ports
Left Rear
Outrigger
SECTION 6, Page 122
Upper Port (Retract)
Right Rear
Outrigger
ML1F-1015AA
SJ-800 Series E Battery Powered
119153
Index
No.
Figure 6.7-2. Hydraulic Outrigger Option - Hydraulic Hose Connections
Skyjack
Part No.
Qty.
Description
(Ref.)
(Ref.)
103069
130843
102554
112062
112063
112064
112065
112066
112067
112068
112069
118216
102085
1
1
1
1
2
1
1
1
8
8
1
-
4
-
1
1
MANIFOLD ASSEMBLY, Outrigger
(For Components, Refer to Figure 6.7-4)
CYLINDER ASSEMBLY, Outrigger
(For Components, Refer to Figures 6.7-3)
FITTING, Connector #6orb-#6
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
10 CLAMP, Double tube 3/8”
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 123
15
Figure 6.7-3A. Hydraulic Outrigger Option - Cylinder Assembly
(Model 8831E with Serial No. 36839 and Below) (Model 8841E with Serial No. 41670 and Below)
11 14
8
10
6
5 2
1
7
8
9
12
4
3
13
ML1F-1076AA
Index
No.
A
1
2
* 3
* 4
* 5
* 6
* 7
* 8
* 9
10
11
12
13
14
15
* 104355
SECTION 6, Page 124
Skyjack
Part No.
115646
115645
118416
106229
106228
106223
106227
106466
106220
106225
106461
106230
106460
102027
118468
118469
104115
Qty.
- CYLINDER ASSEMBLY, Outrigger
Description
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
• HOUSING, Cylinder
• ROD, Cylinder
• WIPER, Rod
• SEAL, Rod
• O-RING, Front gland
• RING, Rod wear
• O-RING, Piston
• RING, Piston wear
• SEAL, Piston
• PISTON
• NUT, Lock 1-1/4”-12 grade C
• GLAND, Front head
• FITTING, Grease 1/8 NPT
• COLLAR, Limit switch activator
• • SCREW, Cup point set 1/4”-30 x 5/16” lg.
VALVE, Pilot check (not part of cylinder)
AR KIT, Seal repair
SJ-800 Series E Battery Powered
119153
15
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)
11
14
8
6
5
10
2
1
7
9
12
8
4
3
13
ML1F-1016AA
Index
No.
A
1
2
* 3
* 4
* 5
* 6
* 7
* 8
* 9
10
11
12
13
14
15
Skyjack
Part No.
120389
120386
120641
106229
106228
120445
106227
120642
106220
106225
120640
106230
120387
102027
118468
118469
104115
Qty.
-
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
Description
CYLINDER ASSEMBLY, Outrigger
• HOUSING, Cylinder
• ROD, Cylinder
• WIPER, Rod
• SEAL, Rod
• O-RING, Front gland
• RING, Rod wear
• O-RING, Piston
• RING, Piston wear
• SEAL, Piston
• PISTON
• NUT, Lock 1-1/4”-12 grade C
• GLAND, Front head
• FITTING, Grease 1/8 NPT
• COLLAR, Limit switch activator
• • SCREW, Cup point set 1/4”-30 x 5/16” lg.
VALVE, Pilot check (not part of cylinder)
* 104355 AR KIT, Seal Repair
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 125
15
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)
11
8
6
5
10
2
1
7
9
12
8
4
3
14
13
ML1F-1016AA
Index
No.
A
1
2
* 3
* 4
* 5
* 6
* 7
* 8
* 9
10
11
12
13
14
15
*
Skyjack
Part No.
126091
126087
126498
106229
106228
120445
106227
120642
106220
106225
120640
106230
120387
102027
126279
104115
104355
Qty.
1
1
1
1
2
1
1
1
1
1
1
1
-
1
1
1
AR KIT, Seal Repair
Description
CYLINDER ASSEMBLY, Outrigger
• HOUSING, Cylinder
• ROD, Cylinder
• WIPER, Rod
• SEAL, Rod
• O-RING, Front gland
• RING, Rod wear
• O-RING, Piston
• RING, Piston wear
• SEAL, Piston
• PISTON
• NUT, Lock 1-1/4”-12 grade C
• GLAND, Front head
• FITTING, Grease 1/8 NPT
• RING, Retaining
VALVE, Pilot check (not part of cylinder)
SECTION 6, Page 126 SJ-800 Series E Battery Powered
119153
2
Figure 6.7-3D. Hydraulic Outrigger Option - Cylinder Assembly
(Model 8831E with Serial No. 37407 and Above) (Model 8841E with Serial No. 43045 and Above)
AO
3
4
5
8
1
6
7
4
16
13
12
9
11
10
14
17
15
M10373AB
Index
No.
A
1
2
3
* 4
5
* 6
* 7
8
9
* 10
* 11
* 12
* 13
14
15
16
17
*
Skyjack
Part No.
132694
152132
104115
103069
106220
120640
120642
106225
106230
120387
106229
106228
120445
106227
126999
102027
132565
132690
126279
104355
SJ-800 Series E Battery Powered
119153
Qty.
-
Description
OUTRIGGER CYLINDER ASSEMBLY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
• 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
• FITTING, Grease 1/8 NPT
• CAP, Rubber Grease
• SPACER, Cylinder Tube
• RING, Retaining 2.5”
AR KIT, Seal repair
SECTION 6, Page 127
Figure 6.7-4. Hydraulic Outrigger Option - Manifold Assembly
3 9
5
7
8
2
6
4
Index
No.
6
7
8
9
4
5
A
1
2
3
SECTION 6, Page 128
Skyjack
Part No.
(Ref.)
111970
103069
103614
107439
103920
128798
128317
128320
103920
104437
103073
113801
103613
103655
120295
119902
104345
104409
102888
1
ML1F-1017AB
Qty.
Description
1
1
1
1
2
4
2
1
2
4
1
1
-
1
9
1
MANIFOLD ASSEMBLY, Outrigger
• BLOCK, Outrigger manifold
• FITTING, Connector #8orb-#8
VALVE ASS’Y, Vickers 24 Volt (replace with Hytos)
• COIL, 24V
• BOLT, Socket head #10-24 x 2” grade 5
VALVE ASS’Y Hytos 24 Volt (replacement for Vickers)
• VALVE ASSEMBLY, Directional 24V spool
• • COIL, 24V Spool valve
• BOLT, Socket head #10-24 x 2” grade 5
• PLUG, Soc-hd #8orb
• FITTING, Elbow 90° #6orb-#6,
• PLUG, Cavity,
• COIL, 24 Volt
• VALVE, N.C. (outrigger holding),
• HARNESS ASSEMBLY, Outrigger manifold
1
4
• • CONNECTOR, 10 pole P.C. Board
• • CONNECTOR, Gray
4 • • CONNECTOR, Black
96” • • CORD, 16/10
SJ-800 Series E Battery Powered
119153
Figure 6.7-5. Hydraulic Outrigger Option - Control Box Assembly
2
4
3
5 6
8 1
7
MS3F-1023AB
Index
No.
7
8
A
1
2
3
4
5
6
Skyjack
Part No.
Qty.
Description
120266
119440
120270
115276
120277
120268
120269
119439
1
1
1
1
1
1
1
1
OUTRIGGER CONTROL BOX ASSEMBLY
• WELDMENT, Control box
• SCREW, Retainer
• WASHER, Flat 1-1/4”
• LANYARD
• SCREW, Wing
• SCREW, Receptacle
• WELDMENT, Control box bottom
102853
111181
114377
119443
4
4
2
1
• SWITCH, Toggle
• GUARD, Toggle
• PLUG, 1/2”
• LABEL, Outrigger
121664
122044
1
1
• BOARD W/CONNECTOR, 10-pin
CABLE ASSEMBLY, Control box outrigger (8831E)
122043 1 CABLE ASSEMBLY, Control box outrigger (8841E)
102888 672” • CABLE, 16/10 (8831E)
102888 840” • CABLE, 16/10 (8841E)
103041
119901
119902
1
1
1
• CONNECTOR, Strain relief
• CONNECTOR, 9 pole P.C. Board
• CONNECTOR, 10 pole P.C. Board
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 129
SECTION 6, Page 130
Figure 6.7-6. 1500 Watt DC Inverter
M10521AB
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
124755
124756
123748
103856
103995
104000
124171
103980
124098
103889
(Ref.)
124895
(Ref.)
124089
105359
105360
103041
124149
(Ref.)
132494
103955
106099
Qty.
Figure 6.7-6. 1500 Watt DC Inverter
Description
1
1
-
1
3
3
1
1
1
-
1
1
2
-
1
1
1
8
INVERTER, 1500 Watt 120V @ 60hz
INVERTER, 1500 Watt 110/220V @ 50hz
COVER, Inverter,
BOLT, Hex head 1/4”-20 grade 5 x 0.75”
AR WASHER, Flat 1/4” SAE
AR WASHER, Lock 1/4” nom x 0.06
1 SUPPORT, Assembly inverter 800
AR NUT, Hex 1/4”-20 grade B
SUPPORT, Inverter
BOLT, Hex head 1/4”-20 grade 5 x 5.00
CONTACTORS AND ELECTRICAL PANEL
(For Components, Refer to Figure 6.6-2)
CABLE ASSEMBLY, Welding #2ga 3/8” - 142” (-,-)
BATTERY CABLES AND FUSE BOX
(For Components, Refer to Figure 6.6-1)
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
(For Components, Refer to Figure 6.1-11)
RELAY, Timer 24V Cut-Off
BOLT, Machine #6-32 x 3/4”
WASHER, Lock #6
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 131
Figure 6.7-7. Scissor Guard Option
SECTION 6, Page 132
ML2F-1004AB
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
116530
103883
103984
103996
103871
103596
103978
116562
116548
116546
116547
101632
103999
103472
116506
116525
103883
103984
103996
116528
116530
103883
103984
103996
116527
116525
103883
103984
103996
116529
116566
116542
116565
116541
101632
103999
103472
116535
116536
100702
116434
Qty.
Figure 6.7-7. Scissor Guard Option
Description
1
8
8
8
8
1
1
1
4
4
1
4
4
4
4
4
4
1
4
4
1
1
4
1
1
4
1
1
4
4
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
• WASHER, Flat 5/16”
FRAME, RH Rear side scissor guard
• MESH, RH Rear scissor
• BOLT, Hex-hd 5/16-18 Gr. 5
• NUT, Lock Hex 5/16”-18 Gr. B
• WASHER, Flat 5/16”
FRAME, LH Front side scissor guard
• MESH, LH Front scissor
• BOLT, Hex-hd 5/16-18 Gr. 5
• NUT, Lock Hex 5/16”-18 Gr. B
• WASHER, Flat 5/16”
FRAME, LH Rear side scissor guard
• MESH, LH Rear scissor
• BOLT, Hex-hd 5/16-18 Gr. 5
• NUT, Lock Hex 5/16”-18 Gr. B
• WASHER, Flat 5/16”
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,
FRAME, Front scissor guard,
• MESH, Front top,
(Model 8831)
(Model 8841)
(Model 8841)
• MESH, Front elbow
• BOLT, Hex-hd 3/8”-16 x 3/4” lg.
• WASHER, Lock 3/8”
• WASHER, Flat 3/8”
8
8
8
4
1
1
1
1
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.
• WASHER, Lock 3/8”
• WASHER, Flat 3/8”
FRAME, Corner, (Machines without Outriggers)
4 • MESH, Rear
20 CAP, Tube end
2 BUMPER
Use Part # 116438 for Machines with Serial #37007 (8831) or
42123 (8841) and below.
Part list continued on the next page.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 133
Index
No.
Skyjack
Part No.
118313
118322
130024
130083
129898
103472
103999
130884
118312
118315
130024
130083
129898
103472
103999
130884
116828
116829
119969
119968
(Ref.)
129841
Qty.
Figure 6.7-7. Scissor Guard Option (Continued)
Description
Part list continued from the previous page.
4
4
4
4
2
1
2
2
4
4
4
4
2
1
2
2
FRAME, Scissor guard center, (Model 8831)
• MESH, Center
• BOLT, Hex-hd M10-1.5 x 65mm
• BOLT, Hex-hd M10-1.5 x 75mm
• NUT, Knurled Insert M10-1.5
• WASHER, Flat 3/8”
• WASHER, Lock 3/8”
• WASHER, Lock M10
FRAME, Scissor guard center, (Model 8841)
• MESH, Center
• BOLT, Hex-hd M10-1.5 x 65mm
• BOLT, Hex-hd M10-1.5 x 75mm
• NUT, Knurled Insert M10-1.5
• WASHER, Flat 3/8”
• WASHER, Lock 3/8”
• WASHER, Lock M10
AR FRAME, Scissor guard, (Model 8831 with one or no extension)
AR FRAME, Scissor guard, (Model 8841 with one or no extension)
1
1
1
4
• MESH, Front/rear
• MESH, Front/rear
(Model 8831)
(Model 8841)
BAR ASSEMBLY, Emergency Lowering Access
(For components, refer to Figure 6.3-1)
PLATE, Scissor guard spacing plate
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 135
Figure 6.7-8. Safety D-ring Assembly
Extension Deck
Optional Location For
Safety D-Rings ac ines it o t
Extension Platform
Platform
Optional Location For
Safety D-Rings
3
2
4
1
5
Index
No.
A
1
2
3
4
5
Skyjack
Part No.
125584
103473
113122
114989
103472
104606
Qty.
-
2
1
1
2
2
Description
SAFETY D-RING KIT
• BOLT, Hex Head 3/8”-16 x 1” Gr. 5
• BRACKET, Safety Ring
• D-RING, Safety
• WASHER, Flat 3/8”
• NUT, Hex Nylon Lock 3/8”-16 Gr. 5
Extension Deck
Optional Location For
Safety D-Rings
M10983AA
SECTION 6, Page 136 SJ-800 Series E Battery Powered
119153
Figure 6.7-9. Work Light Option AN
1
2
3
4
5
6
Index
No.
-
1
2
3
4
5
6
Skyjack
Part No.
137979
141732
141701
138050
103861
104000
103995
Qty.
-
1
1
1
2
2
2
Description
ASSEMBLY, Work light
• 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)
M137979AB
SJ-800 Series E Battery Powered
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
SJ-800 Series E Battery Powered
119153
TM
SECTION 6, Page 139
Figure 6.8-2. Labels And Nameplates (Old Skyjack Logo)
AO
SECTION 6, Page 140
M10003AB_1
SJ-800 Series E Battery Powered
119153
Skyjack
Part No.
(Ref)
146526
118277
106691
106760
106761
109985
108666
108946
102632
146525
129772
102961
103110
103125
106406
106703
117131
114224
111265
120341
(Ref.)
129806
116097
129807
116094
129823
106705
111604
111605
106704
111814
119974
700473
119967
110333
123628
(Ref.)
130369
132775
130362
107800
130367
130363
130376
130378
132833
134807
Index
No.
-
-
2
1
1
2
2
1
1
2
1
1
2
1
2
1
2
2
4
4
4
4
4
AR
AR
AR
AR
4
1
1
1
2
1
1
1
1
1
1
2
2
2
2
4
2
2
4
2
2
1
Figure 6.8-2. Labels And Nameplates (Old Skyjack Logo)
Qty.
Description
AO
(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)
Parts list continued on the following page.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 141
Index
No.
Skyjack
Part No.
Figure 6.8-2. Labels And Nameplates (Old Skyjack Logo) (Continued)
Qty.
Description
1
1
1
4
2
1
2
1
4
4
4
1
1
-
2
1
1
2
1
1
1
1
1
1
2
1
1
117389
120124
102657
702005
102657
102451
119915
115594
124362
114378
120816
124465
(Ref.)
114588
104589
115719
106693
110333
(Ref.)
102975
102631
112906
115982
115531
115604
102599
116648
115326
123488
120090
120089
117387
123274
124080
119909
105352
118212
125024
126928
133035
134409
Parts list continued from the previous page.
1
1
LABEL, Danger, filled tires
LABEL, Connect 110V AC supply here (Machines with AC Outlet on Platform)
AR NAMEPLATE, Serial number (Consult factory)
AR STRIPE, Warning 648” roll)
1 LABEL, SKYJACK (large) (36” wide) (Machines with extension platform)
AR TAPE, Caution
2 LABEL, (Warning) (Full torque)
AR LABEL, Warning (falling hazard)
AR LABEL, CE
1
1
1
1
1
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.
AL
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 143
Figure 6.8-3. Labels - Outrigger
SECTION 6, Page 144
M11523AB
SJ-800 Series E Battery Powered
119153
Index
No.
Skyjack
Part No.
119866
106705
Qty.
4
4
Figure 6.8-3. Labels - Outrigger
Description
LABEL, Danger! Hand/foot pinch
LABEL, Do not alter
NOTE: Supply Model Number, Serial Number, Country and
Language when ordering complete machine labels.
SJ-800 Series E Battery Powered
119153
SECTION 6, Page 145
