Home

Service Manual

1. tA F 02 TO FLASHER IF EQUIPPED OTHERWISE TIE BACK TILT SWITCH RELAY BRAKE STEERING RELAY PIN 90 19 PIN 90 178 2 PIN 85 28 85 17 30 PIN 86 02 BRAKE PIN 86 02 00 s PIN 87 19A PIN 87 17A 5 Ds PIN 87a STEERING PN 87a 176 e 3A BLACK
2. BACK VIEW CU PIN2 05 GREENIBLACK PIN 6 8C BLUE WHITE 22229 90100 i 18 REDIBLAC PINT 19 BLUE a PN8 71 LACT LEGEND TOBASEONTROLS TO HIGH SPEED LIMIT TO JOYSTICK BOX 3 TO LOWER KEYSWITCH TO POTHOLE LIMIT TOTERMINAL BLOCK IN TO TILT SWITCH d p TO ENGINE X TO BATTERY TO REAR MANIFOLD TO BATTERIES TO MOTOR TO WAN MANIFOLD 6 TO HGH SPEED LIMIT SWITCH 18A REDIBLACK lt TOREAR MANIFOLD LLa TO POWER DECK E BATTERY OPARE 0 CONNECTOR _ TOFLASHER CD HORN O e 4 5 CONTROL CABLE OPTIONS NA ee ee D REDWHITE 60 7A BACK VIEW FRONT VIEW 4 ma REAR HARNESS C AJREDWHTE 5 o GREEN
3. BRAKE STEERING RELAY PIN 87a 17C PROPCONTROLREAY PIN 30 50A 8 PIN 85 21C PIN 86 02 PIN 87a 59 Em BEEPER M NI TILT SWITCH RELAY D 02 19A 128 28A 19 59A
4. 510 BASE SW 0 N O CONTACT M PIN 3 10E WHITE BLACK PIN 3 10E WHITE BLACK X2 e DN E PIN 4 RED BLACK 910 PLATFORM SWITCH N C CONTACT 928 EMERGENCY STOP PIN 1 8C BLUE N C CONTACT PIN 2 07 RED PIN PURPLE WHITE PIN 2 05 ORANGE BLACK LED 2 POWER ONILSS LIGHT PIN X1 02 WHITE PIN X2 RED BLACK 0 TO ELECTRIC PANEL PIN 07 RED PIN 2 05 ORANGE BLACH PIN 3 13 ORANGE PIN 4 14E BLACK PIN 5 10E WHITE BLACK CE PIN 6 8C BLUE PIN 7 7A RED BLACK PIN 8 02 WHITE BACK VIEW I ON OW NL M149553AA S3 SKYJACK Page 16 SJIII Conventional Series 6 157928 Section 3 System Component Identification and Schematics CONTROL CABLE OPTIONS WIRE COLOUR EUROPE WIRE NUMBER Service and Maintenance 3 11 Scissor Arm Control Cable Diagram NA WIRE NUMBER GREEN BLACK RED WHITE 218 60 218
5. HOLDING VALVE HARNESS MODEL XX20 E HOLDING VALVE 19 BLACK 1 Ov PIN 1 13 BLACK ix Q WMTE INSERT ORIENTATION BOTTOM FORWARD VALVE RIGHT STEER VALVE HOLDING VALVE HARNESS MODEL XX26 X32 NU PIN 1 t6 WHITE BLACK PIN 1 23 BLACKWHITE FOLDING VALVE LOWER PIN 2 02 WHITE PIN 2 02 WHITE 07 PIN1 19 BLACK 171 lt HOLDING VALVE UPPER 3 A FORWARD REVERSE VALVE LEFT STEER VALVE 27 PIN 1 15 BLUE PIN 1 24 BLUEIBLACK PIN 2 02 WHITE PIN 2 02 WHITE TO ELECTRIC PANEL 9 WIRES 02 WHITE 13 ORANGE EN 14 BLACK 211 _ LOWERING VALVE 15 BLUE 13 ORANGE 6 WHITEIBLACK X Eas 5 02 WHITE y 17 BLUEIRED 23 BLACKWHITE HOLDING VALVE 24 BLUE BLACK 13 ORANGE PROPORTIONAL VALVE 59 ORANGE BLACK 02 WHITE FC 59 ORANGE BLACK o 02 WHITE i f e 02 Sa 9 F 59 16 BRAKE VALVE 02 WHITE 146669 S3 SJIII Conventional Series SKYJACK Page 21 157928 Print View This Page Parts List 3 15 Electrical Panel Diagram LEGEND TO BASE CONTROLS TO JOYSTICK BOX BASE CONTROLS E PIN 1 07 PIN5 NU PIN 2 05 GREENIBLACK PIN 6 8C BLUENIHITE PIN 3 13 ORANGE PIN 7 GREEN POWER DECK OPTION M
6. AB F J DeH ii RIGHT DRIVE 2 AUTO RESET UPPER LIFT jt LUE CASE DRAIN CYLINDER EMERGENCY LOWERING 3 B 3226 4626 4632 BE V HAND PUMP 05 REAR DRIVE 0067 DIFFERENTIAL DIFFERENTIAL MANIFOLD BLOCK jn ff BHB2NSICSA MB 000 VALVE 28 392 BRAKE RELEASE in v HOLDING VALE HOLDING VALVE MANIFOLD BLOCK MANIFOLD BLOCK 341 07 R3 BRAKE ONE WAY N FOI PTI RELIEF VALVE PT ORIFICE 0020 fe FLOW DIVIDER PRESSURE PRESSURE COMBINER OVERLOAD OVERLOAD Lm TRANSDUCER 0 TRANSDUCER SPEED VAEB OPTION LOWER LIFT 04 OPTION LOWER LIFT N His E SIS ES 32261482814632 miu BE CYLINDER C 0067 5 0067 SPEED VALVE A i e Z 7 C5 PDECK C5 PDECK Mol CYLINDER HODNGVANE HOLDING VALVE 4 CASE DRAIN MANIFOLD BLOCK MANIFOLD BLOCK 3 tonne RELEF VAVE HOLDING VALVE HOLDING VALVE g a Jd 41 26 2 C3 STEERING gt RETRACT EXTEND CYLINDER 1 gi mom one 5 VALVE 03 pe SWITCH 28 STEER ORIFICE IC OC EE 29 REFERENCE TABLE X E MB5 P DECK MANIFOLD BLOCK 6 30 ORIFICE MB9 LOWERING PROPORTIONAL 4H 15 m
7. O BROWN es OR IU LS1A 5 3 BLUE BLACKWHITE 2 6 oo 926 BLUE BROWN BLACK BROWN BLACK 221 Xp PIN 1 71 BLACKWHITE PINS NIU LS1B ES TM 9 E PIN 2 21 BLACK PIN 6 NU Or un PIN 3 18 BLACK WHITE PIN 7 19 BLACK BLUE BLACKWHITE 1 5 55 8 a 2 Olio 7 3 246 6 4 E PIN 4 18A BLACK PIN 8 71 BLACKWHITE SMS BROWN BLACK NV 5 gi _ 5 On S V PIN 1 71 BLACK WHITE PIN 5 02 WHITE X BROWN PIN 2 21 BLACK PIN 6 19 BLACK L O Or PIN 3 18 BLACK WHITE PIN 7 28 GREEN 136 _ i PIN 4 18A BLACK PINB NU C On BLUE BLACK WHITE 9X9 N OO HOSLNAG BLUE BLACK WHITE MODEL 32 46 ANSI CSA amp EE RATED EXCEPT MODEL 4632 EE RATED PIN 1 19 BLACK PIN 2 71 BLACK WHITE MODEL 4632 EE RATED 133664 SJIII Conventional Serie
8. Red LED Red LED O3 Green LED Green LED Red LED Red LED O3 Green LED Green LED J E J Results The switch is verifying the new zero position SJIII Series 5 9 Service and Maintenance Section 5 Procedures i The green LED Test and Verify Tilt Circuit will turn on solid Results The switch Red LED Set up button is located on this is ready for normal OS eret Light Indicators face next to harness operation 2 10 Turn main disconnect switch TOL off position 11 Remove jumper wire between 7 and 19 from terminal block 12 Reattach all wires 02 to motor contactor 13 Reinstall any covers that was removed 14 Remove chock or wheel blocks Operations of Tilt Switch The following describes the LED s and what they indicate 15 Proceed to Test and Verify Tilt Circuit Illuminated whenever both tilt axes are within the specified degrees of the zero home learned position Flashes when transitioning in or out of tilt angle limits but built in time delay has not fully occurred Illuminated whenever tilt on one Red LED or more axes is more than the specified degrees out from the zero home position Green amp Red LED On together no blinking when fault detected Tilt Circuit Test 1 Refer to section 2 for test tilt sensor proce
9. View Parts List BACK VIEW FRONT VIEW TO ELECTRIC PANEL CONTROL CABLE f N 8 6 REDWHTE 0P 160 49 GREENWHTE 7 15 BLACK WHITE 23 150 07 6 0 50 14 BLUEBLACK 140 06 RED 5 13 GREEN BLACK OPT 130 05 Veena 4 12 ORANGE BLACK 59 120 04 4 13 RANGE 3 REDBLACK 18 5 1 BLUE 2 OO 10 WHITE BLACK ie T aoe 02 WHITE 1 NOTUSED 3I 15 D D l lt 7 TO PLATFORM CONTROL CONSOLE FRONT VIEW BACK VIEW CONTROL CABLE E o 8 1 RED WHITE 16 8 GREEN 7A N 7 0 15 18 O XO 7 GREENWHITE 49 6 14 24 BLUEBLACK 14 OKO 6 BLUE WHITE 80 E 5 1 GREEN BLACK 13 5 RED 07 4 12 69 ORANGE BLACK 12 4 BLACK 4 3O 18 RED BLACK t 3 ORANGE 13 N 200 Qr O
10. wr Free wheeling za iin Emergency Main Power Ladder Disconnect Base Switch Control Console Brakes 110V Outlet Heceptacle xs Compact Brakes Back View 1 1 3 Entrance Side AC Outlet Receptacle Ensure receptacle is free from dirt and Main Power Disconnect Switch obstructions urn emergency main power disconnect switch to O 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 Base Control 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 Ensure tabs are not locked SJIII Series SKYJACK Page 19 Service and Maintenance Section 1 Scheduled Maintenance Conventional Compact Battery 3 2 Y Battery 8 0 2
11. 5 4 1 5 No Drive or Up Function from Platform or Base Controls CE only 6 4 1 6 No Down or Reverse Only Function from Platform 6 4 1 7 No Up or Forward Only Function from Platform Control 5 6 4 1 8 Up Function from Platform or Base Control 6 4 1 9 No Down Function from Platform or Base Control Console ANSI CSA 7 4 1 10 No Down Function from Platform or Base Control Console CE 7 4 1 11 No Up Function from Base Control COSS 8 4 1 12 No Down Function from Base Control DOrnsolB uu eee end eri o cR ota 8 8 Dive oni 8 4 1 15 Drive or Steer when Platform Fully Lowered 8 4 1 16 No Drive or Steer when Platform nennen nennen nnn nnn nnn nnns 9 4 1 17 Elevated Drive Speed Does not nennen nnns nnn nnns naa narra snae nna 9 4 1 18 Work Platform Drives in Slow Speed 9 4 1 19 Forward Drive Function 10 4 1 20 Reverse Drive Function
12. 64 EMERGENCY STOP 2 9 Wr 21 l D26 D27 b r 02 26 27 709 GREEN 6 RED WHITE 8074 49 GREENWHTE 7 BLACK WHITE 29 6 4 BLUEBLACK 2 aD 5 t GREEN BLACK 218 OP m 4 t oree Buck 8 J OMNE 3 RED BLACK 18 gt 15 BLUE 2 0 _ WHITE BLACK 16 2 WHITE 1 9 H NOTUSED BACK VIEW TO PWR DECK SOLENOID VALVES PIN 1 27 BLACK PIN 2 02 WHITE PIN 3 26 GREEN pe PIN4 N U PINS N U NTROL BOX PIN 1 27 BLACK y PIN 2 09 WHITE PIN 3 26 GREEN PIN4 N U P PIN5 N U M156955AA1 SKYJ
13. 10 98 HORN N 08 d Da H S4 EMERGENCY STOP 4 GB D LED 1 02 Dal SJIII Conventional Series 157928 CTRL BOX HARNESS JOYSTICK HARNESS 218 GREEN BLACK TIED BACK 9 PIN CONNECTOR SUB ASSEMBLY PIN FUNCTION CTRLBOXHARNESS JOYSTICK HARNESS PIN 1 LEFT 24 BLUEIBLACK WHITE RED PIN 2 STEERING VS 128 BROWNRED WHITE CREEN PIN 3 RIGHT 23 BLACKWHITE WHITE PIN 4 FWDJUP B RED YELLOW PIN 5 JOYSTICK VS 08 BLUE WHITEBLACK PIN 6 REV DOWN PURPLEWHIT
14. _____ Main Power Disconnect Switch ___ AB J __________ 5 __ ____ a p RR s __ 9 frenis Compacts Front Side Lift Mechanism Maintenance ac outer receptae as ue s 8 Battery Tray Side NB Pothole Protection Device as 1 5 1 atte Test in Power ase Control Console Battery Steer Cylinder Assembly Test Base Emergency Stop Test Off Platform Base Test Lower Neutral Raise Switch Wheel Tire Assembly Tie Rod Conventionals A B A B gt gt gt J W gt UJ Greasing Points Test Emergency Lowering gt UJ Test Free wheeling I lt g o 5 g lt n a latform Control Console Pothole Protection Device gt UJ gt gt gt Wy a Ww N gt Test Platform Emergency Stop Hydraulic Oil Hydraulic Pump and Motor 2 UJ Test Enable Trigger Switch UJ gt UJ Test Steering Electrical Panel Test Driving Proportional and Main Manifolds Test Brakes Tilt Sensor Test Platform Raising Lowering gt gt gt gt UJ gt UJ Emergency Lowering Access Rod Test Horn
15. 15 4 2 13 Power Extension Platform will not Extend or 15 15 SJIII Conventional Series 157928 SKYJACK Page 1 Section 4 Troubleshooting Information Service and Maintenance 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 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 SJIII Conventional Series SKYJACK Page 3 157928 Service and Maintenance Section 4 Troubleshooting Information Electrical System 4 1 1 Controls Inoperative 1 2 3 10 11 12 13 14
16. ORIFICE ORIFICE C5 PDECK MANIFOLD __ REVERSE DRIVE RIGHT STEER CYLINDER BLOCK VALVE 3H 14 2H 13B CE NONE VALVE LIFT VALVE LOWERINGVALVE oo Ion 3H 17A MWA S BRAKE VALVE IP dt Px p HN iE 9 TS Er Ha 0073 DIA co RETRACT H EXTEND aS X PLATFORM D l L 4 6 CROSS OVER 5 3 4626 lt VALVE VALVE 1 FORWARDDRIVE RELIEF VALVE OPTION N 5 e E e 7 m 02 RUF 34 M Ri STEER LOWERING ORIFICE RELEF H y 2 59 SYSTEM RELIEF VALVE SEE REFERENCE TABLE VALVE T MB5 P DECK PRESSURE VALVE COUNTERBALANCE VALVE PROPORTIONAL P 5 2 25 25 02 25 2 2 225 2 55 es VALVE MAIN MANIFOLD BLOCK m M LOWERING EMERGENCY LOWERING DCMI VALVE VALVE DC MOTOR BLOCK MANUAL Pi HYDRAULIC ii RETURN FILTER gt Sp RESERVOIR M137018AD1 SKYJACK Page 20 SJIII Conventional Series 157928 Print View This Page PartsList 3 14 Main Manifold Harness and Holding Valve Harness
17. Service and Maintenance Section 3 System Component Identification and Schematics LINE CROSSING dc LINE JOINED HYDRAULIC TANK HYDRAULIC 9 FILTER WITH 55 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 699 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 POSITION FOUR WAY CLOSED CENTER CLOSED PORT PILOT LINES Dashed SKYJACK Page 4 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
18. Activate and hold d enable trigger switch Push controller handle and raise the platform to an approximate height of 1 ft 80 5 cm Result Platform should rise Pull controller handle and lower the platform fully Result Platform should lower Test Horn Push horn pushbutton Result Horn should sound Function Tests Compact Pothole Protection Device Test Pothole Sensor IN 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 1 5 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 7 feet 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 platform should not move forward or backward 31 Function Tests Section 1 Scheduled Maintenance Conventional Compact Pothole Protection Pothole Protection Device Device Test Elevated Drive Speed 2 Use the ladder to dismount from WARNING platform Be aware of overhead obstructions 3 On base control console slowly raise the or other possible hazards around the platform
19. 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 The hydraulic oil level should be at or slightly above the top mark of the sight glass C Annual Inspection Forhydraulic oil replacement procedure refer to section 5 Hydraulic Pump and Motor Ensure there are no loose or missing parts and there is no visible damage Tilt Sensor Greasing Point Electrical Panel Hydraulic Electric Tray 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 Tilt Sensor Ensure 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
20. 10 recu 10 7 10 11 kiras 11 4 1 25 Power Extension Platform will not Extend or 12 4 1 26 Power Extension Platform will not 12 4 1 27 Power Extension Platform will not 12 4 1 28 Two or more Functions at one DB eue sic oobssesiobebetvizitbivizd eje det etuevel 12 Hydraulic System C NECESITE 13 DONI ttr rer eter 13 Soc PONN eee 13 13 adu E ens 13 RU MEE SO METRICS 14 4 2 7 Platform will not Drive in Forward or Reverse 14 E 2 14 4 2 9 Brake s will not Release Additional for machines with Integral Brakes 14 4 2 10 Aerial Platform will not hold on a Grade Machines with Integrals 15 ee i eis weve tetas a E od once acess ei a ee ec ea eed 15
21. 10 2 BUE 15 100 e 1 wE 09 V D D 7 SJIII Conventional Series 157928 146650 53 17 View Parts List Print This Page 3 12 Hydraulic Schematic Models 322x C4 BRAKE C4 BRAKE CYLINDER Www 07 CYLINDER M4 BRAKE RIGHT DRIVE 9 UPPER LIFT M C oprice goo EMERGENCY LOWERING c MOTOR CYLINDER no V Xo DIFFERENTIAL VALVE REAR DRIVE MANIFOLD BLOCK An ap as E 0 5 DIFFERENTIAL R3 24132 CY
22. 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 17 Elevated Drive Speed Does not Activate T Loose or broken wire 59 from base terminal strip proportional relay 21CCR ANSI CSA or 21ACR CE Check continuity Replace if defective Loose or broken wire 59 from proportional relay 21 ANSI CSA or 21ACR CE to resistor RST2 Check continuity Replace if defective Resistor RST2 open Check resistor ohms it should be 30 ohms Replace if defective Loose or broken wire 02 from resistor RST2 to base terminal block Check continuity Replace if defective Proportional relay 21 ANSI CSA 21ACR CE defective Check relay replace if defective 4 1 18 Work Platform Drives in Slow Speed Only 1 Loose or broken wire 71 from base terminal block to high speed limit switch LS1A Check continuity Replace if defective 2 Open or defective high speed limit switch LS1A Check switch Replace if defective Loose or broken wire 21 from high speed limit switch LS1A to low voltage protection resistor RST3 Check continuity Replace if defective 4 Defective low voltage protection resistor RST3 Check resistor Replace if defective 5 Loose or broken wire 21 ANSI CSA or 721A CE from low voltage protection resistor RS
23. GREEN WHITE 5 C MANIFOLD HARNESS D C s BLUEWHTE 0 29 18 REDBLACK sl ORANGE 19 2 BLUE 8 96 O NOTUSED 9 1 WHITE 02 Es 4 TILT SWITCH PIN1 19 BLACK D PIN 2 28 GREEN PIN 3 02 WHITE a PIN 4 71 BLUE cu 0 72 BROWN TO FLASHING LIGHT 2 1 ur 02 WHITE DEED UU 22 GREEN 02 MAIN MANIFOLD TOHORN 02 PLATFORM CONTROL BOX 7 2 E 0 REAR HARNESS 40 9 TILT SWITCH IS HORNIFLASHING LIGHT x SJIII Conventional Series 157928 TO FLASHER IF EQUIPPED PROPORTIONAL X CONTROL RELAY 02 Y D G 147790 _ 3 SKYJACK 23 3 17 Harnesses Diagram HORN FLASHING LIGHT HARNESS TOFLASHINGLIGHT ____ 99 GREEN 19 0 49 BLACK 4 02 WHITE 49 BLACK HORN HARNESS TOHORN 0 gt 2 WHTE per 49 BLACK le TO ELECTRIC PANEL 02 WHITE 49 BLACK TILT SWITCH HARNESS 819 TO TIT SWITCH TO ELECTRIC PANEL PIN 1 19 BLACK 19 BLACK PIN 2 28 GREEN 08 GREEN PIN 3 02 WHITE 02 WHITE PN4 NU SKYJACK Page 24 CONTROL MODULE
24. Hydraulic Electric Battery Tray Battery Fuse Tray Pothole Protection Device Battery Tray 1 1 4 Battery Tray Side WARNING Pothole Protection Device Battery acid is extremely corrosive Ensure mechanisms have no sign of Wear proper eye and facial protec visible damage and are free from dirt and tion as well as appropriate protective obstructions clothing contact occurs immedi ately flush with cold water and seek Battery Tray medical attention Ensure tray latch is secure and in proper working order 1 Check battery case for damage Battery Charger Compacts Entrance Side 2 Clean battery terminals and cable ends Ensure charger is secure and shows no thoroughly with a terminal cleaning tool visible damage or wire brush Battery 3 Ensure all battery connections are tight Proper battery condition is essential to good performance and operational safety 4 If applicable check battery fluid level If Improper fluid levels or damaged cables and plates are not covered by at least 1 2 connections can result in component damage 13 of solution add distilled or and hazardous conditions demineralized water WARNING 5 Replace battery if damaged or incapable of holding a lasting charge Explosion hazard Keep flames g g g and sparks away Do not smoke near batteries N WARNING Use original or manufacturer approved parts and components for the aerial platform SKYJACK Page
25. aerial platform when lifting Result When platform reaches an mE appropriate height a warning signal as lift and drive controls should be 2 Raise the platform until approximately a disabled height of 7 feet 2 meters is reached and attempt to drive forward or reverse Result Aerial plattorm should move slower than when it was in stowed position Test Tilt Sensor N WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting WARNING Ensure that there are no personnel or obstructions in the path of travel including blind spots 1 aerial platform on to a slope not greater than 4 5 SKYJACK Page 32 SJIII Series Section 2 MAINTENANCE TABLES AND DIAGRAMS Table of Contents Tables 21 2 eee 5 2 3 Maximum Platform Capacities Evenly Distributed 6 2 4 Torque Specifications SJIII Series SKYJACK Page 1 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 1 Specifications and Features MODEL 3215 3219 3220 3226 2400 Ib 2580 Ib 3510 Ib 4135 Ib 1089 kg 1170 kg 1592 kg 1876 kg 32 32 Overall width 0 81 0 81 70 0 91 Overall length 1 78 2 3 26 64 28 83 Platform Size inside 0 66 m x 1 63 m 0 71x2 1m 21 25 26 32 Working Height 6 4m 7 6 81 9 9 1
26. 3 Lowering valve 2H 13 defective or is sticking Clean valve Replace if defective 4 Defective holding valve 2H 13B 1 or 2H 13B 2 Clean valve Replace if defective 4 2 6 Platform Drives Slow 1 Free wheeling valve V2 open or defective Close valve Replace if defective 2 Flow divider combiner FD1 defective or is plugged Close valve Replace if defective 3 Drive motor M1 or M2 defective Check motors Replace if defective 4 Cushion cylinder C1 defective Check cylinder Replace if defective 4 2 7 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 Close Valve Replace if defective Flow Divider Combiner valve FD1 defective or is plugged Close Valve Replace if defective 4 Counterbalance valve CB1 defective or is plugged Close Valve Replace if defective 4 2 8 Brake s will not Release 1 Brake valve 3H 17A defective or is sticking Clean valve Replace if defective 2 Brake orifice s 07 plugged Remove orifice s Clean and reinstall 3 Brake cylinder s C4 defective Rebuild cylinder s Replace if damaged 4 2 9 Brake s will not Release Additional for machines with Integral Brakes 1 Stuck or defective auto reset value V3 Check valve operation Clean valve Replace if defective 2 Stuck or defective hand pump P2 Check pump op
27. SPEED A SOLENOID DIFF SOLENOID SPEED B SOLENOID PROPORTIONAL RELAY PROPORTIONAL SOLENOID REVERSE SOLENOID TRANSFER RELAY FORWARD SOLENOID RIGHT SOLENOID BRAKE SOLENOID LEFT SOLENOID Print View Parts List M150851AB 1 V SKYJACK Page 29 Print View This Page Parts List 3 23 Electrical Schematic EE Rated Equipped with all options CONTROL BOX BASE BEDV 110 LINE VOLTAGE EXTEND 24V CHARGER EXTEND SOLENOID RETRACT EAE SWITCH 26 110 VAC 4H 26 EXT 09 al V BC 1 CHARGER e 27 S11 S12 4H 27 Fi B3 6V B2 6V B16V 3 RETRACT SOLENOID 21B 21B GREEN BLACK 21B BATTERY 300A BATTERY BATTERY BATTERY TO BATTERIES FUSE 026 027 E sm S1 MAIN 54 IDLE PLTF BASE DISCONNECT MOTOR 4 EMERGENCY KEY SWITCH CONTACTOR STOP IN IDLE POSITION e mm 8
28. si a a CT 9 10 Maintenance and Inspection Schedule 13 Owners 13 ERIS A 25 ala E 13 Maintenance and Service TIDS Lue Gau an casa eu scan uio a 13 Hydraulic System amp Component Maintenance and 14 bits 3g LC T LT metr 14 Service and Maintenance BERE 15 cipue RE TENER RENTE 15 Rc aie d METRE TET ee PES 15 T 2 15 Scheduled Maintenance 1 4 Scheduled Maintenance pna Hisp aa a cU mecs Sad Hm ad PUO C dnm s ba Dp 18 t 25 Tables Owner s Annual Inspection 16 1 2 Maintenance and Inspection 17 SJIII Series SKYJACK Page 5 Section 1 Scheduled Maintenance Operator s Responsibility for Maintenance SKYJACK is continuously improving and expanding product features on its equipment therefore
29. 1 5 87 RELAY RELAY OL 21121121 2401121 2112 O15 Q16 OM O2 lt 05 WHITE p ore 2 CONTROL CABLE OPTIONS 5 CONTROL 8 21 PIN 87 NIU WIRE COLOUR m re lt 9 Q Bin PIN 87a GREENBLACK 218 21B REDWHTE 60 BACK VIEW FRONT VIEW es 72 BLACKWHITE o e P REDWHTE s GREEN TA aS a BLACK WHITE 7 H GREEN WHITE 9 7O A BLUE BLACK 80 HYDRAULIC TRAY MN OPT GREEN BLACK 7 D Vo 5 AS Os i2 9 5 e BRED BLACK a ORANGE 13 40 I WHTEBACK z 8 MAIN MANIFOLD lt lt 2 21 244 1 WHITE 0 _ PLATFORM CONTROL C 4 4 O 5 lt REAR HARNESS e lt gt D 2 4 4 2 TILT SWITCH 2 2 7 HORNIFLASHING LIGHT M149583AA SKYJACK Page 22 SJIII Conventional Series 157928 3 16 Electrical Panel Diagram EE Rated ____ J JC 2 D Print View This Page Parts List
30. ACTUATOR OPEN PORT SJIII Conventional Series 157928 Section 3 System Component Identification and Schematics Service and Maintenance 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 03 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 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 G
31. Holding ANSI CSA 104132 VALVE Control Differential 132749 VALVE Control Proportional 106273 VALVE Control Lift 103623 VALVE Control Brake 103623 VALVE Control Speed A 103623 VALVE Control Speed B 113953 113953 124291 120989 120989 120236 120220 127100 127100 147889 115299 109568 103354 103129 103129 134573 134573 107354 107493 111314 111320 111316 108195 CYLINDER Brake Models 322x CYLINDER Powered extension platform Models 3220 4620 CYLINDER Powered extension platform Model 4626 VALVE Counterbalance VALVE Cross Over Relief Option FILTER ASSEMBLY Return VALVE Flow divider combiner MOTOR Hydraulic Wheel Left hand Models 322x MOTOR Hydraulic Wheel Right hand Models 322x MOTOR Hydraulic Wheel Left hand Models 46xx MOTOR Hydraulic Wheel Right hand Models 46xx BLOCK Manifold Main BLOCK Manifold Emergency lowering BLOCK Manifold Holding valve Models 3220 4620 ANSI CSA BLOCK Manifold Upper holding valve Models xx26 4632 ANSI CSA BLOCK Manifold Lower holding valve Models xx26 4632 ANSI CSA BLOCK Manifold Rear drive BLOCK Manifold Powered extension platform part of cylinder weldment MANIFOLD BLOCK Brake release Models 46xx MANIFOLD BLOCK Proportional control ORIFICE 0 081 diameter Lowering Model 4632 ORIFICE 0 073 diameter Lowering Model 4620 ORIFICE 0 040 diameter Steer ORIFICE 0 067 diameter Emergen
32. If Equipped D UJ Test Pothole Sensor Test Elevated Drive Speed Test Tilt Sensor 2 UJ gt gt A 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 porior to performing quarterly or yearly inspection Note Make a copy of this page or visit the Skyjack web site www skyjack com for a printable copy SJIII Series 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 t
33. System Component Identification and Schematics Service and Maintenance 3 6 Hydraulic Manifold and Port Identifications 2 18 2 59 Differential Valve Proportional Valve Internal Compensator Valve To Main Manifold 3H 18A 2 gt 27 Speed Valve B S ANY To Main Manifold AU AP FD1 V Flow Divier Combiner 2 4 i Auto Reset Valve Free wheeling Valve 2 Hydraulic Fitting 2 5 18 1 A _ l Speed Valve 3H 14 Lift Valve View Parts List CB1 Counterbalance Valve 02 Lowering R4 Relief Valve Model 4620 amp 4632 Only RA RUNE rl S Brake Valve 2 RUE 16 D Quick Disconnect If equipped Forward Valve cU R2 EN lt gt Lift Relief Valve 27 5 4 Cr T gt 2 13 Relief Valve 2170 Lowering Valve 4H 23 Right Steer Valve 4H 15 Reverse Drive Valve 4H 24 Quick Disconnect Left Steer Valve System Relief Valve If equipped M138117AA_S3 SJIII Conventional Series 157928 SKYJACK Page 12 Section 3 System Component Identification and Schematics 27 TORQUE Service and Maintenance 3 7 Platform Control Console Diagram 128
34. 26 3 20 Electrical Schematic Equipped with no 27 3 21 Electrical Schematic Equipped with all E 28 3 22 X Electrical Schematic EE Rated Equipped with no 29 3 23 Electrical Schematic EE Rated Equipped with all 30 SJIII Conventional Series SKYJACK Page 1 157928 Section 3 System Component Identification and Schematics Service and Maintenance 3 1 Electrical Symbol Chart CIRCUITS CROSSING LIMIT SWITCH NO CONNECTION HOURMETER KEY SWITCH 2 LIMIT SWITCH CIRCUITS LIGHT FOOT SWITCH HELD CONNECTED CLOSED LIMIT SWITCH HYDRAULIC C 4 BATTERY VALVE COIL TOGGLE SWITCH PROPORTIONAL LIMIT SWITCH GROUND HYDRAULIC PUSH BUTTON N C HELD OPEN VALVE COIL ELECTRIC FUSE MOTOR ROTARY SWITCH CONTROLLED RECTIFIER PROXIMITY SWITCH CIRCUIT BREAKER EMERGENCY CAM OPERATED PNP 1 STOP BUTTON LIMIT SWITCH TRANSISTOR NPN CAPACITOR ANNN SER SINGLE POLE PRESSURE POTENTIOMETER LEVEL SENSOR SINGLE THROWN VACUUM RELAY SWITCH TEMPERATURE SWITCH SINGLE POLE DOUBLE POLE DOUBLE POLE DOUBLE THROW SINGLE THROW DOUBLE THROW RELAY RELAY RELAY TRIPLE POLE DOUBLE THROW DIODE RHEOSTAT RELAY SJIII Conventional Series SKYJACK Page 3 157928
35. Check continuity Replace if defective Open or defective base key switch 510 Select function with switch Check switch Replace if defective Loose or broken wire 00 from pump motor DCM to circuit breaker Check continuity Replace if defective Defective or tripped circuit breaker CB1 Reset circuit breaker Replace if defective Loose or broken wire 2 from circuit breaker CB1 to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 7A from base terminal block to CM1 control module pin P2 12 CE Check continuity Replace if defective Loose or broken wire 02 from base terminal block to CM1 control module pin P2 11 CE Check continuity Replace if defective 4 1 2 All Controls Except for Down Function Inoperative 1 Loose or broken wire 19A ANSI CSA or wire 19B from base terminal block TB 1 to contactor C1 Check continuity Replace if defective SKYJACK Page 4 SJIII Conventional Series 157928 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 2 3 4 Contactor C1 defective Check contactor Replace if defective Defective pump motor DCM 1 Check motor Replace if defective Loose or broken wire 59 from relay 21CCR ANSI CSA or relay 21ACR CE to proportional valve coil 2H 59 Check continuity Replace if defective Loose or broken wire 02 from proportional valve coil 2H 59 to
36. Defective up valve coil 3H 14 Check continuity through coil Replace if defective 3 Open diode D14 Check diode Replace if defective 4 Open diode D21A ANSI CSA or D21 CE Check diode Replace if defective 5 Machine not level Above high speed limit switch Use on level surface SKYJACK Page 6 SJIII Conventional Series 157928 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 6 Loose or broken wire 19 from base terminal block to tilt switch TS1 ANSI CSA Check continuity Replace if defective 7 Defective tilt switch TS1 ANSI CSA Test tilt switch Replace if defective 8 Loose or broken wire 728 from tilt switch TS1 to tilt relay 28CR ANSI CSA Check continuity Replace if defective 9 Loose or broken wire 02 from tilt switch TS1 to base terminal strip ANSI CSA Check continuity Replace if defective 10 Defective tilt relay 28CR ANSI CSA Check relay Replace if defective 11 Loose or broken wire 19 from tilt relay 28CR to pump motor contactor ANSI CSA Check continuity Replace if defective 12 See 4 1 5 of this section for more troubleshooting information for CE 4 1 9 No Down Function from Platform or Base Control Console ANSI CSA NOTE Down function is not proportionally controlled 1 Loose or broken wire 13 from base terminal block to down valve 2H 13 or holding valve 2H 13 1 or holding valve 2H 13 2 C
37. HARNESSES Print View This Parts List FROM ELECTRIC PANEL 28 BLACK 28E WHITE 60 GREEN FROM ELECTRIC PANEL 02 WHITE RED 10E BLACK WHITE 13 ORANGE 14 BLACK 15 16 WHITE BLACK 18B RED BLACK N U BLUE BLACK N U ORANGE BLACK CHARGER CUTOUT HARNESS TO CONTROL MODULE P3 PIN 3 60 GREEN PIN 4 28 BLACK PIN 6 28E WHITE BACK VIEW 6509 Ce CONTROL MODULE P2 PIN N U PIN 2 10E BLACK WHITE PIN 3 14 BLACK PIN 4 13 ORANGE PIN 5 PIN 6 N U PIN 7 16 WHITE BLACK PIN 8 15 BLUE PIN 9 N U PIN 10 18B RED BLACK PIN 11 02 WHITE V X PIN 12 7A RED Y SSS neo TO ELECTRIC PANEL BLACK 05 WHITE OPT GREEN PIN 1 BLACK PIN 2 05 WHITE BACK VIEW M146588AA 53 SJIII Conventional Series 157928 Print View This Page PartsList 3 18 Limit Switch Assemblies Diagram PIN 1 19 BLACK PIN 2 28 GREEN PIN 3 02 WHITE PIN 4 NIU BROWN BLACK
38. LIMIT SWITCHES gt 4 4 0 21 HOURMETER 2 7 154 155 02 00 71 72 19 2 2 0 22 RELAY LS6 Y 28CR 71 19 va gt ve 23 TILT SWITCH DRIVE OVERRIDE 02 02 WHITE 02 LIMIT SWITCH N C 751 24 3H 18A 1 gt 25 SPEED A SOLENOID 527 D21B 2 TORQUE E LIMIT SWITCHES N C D21 1 T 2H 18A Y SWITCH LS1B gt 26 DIFF SOLENOID 128 18 RED BLACK 18 18 18A 18A 3H 18A 2 zd pile isse 27 SPEED B SOLENOID JOYSTICK pum D21 RST3 71 21 21A 21C 02 PROPORTIONAL 1 gt AAA 28 JOYSTICK PCB RELAY 0218 1 LOW VOLTAGE 08 59 59 ORANGE BLACK 59 1514 59 PROTECTION 59 4l 59 RST2 OUTPUT os D17C 1 02 2 59 PROPORTIONAL SOLENOID REVDN Bes 15 BLUE 15 01771 4H 15 ALS 9 31 REVERSE SOLENOID 5 1 Dis 17CR DO2 3 NUETRAL 17 17 02 T 32 TRANSFER RELAY 14 B 016 m FWD UP 16 16 4 16 33 FORWARD SOLENOID y D17 eet 8 8 ENABLE ol 17B 176 12B PW 23 BLACK WHITE 23 4H 23 35 RIGHT SOLENOID S72 DO2 5 D23 RIGHT 128 36 BRAKE SOLENOID 57 3 m LEFT D24 24 BLUE BLACK 24 4H 24 i 37 LEFT SOLENOID DO2 6 M146624AE1 SKYJACK Page 28 SJIII Conventional Series 157928 SJIII Conventional Series 157928 3 22 Electrical Schematic EE Rated Equipped with no options 1
39. Rocker Switch Controller Emergency Stop Button Operation Light Horn Pushbutton Lift Off Drive Switch e Test Brakes 4 WARNING Brakes will engage instantly when you release the controller handle causing aerial platform to stop immediately 1 Ensure path of intended motion is clear 2 Activate and hold d enable trigger Switch Drive aerial platform i forward and then q backward Test brake by releasing controller handle Result Aerial platform should come to a stop If aerial platform pulls to one side while stopping do not operate aerial platform until brake adjustments have been checked SKYJACK Page 30 platform forward then backward Test brake again by releasing enable 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 SJIII Series Section 1 Scheduled Maintenance Conventional Pothole Protection Device Test Platform Raising Lowering AN WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting 1 Select lift off drive switch to lift position
40. 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 clockwise 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 opera
41. Y per LS1B Q P 26 DIFF SOLENOID S7 12 k 18 RED BLACK 18 18 18A 18A 3H 18A 2 JOYSTICK 27 SPEED B SOLENOID 21CCR D21 8573 1 71 21 e gt 4 21 AAN 21C 02 4 28 PROPORTIONAL JOYSTICK PCB RELAY D21B 1 LOW VOLTAGE 08 pwm 59 59 ORANGE BLACK 59 LS1A 59 PROTECTION 59 59 RST2 OUTPUT 29 0770 D17C 1 4 PROPORTIONAL 13 SOLENOID EA 017 1 D17C xe REV DN 15 BLUE 15 4H 15 31 REVERSE SOLENOID 57 1 D15 17CR 002 3 32 TRANSFER RELAY T NEL B D16 FWD UP 16 WHITE BLACK 16 4H 16 33 FORWARD SOLENOID 57 6 Y 017 002 4 ENABLE 8A ENABLE 17B 176 e 12B PME 23 BLACK WHITE 23 4H 23 35 RIGHT SOLENOID 57 2 nis DO2 5 RIGHT 5g 17A 3H 17A SES 36 BRAKE SOLENOID LEFT D24 528 24 BLUE BLACK 24 4H 24 37 LEFT SOLENOID DO2 6 M147978AB 1 SKYJACK Page 30 SJIII Conventional Series 157928 Section 4 TROUBLESHOOTING INFORMATION Table of Contents ____ _______ gt 3 Electrical System Desi 3959 11 4 4 1 2 All Controls Except for Down Function 4 4 1 3 All Controls Inoperative From Base Control 5 4 1 4 All Controls Inoperative From Platform Control 1
42. fully lower the platform Result The platform should lower 4 Torestore normal operation depress and turn holding valve manual override knobs clockwise 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 SJIII Series 27 Function Tests Section 1 Scheduled Maintenance Lift Drive Steer Enable Trigger Switch Rocker Switch Controller Emergency Stop Button Switch di Operation Light Horn Pushbutton Lift Off Drive Switch Ensure base 9 emergency stop button is pulled out Select off platform base key switch to platform position Ensure main power disconnect switch is in P on position WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform Use the ladder of aerial platform to access platform Close the gate On platform control console pull out x emergency stop button SKYJACK Page 28 1 1 2 3 Platform Control Console e Test Platform Emergency Stop Push in i emergency stop button and attempt to activate any platform function Result selected platform functions should not operate Test Enable Trigger Switch Without activating enable trigger switch attempt to activat
43. heed the following safety precautions could result in 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 emergency main power disconnect switch off when leaving the aerial platform unat tended Remove the key to prevent unauthorized use of the aerial platform WEAR all the protective clothing and personal safety devices issued to you or called for by job 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 DO NOT increase the lateral surface area of the platform Increasing the area exposed to the wind will decrease aerial platform stability DO NOT drive or elevate the aerial platform if it is not firm level surface Do not drive elevated near depressions or holes of any type loading docks debris drop offs and surfaces that may affect the stability of the aerial platform If operation in areas with holes or drop off
44. of crushing hazards or work height It is prohibited Keep all body parts inside platform guardrail S DO NOT exert side forces 9 aerial platform while elevated DO lower the platform i unless the area below is clear of personnel and obstructions DO 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 e STUNT driving and horseplay are prohibited assembly It is prohibited ENSURE ALL tires 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 use the aerial platform without guardrails locking pins and the entry gate in place SJIII Series SKYJACK Page 11 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 exceed the rated cap
45. or the switch automatically exit program mode and return to normal operation using previously stored data 1 Ensure aerial platform is parked on a firm level surface 2 Chock or block wheels to keep the aerial platform c Press and release set up button 3 times VOID d 5 second period has expired prior 3 Lower Raise the platform and secure the scissors completion repeat Step b and c using the maintenance bar Refer to Operating manual for Maintenance Support Procedure e Observe program delay stabilization time y NOTE Only the red LED will Green LED The tilt circuit is only powered when blink for 4 seconds J activating a function t Both LEDs will flash for 1 second Results The switch is Red LED 4 gt Remove any covers to locate and view the tilt learning the new zero 5 ereen D 5 Disconnect all wires 02 from motor contactor position 6 Install jumper wire between 7 and 19 to g Both LEDs will turn terminal strip on solid for 1 second Results The new OF Red LED 7 main disconnect switch to ON position zero position has been OF ereen LEP 8 Verify switch is powered Red green LED will be continually blinking h The green LED will flash and then the red LED will turn on solid for 2 seconds
46. 10 VAC LINE 24V VOLTAGE CHARGER 110 VAC B4 B26V B16V BATTERY 300A BATTERY BATTERY BATTERY TO BATTERIES FUSE CONTROL BOX BASE 510 24V ue me xh pss DD S4 IDLE PLTF BASE KEY SWITCH S1 MAIN STOP IN IDLE POSITION DISCONNECT C1 MOTOR Fr CONTACTOR DCM1 08 8C BLUE WHITE 8 07 528 ws NCHO EMERGENCY STOP SWITCH CB1 7A 07 07 RED 07 07 4 5 5 05 05 03 00 02 15A CIRCUIT NCHO BREAKER 7A GHEEN 7A 00 02 1 9 N 02 N 60 60 RED WHITE 7A 7 A 02 4 gt 58 LED 1 T LED 2 HORN POWER ON LSS 10E 7 POWER ON LIGHT Ty NO H1 d 4 208 49 49 GREEN WHITE 49 HORN 49 i 2H 13 13 ORANGE 13 13 13 2 13 1 002 1 2 13 2 D13 4 002 2 14 14 14 3H 14 e 52 UP DOWN 19 2ga 28 2 2 BATTERY CHARGE SWITCH 014 014 p gt d z 4 2 INDICATOR 29 5 D19A 5 V 5 I 14E ue CRD2 CRD
47. 15 16 17 18 19 20 21 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 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 Check continuity 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 L1CR Check relay Replace if defective Defective or tripped circuit breaker CB2 Reset circuit breaker Replace if defective Loose or broken wire 5 from charger relay L1CR to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 25 from base terminal block TB 1 to base emergency stop switch 528 Check continuity Replace if defective Open or defective base emergency stop switch 528 Close switch Check switch Replace if defective Loose or broken wire 5A from base emergency stop switch S28 to base key switch 510
48. 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 3000 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 SJIII Series Section 5 Procedures 5 2 3 Electronic Tilt Switch Setup Procedure 9 The following information is supplied for replacement or reprogramming of the electronic tilt switch Also 10 included are test and verification instructions Follow the appropriate procedures below 11 Tilt Switch Replacement 12 cane 13 1 Ensure aerial platform is parked on firm level surface 2 Chock or block wheels to keep the aerial platform from rolling forward or backward 3 Lower Raise the platform and secure the scis
49. 20 SJIII Series Section 1 Scheduled Maintenance Conventional Wheel Tire Greasing Point Wheel Motor 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 cracked welds Check each lug nut for proper torque to ensure none are loose Check wheel motor assembly for loose or missing parts and signs of visible damage Ensure wheels are aligned and true vertically and horizontally SJIII Series 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 e Greasing Points Ensure greasing points have no sign of visible damage and are free from dirt and obstructions B Frequent Inspection Locate grease fittings and pump grease as needed SKYJACK Page 21 Service and Maintenance Section 1 Scheduled Maintenance Compact Emergency Lowering Access Rod
50. 3 SYSTEM COMPONENT IDENIFICATION AND SCHEMATICS Table of Contents Charts 3 1 mee bra PN 3 3 2 a 4 dd PH e A 5 Parts List 3 4 xit 7 3 5 9 Diagrams and Schematics 3 6 Hydraulic Manifold and Port ONC AION Ira eb Pal Patr 12 SA Patom cam m m mm 13 3 8 Platform Control Console Powered Extension Platform Modification 14 3 9 Powered Extension Platform Control Console and 15 16 8 pa Medo _ __ _ _ _ 17 gie Models 19 gt Mode Ea 20 314 Main Manifold Harness and Holding Valve 21 22 Electrical Diagram DRE PETS 23 coo Hm 24 Dabo 25 219 Flashing Lam Diagrami
51. 3 1291 84 POTHOLE PROTECTION D14E 1 D21A En P LIMIT SWITCHES N C H O 5 1 2 7K OHMS 154 Q 155 02 71 72 1 NVV 1 28 LS6 28CR 71 214 19 4 79 gt 02 DRIVE OVERRIDE 02 02 WHITE 02 LIMIT SWITCH N C TS1 e 53 3H 18A 1 S27 HIGH SPEED DRIVE TORQUE LIMIT SWITCHES N C D21 1 2H 18A SWITCH SWITCH LS1B p E T ges e S7 128 18 RED BLACK 18 18 18 18A 3H 18A 2 JOYSTICK 21CCR 71 21 Fo 27 1 21 02 JOYSTICK PCB LOW VOLTAGE PWM 59 59 ORANGE BLACK 59 LSTA 59 PROTECTION 59 59 8572 OUTPUT 2 B D17C 1 2 59 4 1 REV DN a 2 BLUE D17 1 D17C 4H 15 15 15 57 1 15 Bis 17CR DO2 3 NUETRAL 17 17 7 02 gt 14 016 FWD UP 16 WHITE BLACK 16 4H 16 16 8 017 DO2 4 8A o ENABLE 17 17 128 28 23 BLACK WHITE 23 4H 23 7 2 002 5 D23 RIGHT 178 17A 3H 17A S7 3 LEFT D24 BLUE BLACK 4H 24 4 24 24 002 6 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 This Page CHARGER BATTERY PACK PUMP MOTOR 15A CIRCUIT BREAKER POWER ON LED HORN DOWN SOLENOID HOLDING VALVE SINGLE CYLINDER HOLDING VALVE TWO CYLINDERS UP SOLENOID BEEPER 0 47uF CAPACITOR MOTOR CONTACTOR HOURMETER TILT RELAY TILT SWITCH
52. 5 19 20 26 Platform Elevated Height 4 6 m 58 6 1 7 9 34 5 39 38 45 Stowed Platform Height 0 88 m 0 99 m 0 97 m 1 1m 74 78 5 82 89 Stowed Height Railings U ght 95 Up 1 88m 1 99 m 2 1m 2 3m Drive Height FULL Standard Operating Time Lift Time No Load 27 s Lower Time No Load 415 Lift Time Rated Load 33 s Lower Time Rated Load 295 Chassis 2 mph 1 9 mph 2 4 mph Normal Drive Speed 3 2 km h 3 0 km h 3 8 km h 0 65 mph 0 64 mph 0 64 mph Elevated Drive Speed i 1 05 km h 1 0 km h 1 0 km h 0 95 1 2 mph High Torque Drive Speed N A 1 5 km h 1 9 km h 12 4 8 16 5 12 Tires Solid Rubber Solid Rubber Hydraulic Oil Type ATF Dexron III ATF Dexron 111 2 9 gal 7 93 gal Tank Capacity SOT 10 9 Weight with standard 3 0 9 m or 4 1 2 m extension platform Refer to nameplate for aerial platforms with 5 1 5 m or 6 1 8 m extension platform 47 S 63s 465 o 162AB SKYJACK Page 2 SJIII Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 1 Specifications and Features Continued MODEL 4620 4626 4632 4100 Ib 4700 lb 5075 Ib 46 1 17 m 91 2 31 42 84 1 07 m x 2 13 26 32 38 Working Height 7 92 9 75 11 6 20 26 32 Platform Elevated Height 6 1m 7 9 m 9 8 38 45 48 5 Stowed Platform Height 0 97 m 1 14m 1 23 m a 77 25 84 5 88 Stowed Hei
53. 8 MOTOR CONTACTOR i POTHOLE PROTECTION 014 1 D21A m RSTI LIMIT SWITCHES N C H O 4 020 HOURMETER 2 7 5 154 Q Q LS5 02 00 71 72 19 4 20 TILT RELAY D13 LS6 71 19 e 19 02 dri DRIVE OVERRIDE 02 02 WHITE 02 LIMIT SWITCH N C TS1 21 TILT SWITCH 22 S3 LIFT OFF S27 HIGH SPEED DRIVE TORQUE LIMIT SWITCHES N C D21 1 2H 18A SWITCH SWITCH LS1B gt 19 vex T 12B 18 RED BLACK 18 18 18 18A M JOYSTICK m 3H 18A 1 23 SPEED A SOLENOID 24 DIFF SOLENOID 25 SPEED B SOLENOID 21CCR D21 RST3 71 21 21A 21 02 AAN PROPORTIONAL 26 JOYSTICK PCB RELAY 08 PWM 59 LOW VOLTAGE 1514 PROTECTION RST2 59 ORANGE BLACK 59 59 OTECTIO 59 1 594 s OUTPUT 017 1 2 59 PROPORTIONAL 2 0 28 4 SOLENOID A A o D17 1 D17C REV DN 715 15 4H 15 o 7 29 REVERSE SOLENOID D15 17CR DO2 3 m 17 17 02 A S7 1 NUETRAL 30 TRANSFER RELAY FWD UP 57 6 016 16 WHITE BLACK 16 4H 16 16 31 FORWARD SOLENOID D17 DO2 4 l
54. ACK Page 14 SJIII Conventional Series 157928 Section 3 System Component Identification and Schematics Service and Maintenance 3 9 Powered Extension Platform Control Console and Harness V o iew 3 Parts List EXTENSION PLATFORM CONTROL CONSOLE BOX DDD POWER CONTROL CONSOLE BACK VIEW WALL FUNCTION CUTOUT 1 27 2 WHITE 08 3 GREEN 26 H H pe 4 N U EXTENSION PLATFORM CYLINDER RARNESS TO POWER CONTROL CONSOLE BACK VIEW pee 1 27 2 WHITE 02 a O 3 GREEN 26 26 gt SJIII Conventional Series 157928 115592 S3 SKYJACK Page 15 Service and Maintenance Section 3 System Component Identification and Schematics 3 10 Base Control Console Diagram View Parts List 910 IDLE SW 52 UP SWITCH N C CONTACT N O CONTACT PIN PURPLE WHITE PIN 3 10E WHITE BLACK X2 n S2 DOWN SWITCH
55. BLUE WHITE 8C 8C l 07 S28 4 STOP SWITCH gt 15 CIRCUIT EON P BREAKER za 07 07 RED 07 07 sA 0 05 03 00 02 15A CIRCUIT 7A GREEN 7A BREAKER 9 02 NS 60 60 RED WHITE 7A 7A 02 4 10 POWER LED HORN pd xd LED 2 POWER ON LSS o POWER ON LIGHT SWITCH 7A a 99 02 4 08 49 49 GREEN WHITE 49 HORN 49 q 12 HORN 25 FLASHER 1222 FLASHING LIGHT 2 99 L 15 OPTION 2H 13 BATTERY CHARGE 14 DOWN SOLENOID INDICATOR 108 yy 98 LIFT 13 ORANGE 13 413 13 poe 1 HOLDING VALVE V 7 DO SINGLE CYLINDER DRIVE D13 4 2 SWITCH Se 16 HOLDING VALVE 2 TWO CYLINDERS 14 BLACK 14 14 3H 14 ot 17 UP SOLENOID 52 X UP DOWN 2g4 028 08 08 SWITCH 014 014 ES 24 18 T n 29 10E yo D19A 19 0 47uF CAPACITOR id 19 19A bd CHD2 CRD3 _ s 20 MOTOR CONTACTOR POTHOLE PROTECTION D14E 1 D21A T BST LIMIT SWITCHES N C H O gt 5 02 21 HOURMETER 2 7 OHMS 154 Q Q LS5 02 EA 71 72 19 28 r4 02 oo oo 22 TILT RELAY 156 71 19 19 e e 23 TILT SWITCH DRIVE OVERRIDE 02 02 WHITE 02 LIMIT SWITCH N C TS1 e 24 NC INR 25 SPEED A SOLENOID S27 HIGH SPEED TORQUE LIMIT SWITCHES D21 1 19 2 18
56. E GREY PIN 7 PWM 59 ORANGEJBLACK BLUE PIN8 GND 02 WHITE BLACK PIN 9 ENABLE VS BLUE WHITE BLUE View Parts List 7A GREEN 8 16 REDWHITE 607A 49 GREEN WHITE 7 15 BLACK WHITE 23 6 BLE BLACK 2 RED 5 oy o 13 GREEN BLACK 218 OPT 4 H ORANGE BLACK 9 3 t H i BUE 2 0 WHITE BLACK 16 1 ox o 3 woruseny BACK VIEW CRDI M156881AA SKYJACK 13 Service and Maintenance Section 3 System Component Identification and Schematics 3 8 Platform Control Console Powered Extension Platform Modification Diagram View Parts List 93 LIFT OFF DRIVE 927 TORQUE m 8 HORN Dd 09
57. F CBI VALVE LOWERING ORIFICE ae VALVE SEE REFERENCE TABLE e e e e e Y DOMI DC MOTOR MB MAIN MANIFOLD BLOCK HYDRAULIC LOWERING PUMP HEY BLOCK MANUAL 3 RETURN FILTER Ee Oe w RESERVOIR M132308AD1 SJIII Conventional Series SKYJACK Page 19 157928 Print This Page View Parts List 3 13 Hydraulic Schematic Models 46xx
58. LEFT WHT RED ENABLE OUT WHT BLU 24V INPUT WHT BLK ENABLE 15589 PCB oodo 24V INPUT WHT BLK BLU PWD OUT A ENABLE WHT YEL GROUND YEL FORWARD UP REVERSE DOWN SJIII Series SKYJACK Page 5 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 steer 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
59. LINDER N RELIEF VALVE HOLDING VALVE PT 1 ORIFICE 0 040 VALVE FD PRESSURE PRESSURE FLOW CUSHION OVERLOAD OVERLOAD 3 842 COMBINER CYLINDER TRANSDUCER TRANSDUCER SPEED VALVEB OPTION 04 OPTION 2 OPTIONAL POWERED z 7 LOWER LIFT mind x EXTENSION DECKSJ3D 30 CYLINDER 7 E 3226 ORIFICE pe 3220 ORIFICE 2 SPEED VALVEA FREEWHEELNG S 0067 S 0067 VALVE lt PN ANSI CSA 4H 26 2H 13B 1 CE MB5 P DECK EXTEND HOLDING VALVE 11 HOLDING VALVE HOLDING VALVE MANIFOLD BLOCK PLATFORM MANIFOLD BLOCK MANIFOLD BLOCK VALVE RELIEF VALVE HOLDING VALVE M3 1 LEFT DRIVE MOTOR C3 STEERING OPTIONAL CYLINDER PRESSURE 5 SWITCH 03 SIERORRCE J 0040 REFERENCE TABLE x T 430 4H23 4H 15 LOWERING LIFT ENT REVERSE DRIVE n STEER 2H 13 ANSI CSA MODE ORIFICE VALVE 3H 14 2H 13B CE LIFTVALVE _ LOWERINGVALVE iiu 7 PIA SJ3 3226 N BRAKE VALVE 9 Er pem z Ee SJ3 4620 0 073 DIA 2H 59 be i NE O 446 CROSS OVER N 4 A FORWARDDRIE RELIEF VALVE OPTION m SJ84626 PROPORTIONAL 4 Ri z LEFT STEER 02 od TH SJ3 4632 0 081 DIA VALVE SYSTEM RELIE
60. Loose or broken wire 09 from lift drive switch S3 to power extension platform enable switch 512 Check continuity Replace if defective Power extension platform enable switch 512 defective Check switch Replace if defective Loose or broken wire 09 from power extension platform enable switch S12 to platform extend retract switch 511 Check continuity Replace if defective Loose or broken wire 218 from platform control box to base terminal block TB 1 Check continuity Replace if defective Open diode D21B 1 Check diode Replace if defective Open diode D21B 2 Check diode Replace if defective Loose or broken wire 02 from extend valve coil 4H 26 to retract valve coil 4H 27 to platform control box Check continuity Replace if defective 4 1 26 Power Extension Platform will not Extend 1 2 3 4 9 Powered extension platform extend retract switch S11 defective Check switch Replace if defective Loose or broken wire 26 from power extension platform extend retract switch 511 to extend valve coil 4H 26 Check continuity Replace if defective Extend valve coil 4H 26 defective Check continuity through coil replace if defective Open diode D26 Check diode Replace if defective Loose or broken wire 202 from extend valve coil 4H 26 to platform control box Check continuity Replace if defective 4 1 27 Power Extension Platform will not Retract 1 2 3 4 5 Powered Platform
61. MODELS SJ 3220 SJ 3226 SJ4620 SJ4626 SJ 4632 Service Manu SJIII Conventional Series ANSI CSA SK ACK Part No 157928AA February 2011 lt 4 This manual is based on Serial Number s 3320 60 002 259 amp Above 3226 27 006 432 amp Above 46xx 70 007 139 amp Above 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 service dskyJack com Parts North America Toll Free 1 800 965 4626 Toll Free Fax 1 888 782 4825 Email parts dskyjack com Parts amp Service Europe Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry Shropshire SY10 8NN UK Phone 44 1691 676 235 Fax 44 1691 676 238 Email infofdskyjackeurope co uk Skyjack Asia Pacific Singapore Phone 65 6449 3710 Fax 65 6449 7690 Email skyJack dsingnet com sg SERVICE AND MAINTENANCE 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 5 Series SKYJACK Page 3 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance The Safety Alert Symbol identif
62. REYIBRN 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 SJIII Conventional Series SKYJACK Page 5 157928 6 Section 3 System Component Identification and Schematics Service and Maintenance 3 4 Hydraulic Schematic Parts List Skyjack _ 153334 VALVE Control Reverse drive Hytos includes 4 16 VALVE Control Forward drive Hytos VALVE Control Right steer Hytos includes 4H 24 VALVE Control Left steer Hytos VALVE Powered platform extend includes 4H 27 Models 3220 4620 4626 VALVE Powered platform retract includes 4H 26 Models 3220 4620 4626 CYLINDER Cushion CYLINDER Lift Models 3220 4620 CYLINDER Lift Models 3226 4626 4632 CYLINDER Steer 153334 103655 VALVE Control Lowering ANSI CSA 107269 VALVE Control Holding ANSI CSA 107269 VALVE Control
63. S10 C1 i IDLE PLTF BASE Y DISCONNECT MOTOR 4 EMERGENCY KEY SWITCH CONTACTOR DCM1 IN IDLE POSITION STOP 5 PUMP MOTOR 08 BLUE WHITE 8C 8C 07 S28 1 6 INVERTER OPTION FUSE UNAVAILABLE ON EE eG RATED MACHINES CB2 CB1 7A _ 07 07 RED 07 07 al __ 5A 220 03 00 02 15 CIRCUIT 5 15A CIRCUIT T BREAKER 7A GREEN 7A BREAKER 7A 02 TIMER 9 INVERTER TIMER 02 60 60 RED WHITE 7A 7A 02 lt gt 10 POWER ON LED 58 LED 1 LED 2 HORN POWER ON LSS 10E 9 7 7A POWER ON LIGHT 00 02 SWITCH LIGHT 11 ra NO d 08 49 49 GREEN WHITE 49 HORN 49 12 HORN 29 add 22 62 FLASHING LIGHT 13 FL 29 T BCI 2H 13 BATTERY CHARGE 14 DOWN SOLENOID INDICATOR 199 13 ORANGE 13 13 13 15 HOLDING VALVE 02 1 SINGLE CYLINDER DRIVE D13 2H 13 2 158 SWITCH ENDOFSTROKE HOLDING VALVE LIMIT SWITCH 5 Te P 14 BLACK 14 14 14A 3H 14A 17 UP SOLENOID X o 2 09 UP DOWN 19 228A 2 2 208 08 SWITCH 014 0144 ict 2 5 2 18 P E 46 29 219 19 0 47 CAPACITOR AS e 19 19A CARI CRD1 CHD2 CRD3 5 po 4 we ue 20 MOTOR CONTACTOR POTHOLE PROTECTION 014 1 D21A B RSTI
64. T3 to proportional relay 21 CCR ANSI CSA or 21ACR CE Check continuity Replace if defective 6 Proportional relay 24 CCR ANSI CSA 24 CE defective Check relay replace if defective 7 Looseor broken wire 02 from proportional relay 21 CCR ANSI CSA or 21ACR CE to base terminal block Check continuity Replace if defective 8 Proportional controller S7 out of adjustment Adjust controller Refer to Section 5 Joystick Adjusting Procedure SJIII Conventional Series SKYJACK Page 9 157928 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 1 19 Forward Drive Function Inoperative 1 2 3 4 9 Loose or broken wire 16 from lift drive switch S3 to base terminal block Check continuity Replace if defective Loose or broken wire 16 from base terminal block to forward drive valve coil 4H 16 Check continuity Replace if defective Forward drive valve coil 4H 16 defective Check continuity through coil Replace if defective Loose or broken wire 02 from forward drive valve coil 4H 16 to base terminal block Check continuity Replace if defective Open diode D16 Check diode Replace if defective 4 1 20 Reverse Drive Function Inoperative 1 2 3 4 5 Loose or broken wire 15 from lift drive switch S3 to base terminal block Check continuity Replace if defective Loose or broken wire 15 from base termi
65. X RA SJIII Conventional Series 157928 108589 108589 108589 103605 104493 104493 103605 115370 105610 103605 103605 103605 153335 153335 153335 153335 103605 103605 130440 103480 106552 BR S S os os os oS oS 2 Service and Maintenance 3 5 Electrical Components Parts List SUPPLY Common 70 CONTROL _ F GROUND B N NORMALLY OPEN CONTACT NORMALLY CLOSED CONTACT Description RELAY 24 Volt Transfer RELAY 24 Volt Proportional ANSI CSA amp EE rated RELAY 24 Volt Tilt switch ANSI CSA amp EE rated COIL 24 Volt Lowering valve ANSI CSA COIL 24 Volt Holding valve ANSI CSA COIL 24 Volt Holding valve ANSI CSA COIL 24 Volt Differential valve COIL 24 Volt Proportional valve COIL 24 Volt Lift valve ANSI CSA COIL 24 Volt Brake valve COIL 24 Volt Speed A COIL 24 Volt Speed B 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 COIL 24 Volt Power extension platform extend option COIL 24 Volt Power extension platform retract option TRANSDUCER Angle BATTERY 6 Volt U2200 BATTERY 6 Volt U2500 BATTERY 6 Volt T2200 Part
66. acity 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 Fall Protection As per the ANSI A92 6 2006 standard The guardrail system of the aerial platform provides fall protection If occupant s of the platform are required to wear personal fall protection equipment PFPE occupants shall comply with instructions provided by the aerial platform manufacturer remanufacturer regarding anchorage s If additional fall protection is required by an employer the authority having jurisdiction Skyjack recommends the use of a fall restraint system to keep an occupant within the confines of the platform and thus not expose the occupant to any fall hazard requiring a fall arrest All personal fall protection equipment must comply with applicable governmental regulations and must be inspected and used in accordance with the manufacturer s recommendations All personal fall protection equipment must be attached only to approved anchorage points within the platform of the aerial platform WARNING Entering and exiting the aerial platform should only be done using the
67. as been learned Red LED Q3 Green LED P Red LED Oe Green LED The green LED will flash and then the red LED will turn on solid for 2 seconds RedLED 3 Green LED 2 Red LED Green LED 20 Results The switch is verifying the new zero position The green will turn on LED solid Results The switch is ready for normal o operation 2 SJIII Series 7 Service and Maintenance Section 5 Procedures LX with iG off 17 Reinstall any covers that was removed position 18 Remove chock or wheel blocks 15 Remove jumper wire between 7 and 19 from 19 Proceed to Test and Verify Tilt Circuit terminal block 16 Reattach all wires 02 to motor contactor SKYJACK Page 8 SJIII Series Section 5 Procedures Service and Maintenance Reprogramming Existing Tilt Switch 9 Reprogram the Tilt Switch a Press and hold the set Set up button is located on this up button for 3 seconds face next to harness Results Both LEDs will 20 be OFF cem I b Both LEDs will flash 3 Red LED Q3 Green LED E J IMPORTANT 7 step must be completed within 5 second period
68. base terminal block TB 1 Check continuity Replace if defective Defective proportional valve coil 2H 59 Check continuity through coil Reading should be 19ohms Replace if defective 4 1 3 All Controls Inoperative From Base Control Console T 2 3 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 10E from base key switch S10 to base up down switch S2 Check continuity Replace if defective Loose or broken wire 10E from base terminal block TB 1 to CM1 control module pin P2 2 CE Check continuity Replace if defective 4 1 4 All Controls Inoperative From Platform Control Console 1 Loose or broken wire 8 from base key switch 510 to base terminal block Check continuity Replace if defective 2 Loose or broken wire 8C or wire 02 from base terminal block to platform emergency stop switch o4 Check continuity Replace if defective 3 Open or defective platform emergency stop switch S4 Clos
69. cy lowering Models 3220 4620 ORIFICE 0 067 diameter Emergency lowering Models 3226 4626 4632 146563 132748 105530 122213 10581 1 105281 105281 104434 104434 137127 ORIFICE 0 040 diameter Differential ORIFICE 0 040 diameter Brake Models 322x ORIFICE 0 020 diameter Brake Models 46xx Parts list continued on the following page SJIII Conventional Series SKYJACK Page 7 157928 6 Service and Maintenance Section 3 System Component Identification and Schematics 3 4 Hydraulic Schematic Parts List Continued Skyjack EJE 106577 106587 129961 129965 310567 146560 102863 113799 104534 104534 106557 107271 103136 146562 SKYJACK 8 4 4 4 4 4 4 4 4 4 4 2 1 1 1 Parts list continued from the following page PUMP Hydraulic Model 4620 except EE rated PUMP Hydraulic Models 4626 4632 except EE rated PUMP Hydraulic ANSI CSA EE rated PUMP Hydraulic EE rated PUMP Hydraulic Standard PUMP Handle Brake release Models 46xx SWITCH Pressure Option e BLOCK Manifold VALVE Relief System VALVE Relief Lift VALVE Relief Holding valve Models 3226 4626 4632 VALVE Emergency lowering VALVE Free wheeling VALVE Auto reset brake release Models 46xx SJIII Conventional Series 157928 Section 3 System Component Identification and Schematics Skyjack L
70. d type Failure to operate with matched approved tires in good condition may result in death or serious injury SKYJACK Page 4 SJIII Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 2 Floor Loading Pressure Total Aerial Total Aerial Platform Load Platform Weight KPa kN m x Ib kg psf 2400 3000 2580 3130 3400 4299 4100 4610 4100 5620 4700 5920 5075 5775 1089 min max min max min min max min max min max 60354AF ANSI Total aerial platform weight with no options max 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 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 SJIII Series SKYJACK Page 5 Service and Maintenance Section 2 Maintenance Tables and Diagram
71. draulic 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 present flush the entire system and add a new change of oil The presence of metal particles also may indicate the possibility of imminent component failure A very small amount of fine particles is normal 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 Samples of hydraulic oil should be drawn from the reser
72. dure SKYJACK Page 10 SJIII Series SKYVACK Reliable lift solutions by people who care www skyjack com
73. e any platform function Result All platform functions should not operate SJIII Series Section 1 Scheduled Maintenance Function Tests Lift Drive Steer Enable Trigger Switch Rocker Switch Controller Emergency Stop Button Switch lt Operation Light Horn Pushbutton Lift Off Drive Switch Test Steering Test Driving NOTE Inclined drive low speed high torque is 1 Ensure path of intended motion is clear not available on 3215 and 3219 models 2 Activate and hold A enable trigger 1 Select lift off drive switch to drive switch position 3 ay move controller handle in i 2 Bae forward direction until aerial platform begins to move and then return handle to center position Result Aerial platform should move in 3 Press rocker switch on top of controller 3 handle to 4 79 left and 41 4 forward direction and then come to a right stop Result Steer wheels should turn left and right i 4 Slowly move controller handle in 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 SJIII Series SKYJACK Page 29 Function Tests Lift Drive Steer Enable Trigger Switch Switch Section 1 Scheduled Maintenance
74. e switch Replace if defective 4 Loose or broken wire 8 or wire 02 from emergency stop switch 54 to battery charge indicator BCI Check continuity Replace if defective 5 Loose or broken wire 8 or wire 02 from battery charge indicator BC1 to joystick S7 Check continuity Replace if defective 6 Defective joystick enable switch 57 6 Check switch Replace if defective 7 Defective joystick neutral switch 57 1 Check switch Replace if defective 8 Defective joystick S7 Check joystick Replace if defective SJIII Conventional Series SKYJACK Page 5 157928 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 1 5 No Drive or Up Function from Platform or Base Controls CE only 1 2 3 Defective tilt relay 28CR1 or Aux tilt relay 2 Check relay Replace if defective Loose or broken wire 02 from base terminal block to tilt relay 28CR1 or Aux tilt relay 28ECH1 Check continuity Replace if defective Loose or broken wire 28 from CM1 control module pin P3 4 to tilt relay 28CR1 Check continuity Replace if defective Loose or broken wire 28E from CM1 control module pin P3 6 to Aux tilt relay 28ECR1 Check continuity Replace if defective Loose or broken wire 19 from base terminal block to Aux tilt relay 28ECR1 Check continuity Replace if defective Loose or broken wire 19A from Aux tilt relay 28ECR1 to tilt relay 28 1 C
75. ection Hydraulic tray EE rated LIMIT SWITCH Drive override RESISTOR 2 7 ohm RESISTOR 25W 30 ohm RESISTOR Low voltage protection Parts list continued on the following page SJIII Conventional Series 157928 Section 3 System Component Identification and Schematics Service and Maintenance E MM nnn n m nn HI 3 5 Electrical Component Parts List Continued Skyjack SJIII Conventional Series 157928 119725 147054 147053 147054 147053 123994 122869 122877 122877 122872 147054 147053 147054 102853 102853 147053 146658 146661 103336 i HS Parts list continued from following page SWITCH Main power disconnect N O CONTACT Raise Lower N C CONTACT Lift Drive N O CONTACT Lift Drive without power extension platform N O CONTACT Lift Drive with power extension platform N C CONTACT Emergency stop Platform control console CONTROLLER ASSEMBLY Proportional SWITCH Neutral SWITCH Right steer SWITCH Left steer SWITCH Pushbutton Enable N O CONTACT Horn N C CONTACT Off Platform N O CONTACT Base SWITCH Powered extension platform extend retract SWITCH Powered extension platform enable N C CONTACT Emergency stop Base control console TILT SWITCH Model 32xx TILT SWITCH Model 46xx HOURMETER SKYJACK Page 11 Section 3
76. ent identified with ANSI meets the ANSI SIA A92 6 2006 standard Equipment identified with CSA meets the CSA B354 2 01 standard Equipment identified with CE meets the requirements for the European countries i e Machinery Directive 98 37 EC and EMC Directive 89 336 EEC and the corresponding EN standards b CSA Canada and CE Europe Operators are required to conform to national territorial provincial and local health and safety regulations applicable to the operation of this aerial platform c ANSI SIA United States Operators are required by the current ANSI SIA A92 6 standards to read and understand their responsibilities in the manual of responsibilities before they use or operate this aerial platform SKYJACK Page 8 SJIII Series Section 1 Scheduled Maintenance Operator s Responsibility for 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 caused by the failure of the operator to follow simple and fundamental safety rules and precautions You as a careful operator are the best insurance against an accident Therefore proper usage of this aerial platform is mandatory The following pages of this manual should be read and understood completely before operating the aerial pla
77. eration Clean pump Replace if defective 3 Defective internal brake piston seals Check brake pack will maintain pressure If pressure is not maintained replace seals 4 Plugged or defective brake orifice 07 Clear obstruction Replace if defective 5 Damaged integral brake in wheel motor nspect wheel motor assembly Repair and replace as necessary SKYJACK Page 14 SJIII Conventional Series 6 157928 Section 4 Troubleshooting Information Service and Maintenance Hydraulic System Continued 4 2 10 Aerial Platform will not hold on a Grade Machines with Integrals Brakes 1 Worn or damaged brake discs Inspect brake discs for wear Replace if worn or damaged 2 Broken or damaged brake compression springs Check springs Replace if defective 4 2 11 Platform does not Steer 1 Right steer valve 4H 23 or 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 03 plugged Clean orifices and reinstall 4 2 12 All System sluggish 1 System Relief Valve defective or not adjusted properly Adjust valve Replace if defective 2 Hydraulic pump P1 worn Check pump Replace if defective 3 Proportional valve 2H 59 contaminated or defective Clean Replace if defective 4 2 13 Power Extension Platform will
78. eries SKYJACK Page 23 Service and Maintenance Section 1 Scheduled Maintenance R Maintenance Lift Cylinder Support Scissor Assembly Scissor Bumper 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 Ensure that you maintain three points of contact to mount dismount platform 3 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 Scissor Bumpers Ensure bumpers are secure and shows no sign of visible damage Rollers Ensurerollers are secure and there is no visible damage Ensurerollers path of travel are free from dirt and obstructions Lift Cylinder s Ensure each lift cylinder is properly secured there are no loose or mi
79. ering 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 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 base position and TI lower the platform with lower neutral raise switch Result Platform should lower SJIII Series Section 1 Scheduled Maintenance Function Tests EV MM aa Compact Back View Conventional Back View Free wheeling Valve Lower Lower Neutral Raise Neutral Raise Switch Switch Emergency Stop Platform Off Base Emergency Stop Button Key Switch Button Test Emergency Lowering Test Free wheeling 1 Raise the platform 1 Ensure path of intended motion is clear 2 Locate holding valve manual override 2 Release the brake manually knob at the base of each lift cylinder Depress and turn counterclockwise If 3 Turn free wheeling valve knob necessary use access rod that is located on the base of the aerial platform 3 On hydraulic electric tray pull out and hold emergency lowering valve to
80. extend retract switch S11 defective Check switch Replace if defective Loose or broken wire 27 from power extension platform extend retract switch 511 to retract valve coil 4H 27 Check continuity Replace if defective Retract valve coil 4H 27 defective Check continuity through coil replace if defective Open diode D27 Check diode Replace if defective Loose or broken wire 02 from retract valve coil 4H 27 to platform control box Check continuity Replace if defective 4 1 28 Two or more Functions at one time 1 Shorted Diode Check continuity of all diodes Replace if defective SKYJACK Page 12 SJIII Conventional Series 157928 Section 4 Troubleshooting Information Service and Maintenance Hydraulic System 4 2 1 All Function Inoperative 1 Proportional valve 2H 59 defective or is sticking Check valve Replace if defective 2 Pump P1 defective Check pump Replace if defective 4 2 2 Platform Drifts Down 1 Defective lift cylinder seals at the gland or holding valve manifold Replace if damaged Note There are no piston seals just wear rings 2 Combination of defective holding valves 2H 13 1 and 2H 13 2 and either defective lowering valve 2H 13 or relief valve R2 or manual lowering valve V1 ANSI CSA Check valves Replace if defective Combination of defective holding valves 2H 13B 1 and 2H 13B 2 and either defective lowering valve 2H 13B or relief valve R2 or manual lower
81. formed 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 on all inspections Maintenance 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 comp
82. functions should not operate Platform Off Base Key Switch 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 access platform 2 Close the gate 3 platform control console pull i emergency stop button 4 Use the ladder to dismount from platform 5 main power disconnect switch to position SJIII Series SKYJACK Page 25 Function Tests Section 1 Scheduled Maintenance Compact Back View Conventional Back View Free wheeling Valve Platform Raise Lower Switch Platform Raise Lower Switch Platform Off Base Key Switch Emergency Stop Button Emergency Stop Button Test Base Emergency Stop 3 Select and hold off platform base key switch to base position Attempt 1 Pushin 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 low
83. ght Railings Up 1 96 m 2 15 2 24 FULL Overall width Overall length Platform Size inside Drive Height Standard Operating Time Lift Time No Load 50s Lower Time No Load 62s Lift Time Rated Load 59s Lower Time Rated Load 495 Chassis 2 0 mph 3 2 km h 0 56 mph 0 90 km h 1 0 mph 1 6 km h 2596 16x5x 12 Solid Rubber Normal Drive Speed Elevated Drive Speed High Torque Drive Speed Gradeability Tires Hydraulic Oil Type ATF Dexron III 7 93 gal 30 163AC Weight with standard 3 0 9 m or 4 1 2 m extension platform Refer to serial nameplate for specific applications 1 Fill hardness 55 Durometer 5 Series SKYJACK Page 3 Service and Maintenance Section 2 Maintenance Tables and Diagrams 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 OUP 2__ Foot Print Area Base Area 7 8220 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 approve
84. heck continuity Replace if defective 2 Loose or broken wire 02 from base terminal block to down valve 2H 13 or holding valve 2H 13 1 or holding valve 2H 13 2 Check continuity Replace if defective 3 Defective down valve 2H 13 Check continuity through coil Replace if defective 4 Defective lift cylinder holding valve 2H 13 1 or holding valve 2H 13 2 Check continuity through coil Replace if defective 4 1 10 No Down Function from Platform or Base Control Console CE 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 28 2 Check continuity Replace if defective 5 Loose or broken wire 13A from Aux down relay 28 2 to down relay 28CR2 Check continuity Replace if defective 6 Loose or broken wire 13B from down relay 28CR2 to down valve 2H 13B or holding valve 2H 13B 1 or holding valve 2H 13B 2 Check continuity Replace if defective SJIII Conventional Series SKYJACK Page 7 157928 6 Service and Maintenance Section 4 Troubleshooting Information Electrical S
85. heck continuity Replace if defective Loose or broken wire 19B from tilt relay 28CR1 to base terminal block Check continuity Replace if defective Loose or broken wire 198 from base terminal block to motor contactor C1 Check continuity Replace if defective 4 1 6 Down or Reverse Only Function from Platform Controls 1 2 3 4 Loose or broken wire from proportional controller S7 to lift drive switch S3 Check continuity Replace if defective Lift Drive switch S3 defective Check switch Replace if defective Defective PWM card on joystick S7 Check joystick card Replace if defective Loose or broken wire 13 down or 15 reverse from lift drive switch S3 to base terminal block Check continuity Replace if defective 4 1 7 No Up or Forward Only Function from Platform Control Console 1 2 3 4 Loose or broken wire B from proportional controller S7 to lift drive switch S3 Check continuity Replace if defective Lift Drive switch 53 defective Check switch Replace if defective Defective PWM card on joystick S7 Check joystick card Replace if defective Loose or broken wire 14 up or 716 forward from lift drive switch S3 to base terminal block Check continuity Replace if defective 4 1 8 No Up Function from Platform or Base Control Console 1 Loose or broken wire 14 from base terminal block to up valve 3H 14 Check continuity Replace if defective 2
86. ies 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 SJIII Series Section 1 SCHEDULE MAINTENANCE INSPECTIONS Table of Contents Operator s Responsibility for Maintenance E 7 7 ON ES te cT 7 7 7 E REDE IET T M 7 Saag 7 E 8 siea tm 9
87. ing valve V1 CE Check valves Replace if defective 4 2 3 Platform Lifts Slowly 1 Openorleaking manual lowering valve V1 Close valve Replace if defective 2 Liftrelief valve R2 defective Check valve Replace if defective 3 Open manual override on holding valve 2H 13 1 or 2H 13 2 ANSI CSA Depress and turn manual override clockwise to close Replace if defective Open manual override on holding valve 2H 13B 1 or 2H 13B 2 CE Depress and turn manual override clockwise to close Replace if defective 4 2 4 Platform does not Lift 1 Open manual lowering valve V1 Close valve Replace if defective 2 Hydraulic oil level too low Fully lower the platform Fill hydraulic tank until fluid is at or slightly above the top mark on the sight glass 3 Platform weight excessive Reduce platform load to maximum capacity 4 Up valve 14 or 3H 14A Machines with end of stroke limit switch LS3 only defective or is sticking Check valve Replace if defective 4 2 5 Platform will not Lower NOTE Down function is not proportionally controlled ANSI CSA Machines only 1 Lowering valve 2H 13 defective or is sticking Clean valve Replace if defective 2 Defective holding valve 2H 13 1 or 2H 13 2 Clean valve Replace if defective SJIII Conventional Series SKYJACK Page 13 157928 6 Service and Maintenance Section 4 Troubleshooting Information Hydraulic System Continued CE Machines only
88. nal block TB 1 to steer right valve coil 4H 23 Check continuity Replace if defective Defective steer right valve coil 4H 23 Check continuity through coil Replace if defective Loose or broken wire 02 from steer right valve coil 4H 23 to base terminal block TB 1 Check continuity Replace if defective Open diode D23 Check diode Replace if defective 4 1 24 Left Steer Inoperative 1 Loose or broken wire 12B from lift drive switch S3 to left steer switch 57 3 Check continuity Replace if defective 2 Defective left steer switch S7 3 Check switch Replace if defective 3 Loose or broken wire 24 from left steer switch 57 3 to base terminal block TB 1 Check continuity Replace if defective 4 Loose or broken wire 24 from base terminal block TB 1 to steer left valve coil 4H 24 Check continuity Replace if defective 5 Defective steer left valve coil 4H 24 Check continuity through coil Replace if defective 6 Loose or broken wire 202 from steer left valve coil 4H 24 to base terminal block TB 1 Check continuity Replace if defective 7 Open diode 024 Check diode Replace if defective SJIII Conventional Series SKYJACK Page 11 157928 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 1 25 Power Extension Platform will not Extend or Retract 1 2 3 Lift Drive switch S3 not in lift position Move switch to lift position
89. nal block to reverse drive valve coil 4H 15 Check continuity Replace if defective Reverse drive valve coil 4H 15 defective Check continuity through coil Replace if defective Loose or broken wire 02 from reverse drive valve coil 4H 15 to base terminal block Check continuity Replace if defective Open diode D15 Check diode Replace if defective 4 1 21 Brake will not Release 1 2 3 Diode D 16 forward or D 15 reverse is shorted or open Check diode Replace if defective Loose or broken wire 17 from base terminal strip to transfer relay 17CR Check continuity Replace if defective Loose or broken wire 202 from base terminal strip to transfer relay 17CR Check continuity Replace if defective Defective transfer relay 17CR Check relay Replace if defective Open or defective diode D17 Check diode Replace if defective Loose or broken wire 178 from base terminal strip to transfer relay 17CR Check continuity Replace if defective Loose or broken wire 17A from transfer relay 17CR to brake coil 3H 17A Check continuity Replace if defective Brake valve coil 3H 17A defective Check continuity through coil Replace if defective Loose or broken wire 202 from brake valve coil 3H 17A to base terminal block Check continuity Replace if defective 4 1 22 High Low Torque Inoperative 1 Open diode D15 1 reverse or D16 1 forward Check diode Replace if defective 2 Loose
90. no visible damage SKYJACK Page 22 SJIII Series Section 1 Scheduled Maintenance Powered Extension Control Console Manual Storage Box Platform Assembly 1 1 6 Platform Assembly Service and Maintenance Platform Control Console Platform Railing Lanyard Attachment Anchor Platform Control Console Ensure all switches and controller are WARNING returned to neutral and are properly WP Ensure that you maintain three points of contact to mount dismount platform Ensure there are no loose or missing 1 Use the ladder of aerial platform to access platform 2 Close gate Ensure there are no loose or missing parts and there is no visible damage Ensure all fasteners are place Ensure all railings are properly positioned and secured 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 securely in Ensure manuals are legible and in good condition Always return manuals to the manual storage box after use 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 SJIII S
91. not Extend or Retract 1 Platform extend valve 4H 26 or platform retract valve 4H 27 defective or is sticking Clean valve Replace if defective 2 Powered platform cylinder C5 seals defective Rebuild cylinder Replace if damaged 3 Mechanical binding in power extension platform mechanism Check for binding Repair as needed 4 2 14 High Low Torque Inoperative 1 Stuck speed valve 3H 18A 1 Clean valve Replace if defective 2 Stuck speed valve 18 2 Clean valve Replace if defective SJIII Conventional Series SKYJACK Page 15 157928 6 Section 5 PROCEDURES Table of Contents Service and Maintenance E NR INTR NONU 3 ODE Ec RR G2 10 CE TE DENT Dt 3 Platform OEN m om t 3 5 1 2 OEM Gontroler TOU DISS IE ease cna d adim dd bes 4 ZU EP diri te T m T 5 Base 5 2 1 System Relief Pressure edat rinm to ta 6 6 5 2 3 Electronic Tilt Switch Setup I panel REPRE wea 7 Pe c WT n 7 EE m I IM TEE 9 10 SJIII Series SKYJACK Page 1 Section 5 Procedures Service and Maintenance General
92. ns 110 LINE VOLTAGE BC 24VCHARGER LICR CHARGER V CUTOUT RELAY 1 CHARGER B4 Ei B3 6V B2 6V B16V n BATTERY BATTERY BATTERY BATTERY CONTROL BOX BASE S10 24V 2225 ao CONTROL BOX IDLE PLTF BASE 3 PACK EMERGENDY KEY SWITCH PUN DCM1 08 BLUE WHITE A 07 528 o 4 EMERGENCY STOP 5 PUMP MOTOR SWITCH 15A CIRCUIT BREAKER CB2 CB1 7A 07 07 RED 07 07 M 5A 5A 05 03 00 02 7 15 NCHO 7A GREEN 7A BREAKER 02 60 60 RED WHITE 7A 7A 02 eee 9 POWER ON LED S8 LED 1 LED 2 HORN POWER ON LSS 10E 9 7A POWER ON LIGHT SWITCH LIGHT gt 10 ry H1 q 08 A 49 49 GREEN WHITE 49 HORN 49 11 2 13 12 DOWN SOLENOID 13 ORANGE 13 13 13 2H 13 1 HOLDING VALVE DOAI SINGLE CYLINDER oie 14 HOLDING VALVE DO2 2 TWO CYLINDERS 14 BLACK 14 14 14 6 15 UP SOLENOID BCI UP DOWN D28A 19 28A 2 2 BATTERY CHARGE SWITCH 014 Di4 Y 2 2 16 BEEPER X INDICATOR T g 08 02 y 17 0 47 CAPACITOR 14E 19A 02 CRD2 CRD3 4 19 19 19A 1 05 4 1
93. ntenance 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 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 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 ligh
94. o 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 all hydraulic manifolds theunderside 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 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 SJIII Series Section 1 Scheduled Maintenance Service and Maintenance Compact Ladder Conventional Back View 110V Outlet Receptacle
95. odels 3220 4620 4626 PIN 4 BLACK PIN 8 02 WHITE TO TERMINAL BLOCK N TO TILT SWITCH No Z TO ENGINE X TO BATTERY NY UO TOMAN MANIFOLD 0 TO HIGH SPEED LIMIT SWITCH ROS ep TO REAR MANIFOLD 111 TO POWER DECK a y E PIN 1 71 BLACK WHITE 5 0 O TO END OF STROKE 02 prr 2 21 ORANGEIBLACK PIN6 NIU 280 5 PN3 18 REDBLACK PIN7 19 BLUE SEES 511926074 18 REB AC PIN 8 11 NHITEIBLACK 5 ATEORW 18A 18A 18 CN TO REAR MANIFOLD 21B GREEN BLACK 18A 18A RED BLACK TO HIGH SPEED LIMIT 02 WHITE TO POTHOLE LIMIT 0 FROM MANDISCONNECT AT MOTOR
96. on the platform and all other warnings in this manual and on the aerial platform Compare the labels on the aerial platform with the labels found within this manual If any labels are damaged or missing replace them immediately 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 extensions 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 non standard components or systems contact the SKYJACK Service Department at North America amp Asia Europe 2 800 275 9522 2 44 1691 676 235 630 262 0006 44 1691 676 239 Include the model and serial number for each applicable aerial platform SJIII Series SKYJACK Page 7 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance Scope of this Manual This manual applies to the ANSI SIA CSA and CE versions of the Series aerial platform models listed on Table 2 1 Equipm
97. onent 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 SJIII Series SKYJACK Page 15 Service and Maintenance Section 1 Scheduled Maintenance Table 1 1 Owner s Annual Inspection Record Model Number Serial Number Recording Date Recording Owner s Name Inspected By 60564AA As described earlier in this section this decal is located on the control compartment cowling It must be completed after an annual inspection has been completed Do not use the aerial platform if an inspection has not been recorded in the last 13 months SKYJACK Page 16 SJIII Series Section 1 Scheduled Maintenance Service and Maintenance SIKY2 CKK Table 1 2 MAINTENANCE AND INSPECTION CHECKLIST Serial Number Model Hourmeter Reading Name Printed Date Time 222222 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 A B F FAIL ANNUALLY A B C R REPAIRED L BI ANNUALLY A B C D Schedule p F R R Schedule Maintenance Inspections Platform Assembly bes Lanyard attachment Anchors 5 ae ACOutietonPlattorm
98. or broken wire 7 from diodes D15 1 and D16 1 to lift drive switch S3 Check continuity Replace if defective SKYJACK Page 10 SJIII Conventional Series 157928 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 3 4 9 Defective lift drive switch S3 Check switch Replace if defective Loose or broken wire 18 from lift drive switch S3 to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 218 from base terminal block TB 1 to high speed limit switch LS1 B Check continuity Replace if defective Defective high speed limit switch LS1 B Check switch Replace if defective Loose or broken wire 18A from high speed limit switch LS1 B to rear drive manifold Check continuity Replace if defective Defective speed valve coil 3H 18A 1 or 18 2 Check continuity through coil Replace if defective Loose or broken wire 02 from rear drive manifold to base terminal block TB 1 Check continuity Replace if defective 4 1 23 Right Steer Inoperative 1 2 3 Loose or broken wire 12 from lift drive switch 53 to right steer switch 57 2 Check continuity Replace if defective Defective right steer switch 57 2 Check switch Replace if defective Loose or broken wire 23 from right steer switch S7 2 to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 23 from base termi
99. peed at the end of handle travel SJIII Series SKYJACK Page 3 Service and Maintenance Section 5 Procedures 5 1 2 Controller Troubleshooting Problem 1 The function will not operate when the handle is 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 regardless of the degree of handle deflection A Perform Maxout adjustment procedures SKYJACK Page 4 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 Integra
100. s Table 2 3 Maximum Platform Capacities Evenly Distributed Manual Extension Platform Powered Extension Platform Maximum Tilt Wind Cutout Speed Setting Total Capacity Extension Capacity 600 Ib 250 Ib 28 mph 2 Persons 1 Person 1 5x3 5 272 kg 113 kg 12 5 m s 550 Ib 250 Ib 28 mph 2 Persons 1 Person 1 5x3 5 249 kg 113 kg 12 5 m s 900 Ib 300 Ib 800 Ib 300 Ib 28 mph 2 Persons 1 Person 2 Persons 1 Person 1 5x3 5 408 kg 136 kg 363 kg 136 kg 12 5 m s 500 Ib 250 Ib 28 mph 2 Persons 1 Person N A 1 5x3 5 227 kg 113 kg 12 5 m s 1300 Ib 300 Ib 1300 Ib 300 Ib 28 mph 3 Persons 1 Person 3 Persons 1 Person 2 5x4 5 590 kg 136 kg 590 kg 136 kg 12 5 m s 1000 Ib 300 Ib 1000 Ib 300 Ib 28 mph 3 Persons 1 Person 3 Persons 1 Person 2 5 4 5 454 136 454 136 12 5 m s 700 Ib 250 Ib 28 mph 2 Persons 1 Person N A 2 5x4 5 318 kg 113 kg 12 5 m s 165AB Total Capacity Capacity NOTE Overall Capacity Occupants and materials not to exceed rated load SKYJACK Page 6 SJIII Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 4 Torque Specifications Cartridge Torge 08 38 58 Lbf ft max 2 240 2 0 40 420 33 90 SAE Plugs Lbf ft max Newton meter Nm Pound force foot Ibf ft Pound force inch Ibf in 60056AD SJIII Series SKYJACK Page 7 Section
101. s SKYJACK Page 25 3 19 Horn Tilt Switch Flashing Light Diagram 22222 _ zu MEN E PIN2 26 PINS O2 WHITE jj MEE 1 1 a T MEE MEO d E i TSi TILT SWITCH ANSICSA De Q0 L2 FLASHING LIGHT i i i i i i 1 S Dd 1 02 WHITE 22 GREEN i i i 3 SKYJACK Page 26 Print View This Page Parts List BLACK 22 WHITE 02 puts BLACK 22 WHITE 02 DUAL FLASHING LIGHT HARNESS 7 J BLACK 22 NS rn WHITE 02 ANSI FEM TERM WHITE 02 RING TERM HORN FLASHING LIGHT HARNESS FROM ELEC PANEL M146648AA S3B SJIII Conventional Series 157928 Print View This Page Parts List 3 20 Electrical Schematic Equipped with no optio
102. s 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 fully lowered ascending or descending only grades up to rated maximum listed in Tables 2 3 are permissible SKYJACK Page 10 ij SJIII Series Section 1 Scheduled Maintenance Operator s Responsibility for Maintenance Safety Precautions Continued Know and understand the safety precautions before going on to next section DO NOT operate on surfaces not capable of holding the weight of the aerial platform DO NOT raise the aerial platform including the rated load e g covers drains and while the aerial platform is on a trenches truck fork lift or other device or vehicle DO NOT operate an aerial 7 4 platform that has ladders scaffolding or other devices mounted on it to increase its size BE AWARE
103. s list continued on the following page 9 128537 122093 103057 146475 110699 117325 117325 129258 119758 119520 119624 147664 123477 102921 310517 121477 103743 146649 147061 147061 121975 121975 122014 125887 126051 125885 126060 121975 119629 146644 116505 SKYJACK Page 10 Service and Maintenance gt JJ 2 JJ Section 3 System Component Identification Schematics 3 5 Electrical Component Parts List Skyjack O aae on o a Parts list continued from the following page CHARGER 24VDC Battery superior universal BATTERY CHARGE INDICATOR BEEPER 24 VDC CONTACTOR Motor 24 Volt CAPACITOR 47UF 50 Volts BREAKER Circuit 15 Amp BREAKER Circuit 15 Amp DIODE ALARM OPTION DIODE PACK DIODE ASSEMBLY DIODE ASSEMBLY MOTOR 24 VDC MOTOR 24 VDC EE rated DIODE FUSE 300 Amp in line fuse FLASHING LIGHT 24VDC Option FLASHER Option HORN Operator Low tone POWER INDICATOR LIGHT Platform control console POWER INDICATOR LIGHT Base control console LIMIT SWITCH High speed LIMIT SWITCH High speed LIMIT SWITCH End of stroke option LIMIT SWITCH Pothole protection Battery tray LIMIT SWITCH Pothole protection Battery tray EE rated LIMIT SWITCH Pothole protection Hydraulic tray LIMIT SWITCH Pothole prot
104. sors using the maintenance bar Refer to Operating manual for Maintenance Support Procedure 4 Pushin emergency stop buttons and turn main disconnect switch to W off position 5 Remove any covers to locate and view the tilt switch 6 Disconnect tilt switch from 4 pin connector 7 Remove old tilt switch from mount NOTE Ensure part number of old and new tilt switch are the same 8 Install new switch to mount in the same orientation as the old switch and connect switch plug to 4 pin connector NOTE The tilt circuit is only powered when activating a function Service and Maintenance BEEN OS ___________________________________ Disconnect all wires 02 from motor contactor Install jumper wire between 77 and 719 to terminal strip Turn main disconnect switch to ON position Verify switch is powered Red or green LED will be continually blinking Red LED O Green LED i Program the Tilt Switch Press and release the set up button 3 a times Observe program delay stabilization time Only the red LED will blink for 4 seconds Red LED Green LED 57 Red LED Green LED Both LEDs will flash for 1 second Results The switch is learning the new zero position Both LEDs will turn on solid for 1 second Results The new zero position h
105. specifications and dimensions are subject to change without notice Aerial Platform Definition A mobile device that has an adjustable position platform supported from ground level by a structure Purpose of Equipment The SKYJACK Compact and Conventional series aerial platforms are designed to transport and raise person nel 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 It can be driven over uneven terrain only when the platform is fully lowered 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 Operator The operator must read and completely understand both this operating manual and the safety panel label located
106. ssing 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 owing up maintenance support into storage bracket Fully lower the platform SKYJACK Page 24 SJIII Series Section 1 Scheduled Maintenance Function Tests Conventional Back View Compact Back View Free wheeling Valve Lower Neutral Raise Switch 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
107. t lt 178 17C 32 12 77 23 23 BLACK WHITE 23 4H 23 33 RIGHT SOLENOID S7 2 D23 DO2 5 C RIGHT a t sz 28 17B 17 34 BRAKE SOLENOID D24 24 24 BLUE BLACK 24 4H 24 9 35 LEFT SOLENOID DO2 6 M146647AC1 SJIII Conventional Series SKYJACK Page 27 157928 Print View This Page Parts List 3 21 Electrical Schematic Equipped with all options 110 VAC LINE VOLTAGE CONTROL BOX BASE 24V CHARGER EXTEND EXTEND SOLENOID RETRACT 2 2 L1CR SWITCH CHARGER 4H 26 ExT 126 CUTOUT RELAY A 1 CHARGER 571 12 4 27 Y B4 Fi B3 6V B2 6V B16V 2 RETRACT SOLENOID 21B 21B GREEN BLACK 21B 300A BATTERY BATTERY BATTERY D26 D27 24V s BATTERY 3 PACK S1 MAIN
108. ted 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 SJIII Series Section 5 Procedures Service and Maintenance 5 1 3 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 STEER RIGHT WHT STEER LEFT STEER
109. ted 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 relative 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 SJIII Series SKYJACK Page 13 Operator s Responsibility for Maintenance Section 1 Scheduled 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 hy
110. teer relay to diodes D17C and D17C 1 Check continuity Replace if defective Open or defective diode D17C or diode D17C 1 Check diode Replace if defective 4 1 14 Drive Only Inoperative 1 Open or defective diode D17 1 Check diode Replace if defective 4 1 15 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 switch LS6 Check switch Replace if defective 3 Loose or broken wire 19 from drive override limit switch 156 to base terminal block Check continuity Replace if defective SKYJACK Page 8 SJIII Conventional Series 157928 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 16 No Drive or Steer when Platform Elevated 1 2 3 Pothole protection bars not fully lowered Clear obstructions Repair as needed Loose or broken wire 71 from base terminal block to pothole protection limit switch LS4 Check continuity Replace if defective Defective pothole protection limit switch LS4 Check switch Replace if defective Loose or broken wire 72 from pothole protection limit switch LS4 to base terminal block Check continuity Replace if defective Loose or broken wire 72 from base terminal block to pothole protection limit switch LS5 Check continuity Replace if defective
111. tform Common sense dictates the use of protective clothing when working on or near machinery Use appropriate safety devices to protect your eyes ears hands feet and body Any modifications from the original design are strictly forbidden without written permission from SKYJACK Inc Electrocution Hazard This aerial platform is not electrically insulated Maintain a Minimum Safe Approach Distance MSAD from energized power lines and parts as listed below The operator must allow for the platform to sway rock or sag This aerial platform does not provide protection from contact with or proximity to an electrically charged conductor DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS Avoid Power Lines Minimum Safe Approach Distance ANSI SIA A92 6 2006 CE Guidance Note and CSA B354 2 01 Requirements Avoidance of danger from overhead lines Voltage Range Minimum Safe Approach Distance Phase to Phase Feet Avoid Contact Adhere strictly to governmental rulings and regulations applicable in your country 45 FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY 60023AD SJIII Series SKYJACK Page 9 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance WARNING Safety Precautions Know and understand the safety precautions before going on to next section Failure to
112. 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 SKYJACK Page 14 SJIII Series 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 per
113. 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 devices 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 SKYJACK Page 12 SJIII Series Section 1 Scheduled Maintenance Operator s Responsibility for Maintenance Maintenance and Inspection Schedule The actual operating environment of the work platform governs the use of the mai
114. ting 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 important 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 s
115. voir 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 assure proper reassembly Clean all metal parts in a clean mineral oil solvent Be sure to thoroughly clean all internal passages After the parts have been dried thoroughly lay them on a clean lint free surface for inspection 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
116. ystem Continued 7 8 9 Defective down valve 2H 13B Check continuity through coil Replace if defective Defective lift cylinder holding valve 2H 13B 1 or holding valve 2H 13B 2 Check continuity through coil Replace if defective Loose or broken wire 02 from holding valve 2H 13B 1 or holding valve 2H 13B 2 or down valve 2H 13B to base terminal block Check continuity Replace if defective 4 1 11 No Up Function from Base Control Console 1 2 3 4 Defective up down switch 52 Check switch Replace if defective Loose or broken wire 14 from up down switch S2 to base terminal switch Check continuity Replace if defective Open diode D14E 1 Check diode Replace if defective Open diode D14E ANSI CSA or diode D14E 2 CE Check diode Replace if defective 4 1 12 No Down Function from Base Control Console 1 2 Defective up down switch S2 Check switch Replace if defective Loose or broken wire 13 from up down switch S2 to base terminal block Check continuity Replace if defective 4 1 13 Steer Only Inoperative 1 2 3 4 5 Defective relay 17 Check relay Replace if defective Loose or broken wire 178 from diodes 023 and 024 to base terminal block TB1 Check continuity Replace if defective Loose or broken wire 17 from 17 steer relay to base terminal block TB1 Check continuity Replace if defective Loose or broken wire 17 from 17CR s

Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents