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VERTICAL MAST

1. S8 HORN 3 LIFT DRIVE TOGGLE H 15 16 18 1 OOOO yon 4 10 4g 2 m 5 8 11 MKD 13 14 e RSTI 9 EMERGENCY STOP B 88 k 02 i LO e pita gt A 7A 1 Lm n 07 g 1 TIE BACK UNUSED WIRES 9 PIN CONNECTOR SUB ASSEMBLY View 990 Parts List SAY SN CTRL BOX 5 ON a PIN FUNCTION CIRLBOXHARNESS JOYSTICK HARNESS PIN 1 LEFT 24 BLUE BLACK WHITE RED PIN 2 STEERING VS 128 BROWNIRED WHITE GREEN PIN3 RIGHT 23 BLACKWHITE WHITE PIN 4 FWDJUP B RE YELLOW PINS JOYSTICKVS BLUE WHITEBLACK kd nS PING REVIDOWN A PURPLEWHTE GREY PIN7 O5VDC PROP 59 ORANGEIBLACK BLUE PIN 8 GND 02 WHITE BLACK Y PIN 9 ENABLE VS 8BBLUE WHITE BLUE e L T L I CTRL BOX CABLE O 10 5110 5110 5 O M NU B1 NU REDMHITE Ct GREEN 02 WHITE B2 NU C2 JUMPER WIRE 9 4 9 4 9 4 A3 07 RED B3 23 BLACKWHITE C3 JUMPER WIRE M NU B4 24 BLUE BLACK C4 JUMPER TO C5 A5 NU 85 49 GREENWHTE C5 JUMPER TO CA al A6 08 BLUEMHITE B6 59 ORANGEIBLACK C6 JUMPERTOC7 amp C8 AT 13 ORANGE B7 NU GREENBLACK C7 JUMPERTO C6 amp C8 6 116 116 1 A
2. Width Length N WARNING Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability Therefore replace tires only with the exact original Skyjack approved type Failure to operate with matched approved tires in good condition may result in death or serious injury SKYVACK Vertical Mast Series Page 37 Model SJ12 155185 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 5 Torque Specifications Location Description Torque ft lb Torque Nm Base pee eae eee wema smweusmesm o e Power Pack Mount BOLT Hex head 3 8 16 x 5 8 Grade 5 Hydraulic Motor Mount BOLT Hex head 1 2 13 x 2 75 Grade 5 Wheel Brake Mount BOLT Hex head 1 2 13 x 4 Grade 5 mast O 0 9 40522 Double Roller Assy Mount Mast 2 SCREW Socket head cap 1 4 20 x 3 4 zinc Chain Mount Assy Single Mast 2 SCREW Socket head cap zinc 1 4 20 x 7 8 Senay oy SEW Stina er Single Roller Assy Mount Mast 3 SCREW Button head cap ZN 1 4 20 x 3 4 Chain Mount Assy Double Mast 3 SCREW Socket head cap zinc 1 4 20 x 7 8 Spacer Plate Mast 4 BOLT Hex head 3 8 16 x 1 25 Grade 8 SKYVACK Page 38 Vertical Mast Series Model SJ12 Q 155185 Section 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS Tab
3. Hose Prefix Hose End Fitting Hose End Fitting H21 FEMALE 37 SWIVEL SHORT 90 FEMALE 379J IC SWIVEL 100R2AT H22 FEMALE 37 SWIVEL FEMALE 372 SWIVEL 100R2AT H25 FEMALE 37 JIC SWIVEL FEMALE 37 1 SWIVEL 100R4 H26 SHORT 902 FEMALE 372 JIC SWIVEL FEMALE 37 1 SWIVEL 100R17 H23 FEMALE 37 SWIVEL LONG 90 FEMALE 37 SWIVEL 100R2AT H29 459 FEMALE 372JIC SWIVEL FEMALE 37 SWIVEL 100817 H30 MEDIUM 902 FEMALE 37 SWIVEL FEMALE 37 SWIVEL 100817 60589 SKYVACK Vertical Mast Series Page 33 Model SJ12 155185 e Service and Maintenance Section 2 Maintenance Tables and Diagrams nnn Table 2 2 Specifications and Features MODEL SJ12 SJ12 we mw 30 n san 265 385 20 in n Drive Height Full Lift Time Rated Load Lower Time Rated Load LO Inn 3 0 mph 0 5 mph 262AA Weights are approximate refer to serial nameplate for specific weight Refer to Section 2 10 Loading Unload of Operating manual for more details SKYZACK Page 34 Vertical Mast Series Model SJ12 Q 155185 Section 2 Locally Concentrated Pressure kP a 650 800 750 700 Maintenance Tables and Diagrams Service and Maintenance Table 2 3 Maximum Platform Capacities MODEL Capacity Maximum EA Wind sien Setting SJ12 CE 227 kg 1 5x3 275AA Table 2 4a Floor Loading Pressure C
4. Main Blersl ERO DA a ee an ants ek R bb opu tM CER IE NR DU EE kk RA d k 59 3 14 Steer Speed Valve Port Identification and Harness ni pr BUR UAR A kay Mes d 60 Als Mast Control E ki pk Cant a atio ka ean lub ep ak aah kk ik ak kb AR ak n ki le 61 A tas a lb n e kk l po TEE A E sa ED kok pa A di pa SAR N RIS 62 217 Base Coantol Cente W w nap DI ke ted 63 Be Nee l EN gn po E 64 SKY ACK Vertical Mast Series Page 39 Model SJ12 155185 Q Notes SKYVACK Page 40 Vertical Mast Series Model SJ12 Q 155185 Section 3 System Component Identification and Schematics 3 1 Hydraulic Symbol Chart Service and Maintenance LINE CROSSING VARIABLE DISPLACEMENT PUMP CO SHUTTLE VALVE VELOCITY FUSE Mi ACCUMULATOR SINGLE ACTING LINE JOINED d j HAND PUMP GAS CHARGED CYLINDER oe HYDRAULIC CUSHION DOUBLE ACTING TANK BEEF VALVE m CYLINDER CYLINDER HYDRAULIC PRESSURE o3 FILTER WITH A REDUCING En A RODDED BYPASS
5. Test tilt switch Replace if defective 15 Loose or broken wire 28 from tilt switch TS1 to tilt relay 28CR Check continuity Replace if defective 16 Loose or broken wire 02 from tilt switch TS1 to base terminal strip Check continuity Replace if defective 17 Defective tilt relay 28CR Check relay Replace if defective 18 Loose or broken wire 19A from tilt relay 28CR to base terminal block Check continuity Replace if defective 19 Loose or broken wire 19A on base terminal block between diode D19A and diode D21 Check continuity Replace if defective 20 Loose or broken wire 19A from base terminal block to pump motor contactor Check continuity Replace if defective 21 Loose or broken wire 59A on base terminal block between diode D14B 1 and diode D17B 1 Check continuity Replace if defective 22 Loose or broken wire 59A from base terminal block to base control relay 59ACR Check continuity Replace if defective 23 Loose or broken wire 02 from base terminal block to base control relay 59ACR Check continuity Replace if defective 24 Defective base control relay 59ACR Check relay Replace if defective 25 Loose or broken wire 7A from base terminal block to lift speed relay 14CR1 Check continuity Replace if defective 26 Defective base lift resistor RST5 Check resistor and make sure it is secure Replace if defective 27 Loose or broken wire 59J from base terminal block to base
6. VALVE CYLINDER ELECTRIC MOTION SPRING APPLIED MOTOR X FIXED ORIFICE TI AL CONTROL VALVE 11 HYDRAULIC RELEASED m BRAKE ENGINE ADJUSTABLE E FLOW DIVIDER Faw BRAKE FLOW CONTROL COMBINER jJ CYLINDER FIXED j TI COUNTER ROTARY DISI PAQEMENT CHECK P y BALANCE VALVE ACTUATOR PUMP wo VARIABLE BI DIRECTIONAL N DISPLACEMENT OIL COOLER VALVE COIL C HYDRAULIC 4 HYDRAULIC MOTOR MOTOR SERIES TWO POSITION THREE POSITION c PARALLEL Ph TWO way j FOUR WAY ER O HYDRAULIC NORMALLY TWO POSITION E CLOSED CENTER Ee MOTOR T CLOSED VALVE THREE WAY VALVE z OPEN PORT S TWO POSITION x THREE POSITION TWO WAY E TWO POSITION FOUR WAY NORMALLY BS THREE WAY VALVE F CLOSED CENTER 2022 PRESSURE MEME n TRANSDUCER MAIN LINES Solid PILOT LINES Dashed SERVO SKY TACK Vertical Mast Series Page 41 Model SJ12 155185 Service and Maintenance Section 3 System Component Identification and Schematics 3 2 Electrical Symbol Chart o CIRCUITS CROSSING LIMIT SWITCH NO CONNECTION HOURMETER jc KEY SWITCH A NO 22e Q G2 LIMIT SWITCH CIRCUITS LIGHT Q4 FOOT SWITCH N O
7. 53 147053 N C CONTACT Lift Drive Platform control console 147054 N O CONTACT Lift Drive Platform control console S4 147053 N C CONTACT Emergency stop Platform control console 55 115573 SWITCH Diagnostic S7 151201 CONTROLLER ASSEMBLY 58 147054 CONTACT Horn Platform control console 10 147053 N C CONTACT Off Platform Base Base control centre 147054 N O CONTACT Off Platform Base Base control centre 28 147053 TT1 103336 TS1 156526 N C CONTACT Emergency stop Base control centre HOUR METER SWITCH Tilt SJ12 aN H AH HSH AH HH AH AH A ik ik 2 A BS ttt 146659 SWITCH Tilt CE SJ16 146658 SWITCH Tilt ANSI CSA SJ12 TS2 155814 SWITCH Tilt Single axis SJ12 151207 SWITCH Tilt Single axis SJ16 SKYVACK Vertical Mast Series Page 47 Model SJ12 155185 Q Service and Maintenance Section 3 System Component Identification and Schematics nnn 3 6 Cylinders and Port Identifications C1 Steer Cylinder O1 Steering Orifice C2 Lift Cylinder O2 Lowering Orifice 2H 13 Emergency Lowering Valve To Main Manifold View Parts List SI Y ACK Page 48 OYE M138117AA_S3 Vertical Mast Series Model SJ12 155185 Section 3 System Component Identification and Schematics Service and Maintenance 3 7 Wheel Brake and Por
8. BE 28 BR GN 8 5 zur 29 PR WH 10 it SoORIBK 59B OR BK 12 CD 7EGY OR 12 X19 DIAG 72 PK 8 asa 12 SWITCH X22 HORN Z m 16 WH BK 12 23 BK WH 8 24 BL BK_8 la X9 MOTOR 14A BK 14 X4 HOUR X24 POS CCT X7 MOTOR CONTACTOR METER BREAKER CONTROLLER X23 NEG CCT BRFAKFR Mi51470AF SKYACK Page 58 Vertical Mast Series Model SJ12 16 160606 Print View This Page Parts List 3 13b Main Electrical Harness B C D E F G H Serial Breakdown Reference Chart X14 DRIVEREV X15 MAST RAISE i SOLENOID SJ 12 14000581 amp below EN PIN 2 02 WH X16 STEER L V X13 DRIVE FWD JX SOLENOID SOLENOID PIN 1 24 BL BK PIN 1 16A WH BK PIN 2 02 WH PIN 2 02 WH X17 STEER R SOLENOID SOLENOID IE E A SDEG eH PIN 1 17 GN BK 7 5DEG PIN 2 02 WH PIN 1 07B GN YL PIN 2 15B BL X20 POTHOLE PIN 3 02 WH LIMIT SWITCH PIN 1 71A GN WH PIN 2 72 PK 4 X18 BATTER CHARGER PIN 1 3A YL PIN 2 05 RD X11 POTHOLE X8 TILT SWITCH 1 5DEG L LIMIT SWITCH PIN 1 18 ROIBK 2 28 X5 MAST LOWER L PIN GY OR PIN 3 02 WH SOLENOID gt DBNST
9. M15737 TAA SKYVACK Page 60 Vertical Mast Series Model SJ12 16 160606 Print View This Page Parts List 3 15 Mast Control Cable A B D E F G H CONNECTION CHART Y TOP OF MAST BOTTOM OF MAST WIRE NUMBER coNNECTOR CAVITY CONNECTOR CAVITY CONNECTOR X1 BLACK 14 X1 A8 X2 2 WHITE 02 X1 A2 X3 4 GREEN 7A X1 C1 X3 2 W RED 07 X1 A3 X3 1 ORANGE 13 X1 A7 xen BLUE 15 X1 A9 X2 3 LIMIT SWITCHES WHITE BLACK 16 X1 A10 X2 4 RED BLACK X1 C9 X2 6 GREEN BLACK X1 C6 X2 11 ORANGE BLACK X1 B6 X2 10 BLUE BLACK X1 B4 X2 8 BLACK WHITE X1 B3 RED WHITE X1 C4 GREEN WHITE 49 X1 B5 ki BLUE WHITE 08 X1 A6 WHITE JUMPER 12A 7B X1 B1 amp C7 CONNECTOR X2 ANSI CSA ONLY CONNECTOR X3 Z u SKYACK Vertical Mast Series Page 61 Model SJ12 16 160606 gt 3 16 Limit Switches Print This Page View Parts List D H LS1 MAST LIMIT SWITCH LS4 SERVICE 20 TRANSLATING PLATFORM ANSI CSA WIRE CAVITY BLACK X1 C5 BLACK WHITE X1 C10 BROWN X1 C3 BLUE X1 C8 YELLOW GREEN NOT USED WIRE NUMBER CAVITY BLACK 71 1 BLACK WHITE 21 2 BROWN 17 NOT USED BLUE 17C NOT USED YELLOW GREEN NOT USED 16 TRANSLATING PLATFORM CE LS5 DRIVE CUTOUT LS4 S
10. HELD CONNECTED LIMIT SWITCH of 4 l BATTERY P COIL i TOGGLE SWITCH y NC PROPORTIONAL LIMIT SWITCH GROUND J HYDRAULIC BUTTON HELD OPEN VALVE COIL o o SILICON r4 FUSE Q EE ROTARY SWITCH CONTROLLED MOTOR A RECTIFIER CIRCUIT HN PROXIMITY BREAKER HORN Pa SWITCH EMERGENCY Q CAM OPERATED PNP v VOLT METER Ak STOP BUTTON Fa LIMIT SWITCH TRANSISTOR CAPACITOR RESISTOR pa ae TIT SWITOH Sen SINGLE POLE PRESSURE POTENTIOMETER t LEVEL SENSOR SINGLE THROWN VACUUM T J RELAY SWITCH SINGLE POLE DOUBLE POLE DOUBLE POLE 1 TEMPERATURE DOUBLE THROW P SINGLE THROW L DOUBLE THROW SWITCH pS RELAY W RELAY IL RELAY o A TRIPLE POLE o DOUBLE THROW DIODE RHEOSTAT or RELAY SKY ACK Page 42 Vertical Mast Series Model SJ12 155185 OYE Section 3 System Component Identification and Schematics Service and Maintenance 3 3 Wire Number and Color Code WIRE WIRE WIRE WIRE COLOR 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 GRN SHLD 000 WHT 21 WHT RED 45 YEL ORG 68 GREY 93 BLK SHLD B1 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
11. Model SJ12 Q 155185 Section 3 System Component Identification and Schematics 3 4 Hydraulic Component Parts List Service and Maintenance n Qty Description 2H 13 151696 1 VALVE Control Emergency lowering 2H 17 102626 1 VALVE Control Steer speed 3H 14A 103623 1 VALVE Control Lift 3H 17 103623 1 VALVE Control Brake 4H 15A 156850 1 VALVE Control Reverse drive Includes 4H 16A 4H 16A VALVE Control Forward drive 4H 23 113953 1 VALVE Control Right steer Includes 4H 24 4H 24 VALVE Control Left steer BP1 154839 1 MOTOR Brake Right BP2 154839 1 MOTOR Brake Left C1 151690 1 CYLINDER Steer C2 151692 1 CYLINDER Lift SJ12 CB1 147889 1 VALVE Counterbalance Main manifold EM1 156877 MOTOR Electric HP1 151678 1 HANDPUMP Brake M1 139412 1 MOTOR Drive Right M2 139412 1 MOTOR Drive Left MB1 156959 1 BLOCK Manifold Powerpack MB2 151457 1 BLOCK Manifold Main MB3 151456 1 BLOCK Manifold Brake MB4 156866 1 BLOCK Manifold Lift cylinder MB5 157372 1 BLOCK Manifold Steer speed O1 151693 1 ORIFICE 0 035 Steering O2 108721 1 ORIFICE 0 032 SJ12 OS 157389 1 ORIFICE 0 018 Steer speed P1 156875 1 PUMP R1 156956 1 VALVE Relief System R2 151684 1 VALVE Relief Lift V1 113752 1 VALVE Reset Brake Vertical Mast Series Model SJ12 155185 OYE SKYVACK Page 45 Service and Maintenance Sectio
12. position On platform control console pull out i emergency stop button Test Base Emergency Stop Light 1 Pull out base emergency stop button Result Emergency stop light should continuously illuminate Test Base Emergency Stop 1 Pushin e emergency stop button and attempt to raise or lower the platform Result Platform raising and lowering functions should not operate SKYVACK Page 25 Function Tests Section 1 Scheduled Maintenance B B He f Base Control Console Emergency Lowering SKYVACK Page 26 Test Off Platform Base Switch N WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting Select off platform base key switch to O off position Attempt to raise or lower the platform Result Platform raising and lowering functions should not operate Select off platform base key switch to Ja platform position Attempt to raise or lower the platform Result Platform raising and lowering functions should not operate Select and hold off platform base key switch to A base position Attempt to raise or lower the platform
13. 3 Loose or broken wire 12B from steer switches S7 2 and S7 3 to lift off drive switch S3 Check continuity Replace if defective 4 Loose or broken wire 17A from diodes 023 and D24 to base terminal block Check continuity Replace if defective 5 Defective relay 17CR Check relay Replace if defective 6 Loose or broken wire 17B from relay 17CR to base terminal block Check continuity Replace if defective 7 Open diode D17B 1 Check diode Replace if defective SKYVACK Vertical Mast Series Page 73 Model SJ12 155185 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 8 Open diode D17B Check diode Replace if defective 9 Defective lift speed relay 14CR1 Check relay Replace if defective 10 Loose or broken wire 59G from 14CR1 lift speed relay to base terminal block Check continuity Replace if defective 11 Defective steer only resistor RSTA Checkresistor and make sure it is secure Replace if defective 4 1 12 Right Steer Inoperative 1 Loose or broken wire 23 from right steer switch S7 2 to control box connector pin B3 Check continuity Replace if defective 2 Loose or broken wire 23 in mast control cable or its connectors Check for continuity between base connector X2 pin 7 and platform connector X1 pin B3 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective 3 Loose or broken wire 23
14. 9 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 10 All hydraulic connections must be kept tight A loose connection in a pressure line will permit the oil to leak out or air to be drawn into the system Air in the system can cause damage to the components and noisy or erratic system operation Maintenance Hints Three simple maintenance procedures have the greatest effect on the hydraulic system performance efficiency and life Yet the very simplicity of them may be the reason they are so often overlooked What are they Simply these 1 Change filters annually The filters will need to be changed more often depending on the operating conditions Dirty dusty high moisture environments may cause the hydraulic system to be contaminated more quickly 2 Maintain a sufficient quantity of clean hydraulic oil of the proper type and viscosity in the hydraulic reservoir 3 Keep all connections tight SKYVACK Page 15 Notes SKYVACK Page 16 Vertical Mast Series Model SJ12 Q 155185 Section 1 Scheduled 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 p
15. Parts List E H 110 VAC LINE VOLTAGE BC 24V CHARGER CHARGER CUTOUT RELAY 1 L1CR Ba 6V Fi BATTERY 300A FUSE B3 6V BATTERY B2 6V BATTERY B16V BATTERY 24V CONTROL BOX MAST BASE aie 4e je CRD1 CHD2 CRD3 f DCM1 E t 10 C1 a IDLE PLTF BASE MOTOR M EMERGENCY 09 KEY SWITCH BONN STOP IN IDLE POSITION B B 7 S1 MAIN 8A 8A 08 BLUE WHITE 08 08 07 528 DISCONNECT 19B ENABLE aa NCHO A EMERGENCY STOP SWITCH LED 1 S5 DIAGNOSTI SPEED an POWER ON LIGHT 7A 07 RED NCH 5A de 05 a CP o3 STEN oz 07 ee 5A A C8 7A GREEN 7A 194 1 19 bi H 194 RED BLACK 198 1 Nan 02 02 SERVICE POSITION LS4 L y 4 LIMIT SWITCHN C H Q 19A LED 2 BP 29 58 POWER ON LIGHT Uer D19A i HORN SWITCH id RED WHITE yopa b
16. Replace if defective Loose or broken wire 8 in mast control cable or its connectors Service and Maintenance Check for continuity between base connector X3 pin 3 and platform connector X1 pin A6 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective Loose or broken wire 8 from control box connector pin A6 to 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 8A or wire 02 from emergency stop switch S4 to joystick S7 Check continuity Replace if defective Defective joystick enable switch S7 6 Check switch Replace if defective Defective joystick neutral switch S7 1 Check switch Replace if defective Defective joystick S7 Check joystick Replace if defective 4 1 8 No Up Function from Platform Control Console 1 2 3 Loose or broken wire B from proportional controller S7 to lift off drive switch S3 Check continuity Replace if defective Lift Off Drive switch S3 defective Check switch Replace if defective Defective joystick S7 Check joystick Replace if defective Vertical Mast Series Model SJ12 155185 SKYVACK Page 71 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 Loose or broken wire 14 from lift off drive switch S3 to cont
17. Resistor Resistor Function Input voltage Output Voltage 25 H 38 E 09 k 12 RST4 4 7K Steer only resistor RST5 2K Baselift resistor 4 8 volts refers to full stroke on the joystick 24 volts represents a full charge on the battery pack 1 2 RST3 220 Platformliftresistor 48 RST6 RST8 468 Hispeed drive resistor 4 8 250 Ohm RST2 Elevated drive resistor 48 24 24 Values given are with all connections tight and free from corrosion or 10 SKYVACK Vertical Mast Series Page 83 Model SJ12 155185 Service and Maintenance 5 1 2 Troubleshooting Diagnostic Switch The SJ12 16 machines are equipped with a diagnostic switch for the purpose of troubleshooting Once the deck is in the service position deck fully extended out the electric signal to the motor controller enable function is disengaged All electrical wiring and components can be checked in the service position other than the signal to the enable of the motor controller To accomplish this you would be required to engage the diagnostic switch Diagnostic Switch Figure 5 1 Horn and Hourmeter Assembly SKYVACK Page 84 OYE TS1 Tilt Switch Section 5 Procedures 5 1 3 Tilt Switch Orientation The design of this equipment and the Tilt Switches require them to be installed in a specific direction Below you will fi
18. Result Platform raising and lowering functions should operate OYE 1 Test Lower Neutral Raise Switch Select and hold off platform base key switch to 8 base position and j Et raise the platform with lower neutral raise switch Result Platform should rise Select and hold off platform base key switch to AB base position and EY lower the platform with lower neutral raise switch Result Platform should lower Test Emergency Lowering WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting Raise the platform On rear of the base pull out and hold emergency lowering valve to fully lower the platform Result The platform should lower Vertical Mast Series Model SJ12 155185 Section 1 Scheduled Maintenance Function Tests f Base Control Console Emergency Lowering 1 2 3 Test Platform Maintenance Limit Switch 1 2 Traverse the platform to maintenance position At the platform control console attempt to activate any function Result All functions should not operate Push the platform back to its operating
19. Section 1 Scheduled Maintenance Mast Platform N 1 1 Scheduled Maintenance Inspections Begin the visual and daily 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 N WARNING To avoid possible injury ensure aerial platform power is off during your visual and daily maintenance inspections NOTE While performing visual and daily inspections in different areas be aware to also inspect limit switches electrical and hydraulic components A caution Ensure aerial platform is on firm and level ground Electrical Maintaining electrical components is essential to good performance and service life of aerial platform SKYVACK Page 20 OYE Perform a visual inspection around the following areas e all wiring harnesses e hydraulic electrical wiring harnesses Hydraulic Maintaining hydraulic components is essential to good performance and service life of the aerial platform Perform a visual inspection around the following areas hoses and fittings e hydraulic cylinder e all hydraulic manifolds e the underside of the base e ground area under the aerial platform 1 1 1 Labels Refer to the labels section in the operat
20. 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 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 SJT 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 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
21. from base terminal block to mast control cable Check continuity Replace if defective 4 Open diode D23 Check diode Replace if defective 5 Loose or broken wire 23 from base terminal block to right steer valve coil 4H 23 Check continuity Replace if defective 6 Loose or broken wire 02 from base terminal block to right steer valve coil 4H 23 Check continuity Replace if defective 7 Defective right steer valve coil 4H 23 Check continuity through coil Replace if defective 4 1 13 Left Steer Inoperative 1 Loose or broken wire 24 from left steer switch S7 3 to control box connector pin B4 Check continuity Replace if defective 2 Loose or broken wire 24 in mast control cable or its connectors Check for continuity between base connector X2 pin 8 and platform connector X1 pin B4 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective 3 Loose or broken wire 24 from base terminal block to mast control cable Check continuity Replace if defective 4 Open diode D24 Check diode Replace if defective 5 Loose or broken wire 24 from base terminal block to left steer valve coil 4H 24 Check continuity Replace if defective 6 Loose or broken wire 02 from base terminal block to left steer valve coil 4H 24 Check continuity Replace if defective 7 Defective left steer valve coil 4H 24 Check continuity through coil Replace if defective SKYVACK Page 74 Ve
22. 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 Vertical Mast Series Model SJ12 155185 Scheduled Maintenance Inspections 7 All hydraulic components must be disassembled 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 8 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
23. 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 T 800 275 9522 44 1691 676 235 630 262 0006 44 1691 676 239 pin Bs Bj Include the model and serial number for each applicable aerial platform SKYVACK Vertical Mast Series Page 7 Model SJ12 155185 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance Scope of this Manual a This manual applies to the ANSI SIA CSA AS and CE versions of the Vertical Mast Series aerial platform models listed on Table 2 1 of the operating manual 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 Machinery Directive 2006 42 EC and Directive 2004 108 EC 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 ANSI SIA United States Operators are required by the current ANSI SIA A92 5 standards to read and understand their responsibilities in the manual of responsibilities before they use or operate this aer
24. ok ka kaka 7 Evi EE V MEANS DA AN RON rS 8 Operator kaki de tan Ps a to A a kk ein nee Pe ke e A Po kb e ko Ye A 8 YA AN PEE ial ake ke eee E a at tap a ee 9 PP T IN m a ki E 10 Ki la efe ee and Te UG ac io ka ks kan ak bk ak DW PE a abso Ru LUE DIES EM Eka Yok Da EL ERa e doc kans pa k 14 Owner s nal Dirspeotion asc aa ie ak pe lose va pa ke pk n a YE FA MUR DIRE eto DEG ap Ru E i 14 EIS DUARTE EEIE A E D TIT MEE 14 Maintenance and Service Safety aed bb aco Ge biens He nei i db bap l e Ie Hi a ort o n Io ie CU Io ab kk l bua fo oe kis 14 Hydraulic System amp Component Maintenance and Repair ped poo anko kinika 15 Darts e FWA Ter MT cca Rc aoe ence ee a A a eee Service and Maintenance SRR MO EIN SURTOUT 17 GON e ch od r k kt ak pt Aa po taste 17 Mpstutenadtce and k akan ak abe bab jo kk ka ak D pa lk a e l kd pal ki ebd kk a a a ak DN CH bM lk a ed kaba kk k 17 Pe Vesti A NEN EIE dea ok ka a PHAR aa ab a kk HOM kk ERE a a Pe pe kk bk a kt a a ian L RD kk pk Ya kk kk pe kk kap pa 17 Scheduled Maintenance Inspections 1 1 Seheduled Maintenance Insnec BOW sa nio tante pak b ka kasek kk koka kk lak da
25. position and latch in place 1 2 4 Platform Control Console Ensure main power disconnect switch is in on position Ensure base pulled out emergency stop button is Select off platform base key switch to Ja platform position WARNING Ensure that you maintain three points of contact to mount dismount platform Open the gate and access the platform Close the gate Vertical Mast Series Model SJ12 155185 On platform control console pull out i emergency stop button Test Platform Emergency Stop 1 Pushin 6 emergency stop button attempt to activate any platform function Result All selected platform functions should not operate 2 Pull out e emergency stop button 3 While activating any platform functions push in emergency stop button Result Current activated aerial platform function should immediately stop operating SKYVACK Page 27 Function Tests Section 1 Scheduled Maintenance Lift Drive Steer Enable Trigger Switch Lift Off Drive Switch Rocker Switch Controller Emergency Stop Button Operation Light Horn Pushbutton Test Enable Trigger Switch 1 Without activating Cx enable trigger switch attempt to activate any platform function Result All platform functions should not operate Test Lift Off Drive Switch Off Position 1 Select lift off drive switch to O off position attempt to activate any pla
26. to drive 4 4 forward and ht reverse 4 Result Aerial platform drive functions should not operate Activate and hold renable trigger switch Slowly move controller handle in 7 L forward direction until aerial platform begins to move and then return handle to center position Result Aerial platform should move in forward direction and then come to a stop 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 Vertical Mast Series Model SJ12 155185 Test Brakes WARNING Brakes will engage instantly when you release the controller handle causing aerial platform to stop immediately Ensure path of intended motion is clear Activate and hold d enable trigger Switch t Drive aerial platform forward and then oll i 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 Drive aerial platform forward and gt backward Test brake again by releasing CG enable trigger switch only Result Aerial platform should come to an instant
27. 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 120 115 110 Locally Concentrated Pressure psi o e 0 50 100 150 200 250 300 350 400 450 500 Load on the Platform Ib SKYVACK Page 36 Vertical Mast Series Model SJ12 Q 155185 Section 2 Maintenance Tables and Diagrams Service and Maintenance Floor Loading Pressure Locally Concentrated Pressure LCP Overall Uniform Pressure OUP Foot Print Area Length x Width Base Area Length x Width Weight of Aerial Platform Capacit Weight of Aerial Platform Capacity LCP 0 4X 2 Ss OUP Foot Print Area Base Area TO
28. 2 from forward drive valve coil 4H 16A to base terminal block Check continuity Replace if defective 10 Forward drive valve coil 4H 16A defective Check continuity through coil Replace if defective 11 Open diode D16A Check diode Replace if defective 12 Tilt switch TS2 defective or out of adjustment Adjust the set up of the tilt switch using section 5 of this manual Replace if defective 4 1 19 Reverse Drive Function Inoperative 1 Loose or broken wire 15 from Lift Off Drive switch S3 to control box connector A9 Check continuity Replace if defective 2 Loose or broken wire 15 in mast control cable or its connectors Check for continuity between base connector X2 pin 3 and platform connector X1 pin A9 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective 3 Loose or broken wire 15 from mast control cable to relay 15BCR Check continuity Replace if defective 4 Loose or broken wire 15B from tilt switch TS2 to relay 15BCR Check continuity Replace if defective 5 Loose or broken wire 02 from base terminal block to relay 15BCR Check continuity Replace if defective 6 Reverse drive relay 15BCR defective Check relay replace if defective 7 Loose or broken wire 15A from relay 15BCR to base terminal block Check continuity Replace if defective 8 Loose or broken wire 15A from base terminal block to reverse drive valve coil 4H 15A Check continui
29. 4 23 572 b s Wines DO27 LV 1 BIGHT 328 12B 17A le SB 17 2H 17C 57 3 DO2 7 d mi LEFT D24 24 za BLUE BLACK 24 HA A IMEEM SEN DO2 8 Cael 02 WHITE 02 02 9 29 36 CHARGER BATTERY PACK PUMP MOTOR MOTOR CONTROLLER POSITIVE CIRCUIT BREAKER 15A NEGATIVE CIRCUIT BREAKER 15A HOURMETER POWER ON LED BEEPER DOWN SOLENOID FLASHING LIGHT OPTION MOTOR CONTACTOR TILT RELAY TILT SWITCH HORN UP SOLENOID HIGH SPEED RELAY LIFT SPEED RELAY PLATFORM LIFT RESISTOR HI SPEED DRIVE RESISTOR ELEVATED DRIVE RESISTOR STEER ONLY RESISTOR BASE LIFT RESISTOR LIFT SPEED RELAY 2 BASE CONTROL RELAY TILT SWITCH 2 REV CUT OUT RELAY FWD CUT OUT RELAY REVERSE SOLENOID BRAKE SOLENOID FORWARD SOLENOID STEER RELAY RIGHT SOLENOID STEER SPEED SOLENOID LEFT SOLENOID SKYVACK Page 64 15147240 Vertical Mast Series Model SJ12 16 160606 Section 4 TROUBLESHOOTING INFORMATION Table of Contents UB uc re ep EFE pcg bas MEC IM M II LIE DM PM I DI 67 Electrical System A LOPE TALIS Ro oo e e o oo oo 68 4 152 AlI Controls Except tor Down Function IBOpetelyve pap pak kk SR ADRES FR 68 42153 All Controls operative From Base Control Console sei ee te Eee Ete ER e e pibon po ab k dak lw kiba kek pak bank 69 4 154 N Up Function from Bas
30. 4 1 10 No Down Function from Platform Control Console NOTE Down function is not proportionally controlled 1 Loose or broken wire A from proportional controller 57 to lift off drive switch 53 Check continuity Replace if defective 2 Lift Off Drive switch S3 defective Check switch Replace if defective 3 Defective joystick S7 Check joystick Replace if defective 4 Loose or broken wire 13 from lift off drive switch S3 to control box connector pin A7 Check continuity Replace if defective 5 Loose or broken wire 13 in mast control cable or its connectors Check for continuity between base connector X2 pin 1 and platform connector X1 pin A7 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective 6 Loose or broken wire 13 from base terminal block to mast control cable Check continuity Replace if defective 7 Loose or broken wire 13 from base terminal block to down valve coil 2H 13 Check continuity Replace if defective 8 Loose or broken wire 02 from base terminal block to down valve coil 2H 13 Check continuity Replace if defective 9 Defective down valve coil 2H 13 Check continuity through coil Replace if defective 4 1 11 Steer Only Inoperative 1 Loose or broken wire 8B from proportional controller S7 to lift off drive switch S3 Check continuity Replace if defective 2 Lift Off Drive switch S3 defective Check switch Replace if defective
31. AULIC OIL 200 mL SECTION B B SPRING ARRANGEMENT SKYVACK Vertical Mast Series Page 55 Model SJ12 16 160606 Q Print View This Page Parts List 3 12a Hydraulic Schematic B D E F G H Serial Breakdown Reference Chart BH Model Serial Number LEF RIGHT e TE ce LEFT RIGHT LIFT V To 27 DRIVE DRIVE CYLINDER 3 MOTOR MOTOR STEER 3 8 CYLINDER L R STEERING STEERING ae EJ BRAKE f MANIFOLD X MB4 Q 2H 13 ASSEMBLY MBS SIE HOL D EMERG w STEER 5 CYLINDER LOWERING VAL Vr MBI B wi _ ASSEMBLY 3 S 8 POWERPACK s SEI E STEER 5 MANIFOLD 5 aj VALVE ASSEMBLY oo n 2 si 52 0002066 i i SAE06 X RI SYSTEM RELIEF SH 17 VAL VE COUNTERBAL ANCE dine g o Fi PUMP 37CC REV R2 lt gt LIFT RELIEF STRAINER VAL VE 2000 51 2 0 42 2 12 0 5 gt HYDRAULIC RESERVOIR MB2 MAIN MANIFOLD ASSEMBLY SKYVACK Page 56 Vertical Mast Series Model SJ12 16 160606 Print View This Page Parts List 3 12b Hydraulic Schematic B D E F G H Serial Breakdown Reference Chart Model Serial Number Bi LEFT RIGHT BRAKE BRAKE M2 RIGHT LEFT LIFT Lh Mi DRIVE DRIVE Cl CYLINDER 4 A MOTOR MOTOR STEER P d CYLINDER MOREM RE
32. B 14 BLACK B8 NU REDIBLACK C8 JUMPER TO C6 amp C7 OOo AQ 15 BLUE 8 NU 9 JUNPERTOCIO O 0 16 WHTEBLACK B10 NU C10 JUMPER TO C9 INSERTION SIDE VIEW SKYVACK Vertical Mast Series Page 51 Model SJ12 155185 Notes SKYVACK Page 52 Vertical Mast Series Model SJ12 Q 155185 Print View This Page Parts List 3 10a Brake and Main Manifold and Hydraulic Identifications B C D E F G H Serial Breakdown Reference Chart Serial Number v1 Auto Reset Valve v MB3 Brake Manifold P 4H 16A To Main Manifold Forward Drive Valve w 4H 23 4H 15A Hand Pump Right Steer Valve Reverse Drive Valve s CB1 p 4H 24 ONY Lett Steer Valve Counterbalance Valve R 5 B1 A gt To Steer Cylinder O HI rake 4 X To Left Brake 3 2 R2 L T ae To Left Drive Motor Lift Relief Valve ca e LA To Right Drive Motor 3H 14A Lift Valve 1 To Right Drive Motor Y Manifold o Main Manifo Brake Valve gt 1 S1 om a W To Steer Cylinder JE AS M n L l To Powerpack Manifold To Lift Cylinder Qo T Z B To Powerpack Manifold To Brake Manifold M151687AD SKYVACK Vertical Mast Series Page 53 Model SJ12 16 160606 Q Print View This Page Parts List 3 10b Brake and Main Manifold and Hydraulic Identifications B D
33. CUIT BREAKER 15 Amp CB2 117325 1 CIRCUIT BREAKER 15 Amp Parts list continued on following page SKYVACK Page 46 Vertical Mast Series Model SJ12 Q 155185 Section 3 System Component Identification and Schematics Service and Maintenance 3 5 Electrical Component Parts List Me ou pin Qty Description Parts list continued from previous page C1 146475 CONTACTOR DCM1 156877 MOTOR F1 310517 FUSE 300 Amp LED 1 147061 LED 2 147061 LS1 156521 POWER INDICATOR LIGHT Platform control console POWER INDICATOR LIGHT Base control centre LIMIT SWITCH High speed LS2 156520 LIMIT SWITCH Pothole protection LS3 156520 LIMIT SWITCH Pothole protection LS4 156522 LIMIT SWITCH Service position Fixed position 156523 LIMIT SWITCH Service position Variable position LS5 156522 RST1 119629 RST2 151646 RST3 156515 RST4 151645 RST5 156527 RST6 151643 RST7 156564 RST8 151647 LIMIT SWITCH Drive cutout CE RESISTOR 2 7k ohm Platform control console RESISTOR 1k ohm 1 watt Base control centre RESISTOR 220 ohm 3 4 watt Base control centre RESISTOR 4 7k ohm 1 watt Base control centre RESISTOR 2k ohm 2 watt Base control centre RESISTOR 250 ohm 1 watt Base control centre RESISTOR 1 5 ohm 1 watt Base control centre RESISTOR 68 ohm 1 watt Base control centre A A AA 51 119725 SWITCH Main power disconnect 52 147054 CONTACT Lift Drive Base control centre
34. DACONNIES PIN 4 NOT USED X6 ELEVATED DRIVE PIN 2 02 WH X LIMIT SWITCH MAST CABLE PIN 1 71 GY OR POWER PIN 2 21 GN WH PIN 1 07 RD PN Sas ac X1 LOWER Poe CONTROLS PIN 4 02 WH co 02 WH co 05 RD 97 RD X2 MAST CABLE cT 07AGNIYL FUNCTIONS co 08 BL WH an 13 OR PIN 1 13 OR f 14 BK a 2 11 i SPLICE 71 DETAIN 15A BL PIN 4 16 WH BK Y 1 15B BL PIN 5 19A RD WH ann 16B WH BK PIN 8 24 BL BK X21 STROBE ZONK PIN 10 59 ORBK OPTION Lp 9 BD BK PIN 11 7B GN YL PIN 1 29 PU WH co 19A RD WH PIN 12 NOT USED PIN 2 02 WH an 21 GN WH 23 BK WH co 24 BL BK m 28 BR GN 29 PR WH ot To 59B OR BK 71 GR OR X19 DIAG oo AA X22 HORN Z 16 WH BK mem 23 BK WH oo la X24 POS CCT X7 MOTOR eek Meee BREAKER CONTROLLER A Tene X23 NEG CCT BREAKER M151470AF SI YI ACK Vertical Mast Series Page 59 Model SJ12 16 160606 Print View This Page Parts List 3 14 Steer Speed Valve Port Identification and Harness F G H D E 2H 17C Steer Speed Orifice Steer Speed J Valve P1 To Main Manifold P2 To Steer Cylinder MB5 Steer Speed Manifold X2 MAIN HARNESS PIN 1 17 2 GN BK PIN 2 02 1 WH X4 STEER SPEED ee Ea LIMIT SWITCH C D SOLENOID TU X3 BRAKE
35. E Total Aerial Total Aerial Platform Load MODEL Platform Weight kPa kN m kg _ SJ12 264AA min Aerial platform weight with no options max Aerial platform weight all options full capacity LCP Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the areas in direct contact with the floor The floor covering tile carpet etc must be able to withstand more that the indicated values above OUP Overall Uniform Pressure is a measure of the average 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 Vertical Mast Series Page 35 Model SJ12 155185 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 4b Floor Loading Pressure ANSI CSA Total Aerial Total Aerial Platform Load Platform Weight 269AA min Aerial platform weight with no options max Aerial platform weight all options full capacity LCP Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the areas in direct contact with the floor The floor covering tile carpet etc must be able to
36. E F G H Serial Breakdown Reference Chart Model Serial Number vi Auto Reset Valve v MB3 Brake Manifold P 4H 16A To Main Manifold Forward Drive Valve 4H 15A Reverse Drive Valve 4H 23 Hand Pump Right Steer Valve 1 4H 24 Counterbalance Valve ies Left Steer Valve 52 Steer Cylinder B1 Right Brak X To Left Brake PEU EHE M2 R2 To Left Drive Motor Lift Relief Valve 1 3H 14A To Right Drive Motor Lift Valve To Steer Cylinder 3H 17 Brake Valve Pi To Powerpack Manifold To Lift Cylinder Ker 2 B To Powerpack Manifold To Brake Manifold 14151459 SKYACK Page 54 Vertical Mast Series Model SJ12 16 Q 160606 Print View This Page Parts List 3 11 Disc Brake Kits and Torque Specifications A B D E F G H B OIL FILL V a 772 HYDRAULIC OIL WN NSS o TA m N Sea ZA w LN e Yj 7 B N Nou a QA e 6 WS SE SECTION A A BRAKE KITS Y K1 KIT BEARING AND SEAL K2 KIT BRAKE STACK K3 KIT O RING TORQUE SPECIFICATIONS 1 TORQUE CASTLE NUT TO 237 Nm 2 TORQUE BRAKE BOLTS TO 115 Nm 3 TORQUE MOUNTING BOLTS TO 115 Nm OIL TYPE CATERPILLAR 0 4 SAE 30 HYDR
37. ECTION FREQUENCY Inspection Schedule PASS C FREQUENTLY F FAIL C ANNUALLY R REPAIRED BI ANNVALLY Schedule Schedule Test Emergency Stop ae _ Test offPiatorm Base swin A B Test Lower Neutral Raise Switch Main Power Disconnect Switch Base Control Switches 100V Outlet Receptacle AB ANSI CSA A B Pothole Protection Device Test Platform Self leveling Test Emergency Power Test Platform Maintenance Limit Switch Wheel Tire Assembly Platform Assembly Test Driving Test Brakes Test Platform Raising Lowering Test Pothole Sensor A Perform Visual and Daily Maintenance Inspections amp Functions Test Refer to Section 2 7 of the Operating Manual Perform Scheduled Maintenance Inspection every three months or 150 hrs Refer to Section 1 0 of this manual Perform Scheduled Maintenance Inspection every year Refer to Section 1 0 of this manual D Perform Scheduled Maintenance Inspection every 2 years Refer to Section 1 0 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 prior 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 SKYVACK Vertical Mast Series Page 19 Model SJ12 155185 Q Scheduled Maintenance Inspections
38. ERVICE WIRE CAVITY WIRE CAVITY BLACK X1 B1 BLACK X1 C5 BLACK WHITE BROWN X1 C7 NOT USED BLACK WHITE BROWN X1 C10 X1 C3 BLUE NOT USED BLUE X1 C8 YELLOW GREEN NOT USED YELLOW GREEN NOT USED M156521AC S3 SKYVACK Page 62 gt Vertical Mast Series Model SJ12 16 160606 Print View This Page Parts List 3 17 Base Control Centre Wiring Diagram A B D E G H 14CR 14681 15BCR 16BCH 17CR 21CR 28CR 59ACR 87 4 87 5 87A 5 87 te 4 87 a Ir 87 2 87 87 T V 52 335 2 MAIN HARNESS i 10 2 LI 24 08 wo 1 e me BA X 2 15 a a 16 07 528 3 O H19A Y PCE CELE ELT SES SHEEP RR lt lt Oj ww Om O e ka alle lt lt lt lt E 5 QI ID e I BSI RAIS S 15 50 B20 1K 68 7 1415147 _ SKYGACK Vertical Mast Series Page 63 Model SJ12 16 160606 3 18 Electrical Schematic Print This Page View
39. F G H Serial Breakdown Reference Chart X14 DRIVE REV X15 DANSE Model Serial Number SOLENOID SJ 12 14000582 amp above X13 DRIVE FWD SOLENOID X16 STEERL SOLENOID X12 BRAKE A X17 STEER R SOLENOID an SOLENOID X10 TILT SWITCH 2 Epa 17 5DEG PIN 1 07B GN YL 1 do PIN 2 16B WH BK ES X20 POTHOLE PIN 3 02 WH LIMIT SWITCH PIN 4 15B BL PIN 1 71A GN WH X26 STEER SPEED PIN 2 72 PK L SOLENOID 3 X18 BATTERY W 6 oo CHARGER E 2 622 L 15 e zx E ge 5 2 PIN 1 3A YL LI PIN 2 05 RD 6 X11 POTHOLE X8 bon 1 d LIMIT SWITCH PIN 1 19 RD BK PIN 2 28 BR GN L PIN 1 71 GY OR NE TASS SER SUM X5 MAST LOWER SOLENOID PIN 1 13 ORG PIN 2 02 WH X X6 ELEVATED DRIVE LIMIT SWITCH X25 ELEVATED PIN 1 71 GY OR 3 CABLE STEER SPEED LIMIT AN EFE NAM POWER X1 LOWER PIN 1 07 RD CONTROLS PIN 2 07A GN YL PIN 3 08 BL WH m pi 02 12 PIN 4 02 WH 05 RD 18 07 RD 14 ci 07A GN YL 14 X2 MAST CABLE 4 cp 0BBUWH 15 FUNCTIONS Ny SPLICE 02 DETAIL 13 0R 14 PIN1 13 OR a oo E cp DAL 12 PIN 4 16 WH BK 3 penyen m 15RBL 10 184 Oo 02 10 02 18 E UE ERU 16B WH BK 12 a E on JO RD EK 11 PIN 11 7B GN YL PIN 1 29 PR WH __198 RD WH 11 PIN 12 NOTUSED PIN 2 02 WH 21 GN WH_ 10 n 2238KWH 8 13 mn Si 3 z 6 24 BL BK 8
40. Figure 5 47 4 Install the tensioner mount assembly to the other end of the double chain following steps 1 and 2 Ensure chains are in the correct orientation See Figure 5 47 SKYVACK Vertical Mast Series Page 99 Model SJ12 155185 Notes SKYVACK Page 100 Vertical Mast Series Model SJ12 Q 155185 SKYGACK Reliable lift solutions by people who care www skyjack com lt
41. KYVACK Vertical Mast Series Page 9 Model SJ12 155185 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance Safety Precautions Know and understand the safety precautions before going on to next section N 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 job site TURN main power disconnect switch O off when leaving the aerial platform unattended Re move the key to prevent unauthorized use of the aerial platform WEAR all the protective clothing and personal safety devices issued to you or called for by job conditions DO NOT wear loose clothing dangling neckties scarves rings wristwatches or other jew elry while operating this lift AVOID entanglement with ropes cords or hoses 6 e AVOID falling Stay within the boundaries of the guardrails DO NOT raise the aerial platform in windy or gusty conditions SKYVACK Page 10 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 on a firm level surface Do
42. NI L R hi E LOWERING __ MB3 wo DI ORIFICE BRAKE C STEERING MANIFOLD _ i ORIFICE _ ASSEMBLY Btls 0 035DIA ge ni Eu eee w STEER LOWERING VALVE NN CYLINDER MANIFOLD HONI AED m i nd ASSEMBLY POWERPACK 2 4 2 SAE06 DRIFICE A 0 018DIA a CH 17C EONS MANIFOLD a ASSEMBLY ty stu _ E EE a SAE06 X z r RI SYSTEM RELIEF 3000PST 31 17 BRAKE CBI VAL VE COUNTERBAL ANCE VAL VE a X PI Y O 2 PUMP OF 37CC REV R2 LIFT RELIEF STRAINER VAL VE 2000 51 HYDRAULIC RESERVOIR MBe MAIN MANIFOLD ASSEMBLY SKYVACK Vertical Mast Series Page 57 Model SJ12 16 160606 Q Print View This Page Parts List 3 13a Main Electrical Harness C D E
43. REUE PER pa e REISK ALA R S EYES Hydraulic System 42 1 f twa a eder km ki ank kr deena nee dence a ola 78 24 AN Funcions Sg eS REO ia Da l 0o 0 7 Ba EE 78 Slo DO A UK kk a e e e e ks MM ME AN MEE 78 ei a l ak TS 78 LUCAM LIU NES e n a n n kn a a ak n een ee e as 78 a GUN FAN a a CO 78 oi a ak kt ab kk kk a a ke Rel O ME ME M ME EE 79 A se Platone will tot Drive ui Forward fa T 79 SIG Paor wu nor DIO ID ROS DO k t ko ta aa a ka eee kk e po 79 Boke swill not ski ka kika at ka o TT 79 STE PII OOo B IBOE e Oe 79 42 12 Platiormi does not Steer Elevated While Driving cocci esse tk ba da bw bobo ko kak kd ki pk p kai dy AE E 79 22 13 Steers Very SIO Wy ete rakont er HUE PES a casi po ek sak ki bk kk ok pa im 79 SKYVACK Vertical Mast Series Page 65 Model SJ12 155185 Q Notes SKYVACK Page 66 Vertical Mast Series Model SJ12 Q 155185 Section 4 Troubleshooting Information Service and Maintenance Introduction The following pages contain a table of Troubleshooting Information for locating and correcting
44. SERVICE MANUAL VERTICAL MAST MODEL 155185AD October 2012 SKYACK a This manual is based on Serial Numbers SJ 12 14 001 105 amp Below 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 servicefaskyjack 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 infoldskyjackeurope co uk Skyjack Asia Pacific Singapore Phone 65 6449 3710 Fax 65 6449 7690 Email skyjack dsingnet com sg OYE SERVICE AND MAINTENANCE Table of Contents Section 1 Scheduled Maintenance Table of Contents Section 2 Maintenance Tables List of Tables Section 3 System Component Identification and Schematics Table of Contents Section 4 Troubleshooting Information Table of Contents Section 5 Procedures List of Procedures SKYVACK Vertical Mast Series Page 3 Model SJ12 155185 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 t
45. VEL GREY 71 RED ORG 97 ORG GREY 03 GRN PUR 26 BLU YEL 49 GRN RED 72 RED BRN 98 RED SHLD 04 RED YEL 27 RED BLK WHT 50 BRN 73 RED PINK 98A BLKSHLD GRN 05 PUR 28 GRN 51 BLK GRN 74 GREY 99 BLK GREY 06 29 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 BLU WHT 33 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 12 PEDIVEU as ORGWHT 58 WHT PUR 81 GREY BLK 109 GRN YEL 13 ORG 36 RED PUR 59 YEL BLU 82 BRN WHT 110A BLU 14 BLK ae ji 60 WHT BLU 83 BLU GREY 110B BRN 15 BLU 38 ORG RED 61 GREV BRN 111 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 1138 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 RED SHLD 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 SKYJACK Vertical Mast Series Page 43 Model SJ12 155185 Q Notes SKYVACK Page 44 Vertical Mast Series
46. alve Replace if defective 4 2 9 Platform will not Drive in Reverse 1 Reverse drive valve 4H 15A defective or is sticking Clean Valve Replace if defective 2 Counterbalance valve CB1 defective or is plugged Clean Valve Replace if defective 4 2 10 Brake s will not Release 1 Brake valve 3H 17 defective or is sticking Clean valve Replace if defective 2 Brake hubs BH1 or BH2 sticking or defective Check for hydraulic pressure at brake hubs If pressure is available rebuild brake hubs 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 C1 seals bypassing Rebuild cylinder Replace if damaged 3 Mechanical binding in king pins Check for binding Repair as needed 4 Orifice 01 plugged Clean Orifices and reinstall 4 2 12 Platform does not Steer Elevated While Driving 1 Orifice 03 plugged Clean Orifices and reinstall 4 2 13 Platform Steers Very Slowly 1 Steer Speed valve 2H 17C stuck in the shifted position or is defective Check valve Replace if defective SKYVACK Vertical Mast Series Page 79 Model SJ12 155185 Q Notes SKY ACK Page 80 Vertical Mast Series Model SJ12 Q 155185 Section 5 PROCEDURES List of Procedures e 83 SEL and WCET a
47. 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 SKYVACK Page 29 Function Tests Section 1 Scheduled Maintenance Rocker Switch Lift Drive Steer Enable Controller Trigger Switch Emergency Stop Button Operation Light Lift Off Drive Switch Horn Pushbutton Test Pothole Sensor e Test Horn IN WARNING SKYGACK 1 Push horn pushbutton Result Horn should sound Test Platform Raising Lowering N WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting Select lift off drive switch to E lift position Without activating 65 enable trigger switch attempt to lift lower the platform Result Aerial platform lift lower functions should not operate Activate and hold de 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 Ensure that you maintain three points of contact to mount dismount platform Dismount from platform and place a block approximately 1 5 3 75 cm under one side of the pothole protection device Open the gate and access the platform Close the gate Raise the plat
48. ce if defective Loose or broken wire 71A from pothole protection limit switch LS2 to pothole protection limit switch LS3 Check continuity Replace if defective Defective pothole protection limit switch LS3 Check switch Replace if defective Loose or broken wire 72 from pothole protection limit switch LS3 to base terminal block Check continuity Replace if defective Open diode D72 Check diode Replace if defective Loose or broken wire 59F from base terminal block to relay21CR Check continuity Replace if defective Defective relay 21CR Check relay Replace if defective 10 Defective elevated drive resistor RST2 Check resistor and make sure it is secure Replace if defective 4 1 17 Work Platform Drives in Slow Speed Only 1 2 3 Loose or broken wire 71 from base wire harness to high speed limit switch LS1 Check continuity Replace if defective Open or defective high speed limit switch LS1 Check switch Replace if defective Loose or broken wire 21 from high speed limit switch LS1 to base terminal block Check continuity Replace if defective Loose or broken wire 21 from base terminal block to high speed relay 21CR Check continuity Replace if defective High speed relay 21CR defective Check relay replace if defective Loose or broken wire 02 from high speed relay 21CR to base terminal block Check continuity Replace if defective Loose or broken wire 59K from base terminal blo
49. ck switch Replace if defective 2 Loose or broken wire 14B from up down switch S2 to base terminal block Check continuity Replace if defective 3 Open diode D14B 1 Check diode Replace if defective 4 Open diode D14B Check diode Replace if defective 5 Loose or broken wire 14 on base terminal block between diode D14B and diode D14 Check continuity Replace if defective SKYVACK Vertical Mast Series Page 69 Model SJ12 155185 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 6 Open diode D14 Check diode Replace if defective 7 Loose or broken wire 14 on base terminal block between diode D14B and low voltage protection resistor RST7 Check continuity Replace if defective 8 Defective low voltage protection resistor RST7 Check resistor and make sure it is secure Replace if defective 9 Loose or broken wire 14A from base terminal block to up valve coil 3H 14A Check continuity Replace if defective 10 Loose or broken wire 02 from base terminal block to up valve coil 3H 14A Check continuity Replace if defective 11 Defective up valve coil 3H 14A Check continuity through coil Replace if defective 12 Machine not level Above high speed limit switch Use on level surface 13 Loose or broken wire 19 from base terminal block to tilt switch TS1 Check continuity Replace if defective 14 Defective tilt switch TS1
50. ck to high speed relay 21CR Check continuity Replace if defective Defective high speed drive resistor RST1 Check resistor and make sure it is secure Replace if defective 4 1 18 Forward Drive Function Inoperative 1 Loose or broken wire 16 from Lift Off Drive switch S3 to control box connector pin A10 Check continuity Replace if defective 2 Loose or broken wire 16 in mast control cable or its connectors Check for continuity between base connector X2 pin 4 and platform connector X1 pin A10 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective 3 Loose or broken wire 16 from mast control cable to relay 16BCR Check continuity Replace if defective 4 Loose or broken wire 16B from tilt switch TS2 to relay 16BCR Check continuity Replace if defective 5 Loose or broken wire 02 from base terminal block to relay 16BCR Check continuity Replace if defective SKYVACK Page 76 Vertical Mast Series Model SJ12 Q 155185 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 6 Forward drive relay 16BCR defective Check relay replace if defective 7 Loose or broken wire 16A from relay 16BCR to base terminal block Check continuity Replace if defective 8 Loose or broken wire 16A from base terminal block to forward drive valve coil 4H 16A Check continuity Replace if defective 9 Loose or broken wire 0
51. control relay 59ACR Check continuity Replace if defective SKYVACK Page 70 Vertical Mast Series Model SJ12 155185 Section 4 Troubleshooting Information Electrical System Continued 4 1 5 Up Function Slow from Base Control Console 1 2 3 Loose or broken wire 14 from base terminal block to lift speed relay 14CR1 Check continuity Replace if defective Loose or broken wire 02 from base terminal block to lift speed relay 14CR1 Check continuity Replace if defective Defective lift speed relay 14CR1 Check relay Replace if defective 4 1 6 No Down Function from Base Control Console 1 2 3 4 5 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 Loose or broken wire 13 from base terminal block to down valve coil 2H 13 Check continuity Replace if defective Loose or broken wire 02 from base terminal block to down valve coil 2H 13 Check continuity Replace if defective Defective down valve coil 2H 13 Check continuity through coil Replace if defective 4 1 7 All Controls Inoperative From Platform Control Console 1 2 3 Loose or broken wire 7 from base key switch S10 to base terminal block Check continuity Replace if defective Loose or broken wire 8 from base terminal block to mast control cable Check continuity
52. d for each inspection Check the schedule on the checklist for the type of inspection to be performed Place a check in the appropriate box after each inspection procedure is completed Use the maintenance and inspection checklist and step by step procedures in Section 5 to perform these inspections If any inspection receives a fail tag and remove the aerial platform from service If any aerial platform component s has been repaired an inspection must be performed again before removing the tag Place a check in the repair column Legend P Pass F Fail R Repaired SKYVACK Page 17 155185 Scheduled Maintenance Inspections Section 1 Scheduled Maintenance Table 1 1 Owner s Annual Inspection Record N WARNING Do not use the aerial platform if an inspection has not been record ed in the last 6 months CE or 18 months ANSI CSA Model This decal must be completed dated and signed after each inspection time intervals as stated above SKYVACK Page 18 Vertical Mast Series Model SJ12 Q 155185 Section 1 Scheduled Maintenance Scheduled Maintenance Inspections SKYGACK Table 1 2 MAINTENANCE AND I NSPECTION CHECKLIST Serial Number Model Hourmeter Reading Name Printed Date Time Signature Each item shall be inspected using the the appropriate section of the Skyjack service manual As each item is inspected write the apropriate grade in the box INSP
53. d or reverse WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting Raise the platform approximately 30 5cm 12 in and attempt to drive forward or reverse Result Aerial platform should move slower than when it was in stowed position Vertical Mast Series Model SJ12 155185 Section 5 Procedures Hydraulic System All adjustments must be made with a calibrated gauge Refer to the serial number plate located on the rear of the machine for system and lift pressure values 5 2 1 System Relief Pressure Adjustment 1 Extend transverse deck to service position then raise the service access door and secure in position with the prop rod provided 2 Locate system pressure test port on power pack manifold Refer to Section 3 Power pack and Port Identification for location 3 Install a calibrated 5000 PSI gauge to the system pressure test port 4 Remove platform control box from guardrail and locate it in the proximity of the work area of the power pack 5 Atthe power pack manifold loosen locknut on system relief valve R1 Refer to Section 3 Power pack and Port Identification for location 6 Select drive with the Lift Drive switch on the platform control box Engage steer right and hold Engage diagnostic switch and hold 8 Observe reading on gauge when steering is at full stroke Adjust system relief valve R1 value listed on the serial number plat
54. duled Maintenance Motor Controller Tilt Sensors Mast Assembly Pothole Protection Device SKYVACK Hydraulic Oil Ensure platform is fully lowered and then visually inspect the hydraulic oil level Motor Controller Ensure the controller is properly secured and there is no visible damage Ensure there are no loose wires or missing fasteners Tilt Sensors Ensure tilt sensors are properly secured and there is no visible damage Pothole Protection Device Ensure mechanisms have no sign of visible damage and are free from dirt and obstructions Limit Switches Ensure limit switches are properly secured with no signs of visible damage and movement is not obstructed Close the compartment access door and latch in place Push the platform back to its operating position and latch in place 1 1 6 Lifting Mechanism Mast Assembly Ensure mast assembly shows no visible damage and no signs of deformation in weldments Complete section 1 2 Function Tests Raise the platform Wear Pads Ensure all bolts are tight there is no visible damage to the wear pads and that no parts are missing Chains Ensure there are no missing parts and all bolts are tight with no signs of visible damage Ensure chains are securely anchored Vertical Mast Series Model SJ12 Q 155185 Section 1 Scheduled Mai
55. e Turn the stem on the relief valve clockwise to increase pressure Turn the stem counterclockwise to decrease pressure 9 Release steer switch diagnostic switch and then tighten the locknut 10 Remove the gauge from the system pressure test port 11 Store prop rod back to its holder then lower Service access door and secure it Push the transverse deck back to the working position Vertical Mast Series Model SJ12 Service and Maintenance 5 2 2 Lift Pressure Adjustment 1 10 Extend transverse deck to service position then raise the service access door and secure in position with the prop rod provided Locate the hose going to the lift cylinder on the main manifold Remove and plug the hose Refer to Section 3 Main Manifold Assembly for location Install a calibrated 5000 PSI gauge to the port on the manifold where the hose was disconnected At the main manifold loosen the locknut on the lift relief valve R2 Select lift with the Lift Drive select switch on the platform control box Engage platform lift function and hold Engage diagnostic switch and hold Observe reading on gauge Adjust lift relief valve R2 to the value listed on the serial number plate Turn the stem of the relief valve clockwise to increase pressure Turn the stem counterclockwise to decrease pressure Release platform lift function diagnostic switch and then tighten the locknut Remove the gauge from the lift port on the manifold Reat
56. e Control Console seereis anc ok pe pe de ered LEER an PEE 69 4 153 Up Function Slow mon Base Control Console E 71 4 156 ING Down Function from Base Control Consolg oo pat PAR EFE kosa arden ke 71 41 2 All Controls Inoperanve From Platform Control Consol ue ese etn EA TR HU kose kikonk ke ep pf 71 4 155 No Up Function from Platform Control Consoli eren 71 4 159 Up Function Slow foui Platon Control Console REOR BERE UIS ke pd panel k Fe so ge kn ko bot EUR CE peni ks 41 10 Ne Down Function from Platform Control Console pe E ske nani 33 dao robo ER Dr 73 41 12 Right Steer NR DN 74 SWEDEN Pe dir b RE o mem 74 2 1414 ING Drive Forward of REVENE tea RI esi ari er ee 75 kk a Ze 75 4 l 10 No Elevated Dine serra eae ee ieee ED IRA 35 A lel Works Platforin Diesin Slow Speed Er Tm 76 4 118 Forward Drive IDODetdll Ve cane ences ro ap pak te VAR EMUR RARA KARE poko denen 76 Reverse DA ve Function TELL a pk tk ki kl e kk l e kk theses a ok n T7 4 1820 Two more Functions ab one TTE a sede ener tk a se ak aa ar kran RA F
57. enance 7 install the power outlet box and the control cable connector block to mast 4 Control Cable Connector Box Power Outlet Box Figure 5 40 Electrical Connector Installation 8 Fish the limit switch cable behind the operating manual storage box through the control cable connector block See Figure 5 40 9 Install the limit switch wires to control cable male connector See Figure 5 41 for wiring information WIRE BLACK BLAC K WHITE BROWN BLUE YELLO W G REEN Figure 5 41 Control Cable Connector Wiring 10 Install the platform control cable to the control cable connector box SKYVACK Page 97 e Service and Maintenance 11 Install the mast cover See Figure 5 42 2 3 Figure 5 42 Mast Cover Installation 1 2 3 SKYZACK Page 98 Section 5 Procedures 5 3 4 0 Function Test Verify the all hydraulic and electrical connections are properly connected Verify no mechanical interference Perform Visual Inspections and the Function Tests as outlined in the Operating Manual 5 3 5 0 Mast Chain Installation 5 3 5 1 Mast Chain Inspection Cracked _ OO CLS f e Lower the mast fully and remove the top cover plate Insepct each chain for slack Each pairing chain should have same amount of slack See Figure 5 43 for maximun allowable slack Replace the chain if required 16 6 mm 0 654 Figure 5 43 Ma
58. erforming any scheduled maintenance inspection procedure refer to service bulletins found in our web site www skyjack com for updates related to service and maintenance of this aerial platform Maintenance and Inspection Death or injury can result if the aerial platform is not kept in good working order Inspection and maintenance should be performed by competent personnel who are trained and qualified on maintenance 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 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 O off position e Repair any damaged or malfunction components before operating aerial platform e Keep records on all inspections Vertical Mast Series Model SJ12 __Scheduled Maintenance 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 Make copies of the maintenance and inspection checklist to be use
59. eries 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 SKYVACK Page 14 OYE Section 1 Scheduled Maintenance Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this aerial platform All maintenance and service procedures should be performed in a well lighted and well ventilated area Anyone operating or servicing this aerial platform must read and completely understand all operating instructions and safety hazards in this manual and operating manual All tools supports and lifting equipment to be used must be of proper rated load and in good working order before any service work begins Work area should be kept clean and free of debris to avoid contaminating components while servicing All service personnel must be familiar with employer and governmental regulations that apply to servicing this type of equipment Keep
60. form until approximately a height of 2 feet 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 the other side of the pothole protection device Result Aerial platform should not move forward or backward Vertical Mast Series Model SJ12 155185 Section 2 MAINTENANCE TABLES Table of Contents Tables Table 2 1 Standard Hose Nundibermg Sy Stein 22209 9 pa ka pk ks ke Ho PEE UA E a ke PAG HA HIS RR 32 dubie Suecieabbn t kaka ki kk a 34 Table 2 5 Cap OUE obli bk a a Db eee 35 Tuble2 25 Floor Losdng Pesssures pep Pent ket CHEER A REE AE HA ALERT UE ORAE bk PE a e Ba 35 Table 24b Moor Logdmg Pressure CAs ob OU LU IE CR RE DP CI REP ko a acm ka DER RA IUE JE D ob IMMER ME 36 Tube Pondus SECTORES Gui fre ire Rae mtr a P UPS Kant 38 SKYVACK Vertical Mast Series Page 31 Model SJ12 155185 e Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 1 Standard Hose Numbering System H1104 0081 2 m LS FITTING LENGTH IN FRACTIONS ARRANGEMENT LENGTH OF 1 4 INCREMENTS LE See Schedu
61. he safety message This Safety Alert Symbol means attention Become alert Your safety is involved N DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury N WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury N 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 SK YIACK Page 4 Vertical Mast Series Model SJ12 155185 Section 1 SCHEDULED MAINTENANCE Table of Contents Operator s Responsibility for Maintenance rer DEFWA NAL k l ky kl e ay l geen ka kb e bag satanic tau esos te Gan case aide Laue aac ap an RO ko a ange 1 Puppe ESEIWREUE an 3 Ur coi ad ATANN Em 7 eio utor SE ER MET e RED AEE 3 ser ewer kk e ee a rere ee ne er er eer re rer eee pk ee ke ee ee er ae ee 7 DA ETE erent n a eT marly ai TA E 7 Optimal A FO SSN NB ak ki ik kak a n kk ak ak a l
62. i 4 6 29 4 NO 8A Lou 13 ORANGE 13 2H 13 L DOZ 1 VI 19 28A D13 p moun Te gt 35 10E v D14B D14 19 19 02 iid BATTERY CHARGE pi pi 4 4 UP DOWN 14B INDICATOR NoHo sg UEDOWN bias 7022 8 02 7A 7B 28 02 V 182 4 9 183 72 28CR 02 49 71 71A 71A 72 19 02 1 GREENMHITE e 2 4 POTHOLE POTHOLE 75 02 LIMIT SWITCH LIMIT SWITCH N C H O 1 1 WHEN PLATFORM STOWBD WHEN PLATFORM STOWED RST7 14 14 asi za BLACK 14 Mod 2 7K OHMS LS1 21CR 1 5 OHM DO23 02 00 71 21 21 a LOW VOLTAGE RESISTOR 4 NN n C 14CR 17 pw 14 02 4 HIGH SPEED T 220 OHM 57 LIMIT SWITCH 59 59C JOYSTICK L nes 59D 59K 8878 4 JOYSTICK PCB 1K OHM 250 OHM 8 0 5VDC 59 59 ORANGE BLACK 59 1 59 _ 59D 59D 59F RST2 59E 59B 4 59B 576 4 OUTPU PEE 02 MEE 59G NE 59B JUMPER 2K OHM ANSI ONLY RST4 12A 7B 7A 59H RSTS 185 14 02 128 Med 12A 12 9 7B 7 gt 14CR2 DRIVE CUTOUT 59A 02 LIMIT SWITCH N C H O 782 53 WHEN DECK EXTENDED saata LIFT OFF DRIVE CE ONLY 02 IN OFF POSITION 1 15BCR 7B GREEN BLACK 7B 7B 15B 15B 4 02 ec L xa 16BCR 16B 168 02 4 157 1 13 NUETRAL BLUE 15 15A 4H 15A revion A 15 15 _ 15 DO2 4 D15A 17 BT A gt B B z 16 16 16 16 uto n L WHITE BLACK 57 6 NO bit 17CR 002 6 71 ENABLE 8B 8B 12B 17 17 02 4 NO 23 23 BLACK WHITE 23
63. ial platform N 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 platform Common sense dictates the use of protective clothing when working on or near machinery Use appropriate safety devices to protect your eyes ears hands feet and body Any modifications from the original design are strictly forbidden without written permission from SKYJACK SKYVACK Page 8 Vertical Mast Series Model SJ12 155185 Section 1 Scheduled Maintenance Operator s Responsibility for Maintenance Electrocution Hazard This aerial platform is not electrically insulated Maintain 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 Per ANSI A92 5 2006 8 10 7 The operator shall perform onl
64. imit Switch Inside the Mast Assembly Using power tools remove the limit switch from its mount N WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform Traverse the platform to maintenance position and access the hydraulic electrical compartment see Figure 5 5 Figure 5 5 Accessing Hydraulic Electrical Compartment SKYVACK Page 85 Service and Maintenance 10 Locate and disconnect the limit switch connector see Figure 5 6 Limit Switch Connector Figure 5 6 Limit Switch Inside the Mast Assembly 11 Remove the limit switch from top of the mast 12 Carefully feed the new limit switch harness connector from top of mast to base 13 Reconnect the limit switch connector at the base 14 Close the compartment door and traverse the platform back to the home position IN WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform 15 Using power tools carefully install the new limit switch to its mount 16 Reinstall the mast cover 17 Using the base control console carefully and gradually raise and remove the wood block 18 Carefully lower the platform SK YIACK Page 86 OYE Section 5 Procedures 5 1 5 Testing Limit Switch 1 2 Ensure path of intended motion is clear With platform fully lowered attempt to drive forwar
65. in mount bolts on mast 1 See Figure 5 16 6 Remove the wear pads on mast 2 Inner chains Mount Bolts Figure 5 16 Mast 2 Components Removal 7 Carefully lift the mast 2 assembly off the base with suitable lifting equipment 8 Place mast 2 assembly on a suitable stand 9 Inspect and replace any worn or damaged components if required Vertical Mast Series Model SJ12 155185 Service and Maintenance 5 3 2 4 Mast 1 Assembly Removal 1 Place the machine on a suitable stand to allow access to the bottom of the machine base 2 Disconnect and remove the emergency lowering valve electrical coil and pull knob from the lift cylinder manifold See Figure 5 17 Emergency Lowering Valve Pull Emergency Lowering Valve Electrical Coil Figure 5 17 Emergency Lowering Pull Knob and Electrical Coil Removal A caution To prevent hydraulic system contaminations cap all hydraulic hoses and fittings after removal 3 Disconnect the lift cylinder hydraulic hose from the main hydraulic manifold Port L See Figure 5 18 Port L Figure 5 18 Lift Cylinder Hydraulic Hose Removal N caution To prevent hydraulic system contaminations cap all hydraulic hoses and fittings after removal SKYVACK Page 91 Service and Maintenance 4 Remove the emergency lowering valve bolts cylinder manifold and the lift cylinder shoulder bolt
66. ing manual and ensure that all labels are in place and are legible 1 1 2 Limit Switches Ensure limit switches are properly secured and no signs of visible damage and movement is not obstructed Detecting limit switch malfunction is essential to safe aerial platform operation Visually inspect all limit switch for the following e broken or missing actuator arm missing fasteners loose wiring Vertical Mast Series Model SJ12 155185 Section 1 Scheduled Maintenance Scheduled Maintenance Inspections Base Control Main Power Disconnect Switch Switches 110 220V Outlet Receptacle eer ee Wheel Tire Assembly E b Battery Charger 1 1 3 Base e Wheel Tire Assembly Main Power Disconnect Switch Turn main power disconnect switch to O off position Ensure all cables are secure and switch is in proper working condition Base Control Switches Ensure there are no signs of visible damage and all switches are in their neutral positions 110 220V Outlet Receptacle ANSI CSA Ensure receptacle is free from dirt and obstructions Battery Charger Ensure charger is secure and shows no visible damage Steer Cylinder Assembly Ensure steer cylinder assembly is properly secured and there are no loose or missing parts Pothole Protection Device Ensure mechanisms have no sign of vi
67. ion If occupant s of the platform are required to wear personal fall protection equipment feet are in contact with the aerial platform PFPE occupants shall comply with instructions or the ground at all times during entering provided by the aerial platform manufacturer and exiting remanufacturer regarding anchorage s If additional fall protection is required by an N WARNING employer or the authority having jurisdiction An operator should not use any aerial Skyjack recommends the use of a fall restraint platform that System to keep an occupant within the confines e does not appear to be working properly ofthe platform and thus not expose the occupant e has been damaged or appears to have worn or to any fall hazard requiring a fall arrest missing parts e has alterations or modifications not approved by All personal fall protection equipment must the manufacturer comply with applicable governmental regulations has safety devices which have been altered or and must be inspected and used in accordance disabled with the manufacturer s recommendations e has been tagged or locked out for non use or repair All personal fall protection equipment must be attached only to approved anchorage points Failure to avoid these hazards could within the platform of the aerial platform result in death or serious injury WARNING Job site Inspection e Do not use in hazardous locations e Perform a thorough job site inspection prior t
68. is no visible damage Ensure platform foot pedal is in good working order and no loose or missing parts and there is no visible damage Lanyard Attachment Anchors Ensure attachment anchors are secure and no visible damage e AC Outlet ANSI CSA Ensure outlet has no visible damage and free from dirt or obstructions SKYVACK Page 22 Platform Control Console Ensure all switches and controller are returned to neutral and are properly secured Ensure there are no loose or missing parts and there is no visible damage e Manuals Ensure a copy of operating manual and certificate are enclosed in manual storage box Check to be sure manual storage box is present and in good condition Ensure manuals are legible and in good condition Always return manuals to the manual storage box after use IN WARNING Ensure that you maintain three points of contact to mount dismount platform 3 Dismount from platform 4 Close the gate Vertical Mast Series Model SJ12 Q 155185 Section 1 Scheduled Maintenance Scheduled Maintenance Inspections Hydraulic Pump and Motor Batteries Hydraulic Main Manifolds Tank 1 1 5 Hydraulic Electrical Compartment d lfapplicable check battery fluid level If plates 1 Access the hydraulic electrical compartment Battery Proper battery condition is essential to good performance and operational safety Improper fluid level
69. itch TS2 Check continuity Replace if defective 11 Loose or broken wire 02 from base terminal block to tilt switch TS2 Check continuity Replace if defective 12 Tilt switch TS2 defective or out of adjustment Adjust the set up of the tilt switch using section 5 of this manual Replace if defective 13 Loose or broken wire 17 from diodes D16A and D15A to base terminal block Check continuity Replace if defective 14 Open diode D17 Check diode Replace if defective 4 1 15 Brake will not Release 1 Diode D16A forward or D15A reverse is shorted or open Check diode Replace if defective 2 Loose or broken wire 17 from base terminal block to brake valve coil 3H 17 Check continuity Replace if defective 3 Brake valve coil 3H 17 defective Check continuity through coil Replace if defective 4 Loose or broken wire 02 from brake valve coil 3H 17 to base terminal block Check continuity Replace if defective 4 1 16 No Elevated Drive 1 Pothole protection bars not fully lowered Clear obstructions Repair as needed 2 Loose or broken wire 71 from base wire harness to pothole protection limit switch LS2 Check continuity Replace if defective SKYVACK Vertical Mast Series Page 75 Model SJ12 155185 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 3 4 8 9 Defective pothole protection limit switch LS2 Check switch Repla
70. le HOSE SIZE HOSEIN WHOLE 4 1 4 Below See Chart INCHES 2 1 2 Below 3 3 4 Using the number above as an example H1104 0081 2 This hose requires a 37 JIC female swivel fitting on one end A medium length 90 JIC female swivel fitting for the other end The Hose must meet or exceed S A E 100R13 hose specification and be a total of 81 1 2 long NOTE Hose ends and hose must be from same manufacturer per S A E J1273 Nov 91 Sections 3 10 and 4 2 Hose ends and hose must be of the same size i e 4 size fittings must be used with 4 size hose Hose Size Chart E 0 04 os 08 10 12 16 20 24 32 40 48 56 64 E Fitting Arrangement Schedule Continued on the following page S A E Hose Specification Hose Prefix Hose End Fitting Hose End Fitting LONG 90 FEMALE 372JIC SWIVEL LONG 909 FEMALE 372 IC SWIVEL H12 SHORT 902 FEMALE 372 J IC SWIVEL SHORT 909 FEMALE 37 1 SWIVEL FEMALE 372 IC SWIVEL REUSABLE MALE PIPE THREAD FITTING FEMALE 37 SWIVEL 452 FEMALE 372J IC SWIVEL 100R4 SKYVACK Page 32 Vertical Mast Series Model SJ12 Q 155185 Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 1 Standard Hose Numbering System Continued Fitting Arrangement Schedule Continued from the previous page S A E Hose Specification 19 90 FEMALE 372JIC SWIVEL 100R13 h2
71. le of Contents Charts 2L aad DOSE esc w kk ja kek l pet a e p EBORE e sp e ai ka Ya Fe Dako pris eben po LR DUM E ego 41 P caer e te A OF n A kk ld kk e 42 CREME Rca SE Tc K A EE 43 Parts List pr Hydra Componeni ree 45 kat kaki MR a AR ak ein dE 46 Diagrams and Schematics Ao Cylindersand Port IdentiBoattosos au e ok ke sa E arr he Rn ane 48 3 7 Whgel Brake wind Port NETS Tem 49 25 Powe msck and Port eu dea eoe kl PIE CREER ano ka e va ba dU tenuis A De EDDA RN DU IL UM UM RE 50 AAA ES Coo ENN METTE 51 2 108 Brake and Main Manifold and Hydraulic Identifications ava bek de lake Aa abi bk abi MEN ke INE 53 3 106 Brake and Main Manifold and Hydraulic Identifications esee eene nennen enne nennen nnne 54 AIL Dise Brake Kits and ng acies piece RE ands baee EHI el lec t Fon ce DIC LI fe Fd C ER pk tee eA a E pa e PEE 56 Hydran Schenn endi pa bee bea pclbuatdebii s d a ke a pak ek I B REN Eat 57 2 959 DE AA a a kk e e B RA L ka A A E kk A UHR POOR E kika se RASIS 58
72. ler Check continuity Replace if defective 2 Loose or broken wire 19A from base terminal block to diagnostic switch S5 Check continuity Replace if defective 3 Loose or broken wire 19A from diagnostic switch S5 to mast control cable Check continuity Replace if defective 4 Loose or broken wire 19A in mast control cable or its connectors Check for continuity between base connector X2 pin 5 and platform connector X1 pin C4 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective SKYVACK Page 68 Vertical Mast Series Model SJ12 155185 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 5 Loose or broken wire 19A from control box connector pin C4 to limit switch LS4 Check continuity Replace if defective 6 Loose or broken wire 19B from limit switch LS4 to control box connector pin C4 Check continuity Replace if defective 7 Defective limit switch LS4 Check limit switch Replace if defective 8 Loose or broken wire 19B in mast control cable or its connectors Check for continuity between base connector X2 pin 6 and platform connector X1 pin C9 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective 9 Loose or broken wire 19B from diagnostic switch S5 to mast control cable Check continuity Replace if defective 10 Loose or broken wire 19B from diagnos
73. m inward as mast 2 is lowered See Figure 5 34 Figure 5 34 Limit Switch Installation Procedure Carefully lift and lower mast 2 onto mast 1 along with chains Ensure to place the inner chain into mast 1 Lower the mast partially to allow working space Align the inner chain within mast 1 and install the chain mounting bolts Use Loctite 242 or equivalent on the mounting bolts and torque to 200 Ib in See Figure 5 35 SKYVACK Page 95 Service and Maintenance 6 Install the wear pads Put on the thicker front wear pads first then the back wear pads Use Loctite 770 or equivalent on the wear pad holes and Loctite 431 or equivalent on the wear pad bolts Figure 5 35 Mast 2 Installation Procedure Fully lower mast 2 onto mast 1 Ensure the cylinder mount bracket is in place Install the clevis pin and the cotter pin at the top of mast 2 See Figure 5 36 Clevis Figure 5 36 Lift Cylinder End Installation Procedure 10 Un roll and place the two outer chain inside mast 1 temporarily Page 96 OYE Section 5 Procedures 5 3 3 3 Mast 3 Installation 1 Carefully lift mast 3 and partially lower it onto mast 2 with use of suitable lifting equipment Align the inner chain anchor to mast 3 bolt holes then install the front wear pads Use Loctite 770 or equivalent on the wear
74. 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 occurs isolate whether the problem is electrical or hydraulic and then isolate and correct the specific problem The content of this section is separated into probable cause and remedy The information 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 SKYVACK Vertical Mast Series Page 67 Model SJ12 155185 e Service and Maintenance Section 4 Troubleshooting Information Electrical System 4 1 1 All Controls Inoperative 1 2 3 Battery charger plugged into external power source Disconnect charger cord Batteries disconnected Connect batteries Dirty or loose battery terminals Clean and tighten connections Battery charge low Check each cell with a hydrometer Reading should be 1 275 fully charged Recharge if low reading Replace if reading difference between cells is 0 050 Main battery cables open or defective Check continuity Replace if defec
75. n 3 System Component Identification and Schematics 3 5 Electrical Component Parts List SUPPLY B Common CONTROL B gI 86 GROUND B Q HT c NORMALLY NORMALLY CLOSED OPEN CONTACT CONTACT ou mi ti Qty Description 14CR 108589 1 RELAY 24 Volt 40 Amp Base control centre Lift speed 14CR1 108589 1 RELAY 24 Volt 40 Amp Base control centre Lift speed 2 15BCR 108589 1 RELAY 24 Volt 40 Amp Base control centre Reverse cutout 16BCR 108589 1 RELAY 24 Volt 40 Amp Base control centre Forward cutout 17CR 108589 1 RELAY 24 Volt 40 Amp Base control centre Steer 21CR 108589 1 RELAY 24 Volt 40 Amp Base control centre High speed 28CR 108589 1 RELAY 24 Volt 40 Amp Base control centre Tilt 59ACR 108589 1 RELAY 24 Volt 40 Amp Base control centre Base control 2H 13 151683 1 COIL 24 Volt Emergency lowering valve 3H 14A 151683 1 COIL 24 Volt Lift valve 3H 17 151683 1 COIL 24 Volt Brake valve 4H 15A 151682 1 COIL 24 Volt Reverse drive valve 4H 16A 151682 1 COIL 24 Volt Forward drive valve 4H 23 151683 1 COIL 24 Volt Right steer valve 4H 24 151683 1 COIL 24 Volt Left steer valve B1 103480 1 BATTERY 6V B2 103480 1 BATTERY 6V B3 103480 1 BATTERY 6V B4 103480 1 BATTERY 6V BC1 122093 1 BATTERY CHARGER INDICATOR Platform control console BP 29 103057 1 BEEPER 4 28 VDC Slow pulsing Base control centre BP 49 146649 1 HORN 24V Low tone CB1 117325 1 CIR
76. n Ske k RN UU EE DUE CM DL AR id ieee M PE ka pep 20 12 Function TOULE iii si kek p kr n kk a ke ka Zin kk L En a a EE e n ED e e a ek Wanna eae 25 Tables Table LI Owner s Anual Dispecti n Red aia sacs i kap ik patan looms k k via ak ok e A FI REN EPUM DICIT RR e era 18 Table 1 2 gad Inspection C EecEl8E kl s s tre ki ka kk a d K ko ENE RAPY kika ka pre kb bd 19 SKYVACK Vertical Mast Series Page 5 Model SJ12 155185 Q Notes SKYVACK Page 6 Vertical Mast Series Model SJ12 Q 155185 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 Purpose of Equipment The SKYJACK Vertical Mast series aerial platform are designed to transport and raise personnel tools and materials to overhead work areas Use of Equipment The aerial platform is a highly maneuverable mobile work station Lifting and driving must be on a flat level compacted surface Manuals Operating The operating manual is considered a fundamental part of the aerial platform It is a very important way to communicate necessary safety information to users
77. nd a picture indicating the direction of both TS1 Tilt Switch as well as TS2 Tilt Switch As indicated in the picture both Tilt Switches are orientated so the wiring harness as well as the reset buttons face the center of the machine Steer Cylinder End of machine Figure 5 2 Tilt Switch Orientation Vertical Mast Series Model SJ12 155185 TS2 Tilt Switch Section 5 Procedures 5 1 4 Mast Limit Switch Replacement 1 Ensure aerial platform is parked on a film level surface Using base control console raise platform to approximately 61 cm 24 in high Place a 2 x 4 solid wood block approximately 71 cm 28 in long between base and platform see Figure 5 3 Using the base control console carefully and gradually lower the platform until it is supported by the wood block Figure 5 3 Limit Switch Inside the Mast Assembly Push in emergency stop buttons and turn main disconnect switch to Or off position Lock switch to prevent unathorized use during this procedure WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform Locate and remove the mast cover see Figure 5 3 Vertical Mast Series Model SJ12 155185 Service and Maintenance Locate the limit switch inside the mast see Figure 5 4 Limit Switch Figure 5 4 L
78. 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 offs is absolutely neces sary 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 elevated Af ter elevation the drive func tion must not be activated 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 de scending grades up to maxi mum rated inclines listed in Table 2 3 Vertical Mast Series Model SJ12 155185 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 in crease its size or work height It is prohibited DO NOT exert side forces on aerial platform while elevated DO NOT use the aerial plat form as a crane It is pr
79. ntenance Function Tests B B Ge e Main Power Disconnect Switch Base Emergency Stop 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 N 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 9 Start Operation of the Operating manual 1 2 1 Test Main Power Disconnect Switch 1 Atrearofthe base turn main power disconnect switch to off position and attempt to activate all aerial platform functions Result Aerial platform functions should not operate Vertical Mast Series Model SJ12 155185 1 2 2 Base Control Console Turn main power disconnect switch to on
80. ntrol cable from the NOTE control cable male connector See Figure 5 9 Ensure all the cables are clear and in place Remove the control cable male connector fromthe 12 Carefully lift the platform mast 4 assembly off the connector block See Figure 5 9 base with use of suitable lifting equipment Remove the limit switch cable from the controlcable 13 Place the platform mast 4 assembly on a suitable connector by using tool Wieland Kontakt Gedreht stand 05 5020710 0 14 Un roll the two outer chain off the mast 3 rollers and Remove the control cable connector box from the place them inside mast 1 See Figure 5 11 mast See Figure 5 9 8 Place all cables and connectors into mast 1 N WARNING Be aware of overhead obstructions or other possible hazards around the machine when lifting A WARNING Ensure all components are secured before lifting 9 Carefully lift the platform mast 4 assembly up about 2 to 3 with use of suitable lifting equipment Ensure the weight of the platform mast 4 assembly is supported by the lifting equipment 10 Remove the outer chain mount bolts on mast 4 Figure 5 11 Positioning of Outer Chains on Mast 3 15 Inspect and replace any worn or damaged components if required SKYVACK Vertical Mast Series Page 89 Model SJ12 155185 Service and Maintenance 5 3 2 2 Mast 3 Assembly Removal 1 2 Carefully lift mast 3 assembly up about 2 to 3 with u
81. o operating the aerial platform to identify potential hazards in your work area aware of moving equipment in the area Take appropriate actions to avoid collision Entering and exiting the aerial platform should only be done using the three points of contact Use only equipped access openings Enter and exit only when the aerial platform is in the fully retracted position Do use three points of contact to enter and exit the platform Enter and exit the platform from the ground only Face the aerial platform when entering or exiting the platform SKYVACK Vertical Mast Series Page 13 Model SJ12 155185 Operator s Responsibility for Maintenance Maintenance and Inspection Schedule The actual operating environment of the work platform governs the use of the maintenance schedule The inspection points covered in Table 1 2 Maintenance and Inspection Checklist indicates the areas of the aerial platform to be maintained or inspected and at what intervals the maintenance and inspections are to be performed Owner s Annual Inspection Record It is the responsibility of the owner to arrange quarterly and annual inspections of the aerial platform Table 1 1 Owner s Annual Inspection Record is to be used for recording the date of the inspection owner s name and the person responsible for the inspection of the work platform Replacement Parts Use only original replacement parts Parts such as batt
82. ohib ited DO NOT sit stand or climb on the guardrails It is prohibited DO NOT climb on base and mast It is prohibited BE AWARE of overhead ob N structions or other possible hazards around the aerial plat form when driving or lifting DO NOT raise the aerial plat LUE form while the aerial platform is on a truck fork lift or other 1 device or vehicle O BE AWARE of crushing haz ards Keep all body parts in side platform guardrail DO NOT lower the platform unless the area below is clear of personnel and obstruc tions ENSURE that there are no personnel or obstruc tions in the path of travel including blind spots DO NOT use with improp erly inflated damaged tires or wheels Tires should be checked daily for pressure torn side walls and soft spots DO NOT alter or disable limit switches or other safety de vices Vertical Mast Series Model SJ12 155185 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance Safety Precautions Continued Know and understand the safety precautions before going on to next section BE AWARE of blind spots when operating the DO NOT use the aerial plat aerial platform form witho
83. onsen tk a a tec UC tans ea ae 95 stc T T a n m a a bk a ok em 96 233A Plattor Mast 4 Assembly Installation EPOR oken ERE enacted 97 AN OUE TISSU ued a a a tcl n ka yan leads a 98 2390 NBlastt hau SANON ki l a ka a e A a n e ek a Ek n a mA 98 FO Met Cham meped oom 98 Ower cham Monnt T ANANA GM kt aan ae DR MORE 99 HC SU Double Chain Mount RET 99 SKYVACK Vertical Mast Series Page 81 Model SJ12 155185 Q Notes SKYACK Page 82 Vertical Mast Series Model SJ12 Q 155185 Section 5 Procedures Service and Maintenance i General The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this section 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 restin an unstable position When raising a portion ofthe equipment ensure that adequate support is provided Electrical System 5 1 1 Resistor Voltage Divider RST2 3 4 5 and 8 Resistor Voltage RST6 Voltage In Resistor Out Common
84. os acca ese seni od e e AR pk a e A venir HEAR TENERE ER Heo 83 Electrical System Diet M 83 24 Troubleshootgg Danos atu cto ER I ea pk pa eh ass RE SERM eru EDD Dol kak e bo ok DL LU tM ks RENE kas 84 2l T S NEN KONTAN MONN s k a rtt po in ke ek P LO MEDECIN NIRE RE OF XE 84 Sule Mast Lust Switch REN SEA a a bk kn a geld an e bd koko Re 85 241559 SIW IAN t 86 Hydraulic System 3 271 System Releet Presse Adinen souin riz sona kan ec pp opa ka kek pa e a ak n eee 87 Pressure in NM E 87 Service Procedures SBR IDI PRG CSRS a a a a ke ik kk o and e ea ER 88 Rx NIME CI iri P 88 Endo dil o ERE ak SR E n EA MERE Ep 88 3 SI kt Plar Mant A Bemotsal e ert ORO FR MGR ERI PER aa ERR ER A 88 x xeu E e nba ioni RERO 90 220 MastzAssemble Reina iaceo RE bk venetian CARPERE eden east ere 90 Ir Rotae nid d nr dem 91 20 NATAS neta e a nodo daw tae 93 LC MM S CCS NG up ua nolan ilar clei etal ent elke beak ld 93 2l eis ON ATI anced
85. pad holes and Loctite 431 or equivalent on the wear pad bolts Figure 5 37 Mast 3 Installation Procedure Install the inner chain mounting bolts Use Loctite 242 or equivalent on the mounting bolts and torque to 200 See Figure 5 37 Install the back wear pads Use Loctite 770 or equivalent on the wear pad holes and Loctite 431 or equivalent on the wear pad bolts Roll the two outer chain out and onto the mast 3 rollers Vertical Mast Series Model SJ12 155185 Section 5 Procedures 5 3 3 4 Platform Mast 4 Assembly Installation 1 Carefully lift the platform mast 4 assembly and partially lower it onto mast 3 with suitable lifting equipment 2 Install the front wear pads then the back ones Use Loctite 770 or equivalent on the wear pad holes and Loctite 431 or equivalent on the wear pad bolts See Figure 5 38 Figure 5 38 Mast 4 Installation Procedure 3 Align the two outer chain anchors and install the mast 4 mounting bolts Use Loctite 242 or equivalent on the mounting bolts and torque to 200 Ib in 4 Fully lower the platform mast 4 assembly 5 Organize the platform cables and the platform power outlet box to their correct orientation and install the cable clamps at the top of the mast 4 Use tie wraps if required See Figure 5 39 Figure 5 39 Mast 4 Electrical Cable Installation Procedure Vertical Mast Series Model SJ12 155185 Service and Maint
86. rical Coil Figure 5 29 Emergency Lowering Valve Installation Fish all the platform cables through mast 1 Ensure all cables are in place Keep the connector block and the power outlet box inside mast 1 Install all the cable clamps and the ground wire See Figure 5 30 Cable Clamps Mast Figure 5 30 Cable Clamps and Mast Electrical Cables Installation Connect all the mast electrical connections to the main harness and connect the electrical connection on the emergency lowering valve coil See Figures 5 29 and 5 30 10 Install the lift cylinder hydraulic hose back to the main manifold port L See Figure 5 31 Vertical Mast Series Model SJ12 155185 Section 5 Procedures 2 Figure 5 31 Lift Cylinder Hydraulic Hose Installation 11 Fish all power inlet electrical wires through a rubber boot and install the base power inlet See Figure 5 32 Base Inlet 3 Connector Figure 5 32 Base Power Inlet Installation 12 Secure the base power inlet with rivets 4 5 Vertical Mast Series Model SJ12 155185 Service and Maintenance 5 3 3 2 Mast 2 Installation Install the chains onto mast 2 if removed see mast chain installation procedure in section 5 3 5 for more information Secure mast 2 at the cylinder mount bracket with straps as shown in Figure 5 33 Figure 5 33 Mast 2 Securing Procedure To avoid the limit switch impacting the mast 2 when lowering press the limit switch ar
87. rical cables from mast 1 14 Carefully lift the mast 1 assembly off the base with suitable lifting equipment 15 Place the mast 1 on a suitable stand 16 Inspect and replace any worn or damaged Figure 5 25 Orientation for Mast 1 Installation components if required 2 Install the mast 1 base mount bolts Use Loctite 242 or equivalent on the mount bolts and torque to 23 Ib ft See Figure 5 26 Figure 5 26 Mast 1 Base Mount Bolts Installation SKYVACK Vertical Mast Series Page 93 Model SJ12 155185 06 Service and Maintenance 3 Insert a suitable pin at the lift cylinder head and secure it with straps See Figure 5 27 Lift Cylinder Head Figure 5 27 Lift Cylinder Securing Procedure 4 Carefully lift and lower the lift cylinder into mast 1 Ensure the orientation of the pin hole is aligned with driving direction of the machine 5 Install the lift cylinder manifold bolts and shoulder bolts in the proper orientation Use Loctile 242 or equivalent on the shoulder bolts and torque them to 13 lb ft See Figure 5 28 Lift Cylinder Manifold Bolts l JM l Shoulder Bolts Figure 5 28 Lift Cyinder Manifold Installation SKYZACK Page 94 OYE Section 5 Procedures Install the emergency lowering valve electrical coil and the pull knob Torque the jam nut to 60 See Figure 5 29 Emergency Lowering Valve Pull t Lowering Nut Valve Elect
88. rol box connector pin A8 Check continuity Replace if defective 5 Loose or broken wire 14 in mast control cable or its connectors Check for continuity between base connector X2 pin 2 and platform connector X1 pin A8 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective 6 Loose or broken wire 14 from base terminal block to mast control cable Check continuity Replace if defective 7 Loose or broken wire 14 on base terminal block between diode D14B and diode D14 Check continuity Replace if defective 8 Open diode D14 Check diode Replace if defective 9 Loose or broken wire 14 on base terminal block between diode D14B and low voltage protection resistor RST7 Check continuity Replace if defective 10 Defective low voltage protection resistor RST7 Check resistor and make sure it is secure Replace if defective 11 Loose or broken wire 14A from base terminal block to up valve coil 3H 14A Check continuity Replace if defective 12 Loose or broken wire 02 from base terminal block to up valve coil 3H 14A Check continuity Replace if defective 13 Defective up valve coil 3H 14A Check continuity through coil Replace if defective 14 Machine not level Above high speed limit switch Use on level surface 15 Loose or broken wire 19 from base terminal block to tilt switch TS1 Check continuity Replace if defective 16 Defective tilt switch TS1 Test til
89. rtical Mast Series Model SJ12 155185 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 14 No Drive Forward or Reverse 1 Defective joystick S7 Check joystick Replace if defective 2 Loose or broken wire 7A from emergency stop switch S4 to control box connector pin C1 Check continuity Replace if defective 3 Open or loose diode D12B Check diode Replace if defective 4 Loose or broken wire 12A from diode D12B to control box connector pin B1 Check continuity Replace if defective 5 Loose or broken jumper wire from 12A pin B1 to 7B pin C7 at mast connector X1 ANSI CSA only Check continuity Replace if defective 6 Loose or broken wire 12A from mast connector X1 pin B1 to drive cutout limit switch LS5 CE only Check continuity Replace if defective 7 Drive cutout limit switch LS5 defective or out of adjustment CE only Check switch for adjustment Replace if defective 8 Loose or broken wire 7B from drive cutout limit switch LS5 to mast connector X1 pin C7 CE only Check continuity Replace if defective 9 Loose or broken wire 7B in mast control cable or its connectors Check for continuity between base connector X2 pin 11 and platform connector X1 pin C6 on cable Check for loose or corroded connections on cable connectors Replace if wire is defective 10 Loose or broken wire 7B from mast control cable to tilt sw
90. s See Figure 5 19 Lift Cylinder Manifold Lift Cylinder Shoulder Bolts Figure 5 19 Lift Cylinder Manifold and Securing Bolts Removal 5 Remove all the cable clamps base support plate and ground wire at the mast 1 base See Figure 5 20 and 5 21 Cable Clamps Mast Electrical Connection Base Support Plate Figure 5 21 Base Support Plate SKYVACK Page 92 e Section 5 Procedures 6 Insert a suitable pin at the lift cylinder end See Figure 5 22 Lift Cylinder End Figure 5 22 Cylinder Lifting Procedure 7 Carefully lift the lift cylinder with attached straps and suitable lifting equipment Ensure all cables are clear out of the way and in place 8 Place the cylinder on a suitable stand 9 Remove the base inlet connector from the base See Figure 5 23 Base Inlet Connector Figure 5 23 Base Inlet Connector Removal 10 Remove the electrical wires from the base inlet connector 11 Disconnect the mast electrical connection from the main harness 12 Remove the mast 1 mount bolts See Figure 5 24 Vertical Mast Series Model SJ12 155185 Section 5 Procedures Service and Maintenance css 5 3 3 0 Mast Installation 5 3 3 1 Mast 1 Installation 1 Carefully lift and lower mast 1 assembly on the base in proper orientation with a suitable lifting equipment See Figure 5 25 Figure 5 24 Mast 1 Mount Bolt Removal 13 Remove all the elect
91. s or damaged cables and connections can result in component damage and hazardous conditions N WARNING Explosion hazard Keep flames and sparks away Do not smoke near batteries N 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 Check battery case for damage Clean battery terminals and cable ends thoroughly with a terminal cleaning tool or wire brush Ensure all battery connections are tight are not covered by at least 1 2 13 mm of solution add distilled or demineralized water Replace battery if damaged or incapable of holding a lasting charge WARNING Use original or manufacturer approved parts and components for the aerial platform Battery Charger Ensure charger is secure and shows no visible damage 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 Hydraulic Tank Ensure hydraulic filler cap is secure Ensure tank shows no visible damage and no evidence of hydraulic leakage Hydraulic Pump and Motor Ensure there are no loose or missing parts and there is no visible damage SKYVACK Vertical Mast Series Page 23 Model SJ12 155185 Scheduled Maintenance Inspections Section 1 Sche
92. se of suitable lifting equipment Ensure the weight of the mast 3 assembly is supported by the lifting equipment 3 Remove the inner chain mount bolts and wear pads on mast 3 See Figure 5 12 2 Figure 5 12 Mast 3 Components Removal NOTE Ensure all the cables are clear and in place 4 Carefully lift mast 3 assembly off the base with use of suitable lifting equipment 5 Place mast 3 assembly on a suitable stand 6 Inspect and replace any worn or damaged components if required 3 90 Secure mast 3 assembly with suitable lifting equipment Section 5 Procedures 5 3 2 3 Mast 2 Assembly Removal 1 Roll the two outer chains out of mast 1 See Figure 5 13 Figure 5 13 Positioning of the Outer Chains on Mast 2 Remove the cotter pin and the clevis pin at the cylinder mount bracket See Figure 5 14 Cotter e Pin d Figure 5 14 Cylinder Mount Bracket Removal Secure and support mast 2 at the cylinder mount bracket using straps and suitable lifting equipment as shown in Figure 5 15 Vertical Mast Series Model SJ12 155185 Section 5 Procedures Figure 5 15 Mast 2 Backet Support 4 Carefully lift mast 2 assembly up about 5 with use of suitable lifting equipment to allow access to the chain mount bolts Ensure the weight of the mast 2 assembly is supported by the lifting equipment 5 Remove the inner cha
93. seal Rebuild cylinder Replace if damaged 4 2 4 Platform Lifts Slowly 1 Holding emergency lowering valve 2H 13 stuck in the shifted position or is defective Check valve Replace if defective 2 Liftrelief valve R2 defective or not adjusted correctly Adjust valve Replace if defective 4 2 5 Platform Does Not Lift 1 Up valve 3H 14A defective or is sticking Check valve Replace if defective 2 Liftrelief valve R2 defective or not adjusted correctly Adjust valve Replace if defective 3 Hydraulic oil level too low Fully lower the platform Fill hydraulic tank with recommended fluid to appropriate level 4 Platform weight excessive Reduce platform load to maximum capacity 4 2 6 Platform will not Lower NOTE Down function is not proportionally controlled 1 Defective holding emergency lowering valve 2H 13 Check valve Replace if defective 2 Lowering orifice O2 plugged or contaminated Clear debris Replace Orifice Replace if defective SKYVACK Page 78 Vertical Mast Series Model SJ12 155185 Section 4 Troubleshooting Information Service and Maintenance Hydraulic System Continued 4 2 7 Platform Drives Slow 1 Drive motor 1 or M2 defective Check motors Replace if defective 4 2 8 Platform will not Drive in Forward 1 Forward drive valve 4H 16A defective or is sticking Clean Valve Replace if defective 2 Counterbalance valve CB1 defective or is plugged Clean V
94. sible damage and are free from dirt and obstructions Vertical Mast Series Model SJ12 155185 The aerial platform is equipped with solid rubber 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 SKYVACK Page 21 Scheduled Maintenance Inspections Section 1 Scheduled Maintenance AC Outlet Manuals Box Lanyard Attachment Anchors Platform Control Console LT LEZ Platform Assembly 1 1 4 Platform Assembly N WARNING Ensure that you maintain three points of contact to mount dismount platform 1 Open the gate and access the platform 2 Close the gate Ensure all railings are properly positioned and secured Ensureallfasteners are securely in place Ensure gate is in good working order Ensure there are no loose or missing parts and there
95. 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 repair work turn Battery Disconnect Switch to L off position Preventive maintenance is the easiest and least expensive type of maintenance Vertical Mast Series Model SJ12 155185 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 hydraulic circuits Tolerance of working parts in the hydraulic system is very close Even small amounts of dirt or foreign materials in the system can cause wear or damage to components as well as general faulty operation of the hydraulic system Every precaution must be taken to assure absolute cleanliness of the hydraulic oil Whenever there is a hydraulic system failure which gives reason to believe that there are metal particles or foreign materials in the system drain and flush the entire system and replace the filter cartridges A complete change of oil must be performed under these circumstances Whenever the
96. st Chain Slack Inspection Inspect each chain for broken cracked stiff or worn links See Figure 5 44 Replace the chain if required d L 3 MAXIMUM Stiff Links Figure 5 44 Mast Chain Condition Inspection Vertical Mast Series Model SJ12 Q 155185 Section 5 Procedures 5 3 5 2 Outer chain Mount Installation 1 Align the chain to the chain mount pin slot and install the outer chain pin See Figure 5 45 Step 1 Insert outer chain i pin Step 2 Install the Spring Pins Figure 5 45 Outer Chain Mount Installation 2 Center the chain pin in the mount then install the spring pins and tap until flush 3 Repeat steps 1 and 2 for the other end of the chain Service and Maintenance 5 3 5 3 Double Chain Mount Installation 1 Align the chains to the chain mount pin slots and install the inner chain pin Ensure the bevelled edge is facing up See Figure 5 46 Step 1 Insert Inner Chain Pin Bevelled Edge Step 2 Install the Spring Pins Figure 5 46 Inner Chain Mount Installation 2 Center the chain pin in the mount then install the spring pins and tap until flush See Figure 5 47 Tensioner Block Clevis Pin Cotter Pin Bevelled Edge Tensioner Mount Block Figure 5 47 Inner Chain Mount Installation 3 Install the tensioner block to the tensioner mount block with use of the clevis pin and cotter pin Ensure the bevelled edge side is facing up See
97. t Identifications View Parts List BH1 Wheel Brake Right To Brake Manifold BH2 Wheel Brake Left A To Brake Manifold To Drive Motor Left B To Main Manifold M1 Drive Motor Right A To Drive Motor Right M2 Drive Motor Left MT49TOGAA S3 SKYVACK Vertical Mast Series Page 49 Model SJ12 155185 Service and Maintenance Section 3 System Component Identification and Schematics 3 8 Powerpack and Port Identifications T To Main Manifold MB1 Powerpack Manifold View Parts List To Main Manifold TP Test Port R1 Relief Valve SKYZACK Page 50 WT51460AD s3b Vertical Mast Series Model SJ12 Q 155185 Section 3 System Component Identification and Schematics Service and Maintenance 3 9 Platform Control Console Wire Diagram
98. t switch Replace if defective 17 Loose or broken wire 28 from tilt switch TS1 to tilt relay 28CR Check continuity Replace if defective 18 Loose or broken wire 02 from tilt switch TS1 to base terminal strip Check continuity Replace if defective 19 Defective tilt relay 28CR Check relay Replace if defective 20 Loose or broken wire 19A from tilt relay 28CR to base terminal block Check continuity Replace if defective 21 Loose or broken wire 19A on base terminal block between diode D19A and diode D21 Check continuity Replace if defective 22 Loose or broken wire 19A from base terminal block to pump motor contactor Check continuity Replace if defective 23 Defective platform lift resistor RST3 Check resistor and make sure it is secure Replace if defective 24 Loose or broken wire 59C from base terminal block to lift speed relay 14CR Check continuity Replace if defective SKY ACK Page 72 Vertical Mast Series Model SJ12 6 Q 155185 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 9 Up Function Slow from Platform Control Console 1 Loose or broken wire 14 from base terminal block to lift speed relay 14CR Check continuity Replace if defective 2 Loose or broken wire 02 from base terminal block to lift speed relay 14CR Check continuity Replace if defective 3 Defective lift speed relay 14CR Check relay Replace if defective
99. tach lift cylinder hose and tighten Store prop rod back to its holder then lower Service access door and secure it Push the transverse deck back to the working position NOTE Pressure setting may vary as machine components wear The lift pressure should be set for rated load only SKYVACK Page 87 155185 Q Service and Maintenance Section 5 Procedures C Service Procedures 5 3 2 0 Platform Mast removal 5 3 Mast Assembly Procedure 5 3 2 1 Platform Mast 4 Removal 5 3 1 0 Preparation 1 Remove the mast cover See Figure 5 7 1 Ensure the aerial platform is on a flat level ground 2 Use base control raise the platform about 16 off j Mast Cover the base SS a 3 Turn main disconnect switch to off position Lock the switch to prevent unauthorized use during this procedure Figure 5 7 Mast Cover Removal 2 Remove the tie wraps and cable clamps off the cables at the mast top See Figure 5 8 Figure 5 8 Tie Wraps and Cable Clamp Removal SKYZACK Page 88 Vertical Mast Series Model SJ12 155185 Section 5 Procedures Remove the power outlet box If equipped off the mast See Figure 5 9 Power Outlet Box Control Cable Connector Box Service and Maintenance Figure 5 10 Mast 4 Components Removal 11 Remove the wear pads front and back See Figure Figure 5 9 Control Box and Power Outlet 5 10 Disconnect the platform co
100. tform function Result All platform functions should not operate e Test Steering 1 Select lift off drive switch to 8 position 2 Without activating switch enable trigger 3 Press rocker switch on top of controller handle to amp jW left and 7 14 right Result Steer wheels should not operate SKYVACK Page 28 4 Activate and hold de enable trigger switch 5 Press rocker switch on top of controller handle to 4 7 left and H 4 right Result Steer wheels should turn left and right Test Drive Cutout Limit Switch CE 1 Traverse platform to any position then T attempt to drive 4 forward and reverse Result Forward and reverse drive functions should not operate 2 Fully retract platform then attempt to drive T aa forward and reverse Result Forward and reverse drive functions should operate Vertical Mast Series Model SJ12 Q 155185 Section 1 Scheduled Maintenance Function Tests Lift Drive Steer Enable Trigger Switch Lift Off Drive Switch Rocker Switch Controller Emergency Stop Button Operation Light Horn Pushbutton Test Driving 1 Ensure path of intended motion is clear Without activating x enable trigger T Ho switch attempt
101. tic switch S5 to motor controller Check continuity Replace if defective 11 Defective resistor RST6 With joystick fully stroked Check resistor and make sure it is secure Replace if defective 12 Loose or broken B cable from batteries to B lug on motor controller Check continuity Replace if defective 13 Loose or broken B cable from main battery disconnect switch S1 to motor contactor C1 Check continuity Replace if defective 14 Loose or broken B cable from motor contactor C1 to motor DCM1 Check continuity Replace if defective 15 Loose or broken B cable from motor DCM1 to B lug on motor controller Check continuity Replace if defective 16 Loose or broken B cable from motor DCM1 to M lug on motor controller Check continuity Replace if defective 17 Defective motor controller Check motor controller input and output voltage Replace if defective 18 Defective motor DCM1 Check motor for operation with 24 volt supply Replace if defective 4 1 3 All Controls Inoperative From Base Control Console 1 Loose or broken wire 07A from base terminal block to base key switch S10 Check continuity Replace if defective 2 Open or defective base key switch 510 Close switch Replace if defective 3 Loose or broken wire 10E from base key switch S10 to base up down switch S2 Check continuity Replace if defective 4 1 4 No Up Function from Base Control Console 1 Defective up down switch S2 Che
102. tive 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 CB1 Check continuity Replace if defective Loose or broken wire 3A from circuit breaker CB1 to charger relay L1CR Check continuity Replace if defective Defective or tripped circuit breaker CB1 Reset circuit breaker Replace if defective Defective battery charger relay L1CR Check relay Replace if defective Loose or broken wire 5 from charger relay L1CR to base emergency stop switch S28 Check continuity Replace if defective Open or defective base emergency stop switch S28 Close switch Check switch Replace if defective Loose or broken wire 5A from base emergency stop switch S28 to base key switch S10 Check continuity Replace if defective Open or defective base key switch S10 Select function with switch Check switch Replace if defective Loose or broken wire 00 from motor controller to circuit breaker CB2 Check continuity Replace if defective Defective or tripped circuit breaker CB2 Reset circuit breaker Replace if defective Loose or broken wire 02 from circuit breaker CB1 to base terminal block Check continuity Replace if defective 4 1 2 All Controls Except for Down Function Inoperative 1 Loose or broken wire 59B from base terminal block to motor control
103. ty Replace if defective 9 Loose or broken wire 02 from reverse drive valve coil 4H 15A to base terminal block Check continuity Replace if defective 10 Reverse drive valve coil 4H 15A defective Check continuity through coil Replace if defective 11 Open diode D16A Check diode Replace if defective 12 Tilt switch TS2 defective or out of adjustment Adjust the set up of the tilt switch using section 5 of this manual Replace if defective 4 1 20 Two or more Functions at one time 1 Shorted diode Check continuity of all diodes Replace if defective SKYVACK Vertical Mast Series Page 77 Model SJ12 155185 Service and Maintenance Section 4 Troubleshooting Information nnn Hydraulic System 4 2 1 All Functions Inoperative 1 Pump P1 defective Check pump Replace if defective 2 Pump coupler broken or defective Check coupler Replace if defective 3 System relief valve R1 stuck open Clean valve Replace if defective 4 2 2 All Functions Sluggish 1 System relief valve R1 defective or not adjusted properly Adjust valve Replace if defective 2 Hydraulic pump P1 worn Check pump Replace if defective 3 Suction strainer contaminated Clean strainer Replace if defective 4 2 3 Platform Drifts Down 1 Defective holding emergency lowering valve 2H 13 Check valve Replace if defective 2 Defective lift cylinder gland seal Check for hydraulic oil leaking from the gland
104. ut guardrails lock ing pins and the entry gate in STUNT driving and horseplay are prohibited place DO NOT attempt to free a snagged platform with lower controls until personnel are removed from DO NOT exceed the rated capacity of the aerial the platform platform Do make sure the load is evenly distrib uted on the platform DO NOT position the aerial platform against an other object to steady the platform DO NOT place materials on the guardrails or ma D terials that exceed the confines of the guardrails E unless approved by Skyjack DO NOT operate if aerial platform is not working prop erly or if any parts are dam aged or worn DO NOT leave aerial plat form unattended with key in key switch DO NOT useunder influence of alcohol or drugs e DO NOT access the hydraulic electrical compartment while the platform is raised SKYVACK Page 12 Vertical Mast Series Model SJ12 Q 155185 Section 1 Scheduled Maintenance Operator s Responsibility for Maintenance Safety Precautions Continued Know and understand the safety precautions before going on to next section Fall Protection As per the ANSI A92 6 2006 standard The e Three points of contact means that two guardrail system of the aerial platform provides hands and one foot or one hand and two fall protect
105. y the work for which he or she is qualified in compliance with all applicable safety related work practices intended to prevent electric shock covered by the Code of Federal Regulations CFR 1910 333 The operator s level of competence shall be established only by persons qualified to do so Operators shall maintain the appropriate minimum approach distance MAD from energized power lines and parts covered by CFR 1910 333 c Unqualified persons must maintain a minimum approach distance of 10 feet from any energized power line up to 50 kV Energized power lines over 50 kV require a greater minimum approach distance to be maintained Refer to CFR 1910 333 As per CSA B354 4 02 The operator shall maintain the minimum safe approach distance MSAD from energized conductors at all times in accordance with the authority having jurisdiction Refer to CFR 1910 333 or the authority having jurisdiction 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 Avoid Contact Adhere strictly to the governmental rulings and regulations applicable in your country 45 FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY 60023AD i S

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