TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)

OPERATING
MAINTENANCE
& PARTS
MANUAL
TM
Printed in U.S.A.
SJM SERIES
TM
SKYJACK CORP. (USA)
3451 Swenson, St. Charles, Illinois 60174 Tel: 1-800-275-9522 Fax: (630) 262-0006
SKYJACK INC.
55 Campbell Road, Guelph, Ontario N1H 1B9 Tel: (519) 837-0888 Fax: (519) 837-3102
107979-8
Revised 2-1-98
TABLE OF CONTENTS
SECTION 1 INTRODUCTION
PURPOSE OF EQUIPMENT .................................................................................................. Page 1
USE OF EQUIPMENT ............................................................................................................ Page 1
WARNINGS ............................................................................................................................. Page 1
DESCRIPTION ........................................................................................................................ Page 1
WORK PLATFORM MAJOR COMPONENTS IDENTIFICATION ............................................ Page 4
SECTION 2 OPERATION
OPERATOR QUALIFICATIONS ............................................................................................... Page 1
OPERATING CONTROL IDENTIFICATION
Base Controls - Electrical ...................................................................................................... Page 1
Base Controls - Hydraulic ...................................................................................................... Page 2
Base Controls - Hydraulic/Manual ......................................................................................... Page 3
Optional Base Controls ......................................................................................................... Page 4
Platform Controls .................................................................................................................. Page 4
Optional Platform Controls .................................................................................................... Page 5
SET-UP PROCEDURE ............................................................................................................ Page 7
OPERATING PROCEDURES
Prestart Checks .................................................................................................................... Page 8
Start and Operation ............................................................................................................... Page 8
Shutdown Procedure ............................................................................................................. Page 9
BATTERY SERVICE AND CHARGING PROCEDURE
Battery Service ................................................................................................................... Page 10
Battery Charging Procedures .............................................................................................. Page 10
BATTERY CHARGER OPERATION - Motor Appliance Charger ............................................ Page 11
BATTERY CHARGER OPERATION - Bycan Charger ........................................................... Page 12
S
E
C
T
1
2
I
O
N
3
SECTION 3 SYSTEMS COMPONENT IDENTIFICATION AND SCHEMATICS
TABLE OF CONTENTS ........................................................................................................... Page 1
SECTION 4 MAINTENANCE AND TROUBLESHOOTING
TROUBLESHOOTING INFORMATION - Proportional Drive and Lift ....................................... Page 1
TROUBLESHOOTING INFORMATION - Hi-Torque Option .................................................... Page 13
TROUBLESHOOTING INFORMATION - 2-Speed Drive ........................................................ Page 23
SECTION 5 PARTS LIST
OPERATORS RESPONSIBILITY FOR MAINTENANCE ........................................................ Page 1
MAINTENANCE AND INSPECTION SCHEDULE ................................................................... Page 1
OWNER’S ANNUAL INSPECTION RECORD ......................................................................... Page 1
GENERAL MAINTENANCE HINTS ........................................................................................ Page 1
HYDRAULIC SYSTEM AND COMPONENT MAINTENANCE AND REPAIR .......................... Page 2
PROPORTIONAL CONTROLLER TROUBLESHOOTING PROCEDURE ................................ Page 7
PROPORTIONAL CONTROLLER ADJUSTMENT PROCEDURE ........................................ Page 9
SECTION 6 PARTS LIST
I
N
D
E
LIST OF ILLUSTRATIONS..............................................................................................Page 2
TABLE
TABLE
TABLE
TABLE
TABLE
TABLE
1-1.
5-1.
5-2.
5-3.
5-4.
5-5.
SJM Series
LIST OF TABLES
SPECIFICATIONS AND FEATURES ................................................
MAINTENANCE SCHEDULE ...........................................................
OWNER’S ANNUAL INSPECTION RECORD ..................................
MAXIMUM PLATFORM CAPACITIES ..............................................
TORQUE SPECIFICATIONS ............................................................
GENERAL SPECIFICATIONS ..........................................................
Final Revision 2-1-98
Section
Section
Section
Section
Section
Section
1,
5,
5,
5,
5,
5,
Page
Page
Page
Page
Page
Page
3
3
4
4
4
5
4
5
X
Page I
6
WARNING
You are required by ANSI/SIA A92.6-1990 to read and understand YOUR RESPONSIBILITIES in the Manual Of
Responsibilities before you use or operate this work platform.
FAILURE TO COMPLY with your REQUIRED RESPONSIBILITIES in the use and operation of the work platform
could result in death or serious injury.
OPERATOR SAFETY REMINDERS
The National Safety Council reminds us that most accidents are caused by the failure of some individuals to follow
simple and fundamental safety rules and precautions. 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.
You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this work platform
is mandatory. The following pages of this manual should be read and understood completely before operating the
work platform. Any modifications from the original design are strictly forbidden without written permission from
SKYJACK, Inc.
SERVICE POLICY AND WARRANTY
SKYJACK, Inc. warrants each new work platform to be free of defective parts and workmanship during the first 12
months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor.
Refer to Warranty Statement for extensions or exclusions.
NOTE
SKYJACK, Inc. is continuously improving and expanding product features on it’s equipment; therefore, specifications
and dimensions are subject to change without notice.
This Safety Alert Symbol Means Attention!
Become Alert! You Safety Is Involved.
DANGER
ELECTROCUTION HAZARD
THIS MACHINE IS NOT INSULATED.
MAINTAIN SAFE CLEARANCES FROM
ELECTRICAL POWER LINES AND
APPARATUS. YOU MUST ALLOW FOR
PLATFORM SWAY, ROCK OR SAG. THIS
WORK PLATFORM DOES NOT
PROVIDE PROTECTION FROM
CONTACT WITH OR PROXIMITY TO AN
ELECTRICALLY
CHARGED
CONDUCTOR.
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.
VOLTAGE RANGE
(PHASE TO PHASE)
(0
(FEET)
300 )
(METERS)
AVOID CONTACT
50 )
10
3.05
50
200 )
15
4.60
(
200
350 )
20
6.10
(
350
500 )
25
7.62
(
500
750 )
35
10.67
1000 )
45
13.72
(
(
(
MINIMUM SAFE APPROACH DISTANCE
300
750
FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!
Page II
Final Revision 2-1-98
SJM Series
SERVICE POLICY AND WARRANTY
SKYJACK, Inc. warrants each new work platform to be free of defective parts and workmanship during the first 12
months. Refer to Warranty Statement on Page iv for details.
NOTE
SKYJACK, Inc. is continuously improving and expanding product features on it’s equipment; therefore, specifications
and dimensions are subject to change without notice.
This Safety Alert Symbol Means Attention!
Become Alert! Your Safety Is Involved.
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.
SCOPE OF THIS MANUAL
This manual applies to the ANSI/SIA, CSA and CE versions of the SJIII Series work platform models listed on Section
1, Page 3. Equipment identified with “ANSI/CSA” meets the ANSI/SIA-A92.6-1990 standards. Equipment identified
with “CSA” meets the CAN3-B354.2&.3-M82 standards. Equipment identified with “CE” meets the requirements for the
European countries, i.e. Machinery Directive 89/392/EEC and EMC Directive 89/336/EEC and the corresponding EN
standards.
SJM Series
Final Revision 2-1-98
Page III
WARRANTY STATEMENT
SKYJACK, Inc. warrants each new work platform to be
free of defective parts and workmanship. During the
first full year, labor and defective parts will be provided
by the local authorized Skyjack dealer without charge.
For the following 48 months, structural components found
to be defective will be replaced or repaired at no charge.
A warranty registration card is supplied with each work
platform. The warranty is only effective when the warranty
card has ben completed and returned to Skyjack within
15 days from the time of billing. When work platforms
are put into stock, the warranty period does not start
until the work platform has been shipped to the dealers
customer. If a unit is put into service and no warranty
card has been mailed to Skyjack, Inc., the warranty period
will commence 15 days from the date the dealer was
invoiced for the work platform.
All warranty claims are subject to approval by Skyjack’s
Service Department. Skyjack, Inc. reserves the right to
limit or adjust claims with regard to defective parts, labor
or travel time based on usual and customery guidelines.
Parts purchased from sources other than Skyjack will
not be covered under this warranty. Misuse or improper
operation, lack of normal maintenenace and inspections
as outlined in this Operating/Maintenance and Parts
Manual, alterations to original design and/or components
or accidents will void all warranty. Batteries are not
covered by this warranty.
The above mentioned warranty statement is exclusive
and no other warranty whether written, oral or implied
shall apply. Skyjack excludes any implied warranty of
merchantability and fitness and acceptd no liability for
consequential damages or for other negligence.
WARRANTY PROCEDURES
The selling distributor or authorized dealer shall be
responsible for the complete handling of customer claims
under this warranty. Here’s what to do:
1. When a customer files a claim under this warranty,
contact Skyjack’s Service Department to verify
warranty coverage. NOTE: The complete serial number
of the work platform is required to verify the claim.
2. When Skyjack’s Service Department verifies warranty
coverage, they will alo issue an RA (Return
Authorization) number for the return of any defective
component(s). All items over $25.00 in value must
be returned to Skyjack, Inc.
Page IV
3. Fill out a Warranty Claim Form from dealer’s supply of
claim forms. Then notify Skyjack’s Service
Department of the warranty claim number on the form
used.
4. The distributor/dealer should then file a warranty claim
with Skyjack, Inc. describing the nature of the defect,
probable cause, work performed, travel hours, and
labor hours listed separately. Warranty labor will be
paid at a rate of $42.00 per hour. The travel allowance
will be paid at the same hourly rate within the dealers
specified territory, limited to a maximum of four (4)
hours. If a part has serviceable components,
PLEASE replace the bad component. For instance,
if you have a bad switch on a controller, please replace
the switch. Hydraulic cylinders should be repacked,
unless they are damaged beyond repair. Engine
failures should be directed to your local engine
distributor and covered by the manufacturers warranty.
Skyjack will accommodate you and your labor. Labor
rates and travel allowances are subject to change
without notice.
5. Warranty claims must be received by Skyjack within
15 working days from the date of the repair. Warranty
claims received with insufficient information will be
returned for correction or completion.
6. Materials returned for warranty inspection must have
the following procedures:
A. Carefully packaged to prevent additional damage
during shipping.
B. Drained of all contents and all open ports capped
or plugged.
C. Shipped in a container tagged or marked with the
RA number.
D. Shipped PREPAID. Any item(s) returned for
warranty by any other means may be refused and
returned unless prior approval from Skyjack is
obtained.
E. Items shipped to the dealer will be sent freight
prepaid and added to the invoice.
Failure to comply with the above procedures may delay
approval and processing of the warranty claim and could
result in the denial of a warranty claim. Skyjack’s dealer’s
accounts must be kept current in order to approve and
issue warranty credits. Skyjack reserves the right to
withhold issuance of warranty credits to a dealer if their
account is not in good standing. This is subject to change
without prior notice.
Final Revision 2-1-98
SJM Series
SECTION 1
INTRODUCTION
PURPOSE OF EQUIPMENT
The SKYJACK SJM Series Work Platform is designed
to transport and raise personnel, tools and materials to
overhead work areas.
USE OF THE EQUIPMENT
The work platform (Fig. 1-2) is a highly maneuverable,
mobile work station. Lifting and driving MUST be on a
flat, level, compacted surface.
WARNINGS
The operator MUST read and completely understand
the safety panel labels (Fig. 1-1) and ALL other
warnings in this manual and on the work platform before
operating the work platform. Compare the labels on the
work platform with the labels found throughout Section 2
of this manual. If any labels are damaged or missing,
replace them immediately.
DESCRIPTION
The work platform consists of three major assemblies,
the platform, lifting mechanism and the base. An
operator’s control box is mounted on the platform railing.
Auxiliary and emergency controls are located at the
base.
PLATFORM - The platform is constructed of a tubular
support frame, a skid-resistant deck surface, and 43-1/
2" high railings (Model 3015) or 41" high railings (Model
3219) with 6" toe boards and mid-rails. The platform can
be entered from the rear thru an entry chain or optional
spring-returned gate with latch. The platform is also
equipped with a 3 ft. extension platform.
SJM Series
toc
2
LIFTING MECHANISM - The lifting mechanism is
constructed from steel tubing making up a scissor-type
assembly. The scissor-type assembly is raised and
lowered by a single-acting hydraulic lift cylinder. A
pump, driven by a DC motor, provides hydraulic power to
the lift cylinder. A safety bar located at the front of the
lifting mechanism prevents (when properly positioned)
the scissor-type assembly from being lowered while
maintenance or repairs are being performed within the
lifting mechanism.
BASE - The base is a rigid one piece weldment which
supports two swing-out trays. One tray contains the
hydraulic components, up/down controls and electrical
components. The other tray contains the battery
charger and four (4) 6 volt 220AH batteries. The front
axle has two drivable wheels, steerable by a hydraulic
cylinder. The rear axle is fixed and has one or two
spring-applied hydraulically-released parking brakes.
OPERATOR’S CONTROL BOX - A removable control
box, mounted at the right front of the platform, contains
controls for work platform motion and emergency
stopping.
SERIAL NUMBER NAMEPLATE - The serial number
nameplate, located at the rear of the machine, lists the
model number, serial number, capacity, platform height
and hydraulic pressures for this work platform. Use this
information for proper operation and maintenance and
when ordering service parts.
OPTIONAL ACCESSORIES - The SKYJACK SJM
Series Work Platform is designed to accept a variety of
optional accessories. These are listed in Table 1-1.
Specifications and Features. Operating instructions for
these options (if required) are located in Section 2 of this
manual.
Final Revision 2-1-98
3
4
5
6
SECTION 1, Page 1
1
Figure 1-1. Safety Panel Labels
(Located at the front center of platform on the railing)
SECTION 1, Page 2
Final Revision 2-1-98
SJM Series
SJM Series
Final Revision 2-1-98
SECTION 1, Page 3
32.0”
(.81m)
2430
(1102kg)
3219
64.0”
(1.63)
64.0”
(1.63)
LENGTH
25.0’
(7.6m)
21.0’
(6.4m)
Working
19.0’
(5.8m)
15.0’
(4.6m)
Platform
78.0”
(1.98m)
79.0”
(2.01m)
Lowered
FULL
FULL
Drive
28” x 64”
(.71x1.63m)
28” x 64”
(.71x1.63m)
Size
• Descent Alarm
• Front Wheel Drive With Tight Turning Radius
• 2-Speed Joystick Forward and Reverse Control
• Swing-out Side Trays
• Spring-Applied Hydraulically-Released Parking Brake
• Puncture-Proof, Solid Rubber Tires
• Manual Lowering Valve
• Driveable at Full Height
• 3 Ft. Extension Platform
• Gradability at 20% +
STANDARD FEATURES
Drive
2 mph
(3.2 kph)
• Spring-Loaded Half-Height Gate
• Spring-Loaded Full-Height Gate
• 110V GFI AC Outlet on Platform
• Movement Alarm
• Solid Rubber, Non-Marking Tires
• Flashing Amber Light
• Additional Parking Brake
• 800W AC Generator
• Operator Horn
• EE- Rating
• Tilt Alarm With Lift Cutout
• “Shop Air” Line To Platform
• Safety Belt/Lanyard Attachment Rings
• 3 Ft. Powered Extension Platform
20%+
20%+
20%+
30
sec.
GRADABILITY
19
sec.
Raise
SPEED
2 mph
(3.2 kph)
OPTIONAL EQUIPMENT
@
@
500 lbs.
(227kg)
500 lbs.
(227kg)
TIRES
Capacity
PLATFORM
* Overall capacity and materials not to exceed rated load. Extension platform 250 lbs./1 occupant
@ 12 x 4.00 x 8 Solid Rubber
30.0”
(.76m)
2200
(998kg)
WEIGHT* WIDTH
3015
MODEL
HEIGHT
Table 1-1. Specifications and Features
WORK PLATFORM MAJOR COMPONENT IDENTIFICATION
OPERATOR’S
CONTROL CONSOLE
EXTENSION
PLATFORM
MAIN
PLATFORM
LIFTING
MECHANISM
SAFETY
BAR
BATTERY
TRAY
BASE
HYDRAULIC/
ELECTRIC
TRAY
Figure 1-2. SKYJACK SJM Series Work Platform
(Model 3015 shown)
SECTION 1, Page 4
Final Revision 2-1-98
SJM Series
SECTION 2
OPERATION
OPERATOR QUALIFICATIONS
Only trained and authorized persons should use this work
platform. Safe use of this work platform requires the
operator to understand the limitations and warnings,
operating procedures and operator’s responsibility for
maintenance. Accordingly, the operator MUST understand
and be familiar with this operating manual, its warnings
and instructions and ALL warnings and instructions on
the work platform. Operator also MUST be familiar with
employer’s work rules and related government regulations
and be able to demonstrate his/her ability to understand
and operate THIS make and model work platform in the
presence of a qualified person.
OPERATING CONTROLS
IDENTIFICATION
The following descriptions are for identification,
explanation and locating purposes only. A qualified
operator MUST read and completely understand these
descriptions before operating this work platform.
Procedures for operating this work platform are detailed
in the “OPERATING PROCEDURES” section on Pages
23 through 25. Both standard and optional controls are
identified in this section. Therefore, some controls may
be included that are not furnished on your work platform.
ELECTRICAL PANEL - This control station is located in
the Hydraulic/Electric Tray. It contains the following
controls:
1. UP/DOWN TOGGLE SWITCH - Selecting and holding
this toggle type switch to “UP” position will raise platform
to desired height. Release switch to stop. Selecting and
holding switch to “DOWN” position will lower platform to
desired height. Release switch to stop.
2. BUZZER ALARM - This audible pulse alarm sounds
when platform is being electrically lowered. On machines
with certain options, this alarm will sound when any
control function is selected.
3. HOURMETER - Activated when the pump/motor runs,
this gauge records work platform operating time.
4. 15 AMP CIRCUIT BREAKER RESETS - In the event
of a power overload or positive circuit grounding, circuit
breaker will pop out. Make the necessary corrections,
then depress the push-button to reset.
Emergency Battery Disconnect Switch
Base Controls - Electrical
Electrical Panel
1
1
3
Figure 2-2. Emergency Battery Disconnect Switch
4
2
Figure 2-1. Electrical Panel and Labels
1.
2.
3.
4.
UP/DOWN TOGGLE SWITCH
BUZZER ALARM
HOURMETER
15 AMP CIRCUIT BREAKERS
SJM Series
toc
1
1. EMERGENCY BATTERY DISCONNECT SWITCH
1. EMERGENCY BATTERY DISCONNECT SWITCH Located on the rear axle, this switch, when in “OFF”
position, disconnects power to all control circuits. Switch
MUST be in “ON” position to operate any control circuit.
Final Revision 2-1-98
3
4
5
6
SECTION 2, Page 1
2
Base Controls - Hydraulic
Emergency Lowering Valve
(Machines with Velocity Fuses)
1
Figure 2-3A. Emergency Lowering Valve
1 & 2. EMERGENCY LOWERING VALVE (Pull-type)
and HOLDING VALVE MANUAL OVERRIDE KNOB Used on machines with holding valves , this system allows platform lowering in the event of an electrical system failure. Use the following procedure to lower the platform:
1.
Depress and turn each red manual override knob
(located at the base of each lift cylinder)
counterclockwise.
2.
Pull the Emergency Lowering Valve knob out to
lower the platform.
3.
Turn each red manual override knob clockwise
to restore normal operation.
1. EMERGENCY LOWERING VALVE (Rotary-type)
1. EMERGENCY LOWERING VALVE (Rotary-type) Located in the hydraulic/electric tray, this valve allows
platform lowering in the event of an electrical system
failure. Turning the valve knob counterclockwise allows
the platform to gradually lower. Valve MUST be fully
closed (clockwise) to restore normal operation.
Free-Wheeling Valve
1
Emergency Lowering System
(Machines with Holding Valves)
1
Figure 2-4. Free-Wheeling Valve
1. FREE-WHEELING VALVE
1. FREE-WHEELING VALVE - The free-wheeling valve
is located at the front of the machine. Turning the valve
knob counterclockwise to a fully opened position allows
fluid to flow through the wheel motors, thus providing
“free-wheeling” so that the work platform can be pushed
or towed without damaging the wheel motors. When towing, DO NOT exceed 2 mph. Valve MUST be closed
tightly (clockwise) for normal operation.
2
Figure 2-3B. Emergency Lowering System
1. EMERGENCY LOWERING VALVE (Pull-type)
2. HOLDING VALVE MANUAL OVERRIDE KNOB
SECTION 2, Page 2
Final Revision 2-1-98
SJM Series
Base Controls - Hydraulic/Manual
Safety Bar
Parking Brake
1
1
Figure 2-5. Parking Brake
1. PARKING BRAKE
1. PARKING BRAKE - The parking brake is essentially
automatic. A pin retracted by single-acting hydraulic
cylinder disengages the brake disc when driving. A spring
inside the cylinder returns the pin to engage the brake
disc for parking, lifting, lowering and stationary steering.
The brake pin MUST be manually disengaged for towing,
pushing or winching. This requires the special procedure
as follows:
Figure 2-6. Safety Bar
1. SAFETY BAR
WARNING
1. SAFETY BAR - Designed to support the scissors
assembly (when properly positioned), the safety bar MUST
be used when inspecting or when performing maintenance
or repairs within the scissor assembly with the platform
raised. To use the safety bar, follow the procedure on the
safety bar label on the base.
DO NOT manually disengage the parking brake if the
work platform is on a slope.
DANGER
CRUSHING HAZARD
Make sure that the work platform is on level ground.
•
For Left-Hand Brake: Using a 3/4" wrench, rotate
the lock-out block on the brake pin 90°
clockwise. The brake pin should be clear of the
brake disc.
•
For Right-Hand Brake: Using a 3/4" wrench,
rotate the lock-out block on the brake pin 90°
counterclockwise. The brake pin should be clear
of the brake disc.
DO NOT reach through the scissor assembly when the
platform is raised without the safety bar properly positioned. Failure to avoid this hazard will result in death
or serious injury!
NOTE
The parking brake(s) will reset automatically when the
work platform is driven.
SJM Series
Final Revision 2-1-98
SECTION 2, Page 3
Optional Base Controls
Platform Controls
Base Control Box
Operator’s Control Box (2 Speed Drive)
4
2
3
1
1
3
5
2
Figure 2-7. Base Control Box
Figure 2-8. Operator’s Control Box
1. PLATFORM/BASE SELECT KEY SWITCH
2. PLATFORM UP/DOWN SWITCH
3. EMERGENCY STOP BUTTON
BASE CONTROL BOX - This metal control station is
mounted on the rear of the base. It contains the following
controls:
1. PLATFORM/BASE SELECT KEY SWITCH - Key to
“PLATFORM” position directs power to the operator’s
control box on the platform. Key to “BASE” position directs
power to the base control box.
2. PLATFORM UP/DOWN SWITCH - To raise the
platform, key to “BASE” position, then move switch to
©“ (up) position. Release switch to stop. To lower the
“©
platform, key to “BASE” position, then move switch to
“ª“ (down) position. Release switch to stop.
3. EMERGENCY STOP BUTTON - When struck, this
red push-button switch disconnects power to both the
base and platform control boxes. In the event of an
emergency or at work platform shut down, push the button
in. To restore power, simply pull the button out.
SECTION 2, Page 4
1.
2.
3.
4.
5.
LIFT/OFF/DRIVE SELECT KEY SWITCH
LIFT ENABLE PUSH-BUTTON
UP/DOWN SELECTOR SWITCH
DRIVE/STEER CONTROLLER
EMERGENCY STOP BUTTON
OPERATOR’S CONTROL BOX - This metal control
station is mounted at the right front of the platform. It
contains the following:
1. LIFT/OFF/DRIVE SELECT KEY SWITCH - Key to
“LIFT” position energizes the lift circuit. Key to “OFF”
position disconnects power to control circuit in the control
box. Key to “DRIVE” position energizes the drive/steer
circuit.
2. LIFT ENABLE PUSH-BUTTON - When depressed
and held, this push-button switch energizes the lift circuit.
It MUST be depressed and held while raising or lowering
the platform from this control station. Release button to
stop.
3. UP/DOWN SELECTOR SWITCH - To raise the
platform, select “LIFT” with the Lift/Off/Drive Select Key
Switch, depress and hold the Lift Enable Push-button,
©“ (up) position. Release
then rotate selector switch to “©
switch to stop. To lower the platform, select “LIFT” with
the Lift/Off/Drive Select Key Switch, depress and hold
the Lift Enable Push-button, then rotate selector switch
ª“ (down) position. Release switch to stop.
to һ
Final Revision 2-1-98
SJM Series
4. DRIVE/STEER CONTROLLER - This one-handed
toggle-type lever controls two-speed drive and left/right
steer motion. This is a “dead-man” control which returns
to neutral and locks when released. To drive forward,
turn key to “DRIVE” position with Lift/Off/Drive Select
Key Switch, then lift lock ring and push handle forward
to desired speed. Release to stop. To drive in reverse,
turn key to “DRIVE” position with Lift/Off/Drive Select
Key Switch, lift lock ring and pull handle backwards to
desired speed. Release to stop. To steer, depress the
side of the rocker on top of the controller handle in the
direction you wish to steer.
5. EMERGENCY STOP BUTTON - When struck, this
red push-button switch disconnects power to the platform
control circuit. In the event of an emergency or at work
platform shut down, push button in. To restore power,
simply pull button out.
Optional Platform Controls
Operator’s Control Box (Proportional Drive and Lift)
4
3
1
2
1. OFF/ON KEY SWITCH - Key to “OFF” position
disconnects power to control circuit in control box. Key
to “ON” position energizes the control circuit.
2. EMERGENCY STOP BUTTON - This red “mushroomhead” shaped button switch is designed to disengage
power to the platform controls when struck in the event
of an emergency or at work platform shut down. To restore
power to the platform controls, simply pull button out.
3. LIFT/OFF/DRIVE SELECT TOGGLE SWITCH - If
“Lift” is selected, the lift circuit is energized. “OFF”
disconnects power from both the lift and drive circuits.
If “DRIVE” is selected, the drive circuit is energized.
NOTE: The toggle switch handle MUST be pulled upward
to select position.
4. PROPORTIONAL CONTROLLER - A one-hand
toggle-type lever to control proportional drive/lift motion
and steer motion. It is a “dead-man” control which returns
to neutral when released. To drive forward, select “DRIVE”
position with the Lift/Off/Drive Toggle Switch, then lift
the controller lock ring and push handle forward to desired
speed. Release to stop. To drive in reverse, select
“DRIVE” position, then lift the controller lock ring and
pull the handle backwards to desired speed. Release to
stop. To steer, select “DRIVE” position with, then depress
the side of the rocker switch on top of the controller
handle in the direction you wish to steer. To raise the
platform, select “LIFT” position with the Lift/Off/Drive
Toggle Switch, then lift the controller lock ring and push
handle forward until desired height is reached. To lower
the platform, select “LIFT” position, then lift the controller
lock ring and pull handle backward until desired height is
reach. Release to stop. NOTE: Platform lowering is
not proportional.
Operator Horn
Figure 2-9. Operator’s Control Box
1.
2.
3.
4.
OFF/ON KEY SWITCH
EMERGENCY STOP BUTTON
LIFT/OFF/DRIVE SELECT TOGGLE SWITCH
PROPORTIONAL CONTROLLER
OPERATOR’S CONTROL BOX - This metal control
station is mounted on the railing at the right front of the
platform. It contains the following controls:
SJM Series
1
Figure 2-10. Operator Horn Push-button
1. OPERATOR HORN PUSH-BUTTON
1. OPERATOR HORN PUSH-BUTTON - Located on the
side of the Operator’s Control Box, this push-button
switch, when depressed, sounds an automotive-type horn.
Final Revision 2-1-98
SECTION 2, Page 5
Powered Extension Platform Control Box
Fold-Down Guardrail System
1
2
Figure 2-11. Powered Extension Platform Control Box
1. ENABLE SWITCH
2. PLATFORM EXTEND/RETRACT SWITCH
1
1
Figure 2-12. Fold-Down Guardrail System
1. GUARDRAIL LOCKING PIN W/LANYARD
POWERED PLATFORM CONTROL BOX - This metal
control station is mounted at the right front of the
extension platform. It contains the following controls:
1. ENABLE SWITCH - This switch, when activated,
brings power to the Platform Extend/Retract Switch. It
must be used while extending or retracting the extension
platform.
2. PLATFORM EXTEND/RETRACT SELECTOR
SWITCH - To extend the platform, select “LIFT” position,
©“ (extend) position until
then move the switch to the “©
desired extension is reached. Release switch to stop.
To retract the platform, select “LIFT” position, then move
ª“ (retract) position until desired
the switch to the һ
retraction is reached. Release switch to stop.
NOTE
FOLD-DOWN GUARDRAIL SYSTEM - This system
when folded down, reduces the shut height of the work
platform for travelling through standard doorways.
1. GUARDRAIL LOCKING PIN W/LANYARD - To fold
the guardrail system down, remove the locking pin at
each pivot point and lower each guardrail. To raise the
guardrail system, swing up each guardrail and lock in
place with the locking pins ensuring that the detent ball
of each pin is clear of the side of the pivot brackets.
(Figure 2-13.)
WARNING
The guardrail system MUST be upright and locked in
place before resuming normal operation. Check the
guardrail system for loose or missing locking pins
before operating this equipment!
On machines equipped with scissor guards, the extension
platform MUST be fully retracted to fully lower the
platform.
DETENT BALL
CLEAR OF SIDE
OF PIVOT
BRACKET
Figure 2-13. Correct Position of Locking Pin
SECTION 2, Page 6
Final Revision 2-1-98
SJM Series
SET-UP PROCEDURE
8.
In the hydraulic/electric tray, check the hydraulic
oil level (scissors MUST be fully lowered) in the
tank. Level should be at or slightly above the top
mark on the gauge. If required, add a quality grade
hydraulic oil. Refer to “RECOMMENDED
HYDRAULIC OILS” for recommendations.
9.
Swing the hydraulic/electric tray to locked closed
position.
10.
Rotate the Free-Wheeling Valve to a fully opened
position (counter-clockwise).
11.
Disengage the Parking Brake (following the
procedure discussed earlier in this section on Page
3).
The following steps are normally required for equipment
being put into service for the first time. After the equipment has been unloaded:
1.
Remove all packing materials and inspect for
damage incurred during transport.
NOTE
Report any damage to delivery carrier immediately.
2.
Inspect work platform thoroughly and remove any
foreign objects.
3.
If equipped with a fold-down guardrail system,
swing up and lock all guardrails in place with
locking pins ensuring that the detent ball of each
pin is clear of the side of the pivot brackets.
(Figure 2-13).
IMPORTANT NOTE
Before pushing or towing the work platform, ensure that
the brake pins have been disengaged. When towing, DO
NOT exceed 2 mph.
4.
Unlock and swing out the battery tray and
hydraulic/electric tray.
12.
5.
In the battery tray, check the water level in all
four batteries. If plates are not covered, carefully
add distilled or demineralized water. If needed,
check the specific gravity in each battery, it
should be 1.260 to 1.275.
Push or tow the work platform to a level, firm test
area where the work platform can be vertically
extended to its maximum working height.
13.
Close the Free-Wheeling Valve by rotating the knob
clockwise.
WARNING
EXPLOSION HAZARD
On machines without Base Control Box:
14A.
Keep flames and sparks away. DO NOT smoke near
batteries.
FIRST AID
On machines with Base Control Box:
14B.
Raise the platform with the Up/Down Switch until
there is adequate clearance to swing down and
position the safety bar.
15.
Lift the Safety Bar from the storage channel and
swing down into position. (Refer to label on base
for proper procedure.)
16.
Slowly lower the platform with the Up/Down Switch
until the scissor assembly is firmly supported by
the safety bar.
Immediately flush eyes with cold water if electrolytic acid
is splattered into them.
6.
Connect the battery charger cord to the proper
voltage source and charge the batteries. (Refer
to “Battery Charging Procedures”, Page 26.)
7.
When charger cycle is complete, disconnect the
battery charger cord and swing the battery tray
to locked closed position.
SJM Series
Raise the platform with the Up/Down Toggle Switch
until there is adequate clearance to lower the safety
bar.
Final Revision 2-1-98
SECTION 2, Page 7
17.
18.
Inspect all hoses, fittings, wires, cables, valves,
etc. for leaks, hidden damage and foreign
material.
Raise the platform until there is adequate
clearance to swing up safety bar. Return Safety
Bar to storage channel.
OPERATOR’S CHECKLIST
INSPECT AND/OR TEST THE
FOLLOWING DAILY OR AT BEGINNING
OF EACH SHIFT
1. OPERATING AND EMERGENCY CONTROLS.
2. SAFETY DEVICES.
19.
Again, raise the platform until the platform has
reached its maximum working height.
3. PERSONAL PROTECTIVE DEVICES.
4. TIRES AND WHEELS.
5. OUTRIGGERS (IF EQUIPPED) AND OTHER
NOTE
STRUCTURES.
Refer to Table 3-3. General Specifications for raise and
lowering times.
6. AIR, HYDRAULIC AND FUEL SYSTEM(S) FOR LEAKS.
7. LOOSE OR MISSING PARTS.
8. CABLES AND WIRING HARNESSES.
20.
21.
Use the Up/Down Switch or Emergency Lowering
Valve to fully lower the platform.
9. PLACARDS, WARNINGS, CONTROL MARKINGS AND
The SJM Series Work Platform is now ready for
use by an authorized, qualified operator who has
read and completely understands ALL of Section
2, OPERATION in this manual.
10. GUARDRAIL SYSTEM.
OPERATING MANUALS.
11. ENGINE OIL LEVEL (IF SO EQUIPPED).
12. BATTERY FLUID LEVEL.
13. HYDRAULIC RESERVOIR LEVEL.
14. COOLANT LEVEL (IF SO EQUIPPED).
OPERATING PROCEDURES
Prestart Checks
1.
Carefully read and completely understand ALL
of SECTION 2, OPERATION in this manual and
ALL warnings and instruction labels on the work
platform.
WARNING
2.
Check for obstacles around the work platform
and in the path of travel such as holes, drop
offs, debris, ditches and soft fill.
3.
Check overhead clearances.
4.
Make sure the batteries are fully charged.
5.
Make sure that the Free-Wheeling Valve and
Emergency Lowering Valve are fully closed.
Start and Operation
Using the Base Controls:
6.
Make sure all guardrails are in place and locked
in position. (Refer to Figure 2-13.)
1.
Turn Emergency Battery Disconnect Switch to
“ON” position.
2.
Use the ladder at the rear of the platform to
access the work platform deck.
3.
Latch the entry chain or gate.
SECTION 2, Page 8
DO NOT OPERATE THIS EQUIPMENT
WITHOUT PROPER AUTHORIZATION AND
TRAINING. DEATH OR SERIOUS INJURY
COULD RESULT FROM IMPROPER USE OF
THIS EQUIPMENT!
Final Revision 2-1-98
SJM Series
Using the Platform Controls:
4.
7.
TO STEER: Press rocker on top of the controller
handle in the direction you wish to steer.
8A.
TO DRIVE FORWARD (2 speed control): Select
“DRIVE” position with Lift/Off/Drive Select Key
Switch. Lift the controller lock ring and push the
controller handle forward to desired speed.
Release to stop.
Pull out the Emergency Stop Buttons.
5A.
TO RAISE THE PLATFORM (2 speed control):
Select “LIFT” position with Lift/Off/Drive Select
Key Switch. Depress and hold the Lift Enable
Push-button, then select “ © “ (up) position with
Up/Down Selector Switch.
8B.
5B.
TO RAISE THE PLATFORM (proportional
control): Select “LIFT” position with the Lift/Off/
Drive Toggle Switch, then lift the controller lock
ring and push the controller handle forward until
desired height is reached. Release handle to
stop.
TO DRIVE FORWARD (proportional control):
Select “DRIVE” position with the Lift/Off/Drive
Toggle Switch, then lift the controller lock ring
and push the controller handle forward to desired
speed. Release handle to stop.
9A.
TO LOWER THE PLATFORM (2 speed control):
Select “LIFT” position with Lift/Off/Drive Select
Key Switch. Depress and hold the Lift Enable
Push-button, then select “ ª “ (down) position
with Up/Down Selector Switch.
TO DRIVE IN REVERSE (2 speed control):
Select “DRIVE” position with Lift/Off/Drive Select
Key Switch. Lift the controller lock ring and pull
the controller handle backwards to desired speed.
Release to stop.
9B.
TO DRIVE IN REVERSE (proportional control):
Select “DRIVE” position with the Lift/Off/Drive
Toggle Switch, then lift the controller lock ring
and pull the controller handle backward to desired
speed. Release handle to stop.
6A.
5B.
TO LOWER THE PLATFORM (proportional
control): Select “LIFT” position with the Lift/Off/
Drive Toggle Switch, then lift the controller lock
ring and pull the controller handle backward until
desired height is reached. Release handle to
stop. NOTE: Platform lowering is not
proportional.
SJM Series
Shutdown Procedure
1.
Completely lower the platform.
2.
Turn the key to “OFF” position and remove key.
3.
Push Emergency Stop Button(s) in.
4.
Turn Emergency Battery Disconnect Switch to
“OFF” position.
Final Revision 2-1-98
SECTION 2, Page 9
BATTERY SERVICE AND CHARGING
PROCEDURES
Battery Service
To reduce the risk of electrical shock, connect charger
only to a properly grounded single phase outlet. DO
NOT use an extension cord longer than 25 feet.
WARNING
EXPLOSION HAZARD
Keep flames and sparks away. DO NOT smoke near
batteries.
1.
Connect charger AC plug to proper voltage
source. Refer to charger nameplate for voltage
requirements.
2.
Charge batteries. DO NOT leave charger
unattended for more than two consecutive days.
Severe overcharging and battery damage will
result if charger fails to turn off.
3.
Disconnect charger from external power source.
CAUTION
Contact with electrolytic acid can cause skin irritation
and damage clothing. Wear a protective apron, gloves
and goggles when working with batteries.
FIRST AID
Immediately flush eyes with cold water if electrolytic acid
is splattered into them. Seek medical attention if
discomfort continues.
1.
Turn Emergency Battery Disconnect Switch to
“OFF” position.
2.
Check battery fluid level in each battery. If plates
are not covered, add distilled or demineralized
water.
3.
Check battery case for damage.
4.
Clean battery terminals and cable ends thoroughly
with a terminal cleaning tool or wire brush.
5.
Make sure all battery connections are tight.
6.
Replace any battery that is damaged or incapable
of holding a lasting charge.
Battery Charging Procedures (EE-Rated
Machines)
WARNING
DO NOT CHARGE BATTERIES IN HAZARDOUS
AREA! THE EE-RATING OF THIS MACHINE DOES
NOT INCLUDE THE CHARGING OF BATTERIES.
1.
Move the work platform to an area designated
for battery charging. (Refer to NFPA 505* for
charging set-up.) *NFPA 505 is a publication of:
National Fire Protection Association, Inc. Batterymarch
Park, Quincy, MA 02269 (USA)
2.
Connect battery charger DC plug into the battery
plug at the rear of the base.
3.
Charge batteries. (Refer to battery charger
operation manual for procedures.)
4.
When charge cycle is completed, disconnect
charger plug from battery plug in the battery tray.
5.
Recheck the battery fluid level in each battery.
If plates are not covered, add distilled or
demineralized water.
Battery Charging Procedures (Standard Machines)
WARNING
EXPLOSION HAZARD
Chargers can ignite flammable materials and vapors.
DO NOT use near fuels, grain dust, solvents or other
flammables
WARNING
SHOCK HAZARD
SECTION 2, Page 10
Final Revision 2-1-98
SJM Series
BATTERY CHARGER OPERATION
OPERATION OF THE COMPLETELY
AUTOMATIC BATTERY CHARGER
(Motor Appliance Charger)
This charger is equipped with an electronic circuit that
will completely recharge the batteries and automatically
turn off after the charge cycle is complete.
The function of the L.E.D. indicators is as follows:
When the AC power is connected to the charger, the
L.E.D.’s will flash several times then flash independently
to check the light circuits. After the flashing sequence is
complete the “INCOMPLETE” light will come on. Five
seconds later, the “CHARGER ON” light will come on and
at the same time, the ammeter will indicate how much
current is going to the batteries.
Figure 2-14. Automatic Battery Charger
BATTERY STATUS
1. GREEN L.E.D......................CHARGE COMPLETE
2. YELLOW L.E.D................................80% CHARGE
3. RED L.E.D........INCOMPLETE CHARGER STATUS
4. YELLOW L.E.D. ..............................CHARGER ON
5. RED L.E.D. ............................ABNORMAL CYCLE
NOTE
On earlier chargers, the charger front panel read as
follows:
BATTERY CONDITION
1. GREEN L.E.D .............................................FULL
2. YELLOW L.E.D. ............................................80%
3. RED L.E.D. .....................................DISCHARGED
CHARGER STATUS
4. YELLOW L.E.D. ..............................CHARGER ON
5. RED L.E.D. ............................ABNORMAL CYCLE
SJM Series
As the charge cycle continues, which can last between
1-1/2 hours and 9 hours for a complete cycle, depending
on the state of charge of the batteries, the “80%” light will
come on and the “INCOMPLETE” light will go off. When
voltage of the batteries reaches approximately 30 volts,
the “80%” light will go off and the “CHARGE COMPLETE”
light will come on. This light will remain on even after the
charger is turned off by the electronic control. After the
charger turns off, the “CHARGE COMPLETE” light will
indicate to the operator that the batteries are healthy and
are fully charged.
If the “80% CHARGE” light continues to stay on after the
charge cycle is complete, this indicates to the operator
that the batteries are not capable of attaining a full charge.
If the “INCOMPLETE” light remains on after the charge
cycle is complete, this indicates to the operator that the
batteries are not capable of attaining even an 80% charge.
If either the “80% CHARGE” or “INCOMPLETE” light
remain on after the charge cycle is complete, the batteries
should be inspected for problems.
Your standard good watering procedures should be used
at all times.
Final Revision 2-1-98
SECTION 2, Page 11
BATTERY CHARGER OPERATION
(Bycan Charger)
Figure 2-15. Bycan Automatic Battery Charger
BATTERY STATUS
1. GREEN L.E.D ...................................COMPLETE
2. YELLOW L.E.D. ........................CHECK BATTERY
3. RED L.E.D. ...................................IN PROGRESS
The charger will start immediately. (Transformer will hum
and fan will come on). The red “IN PROGRESS” L.E.D.
will show charging current.
The current will be high for approximately 30 minutes
then it will taper off. If the current does not taper off,
disconnect the charger and check the batteries for a
shorted cell.
The charging cycle is automatically controlled and the
normal charging time will be 6 to 8 hours.
When the batteries are fully charged, the charger will
shut off and the green “COMPLETE” L.E.D. will come
on. Shut-off voltage is 31
SECTION 2, Page 12
Final Revision 2-1-98
SJM Series
SECTION 3
SYSTEM COMPONENT IDENTIFICATION
AND SCHEMATICS
TABLE OF CONTENTS
ELECTRICAL SYSTEM
FIGURE 3-1. ELECTRICAL SCHEMATIC PARTS LIST - Standard for North America .............................. Page 2
(Shown with Powered Extension Platform Option)
FIGURE 3-1. ELECTRICAL SCHEMATIC - Standard for North America ................................................... Page 3
(Shown with Powered Extension Platform Option)
FIGURE 3-2. ELECTRICAL SCHEMATIC - Other Than North America and EE - Rated ............................ Page 4
(Shown with all options except Powered Extension Platform Option)
FIGURE 3-2. ELECTRICAL SCHEMATIC PARTS LIST - Other Than North America and EE- Rated ........ Page 5
(Shown with all options except Powered Extension Platform Option
FIGURE 3-3. ELECTRICAL PANEL DIAGRAM - Standard for North America .......................................... Page 6
(Shown with Powered Extension Platform Option)
FIGURE 3-4. ELECTRICAL PANEL DIAGRAM - Other Than North America ............................................ Page 7
(Shown with all options except Powered Extension Platform Option)
FIGURE 3-5. ELECTRICAL PANEL DIAGRAM - EE- Rated ..................................................................... Page 8
FIGURE 3-6. CONTROL BOX DIAGRAM ................................................................................................. Page 9
HYDRAULIC SYSTEM
FIGURE 3-7. HYDRAULIC SCHEMATIC PARTS LIST (Machines With Hi-Torque Option) ....................... Page 10
FIGURE 3-7. HYDRAULIC SCHEMATIC (Machines With Hi-Torque Option) ............................................ Page 11
FIGURE 3-8. HYDRAULIC SCHEMATIC (Machines Without Hi-Torque Option) ....................................... Page 12
FIGURE 3-8. HYDRAULIC SCHEMATIC PARTS LIST (Machines Without Hi-Torque Option) .................. Page 13
FIGURE 3-9. HYDRAULIC MANIFOLD COMPONENT AND PORT IDENTIFICATION
(Machines With Hi-Torque Option) ..................................................................................................... Page 14
FIGURE 3-10. HYDRAULIC MANIFOLD COMPONENT AND PORT IDENTIFICATION
(Machines Without Hi-Torque Option) ................................................................................................ Page 15
SJM Series 107979-8
toc
1
2
4
SECTION 3, Page 1
5
6
3
FIGURE 3-1. ELECTRICAL SCHEMATIC - Standard for North America
(Shown with Powered Extension Platform Option)
Ref.
No.
B1 to B4
BC
BCI
BP-13
C1
CAP1
CB1
CB2
17CR1
17CCR1
CRD1
CRD2
Skyjack
Part No.
CRD3
DCM1
D9 to D27
DA1
F1
2H-13
2H-21
103480
108163
103240
103057
103101
103319
117325
117325
108589
108589
104172
106337
104170
104173
107486
102921
108000
102756
103605
103605
2H-21
103605
2H-25
3H-14
3H-17
4H-15
4H-16
4H-23
4H-24
4H-26
103605
105610
103605
107439
107439
107439
107439
107439
4H-27
107439
LS1
LS2
S1
S2
S3
S4
S5
S7
S7-1
S7-2
S7-3
S7-4
S7-5
S9
S11
102668
102668
102600
102853
102752
103225
103141
103334
102768
105733
105733
102768
102768
103141
103141
S15
TT
102853
103336
SECTION 3, Page 2
OEM
Part No.
Units
per
Assy.
Description
1 2 3 4 5 6 7
BATTERY, 6 Volt, 220AH (wet)
BATTERY CHARGER, 24V25A, 120VAC, 60Hz
BATTERY CHARGE INDICATOR
BEEPER, 24 Volt
CONTACTOR, 24 Volt motor
CAPACITOR, 35 Volt
CIRCUIT BREAKER, 15 Amp (Replaces 102331)
CIRCUIT BREAKER, 15 Amp (Replaces 102331)
RELAY, 24 Volt (brake) (Replaces 103425)
RELAY, 24 Volt (cushion) (Replaces 103425)
CORD ASSEMBLY, Control box
CORD ASSEMBLY, Scissor arm (Model 3015)
CORD ASSEMBLY, Scissor arm (Model 3219)
CORD ASSEMBLY, Electrical panel
MOTOR, 24 Volt DC
DIODE, 6 Amp
DIODE ASSEMBLY
FUSE, 200 Amp
COIL, 24 Volt (lowering valve)
COIL, 24 Volt (dump valve)
(Machines without Hi-Torque Option)
COIL, 24 Volt (speed valve)
(Machines with Hi-Torque Option)
COIL, 24 Volt (cushion valve)
COIL, 24 Volt (lift valve)
COIL, 24 Volt (brake valve)
COIL, 24 Volt (reverse drive valve)
COIL, 24 Volt (forward drive spool valve)
COIL, 24 Volt (right steer valve)
COIL, 24 Volt (left steer spool valve)
COIL, 24 Volt (powered platform extend
valve) (option)
COIL, 24 Volt (powered platform retract
valve) (option)
LIMIT SWITCH, High speed cut-out
LIMIT SWITCH, Powered platform cut-out
SWITCH, Main power disconnect
SWITCH, Up/down toggle
SWITCH, Lift/off/drive key select
N.C. CONTACT, Emergency stop
N.O. CONTACT, Up/down selector
CONTROLLER ASSEMBLY, Drive/steer
SWITCH W/ACTUATOR, Speed
SWITCH, Right steer
SWITCH, Left steer
SWITCH W/ACTUATOR, Reverse drive
SWITCH W/ACTUATOR, Forward drive
N.O. CONTACT, Lift enable (later machines)
N.O. CONTACT, Powered platform extend/retract
selector
SWITCH, Enable toggle (powered platform option)
HOURMETER
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AR
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
SJM Series 107979-8
Parts List
SJM Series 107979-8
FIGURE 3-1. ELECTRICAL SCHEMATIC - Standard for North America
(Shown with Powered Extension Platform Option)
SECTION 3, Page 3
Parts List
SECTION 3, Page 4
FIGURE 3-2. ELECTRICAL SCHEMATIC - Other than North America and EE-Rated
(Shown with all options except Powered Extension Platform Option)
SJM Series 107979-8
FIGURE 3-2. ELECTRICAL SCHEMATIC - Other Than North America and EE-Rated
(Shown with all options except Powered Extension Platform Options)
FIGURE 3-2. ELECTRICAL SCHEMATIC - Other Than North America and EE-Rated
(Shown with all options except Powered Extension Platform Options)
Index
No.
Skyjack
Part No.
B1 to B4 103480
BC
111327
110550
BCI
BP-29
C1
CAP1
CB1
CB2
17CR1
17CCR1
28CR1
103240
103057
103101
103319
102331
102331
108589
108589
108589
AC/CR1 106654
110734
CRD1
CRD2
(Ref.)
(Ref.)
(Ref.)
CRD3
(Ref.)
DCM1
107486
107081
D9-D24 102921
DA1
108100
F1
102756
FL-13
103267
FL-22
104535
2H-13
103605
2H-13-1 103605
2H-21
103605
2H-21
103605
2H-25
3H-14A
3H-17
4H-15
4H-16
4H-23
4H-24
103605
105610
103605
107439
107439
107439
107439
SJM Series 107979-8
OEM
Part No.
Description
1 2 3 4 5 6 7
BATTERY, 6 Volt, 220AH (wet)
BATTERY CHARGER, 24V20A, 220 VAC, 50HZ
(Other than North America)
BATTERY CHARGER, 24V20A, 120VAC, 60Hz
(Remote) (EE-Rated Machines)
BATTERY CHARGE INDICATOR
BEEPER, 24 Volt
CONTACTOR, 24 Volt motor
CAPACITOR, 35 Volt
CIRCUIT BREAKER, 15 Amp
CIRCUIT BREAKER, 15 Amp
RELAY, 24 Volt (brake) (Replaces 103425)
RELAY, 24 Volt (cushion) (Replaces 103425)
RELAY, 24 Volt (tilt) (Replaces 103425)
(Machines with Tilt Switch Option)
RELAY, 110V (charger cutout option)
(North America)
RELAY, 240V (charger cutout option)
(Other than North America)
CORD ASSEMBLY, Control box
CORD ASSEMBLY, Scissor arm (Model 3015)
CORD ASSEMBLY, Scissor arm (Model 3219)
CORD ASSEMBLY, Electrical panel
MOTOR, 24 Volt DC (Other than North America)
MOTOR, 24 Volt DC (EE-Rated Machines)
DIODE, 6 Amp
DIODE ASSEMBLY
FUSE, 200 Amp
FLASHER, 24 Volt
FLASHING LIGHT
COIL, 24 Volt (lowering valve)
COIL, 24 Volt (holding valve)
(Machines w/Holding Valve Option)
COIL, 24 Volt (dump valve)
(Machines without Hi-Torque Option)
COIL, 24 Volt (speed valve)
(Machines with Hi-Torque Option)
COIL, 24 Volt (cushion valve)
COIL, 24 Volt (up valve)
COIL, 24 Volt (brake valve)
COIL, 24 Volt (reverse drive spool valve)
COIL, 24 Volt (forward drive spool valve)
COIL, 24 Volt (right steer spool valve)
COIL, 24 Volt (left steer spool valve)
Units
per
Assy.
Index
No.
4
1
4H-26
107439
4H-27
107439
LS1
LS2
LS4
102847
102668
102668
S1
S2
S3
S4
S5
S7
S7-1
S7-2
S7-3
S7-4
S7-5
S8
102600
102853
102752
103225
103141
103334
102768
105733
105733
102768
102768
103141
S9
TS
TT
103141
106471
103336
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AR
1
1
1
1
1
1
Skyjack
Part No.
OEM
Part No.
Units
per
Assy.
Description
1 2 3 4 5 6 7
COIL, 24 Volt (powered platform extend spool
valve (option)
COIL, 24 Volt (powered platform retract spool
valve (option)
LIMIT SWITCH, High speed cut-out
LIMIT SWITCH, Powered platform cut-out
LIMIT SWITCH, End of Stroke
(Machines with End Of Stroke Limit Option)
SWITCH, Main power disconnect
SWITCH, Up/down toggle
SWITCH, Lift/off/drive key select
N.C. CONTACT, Emergency stop
N.O. CONTACT, Up/down selector
CONTROLLER ASSEMBLY
SWITCH W/ACTUATOR, Speed
SWITCH, Right steer
SWITCH, Left steer
SWITCH W/ACTUATOR, Reverse drive
SWITCH W/ACTUATOR, Forward drive
N.O. CONTACT, Operator horn
(Machines with Operator Horn Option)
N.O. CONTACT, Lift enable (later models)
TILT SWITCH (Machines with Tilt Switch Option)
HOURMETER
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 3, Page 5
FIGURE 3-3. ELECTRICAL PANEL DIAGRAM - Standard for North America
(Shown with Powered Extension Platform Option)
Index
No.
1
2
3
4
5
6
7
8
9
13
7
10
11
12
13
14
15
Skyjack
Part No.
Description
OEM
Part No.
1 2 3 4 5 6 7
103057
103336
103101
102756
102331
104173
102518
109111
104409
104345
102853
103011
108000
107745
103319
108589
BEEPER, 24 Volt
HOURMETER
CONTACTOR
FUSE, 200 Amp
CIRCUIT BREAKER, 15 Amp
CORD ASSEMBLY, Panel control
• SOCKET, 10 Pin female
HARNESS, Manifold wiring
• CONNECTOR, Black
• CONNECTOR, Gray
SWITCH, Up/down toggle
STRIP, Terminal
DIODE ASSEMBLY
SWITCH ASSEMBLY, High speed limit
CAPACITOR, 35 Volt
RELAY, 24 Volt
Units
per
Assy.
1
1
1
1
2
1
1
1
2
2
1
1
1
1
1
2
9
12
4
3
5
1
11
6
8
2
10
14
15
SECTION 3, Page 6
SJM Series 107979-8
FIGURE 3-4. ELECTRICAL PANEL DIAGRAM - Other than North America
(Shown with all options except Powered Extension Platform Option)
Index
No.
1
2
3
4
5
6
7
8
9
16
10
10
11
12
13
14
15
16
17
18
13
Skyjack
Part No.
Units
per
Assy.
Description
OEM
Part No.
1 2 3 4 5 6 7
103057
103336
103101
102756
102331
(Ref.)
(Ref.)
109566
104409
104345
103318
103049
103011
108000
105515
103319
108589
109536
103267
106471
BEEPER, 24 Volt
HOURMETER
CONTACTOR
FUSE, 200 Amp
CIRCUIT BREAKER, 15 Amp
CORD ASSEMBLY, Panel control
• CONNECTOR ASSEMBLY., 10 Pole female
HARNESS, Manifold wiring
• CONNECTOR, Black
• CONNECTOR, Gray
CONNECTOR, 8 Pin female
• PIN, Female connector
STRIP, Terminal
DIODE ASSEMBLY
SWITCH ASSEMBLY, High speed limit
CAPACITOR, 35 Volt
RELAY, 24 Volt
SWITCH ASSEMBLY, End-of-stroke limit
FLASHER, 24 Volt
SWITCH, Tilt
1
1
1
1
2
1
1
1
3
2
1
7
1.3
1
1
1
3
1
1
1
9
7
4
3
6
5
17
12
11
18
1
2
8
14
15
SJM Series 107979-8
SECTION 3, Page 7
FIGURE 3-5. ELECTRICAL PANEL DIAGRAM - EE Rated
Skyjack
Part No.
Index
No.
1
2
3
4
5
6
7
8
9
13
7
103057
103336
103101
102756
102331
(Ref.)
(Ref.)
109111
104409
104345
102853
103011
108000
107745
103319
108589
104632
10
11
12
13
14
15
16
9
6
OEM
Part No.
Units
per
Assy.
Description
1 2 3 4 5 6 7
BEEPER, 24 Volt
HOURMETER
CONTACTOR
FUSE, 200 Amp
CIRCUIT BREAKER, 15 Amp
CORD ASSEMBLY, Panel control
• CONNECTOR ASSEMBLY, 10 Pole female
HARNESS, Manifold wiring
• CONNECTOR, Black
• CONNECTOR, Gray
SWITCH, Up/down toggle
STRIP, Terminal
DIODE ASSEMBLY
SWITCH ASSEMBLY, High speed limit
CAPACITOR, 35 Volt
RELAY, 24 Volt
PLUG, Motor disconnect
3
10
1
1
1
1
2
1
1
1
2
2
1
1
1
1
1
2
1
5
2
1
12
8
11
4
SECTION 3, Page 8
14
15
SJM Series 107979-8
FIGURE 3-6. CONTROL BOX DIAGRAM AND PARTS LIST - Standard for North America (shown)
Index
No.
Skyjack
Part No.
1
2
3
103334
103240
(Ref.)
4
5
102752
(Ref.)
6
(Ref.)
7
8
9
10
103012
102921
102956
(Ref.)
OEM
Part No.
Description
1 2 3 4 5 6 7
CONTROLLER ASSEMBLY, Drive/steer
INDICATOR, Battery charge
SWITCH ASSEMBLY, Up/off/down
(Refer to Figure 6-9.)
SWITCH, Key
SWITCH ASSEMBLY, Emergency stop
(Refer to Figure 6-9.)
SWITCH ASSEMBLY, Lift enable
(Refer to Figure 6-9.)
BLOCK, Terminal
DIODE, 6 Amp
PLUG, Snap
CORD ASSEMBLY, Control box
(Refer to Figure 6-9.)
Units
per
Assy.
1
1
1
4
2
1
1
1
8
1
1
2
7
1
3
5
7
9
6
10
NOTE: For machines with Proportional Control Option, refer to Appendix A.
SJM Series 107979-8
SECTION 3, Page 9
FIGURE 3-7. HYDRAULIC SCHEMATIC (Machines With Hi-Torque Option)
FIGURE 3-7. HYDRAULIC SCHEMATIC (Machines With Hi-Torque Option)
Index
No.
C2
Skyjack
Part No.
C5
106581
113873
110681
105888
107932
See fig.6-22
108099
103817
105816
108727
CB1
F1
107396
104133
109568
C3
C4
102877
FC1
FD1
2H-13
2H-13-1
2H-21
2H-25
3H-14
3H-17
4H-15
4H-16
4H-23
4H-24
4H-26
104254
400087
103354
103655
107269
104132
104132
106273
103623
103614
103614
103614
103614
103614
4H-27
103614
M1
110701
M2
110701
110702
110703
SECTION 3, Page 10
OEM
Part No.
Description
1 2 3 4 5 6 7
CYLINDER ASSEMBLY, Lift (Model 3015)
• KIT, Seal repair
CYLINDER ASSEMBLY, Lift (Model 3219)
• KIT, Seal repair
CYLINDER ASSEMBLY, Steer (Model 3015)
CYLINDER ASSEMBLY, Steer (Model 3219)
• KIT, Seal repair
CYLINDER ASSEMBLY, Brake
• KIT, Seal repair
CYLINDER ASSEMBLY, Powered extension
platform (option)
• KIT, Seal repair
VALVE, Counterbalance
FILTER ASSEMBLY, Return (Model 3015 with S/N
15556 and above and Model 3219)
FILTER ASSEMBLY, Return (Model 3015 with S/N
15555 and below)
• ELEMENT, Return filter
FLOW CONTROL, Fixed 0.8 gpm
VALVE, Flow divider/combiner
VALVE, Lowering
VALVE, Holding (Machines w/Holding Valve Option)
VALVE, Speed
VALVE, Cushion
VALVE, Lift
VALVE, Brake
VALVE, Reverse drive (includes 4H-16)
VALVE, Forward drive (includes 4H-15)
VALVE, Right steer (includes 4H-24)
VALVE, Left steer (includes 4H-23)
VALVE, Powered platform extend (includes 4H-27)
(Machines w/Powered Extension Platform Option)
VALVE, Powered platform retract (includes 4H-26)
(Machines w/Powered Extension Platform Option)
MOTOR, Hydraulic drive LH (#HB04075370X)
(Replaces 107515, #HB0407030X)
MOTOR, Hydraulic drive RH (#HB04075370X)
(Replaces 107515, #HB0407030X)
• KIT, Seal repair (For motor, 110701)
• KIT, Seal repair (For motor, 107515)
Units
per
Assy.
Index
No.
1
AR
1
AR
1
1
AR
AR
AR
1
1
AR
1
1
MB1
MB2
MB3
MB4
107354
107369
103615
103494
106689
MB5
103137
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Skyjack
Part No.
107493
MB6
107382
MB7
O2
O3
O4
P1
400085
108053
108002
105811
107485
109216
104534
104534
103136
103136
103138
R1
R2
V1
V2
VF1
OEM
Part No.
Units
per
Assy
Description
1 2 3 4 5 6 7
MANIFOLD BLOCK, Main
MANIFOLD BLOCK, Front axle
MANIFOLD BLOCK, Cushion valve
MANIFOLD BLOCK, Velocity fuse (Standard)
MANIFOLD BLOCK, Holding valve
(Machines w/Holding Valve Option)
MANIFOLD BLOCK, Manual lowering valve
(Machines w/rotary-type lowing valve)
MANIFOLD BLOCK, Manual lowering valve
(Machines w/pull-type lowering valve)
MANIFOLD BLOCK, Powered extension platform
(Machines w/Powered Extension Platform Option)
MANIFOLD BLOCK, Torque/speed control
ORIFICE, Lowering .055 diameter
ORIFICE, Cushion .040 diameter
ORIFICE, Brake .040 diameter
PUMP, Hydraulic (Standard)
PUMP, Hydraulic (EE-Rated Machines)
VALVE, System relief
VALVE, Lift relief
VALVE, Manual lowering
VALVE, Free-wheeling
VELOCITY FUSE, Lift cylinder
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AR
AR
SJM Series 107979-8
Parts List
FIGURE 3-7. HYDRAULIC SCHEMATIC (Machines With Hi-Torque Option)
NOTE: For machines with Proportional Control Option, refer to Appendix A.
SJM Series 107979-8
SECTION 3, Page 11
Parts List
FIGURE 3-8. HYDRAULIC SCHEMATIC (Machines Without Hi-Torque Option)
NOTE: For machines with Proportional Control Option, refer to Appendix A.
SECTION 3, Page 12
SJM Series 107979-8
FIGURE 3-8. HYDRAULIC SCHEMATIC (Machines Without Hi-Torque Option)
Index
No.
C2
C3
Skyjack
Part No.
106581
113873
110681
105888
107932
C5
108099
103817
105816
108727
CB1
F1
107396
104133
109568
C4
102877
FD1
2H-13
2H-13-1
2H-21
2H-25
3H-14
3H-17
4H-15
4H-16
4H-23
4H-24
4H-26
104254
103354
103655
107269
102626
104132
106273
103623
103614
103614
103614
103614
103614
4H-27
103614
M1
110701
M2
110701
110702
110703
SJM Series 107979-8
OEM
Part No.
Description
1 2 3 4 5 6 7
CYLINDER ASSEMBLY, Lift (Model 3015)
• KIT, Seal repair
CYLINDER ASSEMBLY, Lift (Model 3219)
• KIT, Seal repair
CYLINDER ASSEMBLY, Steer (Model 3015)
CYLINDER ASSEMBLY, Steer (Model 3219)
(Refer to Figure 6-22.)
• KIT, Seal repair
CYLINDER ASSEMBLY, Brake
• KIT, Seal repair
CYLINDER ASSEMBLY, Powered extension
platform (option)
• KIT, Seal repair
VALVE, Counterbalance
FILTER ASSEMBLY, Return (Model 3015 with S/N
15556 and above and all Model 3219)
FILTER ASSEMBLY, Return (Model 3015 with S/N
15555 and below)
• ELEMENT, Return filter
VALVE, Flow divider/combiner
VALVE, Lowering
VALVE, Holding (Machines w/Holding Valve Option)
VALVE, Dump
VALVE, Cushion
VALVE, Lift
VALVE, Brake
VALVE, Reverse drive (includes 4H-16)
VALVE, Forward drive (includes 4H-15)
VALVE, Right steer (includes 4H-24)
VALVE, Left steer (includes 4H-23)
VALVE, Powered platform extend (includes 4H-27)
(Machines w/Powered Extension Platform Option)
VALVE, Powered platform retract (includes 4H-26)
(Machines w/Powered Extension Platform Option)
MOTOR, Hydraulic drive LH (#HB04075370X)
(Replaces 107515, #HB0407030X)
MOTOR, Hydraulic drive RH (#HB04075370X)
(Replaces 107515, #HB0407030X)
• KIT, Seal repair (For motor, 110701)
• KIT, Seal repair (For motor, 107515)
FIGURE 3-8. HYDRAULIC SCHEMATIC (Machines Without Hi-Torque Option)
Units
per
Assy.
Index
No.
1
AR
1
AR
1
1
MB1
MB2
MB3
MB4
107354
107369
103615
103494
106689
MB5
103137
AR
AR
AR
1
1
AR
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Skyjack
Part No.
107493
MB6
107382
O1
O2
O3
O4
P1
108053
108053
108002
105811
107485
109216
104534
104534
103136
103136
103138
R1
R2
V1
V2
VF1
OEM
Part No.
Units
per
Assy
Description
1 2 3 4 5 6 7
MANIFOLD BLOCK, Main
MANIFOLD BLOCK, Front axle
MANIFOLD BLOCK, Cushion valve
MANIFOLD BLOCK, Velocity fuse (Standard)
MANIFOLD BLOCK, Holding valve
(Machines w/Holding Valve Option)
MANIFOLD BLOCK, Manual lowering valve
(Machines w/rotary-type lowing valve)
MANIFOLD BLOCK, Manual lowering valve
(Machines w/pull-type lowering valve)
MANIFOLD BLOCK, Powered extension platform
(Machines w/Powered Extension Platform Option)
ORIFICE, Dump .055 diameter (Model 3219)
ORIFICE, Lowering .055 diameter
ORIFICE, Cushion .040 diameter
ORIFICE, Brake .040 diameter
PUMP, Hydraulic (Standard)
PUMP, Hydraulic (EE-Rated Machines)
VALVE, System relief
VALVE, Lift relief
VALVE, Manual lowering
VALVE, Free-wheeling
VELOCITY FUSE, Lift cylinder
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AR
AR
SECTION 3, Page 13
FIGURE 3-9. HYDRAULIC MANIFOLD COMPONENT AND PORT IDENTIFICATION (Machines With Hi-Torque Option)
MB3
CUSHION
MANIFOLD BLOCK
3H-14
LIFT VALVE
2H-13
LOWERING
VALVE
2H-25
CUSHION
VALVE
O3
CUSHION
ORIFICE
4H-15
REVERSE
VALVE
R2
LIFT RELIEF
VALVE
CB1
COUNTERBALANCE
VALVE
R1
SYSTEM RELIEF
VALVE
4H-16
FORWARD
VALVE
TO RIGHT
WHEEL MOTOR
UPPER PORT
TO
MANUAL
LOWERING
MAIN MANIFOLD (Front View)
TO
HI-TORQUE
MANIFOLD
TO
CUSHION VALVE
MANIFOLD
TO MAIN
MANIFOLD
DRIVE (A)
FD1
FLOW DIVIDER/
COMBINER
VALVE
V2
FREE-WHEELING
VALVE
4H-24
LEFT STEER
VALVE
TO
LIFT
CYLINDER
4H-23
RIGHT STEER
VALVE
TO
DRIVE (A)
TO
RETURN
FILTER
TO
CUSHION
MANIFOLD
O2
LOWERING
ORIFICE
TO
LEFT
STEER
MB1
MAIN MANIFOLD
BLOCK
MAIN MANIFOLD (Rear View)
SECTION 3, Page 14
CUSHION VALVE MANIFOLD
FRONT AXLE MANIFOLD
MB2
FRONT AXLE
MANIFOLD BLOCK
TO
PUMP
2H-21
SPEED
VALVE
3H-17
BRAKE
VALVE
TO MAIN
MANIFOLD
TO BRAKE
CYLINDER(S)
TO
DRIVE (B)
MB7
TORQUE/SPEED
MANIFOLD BLOCK
TO
RIGHT
STEER
FC1
FLOW
CONTROL
TO RETURN
FILTER
HI-TORQUE MANIFOLD
SJM Series 107979-8
FIGURE 3-10. HYDRAULIC MANIFOLD COMPONENT AND PORT IDENTIFICATION (Machines Without Hi-Torque Option)
4H-15
REVERSE
VALVE
R2
LIFT RELIEF
VALVE
2H-13
LOWERING VALVE
MANUAL
LOWERING
4H-16
FORWARD
VALVE
FILTER
4H-23
RIGHT STEER
VALVE
DRIVE A
4H-24
LEFT STEER
VALVE
MB3
CUSHION VALVE
MANIFOLD BLOCK
2H-25
CUSHION
VALVE
R1
SYSTEM RELIEF
VALVE
3H-14
LIFT VALVE
RIGHT WHEEL
MOTOR
UPPER PORT
LEFT WHEEL
MOTOR
UPPER PORT
LEFT WHEEL
MOTOR
LOWER PORT
CB1
COUNTERBALANCE
VALVE
RIGHT WHEEL
MOTOR
LOWER PORT
FD1
FLOW DIVIDER/
COMBINER VALVE
02
LOWERING ORIFICE
ACCESS
DRIVE B
DRIVE B
LIFT
DRIVE A
3H-17
BRAKE
VALVE
2H-21
DUMP VALVE
MB1
MAIN MANIFOLD
BLOCK
SJM Series 107979-8
MB2
FRONT AXLE
MANIFOLD BLOCK
PUMP
BRAKE
V2
FREEWHEELING
VALVE
RIGHT
STEER
LEFT STEER
SECTION 3, Page 15
SECTION 4
TROUBLESHOOTING INFORMATION
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.
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
ELECTRICAL SYSTEM
Battery Charger plugged into
external power source.
Batteries disconnected.
Dirty or loose battery terminals.
Battery charge low.
1.
ALL CONTROLS
INOPERATIVE
2.
3.
4.
5.
Main battery cables open or
defective.
Fuse (F1) defective.
Main Battery Disconnect Switch
(S1) open or defective.
Loose or broken wire #3 from Motor
Contactor (C1) to Circuit Breaker
(CB2).
Defective Battery Charger Relay
(L1CR).
Loose or broken wire #03A from
Battery Charger Relay (L1CR) to
Circuit Breaker (CB2).
Defective or tripped Circuit Breaker
(CB2).
Loose or broken wire #7 from
Charger Relay (L1CR) to Base
Terminal Block (TB-1).
Loose or broken wire #00 from
Pump Motor (DCM1) to Circuit
Breaker (CB1).
Defective or tripped Circuit Breaker
(CB1).
Loose or broken wire #2 from Circuit
Breaker (CB1) to Base Terminal
Block (TB-1).
Loose or broken wire #19 from Base
Terminal Block (TB-1) to Contactor
(C1).
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
SJM Series 107979-8
toc
1
2
3
Final Revision 2-1-98
5
6
REMEDY
1.
Disconnect charger cord.
2.
3.
4.
Connect batteries.
Clean and tighten connections.
Check each cell with hydrometer.
Reading should be 1.275 (fully
charged). Recharge if low
reading. Replace if reading
difference between cells is 0.050.
Check continuity. Replace if
defective.
Replace fuse.
Close switch. Check continuity.
Replace if defective.
Check continuity. Replace if
defective
5.
6.
7.
8.
9.
10.
11.
12.
Check relay.
Replace if
defective.
Check continuity. Replace if
defective.
Reset circuit breaker. Replace if
defective.
Check continuity. Replace if
defective.
13.
Check continuity. Replace if
defective.
14.
Reset circuit breaker. Replace if
defective.
Check continuity. Replace if
defective.
15.
16.
Check continuity. Replace if
defective.
SECTION 4, Page 1
4
TROUBLESHOOTING INFORMATION(Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (Continued)
ALL CONTROLS
INOPERATIVE (Cont.)
17.
18.
Loose or broken wire #2 from 17.
Contactor (C1) to Base Terminal
Block (TB-1).
Contactor (C1) defective.
18.
19.
Defective Pump Motor (DCM1).
20.
Loose or broken wire #59B from 20.
Relay
(21CR) to Proportional Valve Coil
(2H-59B).
Loose or broken wire #02 from 21.
Proportional Valve Coil (2H-59B) to
Base Terminal Block (TB-1).
Defective Proportional Valve Coil 22.
(2H-59B).
21.
22.
ALL CONTROLS
INOPERATIVE FROM
PLATFORM (Machines
without Power Deck)
1.
2.
3.
4.
5.
6.
ALL CONTROLS
INOPERATIVE FROM
PLATFORM (Machines
with Power Deck)
1.
2.
3.
4.
5.
6.
SECTION 4, Page 2
Loose or broken wire #07 from Base
Terminal Block (TB-1) to Platform
Emergency Stop Switch (S4).
Open or defective Platform
Emergency stop switch (S4).
Loose or broken wire #7A from
Platform Emergency Stop Switch
(S4) to Key Switch (S3).
Open or defective Key Switch (S3).
19.
Check continuity. Replace if
defective.
Check continuity through coil.
Reading should be 19ohms.
Replace if defective.
Check continuity. Replace if
defective.
2.
Close switch. Replace if
defective.
Check continuity. Replace if
defective.
3.
4.
Close switch. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
1.
Check continuity. Replace if
defective.
2.
Close switch. Replace if
defective.
Check continuity. Replace if
defective.
3.
4.
Loose or broken wire #7B from Key 5.
Switch (S3) to Lift/Drive Select
Switch (S5).
Defective Lift/Drive Select Switch 6.
(S5).
Final Revision 2-1-98
Check contactor. Replace if
defective.
Check motor.
Replace if
defective.
Check continuity. Replace if
defective.
1.
Loose or broken wire #7B from 5.
Keyswitch (S3) to Battery charge
Indicator (BCI).
Loose or broken wire #7B from 6.
Battery Charge Indicator BCI to
Joystick (S7).
Loose or broken wire #07 from Base
Terminal Block (TB-1) to Platform
Emergency Stop Switch (S4).
Open or defective Emergency
Stop Switch (S4).
Loose or broken wire #7A from
Platform Emergency Stop Switch
(S4) to Key Switch (S3).
Open or Defective Key Switch (S3).
Check continuity. Replace if
defective.
Close switch. Replace if
defective.
Check continuity. Replace if
defective.
Check switch.
defective.
Replace if
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
LIFT AND DRIVE
INOPERATIVE FROM
PLATFORM CONTROLS
1.
2.
3.
4.
5.
NO DOWN OR REVERSE
ONLY FUNCTION FROM
PLATFORM CONTROLS
1.
2.
NO UP OR FORWARD
ONLY FUNCTION FROM
PLATFORM CONTROLS
1.
Defective Neutral Switch (S7-1) in 1.
Joystick Controller (S7).
Defective A/B switch (S74) in 2.
Joystick Controller (S7).
Circuit Board (S7-1) defective.
3.
Loose or broken wire #59 from 4.
Joystick Controller (S7) to Platform
Terminal Block (TB-2).
Loose or broken wire #59 from 5.
Platform Terminal Block (TB-2) to
Base Terminal Block (TB-1).
Loose or broken wire “A” from 1.
Proportional Controller (S7) to Lift/
Drive Switch (S5).
Lift/Drive Switch (S5) defective.
2.
Check switch. Replace if
defective.
Check switch. Replace if
defective.
Refer to Section 5, Page 7 P.Q.
Controller Test Procedure.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Check Switch.
defective.
Replace if
A/B Switch (S74) in Proportional 1.
Controller open or defective.
Loose or broken wire “B” from 2.
Proportional Controller (S7) to Lift/
Drive Select Switch (S5).
Lift Drive Select Switch (S5) 3.
defective.
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
2.
Loose or broken wire #14 from Base 1.
Terminal Block (TB-1) to Up Valve
Coil (3H-14).
Defective Up Valve Coil (3H-14).
2.
2.
3.
Check switch.
defective.
Replace if
NO UP FUNCTION
FROM PLATFORM OR
BASE CONTROLS (for
units not equipped w/
Tilt Cut-out option)
1.
3.
Open Diode (D14A).
3.
NO UP FUNCTION FROM
PLATFORM OR BASE
CONTROLS (for
machines equipped with
Tilt Cut-out options)
1.
2.
Machines not level.
Loose or broken wire 19 from Base
Terminal Block (TB-1) to Tilt Switch
Fuse (F2).
Blown or defective Tilt Switch Fuse
(F2).
Defective Tilt Switch (TS1).
1.
2.
Use on level surface.
Check continuity. Replace if
defective.
3.
Loose or broken wire #28 from Tilt
Switch (TS1) to Tilt Relay (28CR).
Loose or broken wire #02 from Tilt
Switch (TS1) to Terminal Strip
(TB-1).
Defective Tilt Relay (28CR).
Loose or broken wire #19A from Tilt
Relay (28CR) to Pump Motor
Contactor.
5.
Check continuity.
defective.
Test Tilt switch.
defective.
Check continuity.
defective.
Check continuity.
defective.
3.
4.
5.
6.
7.
8.
SJM Series 107979-8
Final Revision 2-1-98
4.
6.
7.
8.
Check continuity through coil.
Replace if defective.
Check diode.
Replace if
defective.
Replace if
Replace if
Replace if
Replace if
Check relay. Replace if defective.
Check continuity. Replace if
defective.
SECTION 4, Page 3
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
NO DOWN FUNCTION
FROM PLATFORM
CONTROLS
1.
2.
NOTE: Down function is
NOT Proportionally
Controlled.
3.
4.
5.
6.
7.
NO DOWN FUNCTION
FROM PLATFORM
CONTROLS
(CE Machines Only)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SECTION 4, Page 4
Loose or broken wire #13 from Lift/ 1.
Drive Select Switch (S5) to base
terminal Block (TB-1).
Loose or broken wire #13 from Base 2.
Terminal Block (TB-1) to Down Valve
(2H-13).
Down valve coil (2H-13) defective. 3.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity through coil.
Replace if defective.
Check continuity. Replace if
defective.
Loose or broken wire #2 from Down
Valve Coil (2H-13) to Base Terminal
Block (TB-1).
Loose or broken wire #13 from Down
Valve Coil (2H-13) to Lift Cylinder
Holding Valve(s) (2H-13-1).
Defective Lift Cylinder Holding Valve
Coil(s) (2H-13-1).
Loose or broken wire #02 from Lift
Cylinder Holding Valve Coil(s)
(2H-13-1).
4.
Loose or broken wire #13 from Base
Terminal Block (TB-1) to Lowering
Warning System Module (LWS1).
Defective LWS Time Delay Relay
(41CR).
Loose or broken wire #13A from
Lowering Warning System Module
(LWS1) to Base Terminal Block
(TB-1).
Loose or broken wire #13A from
base Terminal Block (TB-1) to Down
Valve Coil (2H-13A).
Defective Down Valve Coil (2H13A).
Loose or broken wire #13A from
Down Valve Coil (2H-13A) to Base
Terminal Block (TB-1).
Loose or broken wire # 13A from
Down Valve Coil (2H-13A) to Lift
Cylinder Holding Valve (2H-13A-1).
Defective Lift Cylinder Holding Valve
(2H-13A-1).
Loose or broken wire #02 from Lift
Cylinder Holding Valve to Down
Valve Coil (2H-13A).
Loose or broken wire #07 from Base
Terminal Block (TB-1) to High Speed
Limit Switch (LS1).
1.
Check continuity. Replace if
defective.
2.
Check relay. Replace if defective.
3.
Check continuity. Replace if
defective.
4.
Check continuity. Replace if
defective.
5.
Check continuity through coil.
Replace if defective.
Check continuity. Replace if
defective.
Final Revision 2-1-98
5.
Check continuity. Replace if
defective.
6.
Check continuity through coil.
Replace if defective.
Check continuity. Replace if
defective.
7.
6.
7.
Check continuity. Replace if
defective.
8.
Check continuity through coil.
Replace if defective.
Check continuity. Replace if
defective.
9.
10.
Check Continuity. Replace if
defective.
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
NO DOWN FUNCTION
FROM PLATFORM
CONTROLS
(CE Machines Only)
(Continued)
11.
12.
13.
14.
LOWERING WARNING
SYSTEM INOPERATIVE
(CE Machines Only)
1.
2.
3.
4.
5.
6.
7.
Defective High Speed Limit Switch
(LS1).
Loose or broken wire #39 from High
Speed Limit Switch (LS1). to Base
Terminal Block (TB-1).
Loose or broken wire #39 from Base
Terminal Block (TB-1) to Lowering
Warning System Module (LWS1).
Defective LWS Limit Switch Relay
(39CR).
11.
Check switch.
defective.
Check switch.
defective.
Replace if
13.
Check switch.
defective.
Replace if
14.
Check relay.
defective.
Replace if
Loose or broken wire #10A from
Base Terminal Block (TB-1) to
Lowering Warning System Module
(LWS1).
Loose or broken wire #02 from Base
Terminal Block (TB-1) to Lowering
Warning System Module (LWS1)
Defective LWS Limit Switch Relay
(39CR).
Defective Time Delay Cut-out Relay
(13BCR).
Defective Time Delay Relay
(41CR).
Defective Latching Relay (42CR).
Defective High Speed Limit Switch
(LS1).
1.
Check continuity. Replace if
defective.
2.
Check continuity. Replace if
defective.
3.
Check relay.
defective.
Check relay.
defective.
Check relay.
defective.
Check relay.
defective.
Check switch.
defective.
Replace if
1.
Check diode.
defective.
Replace if
12.
4.
5.
6.
7.
PLATFORM LIFTS SLOW
FROM PLATFORM
CONTROLS AND BASE
CONTROLS
1.
Open Diode D14A-1.
STEER ONLY
INOPERATIVE
1.
2.
Defective Relay (17CR2)
1.
Loose or broken wire #59 from Relay 2.
(CR2) to Relay (21ACR).
DRIVE ONLY
INOPERATIVE
1.
Open Diode (D17).
NO DRIVE OR STEER
WHEN PLATFORM
FULLY LOWERED
(All machines)
1.
Loose or broken wire #71 from Base 1.
Terminal Block (TB-1) to Drive
Override Limit Switch (LS6).
Defective Drive Override Switch 2.
(LS6).
Loose or broken wire #19 from Drive 3.
Override Limit Switch (LS6) to Base
Terminal Block (TB-1).
2.
3.
SJM Series 107979-8
Final Revision 2-1-98
1.
Replace if
Replace if
Replace if
Replace if
Replace if
Check relay. Replace if defective.
Check continuity. Replace if
defective.
Check diode.
defective.
Replace e if
Check continuity. Replace if
defective.
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
SECTION 4, Page 5
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
NO DRIVE OR STEER
WHEN PLATFORM
ELEVATED
(All machines)
1.
2.
3.
4.
5.
6.
NO DRIVE OR STEER
FROM PLATFORM
(Machines with Powered
Platform Only)
1.
2.
3.
4.
5.
6.
7.
RIGHT STEER
INOPERATIVE
(Machines without
Powered Platform)
1.
2.
3.
4.
5.
6.
7.
SECTION 4, Page 6
Pot Hole Protection Bars not fully
lowered.
Loose or broken wire #71 from Base
Terminal Block (TB-1) to Pot Hole
Protection Limit Switch (LS4).
Defective Pot Hole Protection Limit
Switch (LS4).
Loose or broken wire #72 from
Pothole Protection Limit Switch
(LS4) to Pothole Protection Limit
Switch (LS5).
Defective Pothole Protection Limit
Switch (LS5).
Loose or broken wire #19 from
Pothole Protection Limit Switch to
Base Terminal Block (TB-1).
1.
Defective Lift/Drive Select Switch
(S5).
Loose or broken wire #12 from Lift/
Drive Select Switch (S5) to
Platform Terminal Block (TB-2).
Loose or broken wire #12 from
Platform Terminal Block (TB-2) to
Powered Platform Limit Switch
(LS2).
Open or defective Powered
Platform Limit Switch (LS2).
Loose or broken wire #12A from
Powered Platform Limit Switch
(LS2).
Loose or broken wire #12A from
Powered Platform Limit Switch
(LS2) to Platform Terminal Block
(TB-2).
Open Diode (D12A).
1.
Defective Steer Right Switch (S72).
Loose or broken wire #23 from Steer
Right Switch (S72) to Lift/Drive
Select Switch (S5).
Defective Lift/Drive Select Switch
(S5).
Loose or broken wire #23A from
Lift/Drive Select Switch (S5) to
Platform Terminal Block (TB-2).
Loose or broken wire #23A from
Platform Terminal Block (TB-2) to
Base Terminal Block (TB-1).
Loose or broken wire #23A from
Base Terminal Block (TB-1) to Steer
Right Valve Coil (4H-23A).
Defective Steer Right Valve Coil
(4H-23A).
Final Revision 2-1-98
2.
Clear obstructions. Repair as
needed.
Check continuity. Replace if
defective.
3.
Check switch.
defective.
4.
Check continuity. Replace if
defective.
5.
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
6.
2.
Replace if
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
3.
Check continuity. Replace if
defective.
4.
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
5.
6.
Check continuity. Replace if
defective.
7.
Check diode.
defective.
Replace if
1.
Check switch.
defective.
Check continuity.
defective.
Check switch.
defective.
Check continuity.
defective.
Replace if
2.
3.
4.
Replace if
Replace if
Replace if
5.
Check continuity. Replace if
defective.
6.
Check continuity. Replace if
defective.
7.
Check continuity through coil.
Replace if defective.
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
RIGHT STEER
INOPERATIVE
(Machines without
Powered Platform)
(Cont.)
8.
8.
Check continuity. Replace if
defective.
9.
Loose or broken wire #02 from
Steer Right Valve Coil (4H-23A) to
Base Terminal Block (TB-1).
Open Diode (D23A).
9.
Replace if
10.
Open Diode (D23A-1)
10.
Check diode.
defective.
Check diode.
defective.
LEFT STEER
INOPERATIVE
(Machines without
Powered Platform)
1.
2.
Defective Steer Left Switch (S73).
Loose or broken wire #24 from Steer
Left Switch (S73) to Lift/Drive
Select Switch (S5).
Defective Lift/Drive Select Switch
(S5).
Loose or broken wire #24A from Lift/
Drive Select Switch (S5) to
Platform Terminal Block (TB-2).
Loose or broken wire #24A from
Platform Terminal Block (TB-2) to
Base Terminal Block (TB-1).
Loose or broken wire #24A from
Base Terminal Block (TB-1) to Steer
Left Valve Coil (4H-24A).
Defective Steer Left Valve Coil (4H24A)
Loose or broken wire #02 from Steer
Left Valve (4H-24A) to Base
Terminal Block (TB-1)
Open Diode (D24A).
Open Diode (D23A-1)
1.
Check switch.
defective.
Check continuity.
defective.
Check switch.
defective.
Check continuity.
defective.
Replace if
1.
7.
Defective Right Steer Switch (S72).
Loose or broken wire #23 from Right
Steer Switch (S72) to Platform
Terminal Block (TB-2).
Loose or broken wire #23 from
Platform Terminal Block (TB-2) to
Base Terminal Block (TB-1).
Loose or broken wire #23 from Base
Terminal Block (TB-2) to Steer Right
Valve Coil (4H-23).
Defective Steer Right Valve Coil
(4H-23).
Loose or broken wire #02 from Steer
Right Valve Coil (4H-23) to Base
Terminal Block (TB-1).
Open Diode (D23).
8.
Open Diode (D23-1).
8.
3.
4.
5.
6.
7.
8.
9.
10.
RIGHT STEER
1.
INOPERATIVE (Machines 2.
with a Powered Platform)
3.
4.
5.
6.
SJM Series 107979-8
Final Revision 2-1-98
2.
3.
4.
Replace if
Replace if
Replace if
Replace if
5.
Check continuity. Replace if
defective.
6.
Check continuity. Replace if
defective.
7.
Check continuity.
defective.
Check continuity.
defective.
Check diode.
defective.
Check diode.
defective.
8.
9.
10.
2.
3.
Replace if
Replace if
Replace if
Replace if
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
4.
Check continuity. Replace if
defective.
5.
Check continuity through coil.
Replace if defective.
Check continuity. Replace if
defective.
6.
7.
Check diode.
defective.
Check diode.
defective.
Replace if
Replace if
SECTION 4, Page 7
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
1.
LEFT STEER
INOPERATIVE (Machines 2.
with a Powered Platform)
1.
7.
Defective Left Steer Switch (S73).
Loose or broken wire #24 from Left
Steer Switch (S73) to Platform
Terminal Block (TB-2).
Loose or broken wire #24 from
Platform Terminal Block (TB-2) to
Base Terminal Block (TB-1).
Loose or broken wire #24 from Base
Terminal Block (TB-1) to Steer Left
Valve Coil (4H-24).
Defective Steer Left Valve Coil
(4H-24).
Loose or broken wire #02 from Steer
Left Valve Coil (4H-24) to Base
Terminal Block (TB-1).
Open Diode (D24).
8.
Open Diode (D24-1).
8.
1.
Loose or broken wire #59 from 1.
Proportional Relay (21CR) to
Resistor (RST2).
2.
Resistor (RST2) open.
3.
4.
5.
6.
NO ELEVATED DRIVE
FUNCTION
2.
3.
4.
WORK PLATFORM
DRIVES IN SLOW
SPEED ONLY
1.
2.
3.
4.
5.
FORWARD DRIVE
FUNCTION
INOPERATIVE
1.
2.
3.
4.
5.
SECTION 4, Page 8
2.
3.
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
4.
Check continuity. Replace if
defective.
5.
Check continuity through coil.
Replace if defective.
Check continuity. Replace if
defective.
6.
7.
Loose or broken wire #59 from 3.
Resistor (RST2) to Proportional
Relay (21CR).
Proportional Relay (21CR) 4.
defective.
1.
Open Diode (D17-1).
Check diode.
Replace if
defective.
Check diode.
Replace if
defective.
Check continuity. Replace if
defective.
OHM Check Resistor, it should
be 30 ohms. Replace if defective.
Check continuity. Replace if
defective.
Check relay, replace if defective.
Check Diode. Replace if
defective.
Check continuity. Replace if
defective.
Loose or broken wire #17A from
Base Terminal Block (TB-1) to High
Speed Limit Switch (LS1).
Open or defective High Speed Limit
Switch (LS1).
Loose or broken wire #21 from High
Speed Limit Switch to Base
Terminal Block (TB-1).
Defective Cushion Relay (17CR).
2.
5.
Check Relay.
defective.
Loose or broken wire #16 from Lift/
Drive Select Switch (S5) to Base
Terminal Block (TB-1).
Loose or broken wire #16 from Base
Terminal Block (TB-1) to Forward
Drive Valve Coil (4H-16).
Forward Drive Valve Coil (4H-16)
defective.
Loose or broken wire #02 from
Forward Drive Valve Coil (4H-16) to
Base Terminal Block (TB-1).
Open Diode (D16).
1.
Check continuity. Replace if
defective.
2.
Check continuity. Replace if
defective.
3.
Check continuity through coil.
Replace if defective.
Check continuity. Replace if
defective.
Final Revision 2-1-98
3.
4.
4.
5.
Check Switch. Replace if
defective.
Check continuity. Replace if
defective.
Replace if
Check diode.
Replace if
defective.
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
REVERSE DRIVE
FUNCTION
INOPERATIVE
1.
2.
3.
4.
5.
BRAKE WILL NOT
RELEASE
1.
Check continuity. Replace if
defective.
3.
Check continuity through coil.
Replace if defective.
Check continuity. Replace if
defective.
4.
5.
Check diode.
defective.
Replace if
1.
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
5.
1.
Defective Up/Down Switch (S2).
2.
Loose or broken wire #14E from 2.
Up/Down Switch (S2) to Base
Terminal Block (TB-1).
Open Diode (D14E).
3.
2.
4.
3.
SJM Series 107979-8
2.
Defective Base/Off/Platform
Select Switch (S3).
Loose or broken wire #10E from
Base/Off/Platform Select Switch
(S3) to Platform Terminal Block
(TB-2).
Loose or broken wire #10E from
Base Terminal Block (TB-1).
Loose or broken wire #10E from
Base Terminal Block (TB-1) to Lift
Up /Down Switch (S2) in Base
Control Box.
Open Diode (D10E)
1.
3.
LIFT DOWN
INOPERATIVE FROM
BASE CONTROLS
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
3.
LIFT UP INOPERATIVE
FROM BASE CONTROLS
1.
Loose or broken wire #17 from Base 1.
Terminal Block (TB-1) to Brake
Valve Coil (3H-17).
Brake Valve Coil (3H-17A) 2.
defective.
Loose or broken wire #02 from 3.
Brake Valve Coil (3H-17A) to Base
Terminal Block (TB-1).
2.
LIFT INOPERATIVE
FROM BASE CONTROLS
(CE Machines Only)
Loose or broken wire #15 from Lift/
Drive Select Switch (S5) to Base
Terminal Block (TB-1).
Loose or broken wire #15 from Base
Terminal Block (TB-1) to Reverse
Drive Valve Coil (4H-15).
Reverse Drive Valve Coil (4H-15)
defective.
Loose or broken wire #02 from
Reverse Drive Valve Coil (4H-15)
to Base Terminal Block (TB-1).
Open Diode (D15).
1.
2.
2.
3.
4.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
5.
Check Diode.
defective.
1.
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
Defective Up/Down Switch (S2).
1.
Loose or broken wire #13 from Up/
Down Switch (S2) to Base Terminal 2.
Block (TB-1).
Final Revision 2-1-98
Check continuity through coil.
Replace if defective.
Check continuity through coil.
Replace if defective.
Check Diode.
defective.
Replace if
Replace if
Check switch. Replace if
defective.
Check continuity. Replace if
defective.
SECTION 4, Page 9
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (Continued)
TWO OR MORE
FUNCTIONS AT ONE
TIME
1.
Shorted Diode.
1.
Check continuity of all Diodes.
Replace if defective.
POWERED PLATFORM
EXTENSION WILL NOT
EXTEND OR RETRACT
1.
Lift/Drive Select Switch (S5) not in
lift position.
Loose or broken wire #09 from
Platform Terminal Block TB-2 to
Powered Platform Enable Switch
(S12).
Powered Platform Enable Switch
(S12) defective.
Loose or broken wire #09A from
Powered Platform Enable Switch
(S12) to Platform Extend/Retract
Switch (S11).
1.
Move switch to lift position.
2.
Check continuity. Replace if
defective.
3.
Check switch.
defective.
4.
Check continuity. Replace if
defective.
Loose or broken wire #19 from 5.
Platform Terminal Block (TB-2) to
Base Terminal Block (TB-1).
Loose or broken wire #02 from 6.
Extend/Valve Coil (4H-26) to
Retract Valve Coil (4H-27) to
Platform Terminal Block (TB-2).
Check continuity. Replace if
defective.
Powered Platform Extend/Retract
Switch (S11) defective.
Loose or broken wire #26 from
Powered Platform Extend/Retract
Switch (S11) to extend Valve Coil
(4H-26).
Extend Valve Coil (4H-26)
defective.
Open Diode (D26).
Loose or broken wire #02 from
Extend Valve Coil (4H-26).
1.
Check switch.
defective.
2.
Check continuity. Replace if
defective.
3.
Check continuity through coil,
replace if defective.
Check diode. Replace if
defective.
Check continuity through coil.
Replace if defective.
Powered Platform Extend/Retract
Switch (S11) defective.
Loose or broken wire #27 from
Powered Platform Extend/Retract
Switch (S11) to Retract Valve Coil
(4H-27).
Retract Valve Coil (4H-27)
defective.
Open Diode (D27).
Loose or broken wire #02 from
Retract Valve Coil (4H-27).
1.
Check switch.
defective.
2.
Check continuity. Replace if
defective.
3.
Check continuity through coil,
replace if defective.
Check diode.
Replace if
defective.
Check continuity, replace if
defective.
2.
3.
4.
POWERED PLATFORM
EXTENSION WILL NOT
EXTEND OR RETRACT
(Cont.)
5.
POWERED EXTENSION
PLATFORM WILL NOT
EXTEND
1.
6.
2.
3.
4.
5.
POWERED EXTENSION
PLATFORM WILL NOT
RETRACT
1.
2.
3.
4.
5.
SECTION 4, Page 10
Final Revision 2-1-98
4.
5.
4.
5.
Replace if
Check continuity. Replace if
defective.
Replace if
Replace if
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
HYDRAULIC SYSTEM (continued)
ALL FUNCTIONS
INOPERATIVE
3.
Proportional Valve (2H-59B) 1.
defective or is sticking.
Compensator Valve (CMP1) 2.
defective or is sticking.
3.
Pump (P1) defective.
1.
Defective Lift Cylinder Seals.
2.
2.
Combination of:
Defective Holding Valves (2H-13-1)
and either defective Lowering Valve
(2H-13) or Relief Valve (R2) or
Manual Lowering Valve (V1).
1.
2.
Open or leaking Manual Lowering 1.
Valve (V1).
2.
Lift Relief Valve (R2) defective.
1.
2.
Open Manual Lowering Valve (V1). 1.
Hydraulic oil level too low.
2.
3.
Platform weight excessive.
4.
3.
Up Valve (3H-14) defective or is
sticking.
4.
1.
2.
PLATFORM DRIFTS
DOWN
PLATFORM LIFTS
SLOWLY
PLATFORM DOES NOT
LIFT
PLATFORM WILL NOT
LOWER
1.
2.
NOTE: Down function is
NOT Proportionally
controlled
PLATFORM DRIVES
SLOW
1.
2.
3.
PLATFORM WILL NOT
DRIVE IN FORWARD OR
REVERSE
Lowering Valve (2H-13) defective or 1.
is sticking.
Defective Holding Valve (2H-13-1) 2.
through (2H-13-4).
Free-Wheeling Valve (V2) open or 1.
defective.
Flow Divider/Combiner (FD1) 2.
defective or is plugged.
Drive Motor (M1) or (M2) defective. 3.
4.
Cushion Valve (2H-25) stuck or 4.
defective.
1.
2.
Open Free-Wheeling Valve (V2).
Forward Drive Valve (4H-16) or
Reverse Drive Valve (4H-15)
defective or is sticking.
Flow/Divider/Combiner Valve (FD1)
defective or is plugged.
Counterbalance Valve (CB1)
defective or is plugged.
3.
4.
SJM Series 107979-8
1.
Final Revision 2-1-98
Check valve.
defective.
Check valve.
defective.
Check pump.
defective.
Replace if
Replace if
Replace if
Rebuild cylinder. Replace if
damaged.
Check valves. Replace if
defective.
Close valve. Replace if defective.
Check valve.
Replace if
defective.
Close valve. Replace if defective.
Fully lower the platform. Fill
hydraulic tank until fluid is at or
slightly above the top mark on the
sight glass.
Reduce platform load to
maximum capacity.
Check valve.
Replace if
defective.
Clean valve. Replace if defective.
Check valve.
defective.
Replace if
Close valve. Replace if defective.
Check valve.
Replace if
defective.
Check motors. Replace if
defective.
Check valve.
Replace if
defective.
1.
2.
Close Valve. Replace if defective.
Clean Valve. Replace if defective.
3.
Clean Valve. Replace if defective.
4.
Clean Valve. Replace if defective.
SECTION 4, Page 11
TROUBLESHOOTING INFORMATION (Proportional Drive and Lift)
TROUBLE
PROBABLE CAUSE
REMEDY
HYDRAULIC SYSTEM (continued)
BRAKE(S) WILL NOT
RELEASE
PLATFORM DOES NOT
STEER
ALL SYSTEMS
SLUGGISH
1.
1.
2.
Brake Valve (3H-17) defective or is
sticking.
Brake Orifice(s) (04) plugged.
3.
Brake Cylinder(s) (C4) defective.
3.
1.
1.
Clean valve.
defective.
2.
Right Steer Valve (4H-23A) or Left
Steer Valve (4H-24A) defective or
sticking.
Steer Cylinder (C3) seals leaking.
2.
3.
Mechanical binding in King Pins.
3.
Rebuild cylinder(s). Replace if
damaged.
Check for binding. Repair as
needed.
1.
System Relief Valve defective or
not adjusted properly.
Hydraulic pump (P1) worn.
1.
Compensator Valve (CMP1)
defective.
Proportional Valve (2H-59B)
contaminated or defective.
3.
Adjust valve.
Replace if
defective.
Check pump. Replace if
defective.
Clean. Replace if defective.
4.
Clean, replace if defective.
Platform Extend Valve (4H-26) or
Platform Retract Valve (4H-27)
defective or is sticking.
Powered Platform Cylinder (C5)
seals defective.
Mechanical binding in powered
platform mechanism.
1.
Clean valve.
defective.
2.
Rebuild cylinder. Replace if
damaged.
Check for binding. Repair as
needed.
2.
3.
4.
POWER EXTENSION
PLATFORM WILL NOT
EXTEND OR RETRACT
1.
2.
3.
SECTION 4, Page 12
Final Revision 2-1-98
2.
2.
3.
Clean valve.
Replace if
defective.
Remove orifice(s). Clean and
reinstall.
Rebuild cylinder(s). Replace if
damaged.
Replace if
Replace if
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Hi-Torque Option)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM
All Controls Inoperative
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
SJM Series 107979-8
Battery Charger plugged into
external power source.
Batteries disconnected.
Battery charge low.
1.
Disconnect charger cord.
2.
3.
Dirty or loose battery terminals.
Main battery cables open or
defective.
Main Battery Disconnect Switch
(S1) open or defective.
Loose or broken wire #3 from Fuse
(F1) to Battery Charger Relay
(L1CR).
Defective Battery Charger Relay
(L1CR).
Loose or broken wire #5 from
Battery Charger Relay (L1CR) to
Circuit Breaker (CB2).
Defective or tripped Circuit
Breaker (CB2).
Loose or broken wire #7 from
Circuit Breaker (CB2) to base
terminal strip.
Loose or broken wire #0 from
Pump Motor (DCM1) to Circuit
Breaker (CB1).
Defective or tripped Circuit
Breaker (CB1).
Loose or broken wire #2 from
Circuit Breaker (CB1) to base
terminal strip.
Loose or broken wire #19 from
base terminal strip to Contactor
(C1).
Defective Contactor (C1).
4.
5.
Connect batteries.
Check each cell with
hydrometer. Reading should be
1.275 (fully charged.). Recharge
if low reading. Replace if
reading difference between cells
is 0.050.
Clean and tighten connections.
Check continuity, replace if
defective.
Close switch. Check continuity,
replace if defective.
Check continuity, replace if
defective.
Defective Fuse (F1).
Loose or broken wire #2 from
Contactor (C1) to base terminal
strip.
Defective Pump Motor (DCM1).
17.
18.
Final Revision 2-1-98
6.
7.
8.
9.
10.
11.
Check relay, replace if
defective.
Check continuity, replace if
defective.
Reset circuit breaker. Replace
if defective.
Check continuity, replace if
defective.
12.
Check continuity, replace if
defective.
13.
Reset circuit breaker. Replace
if defective.
Check continuity, replace if
defective.
14.
15.
Check continuity, replace if
defective.
16.
Check contactor, replace if
defective.
Replace fuse.
Check continuity, replace if
defective.
19.
Check motor, replace if
defective.
SECTION 4, Page 13
TROUBLESHOOTING INFORMATION (Hi-Torque Option)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
Controls Inoperative
From Platform
1.
Loose or broken wire #7 from base
terminal strip to Platform
Emergency Stop Switch (S4).
Platform Emergency Stop Switch
(S4) open or defective.
Loose or broken wire #8 from
Platform Emergency Stop Switch
(S4) to Lift/Off/Drive Key Switch
(S3).
Lift/Off/Drive Key Switch (S3)
open or defective
1.
Check continuity, replace if
defective.
2.
Check switch, replace if
defective.
Check continuity, replace if
defective.
4.
Check switch, replace if
defective.
Defective Lift/Off/Drive Key
Switch (S3) open or defective.
Loose or broken wire #9 from Lift/
Off/Drive Key Switch (S3) to Lift
Enable Switch (S9).
Defective Lift Enable Switch (S9).
1.
Check switch, replace if
defective.
Check continuity, replace if
defective.
4.
Loose or broken wire #9A from
Lift Enable Switch (S9) to Up/
Down Switch (S5).
4.
1.
Up/Down Switch (S5) open or
defective.
Loose or broken wire #14 from Up/
Down Switch (S5) to base
terminal strip.
Loose or broken wire #14 from
base terminal strip to Up Valve
(3H-14).
Up valve coil (3H-14) open or
shorted.
Loose or broken wire #2 from Up
Valve (3H-14) to base terminal
strip.
Diode (D14) or (D21) open at base
terminal strip.
1.
6.
Check diode(s), replace if
defective.
Loose or broken wire #21 from
base terminal strip to Speed Valve
(2H-21).
Speed valve coil (2H-21)
defective.
Loose or broken wire #2 from
Speed Valve (2H-21) to base
terminal strip.
1.
Check continuity, replace if
defective.
2.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
2.
3.
4.
Up/Down Circuit
Inoperative From
Platform
1.
2.
3.
Up Circuit
Inoperative From
Platform
2.
3.
4.
5.
6.
Platform Lifts
Slowly
1.
2.
3.
SECTION 4, Page 14
Final Revision 2-1-98
3.
2.
3.
2.
Check switch, replace if
defective.
Check continuity, replace if
defective.
Check switch, replace if
defective.
Check continuity, replace if
defective.
3.
Check continuity, replace if
defective.
4.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
5.
3.
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Hi-Torque Option)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
Down Circuit
Inoperative From
Platform
1.
2.
3.
4.
5.
6.
7.
8.
No Drive or Steer
From Platform
1.
2.
3.
4.
Up/Down Switch (S5) open or
defective.
Loose or broken wire #13 from Up/
Down Switch (S5) to base
terminal strip.
Loose or broken wire #13 from
base terminal strip to Down Valve
(2H-13).
Down Valve (2H-13) defective.
1.
Loose or broken wire #2 from
Down Valve (2H-13) to base
terminal strip.
Loose or broken wire #13 from
base terminal strip to Holding
Valve (2H-13-1). (if so equipped)
Holding Valve (2H-13-1) defective.
(if so equipped)
Loose or broken wire #2 from
Holding Valve (2H-13-1) to base
terminal strip. (if so equipped)
5.
Lift/Off/Drive Key Switch (S3)
open or defective.
Loose or broken wire #12 to Drive/
Steer Controller (S7) or Powered
Platform Limit Switch (LS2). (if so
equipped)
Powered Platform Limit Switch
(LS2) defective. (If so equipped)
Loose or broken wire #12A from
Powered Platform Limit Switch
(LS2) to Drive/Steer Controller
(S7).
2.
Check switch, replace if
defective.
Check continuity, replace if
defective.
3.
Check continuity, replace if
defective.
4.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
6.
Check continuity, replace if
defective.
7.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
8.
1.
2.
3.
4.
Check switch, replace if
defective.
Check continuity, replace if
defective.
Check switch, replace if
defective.
Check continuity, replace if
defective.
Steer
Inoperative
1.
Loose or broken wire #12 to Drive/
Steer Controller Circuit Board (S7)
to Steer Switches (S7-2)(S7-3).
1.
Check continuity, replace if
defective.
Right Steer
Inoperative
1.
Right Steer Switch (S7-2) in Drive/
Steer Controller (S7) defective.
Loose or broken wire #23 from
Drive/Steer Controller (S7) to
base terminal strip.
Diode (D23) at base terminal strip
open or shorted.
1.
Check switch, replace if
defective.
2.
Check continuity, replace if
defective.
3.
Loose or broken wire #23 from
base terminal strip to Right Steer
Valve (4H-23).
4.
Check diode, replace if
defective.
Check continuity, replace if
defective.
2.
3.
4.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 4, Page 15
TROUBLESHOOTING INFORMATION (Hi-Torque Option)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
Right Steer
Inoperative
(continued)
5.
Left Steer
Inoperative
1.
6.
2.
3.
4.
5.
6.
Forward Direction
Inoperative
1.
2.
3.
4.
5.
6.
Reverse Direction
Inoperative
1.
2.
3.
4.
SECTION 4, Page 16
Right steer valve coil (4H-23)
defective.
Loose or broken wire #2 from Right
Steer Valve (4H-23) to base
terminal strip.
5.
Left Steer Switch (S7-2) in Drive/
Steer Controller (S7) defective.
Loose or broken wire #24 from
Drive/Steer Controller (S7) to
base terminal strip.
Diode (D24) at base terminal strip
open or shorted.
Loose or broken wire #24 from
base terminal strip to Left Steer
Valve (4H-24).
Left steer valve coil (4H-24)
defective.
Loose or broken wire #2 from Left
Steer Valve (4H-24) to base
terminal strip.
1.
Forward Drive Switch (S7-5) in
Drive/Steer Controller (S7)
defective.
Loose or broken wire #16 from
Drive/Steer Controller (S7) to
base terminal strip.
Diode (D16) at base terminal strip
open or shorted.
Loose or broken wire #16 from
base terminal strip to Forward
Drive Valve (4H-16).
Forward drive valve coil (4H-16)
defective.
Loose or broken wire #2 from
Forward Drive Valve (4H-16) to
base terminal strip.
1.
Check switch, replace if
defective.
2.
Check continuity, replace if
defective.
3.
Check diode, replace if
defective.
Check continuity, replace if
defective.
Reverse Drive Switch (S7-4) in
Drive/Steer Controller (S7)
defective.
Loose or broken wire #15 from
Drive/Steer Controller (S7) to
base terminal strip.
Diode (D15) at base terminal strip
open or shorted.
Loose or broken wire #15 from
base terminal strip to Reverse
Drive Valve (4H-15).
1.
Check switch, replace if
defective.
2.
Check continuity, replace if
defective.
3.
Check diode, replace if
defective.
Check continuity, replace if
defective.
Final Revision 2-1-98
6.
2.
3.
4.
5.
6.
4.
5.
6.
4.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
Check switch, replace if
defective.
Check continuity, replace if
defective.
Check diode, replace if
defective.
Check continuity, replace if
defective.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Hi-Torque Option)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
Reverse Direction
Inoperative
(continued)
5.
Brake Will Not
Release
1.
6.
2.
3.
Machine Brakes To
An Abrupt Stop
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SJM Series 107979-8
Reverse drive valve coil (4H-15)
defective.
Loose or broken wire #2 from
Reverse Drive Valve (4H-15) to
base terminal strip.
5.
Loose or broken wire #17 from
base terminal strip to Brake Valve
(3H-17).
Brake valve coil (3H-17)
defective.
Loose or broken wire #2 from
Brake Valve (3H-17) to base
terminal strip.
1.
Check continuity, replace if
defective.
2.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
Loose or broken wire #7 from base
terminal strip to Cushion Relay
(17CR1)
Loose or broken wire #17 from
base terminal strip to Cushion
Relay (17CR1)
Cushion Relay (17CR1)
defective.
Loose or broken wire #17C from
Cushion Relay (17CR1) to
Cushion Relay (17CCR1).
Loose or broken wire #17D from
Cushion Relay (17CR1) to
Cushion Relay (17CCR1).
Cushion Relay (17CCR1)
defective.
Capacitor (CAP1) on Cushion
Relay (17CCR1) defective.
Loose or broken wire #2 from base
terminal strip to Cushion Relay
(17CR1) and (17CCR1).
Loose or broken wire #25 from
Cushion Relay (17CCR1) to
Cushion Valve (2H-25).
Cushion valve coil (2H-25)
defective.
Loose or broken wire #2 from
Cushion Valve (2H-25) to base
terminal strip.
1.
Check continuity, replace if
defective.
2.
Check continuity, replace if
defective.
3.
Check relay, replace if
defective.
Check continuity, replace if
defective.
Final Revision 2-1-98
6.
3.
4.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
5.
Check continuity, replace if
defective.
6.
Check relay, replace if
defective.
Check capacitor, replace if
defective.
Check continuity, replace if
defective.
7.
8.
9.
Check continuity, replace if
defective.
10.
Check continuity through coil,
replace if defective.
Check continuity, replace if
defective.
11.
SECTION 4, Page 17
TROUBLESHOOTING INFORMATION (Hi-Torque Option)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
Work Platform Drives
In Slow Speed Only
1.
2.
3.
4.
5.
6.
Speed 2 Switch (S7-1) in Drive/
Steer Controller defective.
Loose or broken wire #18 from
Drive/Steer Controller (S7) to
base terminal strip.
Diode (D18) at terminal strip open
or shorted.
Loose or broken wire #18A from
Diode (D18) to High Speed Limit
Switch (LS1).
High Speed Limit Switch (LS1)
defective.
Loose or broken wire 321 from
High Speed Limit Switch to base
terminal strip.
1.
2.
3.
4.
5.
6.
Check switch, replace if
defective.
Check continuity, replace if
defective.
Check diode, replace if
defective.
Check continuity, replace if
defective.
Check switch, replace if
defective.
Check continuity, replace if
defective.
Two Or More Functions
At One Time
1.
Diodes shorted.
1.
Check continuity of all diodes,
replace if defective.
Powered Extension
Platform Will Not
Extend Or Retract
1.
Lift/Off/Drive Key Switch (S3) not
in “LIFT” position.
Loose or broken wire #9 from
Operators Control Box to
Powered Platform Enable Switch
(S12).
Powered Platform Enable Switch
defective.
Loose or broken wire #19A from
Powered Platform Control Box to
base terminal strip.
Loose or broken wire #2 from
Platform Extend/Retract Valves
(4H-26) and (4H-27) to Operators
Control Box terminal strip.
Loose or broken wire #9A from
Powered Platform Enable Switch
(S12) to Platform Extend/retract
Switch (S11).
1.
Turn key to “LIFT” position.
2.
Check continuity, replace if
defective.
3.
Check switch, replace if
defective.
Check continuity, replace if
defective.
2.
3.
4.
5.
6.
SECTION 4, Page 18
Final Revision 2-1-98
4.
5.
Check continuity, replace if
defective.
6.
Check continuity, replace if
defective.
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Hi-Torque Option)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (continued)
Powered Extension
Platform
Will Not Extend
1.
2.
3.
4.
Powered Extension
Platform
Will Not Retract
1.
2.
3.
4.
Powered Platform Extend/
Retract Switch (S11) defective.
Loose or broken wire #26 from
Powered Platform Extend/
Retract Switch (S11) to Extend
Valve (4H-26).
Extend valve coil (4H-26)
defective.
Diode (D26) in Operators Control
Box open or shorted.
1.
Powered Platform Extend/
Retract Switch (S11) defective.
Loose or broken wire #27 from
Powered Platform Extend/
Retract Switch (S11) to Retract
Valve (4H-27).
Retract valve coil (4H-27)
defective.
Diode (D27) in Operators Control
Box open or shorted.
1.
2.
3.
4.
2.
3.
4.
Check switch, replace if
defective.
Check continuity, replace if
defective.
Check continuity through coil,
replace if defective.
Check diode, replace if
defective.
Check switch, replace if
defective.
Check continuity, replace if
defective.
Check continuity through coil,
replace if defective.
Check diode, replace if
defective.
HYDRAULIC SYSTEM
Platform Drifts
Down
Platform Lifts
Slowly
1.
2.
Manual Lowering Valve (V1) open
or defective.
Lift cylinder seal defective.
3.
Lift Relief Valve (R2) defective.
3.
4.
Lowering Valve (2H-13) defective.
4.
1.
Speed Valve (2H-21) defective.
1.
2.
Manual Lowering Valve (V1) open
or leaking.
Lift Relief Valve (R2) defective.
2.
1.
3.
SJM Series 107979-8
Final Revision 2-1-98
2.
3.
Close valve, replace
defective.
Rebuild cylinder, replace
damaged.
Check valve, replace
defective.
Check valve, replace
defective.
if
if
if
if
Clean valve, replace if
defective.
Close valve, replace if
defective.
Check valve, replace if
defective.
SECTION 4, Page 19
TROUBLESHOOTING INFORMATION (Hi-Torque Option)
TROUBLE
PROBABLE CAUSE
REMEDY
HYDRAULIC SYSTEM (continued)
Platform Does Not
Lift
1.
Manual Lowering Valve (V1) open.
1.
2.
Hydraulic oil level too low.
2.
3.
Platform weight excessive.
3.
4.
Up Valve (3H-14) defective or is
sticking.
Lift Relief Valve (R2) set too low
or valve is defective.
Pump (P1) defective.
4.
Main Manifold Block (MB1)
obstruction.
Obstruction in lift hose.
7.
8.
Clean hose,
defective.
1.
2.
3.
4.
Lowering Valve (2H-13) defective
or is sticking.
Base guide system obstruction.
Lift Cylinder damaged.
Hydraulic hose obstruction.
5.
Velocity Fuse (VF1) locked.
5.
6.
7.
Lowering Orifice (O2) plugged.
Holding valve (2H-13-1) defective.
(if so equipped)
6.
7.
Clean valve, replace if
defective.
Remove obstruction.
Rebuild or replace lift cylinder.
Clean hose, replace if
defective.
Check for broken line to lift
cylinder. If line is not broken,
raise the platform slightly then
slowly lower the platform with
the manual lowering valve.
Remove and clean the orifice.
Clean valve, replace if
defective.
1.
Speed Valve (2H21) defective or
is sticking.
Flow Divider/Combiner Valve
plugged or is defective.
Free-Wheeling Valve (V2) open or
defective.
Cushion Valve (2H-25) defective
or is sticking.
Drive Motor (M1) or (M2)
defective.
Counterbalance Valve (CB1)
plugged or is defective.
1.
5.
6.
7.
8.
Platform Will Not
Lower
Work Platform Drives
in Slow Speed Only
1.
2.
3.
4.
5.
6.
SECTION 4, Page 20
Final Revision 2-1-98
5.
6.
2.
3.
4.
2.
3.
4.
5.
6.
Close valve, replace if
defective.
Fully lower the platform. Fill
hydraulic tank until fluid is at
or slightly above the top mark
on the sight glass.
Reduce platform load to
maximum capacity.
Check valve, replace if
defective.
Adjust relief valve to proper
setting, replace if defective.
Check pump, replace if
defective.
Clean manifold block.
replace
Clean valve, replace
defective.
Clean valve, replace
defective.
Close valve, replace
defective.
Clean valve, replace
defective.
Check motors, replace
defective.
Clean valve, replace
defective.
if
if
if
if
if
if
if
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (Hi-Torque Option)
TROUBLE
PROBABLE CAUSE
REMEDY
HYDRAULIC SYSTEM (continued)
Work Platform Will Not
Drive in Forward or
Reverse
1.
Free-Wheeling Valve (V2) open.
1.
2.
Forward Drive Valve (4H-16) or
Reverse Drive Valve (4H-15)
defective or is sticking.
Cushion Valve (2H-25) defective
or is sticking.
Flow Divider/Combiner Valve
(FD1) defective or is plugged.
Counterbalance Valve (CB1)
defective or is plugged.
2.
1.
2.
Brake Valve (3H-17) defective or
is sticking.
Brake Orifice(s) (O4) plugged.
3.
Brake Cylinder(s) (C4) defective.
3.
1.
Right Steer Valve (4H-23) or Left
Steer Valve (4H-24) defective or
is sticking.
Steer Cylinder (C3) seals leaking.
Mechanical binding in steering
knuckle or king pins.
1.
Clean valve, replace if
defective.
2.
Rebuild cylinder. Replace if
damaged.
Check for binding. Repair as
needed.
System Relief Valve defective or
not adjusted properly.
Hydraulic Pump (P1) worn.
1.
3.
Flow Control Valve (FC1)
defective or is contaminated.
3.
1.
Platform Extend Valve (4H-26) or
Platform Retract Valve (4H-27)
defective or is sticking.
Powered Platform Cylinder (C5)
seals defective.
Mechanical binding in powered
platform mechanism
1.
Clean valve, replace if
defective.
2.
Rebuild cylinder, replace if
damaged.
Check for binding. Repair as
needed.
3.
4.
5.
Brake(s) Will Not
Release
Work Platform
Does Not Steer
1.
2.
3.
All Systems Sluggish
1.
2.
Powered Extension
Platform Will Not
Extend or Retract
Work Platform Won’t
Climb Grade
SJM Series 107979-8
2.
3.
Final Revision 2-1-98
3.
4.
5.
2.
3.
2.
3.
Close valve, replace if
defective.
Clean valve, replace if
defective.
Close valve, replace if
defective.
Clean valve, replace if
defective.
Clean valve, replace if
defective.
Clean valve, replace if
defective.
Remove orifice(s). Clean and
reinstall.
Rebuild cylinder(s). Replace if
damaged.
Adjust valve, replace if
defective.
Check pump, replace if
defective.
Clean, replace if defective.
SECTION 4, Page 21
TROUBLESHOOTING INFORMATION (2-Speed Drive)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM
All Controls
Inoperative
1.
Main Power Disconnect Switch
(S1) open or defective.
1.
Close switch or replace if no
continuity reading.
2.
Main battery cables open or
defective.
Lift/Off/Drive Key Switch open or
defective.
Battery charge low.
2.
Battery terminals or connector
pins dirty or loose.
Circuit breaker (CB1) or (CB2)
tripped.
5.
Check cable if no continuity
reading, replace.
Close switch or replace if no
continuity reading.
Check each cell with
hydrometer reading should be
1.275 (fully charged). Recharge
if low reading. Replace if
reading difference between cells
is 0.050.
Clean and tighten connections.
6.
Reset circuit breaker(s). Check
for defective wiring.
Wire #7 in plug disconnect broken
or loose.
Pin #7 on terminal strip loose.
Wire #3 from 200 Amp Fuse to
15 Amp Circuit Breaker.
Wire #7 from 15 Amp Circuit
Breaker to Emergency Stop
Button in control box.
200 Amp Fuse (F1) open.
7.
Repair wire or plug if defective.
8.
9.
Tighten pin #7.
Check wire continuity, replace
if open.
Check wire continuity, replace
arm cord if open.
12.
Emergency Stop Button (S4) or
(S6) open or defective.
12.
1.
Lift Enable Switch (S9) defective.
(later models)
Up/Down Platform Switch (S2) or
(S5) defective.
Defective wire #14 in arm cord
assembly or loose connection at
pin #14 of terminal strip.
Up valve coil (3H-14*) open or
shorted.
Diode (D14) or (D21) open or
shorted.
1.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Up Circuit
Inoperative
2.
3.
4.
5.
SJM Series 107979-8
Final Revision 2-1-98
3.
4.
10.
11.
2.
3.
4.
5.
Check continuity in fuse,
replace if open.
Close switch or replace if no
continuity reading.
Check switch, if no continuity
replace switch.
Replace switch.
Check wire continuity and
replace if open. Tighten
connection.
Check coil continuity. Replace
if defective.
Check diode continuity. Replace
if defective.
SECTION 4, Page 23
TROUBLESHOOTING INFORMATION (2-Speed Drive)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (Continued)
Up Circuit
Inoperative (cont.)
6.
7.
8.
9.
10.
Platform Lifts
Slowly
1.
2.
3.
Down Circuit
Inoperative
1.
2.
3.
4.
5.
6.
Right Steering
Inoperative
1.
2.
3.
Motor brushes defective.
(Solenoid clicks, but motor does
not operate.)
Circuit breaker (CB1) or (CB2)
tripped.
Up valve coil (3H-14*) or dump
valve coil (2H-21) or (2H-18B) not
properly grounded.
Dump valve coil (2H-21) or (2H18B) open or shorted.
Defective wire #21 or #18B.
6.
Replace motor brushes.
7.
Reset circuit breaker. Check for
defective wiring.
Check ground. Repair if
necessary.
Dump valve coil (2H-21) or (2H18B) open or shorted.
Diode (D14)or (D14A) open or
shorted.
Batteries not fully charged
1.
8.
9.
10.
2.
Check coil continuity. Replace
if defective.
Replace diode.
3.
Charge batteries.
Lift Enable Switch (S9)
defective.(later models)
Up/Down Platform Switch (S2) or
(S5) defective.
Defective wire #13 in arm cord
assembly or loose connection at
pin #13 or terminal strip.
Down valve coil (2H-13) open or
shorted.
Circuit Breaker (CB1) or (CB2)
tripped.
Down valve coil (2H-13) not
properly grounded.
1.
Check switch, if no continuity
replace switch.
Replace switch
Right steer switch (S7-2)
defective.
Right steer valve coil (4H-23)
open or shorted.
Diode (D23) open or shorted.
1.
2.
2.
3.
Check continuity. Replace if
defective. Tighten connection.
4.
Check coil continuity. Replace
if defective.
Reset circuit breaker. Check for
defective wiring.
Check ground. Repair if
necessary.
5.
6.
3.
4.
4.
5.
6.
SECTION 4, Page 24
Check coil continuity. Replace
if defective.
Check wire continuity and
replace if open. Tighten
connection.
Defective wire #23 in arm cord
assembly or loose connection at
pin 23 on terminal strip.
Circuit Breaker (CB1) or (CB2)
tripped.
Right steer valve coil (4H-23) not
properly grounded.
Final Revision 2-1-98
5.
6.
Replace switch.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective. Tighten connection.
Reset circuit breaker. Check for
defective wiring.
Check ground. Repair if
necessary.
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (2-Speed Drive)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (Continued)
Left Steering
Inoperative
1.
2.
Left steer switch (S7-3) defective.
Left steer valve coil (4H-24) open
or shorted.
Diode (D24) open or shorted.
1.
2.
Defective wire #24 in arm cord
assembly or loose connection at
pin 24 on terminal strip.
Circuit breaker (CB1) or (CB2)
tripped.
Left steer valve coil (4H-24) not
properly grounded.
4.
Forward switch (S7-5) defective.
Forward steer valve coil (4H-16)
open or shorted.
Diode (D16) open or shorted.
1.
2.
Defective wire #16 in arm cord
assembly or loose connection at
pin 16 on terminal strip.
Circuit Breaker (CB1) or (CB2)
tripped.
Forward valve coil (4H-16) not
properly grounded.
Diode (D17) open or shorted.
4.
8.
Brake valve coil (3H-17) open or
shorted.
8.
Reverse Direction
Inoperative
1.
2.
1.
2.
NOTE: On machines
equipped with powered platform option,
platform
MUST be fully retracted
to drive or steer.
3.
Reverse switch (S7-4) defective.
Reverse valve coil (4H-15) open
or shorted.
Diode (D15) open or shorted.
Defective wire #15 in arm cord
assembly or loose connection at
pin 15 of terminal strip.
Circuit Breaker (CB1) or (CB2)
tripped.
Reverse valve coil (4H-15) not
properly grounded.
Diode (D17) open or shorted.
4.
Brake valve coil (3H-17) open or
shorted.
8.
3.
4.
5.
6.
Forward Direction
Forward Direction
Inoperative
Inoperative
1.
2.
NOTE: On machines
NOTE: Onwith
machines
equipped
powered
equipped
with
powered
platform option,
platform
platform
option,
platform
MUST be fully retracted
MUST
be
fully
retracted
to drive or steer.
to drive or steer.
3.
4.
5.
6.
7.
4.
5.
6.
7.
8.
SJM Series 107979-8
Final Revision 2-1-98
3.
5.
6.
3.
5.
6.
7.
3.
5.
6.
7.
Replace switch.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective. Tighten connection.
Reset circuit breaker. Check for
defective wiring.
Check ground. Repair if
necessary
Replace switch.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Reset circuit breaker. Check
for defective wiring.
Check ground. Repair if
necessary.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Replace switch.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Check continuity. Tighten
connection. Replace if
defective.
Reset circuit breaker. Check for
defective wiring.
Check ground. Repair if
necessary.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
SECTION 4, Page 25
TROUBLESHOOTING INFORMATION (2-Speed Drive)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (Continued)
Powered Extension
Platform Will Not
Extend or Retract
(Machines so
equipped)
1.
2.
3.
4.
5.
Powered Extension
Platform Will Not
Extend (Machines so
equipped)
1.
2.
3.
Powered Extension
Platform Will Not
Retract (Machines so
equipped)
Turn key to “LIFT” position.
2.
Check continuity, replace if
defective.
3.
Replace if defective.
4.
Check continuity, replace if
defective.
5.
Check continuity replace if
defective.
See items 1 thru 5 in “Powered
Extension Platform Will Not
Extend or Retract”.
Wire #26 from extend switch to
platform extend coil (4H-26) open
or defective.
Diode (D26) open or shorted.
1.
Check each step.
2.
Check continuity, replace if
defective.
3.
Check diode continuity, replace
if defective.
Check coil continuity, replace
if defective.
Platform extend coil (4H-26) open
or shorted.
4.
1.
See items 1 thru 5 in “Powered
Extension Platform Will Not
Extend or Retract”.
Wire #27 from extend switch to
platform retract coil (4H-27) open
or defective.
Diode (D27) open or shorted.
1.
Check each step.
2.
Check continuity, replace if
defective.
3.
Check diode continuity, replace
if defective.
Check coil continuity, replace
if defective.
2.
4.
Platform retract coil (4H-27) open
or shorted.
4.
1.
2.
Speed switch (S7-1) defective.
Dump valve coil (2H-21) or (2H18B) open or shorted.
Defective wire #18 in arm cord
assembly or loose connection at
pin 18 of terminal strip.
High Speed Limit Switch (LS1)
open or shorted.
Defective wire #21 or 18A from
High Speed Limit Switch.
Cushion relay (17CCR1)
defective
1.
2.
3.
4.
5.
6.
SECTION 4, Page 26
1.
4.
3.
Work Platform Drives
In Slow Speed Only
Lift/Off/Drive Key Select Switch
not in “LIFT” position.
Wire #9 from key switch to
platform extend-retract switch
open or defective.
Platform Extend/Retract Switch
(S11) defective
Wire #2 in powered extension
platform valve control cable open
or defective.
Wire #19 from main control box
open or defective.
Final Revision 2-1-98
3.
Replace switch.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
4.
Replace switch.
5.
Check continuity. Replace if
defective.
Replace relay.
6.
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (2-Speed Drive)
TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM (Continued)
Work Platform
Will Not Climb Grade
1.
Dump valve coil (2H-21) or (2H18B) open or shorted.
High Speed Limit Switch (LS1)
open or shorted.
Defective wire #18 in arm cord
assembly or loose connection at
pin 18 on terminal strip.
Defective wire #21 or 18A from
High Speed Limit Switch.
Speed Switch (S7-1) defective.
1.
6.
Cushion
defective.
6.
1.
Diode(s) shorted.
1.
2.
Valve coils (2H-13, 3H-14*, 4H15, 4H-16, 4H-23, or 4H-24 stuck
in open position.
2.
2.
3.
4.
5.
2 Or More Functions
At One Time
relay
(17CCR1)
2.
Check continuity. Replace if
defective.
Replace switch.
3.
Check continuity. Replace if
defective. Tighten connection.
4.
Check continuity. Replace if
defective.
Check continuity. Replace if
defective.
Replace relay.
5.
Check continuity of all diodes.
Replace if defective.
Depress manual override
several times to free valve.
Clean spool or replace if
defective.
HYDRAULIC SYSTEM
Platform Drifts
Down
1.
Lowering Valve (2H-13) leaking.
1.
2.
Lowering Valve (2H-13) stuck
open.
Lift cylinder seal defective.
2.
Manual Lowering Valve (V1) not
closed.
Lift Relief Valve (R2) defective.
4.
5.
Clean valve and reinstall.
Replace if defective. (See
Section 3, Hydraulic Schematic
for lift relief valve pressure
setting.)
Dump Valve (2H-21) or (2H-18B)
stuck open.
Manual Lowering Valve (V1) not
closed or leaking.
Lift Relief Valve (R2) defective.
1.
Clean valve and reinstall.
Replace if defective.
Clean valve. Replace if leaking.
3.
4.
5.
Platform Lifts
Slowly
1.
2.
3.
SJM Series 107979-8
Final Revision 2-1-98
3.
2.
3.
Clean valve and reinstall.
Replace if defective.
Clean valve and reinstall.
Replace if defective.
Replace seals or replace if
damaged.
Close valve.
Clean valve and reinstall.
Replace if defective. (See
Section 3, Hydraulic Schematic
for lift relief valve pressure
setting.)
SECTION 4, Page 27
TROUBLESHOOTING INFORMATION (2-Speed Drive)
TROUBLE
PROBABLE CAUSE
REMEDY
HYDRAULIC SYSTEMS (Continued)
Platform Does Not
Lift: Motor and
Pump Operate
Platform Will Not
Lower
Work Platform Drives
in Slow Speed Only
1.
Manual Lowering Valve (V1) not
closed. Hydraulic tank level low.
1.
2.
Platform weight excessive.
2.
3.
4.
5.
Hydraulic Pump (P1) defective.
Hydraulic obstruction.
Up Valve (3H-14*) not shifting or
is sticking.
3.
4.
5.
6.
Electrical system malfunction.
6.
7.
Lift Relief Valve (R2) setting too
low or valve is defective.
7.
8.
Main Manifold Block (MB1) output
ports blocked.
8.
1.
Lowering valve (2H-13) defective
1.
2.
3.
4.
Base guide system obstruction.
Lift Cylinder damaged.
Hydraulic hose obstruction.
2.
3.
4.
5.
Electrical system malfunction.
5.
6.
Velocity Fuse (VF1) locked.
6.
7.
8.
Lowering Orifice (O2) plugged.
Holding valve (2H-13-1) defective
7.
8.
1.
1.
2.
Dump Valve (2H21) or (2H-18B)
not shifting.
Electrical system malfunction.
3.
Drive motor(s) clogged.
3.
4.
Flow divider obstruction.
4.
5.
Free-Wheeling Valve (V2) not fully
closed or leaking.
Cushion Valve (2H-25) o-rings
defective.
5.
6.
SECTION 4, Page 28
Final Revision 2-1-98
2.
6.
Close valve. Fill hydraulic tank
until fluid is at or slightly above
the top mark on the sight glass.
(NOTE: Platform MUST be
fully lowered.
Reduce platform load to
maximum capacity.
Consult factory.
Remove obstruction.
Clean valve to allow free spool
movement. Replace if
defective.
Refer
to
Electrical
Troubleshooting portion of this
table; “Up Circuit Inoperative”.
Adjust to proper setting. Refer
to Section 3, Hydraulic
Schematic.
Replace if
defective.
Disassemble and clean.
Remove and clean. Replace if
defective.
Remove obstruction.
Rebuild or replace cylinder.
Remove and clean. Replace if
defective.
Refer
to
Electrical
Troubleshooting portion of this
table;
“Down
circuit
Inoperative.”
Check for broken hydraulic line.
If no line is broken, raise
platform slightly then lower by
slowly opening “Emergency
Lowering Valve.”
Remove, clean then reinstall.
Remove and clean. Replace if
defective.
Clean valves and replace if
defective.
Refer
to
Electrical
Troubleshooting portion of this
table; “Work platform drives in
slow speed only.
Remove and clean. Replace if
defective.
Remove and clean. Replace if
defective.
Close valve.
Remove valve and inspect orings. Replace if defective.
SJM Series 107979-8
TROUBLESHOOTING INFORMATION (2-Speed Drive)
TROUBLE
PROBABLE CAUSE
REMEDY
HYDRAULIC SYSTEM (Continued)
Work Platform Will Not
Drive in Forward or
Reverse
1.
Forward drive spool (4H-16) or
reverse drive (4H-15) sticking.
1.
2.
Free-wheeling Valve (V2) not
fully closed.
Counterbalance Valve (CB1)
clogged.
Cushion Valve (2H-25) stuck
open.
2.
5.
Brake Valve (3H-17) not shifting.
5.
Remove and clean valve.
Replace if defective.
6.
Brake Cylinder (C4) not
releasing.
6.
Remove and check brake
cylinder. Replace if defective.
Remove and clean valve.
Replace if defective.
Refer
to
Electrical
Troubleshooting portion of this
table: “Forward Direction
Inoperative” or “Reverse
Direction Inoperative”.
3.
4.
7.
1.
Steer valve spool (4H-23)/ (4H24)sticking.
1.
2.
2.
3.
Main Manifold Block (MB1) ports
clogged.
Steer Cylinder seal(s) defective.
4.
Hydraulic hose obstruction.
4.
5.
Electrical system malfunction.
5.
8.
Work Platform Won’t
Climb Grade
SJM Series 107979-8
4.
Flow Divider/Combiner Valve
(FD1) stuck closed.
Electrical malfunction.
7.
Work Platform
Does Not Steer
3.
Final Revision 2-1-98
8.
3.
Depress manual override on
each valve. If unit drives, clean
valve spool to allow free
movement. Replace valve if
defective.
Close valve. Replace if
defective.
Remove and clean valve.
Replace if defective.
Remove and clean valve.
Replace if defective.
Depress manual override on
each valve. If wheels turn,
clean valve spool to allow free
movement. Replace valve if
defective.
Remove and clean.
Replace seals or replace
cylinder if damaged.
Remove and clean hoses.
Replace if defective.
Refer
to
Electrical
Troubleshooting portion of this
table; “Right Steering
Inoperative” or “Left Steering
Inoperative”.
SECTION 4, Page 29
TROUBLESHOOTING INFORMATION (2-Speed Drive)
TROUBLE
PROBABLE CAUSE
REMEDY
HYDRAULIC SYSTEMS (Continued)
Work Platform Won’t
Climb Grade
1.
Dump Valve (2H-21) or (2H-18B)
stuck open or not shifting.
System Relief Valve (R1)
pressure setting too low.
1.
3.
Electrical system malfunction.
3.
4.
Cushion Valve (2H-25) o-rings
defective.
Free-wheeling Valve (V2) not fully
closed or leaking.
4.
1.
2.
Battery charge low.
Hydraulic system contaminated.
1.
2.
3.
3.
5.
System Relief Valve (R1)
defective.
System Relief Valve (R1) setting
too low.
Hydraulic pump worn.
1.
Electrical system malfunction.
1.
2.
Extend retract spool valve (4H26) or (4H-27) sticking.
2.
3.
Powered platform cylinder (C5)
seals defective.
Hydraulic hose obstruction.
3.
2.
5.
All Systems
Sluggish
4.
Powered Platform Will
Not Extend or Retract
4.
SECTION 4, Page 30
Final Revision 2-1-98
2.
5.
4.
5.
4.
Remove and clean spool.
Replace if defective.
Adjust to proper setting. Refer
to Section 3, Hydraulic
Schematic.
Refer
to
Electrical
Troubleshooting portion of this
table.
Remove valve and inspect orings. Replace if defective.
Close valve.
Check and charge batteries.
Drain fluid and flush system.
Refill with new fluid.
Replace valve.
Adjust to proper setting. Refer
to Hydraulic Schematic.
Replace pump.
Refer
to
Electrical
Troubleshooting portion of this
table.
Depress manual override on
each valve, if platform extends
or retracts, clean valve spool
to free movement. Replace
valve if defective.
Replace seals or replace
cylinder if damaged.
Remove and clean hoses.
Replace if defective.
SJM Series 107979-8
SECTION 5
MAINTENANCE AND SERVICE
OPERATOR’S RESPONSIBILITY FOR
MAINTENANCE
MAINTENANCE AND INSPECTION
SCHEDULE
Death or injury can result if the work platform is not kept
in good working order. Inspection and maintenance
should be performed by competent personnel who are
familiar with mechanical procedures.
The actual operating environment of the work platform
governs the use of the maintenance schedule. The
inspection points covered in Table 5-1. Maintenance and
Inspection Schedule indicates the areas of the work
platform to be maintained or inspected and at what
intervals the maintenance and inspections are to be
performed.
The operator should be assured that the work platform has
been properly maintained and inspected before using it.
Even if the operator is not directly responsible for the
maintenance of this work platform, the operator should
perform ALL the daily inspections found in Table 5-1.
Maintenance and Inspection Schedule.
NOTE
Replace all worn, damaged or missing parts or labels
discovered during this inspection.
OWNER’S ANNUAL INSPECTION RECORD
It is the responsibility of the owner to arrange daily,
weekly, monthly and annual inspections of the work
platform. Table 5-2. Owner’s Annual Inspection Record is
to be used for recording the date of inspection, owner’s
name and the person responsible for the inspection of this
work platform.
GENERAL MAINTENANCE HINTS
DANGER
CRUSHING HAZARD
DO NOT reach through scissors assembly without the
safety bar properly positioned. Failure to avoid this
hazard will result in death or serious injury!
•
Properly position safety bar if the scissors
assembly is raised.
•
Before attempting any repair work, disconnect
the battery ground (-) lead.
•
Preventive maintenance is the easiest and
least expensive type of maintenance.
5
SJM Series 107979-8
toc
1
2
3
Final Revision 2-1-98
4
6
SECTION 5, Page 1
HYDRAULIC SYSTEM AND COMPONENT
MAINTENANCE AND REPAIR
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.
The following points should be kept in mind when working
on the hydraulic system or any component:
1.
Any structure has limits of strength and durability.
To prevent failure of structural parts of hydraulic
components, relief valves which limit pressure
to safe operating values are included in the
hydraulic circuits.
2.
Tolerance of working parts in the hydraulic system
are very close. Even small amounts of dirt or
foreign material in the system can cause wear
or damage to components, as well as general
faulty operation of the hydraulic system. Every
precaution must be taken to assure absolute
cleanliness of the hydraulic oil.
3.
Samples of hydraulic oil should be drawn from
the reservoir every six months. These samples
should be about two quarts and should be taken
while the oil is warmed through normal operation
of the system. If possible, the sample should
be analyzed by a qualified lubrication specialist
to determine whether it is suitable for further use.
The intervals between oil changes depend on
operating conditions and on the care used in
keeping the oil clean.
4.
5.
6.
Whenever there is a hydraulic system failure
which gives reason to believe that there are metal
particles or foreign materials in the system, drain
and flush the entire system and replace the filter
cartridges. A complete change of oil must be
made under these circumstances.
Whenever the hydraulic system is drained, check
the magnets in the hydraulic reservoir for metal
particles. If metal particles are present, flush
the entire system and add a new change of oil.
The presence of metal particles also may indicate
the possibility of imminent component failure. A
very small amount of fine particles is normal.
DO NOT use synthetic or fire resistant oils in
this work platform. Use ATF Dexron III (ESSO)
or equivalent hydraulic oil. For conditions causing
oil temperatures below -31°F (-35°C) and above
122°F (50°C) consult Skyjack, Inc.
SECTION 5, Page 2
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.
Final Revision 2-1-98
SJM Series 107979-8
Table 5-1. Maintenance and Inspection Schedule
Daily
Weekly
Monthly
3-months
6-months
* 12-months
Mechanical
Structural damage/welds (1)
Parking brake (2)
9
9
Tires and wheels (1) (2)
9
9
9
Guides, rollers and slides (1)
9
9
Entry chain or gate (2)
9
9
Bolts and fasteners (3)
9
9
Safety bar (2)
9
9
Rust (1)
9
9
Wheel brgs (2)King pins (1)
9
Steer cyl ends (8)
9
9
9
Electrical
Battery fluid level (1)
9
9
Control switches (1)(2)
9
9
Cords and wiring (1)
9
9
Battery terminals (1)(3)
9
9
Generator and receptacle (2)
9
9
Terminals and plugs (3)
9
9
Hydraulic
Hydraulic oil level (1)
9
9
Hydraulic leaks (1)
9
9
Lift and lowering times (10)
9
9
Cylinders (1)(2) Steers (3)
9
9
Emergency lowering (2)
9
9
Lift capacity (7)
9
Hyd. oil & oil filter element (9)
9
Notes:
(1) Visually inspect
(2) Check operation
(3) Check tightness
(7) Check relief valve setting. Refer to serial number
nameplate
SJM Series 107979-8
9
(8) Lubricate
(9) Replace
(10) Refer to Table 5-5. General specifications
* Record inspection date in Table 5-2.
(8) Lubricate
(9) Replace
(10) Refer to Table 5-5. General Specifications
Final Revision 2-1-98
SECTION 5, Page 3
Table 5-2. Owner’s Annual Inspection Record
MODEL NUMBER________________________________
SERIAL NUMBER______________________
RECORDING
DATE
RECORDING
YEAR #
1
2
3
4
5
6
7
8
OWNERS
NAME
INSPECTED
BY
Table 5-3. Maximum Platform Capacities
(Evenly Distributed)
Model
Main Platform
Extension Platform
3015
250 lbs. (113.5kg)/1 Occupant
250 lbs. (113.5kg)/1 Occupant
3219
250 lbs. (113.5kg)/1 Occupant
250 lbs. (113.5kg)/1 Occupant
NOTE: Overall capacity - 2 occupants and materials not to exceed rated load.
Table 5-4. Torque Specifications
28-32 in. lbs.
DIRECTIONAL VALVE MOUNTING SCREWS
WHEEL MOTOR MOUNTING BOLTS
70 ft. lbs.
WHEEL MOTOR CASTLE NUT
200 ft. lbs.
WHEEL/TIRE MOUNTING BOLTS
70 ft. lbs.
PARKING BRAKE CYLINDER ROD NUT
35 ft. lbs.
CARTRIDGE
Size
08
38
58
10
12
16
ft. lbs. (max)
20
20
20
25
35
50
in. lbs. (max)
240
240
240
300
420
600
COILS
Size
All Coils
ft. lbs. (max)
4 to 5
in. lbs. (max)
48 to 60
SAE PLUGS
Size
2
4
5
6
8
10
12
16
ft. lbs. (max)
3
10
15
15
25
25
30
35
in. lbs. (max)
36
120
180
180
300
300
360
420
SECTION 5, Page 4
Final Revision 2-1-98
SJM Series 107979-8
Table 5-5. General Specifications
ELECTRICAL SYSTEM
24VDC/6 Volt, 220AH
6 Volt, 220AH (Std)
6 Volt, 250AH (Opt)
BATTERIES (4) (Standard)
12 x 4.00 x 8
Solid Rubber
TIRES (4)
INSIDE TURNING RADIUS - Model - 3015
INSIDE TURNING RADIUS - Model - 3219
OUTSIDE TURNING RADIUS - Model - 3015
OUTSIDE TURNING RADIUS - Model - 3219
GROUND UNDERCLEARANCE
6" (.15m)
6" (.15m)
52" (1.32m)
66" (1.68m)
3" (.08m)
FLOOR LOAD RATING - Model 3015
FLOOR LOAD RATING - Model 3219
112 psi (7.87kg/cm )
123 psi (8.65kg/cm )
TRAVEL SPEED - LOW
.75mph/1.20kph
TRAVEL SPEED - HIGH
2.00mph/3.20kph
LIFT TIME (Model 3015)
LIFT TIME (Model 3219)
19 seconds (no load)
30 seconds (no load)
LOWERING TIME (Model 3015)
LOWERING TIME (Model 3219)
24 seconds (no load)
40 seconds (no load)
LIFT RELIEF PRESSURE (R2) - Model 3015
LIFT RELIEF PRESSURE (R2) - Model 3219
1700 psi
2150 psi
SYSTEM RELIEF PRESSURE (R1) - Model 3015
SYSTEM RELIEF PRESSURE (R1) - Model 3219
2900 psi
2900 psi
PUMP
.161 ci\rev
RETURN FILTER
20 micron
HYDRAULIC SYSTEM CAPACITY
4.00 gal. (15.16 ltr.)
HYDRAULIC TANK CAPACITY
3.00 gal.(11.31 ltr.)
WHEEL MOTORS
SJM Series 107979-8
4 ci/rev
Final Revision 2-1-98
SECTION 5, Page 5
PROPORTIONAL CONTROLLER TROUBLESHOOTING PROCEDURE
POTENTIOMETER
NEUTRAL
SWITCH
S7-1
(OUTSIDE)
STEP 8
STEP 6
STEP 4
STEP 3
STEP 4
STEP 10
STEP11
Figure 5-1. Proportional Controller
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Remove the bottom cover from the platform control box.
Select “DRIVE” with Lift\Drive Select Switch (S5).
Locate the “GND” terminal on Controller Circuit Board and attach Negative meter lead. Refer to Figure 5-1. for
location.
Locate the “VS” terminal on Controller Circuit Board and measure voltage. Refer to Figure 5-1 For location.
Reading should be 24 volts + or - 3 volts. If no voltage is present, refer to “No Drive or Steer From Platform” in
Electrical Troubleshooting. If voltage present, go to Step 5.
Locate “AUX” terminal on Controller Circuit Board. Refer to Figure 5-1. for location. Lift lock ring on controller
handle and move in either direction. Measure voltage at “AUX” terminal. Reading should be 24 volts + or - 3
volts. If no reading present, replace Neutral Switch S7-1. If voltage present, go to Step 6.
Locate the potentiometer on Controller Circuit Board. Refer to Figure 5-1. for location. While holding controller
handle as in Step 5, measure voltage at outside terminals of potentiometer. Reading should be 20 - 21 volts. If
no voltage present on one or both terminals, replace board. If voltage present, go to Step 7.
Release controller handle. Locate and attach meter lead to “AUX” terminal. Lift handle locking ring and slowly
move handle, in either direction, until voltage on “AUX” terminal just turns on. Hold handle in this position.
Measure voltage on the center terminal of the potentiometer. Reading should be 20 - 21 volts. If no voltage
present, replace board. If voltage is present, move controller handle SLOWLY to full stroke, while observing
meter. Reading should drop smoothly to 18 volts. If voltage does not drop or drops erratically, replace board. If
voltage drops smoothly, go to Step 9.
Hold controller handle in the “just on “ position as in Step 7.
Locate “PWM” terminal on the controller board. Refer to Figure 5-1. for location. While holding handle as in Step
9, measure voltage on “PWM” terminal. Reading should be 4 - 5 volts at the just on position (threshold). If no
voltage present, replace board. If reading too high or too low, refer to “Joystick Adjustment Procedure”. Refer
to Page 30. If correct voltage present, go to Step 10.
Move controller handle to the full stroke position. Reading should increase smoothly to 17 - 18 volts. If no
voltage present or increases erratically, replace board. If correct voltage present and increases smoothly, refer
to “All Controls Inoperative” in Electrical Troubleshooting”.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 5, Page 7
PROPORTIONAL CONTROLLER ADJUSTMENT PROCEDURE
METHOD #1
STEP #7
STEP #2
VOM METER
BLACK
RED
WIRE #18
STEP #4
STEP #3
LO = 210nA (.21 AMPS)
HI = 680nA (.68 AMPS)
STEP #8
STEP #11
STEP #10
METHOD #2
STEP #4
STEP #5
STEP #6
STEP #2
STEP #7
Figure 5-2. Proportional Controller Adjustment
SECTION 5, Page 8
Final Revision 2-1-98
SJM Series 107979-8
PROPORTIONAL
CONTROLLER
ADJUSTMENT
PROCEDURE
NOTE:Described are two accepted methods to adjust the proportional controller. Method #1 requires a Volt\Ohm meter
capable of reading milliamps. If a meter is not available, use Method #2.
METHOD #1
NOTE
Jack up drive axle until drive tires clear the ground. Chock other tires to prevent machine from moving.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove the bottom cover from the platform control box.
Locate and remove wire #18 from the “PWM” terminal of the controller board. Refer to Figure 5-2. for location.
Attach positive meter lead to the “PWM” terminal where wire #18 was removed.
Attach negative meter lead to wire #18.
Select “Amps” position on meter.
Select “DRIVE” with the Lift/Drive Select Switch (S5).
Lift the controller handle lockring and move handle in either direction until the pump motor just comes on. Hold
handle in this position.
Locate the “LO” potentiometer on the controller board. Adjust the “LO” potentiometer until the meter reads 210
mA (.21 amps). Refer to Figure 5-2. for location.
Move controller handle to full stroke position and hold.
Locate “HI” potentiometer on controller board. Adjust the “HI” potentiometer until the meter reads 680 mA (.68
amps).
NOTE
Adjusting “LO” potentiometer will affect the “HI” potentiometer and vice versa. Repeat steps 7 through 10 until meter
readingsstabilize.
11.
Paint potentiometer screws with nail polish or RTV silicone, to prevent vibration from changing settings.
METHOD #2
NOTE
Adequate area to Drive MUST be provided to use this Method.
1.
2.
3.
4.
5.
6.
Remove the bottom cover from the platform control box.
Locate the “LO” and “HI” potentiometers on the controller board and turn both potentiometers 6 turns counterclockwise (CCW) each. Refer to Figure 5-2. for location.
Select “DRIVE” with the Lift/Drive Select Switch.
Lift the controller handle lock ring and move handle in either direction until pump motor just comes on. Hold this
position.
Locate the “LO” potentiometer on the controller board. Turn the “LO” potentiometer clockwise (CW) until machines
just starts to move.
Move controller handle to full stroke position. Turn the “HI” potentiometer clockwise (CW) until no increase in
travel speed can be felt.
NOTE
Adjusting “LO” potentiometer will affect the “HI” potentiometer and vice versa. Repeat steps 4 through 6 until drive speeds
stabilize.
7.
Paint potentiometer screws with nail polish or RTV silicone to prevent vibration from changing settings.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 5, Page 9
SECTION 6
PARTS LIST
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 subassemblies 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!
SJM Series 107979-8
toc
1
2
3
Final Revision 2-1-98
4
5
SECTION 6, Page 1
6
6
LIST OF ILLUSTRATIONS
Description
FIGURE 6-1. MAIN PLATFORM AND RAILINGS ........................................................................................... Page 4
FIGURE 6-2. MAIN PLATFORM AND HINGED RAILINGS ............................................................................ Page 6
FIGURE 6-3. 3 FT. MANUAL EXTENSION PLATFORM ................................................................................ Page 8
FIGURE 6-4. 3 FT. POWERED EXTENSION PLATFORM ...........................................................................Page 10
FIGURE 6-5. POWERED EXTENSION PLATFORM CYLINDER ASSEMBLY .............................................Page 12
FIGURE 6-6. HYDRAULIC HOSE CONNECTIONS - Powered Extension Platform .......................................Page 13
FIGURE 6-7. POWERED EXTENSION PLATFORM CONTROL BOX ASSEMBLY .....................................Page 14
FIGURE 6-8. GATE OPTIONS ......................................................................................................................Page 16
FIGURE 6-9. CONTROL BOX ASSEMBLY - Proportional Drive and Lift ................................................... Page 18
FIGURE 6-10. CONTROL BOX ASSEMBLY - 2 Speed Drive ....................................................................... Page 22
FIGURE 6-11. PROPORTIONAL CONTROLLER ASSEMBLY .................................................................... Page 26
FIGURE 6-12. 2 SPEED DRIVE CONTROLLER ASSEMBLY ...................................................................... Page 27
FIGURE 6-13. HYDRAULIC HOSE CONNECTIONS - Scissors .................................................................. Page 28
FIGURE 6-14. SCISSOR ARM ASSEMBLY - Model 3015 ........................................................................... Page 30
FIGURE 6-15. SCISSOR ARM ASSEMBLY - Model 3219 ........................................................................... Page 32
FIGURE 6-16. LIFT CYLINDER ASSEMBLY - Model 3015 .......................................................................... Page 34
FIGURE 6-17. LIFT CYLINDER ASSEMBLY - Model 3219 .......................................................................... Page 35
FIGURE 6-18. BASE AXLES AND WHEELS - Model 3015 ......................................................................... Page 36
FIGURE 6-19. BASE AXLES AND WHEELS - Model 3219 ......................................................................... Page 40
FIGURE 6-20. HYDRAULIC HOSE CONNECTIONS - Base (Steer, Drive and Brake Circuits) ................. Page 44
FIGURE 6-21. BRAKE CYLINDER ASSEMBLY ............................................................................................ Page 46
FIGURE 6-22. STEER CYLINDER ASSEMBLY ............................................................................................ Page 47
FIGURE 6-23. STEER MECHANISM - Model 3015 ..................................................................................... Page 48
FIGURE 6-24. STEER MECHANISM - Model 3219 ..................................................................................... Page 50
FIGURE 6-25. FRONT AXLE MANIFOLD ASSEMBLY ................................................................................ Page 52
FIGURE 6-26. PROPORTIONAL VALVE MANIFOLD ASSEMBLY .............................................................. Page 53
FIGURE 6-27. HYDRAULIC/ELECTRIC TRAY ASSEMBLY - Proportional Drive and Lift .......................... Page 54
FIGURE 6-28. HYDRAULIC/ELECTRIC TRAY ASSEMBLY - 2 Speed Drive with Hi-Torque ..................... Page 58
FIGURE 6-29. HYDRAULIC/ELECTRIC TRAY ASSEMBLY - 2 Speed Drive ............................................... Page 62
FIGURE 6-30. HYDRAULIC HOSE CONNECTIONS - Hydraulic/Electric Tray ........................................................
Proportional Drive and Lift ...................................................................................................... Page 66
FIGURE 6-31. HYDRAULIC HOSE CONNECTIONS - Hydraulic/Electric Tray ...........................................................
2 Speed Drive With Hi-Torque Package ................................................................................. Page 68
FIGURE 6-32. HYDRAULIC HOSE CONNECTIONS - Hydraulic/Electric Tray ...........................................................
2 Speed Drive ......................................................................................................................... Page 70
FIGURE 6-33. MAIN MANIFOLD AND CUSHION VALVE MANIFOLD ASSEMBLY ..................................................
Proportional Drive and Lift ...................................................................................................... Page 72
FIGURE 6-34. MAIN MANIFOLD AND CUSHION VALVE MANIFOLD ASSEMBLY .................................................
2 Speed Drive With Hi-Torque Package ............................................................................. Page 74
SECTION 6, Page 2
Final Revision 2-1-98
SJM Series 107979-8
LIST OF ILLUSTRATIONS
Description
FIGURE 6-35. MAIN MANIFOLD AND CUSHION VALVE ASSEMBLY -2 Speed Drive ................................ Page 76
FIGURE 6-36. ELECTRICAL PANEL ASSEMBLY - Proportional Drive and Lift ..........................................................
(North America and Other Than Europe) ............................................................................... Page 78
FIGURE 6-37. ELECTRICAL PANEL ASSEMBLY - Proportional Drive and Lift (Europe) ............................... Page 80
FIGURE 6-38. ELECTRICAL PANEL ASSEMBLY - Standard and Options ....................................................Page 82
FIGURE 6-39. ELECTRICAL PANEL ASSEMBLY - EE Rated .......................................................................Page 84
FIGURE 6-40. BATTERY TRAY ASSEMBLY .................................................................................................Page 86
FIGURE 6-41. BATTERY CHARGER ASSEMBLY - 110 Volt (Motor Appliance BA611 and BA285) .............Page 88
FIGURE 6-42. BATTERY CHARGER ASSEMBLY - 220 Volt (Motor Appliance BA538) ................................ Page 89
FIGURE 6-43. BATTERY CHARGER ASSEMBLY - 220 Volt (Bycan) ...........................................................Page 90
FIGURE 6-44. BATTERY CHARGER ASSEMBLY - EE Rated ......................................................................Page 91
FIGURE 6-45. BASE CONTROL BOX ASSEMBLY OPTION .........................................................................Page 92
FIGURE 6-46. AC OUTLET ON PLATFORM OPTION ...................................................................................Page 94
FIGURE 6-47. 800W GENERATOR OPTION .................................................................................................Page 96
FIGURE 6-48. AIR HOSE TO PLATFORM OPTION ......................................................................................Page 97
FIGURE 6-49. D-RING LANYARD ATTACHMENTS OPTION ........................................................................Page 98
FIGURE 6-50. SCISSOR GUARD OPTION - French ......................................................................................Page 99
FIGURE 6-51. SCISSOR GUARD OPTION - Other Than France ................................................................ Page 100
FIGURE 6-52. LABELS AND NAMEPLATES .............................................................................................. Page 103
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 3
FIGURE 6-1. MAIN PLATFORM AND RIGID RAILINGS
8
7
4
3
5
14
6
16
9
12
18
13
17
1
15
10
2
11
MA-SJM-01C
SECTION 6, Page 4
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-1. MAIN PLATFORM AND RIGID RAILINGS
Index
No.
Skyjack
Part No.
A
B
1
(Ref.)
(Ref.)
107861
109687
112878
109530
111888
112879
2
13
108735
300437
103999
103472
103978
107865
110740
107864
110741
106520
103845
103404
103996
100702
104183
102975
106893
100297
106896
100493
310014
300437
103999
103472
103543
103856
104000
104127
14
15
108773
112882
16
17
18
103024
310032
310031
3
4
5
6
7
8
9
11
12
SJM Series 107979-8
Units
per
Assy.
Description
MAIN PLATFORM AND RIGID RAILINGS - Model 3015
MAIN PLATFORM AND RIGID RAILINGS - Model 3219
• WELDMENT, Main platform, A
(Machines with manual extension platform)
• WELDMENT, Main platform, A
(Machines with powered extension platform)
• WELDMENT, Main platform, A
(Machines with scissor guard option)
• WELDMENT, Main platform, B
(Machines with manual extension platform)
• WELDMENT, Main platform, B
(Machines with powered extension platform)
• WELDMENT, Main platform, B
(Machines with scissor guard option)
• COVER, Cable protection (Replaces 104634)
• • BOLT, Hex-hd 3/8-16 x 7/8" lg.
• • WASHER, Lock 3/8"
• • WASHER, Flat 3/8"
• • NUT, 3/8-16
• RAILING, Side RH, A
• RAILING, Side RH, B
• RAILING, Side LH, A
• RAILING, Side LH, B
• RAILING, Entry top
• • BOLT, Hex-hd 5/16-18 x 1/2" lg.
• • WASHER, Lock 5/16"
• • WASHER, Flat 5/16"
• CAP, Tube end
• PAD, Foam 25-1/4"
• STRIPE, Warning
• CHAIN ASSEMBLY, Entry
• • LINK, Attaching
• • CHAIN, 25-1/2" lg.
• • LATCH, Chain snap
• BRACKET, Scissor mount (Replaces 107971,109478 and 109477)
• • BOLT, Hex-hd 3/8-16 x 7/8" lg.
• • WASHER, Lock 3/8"
• • WASHER, Flat 3/8"
• PAD, Platform slide
• • BOLT, Hex-hd 1/4-20 x 3/4" lg.
• • WASHER, Lock 1/4"
• COVER, Cable protection
(Model 3015 with Serial Number 18538 and Below)
(Model 3219 with Serial Number 220623 and Below)
• ANGLE, Platform slider 22" lg.
• LOCATOR, Scissor guard
(Machines with scissor guard option)
• CLIP, Control cable #G8
• GUARD, Cable LH (option)
• GUARD, Cable RH
(3015 with serial number 18539 and above)
(3219 with serial number 220624 and above)
Final Revision 2-1-98
1
1
1
1
1
1
4
4
4
4
1
1
1
1
1
2
2
2
2
1
AR
1
1
1
1
1
6
6
6
2
4
4
1
1
2
1
1
1
SECTION 6, Page 5
FIGURE 6-2. MAIN PLATFORM AND HINGED RAILINGS
8
4
7
3
5
6
14
16
9
12
18
17
13
1
15
10
11
2
MA-SJM-35A
SECTION 6, Page 6
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-2. MAIN PLATFORM AND HINGED RAILINGS
Index
No.
Skyjack
Part No.
A
B
1
(Ref.)
(Ref.)
107861
109687
112878
109530
111888
112879
2
13
108735
300437
103999
103472
103978
111812
111817
111815
111818
111821
103845
103404
103996
100702
104183
102975
106893
100297
103896
100493
310014
300437
103999
103472
103543
103856
104000
104127
14
15
16
17
18
108773
112882
103024
310032
310031
3
4
5
6
7
8
9
10
12
SJM Series 107979-8
Units
per
Assy.
Description
MAIN PLATFORM & HINGED RAILINGS - Model 3015
MAIN PLATFORM & HINGED RAILINGS - Model 3219
• WELDMENT, Main platform, A
(Machines with manual extension platform)
• WELDMENT, Main platform, A
(Machines with powered extension platform)
• WELDMENT, Main platform, A
(Machines with scissor guard option)
• WELDMENT, Main platform, B
(Machines with manual extension platform)
• WELDMENT, Main platform, B
(machines with powered extension platform)
• WELDMENT, Main platform, B
(Machines with scissor guard option)
• COVER, Cable protection (Replaces 104634)
• • BOLT, Hex-hd 3/8-16 x 7/8" lg.
• • WASHER, Lock 3/8"
• • WASHER, Flat 3/8"
• • NUT, 3/8-16
• RAILING, Hinged side top RH
• RAILING, Hinged side bottom RH
• RAILING, Hinged side top LH
• RAILING, Hinged side bottom LH
• RAILING, Entry top
• • BOLT, Hex-hd 5/16-18 x 1/2" lg.
• • WASHER, Lock 5/16"
• • WASHER, Flat 5/16"
• CAP, Tube end
• PAD, Foam 25-1/4"
• STRIPE, Warning
• CHAIN ASSEMBLY, Entry
• • LINK, Attaching
• • CHAIN, 25-1/2" lg.
• • LATCH, Chain snap
• BRACKET, Scissor mount (Replaces 107971,109478 and 109477)
• • BOLT, Hex-hd 3/8-16 x 7/8" lg.
• • WASHER, Lock 3/8"
• • WASHER, Flat 3/8"
• PAD, Platform slide
• • BOLT, Hex-hd 1/4-20 x 3/4" lg.
• • WASHER, Lock 1/4"
• COVER, Cable protection
(Model 3015 with Serial Number 18538 and Below)
(Model 3219 with Serial Number 220623 and Below)
• ANGLE, Platform slider 22" lg.
• LOCATOR, Scissor guard
• CLIP, Control cable #G8
• GUARD, Cable LH (option)
• GUARD, Cable RH
(3015 with serial number 18539 and above)
(3219 with serial number 220624 and above)
Final Revision 2-1-98
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
1
2
2
2
2
1
AR
1
1
1
1
1
6
6
6
2
4
4
1
1
2
1
1
1
SECTION 6, Page 7
FIGURE 6-3. 3 FT. MANUAL EXTENSION PLATFORM
10
9
3
12
8
13
4
11
3
2
6
6
7
5
1
5
MA-SJM-02C
SECTION 6, Page 8
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-3. 3 FT. MANUAL EXTENSION PLATFORM
Index
No.
Skyjack
Part No.
A
107749
B
111318
C
113158
D
113159
1
107866
112564
106521
110744
104625
103978
107450
113209
107451
112610
103550
103865
103984
100509
103554
103952
103796
103885
103984
106950
105807
104607
100702
2
3
4
5
6
7
8
9
Description
3 FT. EXTENSION PLATFORM - Model 3015
(Standard machines)
3 FT. EXTENSION PLATFORM - Model 3219
(Standard machines)
3 FT. EXTENSION PLATFORM - Model 3015
(Machines with scissor guard option)
3 FT. EXTENSION PLATFORM - Model 3219
(Machines with scissor guard option)
• WELDMENT, Extension platform, A, B
• WELDMENT, Extension platform, C, D
• RAILING, Extension platform front, A, C
• RAILING, Extension platform front, B, D
• • SCREW, Set 3/8-16 x 5/8" lg.
• • NUT, Hex 3/8-16
• CHANNEL ASSEMBLY, Side handrail, A, B
• CHANNEL ASSEMBLY, Side handrail, C, D
• • CHANNEL, Side handrail, A, B
• • CHANNEL, Side handrail, C, D
• • PAD, Wear
• • BOLT, Hex-hd 5/16-18 x 2" lg.
• • NUT, Lock 5/16-18
• PIN, Locking
• PAD, Rear slide
• • BOLT, Flat-hd 3/8-16 x 1" lg.
• PIPE, Midrail
• • BOLT, Hex-hd 5/16-18 x 1-3/4" lg.
• • NUT, Lock 5/16-18
• PLATE, Railing retainer
• CABLE, Lanyard 6" lg.
• • SCREW, Self-tap #6-1/4” lg.
• CAP, Tube end
Units
per
Assy.
1
1
1
1
4
4
2
2
2
2
6
4
4
2
2
4
2
2
2
2
2
1
2
Items 10 thru 13 are for machines with optional
hinged railings.
10
11
12
13
111826
111825
105807
100509
SJM Series 107979-8
RAILING, Extension platform hinged upper
RAILING, Extension platform hinged lower
CABLE, Lanyard 6” lg.
PIN, Locking
Final Revision 2-1-98
1
1
2
2
SECTION 6, Page 9
FIGURE 6-4. 3 FT. POWERED EXTENSION PLATFORM
19
15
8 21
7 22
14
20
11
2
6
13
13
9
18
16
1
17
3
4
3
10
12
5
MA-SJM-25B
SECTION 6, Page 10
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-4. 3 FT. POWERED EXTENSION PLATFORM
Index
No.
Skyjack
Part No.
1
2
3
113315
106521
110744
104625
103978
113425
4
101297
104606
114825
Description
Units
per
Assy.
14
107450
103550
103865
103984
103424
100759
103796
103885
103984
(Ref.)
15
16
17
18
100702
113304
113305
106450
WELDMENT, Extension platform (Replaces 109689)
1
RAILING, Extension platform front (Model 3015)
1
RAILING, Extension platform front (Model 3219)
1
• SCREW, Set 3/8-16 x 5/8" lg.
4
• NUT, Hex 3/8-16
4
CYLINDER ASSEMBLY, Powered extension platform (For components,
1
refer to Figure 6-5.)(Replaces 108727 by ordering (1), 106450 and (1),
End, 103420)
• BOLT, Hex-hd 3/8-16 x 1-1/4" lg.
2
• NUT, Lock 3/8-16
2
SWITCH ASSEMBLY, Powered platform limit
1
(Replaces 109706 by also ordering (1) Connector 107711)
• SWITCH, Limit
1
• HEAD, Limit switch
1
• ARM, Limit switch
1
• CORD, 18/2
220”
• PLUG ASSEMBLY, 5 Pin male
1
(Replaces 4 pole round connector by also ordering
(1) Connector, 107711)
VALVE & MANIFOLD ASSEMBLY (Refer to Figure 6-6.)
1
PLATE, Control box mounting (Replaces 105538)
1
PIN, Locking
2
CABLE, Lanyard 6" lg.
2
PLATE, Railing retainer
2
CORD ASSEMBLY, Valve manifold
1
(Replaces 109715 by also ordering (1) Connector 107711)
• CORD, 18/3 x 100" lg.
1
• PLUG ASSEMBLY, 5 Pin male
1
(Replaces 4 pole round connector by also ordering
(1) Connector, 107711)
CHANNEL ASSEMBLY, Side handrail
2
• PLUG, Handrail slide
6
• BOLT, Hex-hd 5/16-18 x 2" lg.
4
• NUT, Lock 5/16-18
4
PIN, Cylinder mounting (Early models)
1
• RING, Retaining
2
PIPE, Midrail
2
• BOLT, Hex-hd 5/16-18 x 1-3/4" lg.
2
• NUT, Lock 5/16-18
2
CONTROL BOX ASSEMBLY, Powered ext. platform
1
(For components, refer to Figure 6-7.)
CAP, Tube end
2
WASHER, Flat 3/4" x 2"
2
ISOLATOR, Cylinder rod
2
NUT, Jam 3/4-16
2
111826
111825
105807
100509
Items 18 thru 21 are for machines with optional
hinged railings.
RAILING, Extension platform hinged upper
RAILING, Extension platform hinged lower
CABLE, Lanyard 6” lg.
PIN, Locking
102668
102882
103142
103256
107712
5
6
7
8
9
10
(Ref.)
310009
100509
105807
106950
114826
103257
107712
11
12
13
19
20
21
22
SJM Series 107979-8
Final Revision 2-1-98
1
1
2
2
SECTION 6, Page 11
FIGURE 6-5. POWERED EXTENSION PLATFORM CYLINDER ASSEMBLY
13
12
9
10
2
7
1
11
6
3
14
5
8
4
MA-SJII-29A
Index
No.
Skyjack
Part No.
A
B
1
2
*3
*4
*5
*6
*7
8
*9
10
11
12
13
14
113425
$
106470
108723
103829
103825
106452
106449
108798
103822
103828
106469
114344
103420
106450
103830
107396
Units
per
Assy.
Description
CYLINDER ASSEMBLY, Powered extension platform
CYLINDER ASSEMBLY, Powered extension platform (108727)
• WELDMENT, Cylinder barrel
• GLAND, Cylinder end
• O-RING, Piston
• SEAL, Piston
• RING, Piston wear
• WIPER, Rod
• SEAL, Rod
• SPACER, Stroke limit (w/piston, 106457)
• O-RING, Gland
• ROD, Piston
• PISTON (Replaces 106457, 103822)
• END, Cylinder rod
• NUT, Jam 3/4-16, B
• NUT, Lock 5/8-11, B
KIT, Seal repair
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AR
* Part of Seal Repair Kit, 107396.
$ Order replacement cylinder plus (1) SPHERICAL
BEARING END, 103420 and (1) NUT, 106450
SECTION 6, Page 12
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-6.
HYDRAULIC HOSE CONNECTIONS - Powered Extension Platform
6
1
7
8
5
4
3
2
4
9
MA-SJM-26
Index
No.
Skyjack
Part No.
1
113425
2
3
107382
103614
107439
104409
104345
103073
103069
110062
110061
110063
4
5
6
7
8
310174
9
110064
310173
SJM Series 107979-8
Description
CYLINDER ASSEMBLY, Powered extension platform
(For components, refer to Figure 6-5.)
BLOCK, Valve manifold
VALVE ASSEMBLY, 24 Volt spool
• COIL, 24 Volt spool valve
• CONNECTOR, Black
• CONNECTOR, Gray
FITTING, Elbow 90° #6orb-#6
FITTING, Connector #6orb-#6
HOSE ASSEMBLY, Cylinder retract 49" lg.
HOSE ASSEMBLY, Cylinder extend 10-1/2" lg.
HOSE ASSEMBLY, Valve return 235" lg.
(Model 3015)
HOSE ASSEMBLY, Valve return 293“ lg.
(Model 3219)
HOSE ASSEMBLY, Valve supply 255" lg.
(Model 3015)
HOSE ASSEMBLY, Valve supply 301“ lg.
(Model 3219)
Final Revision 2-1-98
Units
per
Assy.
1
1
1
2
1
1
5
1
1
1
1
1
1
1
SECTION 6, Page 13
FIGURE 6-7.
POWERED EXTENSION PLATFORM CONTROL BOX ASSEMBLY
7
6
5
8
12
5
9
11
1
6
2
7
3
10
3
4
MA-SJII-31D
SECTION 6, Page 14
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-7.
Index
No.
Skyjack
Part No.
A
(Ref.)
B
(Ref.)
1
2
3
4
115539
103041
106401
107712
5
6
7
8
9
10
11
108328
102853
111181
115594
103035
106399
(Ref.)
102837
103100
103141
114377
12
SJM Series 107979-8
POWERED EXTENSION PLATFORM CONTROL BOX ASSEMBLY
Description
BOX ASSEMBLY, Powered ext. platform control
(Later models with toggle switch controls)
BOX ASSEMBLY, Powered ext. platform control
(Early models with rotary switch controls)
• BOX, Control, A
• STRAIN RELIEF, Straight 1/2" , A
• CORD, Coiled 18/3
• CONNECTOR ASSEMBLY, 5 Pole male
(Replaces round connector by also ordering (1)
Connector, 107711)
• LABEL, Platform extend/retract
• SWITCH, Toggle, A
• GUARD, Toggle switch, A
• LABEL, Enable, A
• STRAIN RELIEF, Elbow 90° 1/2", B
• BOX, Control, B
• SWITCH ASSEMBLY, Platform extend/retract, B
• • HEAD, Selector switch
• • BASE, Contact
• • BLOCK, N.O. Contact
• PLUG, Hole 1/2”, A
Final Revision 2-1-98
Units
per
Assy.
1
1
1
1
1
2
2
1
1
1
1
1
1
1
SECTION 6, Page 15
FIGURE 6-8. GATE OPTIONS
2
9
8
5
6
4
3
7
1
12
10
11
MA-SJM-20C
SECTION 6, Page 16
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-8. GATE OPTIONS
Index
No.
Skyjack
Part No.
A
(Ref.)
B
(Ref.)
C
(Ref.)
D
(Ref.)
E
(Ref.)
1
117278
109401
117280
111239
2
3
4
5
6
7
105306
103632
105307
105309
105312
103107
117277
109388
100596
8
9
10
100702
300792
117279
109404
117286
110746
11
12
113661
113662
SJM Series 107979-8
Units
per
Assy.
Description
GATE ASSEMBLY - Half (Model 3015)
(Consists of items 1 thru 9)
GATE ASSEMBLY - Half (Model 3219)
(Consists of items 1 thru 9)
GATE ASSEMBLY - Rigid full (Model 3015)
(Consists of items 2 thru 10)
GATE ASSEMBLY - Rigid full (Model 3219)
(Consists of items 2 thru 10)
GATE ASSEMBLY - Hinged full (All models)
(Consists of items 2 thru 9, 11 and 12)
• WELDMENT, Half gate, A
(Serial number 18713 and above)
• WELDMENT, Half gate, A
(Serial number 18712 and below)(Replaces 107868 by also
ordering (2) hinges, 109388)
• WELDMENT, half gate, B
(Serial number 220805 and above)
• WELDMENT, Half gate, B
(Serial number 220804 and below)
• STOP, Latch
• • BOLT, Self-tap 1/4-14 x 7
• PLATE, Latch release
• PIN, 5/8" x 4-3/16" lg.
• GUIDE, Spring
• SPRING, Compression
• HINGE, Spring return (Stanley 3-1/2” #2060R)
(Model 3015 serial number 18713 and above)
(Model 3219 serial number 220805 and above)
• HINGE, Spring (Stanley Hardware)
(Model 3015 serial number 18712 and below)
(Model 3219 serial number 220804 and below)
(Used with gates 109401, 111239, 109404 and 110746)
• HINGE, Spring (Mallory)
(Used with gates 107868 and 108136)
• CAP, Tube end
• PIN, Cotter 1/8” X 3/32” lg.(Replaces 105310)
• WELDMENT, Full gate, C
(Serial number 18713 and above)
• WELDMENT, Full gate, C
(Serial number 18712 and below)
(Replaces 108136 by also ordering (2) hinges,
109388)
• WELDMENT, Full gate, D
(Serial number 220805 and above)
• WELDMENT, Full gate, D
(Serial number 220804 and below)
WELDMENT, Hinged lower gate, E
WELDMENT, Hinged upper gate, E
Final Revision 2-1-98
-
1
1
1
1
1
1
1
1
1
2
2
2
3
1
1
1
1
1
1
1
SECTION 6, Page 17
FIGURE 6-9. CONTROL BOX ASSEMBLY - Proportional Drive and Lift
3
19
4
11 9
10
1
21
31
18
23
22
15
6
2
5
13 14
8
7
12
24
29
27
26
28
16
30
17
MA-SJM-38
SECTION 6, Page 18
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-9. CONTROL BOX ASSEMBLY - Proportional Drive and Lift
Index
No.
Skyjack
Part No.
A
B
C
D
1
2
400072
310003
310004
310011
108692
108703
108704
104607
115311
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
103957
104185
103240
(Ref.)
102754
104460
103100
103141
105983
108331
(Ref.)
100149
102769
103100
103225
102627
111814
116382
114377
111181
300460
103012
103955
114678
106099
103985
102921
300251
103041
119642
102888
102766
104172
102888
102766
103365
114547
102888
107778
Description
Units
per
Assy.
CONTROL BOX ASSEMBLY, Proportional (ANSI/SIA AND CSA)
CONTROL BOX ASSEMBLY, Proportional (ANSI/SIA AND CSA with horn)
CONTROL BOX ASSEMBLY, Proportional (CE with horn)
CONTROL BOX ASSEMBLY, Proportional (EE-Rated)
• WELDMENT, Control box
1
• COVER, Bottom, A, D
1
• COVER, Bottom, B, C
1
• • SCREW, Set #6-32 x 1/2” lg.
9
• CONTROLLER ASSEMBLY, Proportional drive/lift
1
(For components, refer to Figure 6-11.)
• • SCREW, #8-32 x 1/2” lg.
4
• • WASHER, Lock #10
4
• INDICATOR, Battery charge
1
• SWITCH ASSEMBLY, Key off/on
1
• • HEAD, 2-Position key switch
1
• • • KEY, #455
AR
• • BASE, Contact
1
• • BLOCK, N.O. Contact
1
• LABEL, Power off/on, A, B, D
1
• LABEL, Power off/on, C
1
• SWITCH ASSEMBLY, Emergency stop
1
• • WASHER, Switch
1
• • HEAD, Stop switch
1
• • BASE, Contact
1
• • BLOCK, N.C. Contact
1
• LABEL, Emergency stop, A, B, D
1
• LABEL, Emergency stop, C
1
• SWITCH, Lift/off/drive toggle
1
• PLUG, Hole 7/8"
1
• GUARD, Toggle switch
1
• PLUG, Hole 7/8" (Replaces 102956)
AR
• BLOCK, Terminal
AR
• • SCREW, #6-32 x 3/4” lg.
1
• • SCREW, #6-32 x 1/2” lg.
1
• • WASHER, Lock #6
2
• • NUT, #6-32
2
• DIODE, 6 Amp 1000PIV
2
1
• STRAIN RELIEF, Cable, A, B, C
1
• STRAIN RELIEF, Cable, D
• CABLE ASSEMBLY, Control box, A
1
• • CABLE, 16/10
27"
• • PLUG, 10 Pole male
1
• CABLE ASSEMBLY, Control box, A, B
1
• • CABLE, 16/10
1
• • PLUG, 10 Pin cable
1
• • CONNECTOR, Control box 1/2”
1
• CABLE ASSEMBLY, Control box, C, D
1
• • CABLE, 16/10
27"
• • CONNECTOR ASSEMBLY, 10 Pole male
1
NOTE: Parts list continued on Page 21.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 19
FIGURE 6-9. CONTROL BOX ASSEMBLY - Proportional Drive and Lift (continued)
Index
No.
Description
Skyjack
Part No.
Units
per
Assy.
NOTE: Parts list continued from Page 19.
18
19
20
21
22
23
24
25
106704
115326
115327
102599
108333
(Ref.)
102851
103100
103141
102467
105352
102860
103962
104185
104003
103628
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
LABEL, Operator warning
LABEL, Operating instructions
LABEL, Controller lift/drive
LABEL, Lift/off/drive, A, B, D
LABEL, Lift/off/drive, C
SWITCH ASSEMBLY, Horn push-button, B, C
• HEAD, Push-button switch
• BASE, Contact
• BLOCK, N.O. Contact
LABEL, Horn, B
LABEL, Horn, C
HORN, 24 Volt operator, B, C
• BOLT, #10-32 x 1/2” lg.
• WASHER, Lock #10
• NUT, Machine #10-32
SEAL, Rubber 44” lg., D
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
Items 25 thru 27 are machines with Powered
Extension Platform Option.
26
27
28
28
29
30
(Ref.)
103257
107711
(Ref.)
103257
107711
(Ref.)
103256
107711
106337
104170
102888
102888
102518
102766
114553
114552
102888
102888
107778
107777
113451
SJM Series 107979-8
CORD ASSEMBLY, Powered platform control box
• CORD, 18/3 x 27" lg.
• CONNECTOR ASSEMBLY, 5 Pole female
CORD ASSEMBLY, Valve manifold
• CORD, 18/3 x 27” lg.
• CONNECTOR ASSEMBLY, 5 Pole female
CORD ASSEMBLY, Limit switch
• CORD, 18/2 x 27” lg.
• CONNECTOR ASSEMBLY, 5 Pole female
• CABLE ASSEMBLY, Scissors, A, B (Model 3015)
• CABLE ASSEMBLY, Scissors, A, B(Model 3219)
• • CABLE, 16/10 x 288” lg. (Model 3015)
• • CABLE, 16/10 x 372” lg. (Model 3219)
• • SOCKET, 10 pin female
• • PLUG, 10 pin male
• CABLE ASSEMBLY, Scissors, C, D (Model 3015)
• CABLE ASSEMBLY, Scissors, C, D (Model 3219)
• • CABLE, 16/10 x 288” lg. (Model 3015)
• • CABLE, 16/10 x 372” lg. (Model 3219)
• • CONNECTOR, 10 pole male
• • CONNECTOR, 10 pole female
• STRIP, Terminal mount
Final Revision 2-1-98
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 6, Page 21
FIGURE 6-10. CONTROL BOX ASSEMBLY - 2 Speed Drive
3
1
10
18
8
19
2
4
11
24
6
22
26
5 15
12
7
21
16
9
17
23
13
28
20
25
27
29
14
MA-SJII-43B
SECTION 6, Page 22
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-10. CONTROL BOX ASSEMBLY - 2 Speed Drive
Index
No.
Skyjack
Part No.
A
B
C
D
1
2
104491
106109
114557
114558
108692
108703
108704
104607
103334
3
4
5
6
7
8
9
10
11
12
13
14
103957
103240
102752
104325
102599
108333
(Ref.)
100149
102769
103100
103225
(Ref.)
102837
103100
103141
102627
105351
102657
108328
106704
103012
103955
103985
104172
102888
102766
103365
114547
102888
107778
15
16
17
102921
(Ref.)
108854
103100
103141
108855
Units
per
Assy.
Description
CONTROL BOX ASSEMBLY - ANSI/SIA AND CSA
CONTROL BOX ASSEMBLY - ANSI/SIA AND CSA With Horn
CONTROL BOX ASSEMBLY - CE With Horn
CONTROL BOX ASSEMBLY - EE-Rated
• WELDMENT, Control box (Replaces 100886)
• COVER, Bottom, A, D (Replaces 100148)
• COVER, Bottom, B, C (Replaces 100621)
• • SCREW, Self-tapping #8-32 x 1/2" lg.
• CONTROLLER ASSEMBLY, 2 Speed drive
(For components, refer to Figure 6-12.)
• • SCREW, Machine #8-32 x 1/2" lg.
• INDICATOR, Battery charge
• SWITCH, Key select
• • KEY, Select switch
• LABEL, Lift/off/drive, A, B, D
• LABEL, Lift/off/drive, C
• SWITCH ASSEMBLY, Emergency stop
• • WASHER, Flat
• • HEAD, Stop switch
• • BASE, Contact
• • BLOCK, N.C. Contact
• SWITCH ASSEMBLY, Up/down selector
• • HEAD, Selector switch
• • BASE, Contact
• • BLOCK, N.O. Contact
• LABEL, Emergency stop, A, B, D
• LABEL, Emergency stop, C
• LABEL, Up/off/down, A, B, D
• LABEL, Up/off/down, C
• LABEL, Operator warning
• BLOCK, Terminal
• • SCREW, Machine #6-32 x 3/4" lg.
• • NUT, Machine #6-32
• CABLE ASSEMBLY, Control box, A, B
• • CABLE, 16/10 x 27" lg.
• • PLUG, 10 Pin cable
• • CONNECTOR, Control box 1/2"
• CABLE ASSEMBLY, Control box, C, D
(Replaces 108071 by ordering (1)
Connector, 107777)
• • CABLE, 16/10 x 27" lg.
• • CONNECTOR ASSEMBLY, 10 Pole male
(Replaces 32 pole round connector by also
ordering (1) Connector, 107777)
• DIODE, 6 Amp
• SWITCH ASSEMBLY, Lift enable push-button
• • HEAD, Push-button head (green)
• • BASE, Contact
• • BLOCK, N.O. Contact
• LABEL, Lift enable
1
1
1
11
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
AR
1
1
1
1
1
NOTE: Parts list continued on Page 25.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 23
FIGURE 6-10. CONTROL BOX ASSEMBLY - 2 Speed Drive (continued)
Index
No.
Skyjack
Part No.
Description
Units
per
Assy.
NOTE: Parts list continued from Page 23.
18
19
20
21
22
23
24
25
(Ref.)
102851
103100
103141
102467
105352
102860
105867
103036
103041
103628
113451
(Ref.)
103257
107711
26
(Ref.)
103257
107711
27
(Ref.)
103257
107711
28
106337
102888
102518
102766
104170
102888
102518
102766
114553
29
102888
114552
102888
SJM Series 107979-8
• SWITCH ASSEMBLY, Horn push-button, B, C
• • HEAD, Push-button switch (black)
• • BASE, Contact
• • BLOCK, N.O. Contact
• LABEL, Horn, B
• LABEL, Horn, C
• HORN, 24 Volt operator
• PLUG, Snap-in, (Replaces 102956)
• STRAIN RELIEF, Connector 1/2" , A, B, C
• STRAIN RELIEF, Connector, 12” lg. D
• SEAL, Rubber 44" lg., D
• STRIP, Terminal mount
CABLE ASSEMBLY, Powered platform control box
• CORD, 18/3 x 27” lg.
• CONNECTOR ASSY., 5 Pole female
(Replaces 108193 by ordering (1) Connector,
107712)
CORD ASSEMBLY, Valve manifold
• CORD, 18/3 x 27” lg.
• CONNECTOR ASSY., 5 Pole female
(Replaces 108193 by ordering (1) Connector,
107712)
CORD ASSEMBLY, Limit switch
• CORD, 18/3 x 27” lg.
• CONNECTOR ASSY., 5 Pole female
(Replaces 108193 by ordering (1) Connector,
107712)
CABLE ASSEMBLY, Scissor arm, A, B (Model 3015)
• CABLE, 16/10 x 288" lg.
• SOCKET, 10 Pin
• PLUG, 10 Pin
CABLE ASSEMBLY, Scissor arm, A, B (Model 3219)
• CABLE, 16/10 x 372" lg.
• SOCKET, 10 Pin
• PLUG, 10 Pin
CABLE ASSEMBLY, Scissor arm, C, D (Model 3015)
(Replaces 109498 by ordering (1)
Connector, 107777)
• CABLE, 16/10 x 288" lg.
CABLE ASSEMBLY, Scissor arm, C, D (Model 3219)
(Replaces 108075 by ordering (1)
Connector, 107777)
• CABLE, 16/10 x 372" lg.
Final Revision 2-1-98
1
1
1
1
1
1
1
AR
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 6, Page 25
FIGURE 6-11. PROPORTIONAL DRIVE/LIFT CONTROLLER ASSEMBLY
1
2
4
3
4
5
15
8
10
6
9
7
13
10
12
16
11
17
Index
No.
Skyjack
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
115311
105735
105734
105733
105738
105737
105736
105378
106729
106730
106725
106726
117150
102768
106731
110982
117151
117152
SECTION 6, Page 26
Description
CONTROLLER ASSEMBLY, Proportional drive/lift
• CAP, Elastic
• ACTUATOR, Rocker
• SWITCH, Directional
• KNOB HALF
• SPRING, Compression
• SLIDE LOCK
• HANDLE EXTENSION
• HOUSING
• SPRING, Handle return
• RATCHET
• BUSHING, Spring
• CIRCUIT BOARD ASSEMBLY
• • SWITCH W/ACTUATOR
• SCREW, Hollow
• GASKET, Housing
• BRACKET, Circuit board support
• SPACER, Circuit board
Final Revision 2-1-98
MA-SJM-43
Units
per
Assy.
1
1
2
2
1
1
1
1
1
1
1
1
2
1
1
1
1
SJM Series 107979-8
FIGURE 6-12. 2 SPEED DRIVE CONTROLLER ASSEMBLY
1
2
4
4
3
5
8
10
6
11
14
15
7
9
13 12
Index
No.
Skyjack
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
103334
105735
105734
105733
105738
105737
105736
105378
106729
106730
106725
106726
106092
102768
106731
110982
SJM Series 107979-8
Description
CONTROLLER ASSEMBLY, 2 Speed drive
• CAP, Elastic
• ACTUATOR, Rocker
• SWITCH, Directional
• KNOB HALF
• SPRING, Compression
• SLIDE LOCK
• HANDLE EXTENSION
• HOUSING
• SPRING, Handle return
• RATCHET
• BUSHING, Spring
• CIRCUIT BOARD ASSEMBLY
• • SWITCH W/ACTUATOR
• SCREW, Hollow
• GASKET, Housing
Final Revision 2-1-98
Units
per
Assy.
1
1
1
2
2
1
1
1
1
1
1
1
1
4
1
SECTION 6, Page 27
FIGURE 6-13. HYDRAULIC HOSE CONNECTIONS - Scissors
Lift
Cylinder
Machines
with
Holding
Valve
Option
1
1
7
10
9
8
5
11
12
2
6
4
3
Main
Manifold
MA-SJM-04C
SECTION 6, Page 28
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-13. HYDRAULIC HOSE CONNECTIONS - Scissors
Index
No.
Skyjack
Part No.
1
106581
110683
2
3
4
5
6
103494
103403
103933
103996
103138
114580
102541
111315
(Ref.)
Description
CYLINDER ASSEMBLY, Lift (Model 3015)
(For components, refer to Figure 6-16.)
CYLINDER ASSEMBLY, Lift (Model 3219)
(For components, refer to Figure 6-17.)
BLOCK, Velocity fuse
• O-RING, Manifold seal
• BOLT, Soc-hd 5/16-18 x 1-3/4" lg.
• WASHER, Flat 5/16"
VALVE, Velocity fuse
FITTING, Elbow 45° #6orb-#6
HOSE ASSEMBLY, Lift cylinder (Model 3015)
HOSE ASSEMBLY, Lift cylinder (Model 3219)
MANIFOLD ASSEMBLY, Main
(Refer to Figure 6-33.)
Units
per
Assy.
1
1
1
1
4
4
1
1
1
1
1
NOTE: Items 7 thru 12 are for machines with
Holding Valve Option.
7
8
9
10
11
12
106689
103405
103404
103403
107269
104493
105281
114580
104437
SJM Series 107979-8
BLOCK, Holding valve
• BOLT, Soc-hd 5/16-18 x 2” lg. grade 8
• WASHER, Lock 5/16”
• O-RING, Manifold seal
VALVE, N.C. (holding)
COIL, 24 Volt
ORIFICE, One-way .067 diameter
FITTING, Elbow 45° #6orb-#6
PLUG, Manifold o-ring #6
Final Revision 2-1-98
1
4
4
1
1
1
1
1
1
SECTION 6, Page 29
FIGURE 6-14.
SCISSOR ARM ASSEMBLY - Model 3015
9
12
3
13
2
16
8
14
15
18
1
16
10
4
6
5
17
11
7
12
MA-SJM-15A
SECTION 6, Page 30
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-14.
Index
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Skyjack
Part No.
106602
119093
119094
114614
119095
(Ref.)
100071
100900
101520
100903
310018
100825
104346
100050
310019
100825
104346
100139
100050
100140
100048
100050
100049
102237
103855
104000
106581
105985
105686
101077
100904
103869
100397
109051
300511
106756
104535
103111
103962
104003
SCISSOR ARM ASSEMBLY - Model 3015
Description
SCISSOR STACK, Complete (less cylinder)
• ARM ASSEMBLY, First level
• ARM ASSEMBLY, Second level
• • WELDMENT, Safety bar
• ARM ASSEMBLY, Third level
• KIT, Center pin service
• • BUSHING, Center pin
• • PIN, Center
• • WASHER, Nylon
• • PIN, Retainer
• PIN, End (Replaces 100046)
• • PIN, Roll 1/4” x 1-1/4” lg.
• • PIN, Cotter 1/4” x 1” lg.
• BUSHING, End pin
PIN, Lower roller (Replaces 100047)
• PIN, Retainer 1/4" x 1-3/16" lg.
• PIN, Cotter 1/4" x 1" lg.
ROLLER ASSEMBLY, Retainer
• BUSHING
• ROLLER
ROLLER ASSEMBLY, Scissors
• BUSHING
• ROLLER
PIN, Top roller
• BOLT, Hex-hd 1/4-20 x 1/2” lg.
• WASHER, Lock 1/4”
CYLINDER ASSEMBLY, Lift
(For components, refer to Figure 6-16.)
BLOCK, Cylinder rod end pivot
• BOLT, Hex-hd 3/4-16 x 3" lg.
BLOCK, Cylinder mounting
• BUSHING
• BOLT, Hex-hd 5/16-18 x 4-1/2" lg.
• NUT, Hex 5/16-18
BUMPER, Scissor
• SCREW, Machine #10-32 x 3/4” lg.
LIGHT ASSEMBLY, Flashing (Option)
• BEACON, Amber
• BULB, 24 Volt
• SCREW, Machine #10-32 x 1/2” lg.
• NUT, Hex #10-32
Units
per
Assy.
1
1
1
1
AR
24
6
6
6
8
8
8
20
2
2
2
2
2
2
4
8
4
2
2
2
1
1
1
4
4
4
4
4
4
1
1
1
2
2
NOTE: For hydraulic hose connections,
refer to Figure 6-13.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 31
FIGURE 6-15. SCISSOR ARM ASSEMBLY - Model 3219
10
13
14
4
3
16
15
2
9
17
19
1
11
5
7
6
12
18
13
8
MA-SJM-32A
SECTION 6, Page 32
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-15. SCISSOR ARM ASSEMBLY - Model 3219
Index
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Skyjack
Part No.
109928
119089
119090
114614
119091
119092
(Ref.)
100071
100900
101520
100903
310018
100825
104346
100050
310019
100825
104346
100139
100050
100140
100048
100050
100049
102237
103855
104000
110683
105985
105686
101077
100904
103869
100397
109051
300511
106756
104535
103111
103962
104003
Description
SCISSOR STACK, Complete (less cylinder)
• ARM ASSEMBLY, First level
• ARM ASSEMBLY, Second level
• • WELDMENT, Safety bar
• ARM ASSEMBLY, Third level
• ARM ASSEMBLY, Fourth level
• KIT, Center pin service
• • BUSHING, Center pin
• • PIN, Center
• • WASHER, Nylon
• • PIN, Retainer
• PIN, End (Replaces 100046)
• • PIN, Roll 1/4” x 1-1/4” lg.
• • PIN, Cotter 1/4” x 1” lg.
• BUSHING, End pin
PIN, Lower roller (Replaces 100047)
• PIN, Retainer 1/4" x 1-3/16" lg.
• PIN, Cotter 1/4" x 1" lg.
ROLLER ASSEMBLY, Retainer
• BUSHING
• ROLLER
ROLLER ASSEMBLY, Scissors
• BUSHING
• ROLLER
PIN, Top roller
• BOLT, Hex-hd 1/4-20 x 1/2” lg.
• WASHER, Lock 1/4”
CYLINDER ASSEMBLY, Lift
(For components, refer to Figure 6-17.)
BLOCK, Cylinder rod end pivot
• BOLT, Hex-hd 3/4-16 x 3" lg.
BLOCK, Cylinder mounting
• BUSHING
• BOLT, Hex-hd 5/16-18 x 4-1/2" lg.
• NUT, Hex 5/16-18
BUMPER, Scissor
• SCREW, Machine #10-32 x 3/4” lg.
LIGHT ASSEMBLY, Flashing (Option)
• BEACON, Amber
• BULB, 24 Volt
• SCREW, Machine #10-32 x 1/2” lg.
• NUT, Hex #10-32
Units
per
Assy.
1
1
1
1
1
AR
32
8
8
8
12
12
12
28
2
2
2
2
2
2
4
8
4
2
2
2
1
1
1
4
4
4
4
4
4
1
1
1
2
2
NOTE: For hydraulic hose connections,
refer to Figure 6-13.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 33
FIGURE 6-16. LIFT CYLINDER ASSEMBLY - Model 3015
4
6
7
9
5
10
3
1
2
8
MA-SJM-38A
Index
No.
Skyjack
Part No.
1
2
3
4
*5
*6
*7
*8
*9
10
106581
106558
$
$
106563
106227
106228
106229
106582
106583
114644
108098
Description
CYLINDER ASSEMBLY, Lift
• WELDMENT, Cylinder barrel
• PISTON (Order 114644)
• ROD, Piston (Order 114644)
• GLAND, Front end
• RING, Rod wear
• SEAL, Rod
• WIPER, Rod
• RING, Piston
• O-RING, Gland
• ROD ASSEMBLY, Piston
KIT, Seal repair
Units
per
Assy.
1
1
1
1
1
1
1
1
1
1
AR
* Part of Seal Repair Kit, 108098.
SECTION 6, Page 34
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-17. LIFT CYLINDER ASSEMBLY - Model 3219
4
9
6
7
5
10
3
1
2
8
MA-SJM-27A
Index
No.
Skyjack
Part No.
1
2
3
4
*5
*6
*7
*8
*9
10
110683
110681
$
$
106209
106219
106222
106221
106220
106223
114646
105888
Description
CYLINDER ASSEMBLY, Lift
• WELDMENT, Cylinder barrel
• PISTON (Order 114646)
• ROD, Piston (Order 114646)
• GLAND, Front end
• RING, Rod wear
• SEAL, Rod
• WIPER, Rod
• RING, Piston wear
• O-RING, Gland
• ROD ASSEMBLY, Piston
KIT, Seal repair
Units
per
Assy.
1
1
1
1
1
1
1
2
1
1
AR
* Part of Seal Repair Kit, 105888.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 35
FIGURE 6-18. BASE, AXLES AND WHEELS - Model 3015
24
27
29
25
1
26
8
28
17
18
15
14
16
19
7
22
23
20
4
2
5
6
4
9
3
21
12
10
11
13
15
14
16
MA-SJM-18B
SECTION 6, Page 36
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-18. BASE, AXLES AND WHEELS - Model 3015
Index
No.
Skyjack
Part No.
1
111686
111685
109590
109591
112552
2
3
4
102600
108714
105983
103817
5
6
103897
103981
104488
105890
7
103940
104000
103980
(Ref.)
8
(Ref.)
9
107503
101297
103999
103978
108101
107502
103003
103143
102865
102829
102749
103085
107914
10
11
12
13
14
108020
15
107913
108022
Description
WELDMENT, Base with single brake
(Serial number 15607 and above)
WELDMENT, Base with dual brakes
(Serial number 15607 and above)
WELDMENT, Base with single brake
(Serial number 15606 and below)
WELDMENT, Base with dual brakes
(Serial number 15606 and below)
WELDMENT, Base with dual brakes
(Machines with Scissor Guard Option)
SWITCH, Main power disconnect
• KIT, Switch lockout
LABEL, Power off/on
CYLINDER ASSEMBLY, Brake
(For components, refer to Figure 6-21.)
• BOLT, Hex-hd 5/8-11 x 2" lg.
• NUT, Hex 5/8-11
WELDMENT, Brake pin LH
WELDMENT, Brake pin RH
(Machines with dual brakes)
• BOLT, Soc-hd 1/4-20 x 1-1/4" lg.
• WASHER, Lock 1/4"
• NUT, Hex 1/4-20
TRAY ASSEMBLY, Battery
(Refer to Figure 6-40.)
TRAY ASSEMBLY, Hydraulic/electric
(Refer to Figure 6-27, 6-28, or 6-29)
WELDMENT, Rear axle spindle
• BOLT, Hex-hd 3/8-16 x 1-1/4" lg.
• WASHER, Lock 3/8"
• NUT, Hex 3/8-16
HUB ASSEMBLY, Rear axle
• HUB, Rear axle
• BEARING, Cone
• SEAL, Grease
• CAP, Dust
WASHER, Flat
NUT, Castle 1"-14
PIN, Cotter 3/16" x 1-1/2" lg.
WHEEL/TIRE ASSEMBLY
(12 x 4.00 x 8 Black)
WHEEL/TIRE ASSEMBLY
(12 x 4.00 x 8 Non-Marking)
WHEEL/TIRE ASSEMBLY W/BRAKE
(12 x 4.00 x 8 Black)
WHEEL/TIRE ASSEMBLY W/BRAKE
(12 x 4.00 x 8 Non-Marking)
Units
per
Assy.
1
1
1
1
1
1
1
1
1
1
1
AR
AR
AR
1
1
2
8
8
8
2
2
2
2
2
2
2
2
AR
AR
AR
AR
NOTE: Parts list continued on Page 39.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 37
FIGURE 6-18. BASE, AXLES AND WHEELS - Model 3015 (continued)
Index
No.
Skyjack
Part No.
Description
Description
Units
per
Assy.
NOTE: Parts list continued from Page 37.
16
17
18
19
20
21
103199
(Ref.)
108542
107745
102848
102881
103142
103256
103036
310034
103887
115420
22
117880
114866
119130
23
109505
24
109536
25
26
27
28
29
102668
103017
103256
108119
102847
103017
103260
103036
310021
101229
310020
100967
SJM Series 107979-8
BOLT, Wheel 1/2-20
STEER MECHANISM (Refer to Figure 6-23.)
TREAD, Safety step
SWITCH ASSEMBLY, High speed limit cut-out
(ANSI/SIA and CSA)
• SWITCH, Limit
• HEAD, Limit switch
• ARM, Limit switch
• CABLE, 18/2 x 16" lg.
• STRAIN RELIEF
PIN, Eccentric tray leveler (Replaces 100446)
• BOLT, Hex-hd 5/16-18 x 3/4" lg.
STRAP, Ground (Replaces 104575)
(EE-Rated machines and machines with
non-marking tires)
TILT SWITCH, 8-28 Volt (replaces 106471)
• FUSE, 1 Amp
• KIT, 4 pole recepticle connector
(Machines with Tilt Switch Option)
PLATE, Tilt switch mounting
(Machines with Tilt Switch Option)
SWITCH ASSEMBLY, End-of-stroke limit
(Machines with End-Of-Stroke Limit Option)
• SWITCH, Limit
• HEAD, Limit switch
• CORD, 18/2
SWITCH ASSEMBLY, High speed limit cut-out (CE)
• SWITCH, Limit
• HEAD, Limit switch
• CORD, 18/5
• STRAIN RELIEF. 1/2”
COVER, Limit switch cam
PLATE, Switch adjustment
PIN, Limit switch cam (Replaces 107973)
CAM, Limit switch
Final Revision 2-1-98
20
1
2
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
30” lg.
1
1
1
38” lg.
1
1
1
1
2
SECTION 6, Page 39
FIGURE 6-19. BASE, AXLES AND WHEELS - Model 3219
24
27
29
25
1
26
8
28
15
14
18
17
16
19
7
22
23
20
4
2
5
6
9
3
4
21
12
10
11
13
15
14
16
MA-SJM-48
SECTION 6, Page 40
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-19. BASE, AXLES AND WHEELS - Model 3219
Index
No.
Skyjack
Part No.
1
111691
111690
112613
2
3
4
102600
108714
105983
103817
5
6
103897
103981
104488
105890
7
103940
104000
103980
(Ref.)
8
(Ref.)
9
107503
101297
103999
103978
108101
107502
103003
103143
102865
102829
102749
103085
107914
10
11
12
13
14
108020
15
107913
108022
16
17
18
103199
(Ref.)
109029
Description
WELDMENT, Base with single brake
WELDMENT, Base with dual brakes
WELDMENT, Base with dual brakes
(Machines with Scissor Guard Option)
SWITCH, Main power disconnect
• KIT, Switch lockout
LABEL, Power off/on
CYLINDER ASSEMBLY, Brake
(For components, refer to Figure 6-21.)
• BOLT, Hex-hd 5/8-11 x 2" lg.
• NUT, Hex 5/8-11
WELDMENT, Brake pin LH
WELDMENT, Brake pin RH
(Machines with dual brakes)
• BOLT, Soc-hd 1/4-20 x 1-1/4" lg.
• WASHER, Lock 1/4"
• NUT, Hex 1/4-20
TRAY ASSEMBLY, Battery
(Refer to Figure 6-40.)
TRAY ASSEMBLY, Hydraulic/electric
(Refer to Figure 6-27, 6-28 or 6-29)
WELDMENT, Rear axle spindle
• BOLT, Hex-hd 3/8-16 x 1-1/4" lg.
• WASHER, Lock 3/8"
• NUT, Hex 3/8-16
HUB ASSEMBLY, Rear axle
• HUB, Rear axle
• BEARING, Cone
• SEAL, Grease
• CAP, Dust
WASHER, Flat
NUT, Castle 1"-14
PIN, Cotter 3/16" x 1-1/2" lg.
WHEEL/TIRE ASSEMBLY
(12 x 4.00 x 8 Black)
WHEEL/TIRE ASSEMBLY
(12 x 4.00 x 8 Non-Marking)
WHEEL/TIRE ASSEMBLY W/BRAKE
(12 x 4.00 x 8 Black)
WHEEL/TIRE ASSEMBLY W/BRAKE
(12 x 4.00 x 8 Non-Marking)
BOLT, Wheel 1/2-20
STEER MECHANISM (Refer to Figure 6-24.)
LADDER
Units
per
Assy.
1
1
1
1
1
1
1
1
1
AR
AR
AR
1
1
2
8
8
8
2
2
2
2
2
2
2
2
AR
AR
AR
AR
20
1
2
NOTE: Parts list continued on Page 43.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 41
FIGURE 6-19. BASE, AXLES AND WHEELS - Model 3219 (continued)
Index
No.
Skyjack
Part No.
Units
per
Assy.
Description
NOTE: Parts list continued from Page 41.
19
21
107745
102848
102881
103142
103256
103036
310034
103887
115420
22
106471
23
109505
24
109536
20
25
26
27
28
29
30
102668
103017
103256
108119
102847
103017
103260
103036
310022
101229
310020
100967
108791
SJM Series 107979-8
SWITCH ASSEMBLY, High speed limit cut-out (ANSI/SIA and CSA)
• SWITCH, Limit
• HEAD, Limit switch
• ARM, Limit switch
• CABLE, 18/2 x 16" lg.
• STRAIN RELIEF
PIN, Eccentric tray leveler (Replaces 100446)
• BOLT, Hex-hd 5/16-18 x 3/4" lg.
STRAP, Ground (Replaces 104575)
(EE-Rated machines and machines with
non-marking tires)
TILT SWITCH, 8-28 Volt
(Machines with Tilt Switch Option)
PLATE, Tilt switch mounting
(Machines with Tilt Switch Option)
SWITCH ASSEMBLY, End-of-stroke limit
(Machines with End-Of-Stroke Limit Option)
• SWITCH, Limit
• HEAD, Limit switch
• CABLE, 18/2 x 30" lg.
SWITCH ASSEMBLY, High speed limit cut-out (CE)
• SWITCH, Limit
• HEAD, Limit switch
• CORD, 18/5
• STRAIN RELIEF. 1/2”
COVER, Limit switch cam
PLATE, Switch adjustment
PIN, Limit switch cam (Replaces 107973)
CAM, Limit switch
CLIP, Cable air hose to platform
Final Revision 2-1-98
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
38” lg.
1
1
1
1
AR
2
SECTION 6, Page 43
FIGURE 6-20. HYDRAULIC HOSE CONNECTIONS - Base (Steer, Drive and Brake Circuits)
Steer
Cylinder
3
12
13
12
6
8
Left
Wheel
Motor
6
14
Front Axle
Manifold
8
2
15
15
TO LOWER
FITTING
TO LOWER
FITTING
5
7
Right
Wheel
Motor
5
TO LOWER
FITTING
9
7
9
Main
Manifold
1
8
11
For Machines With
Dual Parking Brake Option
20
17
10
Parking Brake
Cylinder
19
18
16
4
MA-SJM-03A
SECTION 6, Page 44
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-20. HYDRAULIC HOSE CONNECTIONS - Base (Steer, Drive and Brake Circuits)
Index
No.
Skyjack
Part No.
1
(Ref.)
2
(Ref.)
3
(Ref.)
4
(Ref.)
5
(Ref.)
6
7
8
9
10
11
12
13
14
15
107731
107732
114578
107733
105811
107735
103069
107736
107737
103074
Description
MANIFOLD ASSEMBLY, Main
(Refer to Figures 6-33, 6-34 or 6-35.)
MANIFOLD ASSEMBLY, Front axle
(Refer to Figure 6-25.)
CYLINDER ASSEMBLY, Steer
(Refer to Figure 6-22.)
CYLINDER ASSEMBLY, Brake
(Refer to Figure 6-21.)
MOTOR, Hydraulic drive
(Refer to Figure 6-23 or Figure 6-24.)
HOSE ASSEMBLY, Drive 25" lg. w/long 90° tube)
HOSE ASSEMBLY, Drive 25" lg. w/short 90° tube)
FITTING, Elbow 90° #6-#6 (replaces 103073)
HOSE ASSEMBLY, Main manifold to front axle manifold
ORIFICE, Brake .040 dia.
HOSE ASSEMBLY, Brake
FITTING, Connector #6orb-#6
HOSE ASSEMBLY, Steer LH
HOSE ASSEMBLY, Steer RH
FITTING, Adapter #10orb-#6orb
Units
per
Assy.
1
1
1
1
2
2
2
5
2
1
1
2
1
1
4
The following parts are for machines equipped
with Dual Brake Option:
16
(Ref.)
17
18
19
20
114578
105811
107739
103309
SJM Series 107979-8
CYLINDER ASSEMBLY, Brake
(Refer to Figure 6-21.)
FITTING, Elbow 90° #6-#6 (replaces 103073)
ORIFICE, Brake .040 dia.
HOSE ASSEMBLY, Brake to brake
FITTING, Tee #6orb-#6
Final Revision 2-1-98
1
1
1
1
1
SECTION 6, Page 45
FIGURE 6-21. BRAKE CYLINDER ASSEMBLY
12
10
9
8
7
11
6
5
4
3
1
2
MA-SJM-17
Index
No.
Skyjack
Part No.
1
2
3
*4
5
*6
7
*8
*9
10
*11
12
103817
105410
102844
103830
103825
112259
103829
103822
103828
103826
103819
103827
103821
105816
Description
CYLINDER ASSEMBLY, Brake
• HOUSING, Brake cylinder
• SPRING, Brake return
• NUT, Lock 5/8-11 grade C
• SEAL, Piston
• PISTON (Replaces 103820)
• O-RING, Piston
• SPACER
• O-RING, Gland
• SEAL, Rod
• GLAND, Cylinder end
• WIPER, Rod
• ROD, Brake
KIT, Seal repair
Units
per
Assy.
1
1
1
1
1
1
1
1
1
1
1
1
AR
* Part of Seal Repair Kit, 105816.
SECTION 6, Page 46
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-22. STEER CYLINDER ASSEMBLY
3
10
8
9
2
7
5
6
5
4
6
8
4
7
2
1
MA-SJM-08
Index
No.
Skyjack
Part No.
A
107932
B
1
2
3
$
107943
107942
107939
109550
107143
119127
106450
107144
107146
107934
107935
107936
108099
4
5
*6
*7
*8
*9
*10
Description
CYLINDER ASSEMBLY, Steer
(Model 3015 & Later Model 3219)
CYLINDER ASSEMBLY, Steer (Early Model 3219)
• HOUSING, Steer cylinder
• CAP, Cylinder end
• WELDMENT, Rod/piston, A
• WELDMENT, Rod/piston, B
• END, Male spherical rod
• • FITTING, Grease (press in)
• NUT, Jam 3/4-16
• WIPER, Rod
• SEAL, Rod
• O-RING, End cap
• SEAL, Piston
• RING, Piston wear
KIT, Seal repair
Units
per
Assy.
1
2
1
1
2
2
2
2
2
2
1
1
AR
* Part of Seal Repair Kit, 108099.
$ Not available for service, order (1) Cylinder, 107932
(1) Steer Arm, 111300 and (1) Steer Arm, 111306.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 47
FIGURE 6-23. STEER MECHANISM - Model 3015
1
6
8
12
3
13
4
7
3
15
17
11
5
2
16
6
9
7
8
15
14
14
10
16
17
MA-SJM-19
SECTION 6, Page 48
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-23. STEER MECHANISM - Model 3015
Index
No.
Skyjack
Part No.
1
2
(Ref.)
(Ref.)
13
14
107948
107947
107951
104129
107949
107955
107176
107953
107094
100050
109109
104129
101200
107956
107099
103845
103404
111689
107926
$
111688
107925
$
107952
107963
107964
100071
110701
15
16
17
110702
110703
103901
103470
103471
108100
103789
106451
3
4
5
6
7
8
9
10
11
12
Description
WELDMENT, Base (Refer to Figure 6-18.)
CYLINDER ASSEMBLY, Steer
(For components, refer to Figure 6-22.)
• WASHER, Tooth lock 1"
• NUT, Jam 1"-14
BOLT, Shoulder 1/2-13
• WASHER, Brass 5/8" x 1" x 7/64" thk.
• NUT, Jam 1/2-13
ARM, Steer LH with 3/4" bushings (Note A)
ARM, Steer LH with 5/8" bushings (Note B)
ARM, Steer RH with 3/4" bushings (Note A)
ARM, Steer RH with 5/8" bushings (Note B)
BUSHING, Pivot 3/4"
BUSHING, Pivot 5/8"
WASHER, Bronze 3/4" x 1-3/8" x 1/8" thk.
WASHER, Bronze 5/8" x 1" x 1/8" thk.
PIN, Steer arm 3/4" x 2-11/16" lg.
PIN, Steer arm 5/8" x 2-11/16" lg.
• BOLT, Hex-hd 5/16-18 x 1/2" lg.
• WASHER, Lock 5/16"
HOUSING, Wheel motor LH (Note C)
HOUSING, Wheel motor LH (Note D)
HOUSING, Wheel motor LH (Note X)
HOUSING, Wheel motor RH (Note C)
HOUSING, Wheel motor RH (Note D)
HOUSING, Wheel motor RH (Note Y)
WASHER, Bronze 1-1/4" x 2-1/4" x 1/8" thk.
BOLT, Brass retainer
• WASHER, Tooth lock 1/2"
BUSHING, Steer spindle 1-1/4"
MOTOR, Hydraulic drive (#HB04075370X)
(Replaces 107515, #HB0407030X)
• KIT, Motor seal (For motor, 110701)
• KIT, Motor seal (For motor, 107515)
• BOLT, Hex-hd 1/2-13 x 2-1/2” lg.
• WASHER, Lock 1/2"
• NUT, Hex 1/2-13
HUB, Drive wheel
WASHER, Tooth lock 1"
NUT, Wheel motor
Units
per
Assy.
1
1
2
2
2
2
2
1
1
1
1
2
2
2
2
2
2
2
2
1
1
1
1
1
1
2
2
2
6
2
AR
AR
8
8
8
2
2
2
Note A - Machines with serial number 15200 & above.
Note B - Machines with serial number 15199 & below.
Note C - Machines with serial number 15607 & above.
Note D - Machines with serial number 15200 to 15606.
Note X - Machines with 5/8" bushings, order -1Housing, 107926; -1- Arm, 107955; and -1- Washer,
104129.
Note Y - Machines with 5/8" bushings, order -1Housing, 107925; -1- Arm, 107953; and -1- Washer,
104129.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 49
FIGURE 6-24. STEER MECHANISM - Model 3219
1
3
6
8
12
15
7
13
4
3
17
11
5
2
16
6
7
9
8
15
14
14
10
16
17
MA-SJM-19
SECTION 6, Page 50
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-24. STEER MECHANISM - Model 3219
Index
No.
Skyjack
Part No.
1
2
(Ref.)
(Ref.)
13
14
107948
107947
107951
104129
107949
111300
107955
111306
107953
100050
104129
107956
103845
103404
111689
111688
107952
107963
107964
100071
110701
15
16
17
110702
110703
103901
103470
103471
108100
103789
106451
3
4
5
6
7
8
9
10
11
12
Description
WELDMENT, Base (Refer to Figure 6-19.)
CYLINDER ASSEMBLY, Steer
(For components, refer to Figure 6-22.)
• WASHER, Tooth lock 1"
• NUT, Jam 1"-14
BOLT, Shoulder 1/2-13
• WASHER, Brass 5/8" x 1" x 7/64" thk.
• NUT, Jam 1/2-13
ARM, Steer LH with 3/4" bushings (Note J)
ARM, Steer LH with 3/4" bushings (Note K)
ARM, Steer RH with 3/4" bushings (Note J)
ARM, Steer RH with 3/4" bushings (Note K)
BUSHING, Pivot 3/4"
WASHER, Bronze 3/4" x 1-3/8" x 1/8" thk.
PIN, Steer arm 3/4" x 2-11/16" lg.
• BOLT, Hex-hd 5/16-18 x 1/2" lg.
• WASHER, Lock 5/16"
HOUSING, Wheel motor LH
HOUSING, Wheel motor RH
WASHER, Bronze 1-1/4" x 2-1/4" x 1/8" thk.
BOLT, Brass retainer
• WASHER, Tooth lock 1/2"
BUSHING, Steer spindle 1-1/4"
MOTOR, Hydraulic drive (#HB04075370X)
(Replaces 107515, #HB0407030X)
• KIT, Motor seal (For motor, 110701)
• KIT, Motor seal (For motor, 107515)
• BOLT, Hex-hd 1/2-13 x 2-1/2” lg.
• WASHER, Lock 1/2"
• NUT, Hex 1/2-13
HUB, Drive wheel
WASHER, Tooth lock 1"
NUT, Wheel motor
Units
per
Assy.
1
1
2
2
2
2
2
1
1
1
1
2
2
2
2
2
1
1
2
2
2
6
2
AR
AR
8
8
8
2
2
2
Note J - Machines with 6-1/8” arm hole centers
Note K - Machines with 4-1/8” arm hole centers.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 51
FIGURE 6-25. FRONT AXLE MANIFOLD ASSEMBLY
3
2
5
1
4
MA-SJM-06A
Index
No.
Skyjack
Part No.
108440
1
2
3
4
5
107369
108506
103069
103073
103136
103354
SECTION 6, Page 52
Description
MANIFOLD ASSEMBLY, Front axle
(Replaces 107747)
• BLOCK, Manifold
• • PLUG, Expander
• FITTING, Connector #6orb-#6
• FITTING, Elbow 90° #6orb-#6
• VALVE, Free-wheeling
• VALVE, Flow divider/combiner
Final Revision 2-1-98
Units
per
Assy.
1
3
2
4
1
1
SJM Series 107979-8
FIGURE 6-26. PROPORTIONAL VALVE MANIFOLD ASSEMBLY
6
3
2
7
5
6
1
4
MA-SJM-41
Index
No.
Skyjack
Part No.
115308
1
2
3
4
5
6
7
115349
115350
115370
115381
115320
102665
103070
SJM Series 107979-8
Description
MANIFOLD ASSEMBLY, Proportional valve
(Consists of items 1 thru 5)
• BLOCK, Proportional manifold
• VALVE, Proportional
• COIL, 24 Volt (proportional valve)
• VALVE, Pressure compensator
• PLUG, Soc-hd #8orb
FITTING, Elbow 90° #8orb-#6
FITTING, Connector #8orb-#8
Final Revision 2-1-98
Units
per
Assy.
1
1
1
1
1
1
2
1
SECTION 6, Page 53
FIGURE 6-27. HYDRAULIC/ELECTRIC TRAY ASSEMBLY
Proportional Drive and Lift
9
7
10
11
17
5
6
15
14
8
23
24
13
2
12
16
2
1
18
19
20
22
21
3
4
MA-SJM-44
SECTION 6, Page 54
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-27. HYDRAULIC/ELECTRIC TRAY ASSEMBLY
Proportional Drive and Lift
Index
No.
Skyjack
Part No.
1
2
3
106613
100335
(Ref.)
103873
103999
109393
102781
103864
111534
103857
104000
103980
109270
103962
109568
103864
103404
100397
104254
103137
4
5
6
7
8
9
107493
10
11
12
103136
107271
102693
103962
310010
117140
106576
$
107485
107486
108948
109216
107081
109174
109175
103864
103996
104637
100397
Description
WELDMENT, Hydraulic/electric tray
BUSHING, Bronze
MANIFOLD ASSEMBLY, Main (Refer to Figure 6-33)
• BOLT, Hex-hd 3/8-16 x 2-1/2" lg.
• WASHER, Lock 3/8"
SPACER, Manifold
LATCH, Hydraulic/electric tray
• BOLT, Hex-hd 5/16-18 x 1" lg.
KNOB, Rotary latch
BOLT, Hex-hd 1/4-20
WASHER, Flat 1/4
NUT, 1/4-20
WELDMENT, Tank cover
• SCREW, Machine #10-32 x 1/2" lg.
FILTER ASSEMBLY, Return (#12orb thread)
• BOLT, Hex-hd 5/16-18 x 1" lg.
• WASHER, Lock 5/16"
• NUT, Hex 5/16-18
• ELEMENT, Filter
MANIFOLD, Lowering valve
(Machines with rotary-type lowering valve)
MANIFOLD, Lowering valve
(Machines with pull-type lowering valve)
VALVE, Lowering (rotary-type)(velocity fuse)
VALVE, Lowering (pull-type)(holding valve)
CAP W/GASKET, Filler/breather
• SCREW, Machine #10-32 x 1/2" lg.
PUMP & 4 Hp MOTOR ASSEMBLY (Standard machines)
(Model 3015 with Serial Number 18539 and above)
(Model 3219 with Serial Number 220599 and above)
• PUMP, Hydraulic
• MOTOR, 4 Hp, 24VDC
PUMP & 1 Hp MOTOR ASSEMBLY (order 310010)
• PUMP, Hydraulic
• MOTOR, 1 Hp, 24VDC
PUMP & MOTOR ASSEMBLY (EE-Rated machines)
• PUMP, Hydraulic
• MOTOR, 24VDC
• BRUSHES (Set of 8)
• SPRING
• BOLT, Hex-hd 5/16-18 x 1" lg.
• WASHER, Flat 5/16"
• WASHER, Lock 5/16"
• NUT, Hex 5/16-18
Units
per
Assy.
1
2
1
1
1
1
3
1
1
1
1
1
10
1
2
2
2
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
8
4
4
4
4
NOTE: Parts list continued on Page 57.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 55
FIGURE 6-27. HYDRAULIC/ELECTRIC TRAY ASSEMBLY
Proportional Drive and Lift (continued)
Index
No.
Skyjack
Part No.
Description
Units
per
Assy.
NOTE: Parts list continued from Page 55.
13
14
15
16
17
103236
102918
103320
103339
(Ref.)
18
103855
104000
(Ref.)
19
20
21
22
23
24
103090
310024
103073
103999
103978
115308
103872
103999
103978
110998
112447
103940
103995
104000
103980
110007
GAUGE, Oil level/temp
HOSE, Tank 1"
CLAMP, Worm #16
FITTING, Drain plug (magnetic)
PANEL ASSEMBLY, Electrical
(For components, refer to Figure 6-35.)
• BOLT, Hex-hd 1/4-20 x 1/2" lg.
• WASHER, Lock 1/4"
MANIFOLD ASSEMBLY, Cushion valve
• (For components, refer to Figure 6-33.)
COVER, Edge 15" lg.
BRACKET, Proportional valve manifold
• BOLT, hex-hd 3/8-16 x 1” lg.
• WASHER, Lock 3/8”
• NUT, Hex 3/8-16
MANIFOLD ASSEMBLY, Proportional valve
(For components, refer to Figure 6-23.)
• BOLT, Hex-hd 3/8-16 x 2-1/4” lg.
• WASHER, Lock 3/8”
• NUT, Hex 3/8-16
RESISTOR ASSEMBLY, Battery protection (option)
• BUMPER
• • BOLT, Soc-hd 1/4-20 x 1-1/4” lg.
• • WASHER, Flat 1/4
• • WASHER, Lock 1/4
• • NUT, 1/4-20
PROTECTOR, Edge
1
1
1
1
1
4
4
1
1
1
2
2
2
1
2
2
2
1
1
1
1
1
1
AR
NOTE: For hydraulic hose connections, refer to
Figure 6-30.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 57
FIGURE 6-28. HYDRAULIC/ELECTRIC TRAY ASSEMBLY
2-Speed Drive With Hi-Torque Package
10
9
11
7
17
5
6
8 14 15
16
13
12
2
19
18
1
23
20
22
23
21
28
24
3
25
4
24
26
25
27
MA-SJM-22C
SECTION 6, Page 58
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-28. HYDRAULIC/ELECTRIC TRAY ASSEMBLY
2-Speed Drive With Hi-Torque Package
Index
No.
Skyjack
Part No.
1
2
3
106613
100335
(Ref.)
103873
103999
109393
102781
103864
111534
109270
103962
109568
103864
103404
100397
104254
103137
4
5
6
7
8
9
107493
10
11
12
103136
107271
102693
103962
310010
117140
106576
$
107485
107486
108948
109216
107081
109174
109175
103864
103996
103404
100397
Description
WELDMENT, Hydraulic/electric tray
BUSHING, Bronze
MANIFOLD ASSEMBLY, Main (Refer to Figure 6-34.)
• BOLT, Hex-hd 3/8-16 x 2-1/2" lg.
• WASHER, Lock 3/8"
SPACER, Manifold
LATCH, Hydraulic/electric tray
• BOLT, Hex-hd 5/16-18 x 1" lg.
KNOB, Rotary latch
WELDMENT, Tank cover
• SCREW, Machine #10-32 x 1/2" lg.
FILTER ASSEMBLY, Return (#12orb thread)
• BOLT, Hex-hd 5/16-18 x 1" lg.
• WASHER, Lock 5/16"
• NUT, Hex 5/16-18
• ELEMENT, Filter
MANIFOLD, Lowering valve
(Machines with rotary-type lowering valve)
MANIFOLD, Lowering valve
(Machines with pull-type lowering valve)
VALVE, Lowering (rotary-type)(velocity fuse)
VALVE, Lowering (pull-type)(holding valve)
CAP W/GASKET, Filler/breather
• SCREW, Machine #10-32 x 1/2" lg.
PUMP & 4 Hp MOTOR ASSEMBLY (Std. machines)
(Model 3015 with Serial Number 18539 and above)
(Model 3219 with Serial Number 220599 and above)
• PUMP, Hydraulic
• MOTOR, 4 Hp, 24VDC
PUMP & 1 Hp MOTOR ASSEMBLY (order 310010)
• PUMP, Hydraulic
• MOTOR, 1 Hp, 24VDC
PUMP & MOTOR ASSEMBLY (EE-Rated machines)
• PUMP, Hydraulic
• MOTOR, 24VDC
• BRUSHES (Set of 8)
• SPRING
• BOLT, Hex-hd 5/16-18 x 1" lg.
• WASHER, Flat 5/16"
• WASHER, Lock 5/16"
• NUT, Hex 5/16-18
Units
per
Assy.
1
2
1
1
1
1
3
1
1
10
1
2
2
2
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
8
4
4
4
4
NOTE: Parts list continued on Page 61.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 59
FIGURE 6-28. HYDRAULIC/ELECTRIC TRAY ASSEMBLY
2-Speed Drive With Hi-Torque Package (cont.)
Index
No.
Skyjack
Part No.
Units
per
Assy.
Description
NOTE: Parts list continued from Page 59.
13
14
15
16
17
103236
102918
103320
103339
(Ref.)
18
103855
104000
(Ref.)
19
20
21
22
23
24
25
26
27
28
103090
400088
103473
103999
103978
104132
103623
103605
103073
103069
400085
103872
103999
103978
400087
110998
GAUGE, Oil level/temp
HOSE, Tank 1"
CLAMP, Worm #16
FITTING, Drain plug (magnetic)
PANEL ASSEMBLY, Electrical
(For components, refer to Figure 6-36, 6-37, 6-38, 6-39 or 6-40.)
• BOLT, Hex-hd 1/4-20 x 1/2" lg.
• WASHER, Lock 1/4"
MANIFOLD ASSEMBLY, Cushion valve
(For components, refer to Figure 6-34.)
COVER, Edge 15" lg.
BRACKET, High torque manifold
• BOLT, Hex-hd 3/8-16 x 1” lg.
• WASHER, Lock 3/8”
• NUT, Hex 3/8-16
VALVE, N.C. (speed control)
VALVE, 3-Way (brake)
COIL, 24 Volt
FITTING, Elbow 90° #6orb-#6
FITTING, Connector #6orb-#6
MANIFOLD, Torque/speed control
• BOLT, Hex-hd 3/8-16 x 2-1/4” lg.
• WASHER, Lock 3/8”
• NUT, Hex 3/8-16
FLOW CONTROL, Fixed 0.8 gpm
RESISTOR ASSEMBLY, Battery protection (option)
1
1
1
1
1
4
4
1
1
1
2
2
2
1
1
2
2
2
1
2
2
2
1
1
NOTE: For hydraulic hose connections, refer to
Figure 6-31.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 61
FIGURE 6-29. HYDRAULIC/ELECTRIC TRAY ASSEMBLY - 2-Speed Drive
9
10
11
7
17
5
6
8 14 15
16
13
12
2
19
1
18
3
4
MA-SJM-22D
SECTION 6, Page 62
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-29. HYDRAULIC/ELECTRIC TRAY ASSEMBLY - 2-Speed Drive
Index
No.
Skyjack
Part No.
1
2
3
6
7
106613
100335
(Ref.)
103873
103999
109393
102781
103886
103984
111534
109270
8
103962
109568
4
5
102877
9
103864
103404
100397
104254
103137
107493
10
11
12
103136
107271
102693
103962
310010
117140
106576
$
107485
107486
108948
109216
107081
109174
109175
103864
103996
103404
100397
Description
WELDMENT, Hydraulic/electric tray
BUSHING, Bronze
MANIFOLD ASSEMBLY, Main (Refer to Figure 6-35.)
• BOLT, Hex-hd 3/8-16 x 2-1/2" lg.
• WASHER, Lock 3/8"
SPACER, Manifold
LATCH, Hydraulic/electric tray
• BOLT, Hex-hd 5/16-18 x 1-1/2" lg.
• NUT, Lock 5/16-18
KNOB, Rotary latch
WELDMENT, Tank cover
(Replaces cover, 106629; 3/4" tube, 106639)
• SCREW, Machine #10-32 x 1/2" lg.
FILTER ASSEMBLY, Return (#12orb thread)
(Model 3015 with S/N 15556 and above and Model 3219)
FILTER ASSEMBLY, Return (1/2P thread)
(Model 3015 with S/N 15555 and below)
• BOLT, Hex-hd 5/16-18 x 1" lg.
• WASHER, Lock 5/16"
• NUT, Hex 5/16-18
• ELEMENT, Filter
MANIFOLD, Lowering valve
(Machines with rotary-type lowering valve)
MANIFOLD, Lowering valve
(Machines with pull-type lowering valve)
VALVE, Lowering (rotary-type)(velocity fuse)
VALVE, Lowering (pull-type)(holding valve)
CAP W/GASKET, Filler/breather
• SCREW, Machine #10-32 x 1/2" lg.
PUMP & 4 Hp MOTOR ASSEMBLY (Std. machines)
(Model 3015 with Serial Number 18539 and above)
(Model 3219 with Serial Number 220599 and above)
• PUMP, Hydraulic
• MOTOR, 4 Hp, 24VDC
PUMP & 1 Hp MOTOR ASSEMBLY (order 310010)
• PUMP, Hydraulic
• MOTOR, 1 Hp, 24VDC
PUMP & MOTOR ASSEMBLY (EE-Rated machines)
• PUMP, Hydraulic
• MOTOR, 24VDC
• BRUSHES (Set of 8)
• SPRING
• BOLT, Hex-hd 5/16-18 x 1" lg.
• WASHER, Flat 5/16"
• WASHER, Lock 5/16"
• NUT, Hex 5/16-18
Units
per
Assy.
1
2
1
1
1
1
3
3
1
1
10
1
1
2
2
2
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
8
4
4
4
4
NOTE: Parts list continued on Page 65.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 63
FIGURE 6-29. HYDRAULIC/ELECTRIC TRAY ASSEMBLY - 2-Speed Drive
Index
No.
Skyjack
Part No.
Units
per
Assy.
Description
NOTE: Parts list continued from Page 63.
13
14
15
16
17
103236
102918
103320
103339
(Ref.)
18
103855
104000
(Ref.)
19
103090
GAUGE, Oil level/temp
HOSE, Tank 1"
CLAMP, Worm #16
FITTING, Drain plug (magnetic)
PANEL ASSEMBLY, Electrical
(For components, refer to Figure 6-36, 6-37, 6-38, 6-39 or 6-40)
• BOLT, Hex-hd 1/4-20 x 1/2" lg.
• WASHER, Lock 1/4"
MANIFOLD ASSEMBLY, Cushion valve
• (For components, refer to Figure 6-35.)
COVER, Edge 15" lg.
1
1
1
1
1
4
4
1
1
NOTE: For hydraulic hose connections, refer to
Figure 6-32.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 65
FIGURE 6-30. HYDRAULIC HOSE CONNECTIONS - Hydraulic/Electric Tray
(Proportional Drive and Lift)
7
15
14
8
12
2
9
5
10
13
18
21
6
18
20
3
11
17
4
16
1
19
MA-SJM-42A
SECTION 6, Page 66
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-30. HYDRAULIC HOSE CONNECTIONS - Hydraulic/Electric Tray
(Proportional Drive and Lift)
Index
No.
Skyjack
Part No.
1
(Ref.)
2
(Ref.)
3
(Ref.)
4
5
6
7
8
9
10
11
12
108003
(Ref.)
107738
(Ref.)
102854
103032
102665
114742
108003
13
14
109052
(Ref.)
15
16
103323
(Ref.)
17
(Ref.)
18
19
114741
(Ref.)
20
102562
21
103309
SJM Series 107979-8
Description
MANIFOLD ASSEMBLY, Main
(Refer to Figure 6-33.)
PUMP AND MOTOR ASSEMBLY
(Refer to Figure 6-27.)
MANIFOLD ASSEMBLY, Cushion
(Refer to Figure 6-33.)
HOSE ASSEMBLY, Cushion valve to main manifold
FILTER ASSEMBLY, Return (Refer to Figure 6-27.)
HOSE ASSEMBLY, Filter to main manifold
WELDMENT, Tank cover (Refer to Figure 6-27.)
CLAMP, Worm #12
HOSE, Suction 3/4"
FITTING, Elbow 90° #8orb-#6
HOSE ASSEMBLY, Manifold supply
HOSE ASSEMBLY, Manual lowering valve to main
manifold
FITTING, Connector #12orb-#6
LOWERING VALVE AND MANIFOLD
(Refer to Figure 6-27.)
FITTING, Adapter #6-3/8P
HOSE ASSEMBLY, Valve supply (Machines with
powered extension platform) (Refer to Figure 6-6.)
HOSE ASSEMBLY, Valve return (Machines with
powered extension platform) (Refer to Figure 6-6.)
HOSE ASSEMBLY, Proportional valve manifold return
MANIFOLD ASSEMBLY, Proportional valve
(Refer to Figure 6-33.)
HOSE ASSEMBLY, Proportional manifold to
main manifold
FITTING, Tee #6swl-#6-#6
Final Revision 2-1-98
Units
per
Assy.
1
1
1
1
1
1
1
1
11”
3
1
1
1
1
1
1
1
1
1
1
1
SECTION 6, Page 67
FIGURE 6-31. HYDRAULIC HOSE CONNECTIONS - Hydraulic/Electric Tray
(2 Speed Drive With Hi-Torque Package)
7
15
PUMP/MOTOR
ASSEMBLY
14
2
8
9
5
8
13
10
23
12
11
21
6
19
3
20
17
1
22
18
16
4
MA-SJM-46
SECTION 6, Page 68
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-31. HYDRAULIC HOSE CONNECTIONS - Hydraulic/Electric Tray
(2 Speed Drive With Hi-Torque Package)
Index
No.
Skyjack
Part No.
1
(Ref.)
2
(Ref.)
3
(Ref.)
4
5
6
7
8
9
10
11
12
108003
(Ref.)
107738
(Ref.)
102854
103032
102665
102562
108949
13
14
109052
(Ref.)
15
16
103323
(Ref.)
17
(Ref.)
18
19
20
109640
103246
103309
103304
107732
(Ref.)
21
22
23
400096
400097
103309
SJM Series 107979-8
Description
MANIFOLD ASSEMBLY, Main
(Refer to Figure 6-34.)
PUMP AND MOTOR ASSEMBLY
(Refer to Figure 6-28.)
MANIFOLD ASSEMBLY, Cushion
(Refer to Figure 6-34.)
HOSE ASSEMBLY, Cushion valve to main manifold
FILTER ASSEMBLY, Return (Refer to Figure 6-28.)
HOSE ASSEMBLY, Filter to main manifold
WELDMENT, Tank cover (Refer to Figure 6-28.)
CLAMP, Worm #12
HOSE, Suction 3/4"
FITTING, Elbow 90° #8orb-#6
HOSE ASSEMBLY, Manifold supply
HOSE ASSEMBLY, Manual lowering valve to main
manifold
FITTING, Connector #12orb-#6
LOWERING VALVE AND MANIFOLD
(Refer to Figure 6-28.)
FITTING, Adapter #6-3/8P
HOSE ASSEMBLY, Valve supply (Machines with
powered extension platform) (Refer to Figure 6-6.)
HOSE ASSEMBLY, Valve return (Machines with
powered extension platform) (Refer to Figure 6-6.)
QUICK DISCONNECT, Hydraulic
• DISCONNECT, Quick
• FITTING, Tee #6orb-#6
• FITTING, Pipe #4-#6
HOSE ASSEMBLY, High torque manifold return
MANIFOLD ASSEMBLY, High torque
(Refer to Figure 6-34.)
HOSE ASSEMBLY, Pump to high torque manifold
HOSE ASSEMBLY, Brake
FITTING, Tee #6swl-#6-#6
Final Revision 2-1-98
Units
per
Assy.
1
1
1
1
1
1
2
1
11”
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 6, Page 69
FIGURE 6-32. HYDRAULIC HOSE CONNECTIONS - Hydraulic/Electric Tray
(2 Speed Drive)
7
18
19
20
17
8
9
5
2
8
16
15
13
10
11
6
12
3
14
22
1
21
23
4
SECTION 6, Page 70
Final Revision 2-1-98
MA-SJM-14B
SJM Series 107979-8
FIGURE 6-32. HYDRAULIC HOSE CONNECTIONS - Hydraulic/Electric Tray
(2 Speed Drive)
Index
No.
Skyjack
Part No.
1
(Ref.)
2
(Ref.)
3
(Ref.)
4
5
6
7
8
9
10
11
12
13
14
15
108003
(Ref.)
107738
(Ref.)
102854
103032
103294
107741
103329
102665
102562
108949
16
109052
106669
17
(Ref.)
18
19
20
21
103323
103124
103215
(Ref.)
22
(Ref.)
23
109640
103246
103309
103304
SJM Series 107979-8
Description
MANIFOLD ASSEMBLY, Main
(Refer to Figure 6-35.)
PUMP AND MOTOR ASSEMBLY
(Refer to Figure 6-29.)
MANIFOLD ASSEMBLY, Cushion
(Refer to Figure 6-35.)
HOSE ASSEMBLY, Cushion valve to main manifold
FILTER ASSEMBLY, Return (Refer to Figure 6-29.)
HOSE ASSEMBLY, Filter to main manifold
WELDMENT, Tank cover (Refer to Figure 6-29.)
CLAMP, Worm #12
HOSE, Suction 3/4" x 9" lg.
FITTING, Hose barb 3/4B-1/2P (Early models)
FITTING, Reducer 1/2P-3/8P (Early models)
FITTING, Adapter 3/8P-#8orb (Early models)
FITTING, Elbow 90° #8orb-#6
HOSE ASSEMBLY, Manifold supply
HOSE ASSEMBLY, Manual lowering valve to main
manifold
FITTING, Connector #12orb-#6
(Model 3015 with S/N 15556 and above) (Model 3219)
FITTING, Connector 1/2P-#6
(Model 3015 with S/N 15555 and below)
LOWERING VALVE AND MANIFOLD
(Refer to Figure 6-29.)
FITTING, Adapter #6-3/8P
FITTING, Elbow 90° 3/4P
FITTING, Hose 3/4B-3/4P
HOSE ASSEMBLY, Valve supply (Machines with
powered extension platform) (Refer to Figure 6-6.)
HOSE ASSEMBLY, Valve return (Machines with
powered extension platform) (Refer to Figure 6-6.)
QUICK DISCONNECT, Hydraulic
• DISCONNECT, Quick
• FITTING, Tee #6orb-#6
• FITTING, Pipe #4-#6
Final Revision 2-1-98
Units
per
Assy.
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 6, Page 71
FIGURE 6-33. MAIN MANIFOLD AND CUSHION VALVE MANIFOLD ASSEMBLY
(Proportional Drive and Lift)
20
18
22
19
17
1
21
23
6
5
12
7
14
11
10
3
7
24
4
9
9
2
9
15
14
1
27
16
25
29
28
13
26
8
16
14
14
14
15
9
14
9
MA-SJM-47A
SECTION 6, Page 72
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-33. MAIN MANIFOLD AND CUSHION VALVE MANIFOLD ASSEMBLY
(Proportional Drive and Lift)
Index
No.
Skyjack
Part No.
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
(Ref.)
(Ref.)
107354
108506
103614
107439
104409
104345
103943
103623
115320
103655
106273
103605
102856
104437
104133
104534
105610
114669
103069
114578
103072
114667
103615
104132
103605
108002
114666
103324
104419
104437
26
114578
27
103069
28
29
114520
103304
1
2
SJM Series 107979-8
Description
MAIN MANIFOLD AND CUSHION VALVE MANIFOLD
• MANIFOLD ASSEMBLY (Order components)
• • BLOCK, Main manifold
• • PLUG, Expander
• • VALVE ASSEMBLY, 24 Volt spool (drive/steer)
• • • COIL, 24 Volt
• • • CONNECTOR, Black
• • • CONNECTOR, Gray
• • • BOLT, Soc-hd 1/4-20 x 2" lg.
• • VALVE, 3-Way (brake)
• • PLUG, Soc.-hd #8 orb
• • VALVE, N.C. (lowering)
• • VALVE, 3-Way (lift)
• • COIL, 24 Volt
• • PLUG, Soc-hd #3orb
• • PLUG, Soc-hd #6orb
• • VALVE, Counterbalance
• • VALVE, Relief
• • COIL, 24 Volt
• ORIFICE, .055 dia. (lowering)
• FITTING, Connector #6orb-#6
• FITTING, Elbow 90° #6orb-#6
• FITTING, Tee #6orb-#6
• CUSHION VALVE MANIFOLD ASSEMBLY
• • BLOCK, Cushion valve manifold
• • VALVE, N.C. (cushion)
• • COIL, 24 Volt
• • ORIFICE, .040 dia. (cushion)
• • FITTING, Swivel 1/4P-#6
• • FITTING, Elbow 90° 1/4P-#6
• PLUG, Brass 1/16
PLUG, Soc-hd #6orb
(Machines with powered extension platform)
FITTING, Elbow 90° #6orb-#6
(Machines with powered extension platform)
• FITTING, Connector #6orb-#6
(Machines without quick disconnect)
• QUICK DISCONNECT, 1/4P
˜ FITTING ADAPTER, #4-#6
Final Revision 2-1-98
Units
per
Assy.
1
9
2
4
4
4
4
1
1
1
1
2
1
7
1
2
1
1
6
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 6, Page 73
FIGURE 6-34. MAIN MANIFOLD AND CUSHION VALVE MANIFOLD ASSEMBLY
(2 Speed Drive With Hi-Torque Package)
18
17
20
21
19
22
23
1
5
6
7
12
14
10
11
3
24
9
9
4
14
2
9
14
1
14
26
13
25
8
16
14
15
9
14
SECTION 6, Page 74
Final Revision 2-1-98
MA-SJM-101A
SJM Series 107979-8
FIGURE 6-34. MAIN MANIFOLD AND CUSHION VALVE MANIFOLD ASSEMBLY
(2 Speed Drive With Hi-Torque Package)
Index
No.
Skyjack
Part No.
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
(Ref.)
(Ref.)
107354
108506
103614
107439
104409
104345
103943
400086
115320
103655
106273
103605
102856
104437
104133
104534
105610
114669
103069
114578
103072
114667
103615
104132
103605
108002
114666
103324
104419
104437
26
114578
1
2
SJM Series 107979-8
Description
MAIN MANIFOLD AND CUSHION VALVE MANIFOLD
• MANIFOLD ASSEMBLY (Order components)
• • BLOCK, Main manifold
• • PLUG, Expander
• • VALVE ASSEMBLY, 24 Volt spool (drive/steer)
• • • COIL, 24 Volt
• • • CONNECTOR, Black
• • • CONNECTOR, Gray
• • • BOLT, Soc-hd 1/4-20 x 2" lg.
• • PLUG, Cavity
• • PLUG, Soc.-hd #8 orb
• • VALVE, N.C. (lowering)
• • VALVE, 3-Way (lift)
• • COIL, 24 Volt
• • PLUG, Soc-hd #3orb
• • PLUG, Soc-hd #6orb
• • VALVE, Counterbalance
• • VALVE, Relief
• • COIL, 24 Volt
• ORIFICE, .055 dia. (lowering)
• FITTING, Connector #6orb-#6
• FITTING, Elbow 90° #6orb-#6
• FITTING, Tee #6orb-#6
• CUSHION VALVE MANIFOLD ASSEMBLY
• • BLOCK, Cushion valve manifold
• • VALVE, N.C. (cushion)
• • COIL, 24 Volt
• • ORIFICE, .040 dia. (cushion)
• • FITTING, Swivel 1/4P-#6
• • FITTING, Elbow 90° 1/4P-#6
• PLUG, Brass 1/16
PLUG, Soc-hd #6orb
(Machines with powered extension platform)
FITTING, Elbow 90° #6orb-#6
(Machines with powered extension platform)
Final Revision 2-1-98
Units
per
Assy.
1
9
2
4
4
4
4
1
1
1
1
1
1
7
1
2
1
1
7
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 6, Page 75
FIGURE 6-35. MAIN MANIFOLD AND CUSHION VALVE MANIFOLD ASSEMBLY
(2 Speed Drive)
17
12
6
21
18
10
20
19
23
22
7
4
14
9
13
25
1
8
15
9
14
26
14
7
3
22
11
16
2
9
5
7
11
MA-SJM-11C
SECTION 6, Page 76
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-35. MAIN MANIFOLD AND CUSHION VALVE MANIFOLD ASSEMBLY
(2 Speed Drive)
Index
No.
Skyjack
Part No.
(Ref.)
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
108300
107354
108506
103614
107439
104409
104345
103943
102626
103623
103655
106273
103605
102856
104437
104133
104534
105610
108053
103069
103073
103072
114667
103615
104132
103605
108002
114666
103324
108053
103069
26
104660
1
2
SJM Series 107979-8
Description
MAIN MANIFOLD AND CUSHION VALVE
MANIFOLD ASSEMBLY (Order components)
• MANIFOLD ASSEMBLY, Main
• • BLOCK, Main manifold
• • PLUG, Expander
• • VALVE ASSEMBLY, 24 Volt spool (drive/steer)
• • • COIL, 24 Volt
• • • CONNECTOR, Black
• • • CONNECTOR, Gray
• • • BOLT, Soc-hd 1/4-20 x 2" lg.
• • VALVE, N.O. (dump)
• • VALVE, 3-Way (brake)
• • VALVE, N.C. (lowering)
• • VALVE, 3-Way (lift)
• • COIL, 24 Volt
• • PLUG, Soc-hd #3orb
• • PLUG, Soc-hd #6orb
• • VALVE, Counterbalance
• • VALVE, Relief
• • COIL, 24 Volt
• ORIFICE, .055 dia. (lowering)
• FITTING, Connector #6orb-#6
• FITTING, Elbow 90 #6orb-#6
• FITTING, Tee #6orb-#6
• CUSHION VALVE ASSEMBLY
• • BLOCK, Cushion valve manifold
• • VALVE, N.C. (cushion)
• • COIL, 24 Volt
• • ORIFICE, .040 dia. (cushion)
• • FITTING, Swivel 1/4P-#6
• • FITTING, Elbow 90° 1/4P-#6
• ORIFICE, .055 diameter (dump)
FITTING, Connector #6orb-#6
(Machines with powered extension platform)
FITTING, Tee #6orb-#6
(Machines with powered extension platform)
Final Revision 2-1-98
Units
per
Assy.
1
1
9
2
4
4
4
4
1
1
1
1
3
1
7
1
2
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 6, Page 77
FIGURE 6-36. ELECTRICAL PANEL ASSEMBLY - Proportional Drive and Lift
(ANSI/SIA and CSA)
19
9
5
7
13
17
6
4
20
18
1
14
8
16
10
12
11
21
15
MA-SJM-54
SECTION 6, Page 78
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-36. ELECTRICAL PANEL ASSEMBLY - Proportional Drive and Lift
(ANSI/SIA and CSA)
Index
No.
Skyjack
Part No.
17
18
19
(Ref.)
107211
109111
104173
102888
102518
117325
102756
103068
103855
104000
103057
103336
103101
103962
104185
103995
104003
102853
103805
111181
112447
110463
103011
103956
106099
103985
108000
102921
108589
103962
104185
104003
103319
115312
103267
20
21
114378
108442
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
SJM Series 107979-8
Description
PANEL ASSEMBLY, Electrical
• WELDMENT, Electrical panel
• HARNESS, Manifold wiring
• CORD ASSEMBLY, Panel control
• • CABLE, 16/10
• • SOCKET, 10 Pin
• BREAKER, 15 Amp circuit
• FUSE, 200 Amp
• INSULATOR, Fuse
• • BOLT, Hex-hd 1/4-20 x 1/2" lg.
• • WASHER, Lock 1/4"
• BEEPER, 24 Volt
• HOURMETER
• CONTACTOR
• • SCREW, Machine #10-32 x 1/2" lg.
• • WASHER, Lock #10
• • WASHER, Flat #10
• • NUT, Hex #10-32
• SWITCH, Up/down toggle
• LABEL, Up/down
• GUARD, Toggle switch
• BUMPER, Rubber
• • SCREW, Hex-hd 6mm x 14mm
• STRIP, Terminal block
• • SCREW, Machine #6-32 x 1" lg.
• • WASHER, Lock #6
• • NUT, Hex #6-32
• DIODE ASSEMBLY
• • DIODE, 6 Amp
• RELAY, 24 Volt (brake, cushion, proportional)
• • SCREW, Machine #10-32 x 1/2" lg.
• • WASHER, Lock #10
• • NUT, Hex #10-32
• CAPACITOR, 35 Volt
• RESISTOR, 40 Ohm/25W
FLASHER, 24 Volt
(Machines with Flashing Light Option)
LABEL, Hydraulic oil
LABEL, Push switch to down
Final Revision 2-1-98
Units
per
Assy.
1
1
1
67” lg.
1
2
1
2
4
4
1
1
1
2
2
2
2
1
1
1
1
1
1
2
2
2
1
7
4
2
2
2
1
1
1
1
1
SECTION 6, Page 79
FIGURE 6-37. ELECTRICAL PANEL ASSEMBLY - Proportional Drive and Lift
(CE)
9
5
19
7
16
6
10
20
1
14
4
15
8
13
21
24
12
17
18
23
SECTION 6, Page 80
Final Revision 2-1-98
MA-SJM-53
SJM Series 107979-8
FIGURE 6-37. ELECTRICAL PANEL ASSEMBLY - Proportional Drive and Lift
(CE)
Index
No.
Skyjack
Part No.
A
310013
B
310046
1
2
3
107211
109111
114548
102888
107778
117325
102756
103068
103855
104000
103057
103336
103101
103962
104185
103995
104003
112447
110463
103011
103011
103956
106099
103985
108000
102921
108589
103962
104185
104003
103319
115312
310008
310007
310006
106456
117880
310061
300667
105621
104003
310025
117967
102921
102509
300649
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
SJM Series 107979-8
Description
PANEL ASSEMBLY, Electrical
(Without Lowering Warning System Option)
PANEL ASSEMBLY, Electrical
(With Lowering Warning System Option)
• WELDMENT, Electrical panel
• HARNESS, Manifold/holding valve wiring
• CABLE ASSEMBLY, Panel control
• • CABLE, 16/10
• • CONNECTOR ASSEMBLY, 10 Pole female
• BREAKER, 15 Amp circuit
• FUSE, 200 Amp
• INSULATOR, Fuse
• • BOLT, Hex-hd 1/4-20 x 1/2" lg.
• • WASHER, Lock 1/4"
• BEEPER, 24 Volt
• HOURMETER
• CONTACTOR
• • SCREW, Machine #10-32 x 1/2" lg.
• • WASHER, Lock #10
• • WASHER, Flat #10
• • NUT, Hex #10-32
• BUMPER, Rubber
• • SCREW, Hex-hd 6mm x 14mm
• STRIP, Terminal block, A
• STRIP, Terminal block, B
• • SCREW, Machine #6-32 x 1" lg.
• • WASHER, Lock #6
• • NUT, Hex #6-32
• DIODE ASSEMBLY
• • DIODE, 6 Amp
• RELAY, 24 Volt (brake, cushion, proportional,tilt)
• • SCREW, Machine #10-32 x 1/2" lg.
• • WASHER, Lock #10
• • NUT, Hex #10-32
• CAPACITOR, 35 Volt
• RESISTOR, 40 Ohm/25W
• • SCREW, #4
• • WASHER, #4
• • NUT, Hex #4
• FLASHER, 24 Volt
• SWITCH ASSEMBLY, Tilt
• CABLE ASSEMBLY, Tilt switch
• MODULE, Lowering warning system, B
• • SCREW, Machine #10-32 x 1” lg.
• • NUT, Hex #10-32
• PLATE, Diode
• BEEPER, Lowering warning, B
• DIODE, 6 amp
• CLAMP, Plastic
• PLUG, Plastic
Final Revision 2-1-98
Units
per
Assy.
1
1
1
67” lg.
1
2
1
2
4
4
1
1
1
2
2
2
2
1
1
1.3
1.75
3
3
3
1
7
5
5
5
5
1
1
1
1
1
1
1
1
1
2
2
1
1
AR
1
1
SECTION 6, Page 81
FIGURE 6-38.
ELECTRICAL PANEL ASSEMBLY - 2-Speed Drive
9
5
18
19
7
17
12 4
1
21
6
16
14
13
10
11
8
20
3
15
2
MA-SJM-10A
SECTION 6, Page 82
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-38.
Index
No.
Skyjack
Part No.
A
B
1
2
17
18
(Ref.)
(Ref.)
107211
109111
109566
104173
102888
102518
114548
102888
107777
102331
310179
103068
103855
104000
103057
103336
103101
103962
104003
102853
103805
105280
112447
103956
103985
103011
103956
103985
108000
102921
108589
103962
104003
103319
103267
19
108589
20
21
111181
110699
3
4
5
6
7
8
9
10
11
12
13
14
15
16
SJM Series 107979-8
ELECTRICAL PANEL ASSEMBLY - 2-Speed Drive
Description
PANEL ASSEMBLY, Electrical (ANSI/SIA and CSA)
PANEL ASSEMBLY, Electrical (CE)
• WELDMENT, Electrical panel
• HARNESS, Manifold wiring, A
• HARNESS, Manifold/holding valve wiring, B
• CORD ASSEMBLY, Panel control, A
• • CABLE, 16/10 x 67" lg.
• • SOCKET, 10 Pin
• CORD ASSEMBLY, Panel control, B
• • CABLE, 16/10 x 67" lg.
• • SOCKET ASSEMBLY, 10 Pin female (Replaces 108181)
• BREAKER, 15 Amp circuit
• FUSE, 200 Amp (replaces 102756)
• INSULATOR, Fuse
• • BOLT, Hex-hd 1/4-20 x 1/2" lg.
• • WASHER, Lock 1/4"
• BEEPER, 24 Volt
• HOURMETER
• CONTACTOR
• • SCREW, Machine #10-32 x 1/2" lg.
• • NUT, Hex #10-32
• SWITCH, Up/down toggle
• LABEL, Up/down
• LABEL PLATE, Push to reset
• BUMPER, Rubber (Replaces 104697)
• • SCREW, Machine #6-32 x 1" lg.
• • NUT, Hex #6-32
• STRIP, Terminal block
• • SCREW, Machine #6-32 x 1" lg.
• • NUT, Hex #6-32
• DIODE ASSEMBLY
• • DIODE, 6 Amp
• RELAY, 24 Volt (brake, cushion)(Replaces 103425)
• • SCREW, Machine #10-32 x 1/2" lg.
• • NUT, Hex #10-32
• CAPACITOR, 35 Volt
FLASHER, 24 Volt
(Machines with Flashing Light Option)
RELAY, 24 Volt (tilt) (Replaces 103425)
(Machines with Tilt Switch Option)
• GUARD, Toggle switch
• CAPACITOR, .47 (CE), B
Final Revision 2-1-98
Units
per
Assy.
1
1
1
1
1
1
1
1
1
2
1
2
2
2
1
1
1
2
2
1
1
2
1
1
1
1
2
2
1
7
2
2
2
1
1
1
1
1
SECTION 6, Page 83
FIGURE 6-39.
ELECTRICAL PANEL ASSEMBLY - EE-Rated
19
9
11
10
4 12
17
22
16
1
7
6
6
13
8
21
3
15
20
14
18
5
2
MA-SJM -31
SECTION 6, Page 84
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-39.
Index
No.
Skyjack
Part No.
1
2
3
114564
108993
109111
114548
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
102888
107778
117325
102756
103068
103855
104000
103057
103336
103101
103962
104003
102853
103805
105280
112447
103956
103985
103011
103956
103985
108000
102921
108589
103962
104003
103319
102921
108994
108995
104632
104064
111181
SJM Series 107979-8
ELECTRICAL PANEL ASSEMBLY - EE-Rated
Units
per
Assy.
Description
PANEL ASSEMBLY, Electrical (EE-Rated)(replaces 109491)
• WELDMENT, Electrical panel
• HARNESS, Manifold wiring
• CABLE ASSEMBLY, Panel control
(Replaces 108076 by ordering (1) Connector 107778)
• • CABLE, 16/10 x 67" lg.
• • CONNECTOR ASSEMBLY, 10 Pole female (Replaces 108181)
• BREAKER, 15 Amp circuit (replaces 102331)
• FUSE, 200 Amp
• INSULATOR, Fuse
• • BOLT, Hex-hd 1/4-20 x 1/2" lg.
• • WASHER, Lock 1/4"
• BEEPER, 24 Volt
• HOURMETER
• CONTACTOR
• • SCREW, Machine #10-32 x 1/2" lg.
• • NUT, Hex #10-32
• SWITCH, Up/down toggle
• LABEL, Up/down
• LABEL PLATE, Push to reset
• BUMPER, Rubber
• • SCREW, Machine #6-32 x 1" lg.
• • NUT, Hex #6-32
• STRIP, Terminal block
• • SCREW, Machine #6-32 x 1" lg.
• • NUT, Hex #6-32
• DIODE ASSEMBLY
• • DIODE, 6 Amp
• RELAY, 24 Volt (brake, cushion) (Replaces 103425)
• • SCREW, Machine #10-32 x 1/2" lg.
• • NUT, Hex #10-32
• CAPACITOR, 35 Volt
• DIODE, 6 Amp
• COVER, Electrical component
• • GROMMET, Rubber
• PLUG, Motor disconnect
• GASKET, Foam 42-1/2" lg.
• GUARD, Toggle switch
Final Revision 2-1-98
1
1
1
1
1
2
1
2
2
2
1
1
1
2
2
1
1
2
1
1
1
1
2
2
1
7
2
2
2
1
1
1
1
1
1
1
SECTION 6, Page 85
FIGURE 6-40.
BATTERY
TRAY ASSEMBLY
4
7
5
9
10
2
8
6
3
12
1
MA-SJM-09A
SECTION 6, Page 86
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-40.
Index
No.
Skyjack
Part No.
A
B
C
1
(Ref.)
(Ref.)
(Ref.)
107879
109191
105517
105518
111423
104049
100335
102780
103864
103886
103984
103237
106008
103364
105600
103480
106552
108163
2
3
4
5
6
7
113415
110550
8
9
10
11
12
103887
103404
104127
105600
105601
110334
111534
SJM Series 107979-8
BATTERY TRAY ASSEMBLY
Units
per
Assy.
Description
BATTERY TRAY ASSEMBLY - Standard
BATTERY TRAY ASSEMBLY - Europe
BATTERY TRAY ASSEMBLY - EE-Rated
• WELDMENT, Battery tray, A, B
• WELDMENT, Battery tray, C
• • PLYWOOD, 1/4” x 9.5” x 10.5”
• • PLYWOOD, 1/4” x 9.5” x 29”
• • SPACER, Wooden battery 2” x 3” x 11”
• • BRACKET, Battery tray lock
• BUSHING, Bronze
• LATCH, Battery tray
• • BOLT, Hex-hd 5/16-18 x 1" lg.
• • BOLT, Hex-hd 5/16-18 x 1-1/2" lg.
• • NUT, Lock 5/16-18
• CABLE ASSEMBLY, Battery jumper
• CABLE ASSEMBLY, Battery charger
• • PLUG, 50 Amp
• • BOOT, Cable (red)
• BATTERY, 6V 220AH (#T2200) (Standard)
• BATTERY, 6V 250AH (#J250) (Optional)
• CHARGER ASSEMBLY, Battery, 24V25A
115V, 60Hz (#BA285NM), A
• CHARGER ASSEMBLY, Battery, 24V25A
220V, 50Hz (#2440E), B (Replaces 108164 and 111327)
• CHARGER ASSEMBLY, Battery, 24V20A
115V, 60Hz (#B9338) (remote), C
• • BOLT, Hex-hd 5/16-18 x 3/4" lg.
• • WASHER, Lock 5/16"
• COVER, Cable 6" lg., A, B
• BOOT, Cable (red), C
• BOOT, Cable (black), C
• LABEL, Battery charger(located on front of weldment)(not shown)
• KNOB, Rotary latch
Final Revision 2-1-98
1
1
5
3
1
1
2
1
1
2
2
3
1
1
2
4
4
1
1
1
2
2
1
6
4
1
1
SECTION 6, Page 87
FIGURE 6-41. BATTERY CHARGER ASSEMBLY - 110 Volt
(Motor Appliance BA611 and BA285)
21
14
19
18
22
4
10
9
2
11
3
1
17 16
5 12
13
8
20
15
6
7
MA-COMP-33A
Index
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
112258
108163
108554
108555
108556
108557
108558
108559
108560
103364
108561
108565
108564
115315
102773
$
$
115315
115391
115392
111905
700687
119137
108562
108563
Units
per
Assy.
Description
Skyjack
Part No.
CHARGER ASSEMBLY, Battery, 24V25A, 115VAC 60Hz (#BA611)
CHARGER ASSEMBLY, Battery, 24V25A, 115VAC 60Hz (#BA285)
• AMMETER, 0-30
• CAPACITOR
• DIODE
• TRANSFORMER
• HOLDER, Fuse
• CORD, AC
• CORD, DC
• • PLUG, 50 Amp
• RELIEF, Strain
• CIRCUIT BOARD ASSEMBLY, Timer control
• • TRANSFORMER, Timer control
• • RELAY, Timer control
• FUSE, AGC15
• BASE, Charger
• COVER, Charger
• RELAY, Charger cutout 120V, A
• PLUG, Charger cutout, A
• WIRE ASSEMBLY, Charger cutout, A
• FUSE, 45 Amp NON, A
• HOLDER ASSEMBLY, 45 Amp fuse, A
• CLIP, AC Cord
• TRIAC, B
• BREAKER, Circuit, B
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
$ Consult Factory.
SECTION 6, Page 88
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-42.
BATTERY CHARGER ASSEMBLY - 220 Volt
(Motor Appliance BA538)
4
2
13
11
9
1
12
3
8
10
7
6
5
MA-SJM-33
Index
No.
111327
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
Skyjack
Part No.
110892
109102
111895
111896
111898
111899
103364
108561
108558
111897
110855
$
$
110895
CHARGER ASSEMBLY, Battery (MAC#BA538)
24V20A, 220VAC 50Hz
• AMMETER, 0-20 (M9818)
• CAPACITOR (M3448)
• DIODE (M7278)
• TRANSFORMER, Main (TX12319A)
• CORD, AC (M3321)
• CORD, DC (CDC4009)
• • PLUG, 50 Amp
• RELIEF, Strain (M0366)
• FUSE HOLDER (M1374)
• CONTROL CIRCUIT (CB024101613)
• FUSE, AGC10 (M11641)
• BASE, Charger
• COVER, Charger
• CIRCUIT BREAKER (M11723)
Units
per
Assy.
1
1
2
1
1
1
1
2
1
1
1
1
1
1
+$ CONSULT FACTORY.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 89
FIGURE 6-43. BATTERY CHARGER ASSEMBLY - 220 Volt (Bycan)
7
9
8
5
6
4
3
2
1
MA-SJ3-38
Index
No.
Skyjack
Part No.
A
B
1
2
3
4
5
6
7
8
113415
112255
117162
117163
117164
117165
117166
117167
117168
117170
117169
117172
117171
9
SECTION 6, Page 90
Description
CHARGER ASSEMBLY, Battery (2440E, 50-60 Hz)
CHARGER ASSEMBLY, Battery (2440A, 50-60 Hz)
• AMMETER, 50 Amp
• SWITCH, Toggle 4PDT
• RECTIFIER, 70 Amp
• FUSE AND HOLDER, AC
• CONTROLLER
• RELAY, Vehicle disable
• FAN, Cooling
• TRANSFORMER, A
• TRANSFORMER, B
• CAPACITOR, A
• CAPACITOR, B
Final Revision 2-1-98
Units
per
Assy.
1
1
2
1
1
1
1
1
1
1
1
SJM Series 107979-8
FIGURE 6-44.
BATTERY CHARGER ASSEMBLY - EE-Rated
17
13
12
8
7
2
1
4
10
15
16
14 11
5
3
9
6
MA-SJM-28
Index
No.
110550
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Description
Skyjack
Part No.
110854
110855
$
$
110856
108559
108558
110857
108561
109105
108562
110858
110859
108565
109102
110861
103364
110862
CHARGER ASSEMBLY, Battery (MAC#B9338)
24V20A, 115VAC 60Hz
• AMMETER, 0-20 (M9818)
• FUSE, AC AGC10 (M11641)
• BASE, Charger
• COVER W/HANDLE, Charger
• CIRCUIT BREAKER (M7692)
• CORD, AC (M0296)
• HOLDER, Fuse (M1374)
• BUTTON, Charger stop (M8258)
• RELIEF, Strain, AC cord (M0366)
• RELIEF, Strain, DC cord (M6680)
• TRIAC (M8118)
• POWER TRANSFORMER (TX09394A)
• RECTIFIER (M7488)
• CONTROL CIRCUIT, VFC2200 (CBA202413)
• CAPACITOR (M3448)
• CORD, DC (M9186)
• • PLUG, 50 Amp
• TRANSFORMER, Control circuit (M10602)
Units
per
Assy.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
$ Consult factory.
SJM Series 107979-8
Final Revision 2-1-98
SECTION 6, Page 91
FIGURE 6-45. BASE CONTROL BOX ASSEMBLY OPTION
8
9 10
2
8
3
9 10
3
2
11
6
11
1
5
7
4
13
7
12
4
MA-SJII-32A
SECTION 6, Page 92
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-45. BASE CONTROL BOX ASSEMBLY OPTION
Index
No.
Skyjack
Part No.
A
(Ref.)
B
(Ref.)
1
2
3
4
5
6
7
115538
108328
102451
111814
102853
111181
(Ref.)
102769
103100
103225
103041
103255
107712
8
9
10
11
12
13
(Ref.)
102754
104466
103100
103141
103225
(Ref.)
102837
103100
103141
102976
SJM Series 107979-8
Description
BOX ASSEMBLY, Base control
(Later models with toggle up/down switch)
BOX ASSEMBLY, Base control
(Early models with rotary up/down switch)
• BOX, Base control, A
• LABEL, Platform up/down
• LABEL, Platform/base select
• LABEL, Emergency stop (Replaces 105351)
• SWITCH, Toggle, A
• GUARD, Toggle switch, A
• SWITCH ASSEMBLY, Emergency stop
• • HEAD, Stop switch
• • BASE, Contact
• • BLOCK, N.C. Contact
• STRAIN RELIEF, Cord 1/2"
• CORD, 18/4 x 24" lg.
• CONNECTOR ASSEMBLY, 5 Pole male
(Replaces 4 pole round connector by also ordering
Connector, 107711)
• SWITCH ASSEMBLY, Platform/base key select
• • HEAD, Key switch
• • KEY, #455
• • BASE, Contact
• • BLOCK, N.O. Contact
• • BLOCK, N.C. Contact
• SWITCH ASSEMBLY, Platform up/down
• • HEAD, Selector switch
• • BASE, Contact
• • BLOCK, N.O. Contact
• BOX, Base control, B
Final Revision 2-1-98
Units
per
Assy.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AR
1
1
1
1
1
1
1
1
SECTION 6, Page 93
FIGURE 6-46.
AC OUTLET ON PLATFORM OPTION
1
5
8
2
7
3
6
4
MA-SJM-32A
SECTION 6, Page 94
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-46.
Index
No.
Skyjack
Part No.
A
B
C
D
E
F
105933
109923
310101
310099
310102
310100
1
108736
109552
109553
2
3
4
5
6
109700
109698
109699
103035
105269
105269
105269
300331
300331
105271
110333
7
8
AC OUTLET ON PLATFORM OPTION
Units
per
Assy.
Description
AC OUTLET ON PLATFORM - Model 3015 (110V)
AC OUTLET ON PLATFORM - Model 3219 (110V)
AC OUTLET ON PLATFORM - Model 3015 (220V) (ANSI/SIA and CSA)
AC OUTLET ON PLATFORM - Model 3015 (220V) (CE)
AC OUTLET ON PLATFORM - Model 3219 (220V) (ANSI/SIA and CSA)
AC OUTLET ON PLATFORM - Model 3015 (220V) (CE)
(Consists of items 1 thru 9)
• COVER, Cable protection LH (Replaces 105413), A, B
• ELECTRICAL ASSEMBLY, AC Outlet, A
• ELECTRICAL ASSEMBLY, AC Outlet, B
(Consists of items 2 thru 7)
• • BOX, GFI Receptacle
• • RECEPTACLE, 125V GFI, A, B
• • PLATE, Weatherproof GFI cover
• • CONNECTOR, 90° Strain relief
• • CORD, 14/3 x 312" lg., A
• • CORD, 14/3 x 432" lg., B, E
• • CORD, 14/3 x 288” lg., C
• • CORD, 14/3 x 432” lg., D
• • CORD, 14/3 x 432” lg., F
• • PLUG, 3-Prong male recessed, A, B
• LABEL, Connect supply here, A, B
1
1
1
1
1
1
1
1
1
1
1
1
1
1
NOTE: The following parts were used on earlier
machines:
104343
104408
104342
103035
SJM Series 107979-8
BOX, Duplex receptacle
RECEPTACLE, 125V Duplex
PLATE, Weatherproof duplex cover
CONNECTOR, 90 Strain relief
Final Revision 2-1-98
1
1
1
1
SECTION 6, Page 95
FIGURE 6-47. 800W GENERATOR OPTION
4
3
2
1
5
Index
No.
Skyjack
Part No.
(Ref.)
1
2
3
4
5
105882
106049
103404
103996
100397
108398
108399
(Ref.)
107996
SECTION 6, Page 96
Description
800W GENERATOR OPTION
(Order components)
• GENERATOR, 800 Watt
• • BOLT, Carriage 5/16-18 x 1-1/4 “ lg.
• • WASHER, Lock 5/16"
• • WASHER, Flat 5/16"
• • NUT, Hex 5/16-18
• CABLE, Battery positive
• CABLE, Battery negative
• AC OUTLET TO PLATFORM (Refer to Figure 6-46.)
PLATE, Generator mounting (welded to 1st inner scissors)
Final Revision 2-1-98
MA-SJM-24A
Units
per
Assy.
1
4
4
4
4
1
1
1
1
SJM Series 107979-8
FIGURE 6-48. AIR HOSE TO PLATFORM OPTION
2
3
1
3
MA-SJII-41
Index
No.
Skyjack
Part No.
A
B
1
2
310052
310053
109372
(Ref.)
107882
107883
107884
107884
109050
107886
107887
102891
102893
3
SJM Series 107979-8
Description
AIR HOSE TO PLATFORM - Model 3015 (Replaces 109556)
AIR HOSE TO PLATFORM - Model 3219 (Replaces 107888)
• COVER, Hose protection LH
• HOSE ASSEMBLY, Air to platform
• • FITTING, Female disconnect
• • FITTING, Male disconnect
• • HOSE, Air line 1/2" x 330" lg., A
• • HOSE, Air line 1/2" x 450" lg., B
• • FITTING, Hose barb
• • CLAMP, Hose
• LABEL, Connect air here
• STRAP, Tie 7" lg.
• STRAP, Tie 13-1/2" lg.
Final Revision 2-1-98
Units
per
Assy.
1
1
1
1
1
1
2
2
2
AR
AR
SECTION 6, Page 97
FIGURE 6-49. D-RING LANYARD ATTACHMENTS OPTION
2
1
MA SJM-51
Index
No.
Skyjack
Part No.
1
2
113122
114989
SECTION 6, Page 98
Description
D-RING, Lanyard attachment
BRACKET, D-ring
Final Revision 2-1-98
Units
per
Assy.
AR
AR
SJM Series 107979-8
FIGURE 6-50. SCISSOR GUARD OPTION - France
2
1
3
5
4
2
3
6
6
5
5
5
Index
No.
Skyjack
Part No.
114281
1
2
3
4
5
6
113665
103473
103999
103978
113656
103473
103999
103978
114275
103871
103999
114279
112464
101632
103999
103472
114280
SJM Series 107979-8
Description
SCISSOR GUARD ASSEMBLY, (France) (3219)
(For machines with Serial Number 23412 and Above)
BRACKET, Scissor guard front
• BOLT, Hex-hd 3/8-16 x 1” lg.
• WASHER, Lock 3/8”
• NUT, Hex-hd 3/8-16
BRACKET, Scissor guard rear
• BOLT, Hex-hd 3/8-16 x 1” lg.
• WASHER, Lock 3/8”
• NUT, Hex-hd 3/8-16 x 1” lg.
TUBE, Front and rear
• BOLT, Hex-hd 3/8-16 x 1” lg.
• WASHER, Lock 3/8”
MESH, Front and rear
TUBE, Side
• BOLT, Hex-hd 3/8-16 x 3/4” lg.
• WASHER, Lock 3/8”
• WASHER, Flat 3/8
MESH, Side
Final Revision 2-1-98
Units
per
Assy.
2
4
4
4
2
4
4
4
2
4
4
2
4
4
4
4
2
SECTION 6, Page 99
FIGURE 6-51. SCISSOR GUARD OPTION - Other Than France
19
11
12
17
10
13
22
15
7
11
1
1
14
16
20
18
21
2
23
21
4
20
2
8
9
18
3
9
5
6
MA-SJM-36
SECTION 6, Page 100
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-51. SCISSOR GUARD OPTION - Other Than France
Index
No.
Skyjack
Part No.
A
B
1
112925
112955
110709
110479
110465
110499
110345
110483
110484
110481
110482
110480
112380
110520
110490
110509
110489
110599
103915
103999
112883
110600
110525
110488
112354
103978
103472
105946
112557
112861
103860
103995
104000
103980
110502
110531
110613
110536
110610
112464
103978
103998
112555
111183
110570
110569
111182
112299
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
SJM Series 107979-8
Description
SCISSOR GUARD ASSEMBLY (Model 3015)
SCISSOR GUARD ASSEMBLY (Model 3219)
• MAST ASSY., Scissor guard
• • MAST, Scissor guard top
• • MAST, Scissor guard bottom
• • ABSORBER, Gas spring
• • CABLE, Galv. 55-3/4" lg.
• • PAD, Nylon 4" x 6" lg.
• • PAD, Nylon 2-1/2" x 6" lg.
• • SPACER
• • PIN, 1/4" x 2" lg.
• • PULLEY, Bronze
• • BEARING
• HOUSING, Main mast
• RETAINER, Front bumper
• • SPACER, Scissor guard
• • PLATE, Bumper
• BUMPER, Front
• • BOLT, Hex hd 3/8"-16 x 3-1/2" lg.
• • WASHER, Lock 3/8"
• BUMPER, Rear
• RETAINER, Rear bumper
• RING, Split
• LADDER, Euro
• SPACER, Ladder
• • NUT, Hex hd. 3/8"
• • WASHER, Flat 3/8"
• CAP, Tube end 1"
• SUPPORT, Curtain (A)
• SUPPORT, Curtain (B)
• • BOLT, Hex hd. 1/4"-20 x 1-3/4" lg.
• • WASHER, Flat 1/4"
• • WASHER, Lock 1/4"
• • NUT, Hex hd. 1/4"-20
• FASTENER, Curtain cylinder
• ROD, Curtain hanger upper
• ROD, Curtain hanger lower
• ROD, Curtain hanger upper side
• ROD, Curtain hanger lower side
• TUBE, Curtain upper side
• • BOLT, Hex hd. 3/8"-16 x 1-3/4" lg.
• • WASHER, Lock 3/8"
• CHANNEL, Curtain storage side
• CURTAIN, Mesh 60-1/2" x 47"
• CHANNEL, Curtain storage LH
• CHANNEL, Curtain storage RH
• CURTAIN, Mesh 11-1/2" x 47"
• PAD, Nylon 4-9/16" x 6"
Final Revision 2-1-98
Units
per
Assy.
2
2
2
2
4
4
4
8
4
4
4
2
1
2
1
1
4
4
1
2
18
1
2
4
4
8
2
2
4
4
4
4
2
4
4
2
2
2
4
4
2
2
2
2
2
8
SECTION 6, Page 101
FIGURE 6-52.
Index
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Skyjack
Part No.
108441
105672
106695
105959
106760
106761
106515
105983
102896
103077
103110
103125
103297
108665
102975
106691
102505
111605
103706
102894
108946
106705
102657
106704
102627
103805
102599
108442
102912
108855
108666
(Ref.)
107426
111218
105745
117355
103632
105744
117293
117294
105802
105934
108674
109985
107903
110667
104589
104588
LABELS AND NAMEPLATES
Description
KIT, Service label
• LABEL, Danger
• LABEL, Caution
• LABEL, Battery switch
• LABEL, Keep
• LABEL, Clear
• LABEL, Towing instructions (Replaces 102484)
• LABEL, Power off/on
• LABEL, Forklift boot
• LABEL, Safety bar
• STRIPE, Red/blue/red (164" total) Not included in kit.
• STRIPE, White/blue (158" total)Not included in kit.
• LABEL, Free-wheeling valve
• LABEL, Compliance to standards
• STRIPE, Warning (648" roll) Not included in kit.
• LABEL, Operator’s checklist
• LABEL, Emergency lowering (velocity fuse)
• LABEL, Emergency lowering (holding valve)
• LABEL, Skyjack vertical logo
• LABEL, Do not lift from sides
• LABEL, Skyjack logo
• LABEL, Do not alter (near limit switch)
• LABEL, Up/down (on control box)
• LABEL, Operator warning (on control box)
• LABEL, Emergency stop (on control box)
• LABEL, Up/down (on electrical panel)
• LABEL, Lift/off/drive (on control box)
• LABEL, Push to down (on electrical panel)
• LABEL, Daily maintenance (on battery charger)
• LABEL, Lift enable (on control box)
• LABEL, Replacement parts
The following parts are not included in Label Kit:
LABEL, Model designation
• SJM 3015
• SJM 3219
PLATE, Safety label
PLATE, Manual box
• BOLT, Self-tapping 1/4-14 x 3/4" lg.
TUBE, Manual 9" lg.
ENCLOSURE, Manual
LABEL, Manual enclosed
CAP, Manual tube end
CLAMP, Manual tube
LABEL, Platform capacity
LABEL, Annual inspection
For machines with Air Hose To Platform Option:
LABEL, Connect air here
For EE-Rated Machines:
LABEL, Warning, battery charging
LABEL, EE-Rating (diamond symbol)
LABEL, FM Approved
Units
per
Assy.
1
1
1
2
2
1
1
2
1
AR
AR
1
1
AR
1
1
1
2
2
2
AR
1
1
1
1
1
1
1
1
1
2
2
1
1
4
1
1
1
2
2
2
1
2
1
1
1
Supply Model Number and Serial Number when
ordering complete machine labels.
SECTION 6, Page 102
Final Revision 2-1-98
SJM Series 107979-8
FIGURE 6-52. LABELS AND NAMEPLATES
14
ON CONTROL BOX
21 22 23 25 28
1
31
34 33 32
2
30
4
18
5
14
36
17
13
35
15
17
29
4
18
5
30
9
ON
TOP
OF
BASE
AT
FRONT
20
ON
BASE
NEAR
LIMIT
SWITCH
8
ON TOP
OF BASE
AT REAR
(BOTH
SIDES)
11
10
10
7
3
12
6
19
16
26
24
27
ON TOP OF CHARGER
ON ELECTRICAL PANEL
LEFT SIDE VIEW
19
REAR VIEW
RIGHT SIDE VIEW
MA-SJM-21A
SJM Series 107979-8
Section 6, Page 103
Final Revision 2-1-98
Reliable lift solutions by people who care.
www.skyjack.com
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