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Service Manual

1.
2. 3 EMERGENCY STOP 0 a F y D lt Lh a FO 2 21B P o mi 827 di 5 PI 2 09 8 t6 REDWHITE 607A 49 GREEN MTE 7 15 BLACK WHITE 23 6 14 BLUEBLACK 24 RED 5 13 GREEN BLACK 218 OPT 14 BLACK 4 12 H ORANGE BLACK 69 1a ORANGE 3 REDBLACK 18 EF LLLI 2 a Save v P wane 1 s LI BACK VIEW TO PWR DECK SOLENOID VALVES BLACK 27 2MHITE 02 3 GREEN 28 CONTROL OK BLACK 27 24 8 6 3 GREEN 26 a M156955AA DC Electric Scissor Lifts SKYJACK Page 15 Conventional Series 155145 Q Service
3. Print View This Page Parts List 3 14 Hydraulic Schematic Models 46xx A B D E F G H i A RIGHT DRIVE AUTO RESET 04 CH VALVE CASE DRAIN ME EMERGENCY L LOWERING elt 322846264632 cl HAND RUME Pa REAR DANE lt 0067 DIFFERENTIAL DIFFERENTIAL MANIFOLD BLOCK 2H 13 2 ANSIICSA 7 ORFICEQUMO VALVE Low 291382 CE BRAKE RELEASE HOLDINGVANE lt HOLDING VALVE MANIFOLD BLOCK A 4 MANIFOLD BLOCK 07 gt 3 BRAKE ONEWAY Fi P RELIEF VALVE PTI ORIFICE 0020 FLOW DNDER PRESSURE PRESSURE TK COMBINER OVERLOAD OVERLOAD 31842 tal TRANSDUCER TRANSDUCER SPEED 1 DAS 04 OPTION DE oe CYLINDER EMERGENCY CYLINDER EMERGENCY ke 0 LOWERING LOWERING CUSHION 3226 4626 4632 ORIFICE 32204620 ORIFICE HABA JE FREEWHEELING CYLINDER 1 007 5 0067 SPEED VALVE A VALE l C5 PDECK C5 PDECK B3 4 CYLINDER CYLINDER L HOLDNGVAE 3 4 HOLDING VALVE T CASE DR
4. S8 HORN S27 TORQUE SS 128 JH S 18 p HL S3 LIFT OFF DRIVE 94 EMERGENCY STOP ree ll Soll B y ey 15 0 gt lt A k 07 g 7A 21B GREEN BLACK TIED BACK o 78 GREEN 4 RED WHITE 607A 9 GREEN WHITE 7 BLACK WHITE 3 9 PIN CONNECTOR SUB ASSEMBLY _ ey 07 RED 5 GREEN BLACK 218 OPT M BLACK 4 one 2 ORANGE BLACK 59 13 ORANGE 3 RED BLACK 18 15 BLUE 2 oo 0 WHITE BLACK 16 02 WHITE 1 9 NOT USED LA Po HARNESS M oe ee BACK VIEW PIN FUNCTION CTRLBOKHARNESS JOYSTICK HARNESS eee PIN LEFT BUEBACK WHTERED PIN2 STEERNGVS 128 BROWNRED WHTEGREEN RIGHT 23 BLACKWHITE WHITE PIN4 FWDJUP YELLOW II PNS JOYSTICKVS 08 BLUE WHTEBLACK CRDI PING REVIDOWN A PURPLEMHTE GREY PIN7 PWM 59 ORANGE BLACK BLUE AN8 GND WHITE BLACK PINO ENABLE VS BA BLUE WHITE BLUE M156881AA DC Electric Scissor Lifts SKYJACK Page 13 Conventional Series 155145 Q Service and Maintenance Section 3 System Component Identification and Schematics 3 7b Platform Control Console Diagr
5. 3 15 Main Manifold Harness and Holding Valve Harness AC A H INSERT ORIENTATION BOTTOM VIEW FORWARD VALVE RIGHT STEER VALVE REVERSE PIN 1 16 WHITEIBLACK PIN 1 23 BLACK WHITE PIN 2 02 WHITE PIN 2 02 WHITE FORWARD REVERSE VALVE LEFT STEER VALVE PIN 1 15 BLUE PIN 1 24 BLUEIBLACK PIN 2 02 WHITE PIN 2 02 WHITE x TO ELECTRIC PANEL 9 WIRES 02 WHITE amp 13B ORANGE 14 BLACK LOWERING VALVE 13B ORANGE 6 WHITEBLACK 2 RE 02 WHITE 17A BLVE RED 23 BLACKWHITE HOLDING VALVE 04 BLUEIBLACK 138 ORANGE n PROPORTIONAL VALVE 59 ORANGE BLACK 02 WHITE Alle Tan 59 ORANGE BLACK m 02 WHITE A 4 02 WHITE 2 n pe ENS 0 59 w BRAKE VALE ES mj 2 2 q7A BLUEIRED 02 WHITE 7 M146667AA1_S3 DC Electric Scissor LIfts Conventional Series 155145 SKYJACK 23 Print This Page View Parts List
6. 3 16 Electrical Panel Diagram TOLOWER BASE BOX LEGEND me PIN 10E CE TO JOYSTICK BOX 2 TOLOWER KEYSWITCH BOX 7 BE 2 PIN 2 05 GREENIBLACK 8 BLUE WHITE C TOTRINALBLOK N d 389 Diti ipd A TO ENGINE X To BATTERY Le Te TOMANMANFOD Q TOHIGH SPEED LIMIT SWITCH TOREARMANFOLD Li TO POWER DECK e PNT THBACKWHTE PINS 7A GREEN PN2 21 ORANGEBLACK 6 188 CE venose 7 mwan 8 02 02 02 SIRES JE PNS BREDBACQ PNT 19 BWA TOCONTROLMODULE TOHORN 4 18 REDIBLACK PINB 71 BLACKWHTE 1 N LA sa TOREAR MANIFOLD du Gra 08 0 ITEM F 5 PLACES ITEM G 2PLAGES RELAY 1 PINGT RELAY 5 PN 86 A 3A 0 RELAY 42 PIN BB RELAY 46 PIN 6 atta RELAY 3 PIN 86 RELAY 3 PIN 87 RELAY 4 PIV30 FROM KAN DISCONNECT amp CAN _ Li i X o BRAKEISTEERING RELAY RIE PROP CTRL RELAY ol fe TO AT IV PIN 30 178 PIN 30 50 f n 30 PIN 85 17 BRAKE PIN 85 02 PROPORTIONAL 5 PIN 86 02 PIN 86 218 BAK F a k PING 7A PING NU Ge TO CHAR
7. A B D E F G H M MOTORIBRAKE UPPER LIFT CASE DRAN pend un ORFE v 06 28484 REAR DRIVE 0067 DIFFERENTIAL DIFFERENTIAL MANFOLD BLOCK ii a att ORFICE 040 onewe JE MANFOLD BLOCK 1 5 m 24132 FI PTI RELIEF VALVE HOLDING VALVE m psc FLOW DVDER PRESSURE PRESSURE COMBINER OVERLOAD OVERLOAD 8 E TRANSDUCER TRANSDUCER HAND PUMP AUTO RESET LIS OPTION OPTION oe VALVE X LOWER LIFT LOWER LIFT Si B NE EMERGENCY EMERGENCY y LOWERIN 7 1 Ve CUSHION pie 3206 LOWERING 22 3 ME ORIFICE og ORIFICE W gud FREEAHEELING CYLINDER aur d oo SPEED VALVE A VALVE Lo L FRA ko prt BRAKE ONE WAY 20 MBS AN MB3 CS PDECK HODNGWNE t3 i HOLDING VALVE MANIFOLD BLOCK ds MANIFOLD BLOCK mr la CASE DRAIN di CYLINDER RELIEF VALVE HOLDING VALVE HOLDING VALVE LEFT DAVE 407 4H 26 5 MOTOR BRAKE 03 l PS1 OPTIONAL o 2 RETRACT EXTEND STEERORIFICE IC IC PRESSURE a ied B PLATFORM i parom 00 a VALVE S pa K MANIFOLD BLOCK 189 PROPORTIONAL 4 5 4823 MANIFOLD _ WE DAVE RIGHT STEER 2H8 1 w LIFTVALVE LOWERINGVALVE
8. 7 4 1 9 No Down Function from Platform or Base Control Console 7 4 1 10 No Down Function from Base Control 7 Seer Ony Mopper cmm 7 8 43 19 No Drive or Steer when Plafform Fully LOWBIB toten 8 4 1 14 No Drive or Steer when Platform 8 41 15 Elevated Drive Speed Does Not 8 Platformi Dives SAW Speed IND A TA 9 41 17 Forward Drive Function operat dwa bwit da kon bik LE RAN 9 41 18 Reverse Drive Function ausos esee Sec kek kk l ko kk kk es ete etic ta 9 AJISTE Brake wil not F l AS ote ces pene kk n a da n ak n a ak kon a a e e a e kn e dad e A kk 10 4 1 20 Figon Low Torgu gfe AAA EM EE 10 di2 RaM Steer MONER ME on kt e pk tt n a a E A de pa kb E E bon 11 Lm LAA Mire rr ae ees kk et ol ti kk TD 11 4 1 23 Power Extension Platiorm will not Extend or iiie eerte citri 11 41 24 Power Extension Platform will not EXEGUMI iiu dc de ater utero Minero ke BR 12 41 25 Power Extension Platform will not FalEBICL uiui ok dwan
9. DC Electric Scissor Lifts SKYJACK Page 11 Conventional Series 155145 Q Service and Maintenance Section 5 Procedures 5 3 5 Control Module Load Calibration Code Messages amp Definitions During calibration the following failure message may appear Code F01 Check HWFS This message is given if the GP102 startup tests have not completed Check HELP message for more information Code F02 Not Ground Mode This message is given if the machine is not in ground mode P2 2 must be high Calibration can only be carried out in ground mode Code F03 Not Stopped This message is given if any function switch is closed Check DIAGNOSTICS SWITCHES to see which function switch is closed Code F04 Tilted This message is given if the machine is tilted Calibration must be carried out with the machine level If the machine is level use the SETUPS TILT SETUPS to set the GP102 level Code 05 Bad Height This message is given if the height sensor output P4 3 is out of range at the start of calibration The height sensor output must be 3 7V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem Code F06 Check Elev This message is given ifthe elevation switch P2 10 is closed at the start of calibration when the operator has confirmed the PLATFORM DOWN question Ifthe platform is down check the elevation switch wiring Code F08 Check
10. terry ror apa de rer reer teeter tet eT er rT Vitr TA E E 7 Sente Foley and TAN 7 OREL 194 Da cn 7 Cparater Safety Remit E EE 8 EVE UO kk e a too 8 Salay enemas 9 Mamionance and Inspection SOHBOUIS as a ka en dele a a kk IR E EE Foe at pk 12 Owner s BODIE pk dan A ki ki kk pa ep kek ae pe pei ak DO bo RA RE AB RADA BE bak de 12 na n aa n np a a dee i 12 Maintenance and Service Safety TI DE 12 Hydraulic System 8 Component Maintenance and 13 Re es 13 Service and Maintenance ABOUT 15 a 15 ami IS CIN aki kk vo UTR INRA 15 a ero ka eat ke aa ia a moua Ea ek a ana t a a kk a id Cod a Gor vt A on EE PEU E DA AY 15 Scheduled Maintenance Scheduled Maintenance Inspections asuisin 18 2 Foncion T 25 Tables Onnar sAm allnspecion Racord eI 16 ie Mantenance and Inspector CDSORISL ewa al a ia aba kl kk ab a 17 DC
11. a CO WHITE BLACK GREEN 6 61 61 TO POWER CONTROL CONSOLE BACK VIEW FUNCTION CUTOUT 1 BLACK 27 Sez 2 WHITE 08 g3 3 GREEN 26 2947 4 N U EXTENSION PLATFORM CYLINDER HARNESS TO POWER CONTROL CONSOLE BACK VIEW 4 Ti 1 BLACK 27 2 WHITE 02 m 3 GREEN 26 27 T 4 N U w D 115592 S3 DC Electric Scissor Lifts SKYJACK Page 17 Conventional Series 155145 lt gt Service and Maintenance Section 3 System Component Identification and Schematics 3 10 Base Control Console Diagram 10 IDLE SW 2 UP SWITCH N C CONTACT N O CONTACT PIN 1 5A PURPLE WHITE PIN 3 10E WHITE BLACK X2 1E BLAGK 2 DOWN SWITCH S10 BASE SW N O CONTACT PIN 3 10E WHITE BLACK i PIN 4 13 ORANGE PIN 4 7A RED BLACK z 24 um en E 10 PLATFORM SWITCH NC CONTACT 628 EMERGENCY STOP PIN1 8C BLUE N C CONTACT PIN2 07 RED PIN 1 PURPLE WHITE PIN 2 05 ORANGE BLACK LED 2 POWER ONILSS LIGHT PIN Xt 02 WHITE PIN X2 TA RED BLACK 0 TO ELECTRIC PANEL N1 07 RED N2 05 3 13 ORANGE N4
12. vmauaua S we 1 9 NOUS 99 01 AN PE 1 i TO PLATFORM CONTROL CONSOLE FRONT VIEW BACK VIEW CONTROL CABLE o o OPT RED WHITE 16 8 GREEN 7A 23 BLACK WHITE 15 7 GREEN WHITE 49 24 BLUE BLACK 14 6 BLUE WHITE BC 0PT GREENBLACK 13 5 _ 4 69 ORANGE BLACK 12 502 4 BACU 3 2 1 M146650AB 53 DC Electric Scissor Lifts Conventional Series 155145 SKYJACK Page 19 lt gt AC Service and Maintenance Section 3 System Component Identification and Schematics 3 12 Holding Valve amp Horn Harnesses and Limit Switch Diagrams HOLDING VALVE HARNESS MODEL X20 19 BlAcK 2 Q WHTE HOLDING VALVE HARNESS MODEL XX26 XX32 HOLDING VALVE PIN 1 13 BLACK PIN 2 02 WHITE LIMIT SWITCH ASSEMBLY MODEL 32xx 46xx HOLDING VALVE LOWER DE D HOLDING VALVE UPPER me EIS HORN HARNESS W 02 WHTE
13. SO SI KEEP CLEAR Width Width Length Cams Es Length es WARNING Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability Therefore replace tires only with the exact original Skyjack approved type Failure to operate with matched approved tires in good condition may result in death or serious injury DC Electric Scissor Lifts SKYJACK Page 5 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 3 Maximum Platform Capacities Evenly Distributed Manual Extension Platform Powered Extension Platform Maximum Tilt Wind Cutout Total Capacity Extension Capacity Total Capacity Extension Capacity Speed Setting 1 5x3 5 1 5x3 5 227 113 kg 1 1 Person 9 4 id ee l 2Persons LONE e ki 1 5x3 5 NOTE Overall Capacity Occupants and materials not to exceed rated load 132AB BEAUFORT Wind Speed SCALE 3 4 5 4 12 5 19 4 11 5 17 75 Papers and thin branches move flags wave 54 80 194 288 17 75 26 25 13 17 Dust is raised paper whirls up and small branches sway Ground Conditions 80 108 28 8 38 9 26 25 35 5 18 24 25 Shrubs with leaves start swaying Wave crests are apparent in ponds or swa
14. 2218 1 08 59 2 ORANGE BLACK 9 59 59 2129 PROPORTIONAL OUTPUT Dos A SUED 0 i e s D17 1 DITE A 15 BLUE 15 415 e REVIDN a Sa 36 REVERSE SOLENOID 06 NUETRA 17 gn 4 7 TRANSFER RELAY L B 16 WHITE BLACK 16 26 4H E 4 I 38 FORWARD SOLENOID ENABLE 84 Y D17 00210 7 ENABLE He 39 23 23 BLACK WHITE 23 40 RIGHT SOLENOID 572 Dei b 1 AGH d mium SHATA 7 4 sL a VI 41 BRAKE SOLENOID ii MES 42 LEFTSOLENOD M149743AA DC Electric Scissor Lifts SKYJACK Page 27 Conventional Series 155145 Q Print View This Page Parts List 3 19a Electrical Schematic Models 46xx Equipped with all options AB Serial Breakdown 110 vac LINE VOLTAGE Reference Chart CONTROL BOX BASE i POWERED PLATFORM OPTION
15. 2 AME mai UP DOWN D14E 2 28ECR2 28 02 BATTERY CHARGE SWITCH 22 INDICATOR CRDi CRD2 CRD3 ice 08 02 1987 02 di EE POTHOLE PROTECTION 19BCR 02 4 LIMIT SWITCHES N C H O 2 23 W Y 97 71 ASTI 19184 198 25 2 7K OHMS 156 02 00 71 19 81 ws 28E 02 2d DRIVE OVERRIDE D21 koi LIMIT SWITCH N C 28 29 02 27 11 02 02 WHITE 02 HIGH SPEED LIMIT SWITCHES 151 29 7 18B 30 se N O lt gt DO2 7 18 18 RED BLACK 18 18 J 18A NO H 31 N C pen 21ACR DO2 8 IT 7 4 71 21 21 02 li ai MT LOW VOLTAGE T PROTECTION JOYSTICK PCB e LS1A D14E 1 59 4l 59 Fa ORANGE BLACK DUET 2 59 08 59 59 59 59 59 OUTPUT L 7 1 J 34 DI7C 1 02 lt 35 D17 1 D17C REV DN A 4 15 15 BLUE 15 4 4H 15 55 71 o gt PER Bis 17CR DO29 V a 1 NUETRAL 17 177 02 37 ED 016 1 D16 E B 16 16 _ WHITE BLACK 16 i 4H 16 57 5 27 bir V 1 ENABLE 8A I ENABLE 178 17 E NCHO 23 23 BLACK WHITE 23 4H 23 ae an dni D23 FIGHT ap vA 3H 17A 57 3 LEFT 024 20242 V 24 BLUE BLACK 24 Nh a DPI DO2 13 4 CHARGER BATTERY PACK PUMP MOTOR INVERTER OPTION 15A CIRCUIT BREAKER INVERTER OPTION TIMER POWER ON LED HORN BEEPER FLASHING LIGHT OPTION HOLDING VALVE TWO CYLINDERS HOLDING
16. PIN 1 22 BLACK N U BLUE BLACK cro Om NIU ORANGEIBLACK PIN 2 29 GREEN PIN 3 60 GREEN TO GROUND PIN 4 28 BLACK PIN 5 02 WHITE TO ELECTRICAL PANEL A PIN 6 28E WHITE 5 DC Electric Scissor LIfts Conventional Series 155145 SKYJACK Page 25 Print View This Page Parts List 3 18a Electrical Schematic Models 322x Equipped with all options AB B D E F G H Serial Breakdown 110 VAC LINE VOLTAGE Reference Chart CONTROL BOX BASE 7 1 i POWERED PLATFORM OPTION Serial Number P mE SJ3 3220 60002138 amp ab xren soso E above ewicH SWITCH ium CHARGER V 26 PX o T CUTOUT RELAY SJ3 3226 27006059 8 above BET a 1 CHARGER 27 taz Y d 914 Ba 6V B3 B2 6V Bi r RETRACT SOLENOID 21B 21B GREEN BLACK 21B
17. Serial Number e ec 24V CHARGER EXTEND ENABLE EXTEND SOLENOID RETRACT SJ3 46XX 70006694 8 ab did LICR above SWITCH _ CHARGER e 26 T T CUTOUT RELAY 4H 26 EXT vi e 09 1 CHARGER RET 27 tie s 512 L 6V B3 6V 2 Bi6V A RETRACTSOLENOID 21B 21B GREEN BLACK 21B BATTERY 300A BATTERY BATTERY BATTERY 5 FUSE 24 E s BATTERY D27 D26 1 n 41 41 3 pack S1MAIN S10 ci DISCONNECT ij sj IDLE PLTF BASE iig MOTOR EMERGENCY KEY SWITCH CONTACTOR DCMI STOP IN IDLE POSITION BUHEMOTOR Aa 8 8 BLUE WHITE 8 07 528 6 INVERTER OPTION NCHO EMERGENCY L i STOP 50A FUSE SWITCH 7 zm 7A 07 07 RED 07 07 5 5 05 _ 08 00 An 02 154 CIRCUIT E Tal Mt 15A CIRCUIT kise BREAKER 85 7A GREEN 7A 7A zmer 02 INVERTER OPTION T TIMER 58 A paces Semana 1 02 10E 7 i ___ A 108 10 POWER ON LED e NO PRESSURE ANGLE LED 2 Ht q DRY 4 GREEN MAIT ad TRANSDUCER TRANSDUCER POWER ON LIGHT HORN 49 pcm 4 L x PTI ATI 02 02 X 60 60 RED WHITE 60 00 02 4 4 55 LED 1 POWER ON LSS CONTROL 4013 LIGHT MODULE moe PPP PPB ki 29 35 P3 2 29 14 BEEPER 15 0411 ER P BCI Nyylan Mou vr 22 FLASHING LIGHT BATTERY CHARGE 883 888 HERE
18. Steer Cylinder Wheel Tire Tie Rod Tie Rod Conventionals Ensure there are no loose or missing parts tie rod end studs are locked and there is no visible damage Greasing Points Ensure greasing points have no sign of visible damage and are free from dirt and obstructions Frequent Inspection Locate grease fittings and pump grease as needed DC Electric Scissor Lifts SKYJACK Page 21 lt gt Service and Maintenance Section 1 Scheduled Maintenance Compact Emergency Lowering Access Rod Load Tilt Sensor Greasing Point 1 1 5 HydraulidElectric Tray Side Ensure tray latch is secure and in proper working order Pothole Protection Device Ensure mechanisms have no sign of visible damage and are free from dirt and obstructions Hydraulic Tank Ensure hydraulic filler cap is secure Ensure tank shows no visible damage and no evidence of hydraulic leakage Hydraulic Oil Ensure platform is fully lowered and then visually inspect the sight gauge located on the side of the hydraulic oil tank The hydraulic oil level should be at or slightly above the top mark of the sight glass C Annual Inspection Refer to Section 1 Hydraulic System amp Component Maintenance and Repair Hydraulic Pump and Motor Ensure there are no loose or missing parts and there is no visible damage SKYJACK Page 22 Main Manifold Hydraulic Pump
19. lt a man CONTROL MODULE Z 28 BLACK WHITE 60 GREEN M147918AA 53 SKYJACK Page 24 DC Electric Scissor Lifts Conventional Series 155145 Print View This Page Parts List 3 17 Control Module and Beeper Diagram AC A B D E F G H CM OVERLOAD SENSING MODULE a C v M 1 ST LEVEL INSIDE SCISSOR BEEPER 999 B3 8 OOO 29 RED 02 BLUE N U BLACK O w CONNECT GROUND WIRES TO CONTROL MODULE P4 TOPRESSURE TRANSDUCER PIN 1 910A BLACK LE PIN 2 60A GREEN gt TOANGLETRANSDUCER PNS SDWHITE TEN PIN 910 BLACK PIN2 28B GREEN X CONTROL MODULE P2 PIN 1 NU PIN 2 10E BLACKWHITE BACKVIEW 14BLACK dm PIN4 13 ORANGE PIN 5 NU QLD PN6 NU FROM ELECTRIC PANEL PIN 7 16 WHITE BLACK 02 WHITE PIN 8 15 BLUE 7A RED PIN 9 NU Y 10E BLACK WHITE PIN 10 18B RED BLACK 29 GREEN TO BEEPER 13 ORANGE PIN 11 02 WHITE 22 BLACK LIGHT 14 BLACK PIN 12 7A RED 15 BLUE 02 WHITE 29 n TO CONTROL MODULE P3 2
20. sea MEE BRAKE VALVE be i J A F TES l1 d ma H TE QB AT f TH i 4446 CROSS OVER Pia i P EIE FORWARDDRIVE RELIEF VALVE OPTION 5 Lol NY HA 02 Ti _ _ 1 at LOWERING ORIFICE RUE IL LEFT STEER 2598 SYSTEM RELIEF VALE REFERENCE TABLE WE PRESSURE VANE COUNTERBALANCE VALVE REFERENCE TABLE COMPENSATED PROPORTIONAL SJ3D ORIFICE VALVE LOWERING MODEL ORIFICE MAIN MANIFOLD BLOCK MP oj Vi EMERGENCY LOWERING LOWERING 8320 NONE DeMi VALVE VALVE DC MOTOR BLOCK em MANUAL 3 3226 NONE Pi a RETURN FILTER p fur 2 6 L RESERVOIR 155905 DC Electric Scissor LIfts Conventional Series 155145 Q SKYJACK Page 21
21. 8 5 3 3 LED Error Codes Code Breakdown kon anpasan pansan bon ansan kan 9 5 3 4 Hand Held Calibration Diagnostic Tool Key 11 5 3 5 Control Module Load Calibration Code Messages 8 Definitions sse 12 5 9 8 Control Module Load Calibration Procedure korek kk ARE DRA Ak e AS CIR Rep DA 16 Cune L GE YONN iii ae kin ob Mc 20 DC Electric Scissor Lifts SKYJACK Page 1 Conventional Series 155145 6 Q Notes SKYJACK Page 2 DC Electric Scissor Lifts Conventional Series 155145 Section 5 Procedures Service and Maintenance General The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Al ways be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided Platform 5 1 1 OEM Controller Electronics Information Flow Control Single coil or solenoid for single direction The coil has two connections one is wired to the P C Board A ter min
22. Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened Set up elevation switch to manufacturers specifications and calibrate load Code F20 Height lt gt 0 This message occurs if the platform height is not 0 after the platform has been fully lowered during either STATIC lift The platform must return to the same height each time it is fully lowered Check DIAGNOSTICS SYSTEM to check the height Code F28 Bad Height This message indicates a problem with the height sensor output P4 3 during calibration The height sensor output must be between 1 0V and 4 0V at all times Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem DC Electric Scissor Lifts SKYJACK Page 13 Conventional Series 155145 Q Service and Maintenance Section 5 Procedures Code F42 Low Pressure This message indicates that the pressure transducer output P4 2 is too low 0 5V or less at the beginning of calibration Check DIAGNOSTICS SENSORS to read output Code F43 High Pressure This message indicates that the pressure transducer output P4 2 is too high 4 5V or more at the beginning of calibration Check DIAGNOSTICS SENSORS to read output Code F44 Low Pressure This message indicates that the pressure transducer output P4 2 is too low 0 5V or less at a measurement point Check DIAGNOSTICS SENSORS to read outpu
23. j RET 27 tu 4 et s12 Ba Fi B2 3 RETRACT SOLENOID ata GREEN BLACK an BATTERY 300A BATTERY BATTERY BATTERY D26 027 ay yje TUS yije Yije 4 90 te SS len e 3 51 MAIN 510 IDLE PLTF BASE DISCONNECT MOTOR 4 EMERGENCY KEY SWITCH au CONTACTOR DCM1 STOP IN IDLE POSITION a oc BLUE WHITE se al 07 528 NCHO 2 L a ror 50 FUSE 7 CIN CB2 7A 07 07 07 me 5A 5A 05 A 03 00 02 Nelo 15 CIRCUIT ae 7A GREEN 7A ann La 9 58 HORN a M4 o2 m m SWITCH 10E ma A NO PRESSURE ANGLE LED 2 Hi 08 L 49 49 GREEN WHITE 49 TRANSDUCER TRANSDUCER POWER ON LIGHT non Xl i A N PTI 02 02 60 0 RED WHITE 60 n s d 4 gt MAB LED 1 POWER ON LSS CONTROL 1 35 LIGHT MODULE 29 29 ES 8 P3 2 29 2 14 x oS RR Se ee ee NES Bayi now ow i E E SPR Ei ees P3 1 22 e 15 amp x 3 29s K EN T gt USUS 95 T _ Flee mas P3 5 02 16 53 LIFT DRV LOW DRV HI IN LIFT POSITION 17 ig 08 08 _ 18 A 13 13 L ORANGE 13 13 13 T 13A 13B 19 14 14 BLACK 14 2 14 B m T 20 NOHC 10E Ton 02 28i
24. 155145 AC Section 3 System Component Identification and Schematics Service and Maintenance 3 5 Electrical Component Parts List po pa Qty Description Parts list continued from the previous page AT1 130440 1 TRANSDUCER Angle B1 B4 103480 4 BATTERY 6 Volt U2200 B1 B4 106552 4 BATTERY 6 Volt U2500 B1 B4 4 BATTERY 6 Volt T2200 BC 152070 1 CHARGER Battery 24VDC BCI 122093 1 BATTERY CHARGE INDICATOR BP 29 117967 1 BEEPER 9 28 VDC C1 146475 1 CONTACTOR CB1 149780 1 CIRCUIT BREAKER 10 Amp CB2 149780 1 CIRCUIT BREAKER 10 Amp CM1 130439 1 CONTROL MODULE Integrated sensor 002 129258 DIODE D19A ALARM OPTION DA1 119758 1 DIODE PACK DA2 119520 1 DIODE ASSEMBLY DA3 119624 1 DIODE ASSEMBLY DXX 102921 AR DIODE F1 310517 1 FUSE 300 Amp In line fuse FL 22 121477 1 FLASHING LIGHT 24VDC option H1 146649 1 HORN Operator Low tone LED 1 147061 1 POWER INDICATOR LIGHT Platform control console LED 2 147061 1 POWER INDICATOR LIGHT Base control console LS1A 121975 1 LIMIT SWITCH High speed LS1B 121975 1 LIMIT SWITCH High speed LS4 125887 1 LIMIT SWITCH Pothole protection Battery tray LS5 125885 1 LIMIT SWITCH Pothole protection Hydraulic tray LS6 121975 1 LIMIT SWITCH Drive override PT1 134431 1 TRANSDUCER Pressure 2000 psi Model 3220 4626 4632 134432 1 TRANSDUCER Pressure 3000 psi Model 4620 134543 1 TRANSDUCER Pressure 1250 psi Model 3226 RST1 119629
25. 21ACR 108589 1 RELAY 24 Volt Proportional 28 1 108589 1 RELAY 24 Volt Tilt switch 28CR2 108589 1 RELAY 24 Volt Down 28 1 108589 1 RELAY 24 Volt Auxiliary tilt 28 2 108589 1 RELAY 24 Volt Auxiliary down 2H 13B 103605 1 COIL 24 Volt Lowering valve 2H 13B 1 104493 1 COIL 24 Volt Holding valve 2H 13B 2 104493 1 COIL 24 Volt Holding valve 2H 18A 103613 1 COIL 24 Volt Differential valve 2H 59 115370 1 COIL 24 Volt Proportional valve 3H 14 105610 1 COIL 24 Volt Lift valve 3H 17A 103605 1 COIL 24 Volt Brake valve 3H 18A 1 103613 1 COIL 24 Volt Speed A 18 2 103613 1 COIL 24 Volt Speed B 4H 15 153334 1 COIL 24 Volt Reverse drive spool valve Hytos 128320 1 COIL 24 Volt Reverse drive spool valve Hytos If equipped 4H 16 153334 1 COIL 24 Volt Forward drive spool valve Hytos 128320 1 COIL 24 Volt Forward drive spool valve Hytos If equipped 4H 23 153334 1 COIL 24 Volt Right steer spool valve Hytos 128320 1 COIL 24 Volt Right steer spool valve Hytos If equipped 4H 24 153334 1 COIL 24 Volt Left steer spool valve Hytos 128320 1 COIL 24 Volt Left steer spool valve Hytos If equipped 4H 26 103605 1 COIL 24 Volt Power extension platform extend option 4H 27 103605 1 COIL 24 Volt Power extension platform retract option Parts list continued on the following page SKYJACK Page 8 DC Electric Scissor Lifts Conventional Series
26. AGREN 8 16 RED WHITE 074 02 9 49 GREEN WHITE 7 15 BLACKWHTE 23 L 6 oo 14 BLUE BLACK 24 Do 5 oo 13 GREEN BLACK 218 OPT 14 BLACK 4 12 ORANGE BLACK 59 Be 3 13 ORANGE 3 oo 11 RED BLACK 18 2 10 WHITE BLACK 6 am i 19 nose Sa af as TO POWER EXTENSION PLATFORM BACK VIEW SOLENOID VALVES 1 BLACK 27 2WHTE 02 6 26 E TO POWER EXTENSION PLATFORM CONTROL CONSOLE 7 2 WHITE 09 SOREEN 26 M146620AB SKYJACK Page 16 DC Electric Scissor Lifts Conventional Series Q 155145 Section 3 System Component Identification and Schematics Service and Maintenance 3 9 Powered Extension Platform Control Console and Harness EXTENSION PLATFORM CONTROL CONSOLE
27. Check to be sure manual storage box is parts and there is no visible damage 9 present and in good condition Ensure all fasteners are securely in Ensure manuals are legible and in good place condition Ensure all railings are properly positioned Always return manuals to the manual and secured storage box after use Ensure gate is in good working order e Lanyard Attachment Anchors Ensure attachment rings are secure and no visible damage AC Outlet on Platform Ensure outlet has no visible damage and free from dirt or obstructions DC Electric Scissor Lifts SKYJACK Page 23 Service and Maintenance Section 1 Scheduled Maintenance Powered Extension Control Console Lift Cylinder Maintenance Support Scissor Bumper Scissor Assembly e Powered Extension Control Console If Equipped Ensure all switches are returned to neutral and are properly secured Ensure there are no loose or missing parts and there is no visible damage WARNING Ensure that you maintain three points of contact to mount dismount platform 3 Usethe ladder to dismount from platform 1 1 7 Lifting Mechanism 1 Raisethe platform until there is adequate clearance to swing down the maintenance support Maintenance Support Ensure maintenance support is properly secured and shows no visible d
28. WIRE WIRE WIRE Wire coop 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 YEL 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 05 PUR 28 GRN 51 BLK GRN Nos 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 REDE 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 WHT BLU 83 BLU GREY 110B BRN 15 BLU 38 ORG RED 61 GREY BAN 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 113 BLU BRN 18 GRN BLU 41 BLU PUR 64 WHT BRN 88 BLK ORG 114 YEL RED 19 ORG GRN 42 PINK 65 YEL PINK 90 RED GREY 115 WHT PUR 22 PUR GRN 43 WHT YEL 66 ORG YEL 91 RED SHLD 118 PUR PINK This table is to be used as a wi
29. A difference of at least 1V is to be expected Code F15 Check Elev This message is given if the elevation switch P2 10 is closed when the platform has been fully lowered at the end of calibration This message would occur if the DOWN switch was accidentally opened before the platform was fully lowered platform is fully lowered check the elevation switch Code F16 Low Elev open This message is given if the elevation switch P2 10 opened during lift at a too low height below 5 Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened Set up elevation switch to manufacturers specifications and calibrate load Code F17 High Elev open This message is given if the elevation switch P2 10 opened during lift at a too high height above 25 Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened Set up elevation switch to manufacturers specifications and calibrate load Code F18 Low Elev close This message is given if the elevation switch P2 10 closed during lower at a too low height below 5 Check CALIBRATIONS HEIGHT CALS the ElevDown value shows the recorded height where the switch opened Set up elevation switch to manufacturers specifications and calibrate load Code F19 High Elev close This message is given if the elevation switch P2 10 closed during lower at a too high height above 25
30. BATTERY 300A BATTERY BATTERY BATTERY H FUSE 026 027 id aie 00 BATTERY yf 3 pack 510 ci Sa IDLE PLTF BASE MOTOR 4 EMERGENCY KEY SWITCH CONTACTOR STOP IN IDLE POSITION 5 PUMP MOTOR Aa p 08 8c 8c BLUE WHITE 8C 07 528 L dicio EMERGENCY P INVERTER OPTION STOP 50A FUSE 1 SWITCH 7 7 07 RED 5 an 05 e 03 07 07 07 SA 00 02 10A CIRCUIT B tal e 8 BREAKER 10A CIRCUIT ax 7A GREEN 7A 7A INVERTER OPTION r pL men HT o9 Wim S8 HORN 10E P 7A 7A 22 02 198 SWITCH gt 10 POWER ON LED m NO PRESSURE ANGLE LED 2 08 L 49 49 GREEN WHITE 49 TRANSDUCER TRANSDUCER POWER ON LIGHT HORN 49 1 H 11 HORN N PTI 02 02 60 60 RED WHITE 60 9 LED 1 an POWER ON LSS CONTROL l a LIGHT MODULE 29 29 383 PP HE P3 2 29 14 BEEPER S x G amp KES X Sepik ton Y x li FLASHING LIGHT 2 L8 amp amp P3 1 22 3 15 88 8 S N 8 OPTION Ras SER P3 5 02 16 7 HOLDING VALVE TWO CYLINDERS BCI BATTERY CHARGE INDICATOR 08 02 13 ORANGE 13 L 13 13 194 786 19 DOWN SOLENOID X 5 02 LIFT 14 BLACK 14 52 14 a L 20 SOLENOID DRIVE 10E T 28E 02 SWITCH l 14E 21 AUX DOWN RELAY A apr 46 UP DOWN DI4E2 288082 gy 02 SWITCH 22
31. Check continuity Replace if defective 4 1 26 Two or more Functions at one time 1 Shorted Diode Check continuity of all diodes Replace if defective SKYJACK Page 12 DC Electric Scissor Lifts Conventional Series 155145 Section 4 Troubleshooting Information Service and Maintenance Hydraulic System 4 2 1 All Function Inoperative 1 Proportional valve 2H 59 defective or is sticking Check valve Replace if defective 2 Pump P1 defective Check pump Replace if defective 4 2 2 All System sluggish 1 System Relief Valve defective or not adjusted properly Adjust valve Replace if defective 2 Hydraulic pump P1 worn Check pump Replace if defective 3 Proportional valve 2H 59 contaminated or defective Clean Replace if defective 4 2 3 Platform Drifts Down 1 Defective lift cylinder seals at the gland or holding valve manifold Replace if damaged Note There are no piston seals just wear rings 2 Combination of defective holding valves 2H 13B 1 and 2H 13B 2 and either defective lowering valve 2H 13B or relief valve R2 or manual lowering valve V1 Check valves Replace if defective 4 2 4 Platform Lifts Slowly 1 Open or leaking manual lowering valve V1 Close valve Replace if defective 2 Lift relief valve R2 defective Check valve Replace if defective 3 Open manual override on holding valve 2H 13B 1 or 2H 13B 2 Depress and turn manual override clockwis
32. Operator s Responsibility for Maintenance Safety Precautions Continued Know and understand the safety precautions before going on to next section DO NOT exceed the rated capacity of the aerial platform Do make sure the load is evenly distributed on the platform DO NOT attempt to free a snagged platform with lower controls until personnel are removed from the platform DO NOT position the aerial platform against another object to steady the platform DO NOT place materials on the guardrails or materials that exceed the confines of the guardrails unless approved by Skyjack N WARNING Entering and exiting the aerial platform should only be done using the three points of contact Use only equipped access openings Enter and exit only when the aerial platform is in the fully retracted position Do use three points of contact to enter and exit the platform Enter and exit the platform from the ground only Face the aerial platform when entering or exiting the platform Three points of contact means that two hands and one foot or one hand and two feet are in contact with the aerial platform or the ground at all times during entering and exiting DC Electric Scissor Lifts N WARNING An operator should not use any aerial platform that does not appear to be working properly has been damaged or appears to have worn or missing parts has alterations or modifications not approved by the manufacturer has
33. functions should not operate SKYJACK Page 26 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Function Tests Conventional Compact Back View Back View Free wheeling Valve Lower Lower Neutral Raise Neutral Raise Switch Switch Emergency Stop Emergency Stop Button Off Platform Base Switch Button Test Emergency Lowering Test Free wheeling 1 Raise the platform 1 Ensure path of intended motion is clear 2 Locate holding valve manual override 2 Release the brake manually knob at the base of each lift cylinder Depress and turn counterclockwise If 3 Turn free wheeling valve knob necessary use access rod that is located counterclockwise to a fully opened on the base of the aerial platform position and attempt to push pull the aerial platform 3 On hydraulic electric tray pull out and Result Platform should move hold emergency lowering valve to fully lower the platform 4 Turn free wheeling valve knob clockwise Result The platform should lower to a fully closed position for normal operation 4 Torestore normal operation depress and turn holding valve manual override knobs 5 Reengage the brake clockwise DC Electric Scissor Lifts SKYJACK Page 27 lt gt Function Tests Section 1 Scheduled Maintenance Lift Drive Steer Enable Lift Drive Steer Enable Trigger Switch Rocker Switch Trigger
34. 1 Electrical Symbol CMAN 3 3 2 Pedes S AD DEDE a vii ek pa ek a a a pa er a 4 3 3 Wire Colar COUE e e 5 Parts List 3 4 gat ees SO giv PAN KA ete ka Poe a bon a ak 6 3 5 Electrical Gorpenents Farts da bebe Kp vote aks ab piki 8 Diagrams and Schematics 3 6 Hydraulic and Por 16 ANNE ANONS a E PR EE ke ke kak napa kas 11 asa Control Console DISSE teeta take aki koka beki 13 2279 console ai ay gi azi reca edd it ka apik ae 14 3 8a Platform Control Console with Toggle Switch Powered Extension Platform Modification Diagram 15 3 86 Platform Control Console with Rotary Switch Powered Extension Platform Modification Diagram 16 3 9 Powered Extension Platform Control Console and Harness 010 17 Base Conte Console ines 18 211 Scissor Control Cable Diagram ER PGRE 19 3 12 Holding Valve Horn Harnesses and Limit Switch 20 318 Hydraulic Scnemalic Models 399 Ekinin 21 ab Pydfaulic Schematic Model 4690 d pa ER
35. 1 RESISTOR 2 7K ohm RST2 146644 1 RESISTOR 25W 30 ohm RST3 116505 1 RESISTOR Low voltage protection 1 119725 1 SWITCH Main power disconnect 2 147054 2 N O CONTACT Raise Lower S3 116382 1 SWITCH Toggle 4NT1 1 147053 3 N C CONTACT Lift Drive If equipped 147054 3 N O CONTACT Lift Drive without power extension platform If equipped 4 CONTACT Lift Drive with power extension platform If equipped 54 147053 2 N C CONTACT Emergency stop Platform control console S7 123994 1 PROPORTIONAL CONTROLLER ASSEMBLY Parts list continued on the following page DC Electric Scissor Lifts SKYJACK Page 9 Conventional Series 155145 Q Service and Maintenance AC Section 3 System Component Identification and Schematics 3 5 Electrical Component Parts List Continued P a Qty Description Parts list continued from the previous page S7 1 122869 1 SWITCH Neutral 7 2 122877 1 SWITCH Right steer 57 3 122877 1 SWITCH Left steer 57 6 122872 1 SWITCH Enable pushbutton 58 147054 1 CONTACT Horn 10 147053 2 N C CONTACT Off Platform 147054 1 N O CONTACT Base 11 102853 1 SWITCH Extend Retract Powered extension platform 12 102853 1 SWITCH Enable Powered extension platform 527 115574 1 SWITCH Toggle 1NT1 2 528 147053 1 N C CONTACT Emergency stop Base control console TT 103336 1 HOURMETER SKYJACK Page 10 DC Electric Scissor Lifts e lt g
36. 4 1 8 base controls of this section for more troubleshooting information SKYJACK Page 6 DC Electric Scissor Lifts Conventional Series 155145 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 8 No Up Function from Base Control Console 1 Defective up down switch S2 Check switch Replace if defective 2 Loose or broken wire 14E from up down switch S2 to base terminal block Check continuity Replace if defective 3 Open or defective diode D14E 1 Check diode Replace if defective 4 Open or defective diode D14E 2 Check diode Replace if defective 4 1 9 No Down Function from Platform or Base Control Console NOTE Down function is not proportionally controlled 1 Loose or broken wire 13 from base terminal block to CM1 control module pin P2 4 Check continuity Replace if defective 2 Defective down relay 28CR2 or Aux down relay 28ECR2 Check relay Replace if defective 3 Loose or broken wire 02 from base terminal block to down relay 28CR2 or Aux down relay 28ECR2 Check continuity Replace if defective 4 Loose or broken wire 13 from base terminal block to Aux down relay 28ECR2 Check continuity Replace if defective 5 Loose or broken wire 13A from Aux down relay 28ECR2 to down relay 28CR2 Check continuity Replace if defective 6 Loose or broken wire 13B from down relay 28CR2 to down valve 2H 13B or holding valve 2H 13B 1 and 2H
37. Check that valve wiring is not open The LEDs will light but the intensity will not vary G Check trimpot settings Fully CCW turns output off CW turns output fully on 2 The function jumps or lurches when turned on A Perform Threshold adjustment procedures 3 Thefunction reaches maximum speed before the handle is fully deflected A Perform Maxout adjustment procedures 4 The function speed remains constant regardless of the degree of handle deflection A Perform Maxout adjustment procedures SKYJACK Page 4 IRS Option 1 Function speed reacts too slowly or too quickly in relation to handle deflection A Check IRS Ramp trimpot adjustment CW increases ramp time CCW decreases ramp time Integrated Ramp System IRS Provides smooth function response when reacting an abrupt change in handle deflection CW rota tion of the trimpot increases ramp time and slows the response time CCW decreases ramp time and in creases the response time To increase the ramp time turn the adjusting screw a few turns then move the controller handle abruptly Continue to adjust until a smooth response is observed Most controllers have on off contacts which remove power from the PC Board when the handle is returned to the off position When the handle is abruptly returned to neutral the output will not ramp down and the function will stop Ramp
38. Elev This message is given ifthe elevation switch P2 10 is closed at the end of calibration when the platform should be fully raised This message would occur if the UP switch was accidentally opened near the start of the lift Ifthe platform is fully raised check the elevation switch wiring Code 09 Bad Height This message is given if the height sensor output P4 3 is out of range at the start of calibration The height sensor output must be 3 7V Check DIAGNOSTICS SENSORS to see the output Code F10 Bad Height This message is given if the height sensor output P4 3 is out of range at the end of calibration The height sensor output must be between 0 9V and 4 1V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem Code F11 Not Up This message occurs at the start of calibration if the operator selects a function other than UP Select the UP function only SKYJACK Page 12 DC Electric Scissor Lifts Conventional Series Q 155145 Section 5 Procedures Service and Maintenance Code F13 Low Height Range This message occurs at the end of calibration if the height sensor output did not change sufficiently to give a reasonably accurate platform height estimate This message could occur if the UP switch was accidentally opened too early when the platform is not fully raised DIAGNOSTICS SENSORS can be used to check the height sensor output P4 3
39. Models 3220 4620 4626 C1 124291 CYLINDER Cushion C2 120989 CYLINDER Lift Models 3220 4620 120989 CYLINDER Lift Models 3226 4626 4632 C3 120236 CYLINDER Steer C5 127100 CYLINDER Powered extension platform Models 3220 4620 127100 CYLINDER Powered extension platform Model 4626 CB1 147889 CRV1 115299 VALVE Counterbalance VALVE Cross Over Relief Option F1 109568 FILTER Return FD1 103354 VALVE Flow divider combiner M3 134573 MOTOR Hydraulic wheel Left hand M4 134573 MOTOR Hydraulic wheel Right hand MB1 107354 MB2 107493 MB3 130481 130442 MB4 108195 MB5 7 146563 MB9 132748 BLOCK Manifold Main BLOCK Manifold Emergency lowering BLOCK Manifold Holding valve Models 3220 4620 BLOCK Manifold Holding valve Models 3226 4626 4632 BLOCK Manifold Rear drive BLOCK Manifold Powered extension platform part of cylinder weldment BLOCK Manifold Brake release Models 46xx BLOCK Manifold Proportional control sO st m N m mu a a a a ao ao O2 122213 ORIFICE 0 073 diameter Lowering Model 4620 105530 ORIFICE 0 081 diameter Lowering Model 4632 O3 105811 ORIFICE 0 040 diameter Steer Parts list continued on the following page SKYJACK Page 6 DC Electric Scissor Lifts Conventional Series 155145 Section 3 System Component Identification and Schematics Service and Maintenance 3 4 Hydrau
40. PROPORTIONAL LIMIT SWITCH GROUND PA HYDRAULIC d PUSH BUTTON LI HELD OPEN VALVE COIL 9 SILICON FUSE ELECTRIC ROTARY SWITCH CONTROLLED MOTOR RECTIFIER A O PROXIMITY BREAKER HORN era SWITCH EMERGENCY Q CAM OPERATED PNP v VOLT METER STOP BUTTON EN LIMIT SWITCH TRANSISTOR VARIABLE NPN 4 t pA RESISTOR ig RESISTOR qo TRANSISTOR SINGLE POLE PRESSURE POTENTIOMETER t LEVEL SENSOR SINGLE THROWN VACUUM Lo RELAY SWITCH SINGLE POLE DOUBLE POLE DOUBLE POLE TEMPERATURE DOUBLE THROW P SINGLE THROW LL DOUBLE THROW SWITCH DS RELAY W RELAY r RELAY o TRIPLE POLE DOUBLE THROW Y DIODE L RHEOSTAT TILT SWITCH or RELAY DC Electric Scissor Lifts Conventional Series 155145 e lt gt SKYJACK Page 3 Service and Maintenance Section 3 System Component Identification and Schematics 3 2 Hydraulic Symbol Chart LINE CROSSING VARIABLE DISPLACEMENT PUMP gt SHUTTLE VALVE VELOCITY FUSE LINE JOINED HAND PUMP ACCUMULATOR GAS CHARGED SINGLE ACTING CYLINDER Q 9 med HYDRAULIC CUSHIO
41. TOGETHER 5 4 INVALID LOAD CHECK SENSORS 6 4 HEIGHT NOT CALIBRATED 6 1 INVALID HEIGHT CHECK SENSOR 6 5 EMS INPUTS FAULTY 5 2 B SUPPLY TOO LOW 5 1 P4 1 OR P5 1 SHORT TO 0V 4 1 P3 4 SHORT TO SUPPLY 4 2 P3 4 SHORT TO 0V 4 3 P3 4 SHORT TO SUPPLY 4 4 P3 6 SHORT TO 0V 4 5 P3 6 SHORT TO SUPPLY 4 6 FAULT BAD TILT SENSOR 7 1 FAULT BAD HWFS 7 2 FAULT BAD SLAVE ANALOGS 7 3 FAULT BAD STRAIN MONITORS 7 4 FAULT BAD SLAVE MICRO 7 5 FAULT HWFS STALLED 7 6 STARTUP 7 7 FACTORY OVERRIDE 6 7 60405AB Section 5 Procedures In order to read the fault codes a sequence of pauses and flashes can be seen on the LED mounted on the GP102 module The codes are continuously displayed by the LED until the fault is cleared the GP102 reset and no longer detects the fault or idle timeout becomes active The sequence is as follows 1 Quarter second flashes followed by quarter second pauses indicate the first digit 2 A1 5 second pause 3 Quarter second flashes followed by quarter second pauses indicate the second digit 4 A4second pause Repeat steps 1 4 Since the GP102 only reports one error only one code can be read from the LED per instance If the error is cleared and another error is present it will then be presented SKYJACK Page 8 DC Electric Scissor Lifts Conventional Series 155145 Section 5 Procedures Service and Maintenance LLL 5 3 3 LED Error Codes Code Breakdown Chart Diagnostic s
42. VALVE SINGLE CYLINDER DOWN SOLENOID UP SOLENOID AUX DOWN RELAY DOWN RELAY MOTOR CONTACTOR HOURMETER AUX TILT RELAY TILT RELAY SPEED A SOLENOID DIFF SOLENOID SPEED SOLENOID PROPORTIONAL RELAY PROPORTIONAL SOLENOID REVERSE SOLENOID TRANSFER RELAY FORWARD SOLENOID RIGHT SOLENOID BRAKE SOLENOID LEFT SOLENOID M147346AD DC Electric Scissor LIfts Conventional Series 155145 SKYJACK Page 29 Notes SKYJACK Page 30 DC Electric Scissor Lifts Conventional Series 155145 Section 4 TROUBLESHOOTING INFORMATION Table of Contents ie a e a ET a Electrical System 4 41 2 All Controls Inoperative From Base Control 5 4 1 3 All Controls Inoperative From Platform Control 5 41 4 ar Up Function trom Platform ieu udine e kk Ak kw Rau ke 5 4 1 5 No Down or Reverse Function from Platform Controls 0 entere nns 6 4 1 6 No Up or Forward Only Function from Platform Control 6 41 7 Up Function from Platform or Base Control Console eese treten cate l kk pk pa kk ek ak 6 41 8 Mo Up Function from Base Control
43. and Hydraulic Electric Tray Hydraulic Tank Electrical Panel Ensure panel is properly secured and there is no visible damage Ensure there are no loose wires or missing fasteners Proportional and Main Manifolds Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Ensure there are no loose wires or missing fasteners Load Tilt Sensor Ensure load tilt sensor is properly secured and there is no visible damage Emergency Lowering Access Rod If Equipped Ensure rod is properly secured and there is no visible damage DC Electric Scissor Lifts Section 1 Scheduled Maintenance Service and Maintenance Platform Control Console Platform Railing Manual Storage Box Assembly 1 1 6 Platform Assembly Platform Control Console Ensure all switches and controller are AN WARNING returned to neutral and are properly E secured Ensure that you maintain three points of contact to mount dismount platform Ensure there are no loose or missing parts and there is no visible damage 1 Use the ladder of aerial platform to access Manuals platform Ensure a copy of operating manual and other important documents are enclosed in manual 2 Close the gate storage box Ensure there are no loose or missing M
44. base terminal block to base key switch S10 Check continuity Replace if defective 21 Open or defective base key switch S10 Close switch Replace if defective 21 Loose or broken wire 00 from pump motor to circuit breaker CB1 Check continuity Replace if defective 22 Defective or tripped circuit breaker CB1 Reset circuit breaker Replace if defective 23 Loose or broken wire 02 from circuit breaker CB1 to base terminal block Check continuity Replace if defective SKYJACK Page 4 DC Electric Scissor Lifts Conventional Series 155145 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 24 25 26 27 Loose or broken wire 7A from base terminal block to CM1 control module pin P2 12 Check continuity Replace if defective Loose or broken wire 02 from base terminal block to CM1 control module pin P2 11 Check continuity Replace if defective Loose or broken wire 28 from CM1 control module pin P3 4 to tilt relay 28CR1 and down relay 28CR2 Check continuity Replace if defective Loose or broken wire 28E from CM1 control module pin P3 6 to Aux tilt relay 28ECR1 and Aux down relay 28ECR2 Check continuity Replace if defective 4 1 2 All Controls Inoperative From Base Control Console 1 2 Loose or broken wire 10E from base key switch S10 to base up down switch S2 Check continuity Replace if defective Loose or broken
45. e 5A 5A a 05 AA 8 WA 2 NOHO 104 CRCUT BREAKER 74 GREEN 7A BREAKER f Sa fay n 7 10 POWER ON LED al NO PRESSURE ANGLE LED2 Hi 7 W 18 L 4 49 GREEN WHITE 4 TRANSDUCER TRANSDUCER POWER ON LIGHT 9 Xl e 0 N RED WHITE Ar 60 amp ut 2 1 gt na p POWER ONLSS LIGHT 13 P2 8 P32 29 14 BEEPER gee EER a r 888 SES Rh 22 p ei BASHING LIGHT Ras M A2 241382 INLET HOLDING VALVE mu ind 17 TWO CYLINDERS 0 08 09 HOLDING VALE 4 mp SINGLE CYLINDER 13 13 ORANGE 13 A 2 yo 2 E Tu 19 DOWN SOLENOID 0023 X fi n n BLACK E A anu ott D 20 UP SOLENOID we h a 4 21 AUX DOWN RELAY BC UPDOWN DUE BATTERY CHARGE SWITCH 80 INDICATOR CADI 6803 4 22 DOWNRELAY 28CR2 sip ena 5 sf 4 27 MOTOR CONTACTOR POTHOLE PROTECTION 42 LIMIT SWITCHES NC HO 10808 as a 1 1 Y pu 0025 m 71 19 19 194 198 zl ls 5 T 4 T 4 25 HOURMETER 00 71 19 h 2 WAN En gt 26 AUK TILT RELAY DRIVE OVERRIDE 021 1 LIMIT SWITCH 8801 ng L o f 082 4 27 TILTRELAY 2 02 WHITE 0 28091 HIGH SPEED m ee LIMIT SWITCHES 1918 29 SPEED SOLENOID Y m Le ue 30 DIFE SOLENOID ott 18 18 RED BLACK 18 NE zc p Don rut 31 SPEED SOLENOID z 71 2 2 JOYSTICK MET 4 2 La a2 PROPORTIONAL JOYSTICK PCB LSTA 5 Y DUE1 59 gi
46. menu and press the ENTER button 12 The display will show Defaults 0 Custom By using Left Right buttons select the X Group Code from the menu and press the ENTER button 18 The display will show GROUP CODE Refer to 5 3 7 for group code By using the Up Down buttons enter the Group Code then by using Left Right buttons select the Curve from the menu 14 The display will show CURVE Refer to 5 3 7 for curve code By using the Up Down buttons enter the Curve Code followed by pressing the ESCAPE button 15 The display will show Machine Defaults By using Left Right buttons select the Tilt Setups from the menu and press the ENTER button 16 The display will show Tilt Setups Calibrate Level Select the Tilt Setups Calibrate Level from the menu and press the ENTER button 17 The display will show Calibrate Level Yes Enter No ESC Select the Yes from the menu by press the ENTER button 18 The display will show Calibrate Level 0 0 0 0 Select the ESCAPE from the menu once 19 The display will show Tilt Setups Calibrate Level Select the ESCAPE from the menu once again 20 The display will show Setups Tilt Setups By using Left Right buttons select the Load Setups from the menu and press the ENTER button 21 The display will show Load Setups Calibrate Load Select the Load Setups Calibrate Load from the menu and press
47. ok arid ke aka ak kk kk DA EX EROR 12 1 26 TWO Of more Funcions atone UMO 12 Hydraulic System 4 amp 2 JMEUncaon 13 400 ANS ANT INA Eis ra percer andit aia Pere ensi Fu Flap buc edo Fat e uh PER o PR REP pP 13 Ar Petri Diis A Lk 13 qoe 13 A 13 4D BATON Will inoa RF ERO EG ai a 13 ac Paion DEJES SII sinon xp EHE 14 4 2 8 Platform will not Drive in Forward or Reverse sssssscssscscccscctscssssssessesuscescesecunocusecuessssescetecencenacusectesenscs 14 42 5 will MO RDAS Ree eet ee 14 42 10 will not Bold on a Grade 14 4211 Pastor ess 14 4 2 12 Power Extension Platform will not Extend or 0004 0 000 14 42413 Higlybow Torgue kai oak kk aiaia 15 DC Electric Scissor Lifts SKYJACK Page 1 Conventional Series 155145 Q Notes SKYJACK Page 2 DC Electric Scissor Lifts Conventional Series 155145 Section 4 Troubleshooting Information Service and Maintenance Introduction The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble which can develop Careful and accurate analysis of the systems listed in the table
48. platform and must not be used without manufacturer s consent All replacement tires must be of the same size and load rating as originally supplied tires to maintain safety and stability of aerial platform Consult SKYJACK s Service Department for optional tires specifications and installation N WARNING Any unit that is damaged or not operating properly must be immediately tagged and removed from service until proper repairs are completed SKYJACK Page 12 Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this aerial platform All maintenance and service procedures should be performed in a well lighted and well ventilated area Anyone operating or servicing this aerial platform must read and completely understand all operating instructions and safety hazards in this manual and operating manual All tools supports and lifting equipment to be used must be of proper rated load and in good working order before any service work begins Work area should be kept clean and free of debris to avoid contaminating components while servicing All service personnel must be familiar with employer and governmental regulations that apply to servicing this type of equipment Keep sparks and flames away from all flammable or combustible materials Properly dispose of all waste material such as lubricants rags and old parts according to the
49. platform including while the aerial platform is on a the rated load e g covers drains and trenches truck fork lift or other device or vehicle DO NOT operate an aerial platform that has ladders scaffolding or other devices mounted on itto increase its size or work height It is prohibited BE AWARE of crushing hazards Keep all body parts inside platform guardrail DO NOT exert side forces on aerial platform while elevated DO NOT lower the platform unless the area below is clear of personnel and obstructions DO NOT use the aerial platform as a crane It is prohibited ENSUREthatthere are no personnel or obstructions in the path of travel including blind spots DO NOT sit stand or climb on the guardrails It is prohibited BE AWARE of blind spots when operating the aerial platform DO NOT climb on scissor arm STUNT driving and horseplay are prohibited assembly It is prohibited u ENSURE ALL tires are in good condition and lug nuts are properly tightened DO NOT alter or disable limit switches or other safety devices BE AWARE of overhead obstructions or other possible hazards around the aerial platform when driving or lifting DO NOT usethe aerial platform without guardrails locking pins and the entry gate in place SKYJACK Page 10 DC Electric Scissor Lifts Section 1 Scheduled Maintenance
50. relative law provisions obtaining in the country Before attempting any repair work turn Battery Disconnect Switch to the OFF position Preventive maintenance is the easiest and least expensive type of maintenance DC Electric Scissor Lifts Section 1 Scheduled Maintenance SC SSCs Hydraulic System amp Component Maintenance and Repair The following points should be kept in mind when working on the hydraulic system or any component 1 Any structure has limits of strength and durability To prevent failure of structural parts of hydraulic components relief valves which limit pressure to safe operating values are included in the hydraulic circuits Tolerance of working parts in the hydraulic system is very close Even small amounts of dirt or foreign materials in the system can cause wear or damage to components as well as general faulty operation of the hydraulic system Every precaution must be taken to assure absolute cleanliness of the hydraulic oil Whenever there is a hydraulic system failure which gives reason to believe that there are metal particles or foreign materials in the system drain and flush the entire system and replace the filter cartridges A complete change of oil must be made under these circumstances Whenever the hydraulic system is drained check the magnets in the hydraulic reservoir for metal particles If metal particles are present flush the entire system and add a new ch
51. release the lift switch 30 The display will briefly show TOTAL DATA 04 to indicate the number of measurements taken 31 The display will show Calibrate Load Please Lower IMPORTANT If the lower switch is released earlier than full lower position the calibration will have to be aborted and repeated from the beginning 32 Hold the lower switch and keep holding it until the platform is fully lowered 33 When the system detects the lower switch closed the display will show Calibrate Load Lower Empty 34 After a delay the system will stop the platform lowering and will take height amp pressure measurements the display will show MEASURING xx When the measurements have been taken the platform will resume lowering NOTE The lowering stopping measuring lowering process will continue until the platform is fully lowered 35 When the platform is fully lowered release the lower switch 36 The display will show briefly TOTAL DATA 04 to indicate the number of measurements taken 37 The display will show Calibrate Load Caldate mm dd yy It is recommended that the current date be entered here to provide easy taking of the data of last calibration The current date must be entered using the LEFT RIGHT and UP DOWN buttons SKYJACK Page 18 i DC Electric Scissor Lifts Conventional Series 155145 Section 5 Procedures Service and Maintenance 38 Press ENTER to complet
52. safety devices which have been altered or disabled has been tagged or blocked out for non use or repair Failure to avoid these hazards could re sult in death or serious injury Jobsite Inspection Do not use in hazardous locations Perform a thorough jobsite inspection prior to operating the aerial platform to identify potential hazards in your work area Be aware of moving equipment in the area Take appropriate actions to avoid collision SKYJACK Page 11 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance Maintenance and Inspection Schedule The actual operating environment of the work platform governs the use of the maintenance schedule The inspection points covered in Table 1 2 Maintenance and Inspection Checklist indicates the areas of the aerial platform to be maintained or inspected and at what intervals the maintenance and inspections are to be performed Owner s Annual Inspection Record It is the responsibility of the owner to arrange quarterly and annual inspections of the aerial platform Table 1 1 Owner s Annual Inspection Record is to be used for recording the date of the inspection owner s name and the person responsible for the inspection of the work platform Replacement Parts Use only original replacement parts Parts such as batteries wheels railings etc with weight and dimensions different from original parts will affect stability of the aerial
53. the instructions of the Calibration instrument IMPORTANT Make sure the aerial platform is on BASE mode NOTE To ensure a good and clear contact clean the wire terminals before attaching the jumper clip 3 Locate the main manifold inside the hydraulic electric tray 4 Disconnect the black wire 14 from the lift coil 5 Locate the contactor on the electrical panel assembly 6 The jumper connection must be connected between the contractor wire 19B and the lift coil instead of the black wire 14 Main Manifold Contactor JUMPER Insulated Alligator Clip Black wire 14 Wire 19B oil Lift Valve 7 Connect the Easy Cal tool to the P1 connector the CONTROL MODULE SKYJACK Page 16 DC Electric Scissor Lifts Conventional Series Q 155145 Section 5 Procedures Service and Maintenance 8 The display will show Help Press Enter By using Left Right buttons select the Access Level from the menu and press the ENTER button Contact Skyjack Service Department at 44 1691 676 236 for your Access Level Code Number 9 The display will show Access Level Code xxxx By using the Up Down buttons enter the Access Level Code xxxx followed by pressing the ENTER button 10 The display will show Access Level 2 By using Left Right buttons select the Setups from the menu and press the ENTER button 11 The display will show Machine Defaults Select the Machine Defaults from the
54. the lift up switch on Observe the reading on the gauge Adjust the R2 relief valve to the value listed on the serial number plate Turning the stem of the relief valve clockwise will increases pressure Turning the stem counterclockwise will decreases pressure Remove the gauge from lift pressure test port NOTE Pressure setting may vary as aerial platform components wear The lift pressure should be set for rated load only DC Electric Scissor Lifts Conventional Series 155145 Section 5 Procedures Load Sensing System Service and Maintenance NC 5 3 1 Control Module Pin Reference Chart D P4 LED CONTROL MODULE PIN WIRE PLUG AND COLOUR WIRE FUNCTION 1 The Calibration Connection P2 1 Not Used Not Used P2 2 10E Black White Input Power From Base Terminal Strip To Confirm Lower Control Is Selected P2 3 14 Black Raise Platform Input P2 4 13 Orange Lower Platform Input P2 5 Not Used Not Used P2 6 Not Used Not Used P2 7 16 White Black Forward Direction Input P2 8 15 Blue Reverse Direction Input P2 9 Not Used Not Used P2 10 18B Red Black Input From LS1 High Speed Limit Switch To Verify ON OFF Limits P2 11 02 White Negative Input From Base Terminal Strip P2 12 7A Red Main Power Input From Base Terminal Strip P3 1 22 Red Output To FL 22 Flashing Light P3 2 29 Black Output To BP 29 Be
55. to the next measurement height when an EMPTY platform is being calibrated Lower Loaded This message is displayed while the platform is being lowered to the next measurement height when an EMPTY platform is being calibrated Lowering This message is displayed while the platform is being lowered during HEIGHT only calibration Total Data This message is displayed at the end of each phase to confirm the number of measurements recorded by the GP102 Caldate This message is prompting for the date to be entered it is stored to identify when the machine was calibrated The last calibrate date can be viewed in DIAGNOSTICS LOG Press LEFT amp RIGHT to select the flashing digits Press UP amp DOWN to change the flashing digits Press ENTER when the entry is complete IMPORTANT The date 00 00 00 is not allowed Finished This message confirms that calibration is complete and successful DC Electric Scissor Lifts SKYJACK Page 15 Conventional Series 155145 Q Service and Maintenance Section 5 Procedures 5 3 6 Control Module Load Calibration Procedure 1 Move the aerial platform to a test area where the platform can be elevated to its maximum working height and reach 2 Ensure the aerial platform is parked on a firm level surface IMPORTANT Each phase must be completed before the next phase can be carried out All phases must be completed before the aerial platform can be operated IMPORTANT Always follow
56. wire 21A from low voltage protection resistor RST3 to proportional relay 21ACR Check continuity Replace if defective Proportional relay 21ACR defective Check relay replace if defective Loose or broken wire 2 from proportional relay 21ACR to base terminal block Check continuity Replace if defective Proportional controller S7 out of adjustment Adjust controller Refer to Section 5 Joystick Adjusting Procedure 4 1 17 Forward Drive Function Inoperative 1 2 3 Loose or broken wire 16 from lift drive switch S3 to base terminal block Check continuity Replace if defective Loose or broken wire 16 from base terminal block to CM1 control module pin P2 7 Check continuity Replace if defective Loose or broken wire 16 from base terminal block to forward drive valve coil 4H 16 Check continuity Replace if defective Forward drive valve coil 4H 16 defective Check continuity through coil Replace if defective Loose or broken wire 02 from forward drive valve coil 4H 16 to base terminal block Check continuity Replace if defective No output to wire 17 while operating a forward drive function from diode module DM1 at base terminal block TB1 Check for 24 volts at 17 at terminal block Replace diode module if no voltage found or is defective 4 1 18 Reverse Drive Function Inoperative 1 Loose or broken wire 15 from lift drive switch S3 to base terminal block Check continuity Replace if defecti
57. 13B 2 if equipped Check continuity Replace if defective 7 Defective down valve coil 2H 13B Check continuity through coil Replace if defective 8 Defective lift cylinder holding valve coil 2H 13B 1 or 2H 13B 2 if equipped Check continuity through coil Replace if defective 9 Loose or broken wire 02 from holding valve coil 2H 13B 1 or 2H 13B 2 if equipped or down valve coil 2H 13B to base terminal block Check continuity Replace if defective 10 See 4 1 5 platform controls or 4 1 10 base controls of this section for more troubleshooting information 4 1 10 No Down Function from Base Control Console 1 Defective up down switch S2 Check switch Replace if defective 2 Loose or broken wire 13 from up down switch S2 to base terminal block Check continuity Replace if defective 4 1 11 Steer Only Inoperative 1 Defective relay 17CR Check relay Replace if defective 2 Loose or broken wire 17B from diodes D23 and D24 to base terminal block TB1 Check continuity Replace if defective DC Electric Scissor Lifts SKYJACK Page 7 Conventional Series 155145 Q Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 3 4 5 Loose broken wire 17B from 17CR steer relay to base terminal block TB1 Check continuity Replace if defective Loose or broken wire 17C from 17CR steer relay to diodes D17C and D17C 1 Check continuity Replace if de
58. 15 Elevated Drive Speed Does Not Activate 1 Loose or broken wire 59 from base terminal strip to proportional relay 21ACR Check continuity Replace if defective 2 Loose or broken wire 59A from proportional relay 21ACR to resistor RST2 Check continuity Replace if defective 3 Resistor RST2 is open Check resistor ohms it should read approx 30 ohms Replace if defective 4 Loose or broken wire 02 from resistor RST2 to base terminal block Check continuity Replace if defective 5 Proportional relay 21ACR defective Check relay replace if defective SKYJACK Page 8 DC Electric Scissor Lifts Conventional Series 155145 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 16 Platform Drives in Slow Speed Only 1 No output to wire 71 while operating a drive function from diode module DM 1 at base terminal block TB1 Check for 24 volts at 71 at terminal block Replace diode module if no voltage found or is defective Loose or broken wire 71 from base terminal block to high speed limit switch LS1A Check continuity Replace if defective Open or defective high speed limit switch LS1A Check switch Replace if defective Loose or broken wire 21 from high speed limit switch LS1A to base terminal block Check continuity Replace if defective Defective low voltage protection resistor RST3 Check resistor Replace if defective Loose or broken
59. 49 BLACK fa TO ELECTRIC PANEL 02 WHITE 49 BLACK 5 BROWN BLACK LS6 ay L On O ACE 1 1 BLACK WHITE PIN 5 BLUE s G 2 e PIN2 21 BLACK PIN6 188 BROWN On Ot PN3 18 BLACKWHTE PIN7 19 BLACK XD PIN 4 18A BLACK PIN 8 71 BLACKWHITE E BROWN BLACK 3 gt 8 kali Cl 91 m On n XD BLUE BLACK WHITE M129171AA2 M130560AC SKYJACK Page 20 DC Electric Scissor Lifts Conventional Series 155145 Print View This Page Parts List 3 13 Hydraulic Schematic Models 322x
60. 8 7821622 17 19 INDICATOR Aawon gt LM 08 02 P3 5 02 16 02 47 HOLDING VALVE 7 TWO CYLINDERS 1g HOLDING VALVE ASTI SINGLE CYLINDER 2 7K OHMS 02 00 13 ORANGE 13 13 13 13A 13B e a 2 1 19 DOWN SOLENOID X 3 BLACK 2 14 LIFT n 16 20 UP SOLENOID OFF DRIVE 10E Tes 28E T SWITCH LY E 21 AUX DOWN RELAY A P ut UP DOWN subs 2BECR2 1 02 SWITCH 22 DOWNRELAY e CRD2 CRD3 acne 09 192 106 23 MOTOR CONTACTOR jo 08 LI POTHOLE PROTECTION 19BCR LIMIT SWITCHES N C H O 4 24 154 155 Y ou pues 71 72 18 192184 T 25 HOURMETER 186 zt 79 gt 28 02 26 AUX TILT RELAY DRIVE OVERRIDE D21 LIMIT SWITCH N C 28 5 02 gt 27 TILTRELAY D21B 2 02 02 WHITE 211 421 V ug t HIGH SPEED LIMIT SWITCHES LS1B 29 SPEED A SOLENOID Y 27 TORQUE SWITCH ius 30 DIFF SOLENOID e 128 18 RED BLACK 18 18 18 e 31 SPEED B SOLENOID N C mm 21ACR DO2 8 57 71 21 21 21 02 32 PROPORTIONAL RELAY JOYSTICK LOW VOLTAGE T RES PROTECTION 59 59A LSTA Di4E 1 T JOYSTICK PCB H 59 08 59 59 ORANGE BLACK 59 59 2 PROPORTIONAL oureur 34 SOLENOID D17C 1 02 I lt 35 13 D17C A A 1 D17 1 4H 15 REV DN 15 15 1 36 REVERSE SOLENOID pi 15 Dis DO2 9 NUETRAL 1 17 02 37 TRANSFER RELAY mm 14 e 016 L FWD UP 16 _ WH
61. AIN M3 MANIFOLD BLOCK gs 28484 MANIFOLD BLOCK 2494 o LEFT DANE RELIEF VALVE HOLDING VALVE HOLDING VALVE Har PI 4425 AX C3 STEERING Pe RETRACT EXTEND CYLINDER 82 puro NAL INE E OFTIONAL we ln VANE t PRESSURE pe 03 SWITCH 25 T STEER ORIFICE TTE 0 REFERENCE TABLE MANIFOLD BLOCK 30 ORIFICE 189 LOWERING PROPORTIONAL Um ORICE PUER VANE m _ RIGHT STEER Hu 24138 503900 54 ZE MAE _ UFTVAVE LOWERNGVAVE ies EE Z 509 8 MELIH BRAKE VALVE pre HAE zx ke l s g oe 4826 Thee F g a mi H 5484620 073 DA s amp REACT EXTEND w A S 5 BE QM ME ATL 3 L RDDRVE SE ias 5 m i L H _ gn Wu TER la We we 02 RUT t 9840 foot DA 22 al Rt LEFTSTEER LOWERING ORIFICE REEF ew EE r 2H59 SYSTEM RELIEF VALVE SEE REFERENCE TABLE WE MB5 P DECK PRESSURE VALE COUNTERBALANCE VALVE MANIFOLD BLOCK COMPENSATED i L PROPORTIONAL L VALVE WB MAIN MANIFOLD BLOCK MB M LOWERNG TTS EMERGENCY LOWERING DCMI VALVE J VALVE DC MOTOR BLOCK MANUAL 1 MO man RETURN FILTER w RESERVOIR M137018AD1 SKYJACK Page 22 DC Electric Scissor Lifts Conventional Series 155145 Print View This Parts List
62. BLACK 5 10E WHITE BLACK CE N6 8C BLUE 7 TA REDIBLACK N8 02 WHITE 5 2506 4 ap 8 Que 1 707070707070 M149553AA 53 SKYJACK Page 18 DC Electric Scissor Lifts Conventional Series Q 155145 Section 3 System Component Identification and Schematics Service and Maintenance 3 11 Scissor Arm Control Cable Diagram CONTROL CABLE OPTIONS EUROPE NA WIRE COLOUR WIRE NUMBER WIRE NUMBER L ORANGE 3 BWE 9 WHITE 2 18 AED BLACK t1 16 WHITEBLACK 10 o GREEN BLACK 21B 218 REDWHITE 60 7A BACK VIEW FRONT VIEW TO ELECTRIC PANEL CONTROL CABLE 8 t 160 9GREENWHTE 7 15 BLACK WHITE 23 150 07 O BLUEWHTE 6 BLUEBLACK 4 MO 06 5 13 GREEN BLACK we os s 4 o 04 ES 13 ORANGE 3 tt REDBLACK 8 x 2
63. DOWNRELAY CRD2 290R 1 09 jo 08 JL A 19871 02 23 MOTOR CONTACTOR POTHOLE PROTECTION 19BCR LIMIT SWITCHES N C H O 4 154 185 pu 0025 TE 72 19 19 19A 19B ASTI T TT 25 HOURMETER 2 7K OHMS 02 00 gi 19 28 l 02 2 ANN gt 26 AUX TILT RELAY DRIVE OVERRIDE D21 LIMIT SWITCH N C 28ECR 29 02 gt 27 TILT RELAY D21B 2 02 02 WHITE 02 7 2 28CR1 L 28 HIGH SPEED LIMIT SWITCHES LS1B 29 SPEED A SOLENOID Y 27 TORQUE 7A 18B SWITCH 30 DIFE SOLENOID NO RED BLACK 128 ELM 18 1 31 SPEED SOLENOID 21ACR 002 8 57 i 71 s 21 421 21 02 4 PROPORTIONAL JOYSTICK TOW VOLTAGE EM RELAY PROTECTION 1514 6 Y DnE 59 31 594 var JOYSTICK PCB poy 08 59 59 _ ORANGE BLACK 59 7 159 59 2 59 A PROPORTIONAL OUTPUT eee VA SOLENOID D17C 1 02 4 35 REV DN T A4 7 z BLUE lom DI7C ME 15 15 gi A H 36 REVERSE SOLENOID 57 1 15 Dis 17CR 002 9 NUETRAL 17 17 4 02 4 37 TRANSFER RELAY 1 14 B D16 L FWD UP 16 WHITE BLACK 16 4H 16 L 38 FORWARD SOLENOID 57 6 202 10 7 017 ENABLE 8A BA I ENABLE 178 17 25 l 128 23 23 BLACK WHITE 23 4H 23 TV oT 40 RIGHT SOLENOID 57 2 DO2 11 D23 RIGHT 3H 17A 128 4 178 HA 41 BRAKE SOLENOID LEFT D24 DO2 12 24 BLUE BLACK 24 4H 24 24 4 42 LEFT SOLENOID ey tee Ang te Oe et DO2 13 4 M149743AB SKYJACK Page 26 DC Electric Scis
64. E PRAE PD eX eon a RO et a EY esr o CERE EO RD o AR 22 3 15 Main Manifold Harness and Holding Valve 23 ar ED gt Papel D usa siia edis p ebrei aee on del oj epi erp ODER D ol pe a ok RE UI a 24 217 COontrolModuleand Beeper Dig grant kok b k pad b vibe d pik saye pep 25 3 18a Electrical Schematic Models 322x Equipped with all 26 3 18b Electrical Schematic Models 322x Equipped with all 2 27 3 19a Electrical Schematic Models 46 Equipped with all 28 3 19b Electrical Schematic Models 46xx Equipped with all 29 DC Electric Scissor Lifts SKYJACK Page 1 Conventional Series 155145 Q Notes SKYJACK Page 2 DC Electric Scissor Lifts Conventional Series 155145 Section 3 System Component Identification and Schematics Service and Maintenance 3 1 Electrical Symbol Chart CIRCUITS CROSSING LIMIT SWITCH NO CONNECTION HOURMETER a KEY SWITCH se NO 69 LIMIT SWITCH CIRCUITS LIGHT J FOOT SWITCH N O HELD CONNECTED CLOSED LIMIT SWITCH Li or 2 pre 1 NS
65. Electric Scissor Lifts 5 SKYJACK Page 6 Notes DC Electric Scissor Lifts Section 1 Scheduled Maintenance Operator s Responsibility for Maintenance SSS SKYJACK is continuously improving and expanding product features on its equipment therefore specifications and dimensions are subject to change without notice Aerial Platform Definition A mobile device that has a positionable platform supported from ground level by a structure Purpose of Equipment The SKYJACK SJIII Compact and Conventional series aerial platforms are designed to transport and raise personnel tools and materials to overhead work areas Use of Equipment The aerial platform is a highly maneuverable mobile work station Lifting and driving must be on a flat level compacted surface Manuals Operating The operating manual is considered a fundamental part of the aerial platform It is a very important way to communicate necessary safety information to users and operators A complete and legible copy of this manual must be kept in the provided weather resistant storage compartment on the aerial platform at all times Service amp Maintenance The purpose of this is to provide the customer with the servicing and maintenance procedures essential for the promotion of proper machine operation for its intended purpose All information in this manual should be read and understood before any attempt is made to servic
66. GER Borm m 85 2456 2 86 a PINB7a TTC 2 U U L Ualialalalla FM E 49 O T ONE Ot OC 018 O19 O8 Ol Oi ONO p Olomon So a ys 9 ys B 86 57 85 186 57 85 86 57 85 186 gz 85 AUX AX l sza DOW DOWN Tl TI CONTROL CABLE OPTIONS i oe 30 30 02 30 30 RELAY 3 L LI RELAY 6 RELAY 5 LI EUROPE WIRECOLOUR WIRE NUMBER WIRE NUMBER o o o o GREENBIACK 218 28 sym 8 ki so U DOWN RELAY AUX DOWN RELAY TUT RELAY AUX TIT RELAY PIN30 194 PN30 13 PN30 19A 0 19 285 02 PN 86 02 PIN 86 02 PIN 6 02 BACK VIEW FRONT VIEW PIN 86 28 PIN 86 28E PIN 86 28 PIN 86 28E PINGT 198 PING 194 PIN 87 198 PING 194 ME o PIN67a NU AN 67a NU PIN67a NU SA a Y OP REDWATE 5 e l GREEN 7A BATTERY TRAY HYDRAULIC TRAY 29 BLACK WHTE 11 GREENWHITE 9 HO L 72 BLACKINHITE E 72 BLACKIWHITE 2H BLUEBLACK e 138 a BBK PN GREEN BLACK s RED 07 69 ORANGE BLACK 2 BLACK 14 Oh MANMANFOLD f REDBLACK s ORANGE 13 JO t6 WHTEBACK 8 NOT USED a T WWE 9 PLATFORM CONTROL BOX CONTROLMODULE
67. ITE BLACK 16 l m 38 FORWARD SOLENOID Fm l yon 2 8A 8 17B 17 ENABLE 39 B uud 23 BLACK WHITE 23 4H 23 L VI 40 RIGHT SOLENOID ge uu 17A RIGHT 4 128 2 178 17A 41 BRAKE SOLENOID 57 3 D24 DO2 12 LEFT 24 24 _ BLUE BLACK 24 AN 42 LEFT SOLENOID DO2 13 4 CMM an M147346AE SKYJACK Page 28 DC Electric Scissor Lifts Conventional Series 155145 3 19b Electrical Schematic Models 46xx Equipped with all options Print This Page View Parts List AB Serial Breakdown Reference Chart Serial Number 70006693 amp below 43 46 D E H 110 VAC LINE VOLTAGE CONTROL BOX BASE 3 POWERED PLATFORM OPTION EXTEND f EXTEND SOLENOID RETRACT LICR SWITCH 26 TOU cutout RELAY 4H 26 EXT vi apy 09
68. M DURING LIGHTNING OR STORMS eZ DANGER Avoid Power Lines Minimum Safe Approach Distance CE Guidance Note Avoidance of danger from overhead lines Adhere strictly to the governmental rulings and regulations applicable in your country FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY 60023AE CE SKYJACK Page 8 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Operator s Responsibility for 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 jobsite e TURN main power disconnect switch off when leaving the aerial platform unattended Re move the key to prevent unauthorized use of the aerial platform e 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 jewelry while operating this lift AVOID entanglement with ropes cords or hoses AVOID falling Stay within the boundaries of the guardrails DO NOT raise the aerial pla
69. MODELS J 3220 SJ3226 SJ 4620 SJ 4626 SJ 4632 psy Je E 1 A Ye Service Manual ENT E SJIII Conventional Series CE SKYJACK mm Part No 155145AD November 2013 SKYGACK This manual is based on Serial Number s 5113320 60 002 032 TO 60 002 258 52111 3226 27 005 501 TO 27 006 431 SJIII 46xx 70 006 053 TO 70 007 138 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 E mail parts dskyjack com Skyjack Australia Pty Ltd 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel 61 0 28786 3200 Fax 61 0 28786 3222 Parts 8 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 E mail infoldskyjackeurope co uk Skyjack Brasil Alameda Jupiter 710 Loteamento American Park Empresarial Indaiatuba SP Brasil 13347 653 Tel 55 19 3936 0132 DC Electric Scissor Lifts Service Manual Table of Contents Section 1 Scheduled Maintenance Inspections Table of Contents Section 2 Maintenance Tables Table of Contents Section 3 Schematics Table of Contents Section 4 Troublesho
70. N DOUBLE ACTING TANK pe RELIEF VALVE W CYLINDER CYLINDER HYDRAULIC PRESSURE 0 FILTER WITH J Ha REDUCING e le PRESSURE JE y SWITCH L RODDED BYPASS VALVE z CYLINDER ELECTRIC MOTION SPRING APPLIED MOTOR FIXED ORIFICE CONTROL VALVE 11 HYDRAULIC RELEASED BRAKE ADJUSTABLE FLOW DIVIDER BRAKE ENGINE X FLOW CONTROL A COMBINER IT CYLINDER FIXED COUNTER ROTARY cueckvawe Xp MSS VALVE ACTUATOR T Q VARIABLE BI DIRECTIONAL DISPLACEMENT OIL COOLER VALVE COIL HYDRAULIC HYDRAULIC MOTOR MOTOR SERIES TWO POSITION THREE POSITION c PARALLEL B Two WAY FOUR WAY 02 HYDRAULIC NORMALLY TWO POSITION E CLOSED CENTER MOTOR z CLOSED VALVE THREE WAY VALVE EZ OPEN PORT f TWO POSITION Pi THREE POSITION TWO WAY POSITION FOUR WAY Hd NORMALLY Rd WAY VALVE CLOSED CENTER OPEN VALVE CLOSED PORT PRESSURE n TRANSDUCER MAIN LINES Solid PILOT LINES Dashed MW SERVO d MOTOR BRAKE DC Electric Scissor Lifts Conventional Series 155145 SKYJACK Page 4 Section 3 System Component Identification and Schematics Service and Maintenance A nn 3 3 Wire Number and Color Code
71. Relief Pressure Adjustment Locate the system pressure quick disconnect port on the main manifold Install a calibrated 5000 psi gauge to the system pressure quick disconnect port Remove the platform control console the guardrail and disconnect from the main control cable Locate the main control cable plug at the rear of the aerial platform Disconnect the main cable and connect the platform control console into the plug At the main manifold loosen the locknut on the system relief valve R1 Select drive with the lift drive select switch on the platform control console Engaged steer right and hold Observe reading on gauge Adjust the R1 system relief value listed on the serial number plate Turning the stem on the relief valve clockwise will increases pressure Turning the stem counterclockwise will decreases pressure Release steer switch and tighten the locknut Remove the gauge from system pressure test port SKYJACK Page 6 e lt gt Section 5 Procedures 5 2 2 Lift Pressure Adjustment NOTE Adequate area to raise the platform to full height is required for the following steps Locate the lift pressure test port on the main manifold Install a calibrated 5000 psi gauge to the lift pressure quick disconnect port At the main manifold loosen the locknut on the lift relief valve R2 Close the manual lowering valve Use the lift switch at the base control console to raise the platform to full height and hold
72. Switch Rocker Switch Emergency Stop Button Controller Operation Light Emergency Stop Button Operation Light Inclined Drive Level Drive Switch Horn Pushbutton Horn Pushbutton Lift Off Drive Switch Lift Inclined Drive Level Drive Switch Platform Control Console with Toggle Switch Platform Control Console with Rotary Switch 1 2 3 Platform Control Console Test Enable Trigger Switch 1 Ensure base emergency stop button is 1 Pull out emergency stop button pulled out 2 Without activating 454 enable trigger 2 Select off platform base key switch to SM switch attempt to activate any platform platform position function Result All platform functions should not 3 Ensure main power disconnect switch is in p operate on position P e Test Steering WARNING 1 For platform control console with toggle Ensure that you maintain three points of Switch IDA AAGOT IO Monnt Select lift oft drive switch to Ink drive dismount platform position 4 Use the ladder of aerial platform to access For platform control console with rotary platform switch Select lift inclined drive level drive switch 5 Close the gate e to either 4 inclined drive low speed 6 On platform control console pull out high torque level drive high emergency stop button speed low torque position Test Platform Emergency Stop 2 Activate and hold de enable trigger Switch 1 Pus
73. Te an a f 07 al re TA 21B GREEN BLACK TIED BACK o MALE o 5 A 7A GREEN a s ED WHITE 607A 8 GREEN WHITE s BLACK WHITE 2 8C BLUE WHITE 6 t BLUE BLACK 24 on RED 5 OKO GREEN BLACK 218 14 BLACK ORANGE BLACK 59 19 ORANGE REDBLCK 16 98 2 H wes 0g WHITE 1 E A 3 NOT USED aa PIN FUNCTION CTRLBOXHARNESS JOYSTICK HARNESS Ll 1 mE PIN 1 LEFT 24 BLUE BLACK WHITE RED PIN2 STEERING VS 128 BROWN RED WATE GREEN BACK VIEW PIN RIGHT 23 BLACK WHITE WHITE PIN 4 FWD UP B RED YELLOW 6 PINS JOYSTICKVS 08 BLUE WHITE BLACK E ES PIN 6 REVIDOWN PURPLEAVHITE GREY PIN 7 PWM 59 ORANGE BLACK BLUE PIN 8 GND 02 WHITE BLACK CRDI PIN 9 ENABLE VS 8A BLUE WHITE BLUE M146621AA SKYJACK Page 14 e lt gt DC Electric Scissor Lifts Conventional Series 155145 AB Section 3 System Component Identification and Schematics Service and Maintenance 3 8a Platform Control Console with Toggle Switch Powered Extension Platform Modification Diagram Serial Breakdown Reference Chart View Model Serial Number Parts List 3 LIFT OFF DRIVE 8 HORN mean FO S27 TORQUE 2b 70
74. Thru Off The PC Board should be adjusted as outlined in the IRS adjustment procedure If the handle is abruptly returned to neutral OFF the output will ramp down to off Ramp time is factory set to 2 seconds unless otherwise specified NOTE Trimpots should be sealed with nail polish or enamel based paint IN WARNING Do not use RTV silicone DC Electric Scissor Lifts Conventional Series 155145 Section 5 Procedures Service and Maintenance 5 1 3 OEM Controller switch wiring n STEER LEFT STEER COMMON STEER RIGHT WIRE CHART 1 2 3 4 YEL FORWARD UP WHT BLK 24V INPUT PIN 5 HT YEL GRY REVERSE DOWN PIN 6 BLU BLK BU PWM OUT A PIN 7 GROUND PIN 8 WHT BLU ENABLE OUT PIN 9 DOUBLE DOT STEER RIGHT STEER COMMON WHT GRN SINGLE DOT STEER LEFT STEER RIGHT WHT STEER LEFT WHT RED ENABLE OUT WHT BLU 24V INPUT 15589 PCB 24V INPUT WHT BLK ENABLE WHT YEL BLU PWD OUT A BLK GROUND YEL FORWARD UP GRY REVERSE DOWN CONNECTOR DC Electric Scissor Lifts SKYJACK Page 5 Conventional Series 155145 Q Service and Maintenance Base 5 2 1 1 2 10 11 System
75. aded to rated load Press ENTER to confirm if the platform is loaded Please Lift This message is prompting for the platform to be raised The UP switch should be closed SKYJACK Page 14 DC Electric Scissor Lifts Conventional Series Q 155145 Section 5 Procedures Service and Maintenance Please Lower This message is prompting for the platform to be lowered The DOWN switch should be closed Lift Empty This message is displayed while the platform is being raised to the next measurement height when an EMPTY platform is being calibrated Lift Loaded This message is displayed while the platform is being raised to the next measurement height when a LOADED platform is being calibrated Lifting This message is displayed while the platform is being raised during HEIGHT only calibration Measuring This message is displayed when the platform is stopped during calibration when the GP102 takes a measurement There will be a short delay while the machine is allowed to stabilize after movement is stopped Must Go Down This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be lowered Must Go Up This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be raised Please Wait This message indicates that the GP102 is busy the delay will be short no more than 5 s Lower Empty This message is displayed while the platform is being lowered
76. al and the other is wired to or the negative side of the supply voltage Switches to control directional valves may be provided on the controller Adjustment Procedures Adjustments are made by turning a trimpot adjustment screw The trimpots are multi turn end to end devices It may be necessary to turn the adjustment screw several turns to observe a change in output Clockwise CW adjustment of the trimpot increases the output Counter clockwise CCW adjustment of the trimpot decreases the output Adjustments affect output current voltage or per centage of duty cycle to the coil The minimum and maximum output is preset at the factory However for optimum performance they must be adjusted while the equipment is operating Although the following adjustments affect the current voltage or percentage of duty cycle the best way to adjust the function is to observe the response or speed of the function The following adjustments affect func tion response or speed There may be some interaction between adjustments making it necessary to repeat the adjustment in order to achieve the desired response Threshold Adjustments Adjusts the initial current flow or duty cycle affecting the function response or speed when the handle is first moved from the off position Deflect the handle slowly to the position where the controller first turns on Adjust the threshold trimpot screw to the point where the con trolled function ju
77. am Serial Breakdown Reference Chart l Model Serisi Number SJ3 3220 60002137 amp below SJ3 3226 27006058 amp below SJ3 46XX 70006693 amp below S3 LIFT DRIVE SELECTOR BOTTOM SECTION s 2 15 15 ala eu re 3 LIFT DRIVE SELECTOR TOP SECTION S8 HORN View Parts List T a 08 cm re a Di a 9 9 2 z D 3 K 18 49 1 3 LIFT DRIVE SELECTOR MIDDLE SECTION 7 D B S4 EMERGENCY STOP i
78. amage e Scissor Assembly Ensure scissor assembly shows visible damage and no signs of deformation in weldments Ensure all pins are properly secured Ensure cables and wires are properly routed and shows no signs of wear and or physical damage SKYJACK Page 24 Roller e Scissor Bumpers Ensure bumpers are secure and shows no sign of visible damage Rollers Ensure rollers are secure and there is no visible damage Ensure rollers path of travel are free from dirt and obstructions e Lift Cylinder s Ensure each lift cylinder is properly secured there are no loose or missing parts and there is no evidence of damage Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Raise the platform until there is adequate clearance to swing up the maintenance support Swing up maintenance support into storage bracket Fully lower the platform DC Electric Scissor Lifts lt gt Section 1 Scheduled Maintenance Function Tests Conventional Back View Free wheeling Valve Lower Neutral Raise Switch Neutral Raise Emergency Stop Button Off Platform Base Switch Compact Back View Lower Switch Emergency Stop Button 1 2 Function Tests Function tests are designed to discover any malfunctions before aerial platf
79. and Maintenance Section 3 System Component Identification and Schematics 3 86 Platform Control Console with Rotary Switch Powered Extension Platform Modification Diagram Serial Breakdown Reference Chart View Model Serial Number Parts List 60002197 amp below sve 3828 27006058 amp ero sus 70006689 amp eto S3 LIFTIDAIVE SELECTOR 38 HORN BOTTOM SECTION SO LFIDANE SELECTOR 44 Onl FO Terre Tef mL a p DE BIT 2 S3 LIFT DRIVE SELECTOR MIDDLE SECTIO pire O Ds 2 g EN o MAE BA fe 9
80. ange of oil The presence of metal particles also may indicate the possibility of imminent component failure A very small amount of fine particles is normal All containers and funnels used in handling hydraulic oil must be absolutely clean Use a funnel when necessary for filling the hydraulic oil reservoir and fill the reservoir only through the filter opening The use of cloth to strain the oil should be avoided to prevent lint from getting into the system When removing any hydraulic component be sure to cap and tag all hydraulic lines involved Also plug the ports of the removed components NOTE Samples of hydraulic oil should be drawn from the reservoir and tested annually These samples should be taken when the oil is warmed through normal operation of the system The sample should be analyzed by a qualified lubrication specialist to determine if it is suitable for continued use 10 Operator s Responsibility for Maintenance Oil change intervals will depend on the care used in keeping the oil clean and the operating conditions Dirt and or moisture cotamination will dictate that the oil should be changed more often Under normal use and operating conditions the hydraulic oil should be changed every two years Refer to Table 1 2 of this manual All hydraulic components must be dis assembled in spotlessly clean surroundings During disassembly pay particular attention to the identification of parts to assure proper
81. atform DC Electric Scissor Lifts SKYJACK Page 7 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance WARNING Failure to comply with your required responsibilities in the use and operation of the aerial platform could result in death or serious injury Operator Safety Reminders A study conducted by St Paul Travelers showed that most accidents are 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 ofthis aerial platform is mandatory The following pages of this manual should be read and understood completely before operating the aerial platform Common sense dictates the use of protective clothing when working on or near machinery Use appropriate safety devices to protect your eyes ears hands feet and body Any modifications from the original design are strictly forbidden without written permission from SKYJACK Electrocution Hazard This aerial platform is not electrically insulated Maintain a Minimum Safe Approach Distance MSAD from energized power lines and parts as listed below The operator must allow for the platform to sway rock or sag This aerial platform does not provide protection from contact with or proximity to an electrically charged conductor DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING DO NOT OPERATE AERIAL PLATFOR
82. ck switch Replace if defective Loose or broken wire 24 from left steer switch S7 3 to base terminal block Check continuity Replace if defective Loose or broken wire 24 from base terminal block to steer left valve coil 4H 24 Check continuity Replace if defective Defective steer left valve coil 4H 24 Check continuity through coil Replace if defective Loose or broken wire 02 from steer left valve coil 4H 24 to base terminal block Check continuity Replace if defective No output to wire 17B while operating a left steer function from diode module DM1 Check for 24 volts on 17B at the diode module Replace diode module if no voltage found or is defective 4 1 23 Power Extension Platform will not Extend or Retract 1 Lift Drive switch S3 not in lift position Move switch to lift position 2 Loose or broken wire 09 from lift drive switch S3 to power extension platform enable switch 12 Check continuity Replace if defective 3 Power extension platform enable switch S12 defective Check switch Replace if defective 4 Loose or broken wire 09A from power extension platform enable switch S12 to platform extend retract switch 11 Check continuity Replace if defective 5 Loose or broken wire 21B from platform control box to base terminal block Check continuity Replace if defective 6 Open diode D21B 1 Check diode Replace if defective DC Electric Scissor Lifts SKYJACK Page 11 Conventional Se
83. curs immedi ately 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 If applicable check battery fluid level If plates are not covered by at least 13 mm of solution add distilled or demineralized water Replace battery if damaged or incapable of holding a lasting charge N WARNING Use original or manufacturer approved parts and components for the aerial platform DC Electric Scissor Lifts Section 1 Scheduled Maintenance Service and Maintenance Conventional Battery Tray Steer Cylinder Assembly Ensure steer cylinder assembly is properly secured and there are no loose or missing parts Wheel Tire Assembly The aerial platform is either equipped with solid rubber tires or foam filled tires Tire and or wheel failure could result in an aerial platform tip over Component damage may also result if problems are not discovered and repaired in a timely fashion Check all tire treads and sidewalls for cuts cracks punctures and unusual wear Check each wheel for damage and cracked welds Check each lug nut for proper torque to ensure none are loose Check wheel motor assembly for loose or missing parts and signs of visible damage Ensure wheels are aligned and true vertically and horizontally
84. cy Lowering Access Rod AB If Equipped i Lanyard Attachment Anchors AC Outlet on Platform Manuals gt gt gt gt ojojojo Inspection Schedule Schedule A B A B C A B C D Platform Assembly Platform Control Console Powered Extension Control Console If Equipped Lift Mechanism T a el ws Liftcylinder s Function Tests Test Main Power DiscconectSwitth AB se Control Console as Test J 8 LowerNeutralRaise as TesEmegenytewerng as TestFree wheeing 8 1 latform Control Console Test Platform Emergency stop as a Tes gt gt gt ojojw est Brakes 1 gt gt gt gt gt ojojojfojo m z est Platform Raising Lowering Test Lowering Warning est Horn Test Pothole Sensor Test Elevated Drive Speed ab Perform Visual and Daily Maintenance Inspections amp Functions Test Refer to Section 2 of the Operating Manual Perform Scheduled Maintenance Inspection every three months or 150 hrs Refer to Section 1 of this manual Perform Scheduled Maintenance Inspection every year Refer to Section 1 of this manual D Perform Scheduled Maintenance Inspection every 2 years Refer to Section 1 of t
85. e date entry the system will store it Display will show FINISHED 39 Remove the jumper wire and re connect the black wire 14 to the coil removed earlier 40 Close the hydraulic electric tray NOTE Continuing partially complete load calibration If the phase does not need to be repeated just press ENTER to move on If the phase does need to be repeated press UP or DOWN to change NO to YES then press ENTER DC Electric Scissor Lifts SKYJACK Page 19 Conventional Series 155145 Q Service and Maintenance Section 5 Procedures 5 3 7 Curve Group Codes Chart Model Ext Curve Code Group Code 3220 1 Manual Extension Platform 3 3 3220 1 Powered Extension Platform 4 3 3226 1 Manual Extension Platform 5 3 4620 1 Manual Extension Platform 8 3 4620 1 Powered Extension Platform 9 3 4626 1 Manual Extension Platform 12 3 4626 1 Powered Extension Platform 13 3 4632 1 Manual Extension Platform 14 3 60404AE SJ3D SKYJACK Page 20 DC Electric Scissor Lifts Conventional Series 6 Q 155145 SKYVACK Reliable life solutions by people who care www skyjack com e
86. e if defective 3 Flow Divider Combiner valve FD1 defective or is plugged Check Valve Replace if defective 4 Counterbalance valve CB1 defective or is plugged Check Valve Replace if defective 4 2 9 Brake s will not Release 1 Brake valve 3H 17A defective or is sticking Clean valve Replace if defective 2 Brake orifice s 07 plugged Remove orifice s Clean and reinstall 3 Defective internal brake piston seals Check brake pack will maintain pressure If pressure is not maintained replace seals 4 Damaged integral brake in wheel motor Inspect wheel motor assembly Repair and replace as necessary 4 2 10 Aerial Platform will not hold on a Grade 1 Worn or damaged brake discs Inspect brake discs for wear Replace if worn or damaged 2 Broken or damaged brake compression springs Check springs Replace if defective 4 2 11 Platform does not Steer 1 Right steer valve 4H 23 or left steer valve 4H 24 defective or sticking Clean valve Replace if defective 2 Steer cylinder C3 seals leaking Rebuild cylinder s Replace if damaged 3 Mechanical binding in king pins Check for binding Repair as needed 4 Orifices 03 plugged Clean orifices and reinstall 4 2 12 Power Extension Platform will not Extend or Retract 1 Platform extend valve 4H 26 or platform retract valve 4H 27 defective or is sticking Clean valve Replace if defective SKYJACK Page 14 DC Electric Scissor Lifts Conventiona
87. e the machine The updated copy of the manuals are found on the company s website www skyjack com Service Policy and Warranty SKYJACK warrants each new 5 Series work platform to be free of defective parts and workmanship for the first 24 months Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor Contact the SKYJACK Service Department for warranty statement extensions or exclusions Optional Accessories The SKYJACK aerial platform is designed to accept a variety of optional accessories These are listed under Standard and Optional Features in Table 2 1 of the Operating Manual Operating instructions for these options if equipped are located in section 2 of the operating manual For options not listed under Standard and Optional Features contact the SKYJACK Service Department at 44 1691 676 235 44 1691 676 238 B Include the model and serial number for each applicable aerial platform Scope of this Manual a This manual applies to the CE version of the SJIII Series aerial plattorm models listed on Table 2 1 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 Operators are required to conform to national state or territorial provincial and local health and safety regulations applicable to the operation of this aerial pl
88. e to close Replace if defective 4 2 5 Platform does not Lift 1 Open manual lowering valve V1 Close valve Replace if defective 2 Hydraulic oil level too low Fully lower the platform Fill hydraulic tank until fluid is at or slightly above the top mark on the sight glass 3 Platform weight excessive Reduce platform load to maximum capacity 4 Up valve 3H 14 defective or is sticking Check valve Replace if defective 4 2 6 Platform will not Lower NOTE Down function is not proportionally controlled 1 Lowering valve 2H 13B defective or is sticking Clean valve Replace if defective 2 Defective holding valve 2H 13B 1 or 2H 13B 2 Clean valve Replace if defective DC Electric Scissor Lifts SKYJACK Page 13 Conventional Series 155145 Q Service and Maintenance Section 4 Troubleshooting Information Hydraulic System Continued 4 2 7 Platform Drives Slow 1 Free wheeling valve V2 open or defective Close valve Replace if defective 2 Flow divider combiner FD1 defective or is plugged Close valve Replace if defective 3 Drive motor or M4 defective Check motors Replace if defective 4 Cushion cylinder C1 defective Check cylinder Replace if defective 4 2 8 Platform will not Drive in Forward or Reverse 1 Open free wheeling valve V2 Close Valve Replace if defective 2 Forward drive valve 4H 16 or reverse drive valve 4H 15 defective or is sticking Check Valve Replac
89. el Drive Switch Platform Control Console with Toggle Switch Platform Control Console with Rotary Switch Test Platform Raising Lowering Test Lowering Warning A WARNING 1 Raise the platform until approximately a height of 3 to 4 meters is reached then Be aware of overhead obstructions attempt to fully lower the platform or other possible hazards around the Result Platform should stop lowering at aerial platform when lifting a height of 2 5 meters high and an alarm should sound 1 Select lift inclined drive level drive switch to P lift position 2 Release controller handle Test Horn 2 Activate and hold enable trigger switch 1 Push horn pushbutton 3 Push controller handle and raise the Result Hom should sound platform to an approximate height of 0 5 meter Result Platform should rise 4 Pull conttroller handle and lower the platform fully Result Platform should lower SKYJACK Page 30 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Function Tests Compact Pothole Protection Device Test Pothole Sensor WARNING Ensure that you maintain three points of contact to mount dismount plat form Use the ladder to dismount from platform and place a block approximately 3 75 cm under the hydraulic electric tray Use the ladder of aerial platform to access platform Close the gate Raise the platform until approximately a heigh
90. eper P3 3 60 Black White Output To Overload Warning Light On Control Box P3 4 28 Green Black Output To 28CR1 Tilt Relay And 28CR2 Down Relay P3 5 02 White Negative for Flashing Light and Beeper P3 6 28E Green White Output To 28ECR1 Aux Tilt Relay And 28ECR2 Aux Down Relay P4 1 Not Used Not Used P4 2 60A Green Varied Input From Transducer P4 3 28B Green Varied Input From Angle Transducer P4 4 Not Used Not Used P4 5 Not Used Not Used P4 6 910 Black Positive Signal To Angle Transducer P4 7 900 White Negative Signal To Pressure Transducer P4 8 902 White Negative Signal To Angle Transducer P4 9 910A Black Positive Signal To Pressure Transducer DC Electric Scissor Lifts Conventional Series 155145 60303AH SKYJACK Page 7 Service and Maintenance 5 3 2 LED Error Codes Reading the Codes Quick Reference Chart EVERYTHING OK Steady on IN GROUND MODE Steady on OVERLOAD FUNCTIONS DISABLED 6 6 VEHICLE TILTED 1 1 VEHICLE OVERLOADED 1 2 WAITING FOR B ON P2 12 5 2 ARMGUARD ACTIVE 1 3 TOO HIGH DRIVE PREVENTED 1 4 TOO HIGH LIFT UP PREVENTED 1 5 TESTING HWFS 7 8 IDLE TIMEOUT ACTIVE Always off WAITING FOR NEUTRAL 5 5 ARMGUARD ACTIVE 2 3 ELEVATION SWITCH SHIFTED 2 1 ELEVATION SWITCH STUCK 2 2 NO LAST CALDATE 6 3 LOAD NOT CALIBRATED 6 2 DRIVE LIFT INPUTS FAULTY 5 6 UP DOWN SELECT INPUTS ACTIVE
91. equence dependant on LED flash code If the 23 flash code is triggered by armguard it will occur once then clean This is not a true fault but just an indica tion of the reason for the vehicle stop If the 21 or 22 flash code is triggered by a fault with the elevation switch it will not clear Check that the elevation switch correctly opens closes when the platform is raised lowered P3 4 Short To OV 43 P3 6 Short To OV 45 Disconnect plug If fault clears there is a wiring fault from P3 4 or P3 6 to the rest of the vehicle Invalid Load Check Sensors 45 Check the voltage out of the pressure transducer into P4 2 It should be between 0 5V zero pressure and 4 5V maximum pressure and should vary as the platform load amp position varies Check that the battery voltage is not too low Verify battery voltage on P2 12 Disconnect plug P4 if the fault clears there is a wiring fault from P4 1 to the rest of the vehicle DC Electric Scissor Lifts SKYJACK Page 9 Conventional Series 155145 Q Service and Maintenance Section 5 Procedures 5 3 3 LED Error Codes Code Breakdown Chart Continued Vehicle Tilted Vehicle Overloaded Too High Drive Prevented Too High Lift Up Prevented These are not true faults but an indication that vehicle movement is prevented Remove excessive load from the platform Lower the platform if close to maximum height Move the vehicle to level ground Check the voltage ou
92. fective Open or defective diode D17C or diode D17C 1 Check diode Replace if defective 4 1 12 Drive Only Inoperative 1 Open or defective diode D17 1 Check diode Replace if defective 4 1 13 No Drive or Steer when Platform Fully Lowered 1 2 3 Loose or broken wire 71 from base terminal block to drive override limit switch LS6 Check continuity Replace if defective Defective drive override switch LS6 Check switch Replace if defective Loose or broken wire 19 from drive override limit switch LS6 to base terminal block Check continuity Replace if defective 4 1 14 No Drive or Steer when Platform Elevated 1 2 3 Pothole protection bars not fully lowered Clear obstructions Repair as needed Loose or broken wire 71 from base terminal block to pothole protection limit switch LS4 Check continuity Replace if defective Defective pothole protection limit switch LS4 Check switch Replace if defective Loose or broken wire 72 from pothole protection limit switch LS4 to base terminal block Check continuity Replace if defective Loose or broken wire 72 from base terminal block to pothole protection limit switch LS5 Check continuity Replace if defective Defective pothole protection limit switch LS5 Check switch Replace if defective Loose or broken wire 19 from pothole protection limit switch LS5 to base terminal block Check continuity Replace if defective 4 1
93. h in emergency stop button and attempt to activate any platform function Result All selected platform functions should not operate SKYJACK Page 28 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Function Tests Lift Drive Steer Enable Trigger Switch Rocker Switch Controller Inclined Drive Level Drive Switch Lift Off Drive Switch Platform Control Console with Toggle Switch Press rocker switch on top of controller e handle to left and right Result Steer wheels should turn left and right Test Driving 1 Ensure path of intended motion is clear Activate and hold enable trigger switch Slowly move controller handle in T 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 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 Emergency Stop Button Operation Light Horn Pushbutton Lift Drive Steer Enable Trigger Switch Rocker Switch Emergency Stop Button Operation Light Horn Pushbutton Lift Inclined Drive Level Drive Switch Platform Control Console with Rota
94. his manual Perform scheduled inspection every three months or 150 hours 1 Refer to Skyjack s website www skyjack com for latest service bulletins porior to performing quarterly or yearly inspection Note Make a copy of this page or visit the Skyjack web site www skyjack com for a printable copy DC Electric Scissor Lifts lt gt SKYJACK Page 17 Service and Maintenance Section 1 Scheduled Maintenance High Speed Limit Switch High Speed Limit Switch sed Pothole Protection Limit Switch 1 1 Scheduled Maintenance Inspections Begin the scheduled maintenance inspections by checking each item in sequence for the conditions listed in this section 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 Electrical Maintaining the electrical components is essential to good performance and service life of the aerial platform Inspect the following areas for chafed corroded and loose wires base to platform cables and wiring harness battery tray wiring harnesses e hydraulic electrical wiring harnesses SKYJACK Page 18 Hydraulic Maintaining the hydraulic components is essential to good performance and service life of the aerial platform Perform a visual inspect
95. in Manifold View Reverse Drive Parts List Model 46xx 2H 18A Differential Valve If equipped A 3H 18A 2 PO Speed Valve B 2 EN FD1 Flow Divier Combiner Valve UE d va pi Free wheeling Valve B Auto Reset Valve T X Ki Hydraulic a P2 Fittings 3H 18A 1 Hand Pump J Speed Valve A N SKYJACK Page 12 DC Electric Scissor Lifts Conventional Series 155145 AB Section 3 System Component Identification and Schematics Service and Maintenance 3 7a Platform Control Console Diagram Serial Breakdown Reference Chart View Model Serial Number Parts List SJ3 3220 60002138 8 above SJ3 3226 27006059 amp above SJ3 46 70006694 8 above
96. ion around the following areas hoses and fittings all hydraulic cylinders all hydraulic manifolds the underside of the base ground area under the aerial platform 1 1 1 Labels Refer to the labels section in this manual and determine that all labels are in place and are legible 1 1 2 Limit Switches Detecting limit switch malfunction is essential to safe aerial platform operation Ensure limit switches are properly secured and movement is not obstructed Visually inspect all limit switch located inside the scissor arms and the outrigger assemblies for the following e broken or missing actuator arm missing fasteners loose wiring DC Electric Scissor Lifts Section 1 Scheduled Maintenance Service and Maintenance Compact Conventional 220V Outlet Back View Receptacle Free wheeling Valve 7 4 LJ e Main Power Disconnect Switch Base Control Console Brakes Ladder Free wheeling Valve 3 Compact Back View 1 1 3 Entrance Side AC Outlet Receptacle Ensure receptacle is free from dirt and Main Power Disconnect Switch obstructions Turn main power disconnect switch to e Ladder off position ve Ensure there are no loose or missing Ensure all cables are secure and switch parts and there is no visible damage is in proper working condition Base Control Sw
97. itches Ensure there are no signs of visible damage and all switches are in their neutral positions e Free wheeling Valve Knob Compacts Front Side Ensure there are no loose or missing parts and there is no visible damage e Brakes Ensure there are no loose or missing parts and there is no visible damage DC Electric Scissor Lifts SKYJACK Page 19 Service and Maintenance Section 1 Scheduled Maintenance Conventional Battery Charger Battery Tray Battery Fuse Box Tray 1 1 4 Battery Tray Side e Pothole Protection Device Ensure mechanisms have no sign of visible damage and are free from dirt and obstructions Battery Tray Ensure tray latch is secure and in proper working order Battery Charger Compacts Entrance Side Ensure charger is secure and shows no visible damage e Battery Proper battery condition is essential to good performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions WARNING Explosion hazard Keep flames and sparks away Do not smoke near batteries Hydraulic Electric Battery Pothole Protection Device SKYJACK Page 20 Compact Battery Tray WARNING Battery acid is extremely corrosive Wear proper eye and facial protec tion as well as appropriate protective clothing If contact oc
98. k continuity through coil Replace if defective 9 Loose or broken wire 02 from rear drive manifold to base terminal block Check continuity Replace if defective SKYJACK Page 10 DC Electric Scissor Lifts Conventional Series 155145 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 21 Right Steer Inoperative 1 2 3 Loose or broken wire 12B from lift drive switch S3 to right steer switch S7 2 Check continuity Replace if defective Defective right steer switch S7 2 Check switch Replace if defective Loose or broken wire 23 from right steer switch S7 2 to base terminal block Check continuity Replace if defective Loose or broken wire 23 from base terminal block to steer right valve coil 4H 23 Check continuity Replace if defective Defective steer right valve coil 4H 23 Check continuity through coil Replace if defective Loose or broken wire 02 from steer right valve coil 4H 23 to base terminal block Check continuity Replace if defective No output to wire 17B while operating a right steer function from diode module DM1 Check for 24 volts on 17B at the diode module Replace diode module if no voltage found or is defective 4 1 22 Left Steer Inoperative 1 2 3 Loose or broken wire 12B from lift drive switch 53 to left steer switch 57 3 Check continuity Replace if defective Defective left steer switch S7 3 Che
99. l Series Q 155145 Section 4 Troubleshooting Information Service and Maintenance A Hydraulic System Continued 2 Powered platform cylinder C5 seals defective Rebuild cylinder Replace if damaged 3 Mechanical binding in power extension platform mechanism Check for binding Repair as needed 4 2 13 High Low Torque Inoperative 1 Stuck speed valve 3H 18A 1 Clean valve Replace if defective 2 Stuck speed valve 3H 18A 2 Clean valve Replace if defective DC Electric Scissor Lifts SKYJACK Page 15 Conventional Series 155145 Q Notes SKYJACK Page 16 DC Electric Scissor Lifts Conventional Series 155145 Section 5 PROCEDURES Table of Contents Service and Maintenance MHA LE ME 3 Saey and Ee 3 Platform 51 1 OEM Controller Electronics ai qnaa ka kk n Ra n kk kb kob bn 3 BA QEM Controller TUDES kk ee eect nee 4 ae 5 Base 5c System Relief Pressure AD USUI VOI k t kd vesi sis pisan oi kwa kise a REDE ER IRR ERE p e ke AD AKA 6 Doo EN PRA SA AN ail S d e aen diea 6 Load Sensing System bo Control Module Pin Reference eens 7 5 3 2 LED Emor Cod s Quick Reference CHAT orones donus
100. lic Schematic Parts List Continued po pa Qty Description Parts list continued from the following page 04 105281 1 ORIFICE 0 067 diameter Emergency lowering Models 3220 4620 105281 2 ORIFICE 0 067 diameter Emergency lowering Models 3226 4626 4632 O6 104434 1 ORIFICE 0 040 diameter Differential O7 137127 1 ORIFICE 0 020 diameter Brake 1 147661 1 PUMP Hydraulic Models 3220 4620 147662 1 PUMP Hydraulic Models 3226 4626 4632 P2 146560 1 PUMP Handle Brake release Models 46xx PS1 102863 1 SWITCH Pressure Option 113799 1 MANIFOLD BLOCK PT1 134431 TRANSDUCER Pressure 2000 psi Model 3220 4626 4632 134543 TRANSDUCER Pressure 1250 psi Model 3226 134432 TRANSDUCER Pressure 3000 psi Model 4620 R1 104534 1 VALVE Relief System R2 104534 1 VALVE Relief Lift R3 106557 2 VALVE Relief Holding valve Models 3226 4626 4632 V1 107271 1 VALVE Emergency lowering V2 103136 1 VALVE Free wheeling V3 146562 1 VALVE Auto reset brake release Models 46xx DC Electric Scissor Lifts SKYJACK Page 7 Conventional Series 155145 6 Q Service and Maintenance Section 3 System Component Identification and Schematics 3 5 Electrical Components Parts List SUPPLY B Common YA CONTROL 27 4 OD 6 NORMALLY NORMALLY CLOSED OPEN CONTACT CONTACT W me Qty Description 17CR 108589 1 RELAY 24 Volt Transfer
101. mps 108 139 389 500 35 5 45 5 245 31 Tree branches move Power lines whistle It is difficult to open an umbrella 139 172 500 619 45 5 56 5 31 385 ie trees sway It is difficult to walk against the 138AA CE N WARNING This aerial platform is equipped with a load sensing system Do not exceed the rated capacity of the aerial platform Failure to avoid this will prevent operation of all normal controls functions of the aerial platform To resume normal operation remove the additional loads SKYJACK Page 6 DC Electric Scissor Lifts Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 4 Torque Specifications Directional valve mounting bolts 28 32 in lb 2 2 3 6 Nm Wheel mounting bolts 90 ft lb 122 02 Nm Cartridge Size Torque 16 Ft lb max 50 In lb max 240 600 Nm max 33 90 67 80 Coils Size Torque All coils Ft lb max 4to5 In lb max 48 to 60 Nm max 5 42 to 6 78 SAE Plugs Size Torque 2 4 5 6 8 w 12 16 max 35 In Ib max 420 Nm max 47 46 Newton meter Nm Foot pound ft Ib Inch pound in Ib Additional Torque Specifications may be found in Section 3 60056AF DC Electric Scissor Lifts SKYJACK Page 7 SKYJACK Page 8 Notes DC Electric Scissor Lifts Section 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS Table of Contents Charts 3
102. n recorded in the last 6 months 158AA SKYJACK Page 16 DC Electric Scissor Lifts Section 1 Scheduled Maintenance Service and Maintenance SKYGACK Table 1 2 MAINTENANCE AND I NSPECTI ON CHECKLIST Serial Number Model Hourmeter Reading Date Time Name Printed Signature Each item shall be inspected using the the appropriate section of the Skyjack operating manual As each item is inspected write the apropriate grade in the box INSPECTION FREQUENCY DAILY PASS 1 FREQUENTLY FAIL ANNUALLY REPAIRED BI ANNUALLY Schedule Schedule Maintenance nspections les mw Entrance Side Main Power Disconnect as T Base Compacts Front Side sms acometre Cd CT Battery Tray Side Pothole Protection Deviee as menr steer Gyinder Assembly wheetTireAssemby as sesm mms f A amp c Hydraulic Electric Tray Side Pothole Protection Deviee as amp c Pump andwotor as Proportional and Main as Emergen
103. o 3 Platform Elevated Height Stowed Platform Height Stowed Height Railings Up Drive Height Standard Operating Times Lift Time No Load Lower Time No Load Lift Time Rated Load Lower Time Rated Load Normal Drive Speed 3 2 km h Elevated Drive Speed I High Torque Drive Speed 1 8 km h Hydraulic Oil Type ATF Dexron Tank Capacity Liters Weight with standard 0 9m extension platform Refer to serial nameplate for specific applications 130AA Note Emission sound pressure level does not exceed 70 dB A SKYJACK Page 2 DC Electric Scissor Lifts Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 1 Specifications and Features Continued Weight Overall width Working Height Platform Elevated Height Stowed Platform Height Stowed Height Railings Up Stowed Height Railings Down Drive Height Standard Operating Times 24s Lift Time No Load Lower Time No Load o Lift Time Rated Load Lower Time Rated Load o Chassis Normal Drive Speed 3 2 km h Elevated Drive Speed 1 km h High Torque Drive Speed 1 6 km h Gradeability Ramp Angle Tires Solid Rubber 16x5x12 Hydraulic Oil Type ATF Dexron 131AA Weight with standard 1 2m extension platform Refer to serial nameplate for specific applications Note Emission sound pressure level does not exceed 70 dB A DC Electric Sci
104. of Troubleshooting Information will localize the trouble more quickly than any other method This manual cannot cover all possible troubles and deficiencies that may occur If a specific trouble is not listed isolate the major component in which the trouble oc curs isolate whether the problem is electrical or hydraulic and then isolate and correct the specific problem The content of this section is separated into probable cause and remedy The information preceded by a num ber represents the probable cause The following line noted by a dash represents the remedy to the probable cause directly above it See example below for clarification 1 Probable Cause Remedy DC Electric Scissor Lifts SKYJACK Page 3 Conventional Series 155145 Q Service and Maintenance Section 4 Troubleshooting Information HEN Electrical System 4 1 1 All Controls Inoperative 1 Battery charger plugged into external power source Disconnect charger cord 2 Batteries disconnected Connect batteries 3 Dirty or loose battery terminals Clean and tighten connections 4 Battery charge low Check each cell with a hydrometer Reading should be 1 275 fully charged Recharge if low reading Replace if reading difference between cells is 0 050 5 Main battery cables open or defective Check continuity Replace if defective 6 Fuse F1 defective Replace fuse 7 Main battery disconnect switch S1
105. open or defective Close switch Check continuity Replace if defective 8 Loose or broken wire 3 from motor contactor C1 to circuit breaker CB2 Check continuity Replace if defective 9 Defective or tripped circuit breaker CB2 Reset circuit breaker Replace if defective 10 Loose or broken wire 3A from circuit breaker CB2 to charger relay L1CR Check continuity Replace if defective 11 Defective battery charger relay L1CR Check relay Replace if defective 12 Loose or broken wire 5 from charger relay L1CR to base emergency stop switch S28 Check continuity Replace if defective 13 Open or defective base emergency stop switch S28 Close switch Check switch Replace if defective 14 Loose or broken wire 5A from base emergency stop switch S28 to base key switch S10 Check continuity Replace if defective 15 Open or defective base key switch S10 Select function with switch Check switch Replace if defective 16 Loose or broken wire 07 from base key switch S10 to base terminal block Check continuity Replace if defective 17 Loose or broken wire 07 from base terminal block to platform emergency stop switch S4 Check continuity Replace if defective 18 Open or defective platform emergency stop switch S4 Close switch Replace if defective 19 Loose or broken wire 7A from platform emergency stop switch S4 to base terminal block Check continuity Replace if defective 20 Loose or broken wire 7A from
106. orm 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 10 Start Operation of the operating manual 1 2 1 Test Main Power Disconnect Switch 1 At rear of the base turn main power disconnect switch to off position Result Aerial platform functions should not operate DC Electric Scissor Lifts 1 2 2 Base Control Console WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform 1 Use the ladder of aerial platform to access platform 2 Close the gate 3 platform control console pull out emergency stop button 4 Use the ladder to dismount from platform 5 Turn main power disconnect switch to on position SKYJACK Page 25 Function Tests Section 1 Scheduled Maintenance Conventional Compact Back View Back View Free wheeling Valve Lower Lower Neutral Rai
107. oting Table of Contents Section 5 Procedures Table of Contents DC Electric Scissor Lifts SKYJACK Page 3 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance The Safety Alert Symbol identifies important safety messages on aerial platforms safety This Safety Alert Symbol means attention signs in manuals or elsewhere When you see this symbol be alert to the possibility of Become alert Your safety is involved personal injury or death Follow the instructions in the safety message A 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 SKYJACK Page 4 DC Electric Scissor Lifts Section 1 SCHEDULE MAINTENANCE INSPECTIONS Table of Contents Operator s Responsibility for Maintenance Platona pri m 7 BEL od at l e a ak an la aa a a a aka t a ra 7 sg GE WAN is
108. place if defective 3 Defective PWM card on joystick S7 Check joystick card Replace if defective 4 Loose or broken wire 13 down or 15 reverse from lift drive switch S3 to base terminal block Check continuity Replace if defective 4 1 6 No Up or Forward Only Function from Platform Control Console 1 Loose or broken wire B from proportional controller S7 to lift drive switch S3 Check continuity Replace if defective 2 Lift Drive switch 3 defective Check switch Replace if defective 3 Defective PWM card on joystick S7 Check joystick card Replace if defective 4 Loose or broken wire 14 up or 16 forward from lift drive switch S3 to base terminal block Check continuity Replace if defective 4 1 7 No Up Function from Platform or Base Control Console 1 Loose or broken wire 14 from base terminal block to up valve coil 3H 14 Check continuity Replace if defective 2 Loose or broken wire 02 from base terminal block to up valve coil 3H 14 Check continuity Replace if defective 3 Defective up valve coil 3H 14 Check continuity through coil Replace if defective 4 Loose or broken wire 14 from base terminal block to CM1 control module pin P2 3 Check continuity Replace if defective 5 Open diode D14 Check diode Replace if defective 6 Open diode D21 Check diode Replace if defective 7 Machine not level Above high speed limit switch Use on level surface 8 See 4 1 6 platform controls or
109. re 28E from CM1 control module pin P3 6 to Aux tilt relay 28ECR1 Check continuity Replace if defective 5 Loose or broken wire 19 from base terminal block to Aux tilt relay 28ECR1 Check continuity Replace if defective 6 Loose or broken wire 19A from Aux tilt relay 28ECRI to tilt relay 28CR1 Check continuity Replace if defective DC Electric Scissor Lifts SKYJACK Page 5 Conventional Series 155145 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 7 Loose or broken wire 19B from tilt relay 28CR1 to hour meter Check continuity Replace if defective 8 Loose or broken wire 19B from hour meter to motor contactor C1 Check continuity Replace if defective 9 Loose or broken wire 59 from proportional controller S7 to base terminal block Check continuity Replace if defective 10 Loose or broken wire 59 from base terminal block to proportional coil 2H 59 Check continuity Replace if defective 11 Loose or broken wire 02 from base terminal block to proportional coil 2H 59 Check continuity Replace if defective 12 Defective proportional coil 2H 59 Check continuity through coil Replace if defective 4 1 5 No Down or Reverse Function from Platform Controls 1 Loose or broken wire from proportional controller S7 to lift drive switch S3 Check continuity Replace if defective 2 Lift Drive switch 3 defective Check switch Re
110. re number color reference for all electrical drawings and schematics All wire numbers will retain their origional color coding for example if wire 7 is red wire 7A 7B and 7C will also be red DC Electric Scissor Lifts SKYJACK Page 5 Conventional Series 155145 Q Service and Maintenance Section 3 System Component Identification and Schematics 3 4 Hydraulic Schematic Parts List Index Skyjack No Part No 2H 13B 103655 2H 13B 1 107269 2H 13B 2 107269 2H 18A 104132 2H 59B 132749 3H 14 106273 3H 17A 103623 3H 18A 1 103623 18 2 103623 4H 15 153334 Qty Description VALVE Control Lowering VALVE Control Holding VALVE Control Holding VALVE Control Differential VALVE Control Proportional VALVE Control Lift VALVE Control Brake VALVE Control Speed A VALVE Control Speed B VALVE Control Reverse drive Hytos includes 4H 16 128317 VALVE Control Reverse drive Hytos includes 4H 16 If equipped 4H 16 VALVE Control Forward drive Hytos 4H 23 153334 VALVE Control Right steer Hytos includes 4H 24 128317 VALVE Control Right steer Hytos includes 4H 24 If equipped 4H 24 VALVE Control Left steer Hytos cA c A ee a ee cl a 4 26 113953 VALVE Control Powered platform extend includes 4 27 Models 3220 4620 4626 4H 27 VALVE Control Powered platform retract
111. reassembly Clean all metal parts in a clean mineral oil solvent Be sure to thoroughly clean all internal passages After the parts have been dried thoroughly lay them on a clean lint free surface for inspection Replace all O rings and seals when overhauling any component Lubricate all parts with clean hydraulic oil before reassembly Use small amounts of petroleum jelly to hold O rings in place during assembly Be sure to replace any lost hydraulic oil when completing the installation of the repaired component and bleed any air from the system when required All hydraulic connections must be kept tight A loose connection in a pressure line will permit the oil to leak out or air to be drawn into the system Air in the system can cause damage to the components and noisy or erratic system operation Maintenance Hints Three simple maintenance procedures have the greatest effect on the hydraulic system performance efficiency and life Yet the very simplicity of them may be the reason they are so often overlooked What are they Simply these 1 Change filters annually The filters will need to be changed more often depending on the operating conditions Dirty dusty high moisture environments may cause the hydraulic system to be contaminated more quickly 2 Maintain a sufficient quantity of clean hydraulic oil of the proper type and viscosity in the hydraulic reservoir 3 Keep all connections tight DC Electric Sci
112. ries 155145 e lt gt Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued k 8 Open diode D21B 2 Check diode Replace if defective Loose or broken wire 02 from extend valve coil 4H 26 to retract valve coil 4H 27 to platform control box Check continuity Replace if defective 4 1 24 Power Extension Platform will not Extend 1 2 Powered extension platform extend retract switch S11 defective Check switch Replace if defective Loose or broken wire 26 from power extension platform extend retract switch S11 to extend valve coil 4H 26 Check continuity Replace if defective Extend valve coil 4H 26 defective Check continuity through coil replace if defective Open diode D26 Check diode Replace if defective Loose or broken wire 02 from extend valve coil 4H 26 to platform control box Check continuity Replace if defective 4 1 25 Power Extension Platform will not Retract 1 2 Powered Platform extend retract switch S11 defective Check switch Replace if defective Loose or broken wire 27 from power extension platform extend retract switch S11 to retract valve coil 4H 27 Check continuity Replace if defective Retract valve coil 4H 27 defective Check continuity through coil replace if defective Open diode D27 Check diode Replace if defective Loose or broken wire 02 from retract valve coil 4H 27 to platform control box
113. ry Switch 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 switch enable trigger Drive aerial platform 4 forward and then 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 4 b forward and Drive aerial platform then q backward Test brake again by releasing 43 enable trigger switch only Result Aerial platform should come to an instant and abrupt stop If aerial platform does not stop immediately or if aerial platform pulls to one side while stopping do not operate aerial platform until brake adjustments have been checked DC Electric Scissor Lifts lt SKYJACK 29 Function Tests Section 1 Scheduled Maintenance Lift Drive Steer Enable Lift Drive Steer Enable Trigger Switch Trigger Switch Rocker Switch Rocker Switch Emergency Stop Button Controller Operation Light Emergency Stop Button Operation Light Inclined Drive Level Drive Switch Horn Pushbutton Horn Pushbutton Lift Off Drive Switch Lift Inclined Drive Lev
114. se Neutral Raise Switch Switch Emergency Stop Emergency Stop Button Off Platform Base Switch Button Test Base Emergency Stop 3 Select and hold off platform base key switch to base position Attempt 1 Pushin i emergency stop button and to raise or lower the platform attempt to raise or lower the platform Result Platform raising and lowering Result Platform raising and lowering functions should operate functions should not operate Test Lower Neutral Raise Switch 2 Pull out base button 1 Select and hold off platform base key switch to base position and ff Platf B itch Test OnyPlatronn BAse SWIC T raise the platform with lower neutral raise switch A WARNING Result Platform should rise Be aware of overhead obstructions or other possible hazards around the 2 Select and hold off platform base key aerial platform when lifting switch to base position and gv lower the i platform with lower 1 Select off platform base key switch neutral raise switch off position Attempt to raise or lower Result Platform should lower the platform Result Platform raising and lowering functions should not operate 2 Select off platform base key switch to J platform position Attempt to raise or lower the platform Result Platform raising and lowering
115. sor Lifts Conventional Series 155145 Print View This Parts List 3 18b Electrical Schematic Models 322x Equipped with all options AB Serial Breakdown one Reference Chart CONTROL BOX _ BASE POWERED PLATFORM OPTION Serial Number trae 24V CHARGER EXTEND SOLENOD pot ENABLE e SJ3 3220 60002137 amp below CHARGER Pr n ML QUTOUT RELAY V SJ3 3226 27006058 amp below ILA ry l 4H27 vid Ra BLGV Fi B36V B26V RETRACT SOLENOID 218 218 GREENBLACK 218 BATTERY BATTERY BATTERY BATTERY E 06 07 av m 411 0 50 S1 MAIN Pp DEPT BASE DISCONNECT 4 EMERGENCY 5 IN IDLE POSITION CONTACTOR s 5 PUMP MOTOR LEONE ac 07 n NO STOP SWITCH 5 Es 082 7A sifi 07 07 RED 07
116. ssor Lifts SKYJACK Page 13 SKYJACK Page 14 Notes DC Electric Scissor Lifts Section 1 Scheduled Maintenance Service and Maintenance About this Section This section contains the maintenance and inspection schedule that is to be performed References are made to the procedures in Section 5 that outline detailed step by step instructions for checks and replacements Service Bulletins Before performing any scheduled maintenance inspection procedure refer to service bulletins found in our web site www skyjackinc com for updates related to service and maintenance of this aerial platform Maintenance and Inspection Death or injury can result if the aerial platform is not kept in good working order Inspection and maintenance should be performed by competent personnel who are trained and qualified on mantenance of this aerial platform N 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 the OFF position Repair any damaged or malfunction components before operating aerial pla
117. ssor Lifts SKYJACK Page 3 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 2 Floor Loading Pressure Total Aerial Platform 15 Total Aerial Platform Load kPa kN m kPa 133AB min Total aerial platform weight with no options max Aerial platform weight all options full capacity LCP Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the areas in direct contact with the floor The floor covering tile carpet etc must be able to withstand more that the indicated values above OUP Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the whole surface directly underneath it The structure of the operating surface beams etc must be able to withstand more than the indicated values above NOTE The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or architect for that particular structure SKYJACK Page 4 DC Electric Scissor Lifts Section 2 Maintenance Tables and Diagrams Service and Maintenance Floor Loading Pressure Locally Concentrated Pressure LCP Overall Uniform Pressure OUP Foot Print Area Length x Width Base Area Length x Width Weight of Aerial Platform Capacit Weight of Aerial Platform Capacity 04x Foot Print Area Base Area
118. st starts to move then turn the trimpot screw one full turn in the counterclockwise direction This adjustment should be done first Maxout Adjustments Adjusts the full stroke current or duty cycle affecting the maximum function response or speed when the handle is deflected to its full travel Fully deflect the handle and adjust the maxout trimpot for maximum desired function response or speed To obtain proportional resolution it is important that the function starts to slow down as soon as the handle is moved back from the fully deflected position The ideal adjustment occurs when the function just begins to move when the handle is deflected and the output increases until it reaches its maximum desired response or speed at the end of handle travel DC Electric Scissor Lifts Conventional Series 155145 SKYJACK Page 3 Service and Maintenance Section 5 Procedures 5 1 2 OEM Controller Troubleshooting Problem 1 The function will not operate when the handle is moved The LEDs do not light A Check that voltage is present at the positive input terminal B Check that ground is connected to the negative terminal C If there is an in line fuse check to see if it is good D Check the controller on off switch and the connectors Voltage should be present at the X terminal when the controller is turned on E Check that valve wiring is not shorted to ground The LEDs will not light F
119. t Conventional Series 155145 Section 3 System Component Identification and Schematics Service and Maintenance 3 6 Hydraulic Manifold and Port Identifications View Parts List 2H 59B Proportional Valve Internal Compensator Valve To Main Manifold To Main Manifold AD 3H 14 Lift Valve CB1 Counterbalance Valve 02 Lowering Orifice Model 4620 amp 4632 Only R4 Relief Valve Quick Disconnect If equipped R2 Lift Relief Valve 2H 13 5 lt Lowering Valve Relief Valve 4H 23 fi Right Steer Val ig eer Valve Y 4H 15 Reverse Drive Valve R1 Quick Disconnect 4H 24 System Relief Valve If equipped Left Steer Valve M138117AA_S3 DC Electric Scissor Lifts SKYJACK Page 11 Conventional Series 155145 Q Service and Maintenance Section 3 System Component Identification and Schematics 3 6 Hydraulic Manifold and Port Identifications Continued Model 322x V2 To M4 2 18 V3 Free wheeling Valve Wheel Motor Differential Valve Auto Reset Valve From Main Manifold Brake Port 3H 18A 2 Speed Valve B 3H 18A 1 a Speed Valve A Es rifice a po a 9 l 2 FD1 uod Flow Divier Combiner lt Q Wheel Motor s To M3 To M4 06 Wheel Motor Wheel Motor Orifice From Main Manifold Forward Drive To Integral Brake From Ma
120. t Code F45 High Pressure This message indicates that the pressure transducer output P4 2 is too high 4 5V or more at a measurement point Check DIAGNOSTICS SENSORS to read output Code F46 Check Elev This message indicates that the elevation switch opened more than once during calibration lifting Code F47 Check Elev This message indicates that the elevation switch closed more than once during calibration lower Code F48 Bad Pressure This message indicates that the pressure transducer output P4 2 is out of range at the beginning of calibration Check DIAGNOSTICS SENSORS to read output Code F52 Too Few This message indicates that not enough measurements were recorded during calibration lifting or lowering Code F98 Out of Range This message indicates that the fine tune calibration is unacceptable This is probably due to a faulty transducer or faulty open holding valve s emergency lowering valve During calibration the following information messages may appear Platform Down This message is prompting for confirmation that the platform is fully lowered If necessary the DOWN switch can be activated to lower the platform Press ENTER to confirm when the platform is fully lowered Platform Empty This message is prompting for confirmation that the platform is completely empty Press ENTER to confirm if the platform is empty Platform Loaded This message is prompting for confirmation that the platform is lo
121. t form in windy or gusty condi tions DC Electric Scissor Lifts 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 not drive elevated near depressions or holes of any type loading docks debris drop offs and surfaces that may affect the stability of the aerial platform If operation in areas with holes or drop offs is abso lutely necessary elevated driving shall not be allowed Position the aerial platform horizontally only with the platform fully lowered After ensuring that all 4 wheels or outriggers if equipped have contact with level firm surface the aerial platform can be el evated After elevation the drive function must not be ac tivated Elevated driving must only be done on a firm level sur face DO NOT ascend or descend a grade when elevated When fully lowered ascending or descending only grades up to rated maximum listed in Table 2 3 are permissible SKYJACK Page 9 Operator s Responsibility for Maintenance Section 1 Scheduled Maintenance Safety Precautions Continued Know and understand the safety precautions before going on to next section DO NOT operate on surfaces not capable of DO NOT raise the aerial platform holding the weight of the aerial
122. t of 2 meters is reached and attempt to drive forward or reverse Result Aerial platform should not move forward or backward Repeat the steps above with block placed under battery tray Result Aerial platform should not move forward or backward Test Elevated Drive Speed WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting Ensure path of intended motion is clear Raise the platform until approximately a height of 2 meters is reached and attempt to drive forward or reverse Result Aerial platform should move slower than when it was in stowed position DC Electric Scissor Lifts SKYJACK Page 31 SKYJACK Page 32 Notes DC Electric Scissor Lifts Section 2 MAINTENANCE TABLES AND DIAGRAMS Table of Contents Tables 2 1 Specifications and Features bk ok ta aka ia da 2 zo Po Loadg eee 4 20 Maximum Platform Capacities Evenly Distributed ek jo kk 6 EY TOU WE Le oa ndr on 7 DC Electric Scissor Lifts SKYJACK Page 1 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 1 Specifications and Features 3215 3219 3220 3226 Overall width 0 83 m Overall length 2 34 Platform Size inside 0 70mx2 10m Working Height
123. t of the height transducer into P4 3 It should be between 4V and 4 6V and should vary as the platform position varies Testing HWFS Start Up These are not true faults unless they do not clear Overload Functions Disabled Factory Override 67 These are not true faults the GP102 has been configured to suppress overload functionality Idle Timeout Active Fault Bad Tilt Sensor Fault Bad HWFS Fault Bad Slave Analogs Fault Bad Strain Monitors Fault Bad Slave Micro Fault HWFS Stalled Action a function to clear the idle timeout if it occurred Ensure the GP102 is correctly mounted incorrect mounting can cause the bad tilt sensor diagnostic to occur Otherwise there may be an internal problem with the GP102 SKYJACK Page 10 DC Electric Scissor Lifts Conventional Series 155145 Section 5 Procedures Service and Maintenance Ct 5 3 4 Hand Held Calibration Diagnostic Tool Key Functions IN WARNING Only trained and authorized personnel shall be permitted to service and aerial platform IN WARNING Read all instructions closely before attempting each phase or the calibration procedure ESC ENTER Buttons To move back and forth between menu and sub menu LEFT RIGHT Buttons Select menus and setting to be adjusted UP DOWN BUTTONS Adjust setting values
124. tform e Keep records on all inspections Maintenance Instructions This manual consists of four schedules to be done for maintaining on an aerial platform Inspection schedule frequency is shown below Inspection Schedule Daily A Frequently A B Annually A B C Bi annually A B C D e Make copies of the maintenance and inspection checklist to be used for each inspection e Check the schedule on the checklist for the type of inspection to be performed e Place a check in the appropriate box after each inspection procedure is completed e Use the maintenance and inspection checklist and step by step procedures in Section 5 to perform these inspections e inspection receives a fail tag and remove the aerial platform from service f any aerial platform component s has been repaired an inspection must be performed again before removing the tag Place a check in the repair column Legend P Pass F Fail R Repaired DC Electric Scissor Lifts SKYJACK Page 15 lt gt Service and Maintenance Section 1 Scheduled Maintenance Table 1 1 Owner s Annual Inspection Record Model Number Serial Number Inspection Date Recording Owner s Skyjack Name Inc Inspected Skyjack By Inc As described earlier in this section this decal is located on the scissor assembly It must be completed after an annual inspection has been completed Do not use the aerial platform if an inspection has not bee
125. the ENTER button 22 The display will show Calibrate Load Platform Down Asking for confirmation that the platform is fully lowered Check that the platform is fully lowered then press the ENTER button to confirm DC Electric Scissor Lifts SKYJACK Page 17 Conventional Series 155145 Q Service and Maintenance Section 5 Procedures 23 24 25 26 27 28 The display will show Calibrate Loaded Empty Asking for confirmation that the platform is empty Check that the platform is empty By using the Up Down buttons enter the Yes followed by pressing the ENTER button The display will show Calibrate Load Please Lift Waiting for the lift switch to be activated Hold the lift switch and keep holding it until the platform is fully elevated IMPORTANT If the lift switch is released earlier than full height position the calibration will have to be aborted and repeated from the beginning When the system detects the lift switch closed the display will show Calibrate Load Lift Empty After a delay the system will stop the platform lifting and will take height amp pressure measurements the display will show MEASURING xx When the measurements have been taken the platform will resume lifting NOTE The Lifting stopping measuring lifting process will continue until the platform reaches full height 29 When the platform reaches full height
126. tput to wire 17B while operating a drive function from diode module DM1 Check for 24 volts on 17B at the diode module Replace diode module if no voltage found or is defective 6 Loose or broken wire 17B from diode module DM1 to transfer relay 17CR Check continuity Replace if defective 7 Loose or broken wire 17A from transfer relay 17CR to brake coil 3H 17A Check continuity Replace if defective 8 Brake valve coil 3H 17A defective Check continuity through coil Replace if defective 9 Loose or broken wire 02 from brake valve coil 3H 17A to base terminal block Check continuity Replace if defective 4 1 20 High Low Torque Inoperative 1 Open diode D15 1 reverse D16 1 forward Check diode Replace if defective 2 Loose or broken wire 7B from diodes D15 1 and D16 1 to lift drive switch S3 Check continuity Replace if defective 3 Defective lift drive switch S3 Check switch Replace if defective 4 Loose or broken wire 18 from lift drive switch S3 to base terminal block Check continuity Replace if defective 5 Loose or broken wire 18 from base terminal block to high speed limit switch LS1B Check continuity Replace if defective 6 Defective high speed limit switch LS1B Check switch Replace if defective 7 Loose or broken wire 18A from high speed limit switch LS1B to rear drive manifold Check continuity Replace if defective 8 Defective speed valve coil 3H 18A 1 or 3H 18A 2 Chec
127. ve 2 Loose or broken wire 15 from base terminal block to CM1 control module pin P2 8 Check continuity Replace if defective 3 Loose or broken wire 15 from base terminal block to reverse drive valve coil 4H 15 Check continuity Replace if defective 4 Reverse drive valve coil 4H 15 defective Check continuity through coil Replace if defective 5 Loose or broken wire 02 from reverse drive valve coil 4H 15 to base terminal block Check continuity Replace if defective DC Electric Scissor Lifts SKYJACK Page 9 Conventional Series 155145 e lt gt Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 6 No outputto wire 17 while operating a reverse drive function from diode module DM1 at base terminal block TB1 Check for 24 volts at 17 at terminal block Replace diode module if no voltage found or is defective 4 1 19 Brake will not Release 1 No output to wire 17 while operating a drive function from diode module DM1 at base terminal block TB1 Check for 24 volts at 17 at terminal block Replace diode module if no voltage found or is defective 2 Loose or broken wire 17 from base terminal strip to transfer relay 17CR Check continuity Replace if defective 3 Loose or broken wire 02 from base terminal strip to transfer relay 17CR Check continuity Replace if defective 4 Defective transfer relay 17CR Check relay Replace if defective 5 No ou
128. wire 10E from base terminal block to CM1 control module pin P2 2 Check continuity Replace if defective 4 1 3 All Controls Inoperative From Platform Control Console 1 2 Loose or broken wire 8C from base key switch S10 to base terminal block Check continuity Replace if defective Loose or broken wire 8C or wire 02 from base terminal block to platform emergency stop switch 54 Check continuity Replace if defective Open or defective platform emergency stop switch S4 Close switch Replace if defective Loose or broken wire 8 or wire 02 from emergency stop switch S4 to battery charge indicator BCI Check continuity Replace if defective Loose or broken wire 8 or wire 02 from battery charge indicator BC1 to joystick 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 4 No Drive or Up Function from Platform Controls 1 Defective tilt relay 28CR1 Aux tilt relay 28ECR1 Check relay Replace if defective 2 Loose or broken wire 02 from base terminal block to tilt relay 28CR1 or Aux tilt relay 28ECR1 Check continuity Replace if defective 3 Loose or broken wire 28 from CM1 control module pin P3 4 to tilt relay 28CR1 Check continuity Replace if defective 4 Loose or broken wi

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