J1 Plug Pin Identification

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1 D5 D8 D7 D4 D5 D ART_8 J 4 8 D D0 7 R R R R4 TB 80 D D D D4 D D J Plug Pin Identification PIN # WIRE # SIGNAL FUNCTION 0 INPUT Drive Reverse INPUT Drive Forward OUTPUT Brake, Decel Valve signal 4 8 INPUT Steer Left 5 8 OUTPUT Steer signal to Sevcon 5 INPUT Down signal 7 0 OUTPUT Signal to Motion Alarm(s) (optional) 8 7 OUTPUT Sevcon & Hour Meter (motor function requested) 5 INPUT Battery Negative 0 7 INPUT Steer Right 4 INPUT Lift Up INPUT Limit Switch (4V = platform down) OUTPUT Enable, from lower Lift switch 4 OUTPUT To Sevcon (for speed cutback) ART_ 4 7 ] Fuse ] Contactor ] Tilt Sensor 4] Circuit (Diode) Board 5] MotorControl Unit ] Main Harness Connection 7] Control Cable Connection 8] Motion Alarm (option) ] Lift/Lower Switch 0] Platform-Base Selector ] Emergency Stop Switch ] Battery Gauge 4] Hour Meter 5] Battery Cutoff Switch "047ES / 47ES / 47ES" Service & Parts Manual - ANSI Specifications March 008 Page 4-

2 SEVCON MOTOR SPEED CONTROLLER The Sevcon Motor Speed Controller (MC-) is a microprocessor designed with the express purpose of operating the D/C electric motor at varying speeds. The controller uses Pulse-Width Modulation (PWM) technology on the Ground side of the motor to control motor speed. Out of concern for operator safety and to prevent short-circuiting, the Controller monitors certain circuits for potential abnormalities. When the controller senses a problem it errs to the side of safety and stops all motor operation. The green LED will flash a code indicating the reason for the shutdown. Refer to the LED Diagnostics Definitions and Sevcon Motor Speed Controller - Connections on the following pages. Cable Connection Identification B+ Battery Positive Cable from 50 AMP Fuse B- Negative Battery Cable and GROUND wire (5) connection M Motor Ground (Pulse-Width Modulated [PWM] variable speed control) MC- Plug Pin Identification 7 PIN # WIRE # FUNCTION B+ power input (power up) 7 Lift, Drive or Steer functions input (functions requiring motor) 8 Steer Requested (adds additional motor speed for steer) 4 Enable Switch signal input 5 Speed cut-back (4 Volts = full speed, 0 Volts = creep speed) Motor Start Relay signal (GROUND signal to activate Motor Start Relay) 7 4 Lift Valve B- (provides GROUND signal to Lift Valve) 8 none none 4 Accelerator reference signal (. Volts to Potentiometer) 0 none none none none none none ART_8 March 008 Page 4-4 "047ES / 47ES / 47ES" Service & Parts Manual - ANSI Specifications

3 LED Diagnostics Definitions (Flash Codes) LED READING LED Steady On LED Off Flashes Flashes 4 Flashes 5 Flashes DIAGNOSIS Controller is operational and detects no irregularities on monitored circuits. No power-up No power to pin #. No ground to B- post. LED failure or internal controller fault. Procedure fault. Enable depressed at power up. Enable depressed for more then 5 seconds without function request. No signal on wire 7 pin # when function requested. No B- to diode board. Failed diode/s. Damaged wire harness. Internal controller fault. Motor circuit low. Set with unit at rest and is the result of the voltage at M- dropping to approximately 4 volts or lower. Possible causes: Short to ground in the motor circuit between the motor contactor and the M- terminal. Motor circuit high. Set with the unit at rest and is the result of the voltage at M- terminal rising above volts. Possible causes: Motor contactor points are welded shut Motor contactor circuit open. Set when a function is requested but no current can flow through the motor circuit to the M- terminal. Possible causes: Blown 00 amp fuse Malfunctioning motor contactor Worn motor brushes Incomplete circuit to the Sevcon pin # If the motor and contactor circuits are diagnosed as working properly: Sevcon internal fault continued "047ES / 47ES / 47ES" Service & Parts Manual - ANSI Specifications March 008 Page 4-5

4 LED Diagnostics Definitions (continued) LED READING Flashes 7 Flashes 8 Flashes Flashes DIAGNOSIS Accelerator fault. Set with unit at rest, a flash will result in an 80% cutback of motor speed. The Accelerator is the proportional control circuitry for the Sevcon. It works in conjunction with the potentiometer located in the upper control box, which is connected to the joystick handle through a gear arrangement. Measure voltage at terminals 4 and 5 on the platform terminal strip or at the potentiometer plug connection. With the joystick handle in neutral,. volts should be measured on the accelerator circuit (wire #4). Voltage proportionally decreases with the travel of the joystick, with 0 volts at full stroke. With the joystick centered, voltages lower than. or higher than. will trigger a ( flash) code. Battery voltage fault. This includes battery voltage below volts or above 45 volts as measured on pin #. This code will disable all functions. Thermal cutback. Sevcon internal temperatures above 7 degrees F. Will limit motor speed in comparison with over temperature. Resets when cooled. Battery voltage at or below 8 volts As measured on pin #. This code will interrupt or prevent lift function but will allow drive and steer functions. When lift is interrupted due to a flash, the electric motor will still run. March 008 Page 4- "047ES / 47ES / 47ES" Service & Parts Manual - ANSI Specifications

5 Sevcon Motor Speed Controller - Connections The following two pages describe the connections to the Sevcon Motor Speed Controller with a brief description of their function and the voltage measurements under normal conditions. Important: Batteries must be fully charged before troubleshooting! A fully charged battery set on a 4 V DC system will have a nominal voltage of 5. V DC FUNCTION VOLTAGE READING PIN WIRE (WIRE ON EARLY UNITS) Battery Positive Input Pin Wire 7 Lift, Drive or Steer functions requested Switched 5% less than battery voltage Controller power-up and reference point for battery state-of-charge. Green LED indicates controller power-up. Power travels through the upper emergency-stop switch with upper controls selected. 7-Flash code and -flash code indicate low voltage at this terminal. Motorized function is requested 5%-8% less than battery voltage Controller begins the motor run sequence with this signal but still requires a signal on pin 4 and a change on pin before the motor will operate. Pin Wire 8 Steer Function Requested Pin 4 Wire Enable signal input Pin 5 Wire Speed cutback signal from limit switch or Lift circuit When steering is operated 5%-8% less than battery voltage Adds motor speed to compensate for addition of steer requirement during drive operation. Provides a minimum motor speed for steer requirement when only steer is operated. When joystick trigger pulled 5% less than battery voltage. Motor will not start without this input A signal here longer then 5 seconds without a signal on pin- or pin- will result in a -flash code failure. Full speed: 4 V DC Creep speed: 0 V DC. Speed cutback is the elevated drive speed. "047ES / 47ES / 47ES" Service & Parts Manual - ANSI Specifications March 008 Page 4-7

6 Sevcon Motor Speed Controller - Connections (continued) FUNCTION PIN WIRE Motor Start Relay ground signal PIN 7 WIRE 4 Ground signal to Lift solenoid valve PIN WIRE 4 Accelerator reference signal to the potentiometer (upper control box) POST B+ Battery positive cable from 00 amp fuse POST B Battery positive cable from 00 amp fuse POST M- PWM controlled motor ground VOLTAGE READING Idle: 4 V DC When function requested: 0 V DC. This is how the Controller maintains control over the motor circuit. Sevcon controls the Motor Start Relay function ground signal. Will not operate the motor start relay when,, 4 & 7 flash codes occur. 0 volts No ground presence until lift is requested. By providing the ground signal, lift function can be prevented anytime battery voltage falls below 8 volts. This will result in a flash code. From.5 V DC with joystick in the neutral to 0 V DC at full stroke. Controller uses this circuit to monitor joystick input after pins & 4 energize. Controls motor speed in reference to the voltage on this circuit. Voltages above 4.0 V DC or below.0 V DC will result in a flash code. Full battery voltage. No real diagnostic value. Battery ground cable connection Ground path for motor operation All system ground wires (wire #s 5 & 5A) terminate here. Best place to connect ground lead from multimeter while troubleshooting. Idle: V DC V DC During operation, between 5 V DC & 4 V DC. volts is reference voltage used by the controller to monitor motor circuit irregularities at idle. 0 volts at idle = flash code Above 0 volts at idle = 4 flash code No voltage change after Motor Start Relay signal = 5 flash code. March 008 Page 4-8 "047ES / 47ES / 47ES" Service & Parts Manual - ANSI Specifications

7 SECTION 5: SCHEMATICS SECTION 5: SCHEMATICS Hydraulic Schematics ES - Serial # ES - Serial # ES - Serial # ES - Serial # CURRENT 47ES - Serial # CURRENT 47ES - Serial # CURRENT Electric Schematics ES - Serial # ES - Serial # ES - Serial # ES - Serial # CURRENT 47ES - Serial # CURRENT 47ES - Serial # CURRENT "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-

8 HYDRAULIC SCHEMATICS 047ES - Serial # ES - Serial # ES - Serial # ITEM DESCRIPTION Location CBV Counterbalance Valve Main Manifold (MA-) CYL Steering Cylinder Machine Base, Front CYL Lift Cylinder, 047, 47 Scissor Assembly CYL Lift Cylinder, Lower, 47 Scissor Assembly CYL4 Lift Cylinder, Upper, 47 Scissor Assembly FD Flow Divider Main Manifold (MA-) FRR HP Hand Pump, Brakes Brake Release Manifold (MA-) MA- Main Manifold Assembly Machine Base, Battery Compartment MA- Brake Release Manifold Battery Compartment MA- Manifold Assembly Lift Cylinder, 047ES and 47ES only MA-4 Manifold Assembly Lower Lift Cylinder, 47ES only MA-5 Manifold Assembly Upper Lift Cylinder, 47ES only MP Manual Pump Main Manifold (MA-) NV Needle Valve Main Manifold ORF Orifice Plug, Wheel Motors Main Manifold (MA-) ORF Orifice, Down Valve Lift Cylinder Manifold (MA-), 047ES and 47ES only ORF4 Orifice, Down Valve Lower Lift Cylinder Manifold (MA-4), 47ES only ORF5 Orifice, Down Valve Upper Lift Cylinder Manifold (MA-5), 47ES only P Pump Pump Compartment PCF Steering Relief Flow Control Main Manifold (MA-) RV Relief Valve, Lift Relief Main Manifold (MA-) RV Relief Valve, Main Relief Main Manifold (MA-) RV Relief Valve, Steering Main Manifold (MA-) RV4 Relief Valve, Lift Cylinder Lower Lift Cylinder Manifold (MA-4), 47ES only RV5 Relief Valve, Lift Cylinder Upper Lift Cylinder Manifold (MA-5), 47ES only SV Spool Valve, Steering Main Manifold (MA-) SV Spool Valve, Lift Main Manifold (MA-) SV Spool Valve, Drive Main Manifold (MA-) SV4 Spool Valve, Decel Main Manifold (MA-) SV5 Spool Valve, Torque Main Manifold (MA-) SV Spool Valve, Torque Main Manifold (MA-) SV7 Spool Valve, Brakes Main Manifold (MA-) SV8 Poppet Valve, Down Main Manifold (MA-), 047ES and 47ES only SV Spool Valve, Down Lift Cylinder Manifold (MA-), 047ES and 47ES only SV0 Spool Valve, Down Lower Lift Cylinder Manifold (MA-4), 47ES only SV Spool Valve, Down Upper Lift Cylinder Manifold (MA-5), 47ES only TP Test Port Main Manifold (MA-) WB Wheel Brake Drive Wheel WB Wheel Brake Drive Wheel WM Wheel Motor, Right Side Machine Base WM Wheel Motor, Left Side Machine Base March 008 Page 5- "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications

9 HYDRAULIC SCHEMATIC 047ES ES ES Model: / Serial # Reference Art #: 00 Publication Art #: ART_8 MA 5 RV5 CYL4 SV ø.047 ORF5 UPPER LIFT CYLINDER 47ES MA 4 RV4 ø.07 SV0 ORF4 CYL LOWER LIFT CYLINDER 47ES CYL ORF SV ø.07 MA LIFT CYLINDER 047ES & 47ES STEERING CYLINDER BRAKES WB CYL WB 7 SV MA 5 4 TP F PFC E.0 GPM D 5 PSI C MV G RV 850 PSI SV7 H SV B A SV I CBV 500 PSI RV 750 PSI J ORF ø.055 K SV5 NV SV8 SV P 047 & 47 ONLY RV R 00 PSI 047 & PSI 47 L M FD N SV4 O PORT A 8 PORT B PORT B 0 PORT A WM WM RIGHT WHEEL MOTOR LEFT WHEEL MOTOR HP MA P E BRAKE RELEASE HAND PUMP "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-

10 047ES - Serial # CURRENT 47ES - Serial # CURRENT 47ES - Serial # CURRENT ITEM DESCRIPTION Location CBV Counterbalance Valve Main manifold (MA-) CYL Steering Cylinder Machine Base, Front CYL Lift Cylinder, 047, 47 Scissor Assembly CYL Lift Cylinder, Lower, 47 Scissor Assembly CYL4 Lift Cylinder, Upper, 47 Scissor Assembly FD Flow Divider Main manifold (MA-) FRR Steering Relief Flow Control Main manifold (MA-) HP Hand Pump, Brakes Main manifold (MA-) MA- Main Manifold Assembly Machine Base, Battery Compartment MA- Manifold Assembly Lift Cylinder, 047ES and 47ES only MA-4 Manifold Assembly Lower Lift Cylinder, 47ES only MA-5 Manifold Assembly Upper Lift Cylinder, 47ES only MP Manual Pump Main manifold (MA-) NV Needle Valve Main manifold (MA-) ORF Orifice Plug, Wheel Motors Main manifold (MA-) ORF Orifice Disc, Brake Release Main manifold (MA-) ORF Orifice, Down Valve Lift Cylinder Manifold (MA-), 047ES and 47ES only ORF4 Orifice, Down Valve Lower Lift Cylinder Manifold (MA-4), 47ES only ORF5 Orifice, Down Valve Upper Lift Cylinder Manifold (MA-5), 47ES only P Pump Pump Compartment RV Relief Valve, Lift Relief Main manifold (MA-) RV Relief Valve, Main Relief Main manifold (MA-) RV4 Relief Valve, Lift Cylinder Lower Lift Cylinder Manifold (MA-4), 47ES only RV5 Relief Valve, Lift Cylinder Upper Lift Cylinder Manifold (MA-5), 47ES only SV Spool Valve, Steering Main manifold (MA-) SV Spool Valve, Lift Main manifold (MA-) SV Spool Valve, Drive Main manifold (MA-) SV4 Spool Valve, Brake/Decel Main manifold (MA-) SV5 Spool Valve, Torque Main manifold (MA-) SV Spool Valve, Torque Main manifold (MA-) SV Spool Valve, Down Lift Cylinder Manifold (MA-), 047, 47 SV0 Spool Valve, Down Lower Lift Cylinder Manifold (MA-4), 47 SV Spool Valve, Down Upper Lift Cylinder Manifold (MA-5), 47 WB Wheel Brake Drive Wheel WB Wheel Brake Drive Wheel WM Wheel Motor, Right Side Machine Base WM Wheel Motor, Left Side Machine Base March 008 Page 5-4 "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications

11 HYDRAULIC SCHEMATIC 047ES ES ES Model: / Serial # MA 5 RV5 ø.047 Reference Art #: Publication Art #: ART_ CYL4 SV ORF5 UPPER LIFT CYLINDER 47ES MA 4 RV4 ø.07 SV0 ORF4 CYL LOWER LIFT CYLINDER 47ES CYL ORF SV ø.07 MA LIFT CYLINDER 047ES & 47ES CYL STEERING CYLINDER BRAKES WB WB SV S FRR 0.75 GPM 850 PSI SV 7 S 750 PSI RV RV 400 PSI 5 ORF ø.040 MV HP SV5 ø.040 ORF SV S4 S 500 PSI CBV NV MA 8 0 SV4 FD WM RIGHT WHEEL MOTOR WM LEFT WHEEL MOTOR SV P E "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-5

12 Hydraulic Manifold - early style 047ES 4 47ES Model: / Serial # Reference Art #: none NOTE: MA MA MA MA4 MA5 Publication Art #: ART_00 Early style manifold. Refer to Hydraulic Schematic for serial # break COMPONENTS FUNCTION CBV Relief Valve Counter Balance CV Check Valve Flow Control, Brakes SOL Coil (SV) Steer Right SOL Coil SV) Steer Left SOL Coil (SV5) Drive/Decel SOL4 Coil (SV) Lift SOL5 Coil (SV4) Torque SOL Coil (SV) Torque SOL7 Coil (SV) Drive Forward SOL8 Coil (SV) Drive Reverse SOL Coli (SV7) Brakes SOL0 Coil (SV8) Down FD Flow Divider MP Manual Pump Brake Release NV Needle Valve Freewheel ORF Orifice Plug PFC Flow Control Steer Relief RV Relief Valve Lift Relief RV Relief Valve Main Relief RV Relief Valve Steering Relief SV Spool Valve Steering Control SV Spool Valve Lift Control SV Spool Valve Direction Control SV4 Spool Valve Torque SV5 Spool Valve Drive Dump/Decel SV Spool Valve Torque SV7 Spool Valve Brakes SV8 Poppet Valve Down HP Hand Pump Brake Release SOL Coil (SV) Down, Lift Cylinder SV Spool Valve Down, Lift Cylinder SOL Coil (SV0) Down, Lift Cylinder SOL Coil (SV0) Down, Lift Cylinder SV0 Spool Valve Down, Lift Cylinder SOL4 Coil (SV) Down, Lift Cylinder SOL5 Coil (SV) Down, Lift Cylinder SV Spool Valve Down, Lift Cylinder TEST PORT PORTS PUMP TANK TEST PORT 4 BRAKE RELEASE 5 BRAKE STEER 7 STEER 8 RIGHT A RIGHT B 0 LEFT B LEFT A LIFT PLUG 47ES PORT IS PLUGGED 047ES 47ES SOL4 SV8 SOL0 LIFT CYLINDER 047ES - 47ES RV LOWER LIFT CYLINDER 47ES SV0 SOL SOL 7 SOL SOL SV SOL SOL MA- SV SOL 4 5 MP CV MA-4 SV5 UPPER LIFT CYLINDER 47ES SOL5 HP SV SOL4 SOL5 SOL5 SOL7 SOL8 SV SOL7 SOL8 8 FD BRAKE RELEASE HAND PUMP 047ES - 47ES SOL SV SOL 0 MA- MA-5 SOL SV4 SOL MA- D P A F C K N O B E I L J R G H M RV SV SOL4 PFC RV CBV SV7 SOL NV ORF March 008 Page 5- "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications

13 Hydraulic Manifold - current style Model: / Serial # 047ES 47ES 47ES LIFT CYLINDER 047ES - 47ES Reference Art #: none NOTE: Publication Art #: ART_0 Current style manifold. Refer to Hydraulic Schematic for serial # break MA- SV SOL MA MA MA4 MA5 COMPONENTS CBV Relief Valve SOL Coil (SV) SOL Coil SV) SOL Coil (SV5) SOL4 Coil (SV) SOL5 Coil (SV4) SOL Coil (SV) SOL7 Coil (SV) SOL8 Coil (SV) FD Flow Divider FRR Flow Control HP Hand Pump MP Manual Pump NV Needle Valve ORF Orifice Plug ORF Orifice Disc PP Pilot Piston RV Relief Valve RV Relief Valve SV Spool Valve SV Spool Valve SV Spool Valve SV4 Spool Valve SV5 Spool Valve SV Spool Valve SOL Coil (SV) SV Spool Valve SOL Coil (SV0) SOL Coil (SV0) SV0 Spool Valve SOL4 Coil (SV) SOL5 Coil (SV) SV Spool Valve FUNCTION Counter Balance Steer?RIGHT? Steer?LEFT? Brake/Decel Lift Torque Torque Drive Forward Drive Reverse Steer Relief Brake Pump Brake Release Freewheel Flow Restriction Flow Restriction Counter Balance Lift Relief Main Relief Steering Control Lift Control Direction Control Torque Drive Dump/Decel Torque Down, Lift Cylinder Down, Lift Cylinder Down, Lift Cylinder Down, Lift Cylinder Down, Lift Cylinder Down, Lift Cylinder Down, Lift Cylinder Down, Lift Cylinder PORTS PUMP TANK TEST PORT 4 N/A 5 BRAKE STEER 7 STEER 8 RIGHT B LEFT A 0 RIGHT A LEFT B LIFT SOL4 LOWER LIFT CYLINDER 47ES SOL SOL SV0 SOL SOL UPPER LIFT CYLINDER 47ES MA-4 SV SOL4 SOL5 MA- 8 SOL SOL5 SOL8 SOL7 SOL SV5 MA-5 SV SV SOL SV4 FD SOL4 SOL SOL HP SOL5 SV SOL7 SOL8 SV SOL RV CBV PP RV FRR ORF PLUG MP ORF NV "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-7

14 THIS PAGE INTENTIONALLY LEFT BLANK March 008 Page 5-8 "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications

15 ELECTRIC SCHEMATICS NOTES: (Unless otherwise specified). Switch S BASE/PLATFORM makes contact from the CENTER to the LEFT position when placed in BASE.. Switch S UP/ makes contact from the CENTER to the LEFT position when the switch is held in the CONTACT position and automatically returns to the CENTER position when released.. Switch LS breaks the N/C set of contacts and makes the N/O set of contacts when the platform reaches approximately 7 feet. 4. Switch LS and LS makes the N/C set of contacts when the Pothole Bars are down and locked in place. S S ART_ LS & LS LS ART_44 "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-

16 047ES - Serial # ES - Serial # ES - Serial # ITEM DESCRIPTION FUNCTION LOCATION A Tilt Light, 8V Warn when Machine is Tilted Upper Control Box A Level Sensor Activates Tilt Light Inside Lower Control Box A5 Push-Button Switch Activates Horn Upper Control Box A Horn, V - 48V (option) Activated by Operator Under Platform A7 Overload/Motion Alarm (option) Warn of Movement Outside Lower Control Box A8 Motion Light (option) Warn of Movement Front Left Corner of Machine A Hour Meter Record Machine Usage Time Lower Control Panel A Battery Indicator Show Battery Status Lower Control Panel B-4 -V Deep Cycle Battery Power for Motor And Control Circuit Inside Battery Compartment B5 -V Battery Power for Emergency Down Circuit Battery Compartment, 47ES ONLY BD Battery Disconnect Switch Disconnect All Electrical Power Lower Control Box CB Circuit Breaker, 5AMP Manual Control Circuit Protection Lower Control Panel CH Battery Charger Recharges 4-VDC Battery Pack Inside Pump Compartment CHRL Charger Relay Disconnect Electric when Charger ON Inside Charger D - D5 Circuit Board Diodes Directs Signal to Proper Location Inside Lower Control Box D7 Diode w/ring Terminals Suppression Diode Across Contactor Coil D8 D Diode w/stud Base 0-UNF-A Emergency Down Battery Charger Battery Compartment ED Switch, Emergency Down Actuates Emergency Down Valves Battery Compartment, 47ES ONLY ES Switch, Emergency Stop Shut down All Moving Functions Lower Control Panel ES Switch, Emergency Stop Shut down All Platform Functions Upper Control Box F Fuse, 00AMP Main Line Fuse Inside Lower Control Box F Fuse, 8AMP Emergency Down Fuse Battery Compartment, 47ES ONLY LS Limit Switch, Double Pole Enable Drive and High Speed Right Rear Corner of Machine LS Limit Switch, Single Pole Drive Enable if Pothole Deployed On pothole Linkage LS Limit Switch, Single Pole Enable Drive if Pothole Deployed On Pothole Linkage M Motor, 4V, HP Turn the Hydraulic Pump Pump Compartment MC 4-V Contactor Connects Battery (+) to Motor Inside Lower Control Box PWM Controller, DC 50AMP Changes the Motor Speed Inside Lower Control Box POT Potentiometer, 0K Ohms Senses Operator Input Upper Control Box R - R4 Circuit Board Resistors Inside Lower Control Box S Key Switch, N/O Contact Block Select Lower or Upper Controls Lower Control Panel S Switch, Toggle Lift/Lower at Lower Controls Lower Control Panel S Switch, Push Button Enable Other Functions at Platform Upper Control Box Handle S4 Switch, Micro Right Turn Switch Upper Control Box Handle S5 Switch, Micro Left Turn Switch Upper Control Box Handle S Switch, Toggle Select LIFT or DRIVE Upper Control Box S7 Switch, Micro Reverse or Lift Switch Upper Control Box S8 Switch. Micro Forward or Down Switch Upper Control Box S Switch, Toggle TORQUE Switch Upper Control Box SOL Coil, Turn Right Solenoid Activate Turn Right Valve (SV) Main Manifold SOL Coil, Turn Left Solenoid Activate Turn Left Valve (SV) Main Manifold SOL Coil, Decel Solenoid Activate Decel Valve (SV5) Main Manifold SOL4 Coil, Lift Solenoid Activate Lift Valve (SV) Main Manifold SO5- Coil, Torque Solenoid Activate Torque Valves (SV4) (SV) Main Manifold SOL7 Coil, Reverse Solenoid Activate Reverse Valve (SV) Main Manifold SOL8 Coil, Forward Solenoid Activate Forward Valve (SV) Main Manifold SOL Coil, Brake Solenoid Activate Brake Valve (SV7) Main Manifold SOL0 Coil, Down Solenoid Activate Down Valve (SV8) Main Manifold SOL Coil, Down Solenoid Activate Down Valve (SV) Lift Cylinder, 047/47 ONLY SOL Coil, Down Solenoid Activate Down Valve (SV0) Lower Lift Cylinder, 47 ONLY SOL Coil, E-Down Solenoid Activate Emergency Down Valve (SV0) Lower Lift Cylinder, 47 ONLY SOL4 Coil, Down Solenoid Activate Down Valve (SV) Upper Lift Cylinder, 47 ONLY SOL5 Coil, E-Down Solenoid Activate Emergency Down Valve (SV) Lower Lift Cylinder, 47 ONLY March 008 Page 5-0 "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications

17 ELECTRIC SCHEMATIC 047ES ES ES Model: / Serial # Reference Art #: 004 SWITCH CONTACT POSITIONS N/C N/C HELD OPEN N/O N/O HELD CLOSED WIRE CONNECTOR LEGEND P TERMINAL # MALE PIN FEMALE SOCKET EMERGENCY STOP Publication Art #: ART_0 ES ENABLE S MODE SELECT SWITCH S DRIVE LIFT A 0 8 RIGHT S4 S5 LEFT 7 REV/LIFT S7 7 A HORN A FWD/ S8 TILT LIGHT A TORQUE S ON OFF POT OPTIONAL QUICK DISCONNECT S N U R W T J C F H P A V K L LS (SLOW SPEED) UPPER TERMINAL STRIP (-) P P P P 4 P 5 P P 7 P 8 P P 0 P P P P P A HORN OPTION P7 P P7 P D8 P P7 5 LS P7 P P 5 P P0 P0 LS LS S UP PLATFORM S OFF BASE EMERGENCY STOP ES D7 5 MC 4 R D5 R D8 R R4 D7 D4 D D D D J- CIRCUIT BOARD D4 D5 D0 D D D (-) (-) LS 5(-) P7 4 5 P7 P 0 P P 5 0 5(-) 0 5(-) P8- P8- P- P- P4 P4 P4 A7 ALARM A8 LIGHT A A MOTION WARNING LEVEL SENSOR HOUR METER CHRL 04A P P P5 CHARGER INTERLOCK P P 5 P5 04B 5(-) A BATTERY GAUGE CIRCUIT BREAKER P N G CB 05 BD CHRL CH 5 AMP 00 AMP F B - B J 5 M B+ B PWM MC 4 M 4 P 4 P P P 7 MAIN MANIFOLD P 8 SOL4 SV LIFT 7 8 SV STEER SOL SOL RIGHT LEFT P P 0 P 0 SOL7 SOL8 REV FWD SV4 TORQUE SOL5 SV5 SOL DECEL SV7 BRAKE SOL SV DRIVE P P 5A SV8 SOL0 047 & 47 SOL SV TORQUE J WHT BLK LIFT CYLINDER MANIFOLD (047/47) RED 5A SOL SV EMERGENCY (47 ONLY) J GRN D LOWER LIFT UPPER LIFT CYLINDER CYLINDER MANIFOLD MANIFOLD (47) (47) GRN RED SV0 WHT WHT BLK RED GRN SV WHT WHT SOL SOL SOL4 SOL5 B5 F ED BLK "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-

18 047ES - Serial # CURRENT 47ES - Serial # CURRENT 47ES - Serial # CURRENT ITEM DESCRIPTION FUNCTION LOCATION A Tilt Light, 8V Warn when Machine is Tilted Upper Control Box A Level Sensor Activates Tilt Light Inside Lower Control Box A5 Push-Button Switch Activates Horn Upper Control Box A Horn, V - 48V (option) Activated by Operator Under Platform A7 Overload/Motion Alarm (option) Warn of Movement Outside Lower Control Box A8 Motion Light (option) Warn of Movement Front Left Corner of Machine A Hour Meter Record Machine Usage Time Lower Control Panel A Battery Indicator Show Battery Status Lower Control Panel B-4 -V Deep Cycle Battery Power for Motor And Control Circuit Inside Battery Compartment B5 -V Battery Power for Emergency Down Circuit Battery Compartment, 47ES ONLY BD Battery Disconnect Switch Disconnect All Electrical Power Lower Control Box CB Circuit Breaker, 5AMP Manual Control Circuit Protection Lower Control Panel CH Battery Charger Recharges 4-VDC Battery Pack Inside Pump Compartment CHRL Charger Relay Disconnect Electric when Charger ON Inside Charger MC 4-V Contactor Connects Battery (+) to Motor Inside Lower Control Box D - D5 Circuit Board Diodes Directs Signal to Proper Location Inside Lower Control Box R - R4 Circuit Board Resistors Inside Lower Control Box D7 Diode w/ring Terminals Suppression Diode Across Contactor Coil D Diode w/stud Base 0-UNF-A Emergency Down Battery Charger Battery Compartment, 47ES ONLY ED Switch, Emergency Down Actuates Emergency Down Valves Battery Compartment, 47ES ONLY ES Switch, Emergency Stop Shut down All Moving Functions Lower Control Panel ES Switch, Emergency Stop Shut down All Platform Functions Upper Control Box F Fuse, 00AMP Main Line Fuse Inside Lower Control Box F Fuse, 8AMP Emergency Down Fuse Battery Compartment, 47ES ONLY LS Limit Switch, Double Pole Enable Drive and High Speed Right Rear Corner of Machine LS Limit Switch, Single Pole Drive Enable if Pothole Deployed On pothole Linkage LS Limit Switch, Single Pole Enable Drive if Pothole Deployed On Pothole Linkage M Motor, 4V, HP Turn the Hydraulic Pump Pump Compartment PWM Controller, DC 50AMP Changes the Motor Speed Inside Lower Control Box POT Potentiometer, 0K Ohms Senses Operator Input Upper Control Box S Key Switch, N/O Contact Block Select Lower or Upper Controls Lower Control Panel S Switch, Toggle Lift/Lower at Lower Controls Lower Control Panel S Switch, Push Button Enable Other Functions at Platform Upper Control Box Handle S4 Switch, Micro Right Turn Switch Upper Control Box Handle S5 Switch, Micro Left Turn Switch Upper Control Box Handle S Switch, Toggle Select LIFT or DRIVE Upper Control Box S7 Switch, Micro Reverse or Lift Switch Upper Control Box S8 Switch. Micro Forward or Down Switch Upper Control Box S Switch, Toggle TORQUE Switch Upper Control Box SOL Coil, Turn Right Solenoid Activate Turn Right Valve (SV) Main Manifold SOL Coil, Turn Left Solenoid Activate Turn Left Valve (SV) Main Manifold SOL Coil, Decel/Brake Solenoid Activate Decel/Brake Valve (SV5) Main Manifold SOL4 Coil, Lift Solenoid Activate Lift Valve (SV) Main Manifold SOL5- Coil, Torque Solenoid Activate Torque Valves (SV5)(SV) Main Manifold SOL7 Coil, Reverse Solenoid Activate Reverse Valve (SV) Main Manifold SOL8 Coil, Forward Solenoid Activate Forward Valve (SV) Main Manifold SOL Coil, Down Solenoid Activate Down Valve (SV) Lift Cylinder, 047/47 ONLY SOL Coil, Down Solenoid Activate Down Valve (SV0) Lower Lift Cylinder, 47 ONLY SOL Coil, E-Down Solenoid Activate Emergency Down Valve (SV0) Lower Lift Cylinder, 47 ONLY SOL4 Coil, Down Solenoid Activate Down Valve (SV) Upper Lift Cylinder, 47 ONLY SOL5 Coil, E-Down Solenoid Activate emergency Down Valve (SV) Upper Lift Cylinder, 47 ONLY March 008 Page 5- "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications

19 ELECTRIC SCHEMATIC 047ES ES ES Model: / Serial # Reference Art #: 007 Publication Art #: ART_0-R SWITCH CONTACT POSITIONS S4 RIGHT N/C N/C HELD OPEN 7 N/O N/O HELD CLOSED WIRE CONNECTOR LEGEND P TERMINAL # ENABLE S MALE PIN FEMALE SOCKET EMERGENCY STOP ES A S5 LEFT HORN A A MODE SELECT SWITCH S DRIVE LIFT REV/LIFT S FWD/ S8 TILT LIGHT A TORQUE S ON OFF POT LS (SLOW SPEED) S P CHRL P UP PLATFORM S OFF BASE EMERGENCY STOP HOUR METER OPTIONAL BATTERY GAUGE 7 A 0 5 P5 7 A 5 CIRCUIT CB BREAKER PNG 04A 04 CHARGER INTERLOCK ES P5 05 BD CHRL CH P P P P 5 5 AMP 00 AMP F OPTIONAL QUICK DISCONNECT P5 8 P5 4 4 P5 P5 D7 MC B B4 5 P5 P5 MC P P5 5 M S P P P 4 P 5 P P 7 7A 8 4 R D5 R D8 R R4 D D D7 D4 D D D4 SV LIFT 4 4 SOL4 D D5 D D0 D 5 8 P5 0 P5 P J 5 PWM M B+ B N U R W T J C F H P A V K L A P J- CIRCUIT BOARD P 4 SV STEER P 7 SOL P 8 P P 0 P P P P P SOL P P 0 SOL7 REV P 0 SOL8 FWD SV DRIVE P RIGHT LEFT SOL5 SV4 TORQUE SOL SV5 SV SOL BRAKE/DECEL TORQUE 5A MAIN MANIFOLD 4 5( ) P P 5 P P P WHT BLK LIFT CYLINDER MANIFOLD (047/47) 5A SOL SV A 5 0 P 0 P P 5 EMERGENCY (47 ONLY) 4 5 P P RED D GRN P P P P 4 P 5 P P 7 P 8 P P 0 P P P4 P4 P4 WHT P4 P4 LS 5A 5 0 5A 0 5A LOWER LIFT UPPER LIFT CYLINDER CYLINDER MANIFOLD MANIFOLD (47) (47) GRN RED SV0 WHT WHT BLK RED GRN SV WHT WHT SOL SOL SOL4 SOL5 P B5 A HORN OPTION F LS BLK RED 5 0A 0 5A 7A 7 A A A P ED LS A7 A8 LEVEL SENSOR MOTION ALARM OPTIONAL MOTION LIGHT BLK "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-

20 Component Locations ES Models: all Model: / Serial # Reference Art #: none REFER TO ELECTRIC SCHEMATIC Publication Art #: S LIFT/DRIVE A ES E-STOP S TORQUE S4 S5 F7 F8 POT A OVERLOAD/TILT S BLK 5 A5 BLK REMOVABLE CONTROL HARNESS 5 HORN BUTTON PIN # WIRE # S F W 5 R 4 V A H 0 P U T J 7 N C 8 K 4 M (GND) L 5 V U W T X H J F A C S G E R B D P K N L M END VIEW OF REMOVABLE CONTROL HARNESS (OPTIONAL QUICK DISCONNECT) S S PWM D7 MC F D D5 R R4 A8 5 ES CB A BD A TERMINAL BLOCK ON UNDERSIDE OF PLATFORM DECK A March 008 Page 5-4 "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications

21 Model: / Serial # Component Locations 047ES - 47ES - 47ES: all Reference Art #: none Publication Art #: ART_ REFER TO ELECTRIC SCHEMATIC A Terminal Block 47 ONLY LS F ED UPPER LIFT CYL CH LS D B5 A7 B B B B4 "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-5

22 Model: / Serial # Component Locations ES Models: all Reference Art #: none Publication Art #: ART_4 SOL0 STEER RIGHT SOL STEER LEFT SOL REFER TO ELECTRIC SCHEMATIC SOL DECEL LIFT CYLINDER 047ES - 47ES LIFT SOL SOL5 TORQUE SOL SOL4 BRAKE SOL SOL7 SOL8 TORQUE UPPER LIFT CYLINDER 47ES SOL4 SOL5 SOL4 LIFT REVERSE DRIVE FORWARD SOL MAIN MANIFOLD EARLY MODELS MAIN MANIFOLD STEER RIGHT STEER LEFT CURRENT MODELS SOL SOL TORQUE SOL5 DECEL LOWER LIFT CYLINDER 47ES SOL SOL SOL7 SOL8 REVERSE DRIVE FORWARD SOL TORQUE March 008 Page 5- "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications

23 Model: / Serial # Plug Pin Identicication ES Models : all Reference Art #: none Publication Art #: 7 REFER TO ELECTRIC SCHEMATIC PWM J5 Pin Identification PIN # WIRE # FUNCTION B+ power input (power up) 7 Lift, Drive or Steer functions requested (functions requiring motor) 8 Steer Requested (adds additional motor speed for steer) 4 Enable signal input 5 Speed cut-back (4 Volts = full speed, 0 Volts = creep speed) Motor Start Relay signal (GROUND signal to activate Motor Start Relay) 7 4 Lift Valve B- (provides GROUND signal to Lift Valve) 8 none none 4 Accelerator reference signal (. Volts to Potentiometer) 0 none none none none none none Terminal Identification J5 7 POST FUNCTION B+ Battery Positive Cable from 00 AMP Fuse B- Negative Battery Cable and GROUND wire (5) connection M Motor Ground (Pulse-Width Modulated [PWM] variable speed control) D5 D8 D7 D4 D5 D Circuit Board J 4 8 D D0 7 R R R R4 TB 80 D D D D4 D D J Plug Pin Identification PIN # WIRE # SIGNAL FUNCTION 0 INPUT Drive Reverse INPUT Drive Forward OUTPUT Brake, Decel Valve signal 4 8 INPUT Steer Left 5 8 OUTPUT Steer signal to Sevcon 5 INPUT Down signal 7 0 OUTPUT Signal to Motion Alarm(s) (optional) 8 7 OUTPUT Sevcon & Hour Meter (motor function requested) 5 INPUT Battery Negative 0 7 INPUT Steer Right 4 INPUT Lift Up INPUT Limit Switch (4V = platform down) OUTPUT Enable, from lower Lift switch 4 OUTPUT To Sevcon (for speed cutback) "047ES / 47ES /47ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-7

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