Skyjack SJ3014

SERVICE
MANUAL
SJ3013 & SJ3014 micro
DC ELECTRIC SCISSORS
238839ABA
December 2020
ANSI & CE
This manual is for MEWPs with serial numbers:
SJ3013 & SJ3014 micro: 09281002 to 09999999
Please refer to the website (www.skyjack.com) for

contact information, other serial numbers, the most
recent technical manuals, and USB software.
THIS SAFETY ALERT SYMBOL MEANS ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED.
The Safety Alert Symbol identifies important safety

messages on MEWPs, 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.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert
against unsafe practices.
IMPORTANT
IMPORTANT indicates a procedure essential for
safe operation and which, if not followed, may
result in a malfunction or damage to the MEWP.
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Notes
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Table of Contents
Section 1 – Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Read and Heed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1-1 Mobile Elevating Work Platform (MEWP) definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1-2 Purpose of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1-3 Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1-4 Service Policy and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1-5 Ownership of MEWP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1-6 Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2-1 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2-2 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2-3 Maintenance and Service Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2-4 Hydraulic System & Component Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2-5 Maintenance Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2-6 About this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2-7 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5 General inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5-1 Service Bulletins (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5-2 Annual Inspections (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5-3 Labels (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5-4 Pothole protection limit switches (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.6 Base inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6-1 System components tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.7 Lift mechanism inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8 Platform inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.9 Function Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.1 Torque specifications for fasteners (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Torque specifications for fasteners (metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Torque specifications for hydraulic couplings & hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Specifications & Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5 Maximum platform capacities (evenly distributed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.6 Floor loading pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 31
3.1 Platform to Base Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2 Large Current Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 Ground Control Wiring Diagram (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4 Ground Control Wiring Diagram (Page 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.5 Electric Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.6 Hydraulic Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2-1 All Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2-2 No Lift or Steer functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2-3 No Lift from base or platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2-4 No Lower from base or platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2-5 No lift or lower from base controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2-6 No lift from base controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2-7 No lower from base controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2-8 No functions from platform controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2-9 No lift/lower from platform controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2-10 No steer left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2-11 No steer right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2-12 No drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3-1 All Hydraulic Controls Inoperative (No Lift or Steer functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3-2 No Lift function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3-3 No Lower function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3-4 No steer left and/or right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1-1 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 *.PGT Setting File Upload Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3 TS200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3-1 TS200 Pin Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3-2 Display Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3-3 TS200 Menu Table with EZcal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.3-4 Calibrate Level Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3-5 Calibrate Load Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3-6 Callibration Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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Section 1 – Scheduled Maintenance
1.1 Read and Heed 1.1-6 Optional equipment
This MEWP is designed to accept a variety of optional
Skyjack is continuously improving and expanding
accessories. Refer to operation manual for a list of the
product features on its equipment; therefore,
optional accessories. Operating instructions for these
specifications and dimensions are subject to change
options are in the operation manual.
without notice.
For components or systems that are not standard,
1.1-1 Mobile Elevating Work Platform speak to the Skyjack Service Department. Give the
model and serial number for each applicable MEWP.
(MEWP) definition
A mobile machine intended for moving persons, tools,
and material to working positions, consisting of a work
platform with controls, an extending structure, and a
chassis.
1.1-2 Purpose of Equipment

The Skyjack SJ DC Electric Scissor lifts are designed
to move personnel, tools, and materials to working
positions.
1.1-3 Use of Equipment

The MEWP is a highly maneuverable, mobile work
station. Work platform elevation and elevated driving
must only be done on a firm, level surface.
1.1-4 Service Policy and Warranty

Skyjack warrants each new product to be free of
defective parts and workmanship for the first 2 years
or 3000 hours, whichever occurs first. Any defective
part will be replaced or repaired by your local Skyjack
dealer at no charge for parts or labor. In addition,
all products have a 5-year structural warranty.
Contact the Skyjack Service Department for warranty
statement extensions or exclusions.
1.1-5 Ownership of MEWP

Notify Skyjack of MEWP ownership. If you sell or
transfer the ownership of a MEWP, promptly notify
Skyjack of the new owner’s contact information.
Skyjack needs this information to inform the owner of
any updates or additional activities that are necessary
to keep the machine in proper working condition.
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Section 1 – Scheduled Maintenance Maintenance and Inspection Schedule
1.2 Maintenance and 1.2-3 Maintenance and Service Safety

Tips
Inspection Schedule Maintenance and repair should only be performed by
The actual operating environment of the work platform personnel who are trained and qualified to service this
governs the use of the maintenance schedule. The MEWP.
inspection points covered in 1.4 Frequent/Periodic/
All maintenance and service procedures should be
Annual/Pre-Delivery Inspection Checklist, indicates
performed in a well lighted and well ventilated area.
the areas of the MEWP to be maintained or inspected
and at what intervals the maintenance and inspections Anyone operating or servicing this MEWP must read
are to be performed. and completely understand all operating instructions
and safety hazards in this manual and operating
1.2-1 Owner’s Annual Inspection Record manual.
It is the responsibility of the owner to arrange quarterly All tools, supports and lifting equipment to be used
and annual inspections of the MEWP. 1.3 Owner’s must be of proper rated load and in good working
Annual Inspection Record. Owner’s Annual lnspection order before any service work begins. Work area
Record is to be used for recording the date of the should be kept clean and free of debris to avoid
inspection, owner’s name, and the person responsible contaminating components while servicing.
for the inspection of the work platform. Make sure personnel are clear from under
unsupported components/systems that are at risk of
1.2-2 Replacement Parts movement during maintenance.
Use only original replacement parts. Parts such All service personnel must be familiar with employer
as batteries, wheels, railings, etc. with weight and and governmental regulations that apply to servicing
dimensions different from original parts will affect this type of equipment.
stability of the MEWP and must not be used without
manufacturer’s consent. Keep sparks and flames away from all flammable or
combustible materials.
All replacement tires must be of the same size and
load rating as originally supplied tires; to maintain Properly dispose of all waste material such as
safety and stability of MEWP. lubricants, rags, and old parts according to the
relative law provisions obtaining in the country.
Consult Skyjack’s Service Department for optional
tires specifications and installation. Before attempting any repair work, disconnect the
main power conenctors.
WARNING Keep personnel clear of components, systems or
unsupported loads that may move unexpectedly
Any unit that is damaged or not operating properly during maintenance procedures.
must be immediately tagged and removed from
service until proper repairs are completed. Preventive maintenance is the easiest and least
expensive type of maintenance.
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Maintenance and Inspection Schedule Section 1 – Scheduled Maintenance
1.2-4 Hydraulic System & Component 7. All hydraulic components must be disassembled
Maintenance and Repair in spotlessly clean surroundings. During
disassembly, pay particular attention to
The following points should be kept in mind when the identification of parts to assure proper
working on the hydraulic system or any component: reassembly. Clean all metal parts in a clean
mineral oil solvent. Be sure to thoroughly clean
WARNING all internal passages. After the parts have been
Escaping fluid from a hydraulic pressure leak can dried thoroughly, lay them on a clean, lint-free
damage your eyes, penetrate the skin and cause surface for inspection.
serious injury. Use proper personal protection at 8. Replace all O-rings and seals when overhauling
all times. any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
1. Any structure has limits of strength and amounts of petroleum jelly to hold O-rings in
durability. To prevent failure of structural parts of place during assembly.
hydraulic components, relief valves which limit 9. Be sure to replace any lost hydraulic oil when
pressure to safe operating values are included in completing the installation of the repaired
the hydraulic circuits. component, and bleed any air from the system
2. Tolerance of working parts in the hydraulic when required.
system is very close. Even small amounts of dirt 10. All hydraulic connections must be kept tight. A
or foreign materials in the system can cause loose connection in a pressure line will permit
wear or damage to components, as well as the oil to leak out or air to be drawn into the
general faulty operation of the hydraulic system. system. Air in the system can cause damage
Every precaution must be taken to assure to the components and noisy or erratic system
absolute cleanliness of the hydraulic oil. operation.
3. 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 performed under these circumstances.
4. 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.
5. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic
oil reservoir, and fill the reservoir only through
the filter opening. The use of cloth to strain the
oil should be avoided to prevent lint from getting
into the system.
6. When removing any hydraulic component,
be sure to cap and tag all hydraulic lines
involved. Also, plug the ports of the removed
components.
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Section 1 – Scheduled Maintenance Maintenance and Inspection Schedule
1.2-5 Maintenance Hints

Three simple maintenance procedures have the
greatest effect on the hydraulic system performance,
efficiency and life. Yet, the very simplicity of them may
be the reason they are so often overlooked. They are
simply these:
1. Change filters annually. The filters will need
to be changed more often depending on the
operating conditions. Dirty, dusty, high moisture
environments may cause the hydraulic system
to be contaminated more quickly.
2. Maintain a sufficient quantity of clean hydraulic
oil of the proper type and viscosity in the
hydraulic reservoir.
3. Keep all connections tight.
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Maintenance and Inspection Schedule Section 1 – Scheduled Maintenance
1.2-6 About this Section 1.2-7 Maintenance Instructions

This section contains the maintenance and inspection This manual consists of four schedules to be done
schedule that is to be performed. for maintaining on an MEWP. Inspection schedule
References are made to the procedures in Section frequency is shown below:
5 that outline detailed step-by-step instructions for
checks and replacements. Task Frequency
Service Bulletins Perform PDI prior to each

Before performing any scheduled maintenance PDI/Frequent/ delivery, or Frequent
B
inspection procedure, refer to service bulletins found Periodic Inspection every 200 days
in our web site: www.skyjack.com for updates related or 200 hours.
to service and maintenance of this MEWP.
Perform Scheduled
Maintenance and Inspection Annual C Maintenance Inspections
Death or injury can result if the MEWP is not kept in every year.
good working order. Inspection and maintenance
should be performed by competent personnel who Perform at time sensitive
Additional *
are trained and qualified on mantenance of this maintenance intervals.
MEWP.
▪ Make copies of the maintenance and inspection
checklist to be used for each inspection.
WARNING
▪ Check the schedule on the checklist for the type
Failure to perform each procedure as presented of inspection to be performed.
and scheduled may cause death, serious injury or ▪ Place a check in the appropriate box after each
substantial damage. item meets the inspection requirements.
▪ Use the maintenance and inspection checklist
NOTE and step-by-step procedures in Section 1 to
Preventive maintenance is the easiest and least perform these inspections.
expensive type of maintenance. ▪ If any inspection receives a fail, tag and remove
the MEWP from service.
▪ Unless otherwise specified, perform each
▪ If any MEWP component(s) has been repaired,
maintenance procedure with the MEWP in the
an inspection must be performed again before
following configuration:
removing the tag. Place a check in the repair
▪ MEWP parked on a flat and level surface column.
▪ Disconnect the batteries by disconnecting the Legend
main power connectors.
▪ Repair any damaged or malfunction Pass P
components before operating MEWP. Not applicable N/A
▪ Keep records on all inspections.
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Section 1 – Scheduled Maintenance Owner’s Annual Inspection Record
Table 1.3 Owner’s Annual Inspection Record
Inspection
Date
Inspector
Signature
WARNING
Do not use the MEWP if there is no inspection
recorded in the last 13 months. If you do not obey,
there is a risk of death or serious injury.
IMPORTANT
The owner’s annual inspection record is located on
the scissor assembly. It must be filled out after an
annual inspection has been completed. Do not use
the MEWP if an inspection has not been recorded
in the last 13 months.
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Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist Section 1 – Scheduled Maintenance
1.4 Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist

Frequent/Periodic/Annual/PDI Checklist
Vertical Mast, Electric Scissor, Micro Scissor & Rough Terrain
Serial Number: Starting with serial number A/B000 000 000 or 09 000 000 and above Product Owner:
Product User:
Model: Date/Time:
Hourmeter Reading: Inspection Type (Choose one): Pre-delivery Frequent Periodic Annual
Use this table for pre-delivery inspections (PDI) before each rental, lease or sale and as an instruction for all frequent inspections and annual inspections.
Refer to the operation and service manuals for inspection instructions (for example, visual inspection and function tests, torque specs, engine oil, chain
inspection intervals, and more).
B - Do the pre-delivery inspection before the machine is sent out or during the frequent inspections at 200 days or 200 hour P - Pass
Inspection Type Schedule
intervals. For more instructions, refer to the operation and service manuals. N/A - Not Applicable
PDI/Frequent/Periodic B
C - Do the scheduled maintenance Inspections each year. For more instructions, refer to the operation and service manuals.
Annual B+C
Put a check mark on the “Pass” column as you meet the requirements of the inspection of each item. Add a comment if the item does not pass inspection.
Items for Inspection P N/A Items for Inspection P N/A
Service Bulletins. Make sure there are no open service bulletins. B Manifolds. Tight fittings and hoses & no damage or leaks. Tight wire
B
connections, no missing components & correctly working valves.
Annual Inspection. Make sure you complete it within 13 months. B
Main Power Disconnect Switch. Cables tight & in working order. B
Labels. In place, correctly attached & you can read them. B
Base Controls. Operate switches and make sure they all operate correctly. No
B
Limit Switches. Correctly installed & no obstructions or damage. B damage or missing components.
BASE/ENGINE Brakes. Correctly attached & no damage or leaks. B
Engine and Components. Do a check on engine and components for any Brakes. Do a check on disc wear and replace if necessary. C
loose, missing, damaged, or failed items. Make sure you do not exceed the B
recommended fluid, oil and coolant change intervals. Base Weldment. No deformation or cracks. B
Engine and Components. Replace the engine oil and filter. C Grease Points. No obstructions, dirt, or damage. Add grease if necessary. B
Engine Intake Air Filter. No damage or missing component. Remove dirt & dust. B Ladder. Correctly attached & no damage. B
Engine Intake Air Filter. Replace the air filter if necessary. C Tilt Sensor. Correctly attached & no damage. B
Engine Oil. Oil level between “L” and “H”. Make sure you do not exceed the oil LIFTING MECHANISM - MAST/SCISSORS
B
change interval.
Maintenance Support(s). Correctly attached & no damage. B
Radiator. Correctly attached & no damage or missing components. Do a check
B Scissor Assembly & Bumpers. Correctly attached, no deformation/damage.
of coolant level. B
Cables & wires installed with no damage.
Radiator. Do a check of coolant level & condition & replace if necessary. C
Sliders & Rollers. Correctly attached & no obstructions, dirt, or damage/wear. B
Fuel Tank & Lines. Filler cap, tank, fittings and hoses are tightly closed & no
B Lift Cylinder(s). No damage or missing components. Tight fittings and hoses &
damage or leaks. B
no leaks. Correctly installed.
Propane Tank & Lines. Straps are correctly installed to brackets &
B Angle Transducer. Correctly attached & no damage. B
couplers are tight. Make sure there are no damage or leaks.
Outriggers. No damage or missing components. B Scissor Pins. Correctly attached & no damage. B
Pothole Protection. Both sides have no obstructions, dirt or damage. B Mast Assembly. No damage, cracks or deformation. B
Battery/Hydraulic Tray. Trays are latched tightly & no missing components. B Mast Assembly. Lubricate the mast as recommended. C
Batteries. No damage, tight connections & sufficient fluid levels. Clean terminals Chains, Rollers & Control Cables. No damage or missing components. B
B
and cable ends.
Wear Pads. No damage/wear or missing components. Fasteners tight. B
Battery Charger. Correctly attached & no damage. B
PLATFORM
Steer Assembly. Correctly attached & no damage leaks or missing components. B
Railings and Gate. Correctly attached & no damage or missing
B
Wheel/Tire Assembly. Do a check of all tires for damage, missing parts, wear & components.
B
correctly aligned.
Fall-Protection Anchorage. Attachment rings correctly attached & no damage. B
Wheel/Tire Assembly. Wheel nuts torqued as recommended. C
AC Power Socket. No obstructions, dirt, or damage. B
Axles. Correctly attached & no missing components. Tight fittings and hoses &
B Platform Control Console. Operate the switches and make sure they all
no leaks. B
operate correctly. No damage or missing components.
Axles. Do a check and replace oil if necessary. C
Manual Storage Box. Manuals and documents are in the storage the box, in
B
Hydraulic Tank, Pump, Motor & Lines. Filler cap, hoses, and other hydraulic good condition, and you can read them.
B
components are closed tightly & no damage or leaks.
Powered Extension Control Console. Operate switches and make sure they
B
Hydraulic Oil. Level at, or slightly above top mark. B all operate correctly. No damage or missing components.
Hydraulic Oil. Do a check and replace oil and filters if necessary. C Extension Platform. Correctly attached & no damage or missing components. B
Electrical Components. Do a check on all electrical components such as the Function Tests. Refer to the operation manual for your serial number for PASS
motor controller if necessary. Correctly attached & no damage. Tight wire con- B information on how to run these tests. FAIL
nections and fasteners.
199341ADA
Comments:
The undersigned has made sure that all areas in the list have received an inspection.
The undersigned has told the machine owner of all inconsistencies in the inspection and corrected them before machine operation.
Owner: Print Name Signature Date (DD/MM/YY)
User: Print Name Signature Date (DD/MM/YY)
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Section 1 – Scheduled Maintenance General inspections
1.5 General inspections 1.5-1 Service Bulletins (B)

Go to www.skyjack.com and use your machine’s
Do an inspection of the MEWP in this sequence:
serial number to find related open service bulletins.
WARNING 1.5-2 Annual Inspections (B)

Do not operate a MEWP that does not function Do a check on the machine’s service record to find
correctly. Lock and tag the MEWP, and remove it information about previous service performed.
for servicing. Only a qualified service technician
must repair the MEWP. If you do not obey, there is
a risk of death or serious injury.
1.5-3 Labels (B)
Refer to the operation manual for the labels. Make
sure all the labels are in the correct location, are in
WARNING good condition, and you can read them.
Turn the main power disconnect switch to the
off position before you do the visual and daily 1.5-4 Pothole protection limit
maintenance inspections. If you do not obey, there switches (B)
is a risk of death or serious injury. Make sure the pothole protection limit switches 1
are correctly attached, there is no visible damage,

and the movement is not blocked.
CAUTION
Make sure that the MEWP is on a firm, level
surface before you do the visual and daily
maintenance inspections. If you do not obey, there
is a risk of machine damage.
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Base inspection Section 1 – Scheduled Maintenance
6
2 7 5
1.6 Base inspection 3 Wheel nuts
1 Wheel/tire assembly (B, C) ▪ Make sure the wheel nuts are tight.
▪ B - Frequent/periodic/pre-delivery inspection 4 Base weldment (B)
▪ Do a check on all the tire treads and sidewalls ▪ Make sure that the base shows no signs of
for cuts, cracks, and unusual wear. visible damage, deformation, or cracks in the
weldments.
▪ Do a check on each wheel for damage, and
cracked welds. 5 Ladder (B)
▪ Make sure the wheels are correctly aligned ▪ Make sure the ladder is correctly attached.
vertically and horizontally. ▪ Make sure there are no loose or missing parts.
▪ Make sure the wheel motors 2 have no ▪ Make sure there is no visible damage.
loose or missing parts and there is no visible
damage 6 Pothole protection device
▪ Make sure there are no loose or missing parts.
WARNING ▪ Make sure there is no visible damage.
Do not use tires other than the tires that Skyjack ▪ Make sure there is no dirt and blockages.
specifies for this MEWP. Do not mix different types 7 Tilt Switch (B)
of tires or use tires that are not in good condition.
Only replace the tires with the same types that are ▪ Make sure that the angle transducer is
approved by Skyjack. The use of other tires can correctly attached.
make the MEWP less stable. If you do not obey,
there is a risk of death or serious injury.
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Section 1 – Scheduled Maintenance Base inspection
10 8 9
8 Steer cylinder (B)

▪ Make sure that the steer cylinder assembly is
correctly installed.
▪ Make sure there are no loose or missing
fasteners.
▪ Make sure there is no visible damage.
9 Steer linkages assembly (B)
▪ Make sure there are no loose or missing
fasteners and lock-pins.
▪ Make sure that the steer linkages and
bushings are correctly attached.
10 Grease points (B)
▪ Add grease if necessary.
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Base inspection Section 1 – Scheduled Maintenance
7
8 3
6
7
10 9
2
4
1.6-1 System components tray

WARNING
1 Tray
Only use original or manufacturer-approved parts
▪ Make sure that the system components tray and components for the MEWP. If you do not obey,
latches correctly and is in good condition.
there is a risk of death, serious injury, or machine
2 Base controls (B) damage.
▪ Make sure there is no visible damage, and all
the switches are in their off/neutral positions. 4 Battery charger
3 Batteries (B) ▪ Make sure that the battery charger is correctly
installed, and in good condition.
WARNING ▪ Make sure there is no visible damage.
Explosion hazard. Keep flames and sparks away. 5 Main Power Connector (B)
Do not smoke near the batteries. Batteries release ▪ Make sure the connector is in good condition.
explosive gas while you charge them. Charge the
batteries in a well-ventilated area. If you do not ▪ Make sure all cable connections are tight.
obey, there is a risk of death or serious injury. ▪ Make sure there is no visible damage.
6 Manifold
WARNING ▪ Make sure all fittings and hoses are correctly
tightened.
Corrosion hazard. Do not touch battery acid. Wear
the correct PPE. If the battery acid touches you,
▪ Make sure there is no indication of hydraulic
leakage.
immediately flush the area with cold water and get
medical aid. ▪ Make sure there are no loose wires or missing
fasteners.
1. Do an inspection of the battery case for
damage.
2. Make sure all the battery connections are
tight.
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Section 1 – Scheduled Maintenance Base inspection
7
8 3
6
7
10 9
2
4
7 Hydraulic pump and motor (B) 10 Motor controller (B)

▪ Make sure there are no loose or missing parts. ▪ Make sure the motor controller is correctly
▪ Make sure there is no visible damage. attached, and there is no visible damage.
▪ Make sure all bolts are correctly tightened. ▪ Make sure there are no loose wires or missing
fasteners.
▪ Make sure all fittings and hoses are correctly
tightened and there are no hydraulic leaks.
8 Hydraulic oil level (B, C)
▪ B - Frequent/periodic/pre-delivery inspection
▪ Fully lower the platform.
▪ Do a check of the oil level on the dipstick
of the hydraulic filler cap. Add oil if it is
necessary.
▪ C - Annual inspection
▪ Do a check of the hydraulic oil for
contamination and make sure the filter is in
good condition.
▪ Replace the hydraulic oil and filters if
necessary.
9 Electrical components (B)
▪ Do a check on these areas for chafed, corroded,
and loose wires:
1. Base to platform cables and wiring harness
2. Battery tray wiring harnesses
3. Hydraulic and electrical wiring harnesses.
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Lift mechanism inspection Section 1 – Scheduled Maintenance
2
3
1
2
1.7 Lift mechanism inspection 4 Scissor bumpers (B)
1. Raise the platform and deploy the maintenance ▪ Make sure that the bumpers are correctly
attached and have no visible damage.
supports.
5 Lift cylinder and pressure transducer (B)
1 Maintenance support (B)
▪ Make sure that the maintenance supports ▪ Make sure that the lift cylinder is correctly
installed.
are correctly attached and show no visible
damage. ▪ Make sure the pressure transducer is correctly
installed.
2 Sliders (B) ▪ Make sure there is no visible damage.
▪ Make sure that the sliders on the left and right ▪ Make sure there are no loose or missing
side of the MEWP are correctly attached. fasteners.
▪ Make sure there is no visible damage. ▪ Make sure there is no indication of leaks or
▪ Make sure there is no dirt or blockages in the damage.
slider paths. ▪ Make sure there are no loose or missing wires.
3 Scissor assembly (B) 2. Retract the maintenance support into the
▪ Make sure that the scissor assembly shows storage bracket.
no signs of visible damage, deformation, or 3. Fully lower the platform.
cracks in the weldments.
▪ Make sure all the pins and fasteners are
correctly installed.
▪ Make sure that the cables and wires have the
correct routing, and show no signs of wear
and/or physical damage.
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Section 1 – Scheduled Maintenance Lift mechanism inspection
6 Scissor pin inspection (B) 2. Remove damaged pins and bushings. Do an

inspection of the scissor bore after removing the
applicable pins and bushings. Look for signs of
WARNING damage, elongation and ovality of the hole.
Units that show signs of damage must be 3. If there is no structural damage to the scissor
immediately removed from service and repaired arms, replace the pins and bushings with new
by a qualified technician. Speak to the Skyjack components.
service department for directions on how to repair
the unit.
Examples of pivot pin connections with no
1. Do an inspection of the scissor pin connections. damage:
Look for signs of damage on the pins and
scissor arms. These signs can include:
▪ No rust
▪ Pin has not rotated
▪ Noise can be heard from seized pins. ▪ Area is clear of dust or metal shavings
▪ Rust near the pin joint ▪ Pin retainers are installed
▪ Cracks in welds of adjacent metals
▪ Dust or metal shaving from worn components
▪ Broken or missing pin retainer bolts
▪ Broken or missing pin retainers
▪ Rotated pin
▪ Elongated or enlarged pin hole
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Lift mechanism inspection Section 1 – Scheduled Maintenance
Center Pin - Middle
Center Pin - Outer
Center Pin - Inner
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Section 1 – Scheduled Maintenance Lift mechanism inspection
Upper cylinder
mount area
Lower cylinder
7
mount area
Examples of damaged pin connections: 7 Cylinder mount inspection (B)

Broken retainer bolt This inspection must be done as part of the scissor
assembly inspection.
1. Do a structural inspection of the cylinder mount
areas. Look for signs of damage to the mounts.
These signs can include:
▪ Broken, loose or missing pins or bolts
▪ Cracks in welds or the surrounding metal, or
rust forming in the area.
Rust around the pin Rotated pin
Rust around pin boss
Thrust washer
Broken pin boss Stress cracks
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Platform inspection Section 1 – Scheduled Maintenance
6 4
2
3
1.8 Platform inspection 3 AC power socket (B)

WARNING 4 Platform control console (B)
Fall Hazard. Use the three points of contact ▪ Make sure that the control console is locked with
principle when you use the MEWP to enter or exit lock-pins.
the platform. If you do not obey, there is a risk of ▪ Make sure that the platform control cable is
death or serious injury. correctly locked, and there is no visible damage.
▪ Make sure all the switches operate correctly.
1. Use the MEWP ladder to enter the platform.
2. Close the gate. 5 Extension platform (B)
▪ Make sure that the extension platform is correctly
1 Railings and gate (B)
installed.
▪ Make sure there are no loose or missing parts,
▪ Make sure there is no visible damage or missing
and there is no visible damage.
components.
▪ Make sure that the lock-pins and fasteners are
▪ Make sure the lock-pins are correctly attached.
correctly locked.
▪ Make sure that the platform railings are in the 6 Manual storage box (B)
correct position and locked with lock-pins. ▪ Make sure that the operation manual and other
▪ Make sure that the gate is in good condition and important documents are in the manual storage
operates correctly. box.
2 Fall-protection anchorages (B) ▪ Make sure that the documents are in good
condition, and you can read them.
▪ Make sure that the fall-protection anchorages are
correctly installed. ▪ Always put the manuals and other documents
back in the storage box after use.
3. Use the MEWP ladder to exit the platform.
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1.9 Function Tests
Do the function tests to find malfunctions in the
MEWP before it is put into service. The operator must
understand and follow the step-by-step instructions in
the operation manual to do all the MEWP functions.
IMPORTANT
Do not operate a MEWP that does not function
correctly. Lock and tag the MEWP, and remove it
for servicing. Only a qualified service technician
must repair the MEWP. If you do not obey, there is
a risk of death or serious injury.
▪ After repairs are completed, the operator must

do a pre-operation inspection and a series of
function tests again before putting MEWP into
service.
▪ Before you do the function tests, read and
understand the “Start Operation” section of
the operation manual.
▪ Before you do the function tests, look for the
operation manual with the same serial number
as your MEWP. The operation manual has the
instructions on which tests to do and how to
do them correctly and successfully.
Section 2 – Maintenance Tables and
Diagrams
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Section 2 – Maintenance Tables and Diagrams Torque specifications for fasteners (US)
Table 2.1 Torque specifications for fasteners (US)

Torque SAE2 SAE 5 SAE 8 Torque SAE2 SAE 5 SAE 8
Size Size
Type Dry Lubed Dry Lubed Dry Lubed Type Dry Lubed Dry Lubed Dry Lubed
(in-lb) (5) (4) (8) (6) (12) (9) ft-lb 70 55 110 80 150 110
4-40 9/16-12
Nm 0.6 0.5 0.9 0.7 1.4 1.0 Nm 95 75 149 108 203 149
(in-lb) (6) (5) (9) (7) (13) (10) ft-lb 80 60 120 90 170 130
4-48 9/16-18
Nm 0.7 0.6 1.0 0.8 1.5 1.1 Nm 108 81 163 122 230 176
(in-lb) (10) (8) (16) (12) (23) (17) ft-lb 100 75 150 110 220 170
6-32 5/8-11
Nm 1.1 0.9 1.8 1.4 2.6 1.9 Nm 136 102 203 149 298 230
(in-lb) (12) (9) (18) (13) (25) (19) ft-lb 110 85 180 130 240 180
6-40 5/8-18
Nm 1.4 1.0 2.0 1.5 2.8 2.1 Nm 149 115 244 176 325 244
(in-lb) (19) (14) (30) (22) (41) (31) ft-lb 175 130 260 200 380 280
8-32 3/4-10
Nm 2.1 1.6 3.4 2.5 4.6 3.5 Nm 237 176 353 271 515 380
(in-lb) (20) (15) (31) (23) (43) (32) ft-lb 200 150 300 220 420 320
8-36 3/4-16
Nm 2.3 1.7 3.5 2.6 4.9 3.6 Nm 271 203 407 298 569 434
ft-lb 170 125 430 320 600 460
(in-lb) (27) (21) (43) (32) (60) (45) 7/8-9
10-24 Nm 230 169 583 434 813 624
Nm 3.1 2.4 4.9 3.6 6.8 5.1
ft-lb 180 140 470 360 660 500
(in-lb) (31) (23) (49) (36) (68) (51) 7/8-14
10-32 Nm 244 190 637 488 895 678
Nm 3.5 2.6 5.5 4.1 7.7 5.8
ft-lb 250 190 640 480 900 680
(in-lb) ft-lb (66) (50) 8 (75) 12 9 1-8
1/4-20 Nm 339 258 868 651 1220 922
Nm 7.5 5.6 11 8.5 16 12
ft-lb 270 210 710 530 1000 740
(in-lb) ft-lb (76) (56) 10 (86) 14 10 1-12
1/4-28 Nm 366 285 963 719 1356 1003
Nm 8.6 6.3 14 9.7 19 14
ft-lb 280 210 730 540 1020 760
ft-lb 11 8 17 13 25 18 1-14
5/16-18 Nm 380 285 990 732 1383 1030
Nm 15 11 23 18 34 24
ft-lb 350 270 800 600 1280 960
ft-lb 12 9 19 14 25 20 1 1/8-7
5/16-24 Nm 475 366 1085 813 1735 1302
Nm 16 12 26 19 34 27
ft-lb 400 300 880 660 1440 1080
ft-lb 20 15 30 23 45 35 1 1/8-12
3/8-16 Nm 542 407 1193 895 1952 1464
Nm 27 20 41 31 61 47
ft-lb 500 380 1120 840 1820 1360
ft-lb 23 17 35 25 50 35 1 1/4-7
3/8-24 Nm 678 515 1519 1139 2468 1844
Nm 31 23 47 34 68 47
ft-lb 550 420 1240 920 2000 1500
ft-lb 32 24 50 35 70 55 1 1/4-12
7/16-14 Nm 746 569 1681 1247 2712 2034
Nm 43 33 68 47 95 75
ft-lb 670 490 1460 1100 2380 1780
ft-lb 36 27 55 40 80 60 1 3/8-6
7/16-20 Nm 908 664 1979 1491 3227 2413
Nm 49 37 75 54 108 81 ft-lb 750 560 1680 1260 2720 2040
ft-lb 50 35 75 55 110 80 1 3/8-12
1/2-13 Nm 1017 759 2278 1708 3688 2766
Nm 68 47 102 75 149 108 ft-lb 870 650 1940 1460 3160 2360
1 1/2-6
ft-lb 55 40 90 65 120 90 Nm 1180 881 2630 1979 4284 3200
1/2-20
Nm 75 54 122 88 163 122 ft-lb 980 730 2200 1640 3560 2660
1 1/2-12
Nm 1329 990 2983 2224 4827 3606
NOTE: Lubed includes lubricants such as lubrizing, oil, grease, or uncured Loctite.
1374AA
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Torque specifications for fasteners (metric) Section 2 – Maintenance Tables and Diagrams
Table 2.2 Torque specifications for fasteners (metric)
Torque 8.8 10.9

Size
Type Dry Lubed Dry Lubed
(in-lb) (54) (41) (78) (59)
M5 x 0.80
Nm 6.1 4.6 8.8 6.7
(in-lb) (92) (69) (133) (99)
M6 x 1.00
Nm 10.4 7.8 15 11.2
(in-lb) (156) (116) (222) (167)
M7 x 1.00
Nm 17.6 13.1 25.1 18.9
(in-lb) (225) (169) (333) (242)
M8 x 1.25
Nm 25.4 19.1 37.6 27.3
ft-lb 37 28 53 40
M10 x 1.50
Nm 50 38 72 54
ft-lb 65 49 93 69
M12 x 1.75
Nm 88 66 126 94
ft-lb 104 78 148 111
M14 x 2.00
Nm 141 106 201 150
ft-lb 161 121 230 172
M16 x 2.00
Nm 218 164 312 233
ft-lb 222 167 318 238
M18 x 2.50
Nm 301 226 431 323
ft-lb 314 235 449 337
M20 x 2.50
Nm 426 319 609 457
ft-lb 428 321 613 460
M22 x 2.50
Nm 580 435 831 624
ft-lb 543 407 776 582
M24 x 3.00
Nm 736 552 1052 789
ft-lb 796 597 1139 854
M27 x 3.00
Nm 1079 809 1544 1158
ft-lb 1079 809 1543 1158
M30 x 3.50
Nm 1463 1097 2092 1570
ft-lb 1468 1101 2101 1576
M33 x 3.50
Nm 1990 1493 2849 2137
ft-lb 1886 1415 2699 2024
M36 x 4.00
Nm 2557 1918 3659 2744
NOTE: Lubed includes lubricants such as lubrizing, oil, grease, 1375AB
or uncured Loctite.
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Section 2 – Maintenance Tables and Diagrams Torque specifications for hydraulic couplings & hoses
Table 2.3 Torque specifications for hydraulic couplings & hoses

Hydraulic Coupling Torque Chart
O-Ring Port Connectors
Steel Ports Non-ferrous Ports
SAE Size
ft-lb Nm ft-lb Nm
4 14-16 20-22 9-10 12-13
6 24-26 33-35 15-16 20-21
8 50-60 68-78 30-36 41-47
10 72-80 98-110 43-48 60-66
12 125-135 170-183 75-81 102-110
16 200-220 270-300 120-132 162-180
20 210-280 285-380 126-168 171-228
24 270-360 370-490 162-216 222-294
32 - - - -
Hose End Torque Chart Hose End Torque Chart

for JIC for Flat-Face O-Ring Seal (Steel)
Size Steel Brass Size Torque Specification
ft-lb Nm ft-lb Nm ft-lb Nm
Dash Frac. Dash Frac.
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
-4 1/4" 10 11 13 15 5 6 6.75 9 -4 1/4" 10 12 14 16
-6 3/8" 17 19 23 26 12 15 17 20 -6 3/8" 18 20 24 27
-8 1/2" 34 38 47 52 20 24 27.66 33 -8 1/2" 32 40 43 54
-10 5/8" 50 56 69 76 34 40 46.33 55 -10 5/8" 46 56 60 75
-12 3/4" 70 78 96 106 53 60 72.33 82 -12 3/4" 65 80 90 110
-16 1" 94 104 127 141 74 82 100.5 111 -14 1" 65 80 90 110
-20 1 1/4" 124 138 169 188 75 83 101.5 113 -16 1 1/4" 92 105 125 240
-24 1 1/2 156 173 212 235 79 87 107 118 -20 1 1/2 125 140 170 190
-32 2" 219 243 296 329 158 175 214 237 -24 2" 150 180 200 245
1276AA
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Specifications & Features Section 2 – Maintenance Tables and Diagrams
Table 2.4 Specifications & Features
Models SJ3013 & SJ3014 micro
Weight * 820 kg (1808 lb)

Overall width 0.76 m (29.92 in)
Overall length (Platform Retracted) 1.49 m (58.66 in)
Overall length (Platform Extended) 1.8 m (70.87 in)
Platform Size - Inside 1.28 m x 0.76 m
(Platform Retracted) (50.39 in x 29.92 in)
Platform Size - Inside 1.8 m x 0.76 m
(Platform Extended) (70.87 in x 29.92 in)
Height
ANSI CE
Working Height 6.23 m (20 ft 5.23 in) 6.4 m
Platform Elevated Height 4.4 m (14 ft 5.23 in) 4.4 m
Stowed Height (Railings Down) 1.59 m (62.60 in) 1.59 m
Stowed Height (Railings Up) 2.02 m (79.53 in) 2.05 m
Drive Height Full
Standard Operating Times
Lift Time (No Load) 23 s
Lower Time (No Load) 19 s
Lift Time (Rated Load) 25 s
Lower Time (Rated Load) 18 s
Chassis
Normal Drive Speed 3.0 km/h (1.9 mph)
Elevated Drive Speed 0.8 km/h (0.5 mph)
Gradeability (Ramp Angle) 25%
Tires (Solid Rubber) 230M
Sound Pressure Level at Platform Level
Does not exceed: 70 dB(A)
2087AB
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Section 2 – Maintenance Tables and Diagrams Maximum platform capacities (evenly distributed)
Table 2.5 Maximum platform capacities (evenly distributed)
Tilt cutout
Extension platform Manual side
Model Wind rating Total platform capacity force
setting (side-to-side x
capacity front-to-back)
SJ3013
0 m/s 240 kg 100 kg 400 N
& SJ3014 2 Persons 1 Person 1.5˚ × 2.5˚
[0 mph] (529 lb) (220 lb) 90 lbf
micro
2079AB
NOTE
Occupants and materials are not to exceed the rated load. Refer to the capacity label at the entrance of the
platform and the front kick plate for more information and models equipped with options.
Table 2.6 Floor loading pressure

Weights Pressures
Max weight per LCP** OFL**
Model MEWP weight
wheel
kg lb kg lb N/mm2 psi N/mm2 psf
SJ3013 & Min* 820 1808
SJ3014 265 584 0.57 82 0.013 271
micro Max* 1060 2337
2080AB
* Min: Minimum MEWP weight (Unloaded platform, no options/attachments)
Max: Maximum MEWP weight (Platform loaded to capacity with options/attachments)
Wheel is the weight that can be experienced on one wheel.

Note: This is more than 25% of the machine weight due to possible weight distribution over the machine and platform.
** LCP: Local Concentrated Pressure is a measure of how hard the MEWP presses on the area in direct contact with the floor/tire.
OFL: Overall Floor Load (Pressure) is a measure of the average load the MEWP imparts on the whole surface directly underneath the
chassis. This has been calculated by dividing the MEWP weight by the overall floor area occupied by the MEWP (on wheels).
Note: The floor covering (e.g., tile, carpet, etc.) or the structure (e.g., beams) of the operating surface must
be able to withstand more than the values indicated above.
Note: The LCP or OFL that an individual surface can withstand varies from structure to structure and is
generally determined by the engineer or architect for that particular structure.
238839ABA SJ3013 & SJ3014 micro

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Section 3 – System Component
Identification and Schematics
SJ3013 & SJ3014 micro 238839ABA

31
Section 3 – System Component Identification and Schematics Platform to Base Control Cable
3.1 Platform to Base Control Cable
Note: Unmarked wires or connectors or terminals are self-contained components.
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Large Current Wiring Diagram Section 3 – System Component Identification and Schematics
3.2 Large Current Wiring Diagram

BATTERIES
FUSE
BATTERY DISCONNECT
PUMP MOTOR
DRIVE MOTOR
CONTACTOR
DRIVE MOTOR
Note: 1. Unmarked wires or connectors or terminals are self-contained components.

2. * External demand for tin
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3.3 Ground Control Wiring Diagram (Page 1 of 2)
A B C D E F G H
V
CHARGER INTERRUPT
FUSE
STEER
LOWER EMERGENCY STOP RIGHT
LIFT STEER
LEFT
W
CONTACTOR
X
KEY SWITCH
BUZZER
POWER RELAY
Y
HOUR METER
LIFT/LOWER SWITCH
MANUAL BRAKE RELEASE

Z
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3.4 Ground Control Wiring Diagram (Page 2 of 2)
A B C D E F G H
RIGHT MOTOR BRAKE

CHASSIS HARNESS
LEFT MOTOR BRAKE
LOWER VALVE
V
POTHOLE SWITCH
POTHOLE SWITCH
FLASHING LIGHT
FLASHING LIGHT
W
PRESSURE SENSOR
ANGLE SENSOR
SENSOR HARNESS
BATTERIES
24- GROUND HARNESS
Note: Unmarked wires or connectors or terminals are self-contained components.
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3.5 Electric Schematic Diagram
A B C D E F G H
Platform control box

V
Platform emergency stop
left
Buzzer HA1
right
diode Left motor brake
Lift val e Manual brake release W
diode Right motor brake
switch
Flashing light
Lower val e
Flashing light
switch
Power relay
Lift
Angle sensor
Lower Lift/Lower switch
Platform mode
Pressure sensor Base mode
Hour meter Off/Platform/Base Key switch

diode
diode
Contactor Y
Fuse
motor
Fuse
Charger
Pump motor Battery
Base emergency stop

Z
TS200
238839ABA SJ3013 & SJ3014 micro

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3.6 Hydraulic Schematic Diagram
A B C D E F G H
C1 LIFT CYLINDER C2 STEER CYLINDER
CV2
LOWER
OR1
YV1 YV2
LIFT STEER L STEER R
CV1
RV1 Y
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Notes
238839ABA SJ3013 & SJ3014 micro

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Section 4 – Troubleshooting Information
4.1 Introduction
The following pages contain a table of
Troubleshooting for locating and correcting most
service trouble which can develop. Careful and
accurate analysis of the systems listed in the table
of Troubleshooting will localize the trouble more
quickly than any other method. This manual cannot
cover all possible troubles and deficiencies that may
occur. If a specific trouble is not listed, isolate the
major component in which the trouble occurs, isolate
whether the problem is electrical or hydraulic, and
then isolate and correct the specific problem.
The content of this section is separated into “probable
cause” and “remedy.” The information in the left-
hand column, preceded by a number, represents the
“probable cause.” The information in the right-hand
column, in bold text, represents the “remedy” to the
“probable cause” directly beside it. See the example
below for clarification.
1. Probable cause Remedy
SJ3013 & SJ3014 micro 238839ABA

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Section 4 – Troubleshooting Information Electrical System
4.2 Electrical System

NOTE
Functions may be disabled by the load sense system.
Please first ensure the platform is fully lowered, free
of added weight, and there are no faults in the load
sense system
NOTE
Functions may be disabled by the machine control
system. Check for any codes displayed and refer the
code chart in Section 5
4.2-1 All Controls Inoperative

1. Battery cables loose/disconnected Tighten or connect battery cables
2. Battery Discharged or Defective Charge battery or replace if defective
3. Fuse F1 defective or open Check for defective wiring. Replace fuse
4. Loose or broken B+ cable from F1 fuse to battery
Check continuity. Replace if defective.
disconnect connector
5. Open or defective battery disconnect connector Close switch. Replace if defective
6. Loose or broken 24VA wire from battery
Check continuity. Replace if defective
disconnect connector to contactor KM1 common
7. Loose or broken 24VA wire from contactor KM1
Check continuity. Replace if defective
common to fuse F2
8. Fuse F2 defective or open Check for defective wiring. Replace fuse
9. Loose or broken 24VB wire from fuse F2 to
charger interupt
Check charger: if plugged in then unplug. Replace
10. Open or defective charger interrupt.
if defective.
11. Loose or broken 24VC wire from charger interupt
to Base emergency stop switch SB1.
12. Open or defective Base emergency sop switch
Close switch. Replace if defective
SB1.
13. Loose or broken 24VD wire from Base
emergency stop switch SB1 to connector 7P01 Check continuity. Replace if defective.
Pin 1..
14. Loose or broken 24VD wire from connector 7S01
Pin 1 to 7P02 pin 1 (Base to platform control Check continuity. Replace if defective.
cable)
15. Loose or broken 24VD wire from connector 7S02
pin 1 to Platform control E-stop switch SB2
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Electrical System Section 4 – Troubleshooting Information
16. Open or defective Platform emergency sop

switch SB2.
17. Loose or broken 24VE wire from Platform control
E-stop switch SB2 to 7S02 pin 2.
18. Loose or broken 24VE wire from connector 7S01
cable)
19. Loose or broken 24VE wire from connector 7P01
Pin 2 to Off/Platform/Base Key switch SA1.
20. Loose or broken wires between Off/Platform/Base
Key switch SA1 terminals
21. Open or defective Off/Platform/Base Key switch
SA1
22. Loose or broken wire 24VF from Off/Platform/
Base Key switch SA1 to power relay KA1 coil +
23. Loose or broken wire 24V- from power relay KA1
coil - to connector 8S02 pin 1
24. Loose or broken wire 24V- from connector 8P02
pin 1 to Battery -
25. Loose or broken wire 24VB from Fuse F2 to
power relay KA1 coil common.
4.2-2 No Lift or Steer functions

1. Loose or broken M2+ cable from TS200 machine
controller to Pump motor M3
2. Defective Pump motor M3 Replace if defective
3. Loose or broken M2- cable from Pump motor to
TS200 machine controller
Check and repair any active codes and/or
4. Defective TS200 controller.
connection issues Replace if defective.
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4.2-3 No Lift from base or platform

1. Loose or broken wire from TS200 machine
controller pin P9-1 to YV3 lift valve coil + Check continuity. Replace if defective.
(connector 2S03 pin 1)
2. Defective YV3 lift valve coil Replace coil
3. Loose or broken 24- wire from YV3 lift valve coil -
(connector 2S03 pin 2) to connector 8S02 pin 5.
4. Loose or broken 24- wire from connector 8P02
pin 5 to Battery -.
4.2-4 No Lower from base or platform

controller pin P9-2 to connector 12P01 pin 1
2. Loose or broken wire from connector 12S01 pin
1 to YV4 lower valve coil +
3. Defective YV4 lower valve coil Replace coil
4. Loose or broken 24- wire from YV4 lower valve
coil - to connector 12S01 pin 12.
pin 12 to 8S02 pin 1.
pin 1 to Battery -.
4.2-5 No lift or lower from base controls

1. Loose or broken +24V wire from Power Relay
KA1 to lift/lower switch SA2.
2. Open or defective Off/Platform/Base key switch
SA1
3. Loose or broken wire from Off/Platform/Base
key switch SA1 to TS200 machine controller pin Check continuity. Replace if defective.
P12-1
4.2-6 No lift from base controls

1. Loose or broken wire from lift/lower switch SA2 to
TS200 machine controller pin P12-4
2. Open or defective lift/lower switch SA2 Replace if defective
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4.2-7 No lower from base controls

1. Loose or broken wire from lift/lower switch SA2 to
TS200 machine controller pin P12-5
2. Open or defective lift/lower switch SA2 Replace if defective
4.2-8 No functions from platform controls

1. Open or defective Off/Platform/Base key switch
SA1
2. Loose or broken wire from Off/Platform/Base
key switch SA1 to TS200 machine controller pin Check continuity. Replace if defective.
P15-1
3. Loose or broken 24V- wire from Platform joystick
to 7S02 pin 4.
4. Loose or broken 24V- wire from connector 7S01
cable)
5. Loose or broken 24V- wire from connector 7P01
Pin 4 to connector 8S02 pin 3.
pin 3 to battery -
7. Loose or broken power wire from platform
emergency stop to platform control box joystick
8. Defective enable switch or wiring on platform Check wiring and switch. Repair or replace if
control box joystick defective.
9. Loose or broken CAN H and/or CAN L wires from
Platform control box joystick to 7S02 pin 5 and 6.
10. Loose or broken CAN H and/or CAN L wires from
connector 7S01 Pins 5 and 6 to 7P02 pins 5 and Check continuity. Replace if defective.
6 (Base to platform control cable)
11. Loose or broken CAN H and or CAN L wires from
connector 7P01 pins 5 and 6 to TS200 machine Check continuity. Replace if defective.
controller CAN-1 and CAN-2 terminals.
12. Defective platform control box Joystick Replace if defective
4.2-9 No lift/lower from platform controls

1. Defective platform control box wiring, select check wiring and switches. Repair/Replace as
switches and/or Joystick reuired.
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4.2-10 No steer left

controller pin P9-9 to steer left YV1 coil connector Check continuity. Replace if defective.
2S01 pin 1
2. Defective steer left YV1 coil Replace coil
3. Loose or broken 24- wire from steer left YV1 coil
connector 2S01 pin 2 to connector 8S02 pin 7
pin 7 to battery -
5. Defective right steer switch or wiring on upper Check wiring and switch. Repair or replace if
contol joystick defective.
4.2-11 No steer right

controller pin P9-7 to steer right YV2 coil Check continuity. Replace if defective.
connector 2S02 pin 1
2. Defective steer right YV2 coil Replace coil
3. Loose or broken 24- wire from steer right YV2
coil connector 2S02 pin 2 to connector 8S02 pin Check continuity. Replace if defective.
6
pin 6 to battery -
5. Defective left steer switch or wiring on upper Check wiring and switch. Repair or replace if
contol joystick defective.
4.2-12 No drive
1. Defective platform control box wiring, select Check wiring and switches. Repair/Replace as
switches and/or Joystick reuired.
controller pin P9-3 to diode D1
3. Defective diode D1 Check diode Replace if defective.
4. Loose or broken wire from diode D1 to connector
12P01 pin 2
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44
5. Loose or broken wire from connector 12S01 pin

2 to right and/or left motor brake brake connector Check continuity. Replace if defective.
2P04 and/or 2P05 pin 2
6. Loose or broken 24V- wire from right and/or left
motor brake brake connector 2P04 and/or 2P05 Check continuity. Replace if defective.
pin 1 to 12S01 connector pin 11
connector pin 11 to pin 12 and connector 8S02 Check continuity. Replace if defective.
pin 1
pin 1 to battery -
9. Defective right and or left motor brake Check brakes. Replace if defective.
10. Loose or defective wiring from TS200 machine
controller M1+ to right and/or left drive motor
11. Loose or defective wiring from TS200 machine
controller M1- to right and/or left drive motor
12. Defective traction motor Check Motors. Replace if defective.
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Section 4 – Troubleshooting Information Hydraulic System
4.3 Hydraulic System

4.3-1 All Hydraulic Controls Inoperative (No Lift or Steer functions)
Refer to Electrical troubleshooting. Replace pump
1. Pump motor not engaged
motor if defective.
2. Pump motor coupler defective Check coupler. Replace if defective
3. Defective pump P1 Check pump output. Replace if defective.
Check and adjust valve setting. Replace if
4. System relief valve RV1 set too low or stuck open.
defective.
5. Check valve CV1 stuck closed Check valve, Replace if defective
4.3-2 No Lift function

1. Stuck or defective lift valve YV3 Check valve, Replace if defective
2. Check valve CV2 stuck closed Check valve, Replace if defective
4.3-3 No Lower function

3. Stuck or defective lower valve YV3 Check valve, Replace if defective
4. Blocked lower orifice OR1 Check orifice Clean orifice or Replace if defective
4.3-4 No steer left and/or right

1. Stuck or defective steer valve YV1 and or YV2 Check valves, Replace if defective
2. Steer cylinder C5 bypassing, or mechanically Check cylinder and all steer linkage. Repair or
binding replace defective componants as required.
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Section 5 – Procedures
5.1 General
WARNING
The following information is provided to assist you in
the use and application of servicing and maintenance Fall Hazard. Use the three points of contact
procedures contained in this chapter. principle when you use the MEWP to enter or exit
the platform. If you do not obey, there is a risk of
death or serious injury.
NOTE
The illustrations in this manual are for instructional WARNING
purposes only. The models and components DO NOT operate any control on the platform
shown may appear somewhat different from control console without proper fall protection
those on your actual MEWP. secured to the designated location in the platform.
Failure to avoid this hazard could result in death or
5.1-1 Safety and Workmanship serious injury!
Your safety, and that of others, is the first
consideration when engaging in the maintenance of
equipment. Always be conscious of weight. Never
attempt to move heavy parts without the aid of a WARNING
mechanical device. Do not allow heavy objects to Make sure there are no people or obstructions in
rest in an unstable position. When raising a portion of the test area, and there is sufficient space for the
the equipment, make sure that adequate support is scissor and drive functions required for the given
provided. procedures.
Unless specifically noted otherwise, before beginning

any procedure:
1. Park the mobile elevating work platform (MEWP)
on a firm, level surface.
2. Fully lower the machine.
3. Push in the “ ” emergency stop buttons
on the platform control console and the base
control console.
4. Turn the off/platform/base key switch to the
“ ” off position. Remove the key.
5. Turn the main power disconnect switch to the
“ ” off position.
After completing any procedure which involves

modifying, adjusting, or replacing any hydraulic or
electrical components, perform all of the function tests
given in your unit’s operation Manual.
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Section 5 – Procedures *.PGT Setting File Upload Process
5.2 *.PGT Setting File Upload 7. On each machine that needs the settings
uploaded from the *.pgt file, plug the EZCal Pro
Process into the control board. The location of the EZCal
connector is at the bottom right of the control
1. An EZCal Pro with a USB port is required to
board, circled in the following image. An EZCal
enable the external *.pgt file to be transported
cable will be required.
from a laptop/PC to the EZCal Pro
2. There needs to be a *.pgt file available for

upload that is applicable to the machine it is
being uploaded to.
3. USB read/write privilege is required on the PC/
Laptop in use.
4. Connect the EZCal Pro unit to the PC/laptop
that has the *.pgt file intended for upload.
5. Upload *.pgt file onto the EZCal Pro (Note: do

not create folders – leave the file at the top level
of the EZCal directory).
6. Safely remove the EZCal from the USB port.
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48
*.PGT Setting File Upload Process Section 5 – Procedures
8. Turn on the machine at the main power

disconnect and pull out both E-Stops.
9. Enter the “EZCal Pro Menu” by one of the
following methods:
a. Press and hold the key while connecting
the EZcalPro to the controller, or
b. Press and hold the key for about 5
seconds, if the EZcalPro is already connected
to the controller, or 13. The screen will update as the upload happens.
Depending on the size of the upload, you may
c. Press the key while pressing the
see some or all of the following screens:
button (avoids the 5 second delay)
a. “WORKING” ”LOADCOUNT=x” ”%
COMPLETE”
b. The Upload is finished when the screen reads
“OK”.
14. Push in and pull out the E-Stop on the base.
15. Go back into the normal EZCal menu and check
the adjustments have been successfully updated
on the board by using the and key to
select “ADJUSTMENTS”. Check you know what
settings need to be checked for the specific task
10. “EZcal Pro MENU: SETUP” will be displayed.
16. Remove the EZCal Pro from the control board,

close up any trays/doors that were opened and
11. Scroll right and select “LOAD from EZcal” turn off the machine.
Hit Enter 17. Update is completed. Perform any function
checks and tests recommended in the task.
18. If any errors occur during the process, stop the
upload and contact Skyjack for support.
12. Scroll right through the pgt files on the

EZCal until you locate the intended file. The
example used in the image below is called
“Settings Push.pgt”. Check you know the name
of the correct file being uploaded for the task.
Press the up arrow to select “YES”.
Hit Enter
SJ3013 & SJ3014 micro 238839ABA

49
Section 5 – Procedures TS200
5.3 TS200
5.3-1 TS200 Pin Chart
PIN
PLUG PIN OUT
#
P9 1 Output to YV3 lift valve
P9 2 Output to YV4 lower valve and hour meter P1 through diode D3
P9 3 Output to brake release
P9 4 Not Used
P9 5 Output to KM1 contactor and hour meter P1 through diode D4
P9 6 Not Used
P9 7 Output to YV2 steer right valve
P9 8 Input from pothole switches SQ1 and SQ2
P9 9 Output to YV1 steer left valve
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TS200 Section 5 – Procedures
TS200 Pin Chart (Continued)
PIN
PLUG PIN OUT
#
P12 1 Input from Off/Platform/Base keyswitch SA1: Base mode
P12 2 Not Used
P12 3 Not Used
P12 4 Input from lift/lower switch SA2: Lift
P12 5 Input from lift/lower switch SA2: Lower
P12 6 Switched ground output to buzzer HA1
P12 7 Input from scisso angle (height) sensor AS1 (PP1-2)
P12 8 Not Used
P12 9 Not Used
P12 10 Input from lift cylinder prssure sensor PS1
P12 11 Not Used
P12 12 Input from scissor angle (height) sensor AS1 (PP2-2)
P15 1 Input from Off/Platform/Base keyswitch SA1: Platform mode

P15 2 Not Used
P15 3 Not Used
P15 4 Not Used
P15 5 Not Used
P15 6 Not Used
P15 7 Not Used
P15 8 Not Used
P15 9 Not Used
P15 10 Not Used
P15 11 Not Used
P15 12 Not Used
P15 13 Not Used
P15 14 Not Used
P15 15 Ground for scissor angle (height) sensor AS1 and lift pressure sensor PS1
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51
5.3-2 Display Messages and Codes

Under most normal operating conditions the LED
light on the TS200 controller will be on steady and
the Platform control box display will indicate the
approximate bateery charge.
Some machine conditions will flash a code on the
TS200 controller LED and may also display on the
Platform Control Box. These conditions include
interlocks that may occur during normal operation, as
well as faults in the inputs/outputs or in the controller.
An EZcal is required to be connected to the TS200
controller 232 to display text that will indicate the exact
condition.
If the TS200 machine controller LED is not illumonated
then it is not recieving the required power. Check
all power and ground connections, batteries and
ensure there is power at P15-1 when platform mode
is selected and P12-1 when base mode is selected at
the Off/Platform/Base keyswitch.
A new controller will continuously flash quickly until it
is set up and calibrations are performed.
Display Messages and Codes

Display
EZcal Display Message Description
Code
1-X The TS200 has not been properly calibrated; check height and load calibration. (an EZcal is required).
Height and load based functions are required (for example
platform overload is configured), but height and/or load has
NOT CALIBRATED not been calibrated.
Calibrate load which includes height calibration.
1-1 Height based functions are required (for example MAX DRIVE
HEIGHT NOT CALIBRATED is configured), but height has not been calibrated.
Calibrate height (see SETUPS/HEIGHT SETUPS).
Both height and load must be calibrated

FUNCTIONS LOCKED - NOT CALIBRATED
Calibration load and height.
Something is preventing functions operating normally; check EMS inputs and all operator switch inputs
(drive/lift mode, joystick, etc); check for conditions which shut down functions (eg: tilted, too high to drive,
platform overloaded, etc)
2-X NOTE
In ground mode, only the ground input switches
are relevant; while in platform mode the ground
input switches are ignored
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52
Display Messages and Codes (Continued)
Display
Code
The platform and ground EMS inputs indicate the mode in
which the TS200 must operate. If neither input is active, or
2-1 SHUTDOWN - CHECK EMS SWITCHES!
if both are active together, the TS200 does not know how to
function Check EMS switch wiring to P15-1 and P12-1.
FUNCTIONS LOCKED - TOO HIGH The platform is raised too high to allow some functions.
The platform is loaded too high to allow operation – the plat-

FUNCTIONS LOCKED - OVERLOADED
form load must be reduced.
Platform overload features are active, and the platform load

is too low to be valid – this could be caused by erroneous
FUNCTIONS LOCKED - UNDERLOADED
calibration, a sensor fault, or a change in the vehicle mechan-
ics/hydraulics.
An external shutdown is preventing functions – check DIAG-

FUNCTIONS LOCKED - EXTERNAL
NOSTICS/SYSTEM/MODE/ INTERLOCK to see which external
SHUTDOWN
interlock is active.
The platform joystick was selected for too long without trigger
FUNCTIONS LOCKED - TILTED
switch.
During descent, the TS200 can stop movement for a con-

figurable time (see ADJUSTMENTS/ LIFT/ ARMGUARD), to
FUNCTIONS LOCKED - ARMGUARD (CE
allow a safety check that no-one is close to the vehicle. The
ONLY)
operator must release and then re-select DOWN to continue
lowering (after the delay timeout).
2-2 Base control function switches were closed at power-on (or a

RELEASE GROUND SWITCHES!
wiring error is causing an input to be active always).
The platform joystick was not in neutral at power-on (or a wir-

RELEASE JOYSTICK SWITCHES!
ing error is causing an input to be active always).
The platform trigger switch was closed at power-on (or a wir-

ing error is causing the input to be active always)
RELEASE TRIGGER!
The platform trigger switch was closed for too long with no
function selected.
There is a problem with the platform drive/lift select switch –

SELECT DRIVE/LIFT MODE! neither mode is selected Check wiring from drive/lift select
switch.
FAULT: MOTOR CONNECTIONS The TS200 has detected multiple power wiring faults on mo-
SHORTED tors A and/or B.
There is a problem with the platform drive/lift select switch –

CHECK DRIVE/LIFT SELECT SWITCH!
both modes are selected together.
There is a problem with the ground function select switches –

CHECK GROUND INPUT SWITCHES!
more than one is active at the same time.
CHECK JOYSTICK! There is a problem with the platform joystick.
SJ3013 & SJ3014 micro 238839ABA

53
Display
Code
There is a problem with the drive contactor or valve wiring, or with the motor power wiring; disconnect
connector P9 to see if the problem is caused by drive contactor or valve wiring (if the fault clears, check
for an illegal B+ supply in to P9).
Also check motor power wiring; with the drive contactor open the B+ power terminals should be at
3-X
10V-15V (significantly lower than B+).
If the LED is steady at power-on, and the fault (3/5) occurs after a delay when attempting to drive or
lift, the motor may be stalled and causing an overload of the TS200 or there is a power wiring error like
connecting the B+ cable to a motor stud.
FAULT: ENERGIZED VALVE - CHECK P9
WIRING! There is a voltage on one or more valve outputs, when all
3-2
FAULT: VALVE FEEDBACK HIGH - CHECK outputs should be off Check wiring to each valve coil.
VALVE WIRING!
The voltage on the B+ stud of the controller (connected to an
FAULT: CAPBANK VOLTAGE TOO HIGH -
3-3 internal voltage stabilization capacitor bank) is close to B+
CHECK LINE CONT!
when the drive contactor is off.
Check the line contactor tips are not welded; check the
3-4 FAULT: BAD INTERNAL SAFETY OUTPUT!
power wiring for errors.
The TS200 power protection circuits have activated to protect

3-5 MOTOR OVERLOAD! from extreme overload Check for short-circuit power wiring;
check for a seized motor.
Here is a problem with battery supply, the height and/or pressure sensors, the supply to them, or the
temperature sensor inside the TS200.
Check battery supply to EMS inputs P15-1 or P12-1 (relative to the B- stud); the battery supply should be
4-X between 15V and 32V.
Check the output from height and pressure sensors (P12-10, P12-12)
If the TS200 heatsink is very hot then perhaps the controller has temporarily shut down – if so, platform
lowering is still allowed; wait for the controller to cool down.
The internal “5V slave” supply is out of range; if the fault
FAULT: BAD INTERNAL 5V!
remains, the controller may have to be replaced.
FAULT: BAD INTERNAL SECONDARY The internal “secondary control” is not operating correctly; if
4-2 CONTROL! the fault remains, the controller may have to be replaced.
TS200 heatsink temperature exceeds 90ºc, preventing all

FUNCTIONS LOCKED - TOO HOT! functions except lowering Check for excessive motor current
draw; check for good heatsinking to vehicle chassis.
4-3 The internal “12V” supply is out of range; if the fault remains,
FAULT: BAD INTERNAL 12V!
the controller may have to be replaced.
The battery supply is too low – the battery must be re-

FAULT: BATTERY VOLTAGE TOO LOW!
charged.
The battery supply is too high – check that the correct battery
FAULT: BATTERY VOLTAGE TOO HIGH!
4-4 and charger are installed.
The optional battery charger cutout input is preventing func-

FUNCTIONS LOCKED - BATTERY
tions.
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Display
Code
There is a problem with load measurement – the height and/or pressure sensor measurements are out of
range, or the elevation switch disagrees with the height sensor
6-X
Check that the output from height and pressure sensors (P12-10, P12-12) is in range (between 0.5V and
4.5V)
FAULT: CHECK HEIGHT1 SENSOR A height sensor is giving an out-of-range voltage (below 0.5V
or above 4.5V) Check for open- or short-circuit wiring; replace
FAULT: CHECK HEIGHT2 SENSOR height sensor if necessary.
6-1 Both height should read the same height at all times; this
message indicates that the sensors are reading different
FAULT: CHECK HEIGHT SENSORS
heights.
Check for loose sensors; re-calibrate height if necessary.
The pressure sensor is giving an out-of-range voltage (below

0.5V or above 4.5V)
6-2 FAULT: CHECK PRESSURE SENSOR
Check for open- or short- circuit wiring; replace pressure sen-
sor and re-calibrate load if necessary.
During calibration, the height at which the elevation switch

opens (while lifting) and closes (while lowering), is recorded;
during normal operation the elevation switch and platform
6-3 FAULT: CHECK ELEVATION SWITCH
height are continuously compared
Check for open- or short-circuit wiring; check for loose eleva-
tion switch cam; re-calibrate height if necessary.
CANbus messages expected from one or more modules

(Platform controm box to TS200) are not being received, or
messages intended to one or more module cannot be trans-
mitted.
6-6 FAULT: CAN BUS! Check for open- and short- circuit problems with CANbus
wiring; ensure that the CANbus is wired correctly pin-to-pin;
ensure that the vehicle chassis is not erroneously shorted to
the motor wiring (for example, due to insulator breakdown in
the motor).
There is a problem with the power wiring – the voltage on the B+ stud is too low (it should be at least 10V
7-X at all times)
Check for a short-circuit to the B+ stud.
7-1 FAULT: MOTOR A SHORT TO HIGH
The TS200 has detected a power wiring fault on motor A.
7-2 FAULT: MOTOR A SHORT TO LOW
7-3 FAULT: MOTOR B SHORT TO HIGH

The TS200 has detected a power wiring fault on motor B.
7-4 FAULT: MOTOR B SHORT TO LOW
FAULT: MOTOR CONNECTIONS The TS200 has detected multiple power wiring faults on mo-
7-5
SHORTED tors A and/or B.
The voltage on the B+ stud of the controller (connected to an

internal voltage stabilization capacitor bank) is too far from
B+ when the drive contactor is off (a pre-charge circuit in the
FAULT: CAPBANK VOLTAGE TOO LOW -
7-7 module normally applies a voltage to the capacitor bank)
CHECK STUD WIRING!
Check the power wiring for errors
Check wiring to the drive contactor coil, so that the drive
contactor closes when drive is requested.
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When an EZcal is connected to the TS200 machine controller 232 port then there are information only
messages available for which there are no LED blink/Platform Control box display codes.
The TS200 has just been powered on and is carrying out
some initialization steps prior to being ready to operate. If you
STARTUP
select a function during this time, it may be locked out until
you release then re-select it.
The TS200 is ready to operate in platform mode when a func-

tion is selected.
EVERYTHING OK
NOTE: If this is the HELP message when a function is se-
lected, check for open-circuit switches or wiring.
The TS200 is ready to operate in ground mode when a func-

GROUND MODE ACTIVE
tion is selected.
DRIVING
LIFTING Messages indicate that a function is active – the vehicle

LOWERING should be moving as requested by the operator.
STEERING
A platform function is selected but the trigger switch is not

CLOSE TRIGGER
closed.
The vehicle is tilted beyond the limits. Some functions may be

VEHICLE TILTED
prevented.
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5.3-3 TS200 Menu Table with EZcal

When the EZcal hand-held device is connected to
the TS200 control module, a two line display shows
various menus and settings. At any time the top line of
the display describes the currently selected menu and
the bottom line shows the currently selected item in
that menu.
Six buttons on EZcal allow easy navigation through
the menus:
and change the selected item (the bottom line
display)
ENTER enters the selected new menu when available
(top line display changes)
and adjusts the selected item when available (at
“ACCESS LEVEL” 2)
ESC exits the current menu back to the previous
menu
TS200 Menu Table with EZcal
Selection Description
HELP Select this menu to see a description of current TS200 status
DIAGNOSTICS Select this menu to see switch & sensor input status & logged data
ACCESS LEVEL Select this menu & enter correct code to enable adjustments and calibrations
RUN SYSTEM TEST Select this menu to enter system test mode
ADJUSTMENTS Select this menu to see and adjust TS200 adjustments
SETUPS Select this menu to carry out initial set-up of the TS200
CALIBRATIONS This menu is intended for use by TS200 design engineers only!
SERIAL NUMBER Select this menu to view the serial number of the controller
HELP
A message displays current TS200 status, indicating if everything is OK or if there is a reason for restricted
(help message)
functionality
Press ENTER when viewing the current HELP message to see a log of recent HELP messages; press è to see
LOGGED HELP
older messages, and ç to see newer ones; press ESC to return to the current HELP message
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TS200 Menu Table with EZcal (continued)
Menu Selection Description

DIAGNOSTICS
SYSTEM Select this menu to see general TS200 system information
PLATFORM Select this menu to see platform input status

MENU
Select this menu to see ground input status (during calibration, separate measurements are collected during
GROUND
lifting and lowering)
DIAGNOSTICS
INPUTS Select this menu to see other input status
ANALOGS Select this menu to see analog input status
OUTPUTS Select this menu to see TS200 output status
LOG Select this menu to see logged information
MODE Displays current operating mode or interlock
MODE / When current operating mode shows INTERLOCKED, press ENTER to see the reason for the interlock; press
INTERLOCK ESC to return to the current operating mode
SUPPLY Displays battery supply voltage
SUPPLY /
Indicates when battery is “low” (see SETUPS / BATTERY)
LowBatt
SUPPLY /
Indicates when battery is “low” (see SETUPS / BATTERY)
DeadBatt
Displays the estimated battery charge (see SETUPS / BATTERY)

SUPPLY / BCI
NOTE: BCI is also displayed on the platform control box Display Module
MtrV Displays motor voltage of both motors (will be equal, unless steering)
MtrI Displays motor current of both motors

SYSTEM
Displays motor voltage of both motors (will be equal, unless steering)

TEMPERATURE Displays motor current of both motors
TILT Displays tilt values (X˚, Y˚)
TILTED Displays whether system is in tilted mode (measured tilt ex-ceeds tilt trip points)
Displays platform height, calculated from height sensor(s) and data stored during calibration. Press ENTER
when viewing the HEIGHT (which is the average of the two sensors), to see the individual measurements of the
HEIGHT
two sensors, named HEIGHT1 and HEIGHT2 (press è and ç to see both); press ESC to return to the average
HEIGHT
Displays platform load, esti-mated from lift cylinder pres-sure measurement, platform height, and height/pres-
LOAD
sure curves stored during calibration
OVERLOADED Displays whether system is in overload mode (platform load exceeds load trip point, at/above overload height)
Displays whether the most re-cent platform movement was UP or DOWN; this is important if the lift cylinder
LAST MOVED
pressure is affected by the direction of movement
ELEVATED Displays whether system is in elevated mode
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Menu Selection Description

DIAGNOSTICS
TRIGGER Displays ON when platform trigger pressed
DLD Displays drive / lift mode (from drive / lift switch)

PLATFORM
JOY F/R Displays joystick position in the forward/reverse (or up/down) direction (%)
JOY L/R Displays joystick position in the steer left/right direction (%)
CASTERlock Displays YES when steer switch is pressed

GROUND
UP Displays ON when BASE up switch pressed
DOWN Displays ON when BASE down switch pressed
P12-1 Shows P12-1 input status (BASE mode from keyswitch)
P12-2 Not used.
P12-3 Not used.
P12-4 Shows P12-4 input status (LIFT from base controls)
P12-5 Shows P12-5 input status (LOWER from base controls)
P12-9 Not used.

I INPUTS
P15-1 Shows P15-1 input status (PLATFORM mode from keyswitch)
P15-2 Not used.
P15-3 Not used.
P15-5 Not used.
P15-6 Not used.
P15-8 Not used.
P15-9 Not used.
P15-11 Not used.
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Menu Selection Sub-Menu Description

DIAGNOSTICS
vP9-1 Displays state of P9-1 output (YV3 LIFT valve)
vP9-2 Displays state of P9-2 output (YV4 LOWER valve)
vP9-3 Displays state of P9-3 output (brake release)
vP9-4 Not used.
vP9-5 Displays state of P9-5 output (KM1 contactor)
vP9-6 Not used.
vP9-7 Displays state of P9-7 output (YV2 STEER RIGHT valve)
vP9-9 Displays state of P9-9 output (YV1 STEER LEFT valve)

OUTPUTS
lP12-2 Not used.
lP12-3 Not used.
lP12-6 Displays state of P12-6 output (ground to HA1 buzzer/alarm)
lP15-4 Not used.
lP15-7 Not used.
lP15-10 Not used.
PREout Displays state of “safe” pre-valve output
FEEDBACK Select this sub-menu to view feedback status of outputs
Press é or ê to turn on test mode, which allows each output in this menu to be manually turned on / off using
TESTMODE
é and ê
P12-7 Displays voltage measurement of angle (height) sensor AS1 (PP1-2)
P12-10 Displays voltage measurement of lift cylinder pressure sensor PS1
P12-11 Not used.

ANALOGS
P12-12 Displays voltage measurement of angle (height) sensor AS1 (PP1-1)
P15-13 Not used.
P15-14 Not used
PREout Displays “safe” pre-valve output status – LO when off, HI when on

FEEDBACK
P9-x Displays output status of all P9 outputs (ie: valves – LO when all valves off, HI when one or more valves on
CALDATE Displays date entered by operator at end of last calibration
SOFTWARE Displays software version of TS200
POWERED Displays total time that TS200 has been powered

LOG
MAX.BATTERY Displays maximum recorded battery supply voltage
Displays total work time (TS200 records work time during all movement) NOTE: work time is also displayed
WORKTIME
on the op-tional Display Module
ERASE WORK-
Press ENTER, and ENTER again, to confirm clearing WORKTIME to zero
TIME
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ACCESS LEVEL
When the EZcal hand-held device is connected to the 232 port of the TS200 control module, the initial “ACCESS
LEVEL” is 3 – no adjustments can be altered or calibrations carried out. Before adjustments or calibrations can
be made, the “ACCESS LEVEL” must be changed to 2 using the correct access code (2222). ACCESS LEVEL 2
allows calibrations and may allow some adjustments to be changed,
To set “ACCESS LEVEL” 2, carry out the following procedure using EZcal:
ACCESS LEVEL
1) Find the “ACCESS LEVEL” menu (using and ) and select it (using ENTER)
2) The display will show the initial code 0000 with the first 0 flashing
CODE xxxx
3) Set the first digit of the code to 2 (using and )
4) Press to move to the next digit (the first digit will stop flashing, the second will start flashing)
5) Set the second digit of the code to 2
6) Repeat steps 4 and 5 for all the code digits – ensure that the code is correctly entered (if a digit is wrong, press
and to select it again, and and to correct it)
7) Press ENTER to confirm the code; the “ACCESS LEVEL” will change if the correct code is entered
ADJUSTMENTS
MIN Determines the slowest drive speed in all directions (when the joystick is at 0% demand)
Determines the fastest drive speed in the forward direction (when the joystick is at 100% demand in forward
FWD MAX
direction)
Determines the fastest drive speed in the reverse direction (when the joystick is at 100% demand in reverse
REV MAX
direction)
SPIN MAX Determines the fastest drive speed when “spinning” (when the joystick is fully left or right)
DRIVE
ACCEL Determines the rate of increase of drive speed when higher speeds are demanded
DECEL Determines the rate of decrease of drive speed when lower speeds (or stop) are demanded
STEER ACCEL Determines the rate of increase of drive speed when higher “spin” speeds are demanded
STEER DECEL Determines the rate of decrease of drive speed when lower “spin” speeds (or stop) are demanded
BRAKE DELAY Determines the delay when drive ends, before brakes are applied
Determines the slowest drive speed in all directions (when the joystick is at 0% demand), when platform is
MIN
elevated
Determines the fastest drive speed in the forward direction (when the joystick is at 100% demand in forward
FWD MAX
direction), when platform is elevated
DRIVE/ DRIVE/ELEVATED
Determines the fastest drive speed in the reverse direction (when the joystick is at 100% demand in reverse
REV MAX
direction), when platform is elevated
Determines the fastest drive speed when “spinning” (when the joystick is fully left or right), when platform is
SPIN MAX
elevated
ACCEL Determines the rate of increase of drive speed when higher speeds are demanded, when platform is elevated
Determines the rate of decrease of drive speed when lower speeds (or stop) are demanded, when platform is
DECEL
elevated
Determines the rate of increase of drive speed when higher “spin” speeds are demanded, when platform is
STEER ACCEL
elevated
Determines the rate of decrease of drive speed when lower “spin” speeds (or stop) are demanded, when
STEER DECEL
platform is elevated
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ADJUSTMENTS
UP MIN(*) Determines the slowest lifting speed (when the joystick is at 0% demand)
UP MAX(*) Determines the fastest lifting speed (when the joystick is at 100% demand)
DOWN MIN(*) Determines the slowest lowering speed (when the joystick is at 0% demand)
DOWN MAX(*) Determines the fastest lowering speed (when the joystick is at 100% demand)
ACCEL Determines the rate of increase of lift/lower speed when higher speeds are demanded
LIFT
DECEL Determines the rate of decrease of lift/lower speed when lower speeds are demanded
Determines the height above which lifting is prevented. Set to prevent lift above the set height. Ensure to set
MAX LIFT MAX LIFT so that the lift cylinder does not go to end of stroke and over pressurizes (it will be interpreted as an
overloaded platform!)
TIME Determines the time delay when armguard triggers during lowering, before lowering is allowed to continue.
ARMGUARD
Determines the height at which “soft armguard” occurs when lowering. Set to zero to trigger “soft armguard”
@HEIGHT T at the ELEVATION@ height, or nonzero to trigger at the set height IMPORTANT: If armguard function is not
needed, choose 101% to disable.
UP(*) Determines the (fixed) lifting speed in ground mode

GROUNDMODE
DOWN(*) Determines the (fixed) lowering speed in ground mode
ACCEL Determines the rate of increase of lift/lower speeds in ground mode
DECEL Determines the rate of decrease of lift/lower speeds in ground mode
Determines when to sound the alarm – set to “NO” to not sound while driving, to “FWD” or “REV” to sound
DRIVE
while driving in that direction, or to “BOTH” to sound for driving in either direction.
AALARMS
Determines when to sound the alarm – set to “NO” to not sound while lifting/lowering, to “UP” or “DOWN” to
LIFT
sound while lifting or lowering, or to “BOTH” to sound for lifting and lowering.
Determines when to sound the alarm – set to “NO” to not sound depending on tilt, to “ELEVATED” to sound if
TILT
tilted and elevated, or to “ALWAYS” to sound when tilted irrespective of platform height.
CHANGE Select this menu to check correct customer / vehicle model configuration, and/or select new vehicle model
DEFAULTS defaults
SETUPS
TILT SETUPS Select this menu to calibrate tilt (on level ground) and configure tilt shutdown
HEIGHT SET-
Select the menu to calibrate height measurement
UPS
LOAD SETUPS Select this menu to calibrate overload and to configure certain overload related options
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5.3-4 Calibrate Level Procedure

The integral tilt sensor of the TS200 control module
must be calibrated when the machine is perfectly 5.3-5 Calibrate Load Procedure
level; an EZcal hand-held device is required to carry
out this procedure:
The TS200 control module requires calibration before
1. Ensure the MEWP is level front to back and side it can estimate platform load; calibration records the
to side. Use a digital level and a jack to level as lift cylinder pressure at various platform heights, both
required. fully loaded and empty. Use a known accurate weight
2. Connect the EZcal and follow the rest of the of 240Kg (530lbs.) centered on the platform with the
procedure with the access tray closed. Ensure extension deck fully retracted. After the calibration
the EZcal cable is not restrained. procedure is enabled using an EZcal hand-held
3. Enter the “ACCESS LEVEL” 2 code (2222) to device, the MEWP platform is fully raised and lowered
enable calibrations three times:
4. Select the “TILT SETUPS” menu (available
from the “SETUPS” menu) and select the A. DYNAMIC calibration – fully loaded
“CALIBRATE LEVEL” option platform raised & lowered in one continuous
5. The display will show “YES: ENTER, NO: ESC”, movement
asking for confirmation that the vehicle is level B. LOADED calibration – fully loaded platform
6. Press the ENTER button to confirm raised & lowered with stops to take
7. The display will now show the current tilt measurements
measurements; if the leveling procedure was C. EMPTY calibration – unloaded platform
successful then raised & lowered with stops to take
8. Both the “X” and “Y” tilts should be about zero measurements
9. Press the ESC button to exit the “CALIBRATE
LEVEL” option IMPORTANT
10. If the tilt measurements are not zero in step 6, Any changes to the machine mechanics,
try the procedure again – press the ESC button hydraulics, etc. may require re-calibration!
then the ENTER button and repeat from step 4
11. If the tilt measurements still cannot be zeroed, The following procedure must be followed
check that the vehicle is properly parked on COMPLETELY to calibrate the TS200; throughout the
level ground, and check that the TS200 control procedure various checks are made – if any problem
module is correctly and securely installed is detected the procedure stops and displays a
on a vertical surface of the vehicle, with the FLASHING failure message. Explanations of each
connectors at the bottom. message and suggested corrections can be found in
the document at the end of this procedur
NOTE
If the calibration procedure is interrupted, completed
phases need not be repeated. A “REDO” prompt will
appear – answer “NO” if there is no reason to repeat
the phase, or “YES” if the phase must be repeated (for
example, a significant mechanical or hydraulic change
has been made).
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1. Ensure machine parked on level ground, and C. When the UP switch is released, the TS200
TS200 leveled. records the maximum height of the platform
2. Ensure machine both platform and base e-stop 10. The display now shows “PLEASE LOWER …”
switches are pulled out. Operate the machine as A. Close the DOWN switch and KEEP IT
required in BASE MODE CLOSED until the platform is fully lowered
3. Enter the “ACCESS LEVEL” 2 code (2222) using IMPORTANT: If the DOWN switch is released
EZcal to enable adjustments and calibrations early, the calibration will have to be aborted
4. Select the “LOAD SETUPS” menu (available and repeated from the beginning!
from the “SETUPS” menu) and select the 11. When the system detects the DOWN switch
“CALIBRATE LOAD” option closed, the display will show “LOWERING”
5. The display will show “REDO DYNAMIC? YES” A. i) The system will wait for the DOWN switch
– for the first time calibration only “YES” can be to be released once the platform is fully
selected lowered
A. Press the ENTER button to confirm that 12. The load calibration “DYNAMIC” phase is now
dynamic calibration is needed complete
6. The display will show “PLATFORM DOWN?”, 13. The display will show “REDO LOADED? YES”
asking for confirmation that the platform is fully – for the first time calibration only “YES” can be
lowered selected
A. Check that the platform is fully lowered then A. i) Press the ENTER button to confirm that
press the ENTER button to confirm loaded calibration is needed
7. The display will show “PLATFORM LOADED?”, 14. The display will show “PLATFORM LOADED?”,
asking for confirmation that the platform is asking for confirmation that the platform is
loaded loaded
A. Load the platform with the calibration load A. Press the ENTER button to confirm
then press the ENTER button to confirm 15. The display will show “PLEASE LIFT …”, waiting
8. The display will show “PLEASE LIFT …”, waiting for the UP switch to be activated to begin raising
for the UP switch to be activated to begin raising the platform
the platform A. Close the UP switch and keep it closed until
A. Close the UP switch and KEEP IT CLOSED the platform has reached full height
until the platform has reached full height 16. When the system detects the UP switch closed,
the display will show “LIFT LOADED” with the
IMPORTANT
current height (from 0% to 100%)
If the UP switch is released early, the calibration
will have to be aborted and repeated from the 17. After a delay, the system will stop the platform lift
beginning! and take height & pressure measurements; the
display will show “MEASURING #xx”
9. When the system detects the UP switch A. When the measurements have been taken,
closed, the display will show “LIFTING” with an the platform will resume lifting
increasing count
18. The lifting … stopping … measuring … lifting
A. The system will monitor changing height as process will continue until the platform reaches
the platform is lifted, until the UP switch is full height
released
19. When the platform reaches full height (and
B. A counter shows the number of height 100% is displayed), release the UP switch
measurements taken during the lift; a
20. The display shows “TOTAL DATA: xx” to indicate
maximum of 500 measurements can be
the number of measurements taken, then shows
recorded – if the machine lifts too slowly, a
“PLEASE LOWER …”
fault can occur when 500 is reached! If so,
adjust SETUPS/HEIGHT A. Close the DOWN switch and keep it closed
until the platform is fully lowered
SETUPS/SAMPLES@ to a bigger time, to increase the
delay between each measurement
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21. When the system detects the DOWN switch B. Similar to the “LOWER LOADED” phase
closed, the display will show “LOWER LOADED” the lowering … stopping … measuring …
with the current height (from 100% to 0%) lowering process will continue until the
22. Again after a delay, the system will stop the platform is fully lowered, then the DOWN
platform lower and take height & pressure switch can be released
measurements; the display will show C. The display shows “TOTAL DATA: xx” to
“MEASURING #xx” indicate the number of measurements taken
A. i) When the measurements have been taken, 30. The load calibration “EMPTY” phase is now
the platform will resume lowering complete
23. The lowering … stopping … measuring … 31. The collected data is checked to ensure that
lowering process will continue until the platform there were no problems with the recorded
is fully lowered. pressure; checks include making sure that the
24. When the platform is fully lowered (and height loaded pressures are higher than the empty
0% is displayed), release the DOWN switch; the pressures, with sufficient difference to enable
display shows “TOTAL DATA: xx” to indicate the load estimates to be calculated
number of measurements taken 32. The display will show “CALDATE: mm/dd/yy”
25. The load calibration “LOADED” phase is now with the “mm” value flashing
complete A. It is recommended that the current date
26. The display will show “REDO EMPTY? YES” – be entered here to provide easy tracking
for the first time calibration only “YES” can be of the date of last calibration (the date can
selected be seen in the “LOG” menu available in the
“DIAGNOSTICS” menu)
A. Press the ENTER button to confirm that
empty calibration is needed B. Use and to set the month, then press
to move to the date; set the date and
27. The display will show “PLATFORM EMPTY?”,
then the year in the same way
asking for confirmation that the platform is
empty C. Press ENTER to complete date entry (the
system will store it)
A. Remove all load from the platform then press
the ENTER button to confirm 33. The display will show “FINISHED!”
28. The display will show “PLEASE LIFT …”, waiting IMPORTANT
for the UP switch to be activated to begin raising Press the ESC button to exit the “CALIBRATE
the platform LOAD” option (it’s not possible to use the machine
A. Close the UP switch and keep it closed until if you don’t do this)
the platform has reached full height
34. The TS200 is now fully calibrated
B. When the system detects the UP switch
closed, the display will show “LIFT EMPTY”
with the current height (from 0% to 100%)
C. Similar to the “LIFT LOADED” phase the
lifting … stopping … measuring … lifting
process will continue until the platform
reaches full height, then the UP switch can be
released
D. The display shows “TOTAL DATA: xx” to
indicate the number of measurements taken
29. The display will show “PLEASE LOWER …”
A. Close the DOWN switch and keep it closed
until the platform is fully lowered
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5.3-6 Callibration Fault Codes

During calibration, the TS200 control module repeatedly checks for possible problems which might prevent
successful calibration, or subsequently give inaccurate platform load estimates.
If any problem is detected, a flashing error message is immediately displayed and calibration is terminated – the
problem must be resolved, and calibration re-started.
Fault Code List (Software: 2151051_20200731 v7.3)
Most calibration error messages have an “Fxx” number as well as a description, to aid in trouble-shooting:
Fault Code Description
Something is wrong, preventing the TS200 from running – check the HELP message (causes
F01:CANNOT RUN
include line contactor, valve, or motor wiring errors)
F02:NOT GROUND
Calibration can only be carried out from BASE control!
MODE
F03:NOT STOPPED The machine must not already be moving when calibration is begun.
F04:TILTED The machine must be on level ground when calibration is begun.
F05:BAD HEIGHT1 At the start of calibration, the EZfit height sensor is out of range (output must be between 0.9V and
F05:BAD HEIGHT2 4.1V with platform fully lowered)
F06:CHECK ELEV At the start of calibration, the ELEVATION switch (P4-6) is open with platform fully lowered
F07:BAD HEIGHTS During calibration, the two height sensors disagreed too much
The ELEVATION switch (P4-6) is closed with platform fully raised – or the switch changed state
F08:CHECK ELEV
more than once (it should go from closed to open just once, as the platform is raised)
F09:BAD HEIGHT1 The EZfit height sensor is out of range when fully lowered (0%) calibration is recorded (output must
F09:BAD HEIGHT2 be between 0.9V and 4.1V with platform fully lowered)
F10:BAD HEIGHT1 The EZfit height sensor is out of range when fully raised (100%) calibration is recorded (output must
F10:BAD HEIGHT2 be between 0.6V and 4.4V with platform fully raised)
F11:NOT UP When instructed to go up (raise the platform) the DOWN switch was activated, or vice-versa (check
F11:NOT DOWN switch wiring)
More than 500 samples were recorded during dynamic lifting – the machine lifts too slowly Increase
F12: TOO MANY the value of SETUPS/HEIGHT SETUPS/SAMPLE@ to delay longer between each sample (do not
increase too much, as this will cause inaccurate dynamic load estimates
There is not enough difference between the EZfit height sensor output when fully lowered, and fully
F13:LOW HEIGHT raised (minimum allowed difference is 1V)
RANGE
Ensure the UP switch is not released before the platform is fully raised.
The EZfit height sensor output is bad during dynamic lifting (must be between 0.6V and 4.4V
F14: BAD HEIGHT1
always)
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Fault Code List (Software: 2151051_20200731 v7.3) (continued)
The EZfit height sensor output is bad during dynamic lifting (must be between 0.6V and 4.4V
F14: BAD HEIGHT1
always)
The ELEVATION switch (P4-6) is open with platform fully lowered at the end of the dynamic
raising / lowering cycle – or the switch changed state more than once (it should go from closed
F15: CHECK ELEV
to open just once, as the platform is raised, and from open to closed just once, as the platform is
lowered)
The point at which the ELEVATION switch (P4-6) open while the platform was lifting, is too low
F16: LOW ELEV.OPEN (it should open between 5% and 20% height) The actual height where the switch opened can be
seen in CALIBRATIONS/ElevUp
The point at which the ELEVATION switch (P4-6) open while the platform was lifting, is too high
F17: HIGH ELEV.OPEN (it should open between 5% and 20% height) The actual height where the switch opened can be
seen in CALIBRATIONS/ElevUp
The point at which the ELEVATION switch (P4-6) closed while the platform was lowering, is too
F18: LOW ELEV.CLOSE low (it should open between 5% and 20% height) The actual height where the switch opened can
be seen in CALIBRATIONS/ElevDown
F19: HIGH ELEV.CLOSE At the start of calibration, the ELEVATION switch (P4-6) is open with platform fully lowered
F20: HEIGHT1<>0% After fully raising and fully lowering the platform, during dynamic or static calibration, we should
F20:HEIGHT2<>0% always be back at 0% height!
F22: HEIGHT1<>100%
After fully raising the platform, during static calibration, we should always lift to 100% height
F22:HEIGHT2<>100%
During static (loaded or empty) calibration, no more than 20 measurement points can be
F24: TOO MANY recorded! A properly working machine with lift cylinder pressure reliably indicating platform load,
should not require more than 10 measurement points.)
During static (loaded or empty) calibration, the platform height is out of range (below 0% or
F27: BAD HEIGHT
above 100%, or below 0.4V or above 4.6V)
At the end of static (loaded or empty) calibration, the sequence of recorded height
measurements is invalid! During the lifting calibration, height measurements should be increasing
F27: BAD HEIGHTS
from 0% to 100%; during the lowering calibration, height measurements should be decreasing
from 100% to 0%
At the end of dynamic calibration, the recorded height/pressure curve is checked – the expected
curve has a high pressure peak near the bottom (due to maximum lift needed when the scissor
arms are nearly horizontal), a low pressure trough near the middle, and a higher peak near the
F34: REJECT CURVE
top. The difference between the highest pressure and lowest pressure is too small (it should be
at least 0.25V). This could be due to using the wrong range pressure transducer, or due to a
problem with the lift cylinder hydraulics
SJ3013 & SJ3014 micro 238839ABA

67
Fault Code List (Software: 2151051_20200731 v7.3) (continued)
F40: REJECT DELTA At the end of all static calibrations, the loaded and empty height/pressure curves are compared –
DOWN @ the loaded curve should be higher than the empty curve, due to the additional platform load. This
error indicates there is less than 0.2V difference between the loaded and empty curves (or that
the loaded curve is below the empty curve), at the indicated height
IMPORTANT
Ensure that loaded calibration is done with rated
load in the platform, and empty calibration is done
with no load in the platform! Also ensure that the
F40:REJECT DELTA UP correct range pressure transducer is used)
@
NOTE
Only the first problem height is reported, use the
GetCurveW program to review the curves and
determine if the problem is at a particular part of the
curve, or across the complete curve
F42: LOW PRESSURE When the platform is fully lowered, the lift cylinder pressure cannot be checked – therefore
soon after lifting begins during static (loaded and empty) calibration, the lift cylinder pressure
is checked; this ensures that a hydraulic problem is discovered early, instead of waiting till
F43: HIGH PRESSURE calibration has been completed but with bad data! The lift cylinder pressure transducer output
must be between 0.4V and 4.6V at all times
F44: LOW PRESSURE During static (loaded or empty) calibration, the lift cylinder pressure is out of range (below 0.4V or
F45: HIGH PRESSURE above 4.6V)
F46: CHECK ELEV During dynamic calibration, the elevation switch changed state (closed to open, or open to
F47: CHECK ELEV closed) more than once!!
At the start of calibration, the pressure sensor is out of range (output must be between 0.3V and
F48: BAD PRESSURE
4.8V at all times)
At the end of static (loaded or empty) lifting or lowering calibration, too few measurements were
taken (a minimum of 4 measurements is required). Check that SETUPS/HEIGHT SETUPS/MIN
F49: TOO FEW
LIFT is not set too high; recommended values are between 1s for fast lifting machines, and 3s for
slow lifting machines
Something happened to cause calibration to fail – it is recommended to check all sensor wiring
F52: NOT CALIBRATED!
for loose connections, then repeat calibration
This display occurs when all calibrations (dynamic, loaded up, loaded down, empty up, empty
FINISHED! down) have been completed, and the CALDATE has been entered. Be sure to press <ESC> on
the EZcal to exit calibration, before attempting to use the machine
GO UP MORE! During calibration, the operator needs to close the UP or DOWN switch as required to lift or lower
the platform – if the switch is closed in the wrong direction, no fault occurs but the machine does
GO DOWN MORE! not move! This display clarifies the error
During static (loaded or empty) calibration, it may happen that a second measurement is taken
IGNORING very close to the previous measurement (for example if the operator lets go the UP/DOWN switch
– no fault occurs, and this display indicates that the new measurement is being ignored
During calibration, the TS200 sometimes delays while waiting for sensor values to stabilize – this
PLEASE WAIT
display indicates why nothing appears to be happening
238839ABA SJ3013 & SJ3014 micro

68
Fault Code List (Software: 21513050_20210723 V1.0)
Fault Description CODE Display to Show:
EVERYTHING OK 0/0 Battery %

GROUND MODE ACTIVE! 0/0 Battery %
STARTUP! 0/0 Battery %
EXTENDING DECK! 0/0 Battery %
RETRACTING DECK! 0/0 Battery %
EXTENDING OUTRIGGERS! 0/0 Battery %
RETRACTING OUTRIGGERS! 0/0 Battery %
DRIVING! 0/0 Battery %
LIFTING! 0/0 Battery %
LOWERING! 0/0 Battery %
STEERING! 0/0 Battery %
CLOSE TRIGGER 0/0 Battery %
VEHICLE TILTED 0/0 Battery %
SELECT DRIVE/LIFT MODE! 0/0 Battery %
NOT CALIBRATED 1/2 1-2
HEIGHT NOT CALIBRATED 1/3 1-3
FUNCTIONS LOCKED - TEST MODE SELECTED 1/5 1-5
FUNCTIONS LOCKED - POTHOLE 2/1 2-1
FUNCTIONS LOCKED - ARMGUARD 2/1 2-1
FUNCTIONS LOCKED - OVERLOADED 2/2 2-2
FUNCTIONS LOCKED - UNDERLOADED 8/1 8-1
FUNCTIONS LOCKED - TOO HIGH 2/4 2-4
FUNCTIONS LOCKED - TILTED 2/3 2-3
FUNCTIONS LOCKED - EXTERNAL SHUTDOWN 2/9 2-9
FUNCTIONS LOCKED - OUTRIGGERS 2/5 2-5
FUNCTIONS LOCKED - NO VALVE SUPPLY! 2/8 2-8
FUNCTIONS LOCKED - BATTERY! 4/A 4-0
FAULT: CHECK ELEVATION SWITCH 6/3 6-3
FAULT: CHECK PRESSURE SENSOR 6/2 6-2
FAULT: CHECK HEIGHT1 SENSOR 6/1 6-1
FAULT: CHECK HEIGHT2 SENSOR 6/1 6-1
FAULT: CHECK HEIGHT SENSORS 6/1 6-1
FUNCTIONS LOCKED - TOO HOT! 4/2 4-2
FACTORY OVERRIDE F/F Battery %
CHECK GROUND INPUT SWITCHES! 5/A Battery %
CHECK DRIVE/LIFT SELECT SWITCH! 5/1 Battery %
CHECK JOYSTICK SWITCHES! 5/3 Battery %
RELEASE TRIGGER! 3/4 Battery %
RELEASE OUTRIGGER SWITCHES! 2/5 Battery %
RELEASE GROUND SWITCHES! 5/4 Battery %
SJ3013 & SJ3014 micro 238839ABA

69
Fault Code List (Software: 21513050_20210723 V1.0) (continued)
Fault Description CODE Display to Show:
RELEASE JOYSTICK! 5/6 5-6

FUNCTIONS LOCKED - NOT CALIBRATED 1/4 1-4
SHUTDOWN - CHECK EMS SWITCHES! 5/7 5-7
SOME BIG BAD PROBLEM! 9/9 9-9
FAULT: B+ STUD VOLTAGE TOO HIGH - CHECK
3/3 3-3
LINE CONT!
FAULT: BAD INTERNAL 12V! 9/9 9-9
FAULT: BAD 5V SENSOR SUPPLY - CHECK P2-1
4/1 4-1
WIRING!
FAULT: BAD INTERNAL 5V! 9/9 9-9
FAULT: BAD INTERNAL SLAVE! 9/9 9-9
FAULT: BAD INTERNAL TEMPERATURE SENSOR! 9/9 9-9
FAULT: ENERGIZED VALVE - CHECK P5 WIRING! 3/2 3-2
FAULT: ENERGIZED LINE CONTACTOR - CHECK
3/4 3-4
P5 WIRING!
FAULT: MOTOR OVERLOAD! 3/5 3-5
FAULT: B+ STUD VOLTAGE TOO LOW! 7/7 7-7
FAULT: BATTERY VOLTAGE TOO LOW! 4/4 4-4
FAULT: BATTERY VOLTAGE TOO HIGH! 4/5 4-5
FAULT: CAN BUS! 6/6 6-6
FAULT: VALVE FEEDBACK HIGH - CHECK VALVE
3/1 3-1
WIRING!
FAULT: CUSTOMER 1/1 1-1
238839ABA SJ3013 & SJ3014 micro

70
SJ3013 & SJ3014 micro 238839ABA

71
Notes
238839ABA SJ3013 & SJ3014 micro

72
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SERVICE

Please refer to the website (www.skyjack.com) for

BECOME ALERT! YOUR SAFETY IS INVOLVED.

The Safety Alert Symbol identifies important safety

SJ3013 & SJ3014 micro 238839ABA

238839ABA SJ3013 & SJ3014 micro

Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SJ3013 & SJ3014 micro 238839ABA

Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

238839ABA SJ3013 & SJ3014 micro

1.1-2 Purpose of Equipment

1.1-3 Use of Equipment

1.1-4 Service Policy and Warranty

1.1-5 Ownership of MEWP

SJ3013 & SJ3014 micro 238839ABA

1.2 Maintenance and 1.2-3 Maintenance and Service Safety

238839ABA SJ3013 & SJ3014 micro

SJ3013 & SJ3014 micro 238839ABA

1.2-5 Maintenance Hints

238839ABA SJ3013 & SJ3014 micro

1.2-6 About this Section 1.2-7 Maintenance Instructions

Service Bulletins Perform PDI prior to each

SJ3013 & SJ3014 micro 238839ABA

Table 1.3 Owner’s Annual Inspection Record

238839ABA SJ3013 & SJ3014 micro

1.4 Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist

Items for Inspection P N/A Items for Inspection P N/A

BASE/ENGINE Brakes. Correctly attached & no damage or leaks. B

Owner: Print Name Signature Date (DD/MM/YY)

User: Print Name Signature Date (DD/MM/YY)

SJ3013 & SJ3014 micro 238839ABA

1.5 General inspections 1.5-1 Service Bulletins (B)

WARNING 1.5-2 Annual Inspections (B)

are correctly attached, there is no visible damage,

238839ABA SJ3013 & SJ3014 micro

1.6 Base inspection 3 Wheel nuts

SJ3013 & SJ3014 micro 238839ABA

8 Steer cylinder (B)

238839ABA SJ3013 & SJ3014 micro

1.6-1 System components tray

SJ3013 & SJ3014 micro 238839ABA

7 Hydraulic pump and motor (B) 10 Motor controller (B)

238839ABA SJ3013 & SJ3014 micro

1.7 Lift mechanism inspection 4 Scissor bumpers (B)

SJ3013 & SJ3014 micro 238839ABA

6 Scissor pin inspection (B) 2. Remove damaged pins and bushings. Do an

238839ABA SJ3013 & SJ3014 micro

Center Pin - Middle

Center Pin - Outer

Center Pin - Inner

SJ3013 & SJ3014 micro 238839ABA

Examples of damaged pin connections: 7 Cylinder mount inspection (B)

Rust around the pin Rotated pin

Rust around pin boss

Broken pin boss Stress cracks

238839ABA SJ3013 & SJ3014 micro

1.8 Platform inspection 3 AC power socket (B)