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1. PIN 11 02 WHITE PIN 12 RED BLUE BLACK NU ORANGE BLACK N U HORN ECRI 29081 1708 17CR1 17CCR ECR 28082 AUXTLTRELAY TILT RELAY STEERRELAY PROPORTIONALRELAY TRANSFERRELAY CUSHIONRELAY AUXDOWNRELAY DOWN RELAY PIN 30 19 PIN 30 19 PIN 30 59D PIN 30 59A PIN 30 PIN 30 17D PIN 30 13 PIN 30 13A PIN 85 02 PIN 85 02 PIN 85 02 PIN 85 02 PIN 85 02 PIN 85 02 PIN 85 02 PIN 85 02 PIN 86
2. M155903AB_S5 M132623AB DC Electric Scissor Lifts SKYJACK 15 Compact Series 155147 Print View This Page Parts List 3 11 Disc Brake Kits and Torque Specifications ___ O OIL FILL 3 HYDRAULIC OIL ZZ VAY 177 YN 7 BY 2 T UMS NAN VAY 5252 VAY SECTION 5 1 BEARING AND SEAL 2 O RING TORQUE SPECIFICATIONS 1 TORQUE CASTLE NUT 237 Nm 2 TORQUE BRAKE BOLTS 115 Nm 3 TORQUE MOUNTING BOLTS TO 115 Nm OIL TYPE CATERPILLAR 4 SAE 30 HYDRAULIC OIL 200 mL SECTION B B SPRING ARRANGEMENT M154839AA S3 DC Electric Scissor Lifts SKYJACK Page 17 Compact Series 155147 Q 3 12 Hydraulic Schematic
3. This Page Print View Parts List 8 B J LEFT PORT A el 07 DRIVE BRAKE RELEASE 024 DIA 1 PRESSURE MANIFOLD BLOCK DRIVE PORT OVERLOAD BH1 sms ORIFICE STEER TRANSDUCER LEFT t OPTION C2 P2 CYLINDER BRAKE LIFT HAND PUMP Lug dp CYLINDER FREE WHEELING 05 05 06 EMER LOWERING VALVE STEERING 2C STEERING ORFICE 067 DIA ae ORIFICE ORIFICE VALVE Wo FRONT AXLE MANIFOLD BLOCK Bu MB10 2H 13C DECELERATION VALVE i NIN DECELERATION VALVE 4H 16 4 23 MANIFOLD BLOCK ORIFICE 040 DIA PROPORTIONAL FORWARD RIGHT 3215 ONLY MANIFOLD PORT DRIVE STEER BLOCK 20 p m VALVE VALVE i T BRAKE J X 2H 59 VALVE COUNTERBALANCE PRESSURE aa ore COMPENSATED t F 2H 13A PROPORTIONAL 2 LOWERING VALVE N VALVE
4. S3 LIFT DRIVE SELECTOR 58 HORN Service and Maintenance H S4 EMERGENCY STOP Dis H LED 7 SKYJACK Page 12 TH N TOP SECTION p y iN 28 D 18 49 7B S3 LIFT DRIVE SELECTOR MIDDLE SECTION 4 aS B
5. d T 21B GREEN BLACK TIED BACK AGREN 8 16 REDWHITE 6074 49 GREEN WHITE 7 15 BLACK WHITE 23 9 PIN CONNECTOR SUB ASSEMBLY 6f 0980 ORED 5 13 GREEN BLACK 218 OPT 4 12 ORANGE BLACK 13 ORANGE 3 1 RED BLACK 18 i BLUE 2 10 WHITE BLACK 16 1 g NOTUSED CTRL BOX HARNESS n BACK VIEW PIN FUNCTION CTRL BOX HARNESS JOYSTICK HARNESS ER PIN 1 LEFT 24 WHITE RED PIN 2 STEERING VS 12B BROWN RED WHITE GREEN PIN 3 RIGHT 23 BLACKWHITE WHITE PIN 4 FWDJUP B RED YELLOW CRD PIN 5 JOYSTICK VS 08 BLUE WHITEBLACK PIN 6 REVIDOWN A PURPLEWHITE GREY PIN 7 PWM 59 ORANGE BLACK BLUE PIN 8 GND 02 WHITE BLACK PIN 9 ENABLE VS 8A BLUE WHITE BLUE 156881 DC Electric Scissor Lifts SKYJACK Page 11 Compact Series 155147 Section 3 System Component Identification and Schematics Serial Breakdown Reference Chart Model Serial Number SJ3 3215 10000610 amp below SJ3 3219 22020984 amp below S3 LIFT DRIVE SELECTOR BOTTOM SECTION 3 7b Platform Control Console Diagram NO f i
6. BROWN BLACK 6 01802 BLUE BLACK WHITE BROWN BLACK Q QR on BLUE BLACKWHITE e BROWN Om BLUE BLACK WHITE BLACK 2 XD BLACK Ot NO 188 1 BLUE BLACKWHITE XD BROWN BLACK E 019 BLUE BLACKWHITE PIN 17 BLACK PIN 2 21 BLACKWHITE PIN 3 138 BLACK PIN 4 13C BLACK WHITE PIN 1 17A BLACK PIN 2 21 BLACKWHITE PIN3 NIU PIN 4 N U PINS BROWN PIN 6 188 BLUE PIN7 19 BLACK PIN 8 71 BLACK WHITE m 40 I RON COO No CE Model 3215 PINS 7A BROWN PIN 6 188 BLUE PIN7 19 BLACK PIN 8 71 BLACKWHITE 1 0006 No CE Model 3219 V M141511AB_S3 SKYJACK Page 21 Print View This Page Parts List 3 16 Control Module and Beeper Diagram
7. ee ee eee 4 2 3 Maximum Platform Capacities Evenly Distributed 2 4 Torque Specifications DC Electric Scissor Lifts SKYJACK Page 1 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 1 Specifications and Features 3226 MODEL 3215 3219 3220 Overall width 0 83 m Overall length 2 34 Platform Size inside 0 70 2 10 Working Height 1891 kg Oi 3 N 3 3 o 3 Platform Elevated Height 4 5m 5 8m 6 0m 7 9 m Drive Height FULL Standard Operating Times Lift Time No Load 175 185 275 495 Lower Time Load 36 39 5 405 575 Lift Time Rated Load 225 215 33 5 535 Lower Time Rated Load 29s 35 5 285 44 5 Chassis Normal Drive Speed mm Elevated Drive Speed 1 1 km h High Torque Drive Speed 1 8 km h Hydraulic Oil ATF Dexron Ill Type Tank Capacity Liters 10 9 O 130AA Weight with standard 0 9m extension platform Refer to serial nameplate for specific applications Note Emission sound pressure level does not exceed 70 dB A SKYJACK Page 2 DC Electric Scissor Lifts Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 1 Specifications and Features Continued MODEL 4632 Weight 1980 kg 2170 kg 2300 kg Overall width 1 2m Overall length 2 3 Platform Size inside 1
8. L1CR CHARGER CUTOUT RELAY NEGATIV 1 CHARGER F1 B4 6V 300A B3 6V B26 BATTERY FUSE BATTERY BATTERY BATTERY 24V mo 3 PACK 51 MAIN S10 e IDLE PLTF BASE DISCONNECT 4 KEY SWITCH CONTACTOR DCM1 IN IDLE POSITION P A 5 PUMP MOTOR E 8C 8C 07 S28 a 7 2 6 INVERTER OPTION STOP 50A FUSE SWITCH 7 7 CB2 CBI 07 07 02 03 00 02 15 CIRCUIT 15 CIRCUIT BREAKER NCHO BREAKER 85 7 7 02 INVERTER OPTION 9 TIMER 7A 7A 02 198 gt 10 POWER ON LED NO LED 2 H1 49 POWER ON LIGHT HORN 49 11 HORN Electrical Panel TIMER RELAY gt 09 Ko Kol Kol Ko PIN COM 02 WHITE PIN PWR 7A RED PIN LOAD 85 VIOLET 256 PINTRIG 19A WHITEIRED PWR LOAD 198 85 VIOLET REMOTE SWITCH WIRE FROM INVERTER HB FAS
9. Number of Model Extension Curve Code Group Code 3215 1 Manual Extension Platform 1 3 3219 1 Manual Extension Platform 2 3 60404AE_SJ3E DC Electric Scissor Lifts SKYJACK 21 Compact Series 155147 lt SKYVACK Reliable lift solutions by people who care www skyjack com
10. 7 Section 3 System Component Identification and Schematics Service and Maintenance 3 5 Electrical Component Parts List Continued Skyjack 0 me 152070 122093 117967 146475 103319 117325 117325 130439 146640 146592 146601 146585 128196 147664 310517 121477 146649 147061 147061 121975 Il A Parts list continued from following page CHARGER Battery 24 Volt BATTERY CHARGE INDICATOR BEEPER 28 Volt CONTACTOR Motor 24 Volt CAPACITOR 1000 uF 35 Volt CIRCUIT BREAKER 15 Amp CIRCUIT BREAKER 15 Amp CONTROL MODULE Integrated sensor PLATFORM CONTROL CABLE ASSEMBLY SCISSOR ARM CONTROL CABLE ASSEMBLY Model 3219 SCISSOR ARM CONTROL CABLE ASSEMBLY Model 3215 ELECTRIC PANEL CONTROL CABLE ASSEMBLY DIODE MODULE MOTOR 24 Volt FUSE 300 Amp FLASHING LIGHT 24VDC superior universal Operator Low tone POWER INDICATOR LIGHT Platform control console POWER INDICATOR LIGHT Base control console LIMIT SWITCH High speed 139228 LIMIT SWITCH Pothole protection Battery tray 139227 LIMIT SWITCH Pothole protection Hydraulic tray 121975 LIMIT SWITCH Drive override 121975 LIMIT SWITCH Deceleration 134431 134432 119629 144714 116505 119725 147054 147053 147054 116382 147053 123994 122869 122877 122877 SKYJACK Page 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 3 4 1 2 1 1
11. 24V CHARGER LICR CHARGER CUTOUT RELAY NEGATIV 1 CHARGER F1 4 6V 300 6V 2 6V B1 6V FUSE BATTERY BATTERY 24V BATTERY CONTROL BOX BASE C1 MOTOR CONTACTOR DCM1 51 MAIN DISCONNECT S10 S4 IDLE PLTF BASE EMERGENCY KEY SWITCH DC Electric Scissor Lifts Compact Series 155147 TOP IDLE POSITION ne lt 5 PUMP MOTOR VS O NV NN NE 08 BLUE WHITE 8c 8C 4 07 528 1 num EMERGENCY 2 6 INVERTER OPTION 50A FUSE SWITCH 07 07 07 07 5A 05 00 02 15 15 BREAKER 7 GREEN 7A 85 02 9 TIMER S8 1
12. A 7 amp e cci oli PARIE A ENEE ELE 7 8 BN RN RR 8 cic E TT 9 Maintenance and Inspection Schedule suain evil eebele la Heo 12 Annual Inspection 12 12 Maintenance and Service Safety ETE _ __ _ _6___ 12 Hydraulic System amp Component Maintenance and 13 Vil ELCHE IS S DLE RET agi tpg sk ese ee ee eee 13 Service and Maintenance case MM MA M EE 15 15 Suc CER conie _ 15 Niaintenance 15 Scheduled Maintenance 1 1 Scheduled Maintenance TVS cel IEEE 18 ee ee cone eR 25 Tables 11 SSS _________ 16 L2 Maintenance and Inspection 17 DC Electric Scissor Lifts SKYJACK Page 5 Section 1 Scheduled Maintenance Operator s Responsibility for Maintenance O SKYJACK is continuously improving and expanding product features on its equipment therefore specifications and dimensions are subject to change without notice Aerial Platform Definition A mobile device that has a
13. Ae 29 1000uF CAPACITOR ud 17CCR 30 CUSHION RELAY da 18 18 RED BLACK 17D 2H 25 gt _ NO lt 417 31 CUSHION SOLENOID 002 6 Ll 17A 21 21 Here 21 21ACR n um oo 4 I PROPORTIONAL HIGH SPEED LOW VOLTAGE LIMIT SWITCH PROTECTION 59 25 ELEVATED SPEED JOYSTICK PCB ds RESISTOR 59 59 ORANGE BLACK 59 59 A 59 2H 59 l 2 PROPORTIONAL 34 SOLENOID 17 17 5 17CR1 35 TRANSFER RELAY A 15 BLUE 15 4H 15 e REV DN ed 36 REVERSE SOLENOID S7 1 8 D15 DO2 7 4 NUETRAL 17 3H 17 37 BRAKE SOLENOID 5 D16 0028 42 16 WHITE BLACK 16 4H 16 FWD UP e 38 FORWARD SOLENOID 57 6 002 9 L d ENABLE 8A 8A 12B 17 ENABLE ee if 1268 39 STEER RELAY NCHO 23 23 BLACK WHITE 23 4H 23 eA 40 RIGHT SOLENOID ne Y 017 D23 D23 1 DO2 10 E 12B 71 59D 59 41 57 3 LEFT 024 0241 n 24 Bt 42 LEFTSOLENOID DO2 11 154903 DC Electric Scissor Lifts Compact Series 155147 Section 4 TROUBLESHOOTING INFORMATION Table of Contents MN 3 Electrical System 4 1 1 4 1 2 4 1 3 4 1 4 4 1 5 4 1 6 4 1 7 4 1 8 4 1 9 4 1 10 4 1 11 4 1 12 4 1 13 4 1 14 4 1 15 4 1 16 4 1 17 4 1 18 4 1 19 4 1 20 4 1 21 4 1 22 4 1 23 ge T mm 4 All Controls From Base Control Console 5
14. __ AB 2 a HY 1 OVERLOAD SENSING MODULE 52 4 2 1 1 ST LEVEL INSIDE SCISSOR OOO 060 Goo 29 RED 02 BLUE N U BLACK CONNECT GROUND WIRES TO CONTROL MODULE P4 PIN 1 NIU PIN 2 BOA GREEN exc TO PRESSURE TRANSDUCER PIN 3 288 GREEN PIN 1 910A BLACK PIN 2 60A GREEN Lies PIN 3 900 WHITE PINS NIU Eu gt TO ANGLE TRANSDUCER PIN 6 910 BLACK PN1 910 BLACK PIN2 28B GREEN PIN 3 902 WHITE PIN 7 900 WHITE PIN 8 902 WHITE PIN 9 910A BLACK 29 GREEN TO BEEPER BLACK TO LIGHT 02 WHITE TO CONTROL MODULE PIN 1 22 BLACK PIN 2 29 GREEN 210 PIN 3 60 GREEN TO GROUND PIN 4 28 BLACK PIN 5 02 WHITE PIN 6 28E WHITE TO ELECTRICAL PANEL LN j 4 j x 4 _ lt M130612AE SKYJACK Page 22 DC Electric Scissor Lifts Compact Series A 155147 View Parts List Print This Page 3 17a Electrical Schematic Equipped with all options Toggle Switch Serial Breakdown Reference Chart Model Serial Number SJ3 3215 10000611 amp above SJ3 3219 22020985 amp above 110 VAC LINE VOLTAGE
15. 10 Hydraulic System 4 2 1 4 2 2 4 2 3 4 2 4 4 2 5 4 2 6 4 2 7 4 2 8 4 2 9 4 2 10 4 2 11 4 2 12 4 2 13 DC Electric Scissor LIfts AE E OON NUR 11 E 11 E eI TECH 11 mS PE TITTEN 11 rc 11 POE LE E ona 12 ar MEER E 12 _ 12 Platform will not Drive Forward or Reverse 12 12 Brakels will hold machine on AG ei creme 12 Paton dors nor 15 dons rot ROM DET TT Umm 13 SKYJACK 1 Compact Series 155147 Service and Maintenance Section 4 Troubleshooting Information ILLOLIODODE Introduction The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble which can develop Careful and accurate analysis of the systems listed in the table of Troubleshooting Information will localize the trouble more quickly than any other method This manual cannot cover all possible troubles and deficiencies that may occur If a specific trouble is not listed isolate the major component
16. 155147 55 Skyjack ee 108589 108589 108589 108589 108589 108589 108589 108589 127154 103605 137006 104493 103605 115370 106273 103623 153335 153335 153335 153335 5 130440 DC Electric Scissor Lifts Compact Series 155147 A c Ss Ss Ss l c 3 5 Electrical Component Parts List SUPPLY B Common 20 8728 N NORMALLY NORMALLY CLOSED OPEN CONTACT CONTACT Description RELAY 24 Volt RELAY 24 Volt RELAY 24 Volt RELAY 24 Volt RELAY 24 Volt RELAY 24 Volt RELAY 24 Volt Auxillary tilt RELAY 24 Volt Auxillary down RELAY 12 Volt Charger cutout COIL 24 Volt Lowering valve COIL 24 Volt Deceleration valve Model 3215 COIL 24 Volt Holding valve COIL 24 Volt Cushion COIL 24 Volt Proportional valve COIL 24 Volt Lift valve Cushion Steer Transfer Proportional switch Down lt COIL 24 Brake valve COIL 24 Volt Reverse drive spool valve Hytos COIL 24 Volt Forward drive spool valve Hytos COIL 24 Volt Right steer spool valve Hytos COIL 24 Volt Left steer spool valve Hytos BATTERY 6 Volt Trojan T2200 TRANSDUCER Angle Parts list continued on the following page GROUND 5
17. 15 3 11 Disc Brake Kits and Torque 17 RM e cn oT PN 18 3 13 Main Manifold Harness and Holding Valve 55 nennen nnns 19 CE vie Ime 20 3 15 Limit Switch Assemblies 21 3 16 6 and Beeper Diagrami 22 3 17a Electrical Schematic Equipped with all options Toggle 23 3 176 Electrical Schematic Equipped with all options Rotary 24 DC Electric Scissor Lifts SKYJACK Page 1 Compact Series 155147 lt Service and Maintenance Section 3 System Component Identification and Schematics 3 1 Electrical Symbol Chart CIRCUITS CROSSING D NO CONNECTION HOURMETER CIRCUITS LIGHT CONNECTED HYDRAULIC VALVE COIL PROPORTIONAL GROUND HYDRAULIC VALVE COIL ELECTRIC E FUSE MOTOR CIRCUIT BREAKER EMERGENCY 1 STOP BUTTON _ POTENTIOMETER LEVEL SENSOR SINGLE POLE DOUBLE POLE DOUBLE THROW SINGLE THROW RELAY RELAY TRIPLE POLE DOUBLE THROW RELAY KEY SWITCH Eu _ pu FOOT SWITCH TOGGLE SWITCH PUSH BUTTON ROTARY SWITCH LIMIT SWITCH CAM OPERATED LIMIT SWITCH VARIABLE
18. 28 2801 mE 0141 02 02 02 28 7 18 5 29 1000uF CAPACITOR IN 53 17 LIFT ia 30 CUSHION RELAY OFF 27 DRIVE TORQUE 2 25 SWITCH SWITCH gt el 31 CUSHION SOLENOID DO2 6 S7 iti 12B 18 RED BLACK 17A A 21 21 21 21ACR 32 PROPORTIONAL its i HIGH SPEED LOW VOLTAGE RELAY LIMIT SWITCH PROTECTION 59 59A ae 2 ELEVATED SPEED JOYSTICK PCB RESISTOR 017 1 08 59 59 ORANGE BLACK 59 59 59 2 59 PROPORTIONAL OUTPUT SOLENOID 17 17 35 TRANSFER RELAY 13 g REV DN 15 BLUE 15 4H 15 r 5 36 REVERSE SOLENOID 57 1 15 pie 002 7 NUETRAL 17 3 17 9 VA 37 BRAKE SOLENOID 016 DO2 8 lC FWD UP o 16 WHITE BLACK 16 4H 16 2 38 FORWARD SOLENOID 57 6 16 DO2 9 ENABLE 8A 8A o 17 ENABLE o 39 STEER RELAY 1 amp 12 231 23 BLACK WHITE 23 4 23 40 RIGHT SOLENOID Edd 017 023 D23 1 002 10 RIGHT 71 59D i r 59 57 3 LEFT 24 24 1 241 BLUE BLACK 24 4H 24 A 21 42 LEFT SOLENOID DO2 11 M155903AC SKYJACK Page 23 Serial Breakdown Reference Chart Model Serial Number SJ3 3215 10000610 4 below SJ3 3219 22020984 4 below Print View This Page Parts List 3 17b Electrical Schematic Equi
19. 10E 9 7 7 02 19 SWITCH a 2 10 POWER ON LED LED 2 H1 q 08 49 49 49 POWER ON LIGHT HORN 49 11 HORN 11 02 MODULE BP 29 2 P3 2 29 E x 13 BEEPER SON FLASHING LIGHT NON How od 5 1 22 n 14 OPTION LED 1 HOW uw oy X a How wp FL 22 POWER ON LSS 888 388 seRRye LIGHT P3 5 02 15 02 NS 60 60 RED WHITE 60 2x DECELERATION LIMIT SWITCH N C 3215 ONLY 2H 13C 17 DECELERATION 1 1 02 SOLENOID 3215 ONLY PRESSURE ANGLE 157 Q p 13 TRANSDUCER TRANSDUCER 13 13B 217135 ia BONN BDEENDID 71 DO2 2 ORANGE 13 2H 13B 1 13 cs 13A 8 19 HOLDING VALVE DO2 3 14 BLACK 14 52 14 3H 14 l 20 SOLENOID mT vy 28E 28ECR2 14 H 21 AUX DOWN RELAY UP DOWN D14E42 28 28CR2 BATTERY CHARGE SWITCH 22 DOWN RELAY INDICATOR CRD1 CRD2 08 02 19B T D14EM 23 MOTOR CONTACTOR 02 PROTECTION a LIMIT SWITCHES 4 4 24 154 Q Q LS5 71 72 19 19B RST oye 4 25 HOURMETER 2 7 5 156 02 00 71 19 28E 28 1 ANN B 26 AUX RELAY DRIVE OVERRIDE 14 2 LIMIT SWITCH
20. QI J 607A 08 07 21B GREEN BLACK TIED BACK 9 PIN CONNECTOR SUB ASSEMBLY CTRL BOX HARNESS PIN FUNCTION CTRLBOXHARNESS JOYSTICK HARNESS PIN 1 LEFT 24 WHITE RED PIN 2 STEERING VS 12B BROWN RED WHITE GREEN PIN 3 RIGHT 23 BLACKIWHITE WHITE PIN 4 FWD UP B RED YELLOW PIN 5 JOYSTICK VS 08 BLUE WHITEBLACK JOYSTICK HARNESS PIN 6 REV DOWN A PURPLEWHITE GREY PIN 7 PWM 59 ORANGE BLACK BLUE PIN 8 GND 0 WHITE BLACK PIN 9 ENABLE VS 8A BLUE WHITE BLUE D p View Parts List 7A GREEN 8 16 RED WHITE 607 49 GREEN WHITE 7 15 BLACK WHITE 23 6 14 BLUE BLACK 2 7860 5 13 GREEN BLACK 218 OPT 4 t H ORANGE BLACK 8 3 tt H REDBLACK 19 2 10 WHITE BLACK 16 1 9 BW BACK VIEW CRDI M146621AB DC Electric Scissor Lifts Compact Series 155147 Service and Maintenance Section 3 System Component Identi
21. 28E PIN 86 28 PIN 86 17 PIN 86 21A PIN 86 17 PIN 86 17C PIN 86 28E PIN 86 28 PIN 87 19A PIN 87 198 PIN 87 NIU PIN 87 NIU PIN 87 17C PIN 87 25 PIN 87 13 PIN 67 138 V 2 2 PIN 87a N U PIN 87a N U PIN 87a 59 PIN B7a 59 PIN B7a 17D PIN 7a NIU PIN 87a NIU PIN 872 NIU PIN 1 07 RED PIN 5 10E BLUE WHITE n n i Lesa ECRI 1708 HACR TORI BLUE DEUTSCH DEUTSCH PIN 8 71 BLACK WHITE N N N 7 PING 19 ORANGE PIN7 7A REDIHTE eo meee 40 9 PIN4 14E BLACK 8 00 WHITE E 54 3215 CHARGER CUTOUT 1 TOLOWER BASE CTRL SOFT STOP LIMIT SWITCH CONTROL MODULE P3 PIN 3 60 GREEN 6 PIN 4 28 BLACK 5 PIN 6 28E WHITE J EN 023 024 E 3 5 gl LII Q o 7 TA O amp o O18B OE O 9 O21 0 8 0 280 HM O16 o 7 OT O 71 O 233 9 MAIN MANIFOLD S S SOK SASS SSNS SSi Loe lt 00 GREEN YELLOW a 02 5 77 4 q98 0RANGE BarreRY TRAY 13C ORANGE 72 BLKWHT 14 BLACK 15 BLUE 16 WHITE BLACK 17 BUERED HYDRAULIC TRAY 23 BLACK WHITE 1 24 BLUEIBLACK e IL BL BACK VIEW FRONT VIEW 25 ORANGE GREEN p 59 ORANGEJBLACK C
22. Check continuity Replace if defective Defective or tripped circuit breaker CB2 Reset circuit breaker Replace if defective Loose or broken wire 3A from circuit breaker CB2 to charger relay L1CR Check continuity Replace if defective Defective battery charger relay 1 Check relay Replace if defective Loose or broken wire 5 from charger relay L1CR to base emergency stop switch S28 Check continuity Replace if defective Open or defective base emergency stop switch S28 Close switch Check switch Replace if defective Loose or broken wire 5A from base emergency stop switch S28 to base key switch 10 Check continuity Replace if defective Open or defective base key switch 10 Select function with switch Check switch Replace if defective Loose or broken wire 07 from base key switch 510 to base terminal block Check continuity Replace if defective Loose or broken wire 07 from base terminal block to platform emergency stop switch S4 Check continuity Replace if defective Open or defective platform emergency stop switch S4 Close switch Replace if defective Loose or broken wire 7A from platform emergency stop switch S4 to base terminal block Check continuity Replace if defective Loose or broken wire 7A from base terminal block to base key switch 510 Check continuity Replace if defective Open or defective base key switch 10 Close switch Replace if defective Loose or broken wire 00 fro
23. 1 1 TRANSDUCER Pressure 2000 psi Model 3215 TRANSDUCER Pressure 3000 psi Model 3219 RESISTOR 2 7K Ohms RESISTOR Variable 20 Ohms 25W RESISTOR Low voltage protection SWITCH Main power disconnect N O CONTACT Raise Lower N C CONTACT Lift Drive If equipped N O CONTACT Lift Drive without power extension platform If equipped N O CONTACT Lift Drive with power extension platform If equipped SWITCH Toggle Lift Off Drive N C CONTACT Emergency stop Platform control console CONTROLLER ASSEMBLY Proportional SWITCH Neutral SWITCH Right steer SWITCH Left steer Parts list continued on the following page DC Electric Scissor Lifts Compact Series 155147 Service and Maintenance Section 3 System Component Identification and Schematics 3 5 Electrical Component Parts List Continued Skyjack Las arc Parts list continued from the following page 122872 147054 147053 147054 115574 147053 103336 SWITCH Enable pushbutton N O CONTACT Horn N C CONTACT Off Platform N O CONTACT Base SWITCH Toggle Inclined Drive Level Drive N C CONTACT Emergency stop Base control console HOURMETER Purchase locally DC Electric Scissor Lifts SKYJACK Page 9 Compact Series 155147 lt Section 3 System Component Identification and Schematics Service and Maintenance 3 6 Hydraulic Manifold and Port
24. All Controls From Platform Control 5 No Drive or Up Function kom COntrOlS SER eb und 5 Down Reverse Function from Platform 6 No Up or Forward Only Function from Platform Control 6 No Up Function from Platform or Base Control 6 No Up Foancaen from Base Control DORBO S e 7 No Down Function from Platform or Base Control Console 2 7 No Down Function from Base Control 7 Platform Lowers Slowly from Platform and Base Model 3215 7 Platform does not Decelerate when Lowering Model 3215 8 Platform Lifts Slowly from Platform and Base Control console 8 xc el TET OT I OT D NE NEU Penmaes cee tener OE 8 quic METTE MH 8 No Drive or Steer when Platform Fully nnn nnns nnns 8 No Drive or Steer when Platform 8 Elevated Drive Speed Does Not 9 Drives Speed 9 Forward Drive Function 10 UB Mte __ ___ ____ 10 OE RUM 10 Two or more Functions t One _____
25. Not Stopped This message is given if any function switch is closed Check DIAGNOSTICS SWITCHES to see which function switch is closed Code 04 Tilted This message is given if the machine is tilted Calibration must be carried out with the machine level If the machine is level use the SETUPS TILT SETUPS to set the GP102 level Code F05 Bad Height This message is given if the height sensor output P4 3 is out of range at the start of calibration The height sensor output must be 3 7V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem Code F06 Check Elev This message is given if the elevation switch P2 10 is closed at the start of calibration when the operator has confirmed the PLATFORM DOWN question Ifthe platform is down check the elevation switch wiring Code F08 Check Elev This message is given if the elevation switch P2 10 is closed at the end of calibration when the platform should be fully raised This message would occur if the UP switch was accidentally opened near the start of the lift If the platform is fully raised check the elevation switch wiring Code F09 Bad Height This message is given if the height sensor output 4 3 is out of range at the start of calibration The height sensor output must be 3 7V Check DIAGNOSTICS SENSORS to see the output Code F10 Bad Height This message is given if the height sensor output P4 3 is ou
26. Proportional controller S7 out of adjustment Adjust controller Refer to Section 5 Joystick Adjusting Procedure DC Electric Scissor SKYJACK Page 9 Compact Series 155147 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 20 Forward Drive Function Inoperative 1 Loose or broken wire 16 from lift drive switch S3 to base terminal block Check continuity Replace if defective 2 Loose or broken wire 16 from base terminal block to CM1 control module pin P2 7 Check continuity Replace if defective 3 Loose or broken wire 16 from base terminal block to forward drive valve coil 4H 16 Check continuity Replace if defective 4 Forward drive valve coil 4H 16 defective Check continuity through coil Replace if defective 5 Loose or broken wire 02 from forward drive valve coil 4H 16 to base terminal block Check continuity Replace if defective 6 No output to wire 17 while operating a forward drive function from diode module DM 1 at base terminal block TB1 Check for 24 volts at 17 at terminal block Replace diode module if no voltage found or is defective 4 1 21 Reverse Drive Function Inoperative 1 Loose or broken wire 15 from lift drive switch S3 to base terminal block Check continuity Replace if defective 2 Loose or broken wire 15 from base terminal block to CM1 control module pin P2 8 Check continuity Replace if defective 3 Loos
27. Since the GP102 only reports one error only one code can be read from the LED per instance If the error is cleared and another error is present it will then be presented DC Electric Scissor Lifts SKYJACK Page 9 Compact Series 155147 Q Service and Maintenance Section 5 Procedures 5 3 3 LED Error Codes Code Breakdown Chart Diagnostic sequence dependant on LED flash code Check inputs on P2 pins 1 2 3 4 5 6 7 8 P3 4 Short To Supply P3 4 Short To Supply P3 6 Short To Supply 46 Disconnect plug If fault clears there is a problem with the wiring from 4 or P3 6 to the rest of the vehicle Armguard Active Elevation Switch Shifted A 21 Elevation Switch Stuck 22 If the 23 flash code is triggered by armguard it will occur once then clean This is not a true fault but just an indica tion of the reason for the vehicle stop If the 21 or 22 flash code is triggered by a fault with the elevation switch it will not clear Check that the elevation switch correctly opens closes when the platform is raised lowered P3 4 Short To OV P3 6 Short To OV Disconnect plug P3 If fault clears there is a wiring fault from P3 4 or P3 6 to the rest of the vehicle Invalid Load Check Sensors 45 Check the voltage out of the pressure transducer into P4 2 It should be between 0 5V zero pressure and 4 5V maximum pressure and should vary as the platform load amp position varies Waiting For B on P
28. 1 Check continuity through coil Replace if defective 9 Loose or broken wire 02 from holding valve coil 2H 13B 1 or down valve coil 2H 13B to base terminal block Check continuity Replace if defective 10 See 4 1 5 platform controls or 4 1 10 base controls of this section for more troubleshooting information 4 1 10 No Down Function from Base Control Console 1 Defective up down switch S2 Check switch Replace if defective 2 Loose or broken wire 13 from up down switch S2 to base terminal block Check continuity Replace if defective 4 1 11 Platform Lowers Slowly from Platform and Base Model 3215 1 Deceleration limit switch LS7 stuck out of adjustment or is defective Readjust limit switch so it returns to the normally closed position at 14 before completely stowed Check the limit switch is functioning Replace if defective DC Electric Scissor Llfts SKYJACK Page 7 Compact Series 155147 Q Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 12 Platform does not Decelerate when Lowering Model 3215 1 Deceleration limit switch 57 out of adjustment Readjust limit switch so it returns to the normally closed position at 14 before completely stowed Check the limit switch is functioning Replace if defective 2 Loose or broken wire 13C from terminal strip to deceleration valve coil 2H 13C Check continuity Replace if defective 3 Loose or
29. 1 02 os TO ELECTRIC PANEL 12 WIRES X 00 GREENYELLOW 02 WHITE 13B ORANGE 13C ORANGE 3215 ONLY UTME zl Ta 14 BLACK 14 BLACK 15 BLUE 02 WHITE 16 WHITEIBLACK 17 BLUE RED 23 BLACKWHITE CUSHION VALVE 24 BLUEIBLACK 25 ORANGE GREEN 25 ORANGEIGREEN 02 WHITE 59 ORANGE BLACK SPLICE 1 00 GREENYELLOW BRAKE VALVE h PROPORTIONAL VALVE 17 59 ORANGE BLACK wE p WWITE M147332AA_S3A DC Electric Scissor Lifts SKYJACK Page 19 Compact Series 155147 3 14 Electrical Panel Diagram Print This Page View Parts List ___
30. 1mx2 1m Working Height 8 1 m 9 9 m 11 8m 6 1m 7 9 9 8 Platform Elevated Height Stowed Platform Height 1 0m 1 4m 1 2m Stowed Height Railings Up 1 96 m 2 15 2 24 Stowed Height Railings Down 1 6m 1 8m 1 9m Drive Height 6 1m 7 9 9 7 m Standard Operating Times Lift Time No Load 24 5 48 5 505 485 455 625 Lift Time Rated Load 32 5 545 595 Lower Time Rated Load 32 5 32 5 49 5 Chassis Normal Drive Speed 3 2 km h Elevated Drive Speed 1 km h High Torque Drive Speed 1 6 km h Gradeability Ramp Angle 30 25 Tires Solid Rubber 16x5x12 Hydraulic Oil 131AA Weight with standard 1 2m extension platform Refer to serial nameplate for specific applications Note Emission sound pressure level does not exceed 70 dB A DC Electric Scissor Lifts SKYJACK Page 3 Service and Maintenance Section 2 Maintenance Tables and Diagrams kk Table 2 2 Floor Loading Pressure Total Aerial Platform Total Aerial Platform Load min Total aerial platform weight with no options max Aerial platform weight all options full capacity LCP Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the areas in direct contact with the floor The floor covering tile carpet etc must be able to withstand more that the indicated values above OUP Overall Uniform Pressure is a measure of the average
31. Black wire 14 Wire 19B Connect the Easy Cal tool to the P1 connector on the CONTROL MODULE DC Electric Scissor Lifts SKYJACK Page 17 Compact Series 155147 lt Service and Maintenance Section 5 Procedures 8 display will show Help Press Enter By using Left Right buttons select the Access Level from the menu and press the ENTER button Contact Skyjack Service Department at 44 1691 676 236 for your Access Level Code Number 9 display will show Access Level Code By using the Up Down buttons enter the Access Level Code xxxx followed by pressing the ENTER button 10 display will show Access Level 2 By using Left Right buttons select the Setups from the menu and press the ENTER button 11 The display will show Machine Defaults Select the Machine Defaults from the menu and press the ENTER button 12 The display will show Defaults 0 Custom By using Left Right buttons select the X Group Code from the menu and press the ENTER button 13 The display will show X GROUP CODE Refer to 5 3 7 for group code By using the Up Down buttons enter the Group Code then by using Left Right buttons select the Curve from the menu 14 The display will show Refer to 5 3 7 for curve code By using the Up Down buttons enter the Curve Code followed by pressing the ESCAPE button 15 The display w
32. Identifications 2H 59 To Main Manifold View Proportional Valve Parts List Internal Compensator Valve MB2 MB2 Drive Manifold Block Proportional ES Manifold Block To Main Manifold M To Left Wheel Motor no ifi Upper Port Orifice Pp To Pump To Left Wheel Motor To Right Wheel Motor Lower Port Lower Port V3 6 Auto Reset Valve 77 To Right Wheel Motor 6 gt Upper Port To Main Manifold P2 N c 1 el To Drive To Return Filter To Lift Cylinder To Drive To Left Steering To Cushion Manifold To Right Steering MB10 Deceleration Manifold Model 3215 2H 13C Deceleration Valve R2 Lift Relief Valve Emergency Lowering Manifold Block 3H 14 Lift Valve 2H 13B Lowering Valve T 4H 16 Forward Drive Valve 4H 15 Reverse Drive Valve So CB1 Counterbalance Valve 2 25 Cushion Valve 4H 24 Left Steering Valve 2 N 8 2 s Brake Valve 4h 23 H Right Steering Valve ay gt mc To Filter yp R1 To Proportional Valve System Relief Valve Test Port To Cushion Valve To Emergency Lowering 155708 1 SKYJACK 10 DC Electric Scissor Lifts Compact Series ere Service and Maintenance Section 3 System Component Identification and Schematics 3 7a Platform Control Con
33. Pressure Transducer 902 White Negative Signal To Angle Transducer 910A Black Positive Signal To Pressure Transducer PIN WIRE PLUG AND COLOUR WIRE FUNCTION P2 U U U U 0 NO 2 7 10 11 919199 02 09 C P2 2 P 3 4 ee 6 EC NEN MN P2 8 E P2 10 Pe E PX 12 1 PB 3 Eggs 4 LES d 5 P3 6 4 L PA 2 L PE L PA 6 P4 8 SKYJACK 8 DC Electric Scissor Lifts Compact Series lt Q 155147 Section 5 Procedures Service and Maintenance 5 3 2 LED Error Codes Quick Reference Chart TOO HIGH LIFT UP PREVENTED TESTING HWFS TESTNGHWES 78 STARTUP 02 STARTUP FACTORY OVERRIDE 60405AB Reading the Codes In order to read the fault codes a sequence of pauses and flashes can be seen on the LED mounted on the GP102 module The codes are continuously displayed by the LED until the fault is cleared the GP102 reset and no longer detects the fault or idle timeout becomes active The sequence is as follows 1 Quarter second flashes followed by quarter second pauses indicate the first digit 2 A1 5 second pause 3 Quarter second flashes followed by quarter second pauses indicate the second digit 4 A4second pause Repeat steps 1 4
34. Scissor Lifts Section 1 Scheduled Maintenance WARNING Operator s Responsibility for Maintenance Safety Precautions Know and understand the safety precautions before going on to next section Failure to heed the following safety precautions could result in tip over falling crushing or other hazards leading to death or serious injury KNOW all national state or territorial provincial and local rules which apply to your aerial platform and jobsite TURN main power disconnect switch off when leaving the aerial platform unattended Re move the key to prevent unauthorized use of the aerial platform WEAR all the protective clothing and personal safety devices issued to you or called for by job AVOID falling Stay within the conditions DO NOT wear loose clothing dangling neckties scarves rings wristwatches or other jewelry while operating this lift AVOID entanglement with ropes cords or hoses boundaries of the guardrails DO NOT raise the aerial plat form in windy or gusty condi tions DC Electric Scissor Lifts lt DO NOT increase lateral surface area of the platform Increasing the area exposed to the wind will decrease aerial platform stability DO NOT drive or elevate the aer
35. Test Free wheeling latform Control Console Wheel Tire Assembly Tie Rod Conventionals Test Emergency Lowering U gt gt gt gt gt wl ow Pothole Protection Device Hydraulic Tank Test Platform Emergency Stop Hydraulic Oil Hydraulic Pump and Motor Test Enable Trigger Switch gt UJ Test Steering Electrical Panel Test Driving Test Brakes DI o Proportional and Main Manifolds Load Tilt Sensor Emergency Lowering Access Rod If Equipped Test Platform Raising Lowering gt gt gt gt gt Test Lowering Warning gt Test Horn Test Pothole Sensor Test Elevated Drive Speed Perform Visual and Daily Maintenance Inspections amp Functions Test Refer to Section 2 of the Operating Manual B Perform Scheduled Maintenance Inspection every three months or 150 hrs Refer to Section 1 of this manual C Perform Scheduled Maintenance Inspection every year Refer to Section 1 of this manual D Perform Scheduled Maintenance Inspection every 2 years Refer to Section 1 of this manual Perform scheduled inspection every three months or 150 hours T Refer to Skyjack s website www skyjack com for latest service bulletins to performing quarterly or yearly inspection Note Make a copy of this page or visit the Skyjack web si
36. WHT 54 PUR RED 77 BRN GREY 105 GRN BRN 09 YEL 32 GRN BLK 55 YEL PUR 78 RED BLU 106 GRN PINK 10 BLUWHT GRN WHT 56 YEL BLK 79 BRN PUR 107 BLK BLU GREY 11 WHT ORG 34 ORG BLK 57 BRN GRN 80 WHT 108 YEL BRN 2 PEDEM 35 ORG WHT 58 WHT PUR 81 GREY BLK 109 GRN YEL 13 ORG 36 RED PUR 59 YEL BLU 82 BRN WHT 110A BLU 14 BLK WHT BLU 83 BLU GREY 1108 BRN 15 BLU 38 ORG RED 61 GREYIBRN 84 441 GREY GRN 16 WHT BLK 39 BLK RED 62 GREY RED 85 GREY BLU 112 BLU ORG 17 BLU GRN 40 BLU RED 63 GREY YEL 86 87 PUR BLU 113 BLU BRN 18 GRN BLU 41 BLU PUR 64 WHT BRN 88 BLK ORG 114 YEL RED 19 ORG GRN 42 PINK 65 YEL PINK 90 RED GREY 115 WHT PUR 22 PUR GRN 43 WHT YEL 66 ORG YEL 91 REDSHLD 118 PUR PINK This table is to be used as a wire number color reference for all electrical drawings and schematics All wire numbers will retain their origional color coding for example if wire 7 is red wire 7A 7B and 7C will also be red DC Electric Scissor Lifts SKYJACK Page 5 Compact Series 155147 Q Section 3 System Component Identification and Schematics Service and Maintenance 3 4 Hydraulic Schematic Parts List Skyjack 147661 134431 134432 104534 104534 PUMP Hydraulic TRANSDUCER Pressure 2000 psi Model 3215 TRANSDUCER Pressure 3000 psi Model
37. access platform 2 Close the gate 3 platform control console pull out i emergency stop button 4 Use the ladder to dismount from platform 5 main power disconnect switch to position DC Electric Scissor Lifts SKYJACK Page 25 Function Tests Conventional Back View Free wheeling Valve Lower Neutral Raise Switch y Emergency Stop Button e Test Base Emergency Stop 1 emergency stop button and attempt to raise or lower the platform Result Platform raising and lowering functions should not operate Pull out base i emergency stop button Test Off Platform Base Switch WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting Select off platform base key switch off position Attempt to raise or lower the platform Result Platform raising and lowering functions should not operate Select off platform base key switch to A platform position Attempt to raise or lower the platform Result Platform raising and lowering functions should not operate SKYJACK Page 26 Lower Neutral Raise Switch Off Platform Base Switch Section 1 Scheduled Maintenance Compact Back Vie
38. defective or sticking Clean valve Replace if defective 2 Steer cylinder C3 seals leaking Rebuild cylinder s Replace if damaged 3 Mechanical binding in king pins Check for binding Repair as needed 4 Orifices 05 plugged Clean Orifices and reinstall DC Electric Scissor Lifts SKYJACK Page 13 Compact Series 155147 lt Section 5 PROCEDURES Table of Contents Service and Maintenance 3 a E EE EE rt 3 Platform OEN iai ii omm 3 5 1 2 OEM Controller Troubleshooting dunes 4 dicil T m T 5 Base 5 2 1 System Relief Pressure AdIUSITIBIL 2 6 S22 Ei gui t 6 5 2 3 El vated Drive SOUD NR 7 Elevated Drive Speed Adjustment Tn 7 Load Sensing System 53 1 Control Modul Fin i am _______ 8 5 3 2 LED Error Codes Quick Reference 9 208 LED Eror bodas Coge Broakdown apt 10 5 3 4 Hand Held Calibration Diagnostic Tool Key 12 5 3 5 Control Module Load Calibration Code Messages amp 19 5 3 6 Control Module Load Calibrati
39. height where the switch opened Set up elevation switch to manufacturers specifications and calibrate load Code F17 High Elev open This message is given if the elevation switch P2 10 opened during lift at a too high height above 25 Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened Set up elevation switch to manufacturers specifications and calibrate load Code F18 Low Elev close This message is given if the elevation switch P2 10 closed during lower at a too low height below 596 Check CALIBRATIONS HEIGHT CALS the ElevDown value shows the recorded height where the switch opened Set up elevation switch to manufacturers specifications and calibrate load Code F19 High Elev close This message is given if the elevation switch P2 10 closed during lower at a too high height above 2596 Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened Set up elevation switch to manufacturers specifications and calibrate load Code F20 Height lt gt 0 This message occurs if the platform height is not 096 after the platform has been fully lowered during either STATIC lift The platform must return to the same height each time it is fully lowered Check DIAGNOSTICS SYSTEM to check the height Code F28 Bad Height This message indicates a problem with the height sensor output P4 3 during calibration The height sensor
40. o o 3 5 5 198 6 RED WHITE e GREEN 1 TO MAIN MANIFOLD MAIN MANIFOLD Q eee gt 23 BLACK WHITE s GREENWHTE W AD Ohis SF 24 BLUE BLACK s 21B GREEN BLACK NU s RED 07 5 J 69 ORANGE BLACK e BLACK 14 PLATFORM CONTROL BOX d E 18 RED BLACK NU 09K o s ORANGE 13 9 T 16 WHITE BLACK 10 09 2 BLUE 15 2 0 E 10 138 NOTUSED 9 1 WHITE 02 1 REAR HARNESS lt 2 J J J DE J J J 2 Jg D D 1 TO MAIN DISCONNECT SWITCH ASR CONTROL MODULE J J 4 4 J Zu J HORN 3 gt AT MOTOR CONTROL MODULE P2 1 0 BATTERY CABLE PIN 2 10E BLACK WHITE CABLE LAYOUT POTHOLE PIN 3 14 BLACK ENDVEW n POTHOLE LIMIT PIN 4 13 ORANGE wn 5 CONTROL MODULE PIN 7 16 WHITE BLACK 2 4 CONTROL MODULE BATTERY CABLE MER E MAIN MANIFOLD HARNESS 02 PIN 10 18B RED BLACK 49 BLACK REAR MANIFOLD HARNESS SKYJACK Page 20 149689 1 DC Electric Scissor Lifts Compact Series 155147 3 15 Limit Switch Assemblies Diagram Print View This Page Parts List DC Electric Scissor Lifts Compact Series 155147 LS1B
41. of the aerial platform and must not be used without manufacturer s consent All replacement tires must be of the same size and load rating as originally supplied tires to maintain safety and stability of aerial platform Consult SKYJACK s Service Department for optional tires specifications and installation N WARNING Any unit that is damaged or not operating properly must be immediately tagged and removed from service until proper repairs are completed Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this aerial platform All maintenance and service procedures should be performed in a well lighted and well ventilated area Anyone operating or servicing this aerial platform must read and completely understand all operating instructions and safety hazards in this manual and operating manual All tools supports and lifting equipment to be used must be of proper rated load and in good working order before any service work begins Work area should be kept clean and free of debris to avoid contaminating components while servicing All service personnel must be familiar with employer and governmental regulations that apply to servicing this type of equipment Keep sparks and flames away from all flammable or combustible materials Properly dispose of all waste material such as lubricants rags and old parts according to the relativ
42. regardless of the degree of handle deflection A Perform Maxout adjustment procedures IRS Option 1 Function speed reacts too slowly or too quickly in relation to handle deflection A Check IRS Ramp trimpot adjustment CW increases ramp time CCW decreases ramp time Integrated Ramp System IRS Provides smooth function response when reacting to an abrupt change in handle deflection CW rota tion of the trimpot increases ramp time and slows the response time CCW decreases ramp time and in creases the response time To increase the ramp time turn the adjusting screw CW a few turns then move the controller handle abruptly Continue to adjust until a smooth response is observed Most controllers have on off contacts which remove power from the PC Board when the handle is returned to the off position When the handle is abruptly returned to neutral the output will not ramp down and the function will stop Ramp Thru Off The PC Board should be adjusted as outlined in the IRS adjustment procedure If the handle is abruptly returned to neutral OFF the output will ramp down to off Ramp time is factory set to 2 seconds unless otherwise specified NOTE Trimpots should be sealed with nail polish or enamel based paint IV WARNING Do not use RTV silicone SKYJACK Page 4 DC Electric Scissor Lifts Compact Series 155147 Section 5 Procedures Service and Maintenance 5
43. secured Ensure gate is in good working order e Lanyard Attachment Anchors Ensure attachment rings are secure and no visible damage AC Outlet on Platform Ensure outlet has no visible damage and free from dirt or obstructions Service and Maintenance Platform Control Console Platform Railing e Platform Control Console Ensure all switches and controller are returned to neutral and are properly secured Ensure there are no loose or missing parts and there is no visible damage e Manuals Ensure a copy of operating manual and other important documents are enclosed in manual storage box Check to be sure manual storage box is present and in good condition Ensure manuals are legible and in good condition Always return manuals to the manual storage box after use DC Electric Scissor Lifts SKYJACK Page 23 Service and Maintenance Powered Extension Control IQ Console N Section 1 Scheduled Maintenance Maintenance Support Lift Cylinder Scissor Bumper Scissor Assembly e Powered Extension Control Console If Equipped Ensure all switches are returned to neutral and are properly secured Ensure there are no loose or missing parts and there is no visible damage N WARNING Ens
44. 1 3 OEM Controller switch wiring WIRE CHART COLOR TO WHT RED STEER LEFT PIN 1 WHT GRN STEER COMMON PIN 2 STEER RIGHT PIN 3 HT PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 DOUBLE DOT STEER RIGHT STEER COMMON WHT GRN SINGLE DOT TEER LEF STEER RIGHT wur STEER LEFT ENABLE OUT WHT BLU 24V INPUT WHT BLK ENABLE 15589 PCB 24V INPUT WHT BLK BLU PWD OUT A ENABLE WHT YEL BLK GROUND YEL FORWARD UP GRY REVERSE DOWN RED CONNECTOR DC Electric Scissor Lifts 5 5 Compact Series 155147 lt Service and Maintenance Base 5 2 1 2 10 11 System Relief Pressure Adjustment Locate the system pressure quick disconnect port on the main manifold Install a calibrated 5000 psi gauge to the system pressure quick disconnect port Remove the platform control console the guardrail and disconnect from the main control cable Locate the main control cable plug at the rear of the aerial platform Disconnect the main cable and connect the platform control console into the plug At the main manifold loosen the locknut on the system relief valve R1 Select drive with the lift drive select switch on the platform control console Engaged st
45. 2 Maintenance Tables and Diagrams Service and Maintenance AD Table 2 4 Torque Specifications Directional valve mounting bolts 28 32 in Ib 2 2 3 6 Nm Wheel mounting bolts 90 ft lb 122 02 Nm Cartridge 08 5 Ft Ib max lt SAE Plugs gt ___ 2 4 5 6 8 1 16 Newton meter Nm Foot pound ft lb Inch pound in Ib Additional Torque Specifications may be found in Section 3 60056AF DC Electric Scissor Lifts SKYJACK Page 15 Section 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS Table of Contents Charts 3 1 ER 3 3 2 La eser s e E n E eiei esain Den EE TREN is 4 3 3 ge ate 5 T 5 Parts List 3 4 Hucisuno Sch mati PADS 6 3 5 LIST ai T m T Tm ms 7 Diagrams and Schematics 3 6 Hydraulic Manifold and Port 10 RE Mm 11 Platform Control Console Diagram 12 3 8 que 13 3 9 Scissor Arm Control Cable 14 3 10 Electrical Inverter Schematic 8 Panel Diagram Equipped with timer Cutout relay
46. 2 12 Supply Too Low P4 1 Or P5 1 Short To OV Check that the battery voltage is not too low Verify battery voltage on P2 12 Disconnect plug P4 if the fault clears there is a wiring fault from P4 1 to the rest of the vehicle SKYJACK Page 10 DC Electric Scissor Lifts Compact Series lt Q 155147 Section 5 Procedures Service and Maintenance 5 3 3 LED Error Codes Code Breakdown Chart Continued Vehicle Tilted Vehicle Overloaded Too High Drive Prevented Too High Lift Up Prevented These are not true faults but an indication that vehicle movement is prevented Remove excessive load from the platform Lower the platform if close to maximum height Move the vehicle to level ground Invalid Height Check Sensor 65 Check the voltage out of the height transducer into P4 3 It should be between 4V and 4 6V and should vary as the platform position varies Testing HWFS Start Up These are not true faults unless they do not clear Overload Functions Disabled Factory Override 67 These are not true faults the GP102 has been configured to suppress overload functionality 78 77 Idle Timeout Active Always Off Fault Bad Tilt Sensor Fault Bad HWFS Fault Bad Slave Analogs Fault Bad Strain Monitors Fault Bad Slave Micro Fault HWFS Stalled Action a function to clear the idle timeout if it occurred Ensure the GP102 is correctly mounted incorrect mounting can cause the b
47. 3219 VALVE Relief System VALVE Relief Lift VALVE Emergency lowering VALVE Free wheeling 107271 103136 103655 1 VALVE Control Lowering 134822 1 VALVE Control Deceleration Model 3215 107269 1 VALVE Control Holding 128113 1 VALVE Control Cushion 132749 1 VALVE Control Proportional 106273 1 VALVE Control Lift 103623 1 VALVE Control Brake 153334 1 VALVE Control Reverse drive Hytos includes 4H 16 1 VALVE Control Forward drive Hytos 153334 1 VALVE Control Right steer Hytos includes 4H 24 1 VALVE Control steer Hytos 130709 1 CYLINDER Lift 121087 1 CYLINDER Steer 147888 1 VALVE Counterbalance 2750 psi 109568 1 FILTER Return 139412 1 MOTOR Hydraulic drive White Hydraulics 139412 1 MOTOR Hydraulic drive White Hydraulics 107354 1 BLOCK Manifold Main 139307 1 BLOCK Manifold Steering 103615 1 BLOCK Manifold Cushion valve 130481 1 BLOCK Manifold Holding valve 129656 1 BLOCK Manifold Lowering valve 132748 1 BLOCK Manifold Proportional control 136419 1 BLOCK Manifold Deceleration valve Model 3215 130046 1 ORIFICE 0 063 diameter Lowering Model 3219 108002 1 ORIFICE 0 040 diameter Cushion 108002 2 ORIFICE 0 04 diameter Steering 105281 1 ORIFICE 0 067 diameter Emergency Lowering 147656 1 ORIFICE 0 024 diameter Drive 1 1 1 1 1 1 1 SKYJACK 6 DC Electric Scissor Lifts Compact Series lt
48. ENSORS to read output Code F52 Too Few This message indicates that not enough measurements were recorded during calibration lifting or lowering Code F98 Out of Range This message indicates that the fine tune calibration is unacceptable This is probably due to a faulty transducer or faulty open holding valve s emergency lowering valve During calibration the following information messages may appear Platform Down This message is prompting for confirmation that the platform is fully lowered If necessary the DOWN switch can be activated to lower the platform Press ENTER to confirm when the platform is fully lowered Platform Empty This message is prompting for confirmation that the platform is completely empty Press ENTER to confirm if the platform is empty Platform Loaded This message is prompting for confirmation that the platform is loaded to rated load Press ENTER to confirm if the platform is loaded Please Lift This message is prompting for the platform to be raised The UP switch should be closed Please Lower This message is prompting for the platform to be lowered The DOWN switch should be closed DC Electric Scissor LIfts SKYJACK 15 Compact Series 155147 lt Service and Maintenance Section 5 Procedures Lift Empty This message is displayed while the platform is being raised to the next measurement height when an EMPTY platform is being calibrated Lift Loaded This mess
49. ER ON LIGHT HORN 49 11 HORN CM1 CONTROL 11 00 02 DS y 8229 P3 2 29 VA 13 BEEPER y RS dp X 52 2 m 2 j4 FLASHING LIGHT LED 1 nd ono ca aub 1 22 OPTION POWER ON LSS m n 885 Lm LIGHT 9 gt wmm gt oan 23 5 02 15 02 NS 60 60 RED WHITE 60 4 16 DECELERATION LIMIT SWITCH N C 3215 ONLY 2H 13C DECELERATION 1 1 17 SOLENOID 3215 ONLY LIFT DRV LOW DRV PRESS IRE 21 B 2H T3B 13 13 IN LIFT POSITION TRANSDUCER TRANSDUCER 1 18 DOWN SOLENOID 13 13 ORANGE 13 1 1 13A 13B 13 A 24 2 T 19 HOLDING VALVE none DO2 3 14 14 14 52 14 14 gt e e 20 UPSOLENOID zal 4 47 10 E 28ECR2 ae ERE 21 AUX DOWN RELAY A e pe UP DOWN 28 BATTERY CHARGE SWITCH 4 28 22 DOWN RELAY INDICATOR CRDi CHD2 CRD3 Y 08 02 14 4 195 1 4 23 MOTOR CONTACTOR gt gt f gt gt POTHOLE PROTECTION 2 LIMIT SWITCHES N C H O 4 DOES as 1 19 19 198 RSTI LA 2 2 9B TT 25 HOURMETER 2 7K OHMS EA 1 02 00 28E 28ECR1 ANN P 8 26 AUX TILT RELAY DRIVE 2 LIMIT SWITCH 2 28CR1 g 27 TILT RELAY 0141 02 02 WHITE 02 28 7 188
50. JACK Page 16 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Service and Maintenance SKY ACK Table 1 2 MAINTENANCE AND I NSPECTION CHECKLIST Serial Number Model Hourmeter Reading Name Printed Date Time Signature Each item shall be inspected using the the appropriate section of the Skyjack operating manual As each item is inspected write the apropriate grade in the box INSPECTION FREQUENCY Inspection Schedule 55 1 FREQUENTLY F FAIL ANNUALLY A B C R REPAIRED BI ANNUALLY A B C D Schedule P Schedule Schedule Maintenance nspections Platform Assembly __ ne Main Power DisconnectSwich as J m memes wen Lewes eres Compacts Front Side Lift Mechanism Brakes ABC Maintenance Support AC Outlet Receptacle Scissor Assembly 8 1 1 Battery Tray Side Roles AB Pothole Protection Devices as 1 8 Battery Charger AB Test Main Power Discconect Switch AB ase Control Console Steer Cylinder Assembly Test Base Emergency Stop Test Off Platform Base Test Lower Neutral Raise Switch A B A B Greasing Points A B C Hydraulic Electric Tray Side
51. LE EP gt NN Pothole Protection Device Battery Tray N WARNING Battery acid is extremely corrosive Wear proper eye and facial protec tion as well as appropriate protective clothing If contact occurs immedi ately flush with cold water and seek medical attention 1 Check battery case for damage 2 Clean battery terminals and cable ends thoroughly with a terminal cleaning tool or wire brush 3 Ensure all battery connections are tight 4 If applicable check battery fluid level If plates are not covered by at least 13 mm of solution add distilled or demineralized water 5 Replace battery if damaged or incapable of holding a lasting charge WARNING Use original or manufacturer approved parts and components for the aerial platform SKYJACK Page 20 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Conventional Battery Tray Steer Cylinder Assembly Ensure steer cylinder assembly is properly secured and there are no loose or missing parts e Wheel Tire Assembly The aerial platform is either equipped with solid rubber tires or foam filled tires Tire and or wheel failure could result in an aerial platform tip over Component damage may also result if problems are not discovered and repaired in a timely fashion Check all tire treads and sidewalls for cuts cracks punctures and unusual wear Check each wheel for damage and cracke
52. MODELS SJ 3215 5 3219 KEEP CLEAR wa Service Manual 5 Compact Series Part No 155147AD November 2013 This manual is based on Serial Numbers 3215 10 000 574 TO 10 000 630 22019977 TO 220772797 Please refer to the website www skyjack com for older Serial Numbers Skyjack Service Center 3451 Swenson Ave St Charles Illinois 60174 USA Phone 630 262 0005 Toll Free 1 800 275 9522 Fax 630 262 0006 Email servicefdskyjack com Parts North America Toll Free 1 800 965 4626 Toll Free Fax 1 888 782 4825 E mail parts askyjack com Skyjack Australia Pty Ltd 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel 61 0 28786 3200 Fax 61 0 28786 3222 Parts amp Service Europe Unit 1 Maes Clawdd Maesbury Road Industrial Estate Oswestry Shropshire SY10 8NN UK Phone 44 1691 676 235 Fax 44 1691 676 238 E mail info askyjackeurope co uk Skyjack Brasil Alameda Jupiter 710 Loteamento American Park Empresarial Indaiatuba SP Brasil 13347 653 Tel 55 19 3936 0132 DC Electric Scissor Lifts Service Manual Table of Contents Section 1 Scheduled Maintenance Inspections Table of Contents Section 2 Maintenance Tables Table of Contents Section 3 Schematics Table of Contents Section 4 Troubleshooting Table of Contents Section 5 Procedures Table of Contents DC Electric Sc
53. ON FOUR WAY CLOSED CENTER CLOSED PORT PILOT LINES Dashed SKYJACK Page 4 lt Service and Maintenance 4500 VELOCITY FUSE SINGLE ACTING CYLINDER DOUBLE ACTING CYLINDER DOUBLE ACTING DOUBLE RODDED CYLINDER SPRING APPLIED E HYDRAULIC RELEASED BRAKE BRAKE CYLINDER BI DIRECTIONAL HYDRAULIC MOTOR THREE POSITION _ FOUR WAY E CLOSED CENTER ROTARY ACTUATOR OPEN PORT DC Electric Scissor Lifts Compact Series 155147 Service and Maintenance Section 3 System Component Identification and Schematics 3 3 Wire Number and Color Code WIRE WIRE WIRE wine WIRE WIRE WIRE WIRE WIRE WIRE NO COLOR NO NO COLOR NO COLOR NO COLOR 00 WHT 20 ORG BLU 44 YEL WHT 67 ORG BRN 92 GRNSHLD 000 WHT 21 WHT RED 45 YEL ORG 68 GREY BLKSHLD Bi BLU PINK 23 BLK WHT 46 RED BLK 69 WHT GRN 95 YEL GREY 01 PUR BLK 24 BLU BLK 47 PUR ORG 70 ORG PINK 96 WHT GREY 02 WHT 25 BRN BLK 48 7 RED ORG 97 ORG GREY 0 GRN PUR 26 BLU YEL 49 GRN RED 72 RED BRN 98 REDSHLD 04 RED YEL 27 RED BLKWHT 50 BRN 73 RED PINK 98A BLKSHLD 05 PUR 28 GRN 51 BLK GRN 74 ad 99 BLK GREY 06 9 GREY ORG 52 GRN BLU 75 GREY PUR 103 BLK PUR 07 RED 30 RED GRN 53 BRN RED 76 BRN BLU 104 GRN ORG 08 PUR WHT 31 RED
54. REEN _ PIN X2 02 WHITE PIN 1 07 RED PIN 2 BLUE PIN 3 13 ORANGE PIN 4 14E BLACK PIN 5 10E BLUE BLACK PIN 6 80 BLUE WHITE PIN 7 GREEN PIN 8 02 WHITE o y 1 8 2 c 4 5 M149686AA_S3 DC Electric Scissor Lifts SKYJACK Page 13 Compact Series 155147 Section 3 System Component Identification and Schematics Service and Maintenance CONTROL CABLE OPTIONS EUROPE WIRE COLOUR WIRE NUMBER NA WIRE NUMBER 3 9 Scissor Arm Control Cable GREEN BLACK REDMHITE 1B 60 218 View Parts List BACK VIEW FRONT VIEW TO ELECTRIC PANEL CONTROL CABLE jg eS o ME Bs 1 GREEN 8 16 RED WHITE 160 49 7 15 BLACK WHITE 23 150 07 6 XO 4 4 140 RED 5 18 _ GREEN BLACK OP
55. RESISTOR SINGLE POLE SINGLE THROWN RELAY DOUBLE POLE DOUBLE THROW RELAY RHEOSTAT LIMIT SWITCH N O HELD CLOSED LIMIT SWITCH LIMIT SWITCH N C HELD OPEN SILICON CONTROLLED RECTIFIER PROXIMITY SWITCH PNP TRANSISTOR NPN TRANSISTOR PRESSURE VACUUM SWITCH TEMPERATURE SWITCH I TILT SWITCH DC Electric Scissor Lifts Compact Series 155147 Q 5 3 Section 3 System Component Identification and Schematics LINE CROSSING dc LINE JOINED HYDRAULIC TANK HYDRAULIC 9 FILTER WITH BYPASS ELECTRIC MOTOR ENGINE FIXED DISPLACEMENT PUMP VARIABLE DISPLACEMENT HYDRAULIC MOTOR SERIES Rm PARALLEL HYDRAULIC MOTOR TWO POSITION TWO WAY NORMALLY OPEN VALVE PRESSURE TRANSDUCER ANANANAN NAAAAAAA WVVYVVY SERVO 3 2 Hydraulic Symbol Chart VARIABLE DISPLACEMENT PUMP HAND PUMP RELIEF VALVE PRESSURE REDUCING VALVE FIXED ORIFICE ADJUSTABLE FLOW CONTROL lt gt VALVE gt OIL COOLER TWO POSITION TWO WAY NORMALLY CLOSED VALVE TWO POSITION THREE WAY VALVE MAIN LINES Solid 9 SHUTTLE VALVE ACCUMULATOR GAS CHARGED CUSHION CYLINDER PRESSURE SWITCH MOTION CONTROL VALVE FLOW DIVIDER COMBINER COUNTER BALANCE VALVE VALVE COIL TWO POSITION THREE WAY VALVE THREE POSITI
56. T 130 05 4 12 ORANGE BLACK 6 que ES 13 RANGE 3 REDBLACK 18 2 OO 0 WHITE BLACK ie 1O 02 WHITE 1 IL NOT USED 90 01 N 1 TO PLATFORM CONTROL CONSOLE 2 FRONT VIEW BACK VIEW CONTROL CABLE T o 8 Olis RED WHITE 16 oo 8 GREEN 7A X 7 0 15 28 BLACK WHITE 18 17 GREENWHITE 49 N 6 O 14 24 BLUEBLACK 14 OKO 6 BLUE WHITE 80 5 0 1 GREEN BLACK 13 5 RED 07 4 12 69 ORANGE BLACK 12 4 BLACK 4 3O 18 RED BLACK t DWE 3 ORANGE 13 N LO Qr 16 10 2 100 e 1 wE og CNN D S M146650AB S3 SKYJACK Page 14 DC Electric Scissor Lifts Compact Series 155147 Service and Maintenance Section 3 System Component Identification and Schematics 3 10 Electrical Inverter Schematic amp Panel Diagram Equipped with timer cutout relay AB Electrical Schematic 110 VAC LINE VOLTAGE A View Parts List BC 24V CHARGER
57. VALVE VA p INO N LA RELIEF 4H 15 4 R VALVE REVERSE LEFT OWERNG _ pd n ied STEER ORIFICE VALVE VALVE VALVE 068 DIA 3219 ONLY HYDRAULIC s Y QUICK u 7 gt MAIN MANIFOLD BLOCK MB3 FI CUSHION lt gt DUREE EMERGENCY 1 LOWERING FILTER 040 DIA VALVE LOWERING VALVE i 2925 BLOCK VALVE BLOCK CUSHION P PUMP 1 HYDRAULIC TANK M155713AC SKYJACK Page 18 DC Electric Scissor Lifts Compact Series 155147 3 13 Main Manifold Harness and Holding Valve Harness Print View This Page Parts List LEFT FORWARD VALVE RIGHT STEER VALVE REVERSE BLACK HEIRSHMAN BLACK HEIRSHMAN INSERT ORIENTATION PIN 1 16 WHITEIBLACK PIN 1 23 BLACKWHITE REVERSE VALVE LEFT STEER VALVE REY MAIN MANIFOLD HARNESS 1984 P ae i ie Ne 5 HOLDING VALVE 2 WHITE gt PIN 2 02 WHITE PIN 2 02 WHITE PIN 1 BLACK F PIN 2 WHITE EC RIGHT pen ipii HOLDING VALVE rare 13B ORANGE 02 WHITE 2 SOFT STOP VALVE 180 ORANGE 2
58. able Resistor RST2 out of adjustment or open Check resistor ohms it should read approx 13 ohms Refer to elevated drive speed set up in section 5 2 4 of this manual Readjust as necessary or replace if defective Loose or broken wire 02 from resistor RST2 to base terminal block Check continuity Replace if defective Proportional relay 21ACR defective Check relay replace if defective 4 1 19 Platform Drives in Slow Speed Only 1 No output to wire 17A while operating a drive function from diode module 1 at base terminal block TB1 Check for 24 volts at 17A at terminal block Replace diode module if no voltage found or is defective 2 Loose or broken wire 17A from base terminal block to high speed limit switch LS1B Check continuity Replace if defective 3 Open or defective high speed limit switch LS1B Check switch Replace if defective 4 Loose or broken wire 21 from high speed limit switch LS1B to low voltage protection resistor RSTS Check continuity Replace if defective 5 Defective low voltage protection resistor RST3 Check resistor Replace if defective 6 Loose or broken wire 21A from low voltage protection resistor RST3 to proportional relay 21ACR Check continuity Replace if defective 7 Proportional relay 21ACR defective Check relay replace if defective 8 Loose or broken wire 2 from proportional relay 21ACR to base terminal block Check continuity Replace if defective 9
59. ad tilt sensor diagnostic to occur Otherwise there may be an internal problem with the GP102 DC Electric Scissor LIfts SKYJACK Page 11 Compact Series 155147 lt Service and Maintenance Section 5 Procedures 5 3 4 Hand Held Calibration Diagnostic Tool Key Functions IV WARNING Only trained and authorized personnel shall be permitted to service and aerial platform WARNING Read all instructions closely before attempting each phase or the calibration procedure ESC ENTER Buttons To move back and forth between menu and sub menu LEFT RIGHT Buttons Select menus and setting to be adjusted UP DOWN BUTTONS Adjust setting values SKYJACK Page 12 DC Electric Scissor Lifts Compact Series lt Q 155147 Section 5 Procedures Service and Maintenance 5 3 5 Control Module Load Calibration Code Messages amp Definitions During calibration the following failure message may appear Code 01 Check HWFS This message is given if the GP102 startup tests have not completed Check HELP message for more information Code 202 Not Ground Mode This message is given if the machine is not in ground mode P2 2 must be high Calibration can only be carried out in ground mode Code F03
60. age is displayed while the platform is being raised to the next measurement height when a LOADED platform is being calibrated Lifting This message is displayed while the platform is being raised during HEIGHT only calibration Measuring This message is displayed when the platform is stopped during calibration when the GP102 takes a measurement There will be a short delay while the machine is allowed to stabilize after movement is stopped Must Go Down This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be lowered Must Go Up This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be raised Please Wait This message indicates that the GP102 is busy the delay will be short no more than 5 s Lower Empty This message is displayed while the platform is being lowered to the next measurement height when an EMPTY platform is being calibrated Lower Loaded This message is displayed while the platform is being lowered to the next measurement height when an EMPTY platform is being calibrated Lowering This message is displayed while the platform is being lowered during HEIGHT only calibration Total Data This message is displayed at the end of each phase to confirm the number of measurements recorded by the GP102 Caldate This message is prompting for the date to be entered it is stored to identify when the machine was calibrated The las
61. aintenance Operator s Responsibility for Maintenance Safety Precautions Continued Know and understand the safety precautions before going on to next section DO NOT exceed the rated capacity of the aerial platform Do make sure the load is evenly distributed on the platform DO NOT attempt to free a snagged platform with lower controls until personnel are removed from the platform DO NOT position the aerial platform against another object to steady the platform DO NOT place materials on the guardrails or materials that exceed the confines of the guardrails unless approved by Skyjack N WARNING Entering and exiting the aerial platform should only be done using the three points of contact Use only equipped access openings Enter and exit only when the aerial platform is in the fully retracted position Do use three points of contact to enter and exit the platform Enter and exit the platform from the ground only Face the aerial platform when entering or exiting the platform Three points of contact means that two hands and one foot or one hand and two feet are in contact with the aerial platform or the ground at all times during entering and exiting WARNING An operator should not use any aerial platform that does not appear to be working properly has been damaged or appears to have worn or missing parts has alterations or modifications not approved by the manufacturer has safety device
62. all labels are in place and are legible 1 1 2 Limit Switches Detecting limit switch malfunction is essential to safe aerial platform operation Ensure limit switches are properly secured and movement is not obstructed Visually inspect all limit switch located inside the scissor arms and the outrigger assemblies for the following broken or missing actuator arm e missing fasteners loose wiring SKYJACK Page 18 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Service and Maintenance Compact Conventional 220V Outlet Back View Receptacle Free wheeling Valve T Base Control gt N Main Power Console Ladder Disconnect Switch Compact Back View 1 1 3 Entrance Side AC Outlet Receptacle Ensure receptacle is free from dirt and Main Power Disconnect Switch obstructions Turn main power disconnect switch to off position Ladder mE Ensure there are no loose or missing Ensure all cables are secure and switch parts and there is no visible damage is in proper working condition e Base C
63. broken wire 02 from terminal strip to deceleration valve coil 2H 13C Check continuity Replace if defective 4 Defective deceleration valve coil 2H 13C Check coil Replace if defective 4 1 13 Platform Lifts Slowly from Platform and Base Control console 1 Open diode D14 1 Check diode Replace if defective 4 1 14 Steer Only Inoperative 1 Defective relay 17CR Check relay Replace if defective 2 output to wire 590 while operating a steer only function from diode module DM 1 at base terminal block TB1 Check for 24 volts at 59D at terminal block Replace diode module if no voltage found or is defective Loose or broken wire 59D from 17CR steer relay to base terminal block TB1 Check continuity Replace if defective 4 Loose or broken wire 59 from 17CR steer relay to base terminal block TB1 Check continuity Replace if defective o 4 1 15 Drive Only Inoperative 1 output to wire 71 while operating a drive only function from diode module DM1 at base terminal block TB1 Check for 24 volts at 71 at terminal block Replace diode module if no voltage found or is defective 4 1 16 No Drive or Steer when Platform Fully Lowered 1 Loose or broken wire 71 from base terminal block to drive override limit switch LS6 Check continuity Replace if defective 2 Defective drive override limit switch LS6 Check switch Replace if defective 3 Loose or broken wire 19 from drive override limit switc
64. ch 3 Press rocker switch on top of controller e Test Brakes handle to left and 41 right WARNING Result Steer wheels should turn left and Brakes will engage instantly when you right release the controller handle causing aerial platform to stop immediately Test Driving a 1 Ensure path of intended motion is clear 1 Ensure path of intended motion is clear 2 Activate and hold 54 enable trigger switch 2 Activate and hold enable trigger 1 switch 3 Drive aerial platform a forward and then q backward Test brake by releasing controller handle Result Aerial platform should come to 3 Slowly move controller handle in f forward direction until aerial platform 4 begins to move and then return handle center position Result Aerial platform should move in forward direction and then come to a Stop A Slowly move controller handle in y reverse direction until aerial platform begins to move and then return handle to center position Result Aerial platform should move in reverse direction and then come to a stop a stop If aerial platform pulls to one side while stopping do not operate aerial platform until brake adjustments have been checked Drive aerial platform 7 forward then backward Test brake again by releasing fx e
65. ck Check continuity Replace if defective 4 1 6 No Up or Forward Only Function from Platform Control Console 1 Loose or broken wire B from proportional controller S7 to lift drive switch S3 Check continuity Replace if defective 2 Lift Drive switch S3 defective Check switch Replace if defective 3 Defective PWM card on joystick S7 Check joystick card Replace if defective 4 Loose or broken wire 714 up or 16 forward from lift drive switch S3 to base terminal block Check continuity Replace if defective 4 1 7 Up Function from Platform or Base Control Console 1 Loose or broken wire 14 from base terminal block to up valve coil 3H 14 Check continuity Replace if defective 2 Loose or broken wire 02 from base terminal block to up valve coil 3H 14 Check continuity Replace if defective 3 Defective up valve coil 3H 14 Check continuity through coil Replace if defective 4 Loose or broken wire 14 from base terminal block to CM1 control module pin P2 3 Check continuity Replace if defective 5 Open diode D14 1 Check diode Replace if defective 6 Open diode D14 2 Check diode Replace if defective 7 Machine not level Above high speed limit switch Use level surface 8 See 4 1 6 platform controls or 4 1 8 base controls of this section for more troubleshooting information SKYJACK Page 6 DC Electric Scissor Lifts Compact Series lt Q 155147 Service and Maintenance Sec
66. ck continuity Replace if defective 6 Loose or broken wire 19A from Aux tilt relay 28ECH1 to tilt relay 28CR1 Check continuity Replace if defective DC Electric Scissor Llfts SKYJACK Page 5 Compact Series 155147 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 7 Loose or broken wire 19B from tilt relay 28CR1 to hour meter Check continuity Replace if defective 8 Loose or broken wire 19B from hour meter to motor contactor C1 Check continuity Replace if defective 9 Loose or broken wire 59 from proportional controller S7 to base terminal block Check continuity Replace if defective 10 Loose or broken wire 59 from base terminal block to proportional coil 2H 59 Check continuity Replace if defective 11 Loose or broken wire 02 from base terminal block to proportional coil 2H 59 Check continuity Replace if defective 12 Defective proportional coil 2H 59 Check continuity through coil Replace if defective 4 1 5 No Down or Reverse Function from Platform Controls 1 Loose or broken wire from proportional controller S7 to lift drive switch S3 Check continuity Replace if defective 2 Lift Drive switch 53 defective Check switch Replace if defective 3 Defective PWM card on joystick S7 Check joystick card Replace if defective 4 Loose or broken wire 213 down or 715 reverse from lift drive switch S3 to base terminal blo
67. d welds Check each lug nut for proper torque to ensure none are loose Check wheel motor assembly for loose missing parts and signs of visible damage Ensure wheels are aligned and true vertically and horizontally Service and Maintenance Steer Cylinder Wheel Tire Tie Rod Tie Rod Conventionals Ensure there are no loose or missing parts tie rod end studs are locked and there is no visible damage Greasing Points Ensure greasing points have no sign of visible damage and are free from dirt and obstructions Frequent Inspection Locate grease fittings and pump grease as needed DC Electric Scissor Lifts SKYJACK Page 21 Service and Maintenance Section 1 Scheduled Maintenance Compact Emergency Lowering Access Rod Load Tilt Sensor Main Manifold Greasing Point 1 1 5 Hydraulic Electric Tray Side Ensure tray latch is secure and in proper working order Pothole Protection Device Ensure mechanisms have no sign of visible damage and are free from dirt and obstructions Hydraulic Tank Ensure hydraulic filler cap is secure Ensure tank shows no visible damage and no evidence of hydraulic leakage Hydraulic Oil Ensure platform is fully lowered and then visually inspect the sight gauge located on the side of the hydraulic oil tank hydraulic oil level should be at or slightly above the top mark of the sight glass C An
68. e law provisions obtaining in the country Before attempting any repair work turn Battery Disconnect Switch to the OFF position Preventive maintenance is the easiest and least expensive type of maintenance SKYJACK Page 12 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Operator s Responsibility for Maintenance Hydraulic System amp Component Maintenance and Repair The following points should be kept in mind when working on the hydraulic system or any component 1 Any structure has limits of strength and durability To prevent failure of structural parts of hydraulic components relief valves which limit pressure to safe operating values are included in the hydraulic circuits Tolerance of working parts in the hydraulic system is very Close Even small amounts of dirt or foreign materials in the system can cause wear or damage to components as well as general faulty operation of the hydraulic system Every precaution must be taken to assure absolute cleanliness of the hydraulic oil Whenever there is a hydraulic system failure which gives reason to believe that there are metal particles or foreign materials in the system drain and flush the entire system and replace the filter cartridges A complete change of oil must be made under these circumstances Whenever the hydraulic system is drained check the magnets in the hydraulic reservoir for metal particles If metal particles are p
69. e or broken wire 15 from base terminal block to reverse drive valve coil 4H 15 Check continuity Replace if defective 4 Reverse drive valve coil 4H 15 defective Check continuity through coil Replace if defective 5 Loose or broken wire 02 from reverse drive valve coil 4H 15 to base terminal block Check continuity Replace if defective 6 No output wire 17 while operating a reverse drive function from diode module DM 1 at base terminal block TB1 Check for 24 volts at 17 at terminal block Replace diode module if no voltage found or is defective 4 1 22 Brake will not Release 1 Loose or broken wire 17 from base terminal strip to brake coil 3H 17 Check continuity Replace if defective 2 Brake valve coil 3H 17 defective Check continuity through coil Replace if defective 3 Loose or broken wire 02 from brake valve coil 3H 17 to base terminal block Check continuity Replace if defective 4 1 23 Two or more Functions at one time 1 Shorted diode Check continuity of all diodes Replace if defective SKYJACK Page 10 DC Electric Scissor Lifts Compact Series lt Q 155147 Service and Maintenance Section 4 Troubleshooting Information Hydraulic System 4 2 1 All Functions Inoperative 1 Proportional valve 2H 59 defective or is sticking Check valve Replace if defective 2 Compensator portion of proportional valve defective or is sticking Check valve Replace if defective 3 Pu
70. eer right and hold Observe reading on gauge Adjust the R1 system relief value listed on the serial number plate Turning the stem on the relief valve clockwise will increases pressure Turning the stem counterclockwise will decreases pressure Release steer switch and tighten the locknut Remove the gauge from system pressure test port SKYJACK Page 6 Section 5 Procedures 5 2 2 Lift Pressure Adjustment NOTE Adequate area to raise the platform to full height is required for the following steps Locate the lift pressure test port on the main manifold Install a calibrated 5000 psi gauge to the lift pressure quick disconnect port At the main manifold loosen the locknut on the lift relief valve R2 Close the manual lowering valve Use the lift switch at the base control console to raise the platform to full height and hold the lift up switch on Observe the reading on the gauge Adjust the H2 relief valve to the value listed on the serial number plate Turning the stem of the relief valve clockwise will increases pressure Turning the stem counterclockwise will decreases pressure Remove the gauge from lift pressure test port NOTE Pressure setting may vary as aerial platform components wear The lift pressure should be set for rated load only DC Electric Scissor Lifts Compact Series 155147 Section 5 Procedures Service and Maintenance 5 2 3 Elevated Drive Speed Setup Eleva
71. erate 2 Without activating Section 1 Scheduled Maintenance Lift Drive Steer Enable Trigger Switch Rocker Switch Emergency Stop Button Operation Light Emergency Stop Button Switch Operation Light Horn Pushbutton Lift Inclined Drive Level Drive Switch Platform Control Console with Rotary Switch Test Enable Trigger Switch 1 Pull out D emergency stop button enable trigger switch attempt to activate any platform function Result All platform functions should not operate Test Steering 1 For platform control console with toggle switch 1 Select lift off drive switch to drive position For platform control console with rotary switch Select lift inclined drive level drive switch to either inclined drive low speed high torque or B level drive high speed low torque position 2 Activate and hold d enable trigger switch SKYJACK Page 28 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Function Tests Lift Drive Steer Enable Trigger Switch Lift Drive Steer Enable Trigger Switch Rocker Switch Rocker Switch Emergency Stop Button Controller Operation Light Emergency Stop Button Switch Operation Light Inclined Drive Level Drive Horn Pushbutton Horn Pushbutton Lift Off Drive Switch Lift Inclined Drive Level Drive Switch Platform Control Console with Toggle Switch Platform Control Console with Rotary Swit
72. essing the ENTER button 25 display will show Calibrate Load Please Lift Waiting for the lift switch to be activated 26 Hold the lift switch and keep holding it until the platform is fully elevated IMPORTANT If the lift switch is released earlier than full height position the calibration will have to be aborted and repeated from the beginning 27 When the system detects the lift switch closed the display will show Calibrate Load Lift Empty 28 Afteradelay the system will stop the platform lifting and will take height amp pressure measurements the display will show MEASURING xx When the measurements have been taken the platform will resume lifting NOTE The Lifting stopping measuring lifting process will continue until the platform reaches full height 29 When the platform reaches full height release the lift switch 30 The display will briefly show TOTAL DATA 04 to indicate the number of measurements taken 31 The display will show Calibrate Load Please Lower IMPORTANT If the lower switch is released earlier than full lower position the calibration will have to be aborted and repeated from the beginning 32 Hold the lower switch and keep holding it until the platform is fully lowered 33 When the system detects the lower switch closed the display will show Calibrate Load Lower Empty 34 After a delay the system will stop the platform lowering and wil
73. fective 2 Hydraulic oil level too low Fully lower the platform Fill hydraulic tank with recommended fluid to appropriate level 3 Platform weight excessive Reduce platform load to maximum capacity 4 Up valve 3H 14 defective or is sticking Check valve Replace if defective 5 Plugged deceleration valve 2H 13C Model 3215 Clear obstruction from valve Replace if defective DC Electric Scissor Llfts SKYJACK 11 Compact Series 155147 lt Section 4 Troubleshooting Information Service and Maintenance Hydraulic System Continued 4 2 6 Platform will not Lower NOTE Down function is not proportionally controlled 1 Lowering valve 2H 13A defective or is sticking Clean valve Replace if defective 2 Defective holding valve 2H 13A 1 Clean valve Replace if defective 3 Lowering orifice 02 3219 only plugged or contaminated Clear debris Replace Orifice Replace if defective 4 Emergency lowering orifice O6 plugged or contaminated Clear debris Replace Orifice Replace if defective 5 Plugged deceleration valve 2H 13C Clear obstruction from valve Replace if defective 4 2 7 Platform Lowers Slowly 1 Stuck or defective deceleration 2H 13C Check valve Replace if defective 4 2 8 Platform Drives Slow 1 Free wheeling valve V2 open or defective Close valve Replace if defective 2 Drive orifice O7 loose or missing Check for orifice Reinstall 3 Drive
74. ffolding or other devices HA mounted on it to increase its size BE AWARE of crushing hazards or work height It is prohibited Keep all body parts inside platform guardrail DO NOT exert side forces on aerial platform while elevated DO NOT lower the platform END unless the area below is clear of personnel obstructions DO NOT use the aerial platform as a crane It is prohibited ENSUREthatthere are no personnel or obstructions in the path of travel including blind spots DO NOT sit stand or climb on the guardrails It is prohibited BE AWARE of blind spots when operating the aerial platform DO NOT climb on scissor arm STUNT driving and horseplay are prohibited assembly It is prohibited u ENSURE ALL tires are in good condition and lug nuts are properly tightened DO NOT alter or disable limit switches or other safety devices BE AWARE of overhead obstructions or other possible hazards around the aerial platform when driving or lifting DO NOT usethe aerial platform without guardrails locking pins and the entry gate in place SKYJACK Page 10 DC Electric Scissor Lifts Section 1 Scheduled M
75. fication and Schematics 3 8 Base Control Console Diagram View 2 UP SWITCH N O CONTACT Parts List PIN 3 10E BLUE BLACK X2 I PIN 4 14E BLACK E 5 22 Qu OL c2 DOWN SWITCH CONTACT poro PIN 3 10E BLUE BLACK 610 BASE SW PIN 4 13 ORANGE N O CONTACT TT PIN 3 10E BLUE BLACK X2 PIN 4 7A GREEN X2 S10 IDLE SW UM N C CONTACT TO CHARGER CUTOUT A PIN 1 5A PURPLE WHITE PIN 1 3A BLUE PIN 2 07 RED PIN 2 05 ORANGE BLACK S10 PLTF SW lt N C CONTACT p PIN 1 8C BLUE WHITE 528 EMERGENCY STOP PIN 2 07 RED X N C CONTACT PIN 5A PURPLE WHITE LED 2 POWER ON LSS LIGHT 1 PIN 2 05 ORANGE BLACK PIN X1 G
76. h LS6 to base terminal block Check continuity Replace if defective 4 1 17 No Drive or Steer when Platform Elevated 1 Pothole protection bars not fully lowered Clear obstructions Repair as needed 2 Loose or broken wire 71 from base terminal block to pothole protection limit switch LS4 Check continuity Replace if defective 3 Defective pothole protection limit switch LS4 Check switch Replace if defective 4 Loose or broken wire 72 from pothole protection limit switch LS4 to base terminal block Check continuity Replace if defective SKYJACK Page 8 DC Electric Scissor Lifts Compact Series lt Q 155147 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 9 6 f Loose or broken wire 272 from base terminal block to pothole protection limit switch LS5 Check continuity Replace if defective Defective pothole protection limit switch LS5 Check switch Replace if defective Loose or broken wire 19 from pothole protection limit switch LS5 to base terminal block Check continuity Replace if defective 4 1 18 Elevated Drive Speed Does Not Activate 1 2 Loose broken wire 59 from base terminal strip to proportional relay 21ACR Check continuity Replace if defective Loose or broken wire 59A from proportional relay 21ACR to resistor RST2 Check continuity Replace if defective NOTE The resistor on this machine is adjust
77. ial platform if itis not ona firm level surface Do not drive elevated near depressions or holes of any type loading docks debris drop offs and surfaces that may affect the stability of the aerial platform operation in areas with holes or drop offs is abso lutely necessary elevated driving shall not be allowed Position the aerial platform horizontally only with the platform fully lowered After ensuring that all 4 wheels or outriggers if equipped have contact with level firm surface the aerial platform can be el evated After elevation the drive function must not be ac tivated Elevated driving must only be done on a firm level sur face DO NOT ascend or descend a grade when elevated When fuly lowered ascending or descending only grades up to rated maximum listed in Table 2 3 are permissible SKYJACK Page 9 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance Safety Precautions Continued Know and understand the safety precautions before going on to next section DO NOT operate on surfaces not capable of NOT raise the aerial platform holding the weight of the aerial platform including while the aerial platform is on a the rated load e g covers drains and trenches truck fork lift or other device or vehicle e DO NOT operate an aerial 4 platform that has ladders No sca
78. ill show Machine Defaults By using Left Right buttons select the Tilt Setups from the menu and press the ENTER button 16 The display will show Tilt Setups Calibrate Level Select the Tilt Setups Calibrate Level from the menu and press the ENTER button 17 The display will show Calibrate Level Yes Enter No ESC Select the Yes from the menu by press the ENTER button 18 display will show Calibrate Level Tilt 0 0 0 0 Select the ESCAPE from the menu once 19 The display will show Tilt Setups Calibrate Level Select the ESCAPE from the menu once again 20 display will show Setups Tilt Setups By using Left Right buttons select the Load Setups from the menu and press the ENTER button 21 The display will show Load Setups Calibrate Load Select the Load Setups Calibrate Load from the menu and press the ENTER button 22 The display will show Calibrate Load Platform Down Asking for confirmation that the platform is fully lowered Check that the platform is fully lowered then press the ENTER button to confirm SKYJACK Page 18 DC Electric Scissor Lifts Compact Series lt 155147 Section 5 Procedures Service and Maintenance 23 The display will show Calibrate Loaded Empty Asking for confirmation that the platform is empty Check that the platform is empty 24 By using the Up Down buttons enter the Yes followed by pr
79. in which the trouble oc curs isolate whether the problem is electrical or hydraulic and then isolate and correct the specific problem The content of this section is separated into probable cause and remedy The information preceded by a num ber represents the probable cause The following line noted by a dash represents the remedy to the probable cause directly above it See example below for clarification 1 Probable Cause Remedy DC Electric Scissor Lifts SKYJACK Page 3 Compact Series 155147 lt Section 4 Troubleshooting Information Service and Maintenance Electrical System 4 1 1 All Controls Inoperative 1 2 3 10 11 12 13 14 15 16 17 18 19 20 21 21 22 23 Battery charger plugged into external power source Disconnect charger cord Batteries disconnected Connect batteries Dirty or loose battery terminals Clean and tighten connections Battery charge low Check each cell with a hydrometer Reading should be 1 275 fully charged Recharge if low reading Replace if reading difference between cells is 0 050 Main battery cables open or defective Check continuity Replace if defective Fuse F1 defective Replace fuse Main battery disconnect switch S1 open or defective Close switch Check continuity Replace if defective Loose or broken wire 3 from motor contactor C1 to circuit breaker CB2
80. ing valve manual override knobs clockwise Off Platform Base Switch Function Tests Compact Back View Emergency Stop Button Test Free wheeling 1 2 Ensure path of intended motion is clear Release the brake manually Turn free wheeling valve knob counterclockwise to a fully opened position and attempt to push pull the aerial platform Result Platform should move Turn free wheeling valve knob clockwise to a fully closed position for normal operation Reengage the brake DC Electric Scissor Lifts 5 27 Function Tests Lift Drive Steer Enable Trigger Switch Rocker Switch Controller Inclined Drive Level Drive Horn Pushbutton Lift Off Drive Switch Platform Control Console with Toggle Switch 1 2 3 Platform Control Console 1 Ensure base D emergency stop button is pulled out 2 Select off platform base key switch to platform position 3 Ensure main power disconnect switch is in on position WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform 4 Use the ladder of aerial platform to access platform 5 Close the gate 6 On platform control console pull out emergency stop button Test Platform Emergency Stop 1 Push i emergency stop button and attempt to activate any platform function Result selected platform functions should not op
81. ise CCW adjustment of the trimpot decreases the output Adjustments affect output current voltage or per centage of duty cycle to the coil The minimum and maximum output is preset at the factory However for optimum performance they must be adjusted while the equipment is operating Although the following adjustments affect the current voltage or percentage of duty cycle the best way to adjust the function is to observe the response or speed of the function The following adjustments affect func tion response or speed There may be some interaction between adjustments making it necessary to repeat the adjustment in order to achieve the desired response Threshold Adjustments Adjusts the initial current flow or duty cycle affecting the function response or speed when the handle is first moved from the off position Deflect the handle slowly to the position where the controller first turns on Adjust the threshold trimpot screw to the point where the con trolled function just starts to move then turn the trimpot screw one full turn in the counterclockwise direction This adjustment should be done first Maxout Adjustments Adjusts the full stroke current or duty cycle affecting the maximum function response or speed when the handle is deflected to its full travel Fully deflect the handle and adjust the maxout trimpot for maximum desired function response or speed To obtain proportional resolution it is impor
82. ise Switch Li Emergency Stop Button 1 2 Function Tests Function tests are designed to discover any malfunctions before aerial platform is put into service The operator must understand and follow step by step instructions to test all aerial platform functions WARNING Never use a malfunctioning aerial platform If malfunctions are discovered aerial platform must be tagged and placed out of service Repairs to aerial platform may only be made by a qualified service technician After repairs are completed operator must perform a pre operation inspection and a series of function tests again before putting aerial platform into service Prior to performing function tests be sure to read and understand Section 2 10 Start Operation of the operating manual 1 2 1 Test Main Power Disconnect Switch 1 Atrear of the base turn main power disconnect switch to off position Result Aerial platform functions should not operate Off Platform Base Switch Compact Back View Lower Neutral Raise Switch Emergency Stop Button 1 2 2 Base Control Console WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform 1 Use the ladder of aerial platform to
83. issor Lifts SKYJACK Page 3 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance The Safety Alert Symbol identifies important safety messages on aerial platforms safety This Safety Alert Symbol means attention signs in manuals or elsewhere When you see this symbol be alert to the possibility of Become alert Your safety is involved 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 aerial platform SKYJACK Page 4 DC Electric Scissor Lifts Section 1 SCHEDULE MAINTENANCE INSPECTIONS Table of Contents Operator s Responsibility for Maintenance x cxi ar ee ees 7 eee T RU ED 7 rome dec eee 7 RI 7
84. istributed Manual Extension Platform Powered Extension Platform Maximum Tilt Extension Capacity 1 Person 1 Person 1 Person 1 Person 1 Person 1 Person 1 Person 1 Person Total Capacity Extension Capacity Wind Speed No Wind 9 4 m s No Wind 9 4 m s No Wind No Wind 12 5 m s 12 5 m s No Wind 9 4 m s Cutout Setting 1 5x3 5 1 5x3 5 1 5 3 5 1 5 3 5 317 kg 113 1 Person NOTE Overall Capacity Occupants and materials not exceed rated load 132AB BEAUFORT Wind Speed Ground Conditions SCALE E 3 4 5 4 12 5 19 4 11 5 17 75 Papers and thin branches move flags 54 80 194 288 1775 2625 13 17 Dust is raised paper whirls small branches sway 80 108 288 5809 26 25 _ 35 5 18 _ 24 25 Shrubs with leaves start swaying Wave crests apparent in ponds or swamps 108 139 389 500 35 5 455 245 391 branches move Power lines whistle It is difficult to open an umbrella 139 172 500 619 45 5 56 5 31 385 trees sway It is difficult to walk against the 138AA CE This aerial platform is equipped with load sensing system Do not exceed rated capacity of the aerial platform Failure to avoid this will prevent operation of all normal controls functions of the aerial platform To resume normal operation remove the additional loads SKYJACK Page 6 DC Electric Scissor Lifts Section
85. l take height amp pressure measurements the display will show MEASURING xx When the measurements have been taken the platform will resume lowering NOTE The lowering stopping measuring lowering process will continue until the platform is fully lowered 35 When the platform is fully lowered release the lower switch 36 The display will show briefly TOTAL DATA 04 to indicate the number of measurements taken 37 The display will show Calibrate Load Caldate mm dd yy It is recommended that the current date be entered here to provide easy taking of the data of last calibration The current date must be entered using the LEFT RIGHT and UP DOWN buttons DC Electric Scissor LIfts SKYJACK Page 19 Compact Series 155147 Q Service and Maintenance Section 5 Procedures 38 Press ENTER to complete date entry the system will store it Display will show FINISHED 39 Remove the jumper wire and re connect the black wire 14 to the coil removed earlier 40 Close the hydraulic electric tray NOTE Continuing partially complete load calibration If the phase does not need to be repeated just press ENTER to move If the phase does need to be repeated press UP or DOWN to change to YES then press ENTER SKYJACK Page 20 DC Electric Scissor Lifts Compact Series lt 155147 Section 5 Procedures Service and Maintenance 5 3 7 Curve Group Codes Chart
86. latform should rise 4 Pull conttroller handle and lower the platform fully Result Platform should lower SKYJACK Page 30 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Pothole Protection Device Test Pothole Sensor JIN WARNING Ensure that you maintain three points of contact to mount dismount plat form Use the ladder to dismount from platform and place a block approximately 3 75 cm under the hydraulic electric tray Use the ladder of aerial platform to access platform Close the gate Raise the platform until approximately a height of 2 meters is reached and attempt to drive forward or reverse Result Aerial platform should not move forward or backward Repeat the steps above with block placed under battery tray Result Aerial plattorm should not move forward or backward Function Tests Test Elevated Drive Speed WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting Ensure path of intended motion is clear Raise the platform until approximately height of 2 meters is reached and attempt to drive forward or reverse Result Aerial plattorm should move slower than when it was in stowed position DC Electric Scissor Lifts SKYJACK Page 31 Section 2 MAINTENANCE TABLES AND DIAGRAMS Table of Contents Tables 21 2 eec
87. lectric Scissor Lifts SKYJACK Page 13 Section 1 Scheduled Maintenance Service and Maintenance About this Section This section contains the maintenance and inspection schedule that is to be performed References are made to the procedures in Section 5 that outline detailed step by step instructions for checks and replacements Service Bulletins Before performing any scheduled maintenance inspection procedure refer to service bulletins found in our web site www skyjackinc com for updates related to service and maintenance of this aerial platform Maintenance and Inspection Death or injury can result if the aerial platform is not kept in good working order Inspection and maintenance should be performed by competent personnel who are trained and qualified on mantenance of this aerial platform WARNING Failure to perform each procedure as pre sented and scheduled may cause death serious injury or substantial damage NOTE Preventive maintenance is the easiest and least expensive type of maintenance e Unless otherwise specified perform each maintenance procedure with the aerial platform in the following configuration Aerial platform parked on a flat and level surface Disconnect the battery by turning the main power disconnect switch to the OFF position e Repair any damaged or malfunction components before operating aerial platform e Keep records all inspections Mainte
88. load the aerial platform imparts on the whole surface directly underneath it The structure of the operating surface beams etc must be able to withstand more than the indicated values above NOTE The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or architect for that particular structure SKYJACK Page 4 DC Electric Scissor Lifts Section 2 Maintenance Tables and Diagrams Service and Maintenance Floor Loading Pressure Locally Concentrated Pressure LCP Overall Uniform Pressure OUP Foot Print Area Length x Width Base Area Length x Width Weight of Aerial Platform Capacity Weight of Aerial Platform Capacity LCP 0 4 X OUPS Foot Print Area Base Area 7111 S220 _ Length N WARNING Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability Therefore replace tires only with the exact original Skyjack approved type Failure to operate with matched approved tires in good condition may result in death or serious injury DC Electric Scissor Lifts SKYJACK Page 5 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 3 Maximum Platform Capacities Evenly D
89. m pump motor DCM 1 to circuit breaker Check continuity Replace if defective Defective or tripped circuit breaker CB1 Reset circuit breaker Replace if defective Loose or broken wire 02 from circuit breaker CB1 to base terminal block Check continuity Replace if defective SKYJACK Page 4 DC Electric Scissor Lifts Compact Series lt 155147 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 24 20 26 27 Loose or broken wire 7A from base terminal block to CM1 control module pin P2 12 Check continuity Replace if defective Loose or broken wire 02 from base terminal block to CM1 control module pin P2 11 Check continuity Replace if defective Loose or broken wire 28 from CM1 control module pin 4 to tilt relay 28CR1 and down relay 28CR2 Check continuity Replace if defective Loose or broken wire 28E from CM1 control module pin P3 6 to Aux tilt relay 28ECR1 and Aux down relay 28ECR2 Check continuity Replace if defective 4 1 2 All Controls Inoperative From Base Control Console ds 2 Loose or broken wire 10 from base key switch 510 to base up down switch 52 Check continuity Replace if defective Loose or broken wire 10 from base terminal block to CM1 control module pin P2 2 Check continuity Replace if defective 4 1 3 Controls Inoperative From Platform Control Console Ts 2 Loose or br
90. motor M1 or M2 defective Check motors Replace if defective 4 Cushion valve 2H 25 is stuck or defective Check valve Replace if defective 4 2 9 Platform will not Drive in Forward or Reverse 1 Open free wheeling valve V2 Close Valve Replace if defective 2 Forward drive valve 4H 16 or reverse drive valve 4H 15 defective or is sticking Clean Valve Replace if defective 3 Counterbalance valve CB1 defective or is plugged Clean Valve Replace if defective 4 2 10 Brake s will not Release 1 Brake valve 3H 17 defective or is sticking Clean valve Replace if defective 4 2 11 Brake s will hold machine on grade 1 Brake valve 3H 17 defective or is sticking Clean valve Replace if defective 2 Auto reset valve V3 defective or is sticking Clean valve Replace if defective 3 Brake Hubs defective Rebuild hubs Replace if damaged SKYJACK Page 12 DC Electric Scissor Lifts Compact Series lt Q 155147 Service and Maintenance Section 4 Troubleshooting Information Hydraulic System Continued 4 2 12 Platform does not Steer Left 1 Left steer valve 4H 24 defective or sticking Clean valve Replace if defective 2 Steer cylinder C3 seals leaking Rebuild cylinder s Replace if damaged 3 Mechanical binding in king pins Check for binding Repair as needed 4 Orifices 05 plugged Clean Orifices and reinstall 4 2 13 Platform does not Steer Right 1 Right steer 4H 23
91. mp P1 defective Check pump Replace if defective 4 2 2 All Functions Sluggish 1 System relief valve R1 defective or not adjusted properly Adjust valve Replace if defective 2 Hydraulic pump P1 worn Check pump Replace if defective 4 2 3 Platform Drifts Down 1 Defective lift cylinder gland seal Check for hydraulic oil leaking from the gland seal Rebuild cylinder Replace if damaged 2 Combination of Defective holding valve 2H 13A 1 and either defective lowering valve 2H 13A or relief valve R2 or manual lowering valve V1 Check valves Replace if defective 3 Defective o ring between lift cylinder and holding valve manifold block or loose bolts holding the manifold Check for hydraulic oil leaking from between cylinder and manifold Tighten bolts on manifold or replace o ring Replace manifold if damaged 4 2 4 Platform Lifts Slowly 1 Open or leaking manual lowering valve V1 Close valve Replace if defective 2 Lift relief valve R2 defective or not adjusted correctly Adjust valve Replace if defective 3 Open manual override on holding valve 2H 13A 1 Depress and turn manual override clockwise to close Replace if defective 4 Stuck or defective deceleration valve 2H 13C Model 3215 Check valve Replace if defective 5 Stuck or defective emergency lowering orifice O6 Check orifice Replace if defective 4 2 5 Platform Does Not Lift 1 Open manual lowering valve V1 Close valve Replace if de
92. nable trigger switch only Result Aerial platform should come to an instant and abrupt stop If aerial platform does not stop immediately or if aerial platform pulls to one side while stopping do not operate aerial platform until brake adjustments have been checked DC Electric Scissor Lifts SKYJACK Page 29 Function Tests Section 1 Scheduled Maintenance Lift Drive Steer Enable Lift Drive Steer Enable Trigger Switch Rocker Switch Trigger Switch Rocker Switch Emergency Stop Button Controller Operation Light Inclined Drive Level Drive Emergency Stop Button Switch Horn Pushbutton Horn Pushbutton Lift Off Drive Switch Lift Inclined Drive Level Drive Switch Platform Control Console with Toggle Switch Platform Control Console with Rotary Switch Test Platform Raising Lowering Test Lowering Warning ay WARNING 1 Raise the platform until approximately a height of 3 to 4 meters is reached then or other possible hazards around the Result Platform should stop lowering at aerial platform when lifting a height of 2 5 meters high and an alarm should sound 1 Select lift inclined drive level drive switch to 5 p lift position 2 Release controller handle Test Horn 2 Activate and hold enable trigger switch 1 Push horn pushbutton 3 Push controller handle and raise the 555 platform to an approximate height of 0 5 meter Result P
93. nance Instructions This manual consists of four schedules to be done for maintaining on an aerial platform Inspection schedule frequency is shown below Inspection Schedule Daily A Frequently A B Annually A B C Bi annually A B C D e Make copies of the maintenance and inspection checklist to be used for each inspection e Check the schedule on the checklist for the type of inspection to be performed e Place a check in the appropriate box after each inspection procedure is completed e Use the maintenance and inspection checklist and step by step procedures in Section 5 to perform these inspections e inspection receives a fail tag and remove the aerial platform from service f any aerial platform component s has been repaired an inspection must be performed again before removing the tag Place a check in the repair column Legend P Pass F Fail R Repaired DC Electric Scissor Lifts SKYJACK Page 15 Service and Maintenance Section 1 Scheduled Maintenance Table 1 1 Owner s Annual Inspection Record Model Number Serial Number Inspection Date Recording Owner s Skyjack Name Inc Inspected Skyjack By Inc As described earlier in this section this decal is located on the scissor assembly It must be completed after an annual inspection has been completed Do not use the aerial platform if an inspection has not been recorded in the last 6 months 158AA SKY
94. nsions or exclusions Optional Accessories The SKYJACK aerial platform is designed to accept a variety of optional accessories These are listed under Standard and Optional Features in Table 2 1 of the Operating Manual Operating instructions for these options if equipped are located in section 2 of the operating manual For options not listed under Standard and Optional Features contact the SKYJACK Service Department at 44 1691 676 235 44 1691 676 238 Include the model and serial number each applicable aerial platform Scope of this Manual a This manual applies to the CE version of the Series aerial platform models listed on Table 2 1 Equipment identified with CE meets the requirements for the European countries 1 Machinery Directive 2006 42 EC and Directive 2004 108 EC and the corresponding EN standards b Operators are required to conform to national state or territorial provincial and local health and safety regulations applicable to the operation of this aerial platform DC Electric Scissor Lifts 5 7 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance WARNING Failure to comply with your required responsibilities in the use and operation of the aerial platform could result in death or serious injury Operator Safety Reminders A study conducted by St Paul Travelers showed that most accidents are ca
95. nual Inspection Refer to Section 1 Hydraulic System amp Component Maintenance and Repair Hydraulic Pump and Motor Ensure there are no loose or missing parts and there is no visible damage Greasing Point Hydraulic Electric Tray Hydraulic Pump and Hydraulic Tank Electrical Panel Ensure panel is properly secured and there is no visible damage Ensure there are no loose wires or missing fasteners Proportional and Main Manifolds Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Ensure there are no loose wires or missing fasteners Load Tilt Sensor Ensure load tilt sensor is properly secured and there is no visible damage Emergency Lowering Access Rod If Equipped Ensure rod is properly secured and there is no visible damage SKYJACK Page 22 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Manual Storage Box Platform Assembly 1 1 6 Platform Assembly 1 2 WARNING Ensure that you maintain three points of contact to mount dismount platform Use the ladder of aerial platform to access platform Close the gate Ensure there are no loose or missing parts and there is no visible damage Ensure all fasteners are securely in place Ensure all railings are properly positioned and
96. oken wire 8C from base key switch 510 to base terminal block Check continuity Replace if defective Loose or broken wire 8 or wire 02 from base terminal block to platform emergency stop switch 54 Check continuity Replace if defective Open or defective platform emergency stop switch S4 Close switch Replace if defective Loose or broken wire 8 or wire 02 from emergency stop switch S4 to battery charge indicator BCI Check continuity Replace if defective Loose or broken wire 8 or wire 02 from battery charge indicator BC1 to joystick 57 Check continuity Replace if defective Defective joystick enable switch 57 6 Check switch Replace if defective Defective joystick neutral switch 57 1 Check switch Replace if defective Defective joystick S7 Check joystick Replace if defective 4 1 4 No Drive or Up Function from Platform Controls 1 Defective tilt relay 28CR1 or Aux tilt relay 28ECR1 Check relay Replace if defective 2 Loose or broken wire 02 from base terminal block to tilt relay 28CR1 or Aux tilt relay 28ECR1 Check continuity Replace if defective 3 Loose or broken wire 28 from 1 control module pin P3 4 to tilt relay 28CR1 Check continuity Replace if defective 4 Loose or broken wire 28E from CM1 control module pin P3 6 to Aux tilt relay 28ECR1 Check continuity Replace if defective 5 Loose or broken wire 19 from base terminal block to Aux tilt relay 28ECR1 Che
97. on 17 0 ees ces eee ees een ie ani 21 DC Electric Scissor Llfts SKYJACK Page 1 Compact Series 155147 Section 5 Procedures Service and Maintenance General The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Al ways be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided Platform 5 1 1 OEM Controller Electronics Information Flow Control single coil or solenoid for single direction The coil has two connections one is wired to the PC Board A ter minal and the other is wired to or the negative side of the supply voltage Switches to control directional valves may be provided on the controller Adjustment Procedures Adjustments are made by turning a trimpot adjustment screw The trimpots are multi turn end to end devices It may be necessary to turn the adjustment screw several turns to observe a change in output Clockwise CW adjustment of the trimpot increases the output Counter clockw
98. ontrol Switches Ensure there are no signs of visible damage and all switches are in their neutral positions Free wheeling Valve Knob Compacts Front Side Ensure there are no loose or missing parts and there is no visible damage e Brakes Ensure there are no loose or missing parts and there is no visible damage DC Electric Scissor Lifts SKYJACK Page 19 Service and Maintenance Conventional Battery Charger 6555509 Wwe Wy j Hydraulic Electric Battery Fuse Box Tray Battery Tray 1 1 4 Battery Tray Side e Pothole Protection Device Ensure mechanisms have no sign of visible damage and are free from dirt and obstructions e Battery Tray Ensure tray latch is secure and in proper working order e Battery Charger Compacts Entrance Side Ensure charger is secure and shows no visible damage Battery Proper battery condition is essential to good performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions WARNING Explosion hazard Keep flames and sparks away Do not smoke near batteries Section 1 Scheduled Maintenance Compact Battery 2 7 4 l 2 7 4 7 3 2 i 7 p 7 4 __ 7 5 2 soo v 350 TE
99. output must be between 1 0V and 4 at all times Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem Code F42 Low Pressure This message indicates that the pressure transducer output P4 2 is too low 0 5V or less at the beginning of calibration Check DIAGNOSTICS SENSORS to read output SKYJACK Page 14 DC Electric Scissor Lifts Compact Series lt Q 155147 Section 5 Procedures Service and Maintenance Code F43 High Pressure This message indicates that the pressure transducer output P4 2 is too high 4 5V or more at the beginning of calibration Check DIAGNOSTICS SENSORS to read output Code F44 Low Pressure This message indicates that the pressure transducer output P4 2 is too low 0 5V or less at a measurement point Check DIAGNOSTICS SENSORS to read output Code F45 High Pressure This message indicates that the pressure transducer output P4 2 is too high 4 5V or more at a measurement point Check DIAGNOSTICS SENSORS to read output Code F46 Check Elev This message indicates that the elevation switch opened more than once during calibration lifting Code F47 Check Elev This message indicates that the elevation switch closed more than once during calibration lower Code F48 Bad Pressure This message indicates that the pressure transducer output P4 2 is out of range at the beginning of calibration Check DIAGNOSTICS S
100. peed is in range tighen and apply loctite 222MS to the set screw Tie a tiewrap to the left of the slide wiper on the resistor Tiewrap DC Electric Scissor LIfts Compact Series 155147 SKYJACK Page 7 Service and Maintenance Section 5 Procedures Load Sensing System 5 3 1 Control Module Pin Reference Chart P3 P2 OWO GVO qu 9099 NOB OOO DOAL GPl2 CONTROL The Calibration Connection Not Used Input Power From Base Terminal Strip To Confirm Lower Control Is Selected Raise Platform Input Lower Platform Input ot Used ot Used Forward Direction Input everse Direction Input Not Used Input From LS1 High Speed Limit Switch To Verify ON OFF Limits Negative Input From Base Terminal Strip Main Power Input From Base Terminal Strip Output To FL 22 Flashing Light Output To BP 29 Beeper Output To Overload Warning Light On Control Box Output To 28 1 Tilt Relay And 28CR2 Down Relay Negative for Flashing Light and Beeper Output To 28ECR1 Aux Tilt Relay And 28ECR2 Aux Down Relay Not Used Varied Input From Transducer Varied Input From Angle Transducer Not Used Not Used Positive Signal To Angle Transducer 7 Negative Signal To
101. positionable platform supported from ground level by a structure Purpose of Equipment The SKYJACK Compact and Conventional series aerial platforms are designed to transport and raise personnel tools and materials to overhead work areas Use of Equipment The aerial platform is a highly maneuverable mobile work station Lifting and driving must be on a flat level compacted surface Manuals Operating The operating manual is considered a fundamental part of the aerial platform It is a very important way to communicate necessary safety information to users and operators A complete and legible copy of this manual must be kept in the provided weather resistant storage compartment on the aerial platform at all times Service amp Maintenance The purpose of this is to provide the customer with the servicing and maintenance procedures essential for the promotion of proper machine operation for its intended purpose All information in this manual should be read and understood before any attempt is made to service the machine The updated copy of the manuals are found on the company s website www skyjack com Service Policy and Warranty SKYJACK warrants each new Series work platform to be free of defective parts and workmanship for the first 24 months Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor Contact the SKYJACK Service Department for warranty statement exte
102. pped with all options Rotary Switch 110 VAC LINE VOLTAGE 24V CHARGER LICR CHARGER CUTOUT RELAY 1 CHARGER F1 B4 6V 300A 6V B2 B16V 5 FUSE BATTERY BATTERY BATTERY CONTROL BOX BASE id 4i pum S1 MAIN S10 IDLE PLTF BASE DISCONNECT MOTOR 4 EMERGENCY KEY SWITCH CONTACTOR 5 Page 24 IDLE POSITION STO 5 PUMP MOTOR aT Ep 08 8C 8C BLUE WHITE 8C 6C 07 S28 SS SS A EMERGEN GY 2 6 INVERTER OPTION STOP 50A FUSE SWITCH 7 RED piu 7 07 07 07 07 sa 05 00 02 15A CIRCUIT m 15A CIRCUIT 7A GREEN 7A BREAKER 85 7A 02 INVERTER OPTION 9 5 TIMER xd L HORN 10E 9 7A 7A 02 19 SWITCH 10 POWER ON LED NO LED 2 H1 q 08 49 49 GREEN WHITE 49 POW
103. resent 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 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 When removing any hydraulic component be sure to cap and tag all hydraulic lines involved Also plug the ports of the removed components NOTE of hydraulic oil should be drawn from the reservoir and tested annually These samples should be taken when the oil is warmed through normal operation of the system The sample should be analyzed by a qualified lubrication specialist to determine if it is suitable for continued use 10 Oil change intervals will depend on the care used in keeping the oil clean and the operating conditions Dirt and or moisture cotamination will dictate that the oil should be changed more often Under normal use and operating conditions the hydraulic oil should be changed every two years Refer to Table 1 2 of this manual All hydraulic components must be dis assembled in spotlessly clean surroundings During disassembly pay particular attention to the identification of parts to ass
104. s which have been altered or disabled has been tagged or blocked out for non use or repair Failure to avoid these hazards could re sult in death or serious injury Jobsite Inspection Do not use in hazardous locations Perform a thorough jobsite inspection prior to operating the aerial platform to identify potential hazards in your work area Be aware of moving equipment in the area Take appropriate actions to avoid collision DC Electric Scissor Lifts SKYJACK Page 11 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance Maintenance and Inspection Schedule The actual operating environment of the work platform governs the use of the maintenance schedule The inspection points covered in Table 1 2 Maintenance and Inspection Checklist indicates the areas of the aerial platform to be maintained or inspected and at what intervals the maintenance and inspections are to be performed Owner s Annual Inspection Record It is the responsibility of the owner to arrange quarterly and annual inspections of the aerial platform Table 1 1 Owner s Annual Inspection Record is to be used for recording the date of the inspection owner s name and the person responsible for the inspection of the work platform Replacement Parts Use only original replacement parts Parts such as batteries wheels railings etc with weight and dimensions different from original parts will affect stability
105. sole Diagram Serial Breakdown Reference Chart View Model Serial Number Pa rts List SJ3 3215 10000611 amp above SJ3 3219 22020985 amp above S27 TORQUE 2 58 HORN c FLOS e 3 08 3 LIFT OFF DRIVE 54 EMERGENCY STOP D 08 6074 LD 5 AL Qu
106. t calibrate date can be viewed in DIAGNOSTICS LOG Press LEFT 8 RIGHT to select the flashing digits Press UP amp DOWN to change the flashing digits Press ENTER when the entry is complete IMPORTANT The date 00 00 00 is not allowed Finished This message confirms that calibration is complete and successful SKYJACK Page 16 DC Electric Scissor Lifts Compact Series lt Q 155147 Section 5 Procedures Service and Maintenance 5 3 6 Control Module Load Calibration Procedure 1 re oll Lift Valve Move the aerial platform to a test area where the platform can be elevated to its maximum working height and reach Ensure the aerial platform is parked on a firm level surface IMPORTANT Each phase must be completed before the next phase can be carried out All phases must be completed before the aerial platform can be operated IMPORTANT Always follow the instructions of the Calibration instrument IMPORTANT Make sure the aerial platform is on BASE mode NOTE To ensure a good and clear contact clean the wire terminals before attaching the jumper clip Locate the main manifold inside the hydraulic electric tray Disconnect the black wire 14 from the lift coil Locate the contactor on the electrical panel assembly The jumper connection must be connected between the contractor wire 19B and the lift coil instead of the black wire 14 Main Manifold Contactor JUMPER Insulated Alligator Clip
107. t of range at the end of calibration The height sensor output must be between 0 9V and 4 1V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem Code F11 Not Up This message occurs at the start of calibration if the operator selects a function other than UP Select the UP function only DC Electric Scissor Llfts SKYJACK 13 Compact Series 155147 lt Section 5 Procedures Fee Code F13 Low Height Range This message occurs at the end of calibration if the height sensor output did not change sufficiently to give a reasonably accurate platform height estimate This message could occur if the UP switch was accidentally opened too early when the platform is not fully raised DIAGNOSTICS SENSORS can be used to check the height sensor output P4 3 A difference of at least 1V is to be expected Code F15 Check Elev This message is given if the elevation switch P2 10 is closed when the platform has been fully lowered at the end of calibration This message would occur if the DOWN switch was accidentally opened before the platform was fully lowered If the platform is fully lowered check the elevation switch Code F16 Low Elev open This message is given if the elevation switch P2 10 opened during lift at a too low height below 596 Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded
108. tant that the function starts to slow down as soon as the handle is moved back from the fully deflected position The ideal adjustment occurs when the function just begins to move when the handle is deflected and the output increases until it reaches its maximum desired response or speed at the end of handle travel DC Electric Scissor Llfts Compact Series 155147 SKYJACK Page 3 Service and Maintenance Section 5 Procedures 5 1 2 OEM Controller Troubleshooting Problem 1 The function will not operate when the handle 15 moved The LEDs do not light A Check that voltage is present at the positive input terminal B Check that ground is connected to the negative terminal C Ifthere is an in line fuse check to see if it is good D Check the controller on off switch and the connectors Voltage should be present at the X terminal when the controller is turned on E Check that valve wiring is not shorted to ground The LEDs will not light Check that valve wiring is not open The LEDs will light but the intensity will not vary G Check trimpot settings Fully CCW turns output off CW turns output fully on 2 The function jumps or lurches when turned A Perform Threshold adjustment procedures 3 The function reaches maximum speed before the handle is fully deflected A Perform Maxout adjustment procedures 4 The function speed remains constant
109. te www skyjack com for a printable copy DC Electric Scissor Lifts SKYJACK Page 17 Service and Maintenance High Speed Limit Switch 1 1 Scheduled Maintenance Inspections Begin the scheduled maintenance inspections by checking each item in sequence for the conditions listed in this section N WARNING To avoid injury do not operate an aerial platform until all malfunctions have been corrected WARNING To avoid possible injury ensure aerial platform power is off during your visual and daily maintenance inspections Electrical Maintaining the electrical components is essential to good performance and service life of the aerial platform Inspect the following areas for chafed corroded and loose wires base to platform cables and wiring harness battery tray wiring harnesses e hydraulic electrical wiring harnesses Section 1 Scheduled Maintenance High Speed Limit Switch Pothole Protection Limit Switch Hydraulic Maintaining the hydraulic components is essential to good performance and service life of the aerial platform Perform a visual inspection around the following areas e hoses and fittings all hydraulic cylinders e all hydraulic manifolds the underside of the base e ground area under the aerial platform 1 1 1 Labels Refer to the labels section in this manual and determine that
110. ted drive speed will need to if the adjustable resistor or proportional valve coil have been replaced Install the new components Use a multi meter to measure resistance of the variable resistor approximately 13 Ohms Measure Resistance Across these 2 points 59A NA q L Set Screw A Ww IN Wire Turn Wiper NOTE Each wire turn on resistor is approximately 0 5 Ohms If adjustment is needed loosen the set screw the slide wiper and move the wiper to the left to increase the resistance or to the right to reduce the resistance Elevated Drive Speed Adjustment 1 2 Lay out a 3 048 meter 10 long drive area on the floor with a start and finish line Elevate the platform to enable high speed cutout limit switch NOTE Aerial work platform must be at full elevated drive speed before crossing the start line Drive the aerial work platform at full stroke of the joystick across the 3 048 meter 107 test area and measure drive time o Acceptable Range Speed m s 10 03 Minimum 13 64 NOTE Each wire turn on the resistor is approximately 0 6 seconds To adjust the speed to achieve midpoint between maximum and minimum speed loosen the set screw on the slide wiper and move the wiper to the left to increase the speed or to the right to reduce the speed Once the s
111. tion 4 Troubleshooting Information MEM d Electrical System Continued 4 1 8 No Up Function from Base Control Console 1 Defective up down switch S2 Check switch Replace if defective 2 Loose or broken wire 14 from up down switch S2 to base terminal block Check continuity Replace if defective Open or defective diode D14E 1 Check diode Replace if defective 4 Open or defective diode D14E 2 Check diode Replace if defective 4 1 9 No Down Function from Platform or Base Control Console NOTE Down function is not proportionally controlled 1 Loose or broken wire 13 from base terminal block to CM1 control module pin P2 4 Check continuity Replace if defective 2 Defective down relay 28CR2 or Aux down relay 28ECR2 Check relay Replace if defective 3 Loose or broken wire 02 from base terminal block to down relay 28CR2 or Aux down relay 28ECR2 Check continuity Replace if defective 4 Loose or broken wire 13 from base terminal block to Aux down relay 28ECR2 Check continuity Replace if defective 5 Loose or broken wire 13A from Aux down relay 28ECR2 to down relay 28CR2 Check continuity Replace if defective 6 Loose or broken wire 138 from down relay 28CR2 to down valve 2H 13B or holding valve 2H 13B 1 Check continuity Replace if defective 7 Defective down valve coil 2H 13B Check continuity through coil Replace if defective 8 Defective lift cylinder holding valve coil 2H 13B
112. ure proper reassembly Clean all metal parts in a clean mineral oil solvent Be sure to thoroughly clean all internal passages After the parts have been dried thoroughly lay them on a clean lint free surface for inspection Replace all O rings and seals when overhauling any component Lubricate all parts with clean hydraulic oil before reassembly Use small amounts of petroleum jelly to hold O rings in place during assembly Be sure to replace any lost hydraulic oil when completing the installation of the repaired component and bleed any air from the system when required All hydraulic connections must be kept tight A loose connection in a pressure line will permit the oil to leak out or air to be drawn into the system Air in the system can cause damage to the components and noisy or erratic system operation Maintenance 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 What are they 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 DC E
113. ure that you maintain three points of contact to mount dismount platform Use the ladder to dismount from platform 1 1 7 Lifting Mechanism 1 Raise the platform until there is adequate clearance to swing down the maintenance support e Maintenance Support Ensure maintenance support is properly secured and shows no visible damage Scissor Assembly Ensure scissor assembly shows no visible damage and no signs of deformation in weldments Ensure all pins are properly secured Ensure cables and wires are properly routed and shows no signs of wear and or physical damage Roller Scissor Bumpers Ensure bumpers are secure and shows no sign of visible damage Rollers Ensure rollers are secure and there is no visible damage Ensure rollers path of travel are free from dirt and obstructions Lift Cylinder s Ensure each lift cylinder is properly secured there are no loose or missing parts and there is no evidence of damage Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Raise the platform until there is adequate clearance to swing up the maintenance support Swing up maintenance support into storage bracket Fully lower the platform SKYJACK Page 24 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Function Tests Conventional Back View Free wheeling Valve Lower Neutral Ra
114. used by the failure of the operator to follow simple and fundamental safety rules and precautions You as a careful operator are the best insurance against an accident Therefore proper usage of this aerial platform is mandatory The following pages of this manual should be read and understood completely before operating the aerial platform Common sense dictates the use of protective clothing when working on or near machinery Use appropriate safety devices to protect your eyes ears hands feet and body Any modifications from the original design are strictly forbidden without written permission from SKYJACK Electrocution Hazard This aerial platform is not electrically insulated Maintain a Minimum Safe Approach Distance MSAD from energized power lines and parts as listed below The operator must allow for the platform to sway rock or sag This aerial platform does not provide protection from contact with or proximity to an electrically charged conductor DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS DANGER Avoid Power Lines Minimum Safe Approach Distance CE Guidance Note Avoidance of danger from overhead lines Adhere strictly to the governmental rulings and regulations applicable in your country FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY 60023AE CE SKYJACK Page 8 DC Electric
115. w Emergency Stop Button 3 Select and hold off platform base key switch to base position Attempt to raise or lower the platform Result Platform raising and lowering functions should operate Test Lower Neutral Raise Switch 1 Select and hold off platform base key switch to base position and T raise the platform with lower neutral raise switch Result Platform should rise Select and hold off platform base key switch to TI lower the platform with lower neutral raise switch Result Platform should lower base position and DC Electric Scissor Lifts Section 1 Scheduled Maintenance Conventional Back View Free wheeling Valve Lower Neutral Raise Swi tch Lower Neutral Raise Switch Li Emergency Stop Button Test Emergency Lowering 1 2 Raise the platform Locate holding valve manual override knob at the base of each lift cylinder Depress and turn counterclockwise If necessary use access rod that is located on the base of the aerial platform On hydraulic electric tray pull out and hold emergency lowering valve to fully lower the platform Result The platform should lower To restore normal operation depress and turn hold

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