SJIII Compact Series Service Manual Models 3215 & 3219 Skyjack Head Office 55 Campbell Rd. Guelph, Ontario N1H 1B9 Phone: 519-837-0888 Toll Free: 1-800-265-2738 Fax: 519-837-8104 Email: skyjack@skyjack.com www.skyjack.com Part No.
USE THE SERIAL NUMBER OF YOUR MACHINE TO DETERMINE THE CORRECT OPERATING MANUAL TO USE Manual Part # Release Date MODELS 117129AH 118941AI 143909AA April 2008 August 2004 April 2007 3015 151981 & Below Not Used 3215 Not Used 151982 to 154002 10 000 001 to 10 000 329 10 000 330 & Above 3219 236285 & Below 236286 to 268399 22 000 001 & 22 013 837 22 013 838 & Above Not Used 113AA Skyjack Service Center 3451 Swenson Ave. St.
SERVICE AND MAINTENANCE Table of Contents Section 1 - Scheduled Maintenance Inspections Table of Contents Section 2 - Maintenance Tables Table of Content Section 3 - Schematics List of Contents Section 4 - Troubleshooting Troubleshooting Section 5 - Procedures List of Procedures List of Tables SJIII Series SKYJACK, Page 3
Operator’s Responsibility for Maintenance Section 1 - Scheduled Maintenance The Safety Alert Symbol identifies important safety messages on aerial platforms, safety signs in manuals or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message. This Safety Alert Symbol means attention! Become alert! Your safety is involved.
1 Section 1 schedule maintenance inspections Table of Contents Operator’s Responsibility for Maintenance Aerial Platform Definition...............................................................................................................................................7 Purpose of Equipment..................................................................................................................................................7 Use of Equipment...................................................
Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications and dimensions are subject to change without notice. Aerial Platform Definition A mobile device that has an adjustable position platform supported from ground level by a structure.
Operator’s Responsibility for Maintenance Section 1 - Scheduled Maintenance Scope of this Manual a. This manual applies to the ANSI/SIA, CSA and CE versions of the SJIII Series aerial platform models listed on Table 2.1. - Equipment 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.
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.
Operator’s Responsibility for Maintenance Section 1 - Scheduled Maintenance Safety Precautions Know and understand the safety precautions before going on to next section. warning Failure to heed the following safety precautions could result in tip over, falling, crushing, or other hazards leading to death or serious injury. • KNOW all national, state or territorial/provincial and local rules which apply to your aerial platform and jobsite.
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 including the rated load, e.g. covers, drains, and trenches. • DO NOT operate an aerial platform that has ladders, scaffolding or other devices mounted on it to increase its size or work height. It is prohibited.
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 capacity of the aerial platform. Do make sure the load is evenly distributed on the platform. WARNING Entering and exiting the aerial platform should only be done using the three points of contact.
Section 1 - Scheduled Maintenance Maintenance and Inspection Schedule The actual operating environment of the work platform governs the use of the maintenance schedule. The inspection points covered in Table 1.2. Maintenance and lnspection 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.
Operator’s Responsibility for Maintenance Hydraulic System & Component Maintenance and Repair Section 1 - Scheduled Maintenance 7. 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.
Section 1 - Scheduled Maintenance About this Section This section contains the maintenance and inspection schedule that is to be performed. Service and Maintenance Maintenance Instructions This manual consists of four schedules to be done for maintaining on an aerial platform. Inspection schedule frequency is shown below: References are made to the procedures in Section 5 that outline detailed step-by-step instructions for checks and replacements.
Service and Maintenance Section 1 - Scheduled Maintenance Table 1.1 Owner’s Annual Inspection Record Model Number: ____________________________ Recording Date Recording Year # Owner’s Name Inspected By 1 2 Serial Number: ____________________________ 3 4 5 6 7 8 9 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.
Section 1 - Scheduled Maintenance Service and Maintenance Table 1.2 MAINTENANCE AND INSPECTION CHECKLIST Serial Number: Model: Hourmeter Reading: Operator's Name (Printed): Date: Time: Operator's 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.
Service and Maintenance Section 1 - Scheduled Maintenance High Speed Limit Switch High Speed Limit Switch Pothole Protection Limit Switch CONVENTIONALS 1.1 Scheduled Maintenance Inspections Begin the scheduled maintenance inspections by checking each item in sequence for the conditions listed in this section. WARNING To avoid injury, do not operate an aerial platform until all malfunctions have been corrected.
Section 1 - Scheduled Maintenance Service and Maintenance Compact Conventional (Back View) Ladder 110V Outlet Receptacle Free-wheeling Valve Brakes Ladder Base Control Console Emergency Main Power Disconnect Switch 110V Outlet Receptacle Free-wheeling Valve Compact (Back View) Brakes 1.1-3 Entrance Side • Main Power Disconnect Switch -- Turn emergency main power disconnect switch to “ ” off position.
Service and Maintenance Section 1 - Scheduled Maintenance Conventional Compact Battery Charger Battery Charger Battery Tray Battery Fuse Box Battery Hydraulic/Electric Pothole Protection Device Tray 1.1-4 Battery Tray Side Battery Tray WARNING Battery acid is extremely corrosive - Wear proper eye and facial protection as well as appropriate protective clothing. If contact occurs, immediately flush with cold water and seek medical attention.
Section 1 - Scheduled Maintenance Service and Maintenance Conventional Wheel/Tire Steer Cylinder Wheel/Tire Greasing Point Wheel Motor Tie Rod • Steer Cylinder Assembly -- Ensure steer cylinder assembly is properly secured and there are no loose or missing parts. • Tie Rod (Conventionals) -- Ensure there are no loose or missing parts, tie rod end studs are locked and there is no visible damage.
Service and Maintenance Compact Section 1 - Scheduled Maintenance Tilt Sensor Emergency Lowering Access Rod Greasing Point Electrical Panel Hydraulic/Electric Tray Main Manifold Greasing Point Hydraulic Tank 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. • -- Ensure there are no loose wires or missing fasteners.
Section 1 - Scheduled Maintenance Service and Maintenance Platform Control Console Platform Railing Manual Storage Box Lanyard Attachment Anchor Platform Assembly 1.1-6 Platform Assembly • WARNING Ensure that you maintain three points of contact to mount/dismount platform. 1. Use the ladder of aerial platform to access platform. 2. Close the gate. -- Ensure there are no loose or missing parts and there is no visible damage. -- Ensure all fasteners are securely in place.
Service and Maintenance Section 1 - Scheduled Maintenance Maintenance Support Lift Cylinder Scissor Bumper Scissor Assembly Roller • Powered Extension Control Console (If Equipped) -- Ensure all switches are returned to neutral and are properly secured. -- Ensure there are no loose or missing • Scissor Bumpers -- Ensure bumpers are secure and shows no sign of visible damage. • Rollers -- Ensure rollers are secure and there is no visible damage. parts and there is no visible damage.
Section 1 - Scheduled Maintenance Function Tests Conventional (Back View) Compact (Back View) Free-wheeling Valve Lower/ Neutral/Raise Switch Lower/ Neutral/Raise Switch Emergency Stop Button 1.2 Function Tests Platform/Off/Base Key Switch Emergency Stop Button 1.2-2 Base Control Console 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.
Function Tests Section 1 - Scheduled Maintenance Conventional (Back View) Compact (Back View) Free-wheeling Valve Platform Raise/Lower Switch Platform Raise/Lower Switch Emergency Stop Button • Platform/Off/Base Key Switch Test Base Emergency Stop 3. Select and hold off/platform/base key switch to “ ” base position. Attempt to raise or lower the platform. Result: Platform raising and lowering functions should operate. 1. Push in “ ” emergency stop button and attempt to raise or lower the platform.
Section 1 - Scheduled Maintenance Function Tests Conventional (Back View) Compact (Back View) Free-wheeling Valve Lower/ Neutral/Raise Switch Emergency Stop Button • Test Emergency Lowering Lower/ Neutral/Raise Switch Platform/Off/Base Key Switch • Emergency Stop Button Test Free-wheeling 1. Raise the platform. 1. Ensure path of intended motion is clear. 2. Locate holding valve manual override knob at the base of each lift cylinder. Depress and turn counterclockwise.
Function Tests Section 1 - Scheduled Maintenance Rocker Switch Lift/Drive/Steer Enable Trigger Switch Controller Emergency Stop Button/ Operation Light Lift/Inclined Drive/Level Drive Switch Horn Pushbutton 1.2-3 Platform Control Console • ” emergency stop button is 1. Ensure base “ pulled out. 2. Select off/platform/base key switch to “ platform position. 3. Ensure main power disconnect switch is in “ ” on position.
Section 1 - Scheduled Maintenance Function Tests Rocker Switch Lift/Drive/Steer Enable Trigger Switch Controller Emergency Stop Button/ Operation Light Lift/Inclined Drive/Level Drive Switch Horn Pushbutton • Test Driving 1. Ensure path of intended motion is clear. 1. Ensure path of intended motion is clear. 2. Activate and hold “ switch. ”enable trigger 3. Slowly move controller handle in “ ” forward direction until aerial platform begins to move, and then return handle to center position.
Function Tests Section 1 - Scheduled Maintenance Conventional Compact Pothole Protection Device Pothole Protection Device • CONVENTIONALS Test Platform Raising/Lowering • 1. Raise the platform until approximately a height of 3 to 4 meters is reached then attempt to fully lower the platform. Result: Platform should stop lowering at a height of 2.5 meters high and an alarm should sound. WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting. 1.
Section 1 - Scheduled Maintenance Function Tests Conventional Compact Pothole Protection Device Pothole Protection Device • CONVENTIONALS Test Pothole Sensor WARNING Ensure that you maintain three points of contact to mount/dismount platform. 1. Use the ladder to dismount from platform and place a block, approximately 1.5” (3.75 cm), under the hydraulic/electric tray. 2. Use the ladder of aerial platform to access platform.
Service and Maintenance Section 1 - Scheduled Maintenance Platform Control Console Platform Railing Manual Storage Box Platform Assembly • Test Tilt Sensor (If Equipped) 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. Move the aerial platform on to a slope not greater than 4.5°. 2. Use the ladder to dismount from platform. 3.
Section 2 maintenance tables and diagrams Table of Contents Tables 2.1a Specifications and Features (ANSI/CSA)...........................................................................................................2 2.1b Specifications and Features (CE)......................................................................................................................4 2.1c Specifications and Features (AS)..................................................................................................
Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.1a Specifications and Features (ANSI/CSA) MODEL Weight * 3215 3219 3220 3226 2400 lb. 2580 lb. 3400 lb. 4180 lb. 1089 kg 1170 kg 1542 kg 1896 kg Width Length Platform Size 32" 32" 0.81 m 0.81 m 70.0” 91" 1.78 m 2.3 m 26” x 64” 28” x 83” 0.66 m x 1.63 m 0.71 x 2.1 m Height Working Height Platform Elevated Height Stowed Platform Height Stowed Height Railings Up 21’ 25’ 26’ 32’ 6.4 m 7.6 m 8.1 m 9.
Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.1a Specifications and Features (ANSI/CSA) (Continued) MODEL Weight * 4620 4626 4632 6826 6832 4100 lb. 4700 lb. 5075 lb. 5380 lb. 5680 lb. 1860 kg 2132 kg 2302 kg 2440 kg 2576 kg Width Length Platform Size 46" 68" 1.17 m 1.73 m 91" 99.5" 2.31 m 2.52 m 42" x 84" 57" x 84" 1.07 m x 2.13 m 1.45 m x 2.
Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.1b Specifications and Features (CE) MODEL Weight * 3215 3219 3220 3226 1090 kg 1170 kg 1542 kg 1896 kg Width 0.81 m 0.81 m Length 1.78 m 2.3 m 0.66 x 1.63 m 0.71 x 2.1 m Platform Size Height Working Height 6.4 m 7.6 m 8.1 m 9.9 m Platform Elevated Height 4.6 m 5.8 m 6.1 m 7.9 m Stowed Platform Height 0.88 m 0.99 m 0.97 m 1.1 m Stowed Height Railings Up 1.88 m 1.99 m 2.1 m 2.
Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.1b Specifications and Features (CE) (Continued) MODEL Weight † 4620 4626 4632 6826 6832 1860 kg 2130 kg 2300 kg 2440 kg 2700 kg Width 1.17 m 1.73 m Length 2.31 m 2.52 m 1.07 x 2.11 m 1.53 x 2.05 m Platform Size Height Working Height 7.92 m 9.75 m 11.6 m 9.75 m 11.6 m Platform Elevated Height 6.1 m 7.9 m 9.7 m 7.9 m 9.7 m Stowed Platform Height 0.97 m 1.14 m 1.23 m 1.27 m 1.
Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.1c Specifications and Features (AS) MODEL Weight * 3215 3219 3220 3226 1090 kg 1170 kg 1583 kg 1864 kg Width 0.81 m 0.84 m Length 1.78 m 2.32 m 0.66 x 1.57 m 0.71 x 2.13 m Platform Size Height Stowed Platform Height 0.88 m 0.99 m 0.97 m 1.15 m Platform Elevated Height 4.6 m 5.8 m 6.1 m 7.9 m Working Height 6.4 m 7.6 m 7.92 m 9.75 m Stowed Height Railings Up 1.88 m 1.99 m 2.02 m 2.
Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.1c Specifications and Features (AS) (Continued) MODEL Weight † 4620 4626 4632 6826 6832 1860 kg 2130 kg 2300 kg 2440 kg 2700 kg Width 1.17 m 1.73 m Length 2.31 m 2.52 m 1.07 x 2.11 m 1.53 x 2.05 m Platform Size Height Working 7.92 m 9.75 m 11.6 m 9.75 m 11.6 m Platform Elevated 6.1 m 7.9 m 9.7 m 7.9 m 9.7 m Fixed Railing 1.96 m 2.15 m 2.24 m 2.37 m 2.51 m Platform Lowered 0.97 m 1.14 m 1.
Service and Maintenance Section 2 - Maintenance Tables and Diagrams Floor Loading Pressure Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP): Foot Print Area = Tread Contact Area Base Area = Length x Width LCP = Aerial Platform Weight + Capacity OUP = Foot Print Area x 4 (Tires) Width Aerial Platform Weight + Capacity Base Area Width Length Length WARNING Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can a
Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.2a Floor Loading Pressure (ANSI/CSA) MODEL 3215 3219 3220 3226 4620 4626 4632 6826 6832 Total Aerial Platform Load Total Aerial Platform Weight Wheel LCP** OUP** lb. kg lb. kg psi KPa (kN/m2) psf KPa (kN/m2) min* 2400 1089 960 435 100 689.48 160 7.66 max* 3000 1361 1200 544 110 758.42 200 9.58 min* 2580 1170 1032 468 100 689.48 170 8.14 max* 3130 1420 1252 568 110 758.42 210 10.
Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.2b Floor Loading Pressure (CE) Total Aerial Platform Weight MODEL 3215 3219 3220 3226 4620 4626 4632 6826 6832 Total Aerial Platform Load Wheel LCP** OUP** 2 kg kg KPa (kN/m ) KPa (kN/m2) min* 1089 435 689.5 7.5 max* 1361 544 758.5 9.5 min* 1170 468 689.5 8.0 max* 1420 568 758.5 10.0 min* 1542 616 758.5 8.5 max* 1950 780 896.5 11.5 min* 1896 746 827.5 10.0 max* 2091 836 896.5 11.
Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.2c Floor Loading Pressure (AS) MODEL 3215 3219 3220 3226 4620 4626 4632 6826 6832 Total Aerial Platform Load Total Aerial Platform Weight Wheel LCP** OUP** kg lb. kg lb. KPa (kN/m2) psi KPa (kN/m2) psf min* 1089 2400 435 960 689.48 100 7.66 160 max* 1361 3000 544 1200 758.42 110 9.58 200 min* 1170 2580 468 1032 689.48 100 8.14 170 max* 1420 3130 568 1252 758.42 110 10.
Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.3a Maximum Platform Capacities (Evenly Distributed) (ANSI/CSA) Manual Extension Platform MODEL Total Capacity 600 lb. 3215 272 kg 550 lb. 3219 249 kg 900 lb. 3220 408 kg 500 lb. 3226 227 kg 1300 lb. 4620 590 kg 1000 lb. 4626 454 kg 700 lb. 4632 318 kg 1200 lb. 6826 544 kg 850 lb. 6832 386 kg 2 Persons 2 Persons 2 Persons 2 Persons 3 Persons 3 Persons 2 Persons 3 Persons 3 Persons Extension Capacity 250 lb.
Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.3b Maximum Platform Capacities (Evenly Distributed) (CE) MODEL Manual Extension Platform Total Capacity Maximum Wind Extension Capacity Speed Powered Extension Platform Extension Capacity Total Capacity Tilt Cutout Setting 3215 227 kg 2 Persons 113 kg 1 Person N/A No Wind 1.5 x 3.5 3219 227 kg 2 Persons 113 kg 1 Person N/A No Wind 1.5 x 3.5 No Wind 1.5 x 3.5 No Wind 1.5 x 3.
Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.3c Maximum Platform Capacities (Evenly Distributed) (AS) Max. Side Force (N) Max. Wind (m/s) 400 0 227 kg 2 Persons 113 kg 200 12.5 227 kg 1 Person 227 kg 400 0 249 kg 2 Persons 113 kg 200 12.5 120 kg 1 Person 120 kg 400 0 408 kg 2 Persons 136 kg 200 12.5 227 kg 1 Person 227 kg 400 0 227 kg 2 Persons 113 kg 200 12.5 120 kg 1 Person 120 kg 4620 400 12.
Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.4 Torque Specifications Directional valve mounting bolts Wheel mounting bolts Wheel motor castle nut Parking brake cylinder rod nut 28-32 lbf.in 70 lbf.ft 200 lbf.ft 35 lbf.ft 2.16 – 3.61 Nm 94.92 Nm 271.20 Nm 47.46 Nm Cartridge Size Torque Lbf.ft (max) Lbf.in (max) Nm (max) 08 20 240 27.12 38 20 240 27.12 58 20 240 27.12 10 25 300 33.90 12 35 420 47.46 16 50 600 67.80 Coils Size All coils 4 to 5 48 to 60 5.42 to 6.
Section 3 System component idenification and schematics Table of Contents Charts 3.1 Electrical Symbol Chart...................................................................................................................................3 3.2 Hydraulic Symbol Chart...................................................................................................................................4 3.3 Wire Number and Color Code.................................................................................
Service and Maintenance Section 3 - System Component Identification and Schematics 3.
Section 3 - System Component Identification and Schematics Service and Maintenance 3.
Service and Maintenance Section 3 - System Component Identification and Schematics 3.3 Wire Number and Color Code WIRE NO. WIRE COLOR WIRE NO. WIRE COLOR WIRE NO. 00 WHT 20 ORG/BLU 44 YEL/WHT 67 000 WHT 21 WHT/RED 45 YEL/ORG B1 BLU/PINK 23 BLK/WHT 46 01 PUR/BLK 24 BLU/BLK 02 WHT 25 03 GRN/PUR 04 05 WIRE NO.
Section 3 - System Component Identification and Schematics Service and Maintenance 3.
Service and Maintenance Section 3 - System Component Identification and Schematics 3.5 Hydraulic Schematic Parts List Index No. Skyjack Part No. Qty.
3.6 Electrical Component Parts List SUPPLY (B+) (Common) CONTROL (B+) GROUND (B-) NORMALLY CLOSED CONTACT Index No. Skyjack Part No. Qty.
Service and Maintenance Section 3 - System Component Identification and Schematics 3.6 Electrical Component Parts List Index No. Skyjack Part No. Qty. Description Parts list continued on the following page.
Section 3 - System Component Identification and Schematics Service and Maintenance 3.6 Electrical Component Parts List (Continued) Index No. Skyjack Part No. Qty. Description Parts list continued on the following page. S4 S7 S7-1 S7-2 S7-3 S7-6 S8 S10 S28 TS1 TT N.C. CONTACT (Emergency stop) (Platform control console) CONTROLLER ASSEMBLY, Proportional SWITCH, Neutral SWITCH, Right steer SWITCH, Left steer SWITCH, Enable pushbutton N.O. CONTACT (Operator’s horn) N.C.
Service and Maintenance Section 3 - System Component Identification and Schematics 3.
Section 3 - System Component Identification and Schematics Service and Maintenance 3.8 Base Control Console Diagram S2 - UP SWITCH N.O. CONTACT PIN 3 - 10E BLUE/BLACK (X2) PIN 4 - 14E BLACK S2 - DOWN SWITCH N.O. CONTACT PIN 3 - 10E BLUE/BLACK PIN 4 - 13 ORANGE S10 - BASE SW N.O. CONTACT PIN 3 - 10E BLUE/BLACK (X2) PIN 4 - 7A GREEN (X2) S10 - IDLE SW N.C. CONTACT PIN 1 - 5A PURPLE/WHITE PIN 2 - 07 RED TO CHARGER CUTOUT PIN 1 - 3A BLUE PIN 2 - 05 ORANGE/BLACK S10 - PLTF SW N.C.
Service and Maintenance Section 3 - System Component Identification and Schematics 3.9 Scissor Arm Control Cable CONTROL CABLE OPTIONS WIRE COLOUR GREEN/BLACK RED/WHITE EUROPE WIRE NUMBER 21B 60 N.
Section 3 - System Component Identification and Schematics Service and Maintenance 3.10 Electrical Inverter Option: Schematic & Panel Diagram (ANSI/CSA - Equipped with timer cutout relay) Electrical Schematic 110 VAC LINE VOLTAGE 24V CHARGER BC L1CR CHARGER CUTOUT RELAY B4 6V BATTERY 8C GREEN 7A RED/WHITE 07 S28 EMERGENCY STOP SWITCH 5A 5A C1 MOTOR CONTACTOR 3 4 DCM1 3A CB2 03 00 85 TIMER 7A LED-2 POWER ON LIGHT 7A CB1 02 02 02 7A 19A H1 HORN 49 22 DECELERATION LIMIT SWITCH N.
A B C 3.11 Hydraulic Schematic - Model 3215 D E M1 RIGHT DRIVE MOTOR C3 STEER CYLINDER MB2 FRONT AXLE MANIFOLD BLOCK V2 FREE-WHEELING VALVE PORT PLUGGED 2H-59 PRESSURECOMPENSATED PROPORTIONAL VALVE 3H-17 BRAKE VALVE R1 SYSTEM RELIEF VALVE HYDRAULIC QUICK DISCONNECT F1 RETURN FILTER M P1 PUMP L PT1 PRESSURE OVERLOAD TRANSDUCER OPTION OPTIONAL PRESSURE SWITCH R O5 STEERING ORIFICE .040 DIA. G O5 STEERING ORIFICE .040 DIA.
A B C 3.12 Hydraulic Schematic - Model 3219 D E F G PT1 PRESSURE OVERLOAD TRANSDUCER OPTION M1 RIGHT DRIVE MOTOR C3 STEER CYLINDER MB2 FRONT AXLE MANIFOLD BLOCK V2 FREE-WHEELING VALVE MB9 PROPORTIONAL MANIFOLD BLOCK 2H-59 PRESSURECOMPENSATED PROPORTIONAL VALVE 3H-17 BRAKE VALVE R1 SYSTEM RELIEF VALVE HYDRAULIC QUICK DISCONNECT O5 STEERING ORIFICE .040 DIA. O6 EMER. LOWERING ORFICE .067 DIA.
A B 3.
A B 3.
3.15 Electrical Panel Diagram (ANSI/CSA) D E TO TILT SWITCH TO ENGINE TO BATTERY TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH TO REAR MANIFOLD TO POWER DECK 28 19A 02 17 02 21A 02 17 28A 59 59 59A 17C 02 17C 25 02 17D 02 02 22 29 D14E 02 07 7A 8C 13 13A 49 14E B 59 21 B D14-1 D14 D28A 14 D13 B 19 R 19A 29 D19A 02 BATTERY TRAY 72 - BLACK/WHITE 71 - BLACK D14E-1 72 D15 D16 15 16 D17-1 17 17A D17 71 D23 23 D24-1 D24 24 N.
28E 19A TO HIGH SPEED LIMITS TO POTHOLE LIMIT TO SOFT STOP LIMIT SWITCH 02 17 02 21A 02 17 17C 59 59 17D 02 17C 25 02 28E 13A 02 28 13B 02 TO LOWER KEYSWITCH BOX TO TERMINAL BLOCK TO TILT SWITCH TO BATTERY TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH TO REAR MANIFOLD TO POWER DECK TO OUTRIGGER SOLENOID CABLES TO END OF STROKE TO FLASHER TO HORN/FLASHING LIGHT BACK VIEW N.
A B 3.
A B BROWN 3.
A B C 3.
A B C 3.
A 3.
A 3.
A 3.
A 3.
A 3.
Section 4 Troubleshooting Information Table of Contents Introduction...................................................................................................................................................................3 Electrical System 4.1-1 4.1-2 4.1-3 4.1-4 4.1-5 4.1-6 4.1-7 4.1-8 4.1-9 4.1-10 4.1-11 4.1-12 4.1-13 4.1-14 4.1-15 4.1-16 4.1-17 4.1-18 4.1-19 4.1-20 4.1-21 4.1-22 4.1-23 4.1-24 4.1-25 All Controls Inoperative.....................................................................
Table of Contents (Continued) 4.3-5 4.3-6 4.3-7 4.3-8 4.3-9 4.3-10 4.3-11 4.3-12 4.3-13 4.3-14 4.3-15 4.3-16 4.3-17 4.3-18 4.3-19 4.3-20 4.3-21 4.3-22 4.3-23 4.3-24 4.3-25 4.3-26 4.3-27 4.3-28 4.3-29 4.3-30 4.3-31 4.3-32 4.3-33 4.3-34 4.3-35 4.3-36 4.3-37 4.3-38 Flash Code F05: Bad Height........................................................................................................................14 Flash Code F06: Check Elev.........................................................................
Service and Maintenance Section 4 - Troubleshooting Information 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.
Section 4 - Troubleshooting Information Service and Maintenance Electrical System 4.1-1 All Controls Inoperative 1. Battery charger plugged into external power source. -- Disconnect charger cord. 2. Batteries disconnected. -- Connect batteries. 3. Dirty or loose battery terminals. -- Clean and tighten connections. 4. Battery charge low. -- Check each cell with a hydrometer. Reading should be 1.275 (fully charged). Recharge if low reading. Replace if reading difference between cells is 0.050. 5.
Service and Maintenance Section 4 - Troubleshooting Information Electrical System (Continued) 4.1-3 All Controls Inoperative From Base Control Console 1. Loose or broken wire #07 from base terminal block to platform emergency stop switch S4. -- Check continuity. Replace if defective. 2. Open or defective platform emergency stop switch S4. -- Close switch. Replace if defective. 3. Loose or broken wire #7A from platform emergency stop switch S4 to base terminal block. -- Check continuity.
Section 4 - Troubleshooting Information Service and Maintenance Electrical System (Continued) 7. Loose or broken wire #19B from tilt relay 28CR1 to base terminal block. -- Check continuity. Replace if defective. 8. Loose or broken wire #19B from base terminal block to motor contactor C1. -- Check continuity. Replace if defective. 4.1-6 No Down or Reverse Only Function from Platform Controls 1. Loose or broken wire “A” from proportional controller S7 to lift/drive switch S3. -- Check continuity.
Service and Maintenance Section 4 - Troubleshooting Information Electrical System (Continued) 12. Open or defective diode D14E-1 -- Check diode. Replace if defective. 13. See 4.1-5 of this section for more troubleshooting information. 4.1-9 No Down Function from Platform or Base Control Console (ANSI/CSA only) 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. -- Check continuity. Replace if defective.
Section 4 - Troubleshooting Information Service and Maintenance Electrical System (Continued) 3. Open diode D14E-1. -- Check diode. Replace if defective. 4. Open diode D14E. -- Check diode. Replace if defective. 4.1-12 No Down Function from Base Control Console 1. Defective up/down switch S2. -- Check switch. Replace if defective. 2. Loose or broken wire #13 from up/down switch S2 to base terminal block. -- Check continuity. Replace if defective. 4.
Service and Maintenance Section 4 - Troubleshooting Information Electrical System (Continued) 4.1-18 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 LS6 to base terminal block. -- Check continuity. Replace if defective. 4.
Section 4 - Troubleshooting Information Service and Maintenance Electrical System (Continued) 7. Proportional relay 21ACR defective. -- Check relay, replace if defective. 8. Loose or broken wire #2 from proportional relay 21ACR to base terminal block. -- Check continuity. Replace if defective. 9. Proportional controller S7 out of adjustment. -- Adjust controller. Refer to Section 5, Joystick Adjusting Procedure. 4.1-22 Forward Drive Function Inoperative 1.
Service and Maintenance Section 4 - Troubleshooting Information Hydraulic System 4.2-1 All Functions Inoperative 1. Proportional valve 2H-59 defective or is sticking. -- Check valve. Replace if defective. 2. Compensator portion of proportional valve defective or is sticking. -- Check valve. Replace if defective. 3. Pump P1 defective. -- Check pump. Replace if defective. 4.2-2 All Functions Sluggish 1. System relief valve R1 defective or not adjusted properly. -- Adjust valve. Replace if defective. 2.
Section 4 - Troubleshooting Information Service and Maintenance Hydraulic System (Continued) 4.2-6 Platform will not Lower NOTE Down function is not proportionally controlled. 1. Lowering valve 2H-13 (ANSI/CSA) or 2H-13B (CE) defective or is sticking. -- Clean valve. Replace if defective. 2. Defective holding valve 2H-13-1(ANSI/CSA) or 2H-13B-1 (CE). -- Clean valve. Replace if defective. 3. Lowering orifice O2 (3219 only) plugged or contaminated. -- Clear debris. Replace Orifice. Replace if defective.
Service and Maintenance Section 4 - Troubleshooting Information Hydraulic System (Continued) 4.2-10 Brake(s) will not Release 1. Brake valve 3H-17 defective or is sticking. -- Clean valve. Replace if defective. 2. Brake orifice 04 plugged. -- Remove orifice. Clean and reinstall. 3. Brake cylinder C4 defective. -- Rebuild cylinder. Replace if damaged. 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.
Section 4 - Troubleshooting Information Service and Maintenance Load Sensing System - CE 4.3-1 Flash Code F01: Check HWFS 1. This message is given if the GP102 startup tests have not completed. -- Check HELP message for more information. 4.3-2 Flash Code F02: Not Ground Mode 1. This message is given if the machine is not in ground mode (P2-2 must be high). -- Calibration can only be carried out in ground mode. 4.3-3 Flash Code F03: Not Stopped 1.
Service and Maintenance Section 4 - Troubleshooting Information Load Sensing System - CE 4.3-11 Flash Code F12: Too Many 1. This message occurs if the DYNAMIC lift takes too long. This message could occur if the UP switch was not released at the end of the dynamic lift. -- If the machine takes more than two minutes to lift, the GP102 may need modification to avoid this problem. 4.3-12 Flash Code F13: Low Height Range 1.
Section 4 - Troubleshooting Information Service and Maintenance Load Sensing System - CE (Continued) 4.3-18 Flash Code F19: High Elev.close 1. This message is given if the elevation switch (P2-10) closed during lower at a too high height (above 25%). -- When the switch is closed, overload detection is normally disabled but if the switch closes above 25%, the platform is too high to allow disabled overload.
Service and Maintenance Section 4 - Troubleshooting Information Load Sensing System - CE (Continued) 4.3-26 Flash Code F27:Bad Height 1. This message indicates a problem with the height sensor output (P4-3) during the STATIC phases. -- The height sensor output must be between 1.0V and 4.0V at all times. Check DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem. 4.3-27 Flash Code F30:Bad Heights 1.
Section 4 - Troubleshooting Information Service and Maintenance Load Sensing System - CE (Continued) 4.3-33 Flash Code F42:Low Pressure 1. This message indicates that the pressure is too low (0.5V or less) when the elevation switch opens during the DYNAMIC lift. This message would occur if the pressure sensor was disconnected, or if there were some other wiring error. -- Check DIAGNOSTICS / SENSORS to check the pressure. 4.3-34 Flash Code F43:High Pressure 1.
Section 5 Procedures List of Procedures Service and Maintenance General..........................................................................................................................................................................3 Safety and Workmanship..............................................................................................................................................3 Platform 5.1-1 OEM Controller Electronics Information...............................................
Section 5 - Procedures General The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter. Safety and Workmanship Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always 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.
Service and Maintenance 5.1-2 OEM 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. If there 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.
Section 5 - Procedures 5.
Service and Maintenance Base 5.2-1 System Relief Pressure Adjustment 1. Locate the system pressure quick disconnect port on the main manifold. 2. Install a calibrated 5000 psi gauge to the system pressure quick disconnect port. 3. Remove the platform control console the guardrail and disconnect from the main control cable. 4. Locate the main control cable plug at the rear of the aerial platform. 5. Disconnect the main cable and connect the platform control console into the plug. 6.
Section 5 - Procedures Service and Maintenance 5.2-3 Electronic Tilt Switch Setup Procedure The following information is supplied for replacement or reprogramming of the electronic tilt switch. Also included are test and verification instructions. Follow the appropriate procedures below. 9. Disconnect all wires #02 from motor contactor. 10. Install jumper wire between #7 and #19 to terminal strip. 11. Turn main disconnect switch to “ ” ON position. Tilt Switch Replacement 12.
Service and Maintenance 14. Turn main disconnect switch to “ position. Section 5 - Procedures ” off 15. Remove jumper wire between #7 and #19 from terminal block. 16. Reattach all wires #02 to motor contactor. SKYJACK, Page 8 17. Reinstall any covers that was removed. 18. Remove chock or wheel blocks. 19. Proceed to Test and Verify Tilt Circuit.
Section 5 - Procedures Service and Maintenance Reprogramming Existing Tilt Switch Light Indicators 9. Set up button is located on this face next to harness b. R Gre ed LE en D LE D Ensure aerial platform is parked on a firm level surface. 2. Chock or block wheels to keep the aerial platform from rolling forward or backward. Lower/Raise the platform and secure the scissors using the maintenance bar.
Service and Maintenance i. 10. The green LED will turn on solid. Results: The switch is ready for normal operation. Section 5 - Procedures Test and Verify Tilt Circuit Red LED Light Indicators Green LED Turn main disconnect switch to “ position. Set up button is located on this face next to harness ” off 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.
Section 5 - Procedures Service and Maintenance Load Sensing System - CE 5.
Service and Maintenance 5.
Section 5 - Procedures 5.3-3 Service and Maintenance LED Error Codes - Code Breakdown Chart Diagnostic sequence dependant on LED flash code: No Last Caldate 63 Load Not Calibrated 62 Height Not Calibration An EZcal is required! 61 Waiting For Neutral 55 Drive/Lift Inputs Faulty! 56 Up/Down Select Inputs Active Together 54 EMS Inputs Faulty! Check inputs on P2 pins 1,2,3,4,5,6,7,8. 52 P3-4 Short To Supply! 42 P3-4 Short To Supply? 44 P3-6 Short To Supply? 46 Disconnect plug P3.
Service and Maintenance 5.3-3 Section 5 - Procedures LED Error Codes - Code Breakdown Chart (Continued) Vehicle Tilted 11 Vehicle Overloaded 12 Too High - Drive Prevented 14 Too High - Lift Up Prevented 15 These are not true faults but an indication that vehicle movement is prevented. Remove excessive load from the platform. Lower the platform if close to maximum height. Move the vehicle to level ground. Invalid Height - Check Sensor 65 Check the voltage out of the height transducer, into P4-3.
Section 5 - Procedures 5.3-4 Service and Maintenance Hand Held Calibration/Diagnostic Tool Key Functions warning Only trained and authorized personnel shall be permitted to service and aerial platform. warning Read all instructions closely before attempting each phase or the calibration procedure.
Service and Maintenance 5.3-5 Section 5 - Procedures Control Module Load Calibration - Code Messages & Definitions During calibration the following failure message may appear: F01: Check HWFS -- This message is given if the GP102 startup tests have not completed. Check HELP message for more information. F02: Not Ground Mode -- This message is given if the machine is not in ground mode (P2-2 must be high).Calibration can only be carried out in ground mode.
Section 5 - Procedures Service and Maintenance F13: Low Height Range -- This message occurs at the end of calibration if the height sensor output did not change sufficiently to give a reasonably accurate platform height estimate. DIAGNOSTICS / SENSORS can be used to check the height sensor output (P43) when the platform is fully lowered and fully raised; a difference of at least 1V is to be expected.
Service and Maintenance Section 5 - Procedures F44: Low Pressure -- This message indicates that the pressure is too low (0.5V or less) at a measurement point. Check DIAGNOSTICS / SENSORS to check the pressure. F45: High Pressure -- This message indicates that the pressure is too high (4.5V or more) at a measurement point. Check DIAGNOSTICS / SENSORS to check the pressure. F46: Check Elev -- This message indicates that the elevation switch opened more than once during calibration lifting.
Section 5 - Procedures Service and Maintenance Lower Loaded -- This message is displayed while the platform is being lowered to the next measurement height, when an EMPTY platform is being calibrated. Lowering -- This message is displayed while the platform is being lowered, during HEIGHT-only calibration. Measuring # -- This message is displayed when the platform is stopped during calibration, when the GP102 takes a measurement.
Service and Maintenance 5.3-6 Section 5 - Procedures Control Module Load Calibration Procedure 1. Move the aerial platform to a test area where the platform can be elevated to its maximum working height and reach. 2. Ensure the aerial platform is parked on a firm, level surface. IMPORTANT Each phase must be completed before the next phase can be carried out. All phases must be completed before the aerial platform can be operated. IMPORTANT Always follow the instructions of the Calibration instrument.
Section 5 - Procedures 8. Service and Maintenance The display will show “Help: Press Enter”. By using Left/Right buttons, select the “Access Level ( ? )” from the menu and press the ENTER button. Contact Skyjack Service Department at: (44) 1691-676 236 for your Access Level Code Number. 9. The display will show “Access Level Code (xxxx)”. By using the Up/Down buttons, enter the Access Level Code (xxxx) followed by pressing the ENTER button. 10. The display will show “Access Level 2”.
Service and Maintenance Section 5 - Procedures 24. The display will show “Calibrate: Loaded Empty? No”. Asking for confirmation that the platform is empty? Check that the platform is empty 25. By using the Up/Down buttons, enter the “Yes” followed by pressing the ENTER button. 26. The display will show “Calibrate Load: Please Lift......”. Waiting for the lift switch to be activated. 27. Hold the lift switch and keep holding it until the platform is fully elevated.
Section 5 - Procedures Service and Maintenance 39. Press ENTER to complete date entry (the system will store it). 40. The display will show “Calibrate Load” option. 41. Press the ESC button to exit the “Calibrate Load” option. 42. Remove the jumper wire and re-connect the black wire #14 to the coil removed earlier. 43. Close the hydraulic/electric tray. NOTE Continuing partially complete load calibration.
Service and Maintenance 5.
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