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Service Manual

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8. 146125 a 37 2A INS 15 15 16 16 19 20 oa 58 10081 10CR2 10BCR 15CR 16CR 17CR 19 2008 20ACRI 20ACR2 28CR HOU
9. FEMALE QDC ENABLE 15 8A WHITE BLUE MALE QDC GROUND 02 WHITE c5 L Z 53 LIFT DRIVE SELECTOR Sa E ed or X V
10. AON39u3W3 HOLIMS A3 95 5 8 015 SKYJACK Page 32 901 H3O IHLNO 54 82 1 39 ve 200 1m u3ooiino 90 t om vL vL a 8738 1331 t ez zoa voL ur t an 08 H3DDIHLNO 90 T 1 ama z font ge 5 gt zoa 20 Sruv 9 9L 9 T ozzod ase 10 T mi a ZL
11. Serial Breakdown DIESEL VALVE SOLENOID 2037 Reference Chart 37 RED HOLD Serial Number 57 WHITE PULL 37002423 amp Below V DIESEL VALVE SOLENOID s la 02 WHITE 37 BLUE WHITE 57 BLACKWHITE BACK VIEW 321 ENGINE STARTER 57 BLACKWHITE ALTERNATOR TRIGGER 103 RED 10 GA PN1 NU PIN 2 37 BLUE WHITE 18 GA p PIN3 NU 5 O ENGINE STARTER ENGINE CONTACTOR GLOWPLUG 32A GREENIBLACK ALTERNATOR MAIN MAIN ENGINE STARTER 1 10GA PRESSURE SWITCH OPS1 e a 2A BLACK RED HIGH on 2 WHITE H THROTTLE SOLENOID 1 HTS 34C ie TEMPERATURE SWITCH 02 WHITE IPS 34C GREEN WHITE WHITE T a
12. M2 FRONT RIGHT C3 WHEELMOTOR ASE DRAIN C2 CAS y M3 V LIFT CYLINDER WHEELMOTOR 6826 6832 M1 LEFT CASE DRAIN WHEELMOTOR CUN PE OE R4 2H 13 2 ANSI CSA LEFT 1 RELIEF 2H 13B 2 CE PRESSURE VALVE HOLDING OVERLOAD VALVE SPLITTER TRANSDUCER MANIFOLD DUE OPTION ANSI CSA MANIFOLD BLOCK MB6 MEE STANDARD CE LOWER MBA we r LIFT NNI CYLINDER bold YS 1 6826 6832 O ee VALVE 067 n VALVES 1 Ec 2H 13 1 ANSI CSA R3 Z 2H 13B 1 RELIEF W HOLDING m CYLINDER CYLINDER CYLINDER CYLINDER HEINE VALVE OUTRIGGER OUTRIGGER OUTRIGGER
13. S 02s e or M 2 T GION310S Seed 2 5 65 NMOG 1431 90h gt Iu Q GION310S 1 200 an ava 1337 90 vl vL ovi8 vL es gt GION310S 1 1 T 70 pem m m yovia ama y _______ 566000 au C Ho 90 Lm ez e ama m e Q 1 bee id 20 9 9 97 xovig aau ww ase 92908 P dn HON zik a 1 GIONFIOS H3DDMLNO 1 1
14. OUP Base Area A T D fA AV UA AA AA ODS Cv v v V Y CS V V V M Width 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 SJRT Compact Series Engine Powered SKYJACK Page 5 143899 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 2a Floor Loading Pressure ANSI CSA Total Aerial Platform Total Aerial Platform
15. Net T 87 2 15 16 19 20 oa 10CRI 100R2 108CR 15CR 16CR 19CR 20ACR1 FLASHER HOURMETER 17 FL29 10 2A 0 1 2A 02 15 02 16 02 17 MAN 19 02 20 02 5 168 02 02 10A 10A af m m 16A i CIRCUIT BREAKER O 20ACR2 28ACRI m 9 E 3508 35ACR CBI 15A 18A 7 4 348 10A 94 58 9 g 280 0 go b2 th 41 bo At B3 02 31 B N m EMERGENCY STOP 188 32A 02 34C 34B EN AMA o6 LEGEND 4 2 CIRCUITBREAKER CB3 POWER ON C MANMANFOLD HARNESS pce Ipo E A 3A 0 HARNESS pr 2 9 GLOW PLUG PLATFORM CONTROL BOX LIGHT GPL ae NI OUTRIGEN HARNESS o STARTSWITCH OR 530 LT FUEL SELECT TLTSWITCH SWITCH 33 0600 7390000 59 zo O TE 300000000 o els 6 HIGH SPEED LIMIT SWITCH 2120000000 ncs 2 2 20772425 505 0037 MI
16. AVNI 2 GIONSIOS 3AWA og A_ 600 4 4 NIV vel e e el GION310S 62 AAIWA 1 881 GIONTIOS mE 521 H31H3ANI 42 vor H3MOd NIV 92 8080 on 0 56 80 80 Aviad 31LLOHHL 52 vse ANYWA H3MOd ve e JILLOHHL c ev Wee ve ve ve 80 tIS w 26 Movig N33u5 ce 80 1915 918 1915 02 0 189 V SC 61 20 00 85 8 LHOcE 41 52 YHOLVNYALIV 91 LOANNOOSIG 285 901 YOLOW 13 31 15 Il MS 18V1S ve 2800 WEY gy l 2 MOTD 1 n ie 18 n 80
17. TW WO OUTRIGGER OPTION EU This Page View Parts List FROM HYDRAULIC GENERATOR iii CONTROL CABLE PIN 1 09 BLACK PIN 2 85 GREEN PIN 3 86 WHITE 2 OQUTRIGGER HYDRAULIC GENERATOR HARNESS FROM HYDRAULIC GENERATOR CONTROL BOX Y 86D ORG B
18. 32 Trn Eod uer UU m ER 32 _ FiS Etre PU TH TUIS 32 ode Low EU OD aeui Ee Hp _ CHE ef 32 32 e m 32 Hian ECOS DOMI E PLC bir 33 t MUR 33 SKYJACK 2 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Table of Contents Continued 33 Ft 555 EEEn 33 T 33 Mid ri 33 doat Fash ge RE 33 Fe OPECI EIO 33 gt Tm 32 Tem 34 43 28 Flash code OUN 34 42559 Fe nner
19. PIN 3 02 WHITE TO OUTRIGGER LIMIT SWITCHES PIN 4 44 RED n 2 E 5 OUTR CONTROL BOX CONTROL MODULE P4 CONTROL MODULE P2 LEFT FRONT OUTRIGGER PIN 1 02 WHITE PIN 1 78 BLACK WHITE PIN 1 68A WHITE TO ELECTRIC PANEL i gi PIN 2 35C WHITEIBLACK PIN 2 77 BLUEIBLACK PIN 2 67A REDIWHITE A 2 TILT SWITCH CONNECTOR PIN 70 GREEN BLACK PIN 76 RED BLACK PIN 3 66A BLUE WHITE 4 i 4 4 70 RED WHITE PIN 4 75 ORANGE BLACK PIN 4 65A GREEN WHITE RIGHT FRONT OUTRIGGER PIN 5 71 ORANGE PIN 5 74 BLACK PIN 70 GREEN BLACK PIN BLACK 104 PIN 2 WHITE 66 PIN 6 72 RED PIN 6 73 BLUE PIN 6 79 GREEN PIN 3 GREEN 63 PIN 4 RED 62 PIN 7 73 BLUE PIN 7 72 RED PIN 7 REDWHITE Ai PIN 8 74 BLACK PIN 8 71 ORANGE PIN 8 65 GREEN BLACK Ot PIN 9 75 ORANGE BLACK PIN 9 35C WHITE BLACK PIN 9 28 GREEN id PIN 10 76 RED BLACK PIN 10 44 RED PIN 3 GREEN 64 PIN4 RED 63
20. 34 23930 Flash Code OUV 34 34 4 3 32 Flash Code F40 Reject nier iai viris 34 kod FIZN Fron _ 34 4304 Flash Code 2 34 42025 uic CRT T TT 34 43008 Flash Code F45 High Chai dal alo IE PAPE n pri rh edu p vei A 35 2 35 Aoo FE Oe Fa 40 2 oiner Eana EAEra raien 35 SJRT Compact Series SKYJACK Page 3 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Introduction The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble which can develop Careful and accurate analysis of the systems listed in the table of Troubleshooting Information will localize the trouble more quickly than any other method This manual cannot cover all possible troubles and deficiencies that may occur 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 spe
21. PIN 16 65 GREEN BLACK PIN 2 65A WHITE PIN 2 65A GREEN WHITE PIN 3 66A WHITE PIN 3 66A BLUE WHITE 02 PIN 4 67AWHITE PIN 4 67A RED WHITE P2 17C WHTEBLACK 61210 PIN 5 68A WHITE PIN 5 68A WHITE 3 HYDRAULIC GENERATOR 12 PIN CONNECTOR PLUG PNe NU TOOUTRIGGER 02 WHITE d ch m OO PIN 1 EMPTY PIN 7 14 BLACK 2x CONTROLBOX 560 PIN2 EMPTY PIN 8 17 BLUE law CONTROL CABLE AOD aliis PIN 3 EMPTY PIN 9 43 RED BLACK PIN1 74BLAOK PINT TIORANGE PIN1 T2 RED PIN 1 73 BLUE PIN 4 02 WHITE D PIN 10 43A REDIMHITE PIN2 O2WHITE PN2 02WHTE PIN2 02WHITE PIN2 02 WHITE PINS 2 ORANGE BLACK PIN 11 86A ORANGE BLACK WHITE PIN 6 09 ORANGE PIN 12 86D ORANGE BLACK WHITE LEFTREAROUTRUP LEFTFRONTOUTRUP RIGHT FRONT OUTRUP RIGHT REAR OUTR UP TILT SWITCH PIN 1 10 BLACK k PIN 2 28 GREEN y xe 0 PIN 11 10A BLACK 2 5 B 15 29 PIN 12 10A BLACK 22 Te zal PIN 13 10A GREEN BACK VEW BACK VIEW X
22. IL ALL LT TT SKYJACK Page 18 OF T 13 24 000000000000 LEE 2 e j BACK VIEW L mi 15 BLUE 81 ES 13 ORANGE CO Fart GREEN 49 10 BLUERED CO GREEN WHITE 34 10 BLUE WHITE e GREEN BLACK 32 09 ORANGE RED CO 2 RED WHITE 81 08 BLACK RED O BLUE BLACK 24 07 RED GREEN 22 CO F amp F BLACK WHITE 23 07 RED EF BLACK WHITE RED 20 05 WHITE BLACK RED CO OO FEF ORANGE BLACK 19 05 WHITE
23. 0L E 31LLOBHL HOIH Ove SLH SOMd MOTD 2 gd 3NION3 00 uo1volai omamo 50 o zo 1449 m 5 30 mH ve a o 7 20 80 3NION3 135310 _ 40 HOLIMS LA 9 2016 zs 4015 asva XO8 IOH1INOS vS AON3OH3I3 HOLIMS 95 015 Serial Number Reference Chart 37002423 amp Below 2 5 SJRT Compact Series 143899 Engine Powered View Parts List Print This Page
24. EE SATIVA SNIB3MOTNIVIA GION310S 8 uadWnr XO8 10H1NOO 8 1 0p a GION3110S SATIVA 09 20 UE nag raa H31H3ANI 9c H3MOd NIV E P 4 9 46 5 1 ANYWA 7 31LLOBHL i 1 4 O_O rot Orr ve 80 pu tIS fe ee eT 80 LYVLS 3NION3 915 iz 61 80 8l 008 YOLVNHSLIY 91 LOANNOOSIG NIV YOLOW 713 SNIONS yt zo MS 18918 pile 1 18 80 HOLIMS MOTD els 20 18 veta HOLMS al MS 330H9 dunivaadWal az az MOID isii 3NION3 HOLOVINOD al 15 HOLIMS 3unssaud 6 aons _________ _____________ 138310 a
25. Platform Engine Base Key Switch Emergency Lowering Base Control Console Valve Main Power Disconnect Free wheeling Brake Hand 27 Pump Brake Auto Reset Valve E Switch Main Manifold Test Platform Raise Lower Switch Test Free wheeling 1 Select platform engine base key switch to 1 j base position and raise or lower the 2 T platform with platform raise or lower switch 3 Result Platform raising and lowering functions should operate Test Emergency Lowering 1 Raise the platform 2 Locate holding valve manual override 5 knob at the base of each lift cylinder Depress and turn counterclockwise If 29 3 necessary use access rod that is located on the base of the aerial platform 3 On hydraulic fuel compartment pull out and hold emergen
26. 1 OHON ss 4 _____ __ ________ _ _ __ __ ______________ _______________________ _ __ _ ____ _______________________________ __________ ETT XY T 2LIHM 9i a 8 9 28 GIONTIOS xe GION310S SATVA pee cog AV 138 3SH3A3H os 106 SATIVA 5 GION3IOS SATIVA 8v 01 204 acir GIONSIOS 4 Wwe 6 20 1431 8 ONIH33IS SL 4 v OHON 88 v8 v8 80 vc 1391 45 2 5 105 py Q33dS AvHH 9478 4008 Lo 318vN3 1 GIONXIOS3AWA GION3IOS 3A1VA zv q3ads dWnd 9 AV T38 1010100 ads IH NOLWASTS 66 NadO ATIVINBON HOLIMS 100100 5 51835 JILLOHYHL 8e GION31OS 141 ve NOILdO NOLLOW TIVWS L NOILdO 1H9I15NIHSV 14 NOILISOd
27. 4 00 HOLIMS 22 200 gt gt 6 iH vis 15 0L Y3LIWHYNOH GIONSIOS g 4 4 3NWA 139310 00 zeaz Ze vee ve aay ama 01 4 4 4 3NWA 199310 ve 0L 1 4 ve ve Ove ave ver ve t GION3IOS 1 56504 31L108H1 Ove S1H Ove Ove 50 50 4 4 00 50 50 0L 1493 HOLVOIONI NO 06 easi v omamo 4 OF m 30 10 5 20 20 20 oL aL e X 4 ve 90 S0 c 20 40 80 3NION3 20 HOLIMS HOLIMS NMOG dN 3015 zs AON3OH3IN3 4018 3701 asva IOHINOO HOLIMS AM 95 5 015 2 5 lt JUN View Parts List Print This Page 3 23a Electrical Schematic CE All Option With Kubota Diesel Engine GION310S NMOG HV3H 1331 GION3IOS H399IlH1nO dn uv3u 1331 GIONGIOS GION31OS H399lHLnO dn GION3IOS 1NOHH GION3T1OS Y39914LNO LNOWS GIO
28. Outrigger Settings SKYJACK Page 12 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance EEE o I aa 5 3 6 Outrigger Control Module Instructions When EZcal hand held device is connected to the OCM1 control module a two line displays shows various menus and settings At any time the top line of the display describes the currently selected menu and the bottom line shows the currently selected item in that menu oix buttons on EZcal allow easy navigation through the menus and change the selected item the bottom line display ENTER enters the selected new menu when available top line display changes and adjusts the selected item when available ESC exits the current menu back to the previous menu TOP LEVEL MENU OPTIONS HELP Select this menu to see a description of current OCM1 status DIAGNOSTICS Select this menu to see switch input status amp logged data ACCESS LEVEL Select this menu amp enter correct code to enable adjustments and calibrations ADJUSTMENTS Select this menu to see and adjust OCM1 settings NOTE this menu provides for adjustments which might be needed for different work activities SETUPS Select this menu to carry out initial set up of the OCM1 NOTE this menu provides for set ups which are needed to configure the OCM1 for a particular vehicle HELP MENU OPTIONS help message A message displays current OCM1 status indicatin
29. TRANSDUCER HARNESS M O1 TO BEEPER 20 E 02 BLUE 22 BLACK 29 RED 29 GREEN N U BLACK 02 WHITE TO ANGLE TRANSDUCER PIN 1 910 BLACK PIN 2 28B GREEN PIN 3 902 WHITE BLUE HEATSHRINA TO CONTROL MODULE P4 MV f GREEN YELLOW HEATSHRINK PIN 288 GREEN PIN 4 N U PINS NIU PIN 6 910 BLACK PIN 7 900 WHITE PIN 8 902 WHITE PIN 9 910A BLACK TO PRESSURE TRANSDUCER PIN 1 910A BLACK PIN 2 60A GREEN PIN 3 900 WHITE M138158AB_1 5 21 3 _ 1 103 LE ALTERNATOR MAIN ENGINE STARTER CONTACTOR PROPANE LOCKOFF SOLENOID AT PROPANE REGULATOR VAPORIZOR PROPANE VALVE SOLENOID 2P 60 2 50 ORANGE 00 WHITE CHOKE SOLENOID 05 2 02 WHITE PROPANE LOCKOFF SOLENOID AT CARBURETOR GAS LOCKOFF SOLENOID AT CARBURATOR PROPANE VALVE SOLENOID 2P 50 1 50 ORANGE 00 WHITE GAS SOLENOID 2641 11 BLUE 00 WHITE 3 13 Engine Wiring Diagram Dual Fuel System Kubota Engine 1 SSO
30. 8 2 8 8 75 8 8 8 8 gt lt D vo u3onasNvu u3onasNvu 24 4 20 STONY 3unssaud 09 09 09 00 H3MOd 5 D 6v N33u5 6v NHOH 382 1 85 4 382 2 20882 2 382 382 T 0 82 4 i p rn ver gt m et 921 voL ve 4 ae 80 80 1 vse 4 zo LJ de 4 LI we ve ve ve H IH MOT 2 tIS Ww ze Xovig Nasuo T 1HVLS 3NION3 Lu 918 4 2 4 4 205 700 ve ve igo 00 rni T al H3MOd zes Lio eo t ve MS 18v1S e sort 0 4 18 nm n n n HOLIMS 3MOHO 165 Lu MOID 4 1 Ze ve ve 18 1640 c MS 00 1 we ve 0L 0L 9mda MOTO 14 800 al 00 vee HOLIMS 2 aunssaud gt gt 18 9 w or zsa Y3LIWHNOH zeaz 1 vee vee vee vel 0L 0 4 01 0 gl OvE S1
31. 18 4 1 28 Platform will Not Lift from Platform or Base Control Console with Outriggers Extended or Retracted 19 4128 Down Circuit Inoperative from Platform us evan veve xs GE pe PH E E 19 41 230 Down Circuit inoperative from 20 4 1 31 No Down Function Additional for machines with Load Sensing System 20 412 Hydraulic Generator _ ______ 21 4 1 33 Hydraulic Generator will not Shut Off from Generator Switch 21 4 1 34 All Outriggers Inoperative Auto Level and 22 4 1 35 All Outriggers Inoperative Auto Level and Manual from Platform Controls 22 4 1 36 All Outriggers Inoperative Base Controls 23 4 1 37 All Outriggers Inoperative Auto Level only Led Power Indicator Light at Outrigger Control Module OCM1 Not On Constant 23 4 1 38 All Outriggers Inoperative Auto Level only Led Power Indicator Light at Outrigger Control Module OCM1 Flashing 24 44 39 Left Front Outrigger moperauve ticas epo kr 25 4 1 40 Right Front Outrigger Inoperative 25 SJRT Compact Series SKYJACK Page 1 E
32. 61CR 17008 65CR UP RELAY 14CR PIN 7 28 GREEN BLACK JUMP J17E PIN30 36AYELLOW PIN 8 02 WHITE 2 PIN 85 14 BLACK PIN 9 02 WHITE BLACK OUTRIGGER CONTROL BOX OUTRIGGER MANIFOLD LEFT REAR OUTRDOWN LEFT FRONT OUTRDOWN RIGHT FRONT OUTR DOWN RIGHT REAR OUTR DOWN PIN 86 02 WHITE PIN 10 36A YELLOW OUTRIGGER LIMIT SWITCHES PIN 1 35C WHITE BLACK x2 OUTR MANIFOLD PIN 1 17C WHITEIBLACK PIN87 14ABLK WHT PIN 11 61 GREEN PIN 1 61 OUTR CTRL BOX CN20 PIN 2 78 BLACK WHITE x2 PIN 2 02 WHITE PIN1 78BLACKWHITE PIN1 75ORANGEJBLACK PIN 76RE
33. 5 39uv1 3ATVA 631 38 TaTi3uvd Salu3s Av T38 100102 GdS IH NOLLVA3T3 Av 13H 7T3TI3uHvd saiu3s 631 38 GIONTIOS IMYA 131 Av 38 NOILdO JINON 1081NOO 3unss3ud STONY NHOH 318VN3 Xnv TIVWS d318VN3 9 TIVWS dT8VN3 9 d18VN3 5 3ATVA NIV GION310S 9NIGTOH GION3IOS SATIVA 9NIGTOH NOILdO H3 1H3ANI AV T3H H3MOd NIV 3I8VN3 31LLO8HL ANYWA H3MOd JILLOHYHL 19 18 uaxvaua v SZ AH3LIV8 AZL YOLVNHSLIV YOLOW 13 YALYVLS Av 13H 9 HOLIMS 9 YALYVLS GION31OS 135310 GION31IOS 31LLOBHI 9 YOLVOICI Serial Number Reference Chart 37002423 amp Below c 2 5
34. MEME f N P 5 24 BLACK RED DISCONNECT O jm 5 5 D Deursen D PING 37 BLUEMHITE SWITCH St d i ka 1 PINT 3A BLUE z TO LOAD SENSING n OUTRIGGER TNR PINS 31 CONTROL MODULE P2 amp eeg 4 E mod LIMIT SWITCHES BACKVEW 009000000990 0000060909096 s 90990 PIN 3 14 BLACK ORANGE BLACK 19 51 5 WHITEBLACKRED n il i di PIN 4 13 ORANGE BLACKIWHITEIRED 20 2 8 8 BACK VIEW PINS NIU BLACKWHITE 23 CO CO Q7 RED GREEN PIN 6 NIU BLUEIBLACK 24 CRD BACK VIEW 5 amp PIN7 16 WHITE BLACK REDWHTEQU 09 ORANGERED eee 4 GREENBLACK G2 CO CO 0 BUENHTE OUTR MODULE T 5 GREENMHITE 34 e 10 BLUEIRED PIN 1 10A BLACK 5 GREEN S E 18 ORANGE PIN2 NIU S PN 11 02 WHITE 1 NOOUTRIGGER JUMPER PLUG UP RELAY JUMPER NO HYDR GEN JUMPER PLUG PINS O2WHITE PIN 12 10A BLUEBLACK ORANGE GREEN 60 1 O O 4 BLACK PIN 1 amp 7 GRNIRED 28 284 BLACK 14 144 PIN 9 amp 10 RED 49 434 PIN 4 44 GREEN REDJBLACKWHTE NOTUSED ae cu ye 7 vA ute NOTE ONLY USED WITH GROUND GRNIBLAMIHT TO 00 e O
35. e di gt C 865 921 1381 uvau 1H9IH LHOI INOS L431 356 ose ose vies 4 60 4 60 cune v 987100 NI NMOHS SH35914LNO 1NOHJ 1NOUJ uad 5919 nn LH LHOIW 1431 T 19 ERE og ug 59 79 or 1 voL vol 99 1957 2951 991 7957 1 4 j N34O 6 8 ver 277 27 vor 5 4 g 1 Ll vez 7 SE sz dd 88 WW HH 99 99 aa 4 via t 4 440 49898 p Ye 98 TL M 12 60 40998 58 HOLIMS 4 HOLVHIN39 998 60 25 60 91 200 98 2 a98 f a98a l gt NOILdO HOLVH3N39 iz 94 1 4 1 8i ovigs dau 8i 8i ri zoa sia 1225 lt 4 9 25 89 vel vata vea T p 91 XOV18 3LIHM 94 a 8 T9 szoa 945 4 2 n Visus vol L voL gt zvzo
36. FUEL SELECT SWITCH S33 PIN 1 50 ORANGE PIN 2 37 BLUE WHITE PIN3 11 BLUE 50 50 E 00 IGNITION COIL 37 BLUE WHITE 00 WHITE ENGINE GROUND 00 WHITE HIGH THROTTLE SOLENOID HTS 34C 34C GREEN WHITE 02 WHITE BACK VIEW Gi 10 GA v a FLASHER FL29 elle PE 3A 0 9 e o Bona BACK VIEW 0 69160 Hosinda 00100 z 0 FUEL PUMP 11 BLUE 00 WHITE 000 0 0 HOURS ELECTRIC PANEL N U PIN2 34C GREEN WHITE PINS 02 WHITE PIN 4 32A GREEN BLACK PIN 5 2A BLACK RED PING 37 BLUE WHITE PIN7 3A BLUE 31 REDWHITE A n FUEL PUMP POS BLACK NEG WHITE BLACK
37. 5 5 5 B lt lt 10A BLACK e 35 BLACKWHITE 5 isle 5 OUTRIGGER 12 PIN CONNECTOR PLUG UP RELAY 14CR HYDRAULIC GENERATOR 12 PIN CONNECTOR PLUG 00 WHITE 14GA Lu LL db PIN 1 28A GREENWHITE 2 WHITE PINT EMPIY PINT 148LACK D 7 PIN 2 178 BLUE BLACK _ MBAK PIN2 EMPTY PIN 8 17B BLUE BLACK Ow OR els 14A BLKWHT 2 1 46 O PIN 3 86A ORANGE BLACKWHITE PIN3 EMPTY 9 43 RED BLACK a PIN 4 10A BLUEMHITE 36A YELLOW PIN 4 O2WHITE 2x PIN 10 43A REDWHITE F1 FUSE ha PIN 5 09 ORANGE 2 PINS 2AORANGEBLACK PIN 11 86A ORANGE BLACKIWHITE 300 AMP Us PIN 6 44 RED PIN6 O9ORANGE PIN 12 86D ORANGEIBLACKIWHITE PIN 7 28 E PIN 8 02 WHITE 2x m PIN 9 02 WHITEIBLACK a MAIN BATTERY AIN MANIFOLD HARNESS PIN 10 36A YELLOW Bi 02 WHITE 17B BLUE RED PIN 11 61 GREEN Y 13B ORANGE 180 RED BLACK 1 03 BLUE 14GA MA BLACK _ 20A BLACKWHITEIRED 15A BLUE 23 BLACKWHITE l 0 18 BLUENELLON 24 BLUEBLACK LS BA WHITEIBLACK 30 DOO ooo ooo Doo Ooo oo ooo q 02 WHITE TO ENGINE 16B WHITE RED 860 ORANGE BLACK WHITE Nu PIN 32A MAIN Al umi VIEW lt gt
38. GIONXIOSONITIOH LUA ess 5 T an vor 82 vez vee 8 Y Y rri dd 99 WW HH 59 99 42 9 via Av HU 4018 S4 4 HOAH vag end gg 1 49 80898 NO p e uolvus3o 77 898 7 98 80098 HOLIMS E 64 HOIVH3N3O HOJVH3N39 098 60 60 eis eL GIONTIOS 1 4 A 91 200 HOLVH3N39 a98 v Lad 04 60 69 gt 89 gt 19 gt e vel r4 9L GIONSIOS 3AWA TIVS 981 vel 8i ovig aau m e 09395 GION3108 59 248 Wat Av v9 e IL OHON 9 9 9L v 5 75 GIONS1OS 3 A1VA 9 VAR 4 VOL Vol vor GION310 MVA 7 p s 4 19
39. 6 Ord 62 4 ez sza 84 Lyd 2L ze za 2 12 7 9 4 4 2 8082 an dn Ll 868 1 1 4 1431uvau 1HOlH INOW 396 L ose ose ase vt 22 12 026 1 ves ues 60 2408 ABH 0 1 4 u399Iuino 60 496 24 vi GALOWHL3Y vL NI NMOHS SH399IH1n0 He 02721 1NOHJ BEN 8919 0 L ia 19 9 29 9 v9 vol vol 8059 1951 2991 991 7951 1 14 99 438010 N3dO SSHOLIMS 83998100 4 8 vol V9E VOL 5 9NITIOH jg 1 ZEe0d 4 Dite 11 3H 227 vez 8c 99 Y 5 99 WW HH 99 33 ne 2 98 vid 4018 uOlvH3N3O 69 330 1 J mE 6 60 ONIHOLWI E NO 99 498 58 58 pee TT oa 19 HQAH 098 60 60
40. pP Length Platform Size 56 x 99 1 4 2 5 56 99 1 4 2 5 N N N N 3 3 3 3 ft 38 ft Platform Elevated ft 32 ft 3500 High Throttle 2050 Low Throttle 3500 High Throttle 2050 Low Throttle Foam filled OTR Outrigger 26 x 12 Sound Pressure 96 dB A 60440AG ANSI o 2 Oi N 32 ft 9 26 ft 7 8 ft i 26 ft ft 3 3 2 o 0 Weights are approximate refer to serial nameplate for specific weight SKYJACK Page 2 SJRT Compact Series Engine Powered 143899 Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 1b Specifications and Features CE Compact RT s wef ee pem Tom ___ om Lower Rated Load 36 sec 36 sec Kubota Diesel 3500 High Throttle 2050 Low Throttle Kubota Dual Fuel 3500 High Throttle 2050 Low Throttle Foam filled OTR Outrigger 26 x 12D Sound Pressure Gradeability Torque Equivalent To Weights are approximate refer to serial nameplate for specific weight 60440AH CE SJRT Compact Series SKYJACK Page 3 Engine Powered 143899 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 1 Specifications and Features AS Compact RT s Model 6826 6832 N
41. SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 10 11 12 13 14 15 16 17 Defective outrigger limit switch 1566 Check switch Replace if defective Loose or broken wire 66A from outrigger limit switch LS66 to outrigger board Check continuity Replace if defective Loose or broken wire 10A from outrigger board to outrigger limit switch LS65 Check continuity Replace if defective Defective outrigger limit switch LS65 Check switch Replace if defective Loose or broken wire 65A from outrigger limit switch LS65 to outrigger board Check continuity Replace if defective Check for power on wire 65 at outrigger control module at pin P2 8 voltage present proceed to outrigger control module troubleshooting Loose or broken wire 65 from outrigger control module at pin P2 8 to outrigger board Check continuity Replace if defective Open diode D14A 2 at base terminal block TB1 Check diode Replace if defective 4 1 28 Platform will Not Lift from Platform or Base Control Console with Outriggers 1 2 Extended Retracted Defective lift enable relay 65CR Check relay Replace if defective Defective lift disable relay 17DCR Check relay Replace if defective Loose or broken wire 14 from base terminal block TB1 to outrigger generator harness connector Check continuit
42. Vel tb Av 138 TIVWS 9v 9 4 voL vol OHON NOldO 4 60 4 a 5 22 v yovga v vL 62 99 vv t bara 80 E o o oe v v L Li m NOLLISOd NI IH m P2 11 P4 8 P43 P49 P47 4 2 P2 10 P3 6 2 2 P2 12 JINON 1OH1NOO ev 02 P3 5 910 4 6 29 P3 2 22 1 16 2 7 15 P2 8 14 28 P3 4 13 2 4 60 P3 3 02 902 28B 910A 900 60A 35B 28 10 10 52 16 Or gt D voL _ 6 gt 3unss3ud 09 09 09 zo zo 00 Hv se NO H3MOd ran NHOH D 6v 6v N3349 6v 80 318VN3 Xnv dWnadwnamwws 9 7 382 NHOH 140387 85 AYBHSISVNS 1 4 dna 382 AYISHSIEVNS pg 1 382 382 301 2 T 1 dna 39uvi vez
43. 1 2 76 4 Sr 08 80 gt 8008 IMYA gt 43385 HOIH goz Hz 902 5 gt 46 GIONSIOS zp 1 1 4 1 18 vit m m m T GIONTIOSSAVA s zoa voz Hr 01 voL o 1 lt 02 2 4 LNOLNO 4 d use 58 vor NadO ATIVINHON ATY ge 1 4 4 HOLIMS 931035 voz voz vy LNOLNO 3NBQ 4 voz T ered yovse i AH 4 80 i 318VN3 IILLOHHL 60 60 60 GIONSIOS 1 tzoa 1 4 INYA 14 vel ell 6z dg ES 8 2 e 62 osza vel vL xovig vL 5 6 4 Wy NOLLOW TIY asza 882 m o TNS ze e SONVUO a a zed a NOILISOd NI 8 CIE e
44. 225 vies 3 18VN3 vL 9 1 uxoouino Av T3u eL NOILISOd Q310VH13H NI NMOHS 1NOU3 uvau 1391 1H9IH 1H9IH 3 18VN3 oz 991 10 3 18VN3 iang3oomino 69 038010 N3dO ATIVIWHON S3HOLIMS 89 GION310S 98 6 Zd 82 19 99 59 4 4018 99 gg 1 0 SNIHOLY1 60 99 m NO HOLIMS lem GION310S 91 09 9 es 4 HOLWH3N39 95 GIONTIOS3AWA 1 o q 7 H3TIOHINOO 5 46
45. gt GIONIS 0 UA 88600 gt 4 HO1VH3N39 HAH 098 amp 60 o 318 vN3 ic d dig 89 WEE NOLLdO HO1VH3N39 Aaa 1 4 __ 4 dnd vez vi vv 95 tv asia GION31OS 81 20 4 39 1 d vi 200 que p GIONTIOS3AWA 1 d 2 1 9 25 891 891 4 77 vel be 65 t 9i 9 9 8 bi 925 GIONSIOS 1 4 vol val vol to C GIONSTOS 4 L 4 4 0 H ved Host in zn B m8 m at V 58 GIONSIOS n vol o GIONTIOS 3AWWA PAI a d 1 as M var mam 88 oy ezoa GIONSIOS 1 1 4 4 5 1 1491 ve xovig ana gt 13916 8 GIONSIOS g 1 1 4 4 Q ONIHS3IS
46. 3nd 00 01 T 4 9 HON Ors StH Ove Ove ove ave Vet ve t 9z zoa S A vi amp 90 vie ve ve 50 50 051 2001 1091 v 00 S0 G3H 31IHM 50 0L NOILISOd qe NO 1840 2 4 4 301 4 1081NOO 00 IOHINGS wor 28 or Te Ay 20 20 Y zs SE Te 20 20 ces LL MS en dois TOULNOD View Parts List Print This Page 3 22a Electrical Schematic ANSI CSA All Option With Kubota Diesel Engine M129301AB GION31OS H355lH1n0 904 8 0 50 v GION310S YOL 5 3 a i a GIONS10 60 SKYJACK 33 de L Em g i m GION310S 395Iu1no 20 9 Z 94 eL 22 20 GION3108 10 GIONSIOS H399IB1nO poi gx AG GION3IOS 5 gx BO E
47. cd ts tutu E Edd Redde Er an i eS te RE UCM M maa aie Chas cocum eee SpA PUMP PUMP CN PUMP RESERVOIR M137360Al SJRT Compact Series SKYJACK Page 13 Engine Powered 143899 Print View This Page Parts List 3 6 Hydraulic Manifolds And Ports Identification ____ 1 9 1 686 HY 1 59 4H 15B COUNTERBALANCE PARALLEL VALVE REVERSE DRIVE VALVE 57 4 20 SERIES PARALLEL S8 S8 ne 4H 16A 4H 15A FORWARD REVERSE CB2 lt lt lee we LL ME 5 e PARALLEL 2 EL VALVE VALVE COUNTERBALANCE 252 2 VALVE 8 Le PARALLEL 222779 o 09 FORWARD Ke DRIVE 4 VALVE 4912 S10 S6 5 ato ORIFICE 2H 20B SE Q HIGH T VALVE Cam 5 see za 5 2H 13 ANSI CSA 2H13B CE LOWERING VALVE S 9 2H 17A ANSI CSA o gt U In Ee 4 FREEWHEEL 7 LEFTSTEER 2H17B CE VALVE VALVE gene PUMP DUMP HP2 VALVE HAND PUMP TO TO TO LIFT V6 52 AE STEER LIFT RELIEF AUTO 2H 18B ANSI CSA CYLINDER CYLINDER
48. from the menu and press the ENTER button Contact Skyjack Service Department at 44 1691 676 236 for your Access Level Code Number 9 display will show Access Level Code By using the Up Down buttons enter the Access Level Code xxxx followed by pressing the ENTER button 10 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 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 SJRT Compact Series SKYJACK Page 25 Engine Powered 143899 Service and Maintenance Section 5 Procedures 13 14 15 16 17 18 19 20 The display will show X GROUP CODE Refer to 5 4 8 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 The display will show CURVE Refer to 5 4 8 for curve code By using the Up Down buttons enter the Curve Code followed by pressing the ESCAPE button The display will show Machine Defaults By using Left Right buttons select the Tilt Setups from the menu and press the ENTER button The display will show Tilt Setups Calibrate
49. lt lt b Se lt lt 05 38 22 22 2 8 5353 555 5 2 05 32 GLOW PLUG CHOKE SWITCH 31 S WZ KEY SWITCH 510 x TO HORN 94 05 13 08 07 09 14 10 23 24 49 60 02 i UP DOWN E EE SWITCH 52 49 49 BLACK Q A V 17A 14A 18 14 44 28 28A M lt NN X gt 155 Bis A NN AN LN 2 55 t z HIGH SPEED LIMIT SWITCH 9 10A BLUE N 35 BROWN E e 5 OUTRIGGER 12 PIN CONNECTOR PLUG UP RELAY 14CR HYDRAULIC GENERATOR 12 PIN CONNECTOR PLUG SONO 00 WHITE 14GA 4 i PIN 1 28A GREENWHITE 02 WHITE PN1 EMPTY 7 14 BLACK 2 allg PIN 2 BLUEIBLACK 2 MBA PIN2 EMPTY 8 TL DAE PIN 3 ORANGE BLACK WHITE 22 4A BLKIWHT PIN3 EMPTY PIN9 43 RED BLACK C 9 f TIT T PIN 4 10A BLUE WHITE 36A YELLOW PIN4 O2WHITE 2x 10 4 FLASHING LIGHT _ PINS 09 ORANGE 2 PNS 2AORANGEBLAOK PIN 11 ORANGE BLACKIWHITE A BEEPER PING 4 RED PING C9ORANGE ORANGE BLACK WHITE 300 AMP PE PIN7 28 GREENBLACK
50. stop 1 Drive aerial platform Pi forward Test brake again by releasing 57 enable trigger switch only Result Aerial platform should come to an instant and abrupt stop SJRT Compact Series Engine Powered 143899 Section 1 Scheduled Maintenance Function Tests Drive Steer Enable Trigger Switch ocker Switch Drive Steer Se S p Torque Switch Low High Throttle Switch Low High Speed Range Switch Operation Light Horn Pushbutton Raise Off Lower Switch Glow Plug Choke Pushbutton Off Lift Drive Key O Switch Emergency Stop Button Engine Start Pushbutton Lift Enable Pushbutton Test Speed Limit Test Lowering Warning CE u 1 h WARNING 1 Select off lift drive key switch to I V lift Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting Ensure path of intended motion is clear Select off lift drive key switch to 5 lift position Raise the platform to an approximate height of 13 ft 4 m Select off lift drive key switch to drive position and attempt to drive forward or reverse Result Aerial platform should move slower than when it was in stowed position 4 position Fully lower the platform Result Platform should stop lowering at an approximate height of 2 5 meters and an alarm should sound Release platfo
51. L NG IA 5 998 um vLHv vL vL vL PA LLH m m ovig ama LN DA dn 9989 gt eZ ama uvad 12 200 9 92 92 ovig aau 088 ZL Hy 22 ZL 52 1NOHd PA 61 200 9 E 92 s IA 14981 n n 20 Hon 4 voz voz 99 20 924 02 0 02 9 24 61 61 N3349 61 OSE gt NOILISOd ose ose ose NI NMOHS SH395IHLnO VOL 4 voL ose 3uHwWama ose 1NOY4 1431 65 red ose jose 1NOH4 LHOIH v99 veo vor uvau 1 OLNY HLIM zd 9 uvau 1431 led 89 VOL 8951 1 voL 8 24 99 N3dO 5019 59 6 24 N N 01 24 vy vv bpd 8 4 Y LL 4 e 9 Y 2e bpd SL Y sz Std gt 4 ve 9 EL ca Y ES 4 a 12 E Na 1 Na ie 22 22 24
52. gt o Base Weldment Wheel Tire Assembly Axles Steer Cylinder Assembly Tie Rod Ladder Outriggers If Equipped gt gt gt w gt Manual T c 5 8 5 5 Platform Control Console Test Emergency Stop Test Lift Enable Test Platform Raising Lowering Test Enable Trigger Switch gt Test Steering Test Horn gt gt w Test Driving Test Brake Test Speed Limit Test Lowering Warning CE gt gt gt gt Test Powerdeck Enable If equipped gt Test Extension Platform s If equipped gt gt Test Tilt Sensor If Equipped m 6 5 9 0 Test Emergency Stop Test Base Lift Enable Test Lower Neutral Raise Switch gt gt w gt gt Test Emergency Lowering Models 71xx 8831 41 amp 9241 gt Test Emergency Lowering Model 8243 8850 amp 9250 Test Emergnecy Powered Extension Platform Retraction Switch Model 8850 amp CE 9250 Test Main Power Discconect Switch gt gt m m gt Perform Visual and Daily Maintenance Inspections amp Functions Test Refer to Section 2 7 of the Operating Manual B Perform Scheduled Maintenance Inspection every three months 150 hrs Refer to Section 1 0 of this manual C Perform Scheduled Maint
53. 14 Loose or broken wire 02 from relay 20ACR to base terminal block TB1 reverse drive only Check continuity Replace if defective 15 Defective relay 20ACR2 reverse drive only Check relay Replace if defective SKYJACK Page 16 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 23 Up Circuit Inoperative from Platform T 2 3 4 5 Lift Drive select switch S3 in drive position Select lift on lift drive select switch Defective contact lift drive select switch S3 between wire B and wire 14 Check continuity through contact Replace if defective Defective forward switch 57 5 on controller S7 Check switch Replace if defective Loose or broken wire from forward switch 57 5 to contact on lift drive select switch S3 Check continuity Replace if defective Loose or broken wire 14 from contact on lift drive select switch S3 to base terminal block TB1 Check continuity Replace if defective 4 1 24 Up Circuit Inoperative from Base Control Console 1 2 3 4 5 Loose or broken wire 10E from base terminal block TB1 to base up down switch 52 Check continuity Replace if defective Loose or broken wire 14E from base up down switch S2 to base terminal block TB1 Check continuity Replace if defective Defective base up down switch 52 Check switch Replace if defec
54. 60023AD SJRT Compact Series SKYJACK Page 9 Engine Powered 143899 Service and Maintenance Operator s Responsibility for Maintenance Safety Precautions Know and understand the safety precautions before going on to next section WARNING Failure to heed the following safety pre cautions could result in tip over falling crushing or other hazards leading to death or serious injury KNOW all national state provincial and local rules which apply to your aerial platform and job site TURN the emergency main power disconnect switch off when leaving the aerial platform unat tended Remove the key to prevent unauthorized use of the aerial platform WEAR all the protective clothing and personal safety devices issued to you or called for by job conditions DO NOT wear loose clothing dangling neckties scarves rings wristwatches or other jewelry while operat ing this aerial platform AVOID entanglement with ropes cords or hoses AVOID falling Stay within the boundaries of the guardrails DO NOT raise the aerial plat form in windy or gusty condi tions DO NOT increase the lateral surface area of the platform Increasing the area exposed to the wind will decrease aerial platform stability DO NOT drive or elevate the
55. 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 SKYJACK Page 14 SJRT Compact Series Engine Powered 143899 Section 1 Scheduled Maintenance Service and Maintenance Inspections 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 an
56. FUEL SELECT SWITCH 33 KEYWAY TO THE RIGHT PRESSURE SWITCH OPS1 2A BLACK RED 2B WHITE 28 aD 2A Y CHOKE RELAY 31CR PIN 87 31A PIN 86 02 WHITE PIN 30 BLUE PIN 85 31 RED WHITE PIN 87a NOT USED ex 22 Print This Page TEMPERATURE SWITCH TPS1 2B WHITE STARTER SOLENOID 32A GREEN BLACK STARTER MOTOR 57 BLACK WHITE View Parts List BACK VIEW ee Se 5 cl a p ecce en 0 poen 37 ALTERNATOR TRIGGER PIN 1 N U PIN 2 37 BLUE WHITE PIN3 NU M137528AC SJRT Compact Series Engine Powered 143899 Print View This Page Parts List 3 14a Engine Wiring Diagram Diesel Fuel System Kubota Engine
57. MAIN ENGINE STARTER TR GLOW PLUG LIGHT 3 14b Engine Wiring Diagram Diesel Fuel System Kubota Engine BACK VIEW 8 ENGINE STARTER 57 BLACK WHITE ENGINE GLOW PLUG EGP 91A RED 10 GA FRAME GROUND ATTACH AT BELL HOUSING AIR FILTER BRKT 00 WHITE HIGH THROTTLE SOLENOID HTS 34C 02 WHITE 34C GREENWHITE ELECTRIC PANEL N1 NU 2 34C GREENMHITE 3 02 WHITE 4 32A GREEN BLACK 5 2A BLACK RED N 6 37 BLUE WHITE N7 3ABLUE 8 31 REDWHITE gt 70 70 Uu 53 34 ROMA BACK VIEW 99 D 8 8 DIESEL VALVE SOLENOID 2087 00 BLACK COMMON 37 RED HOLD 57A WHITE PULL DIESEL VALVE SOLENOID WHITE 37 57A BLACKWHITE 7 57A 00 57A ee TEMPERATURE SWITCH TPS1 20 WHITE Print View This Page Parts List 103 RED 10 GA ALTERNATOR TRIGGER PIN NU PIN 2 37 BLUEMHITE 18 GA PIN3 NU ENGINE STARTER YL CONTACTOR E 30A GREENIBLACK PRESSURE SWITCH OPS 2B BLACKIRED 2C WHITE 26 101
58. SKYJACK Page 14 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance 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 Always follow the instructions of the Calibration instrument Ensure aerial platform is parked on a firm and level surface 2 Elevate the scissors high enough to lay a level accross the base tubes Ensure there is debris on the base and the level sits flat Do not elevate aerial platform higher than the high speed tilt override limit switch 3 Manually operate the outriggers and level the machine in 4 places left side right side front and rear All 4 outriggers must be firmly placed and all 4 tires are off the ground 4 Double check that the aerial platform is level at all 4 points 5 Connect the EZcal tool to the P1 connector on the CONTROL MODULE 6 Thedisplay will show Help Press Enter By using Left Right buttons select the Access Level 3 from the menu and press the ENTER button 7 display will show Access Level Code 0000 By using the Up Down buttons enter the Access Level Code 1 31 gt 2 2 followed by pressing the ENTER button 8 The display will show Access Level 2 By using Left Right buttons select the Setups from the menu and press the ENTER button 9 display will show Setups Change Defaults S
59. YOO MCAL COO JO NOB OOO MOB C Pie CONTROL MODULE PLUG AND COLOUR WIRE FUNCTION P1 The Calibration Connection Input Power From Base Terminal Strip To Confirm Lower Control Is Selected Raise Platform Input Lower Platform Input ot Used Z Not Used ot Used 16 White Black Forward Direction Input Reverse Direction Input Not Used Not Used 7 10 35B Red Black Input From LS1 High Speed Limit Switch To Verify ON OFF Limits 1 2 15 1 1 Negative Input From Base Terminal Strip Main Power Input From Base Terminal Strip Output To FL 22 Flashing Light Output To BP 29 Beeper Output To Overload Warning Light On Control Box Output To 28 1 Tilt Relay And 28CR2 Down Relay Negative for Flashing Light and Beeper Output To 28ECR1 Aux Tilt Relay And 28ECR2 Aux Down Relay Not Used Varied Input From Transducer Varied Input From Angle Transducer Not Used Not Used Positive Signal To Angle Transducer Negative Signal To Angle Transducer 902 White Negative Signal To Pressure Transducer 910A Black Positive Signal To Pressure Transducer SJRT Compact Series SKYJACK Page 17 Engine Powered 143899 Service and Maintenance Section 5 Procedures 5 4 2 LED Error Codes Quick Reference Chart IN GROUND MODE 7 8 6 3 2 3 4 5 6 3 4 5 6 4 7 1 7 2
60. calibration is unacceptable This probably is due to the wrong load being in the platform i e specifying EMPTY if the platform is loaded or the other way round or Having the incorrect pressure transducer installed During calibration the following information messages may appear 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 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 Lower Empty This message is displayed while the platform is being lowered to the next measurement height when an EMPTY platform is being calibrated SJRT Compact Series SKYJACK 23 Engine Powered 143899 Service and Maintenance Section 5 Procedures Lower Loaded This
61. display will show MEASURING 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 36 When the platform is fully lowered and height 0926 is displayed release the lower switch 37 The display will show briefly TOTAL DATA 04 to indicate the number of measurements taken 38 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 39 Press ENTER to complete date entry the system will store it 40 The display will show Calibrate Load option 41 Press the ESC button to exit the Calibrate Load option SJRT Compact Series SKYJACK Page 27 Engine Powered 143899 Service and Maintenance Section 5 Procedures 42 Remove the jumper wire and re connect the black wire 14 to the coil removed earlier 43 Close the hydraulic electric tray NOTE Continuing partially complete load calibration Once a calibration phase has been successfully completed it is not required to do it again unless of course a change to the vehicle such as a replacement sensor requires that calibration be repeated This is useful if the calibration procedure is interrupted the remaining phases
62. 892 e eh e 1417 NI m IH HOLL S sa 4 D 6v 6v T rad zoa 4 aT NHOH lt 88 sayo zayo vor ve uadwnr 1Hon A 10H1NOO 4 80 1 1 09 09 09 00 7 SWHO zara LLSH 4 4 zr We ve ve ve r 3LLOUHL HOIH MOT 18 e 4 ze T 15 15 3NION3 gis 24 4 80 80 4 00 0 ve 80 189 il m 6 zes 801 N 4 MS 19915 20 ob ob ANIONS 2490 ta 4 n n n n 80 Y 1 MOTD 4 4 J 4 els 00 05 28 15 28 28 ve ve 801 oae 2 09 42 1540 H 4 MS 00 l ve 01 MOTO 1 09 42 sdi Loo ANIONS 00 os HOLIMS LAC 99 gt gt p Svo LL 00 ee o Li 02 MS 193135 ual3WHnoH 1804698 4 4 00 vee OL dd d udwnr ob 11 200 N39 4 3 4 Ove SLH ove Ove ave ver 1 ey ve 91 vie sO vie v
63. FAULT BAD TILT SENSOR FAULT BAD HWFS FAULT BAD SLAVE MICRO FAULT HWFS STALLED FAULT P2 5 FAULTY FAULT P2 6 FAULTY FAULT P2 8 STUCK ON FAULT P2 8 ALWAYS ON FAULT P2 8 ALWAYS OFF CANNOT LEVEL BAD TILT SENSOR 74 FAULT BAD TILT SENSOR A FAULT BADHWFS FAULT BADSLAVEMICRO 7S FAULT HWFS STALLED 76 FAULT P2 5 FAULTY __ A FAULT P2 6 FAULTY 8 20 FAULT P28STUCKON BS FAULT P2 8ALWAYSON 84 FAULT P2 8 ALWAYS OFF O 60412 These are internal faults If the fault persists after the power has been reset the outrigger control module may need to be replaced SJRT Compact Series SKYJACK Page 11 Engine Powered 143899 AD Service and Maintenance Section 5 Procedures 5 3 5 Hand Held Calibration Diagnostic Tool Key Functions WARNING Only trained and authorized personnel shall be permitted to service an aerial platform N WARNING Read all instructions closely before attempting each phase of this procedure ru C o 210 SYMBOL KEY FUNCTIONS p 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 C J
64. Loose or broken wire 18A from relay 17CR to base terminal block TB1 Check continuity Replace if defective Loose or broken wire 18A from base terminal block TB1 to relay 28ACH1 Check continuity Replace if defective Defective relay 28ACR1 Check relay Replace if defective Loose or broken wire 18B from relay 28ACH1 to base terminal block TB1 Check continuity Replace if defective Loose or broken wire 18B from base terminal block TB1 to small pump dump valve coil 2H 18B Check continuity Replace if defective Defective small pump dump valve coil 2H 18B Check coil Replace if defective Loose or broken wire 02 from small pump dump coil 2H 18B to base terminal block TB1 Check continuity Replace if defective 4 1 20 Second Drive Speed Inoperative 1 Defective second speed switch 57 1 in controller 57 Check switch Replace if defective SKYJACK Page 14 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 2 Defective controller 57 Check controller Replace if defective 3 Loose or broken wire 19 from controller S7 1 to relay 19CR Check continuity Replace if defective 4 Loose or broken wire 02 from platform terminal block TB1 to relay 19CR Check continuity Replace if defective 5 Defective relay 19CR Check relay Replace if defective 6 Loose or broken wire 10A from base termina
65. MOTD els Le 901 18 HOLIMS 3univu3dWwa3l 1 MS 1 az vza 9 1901 HOLOVINOD o ule 4 H31HVIS 00 vee HOLIMS 22 200 gt gt 110 s VIS 25 ol GION310S 8 al 00 45 0 AV BU SATA vi 82 Ove are ver v ve GION310S 92200 S1LLOBHI Ove S1H Ove 50 90 3NION3 ko 1493 20 90 G3u 31IHM 90 1Hon 89 NO H3MOd Ama 06 zan d 4 4 20 vee 30 1149 o i 40 40 5 ANIONS VE 0 50 5 20 20 80 HOLIMS gt Sed 4016 28 015 NOLLISOd asva TOHLNOO P HOLIMS 95 015
66. N FLASHER ES GLOW PLUG RELAY AA RED 10 GA PIN 87 91A RED 10 GA SEP PIN1 NU PIN 85 31 ES PN PIN 4 91A RED a F PIN 5 32A GREEN BLACK e ELECTRIC PANEL d i PIN N U Ja m EA PIN 2 340 GREEN WHITE O PINS 2 DR 6x x Y wb ae 0 Sf NS PIN 32A GREENBLACK QD T J GLOW PLUG LIGHT GLOWPLUG PINS 2ABLACKRED imul LIGHT PING 37 BLUE WHITE EN on PINT N U 7 515 5 PIN8 31 Y v 4 BACKVEW Lr 6 837 D pa icr eh ic Z 38 9 18 ER MEER T L t NE ET 2 PES a 5 H cms XS A 137884 SJRT Compact Series Engine Powered 143899 Q SKYJACK Page 23 Serial Number 37002424 amp Above GLOW PLUG LIGHT GPL1 90 RED 91A RED Serial Breakdown Reference Chart O 108 ALTERNATOR MAIN FL 29 3 ok fo i H SKYJACK 103
67. VALVE RESET 2H18C CE VALVE SMALL PUMP DUMP VALVE EMERGENCY SYSTEM 3H 14A 55 4 23 VALVE LOWERING RELIEF LIFT VALUE VAINE RIGHT STEER PULL VALVE VALVE MAIN MANIFOLD 138189 3 SKYJACK 14 SJRT Compact Series Engine Powered 143899 B __ CV3 CHECK VALVE CV4 CHECK VALVE Soo 69 S SPLITTER MANIFOLD SJRT Compact Series Engine Powered 143899 CV5 CHECK VALVE 4H 72A OUTRIGGER RIGHT FRONT RETRACT 4H 73A OUTRIGGER RIGHT REAR RETRACT 3 6 Hydraulic Manifolds And Ports Identification Continued 4H 71A OUTRIGGER LEFT FRONT RETRACT lt y 5 gt 02 c3 ed SS s A Qe Print View Parts List This Page 4 74 OUTRIGGER LEFT REAR RETRACT lt gt i 4H 78A amp ghe OUTRIGGER Dai OO LEFT REAR EXTEND 4H 75A OD e OUTRIGGER LEFT FRONT W EXTEND 2H 17C OUTRIGGER 4H 76A HOLDING 4H 77A OUTRIGGER VALVE OUTRIGGER RIGHT FRONT RIGHT REAR EXTEND EXTEND OUTRIGGER CYLINDER lt lt EN OUTRIGGER MANIFOLD M138075AB_1 138045 1 SKYJACK Page 15 Print View This Page Parts List 3 7 Control Box Diagram With All Options o TARAA 53 LIFT DRIVE SELECTOR BOTTOM SECTION 515 START 58 HORN
68. Zz GIONST0S OL 121 80 09 09 09 00 dny 21 LHON 9 vol SU Sc NIV 801 80 80 72 t NO 4 4 e vee ve ve ve 10 n dis 4 4 19 15 Ww T 80 1 18 Sis iz i 02 voz 6 2047 00 ve vel 89 189 any 006 94 ul 4 T ze H3MOd zes HOLOW 801 15 z0 1 T ve on MS LUVIS HOLE 0 El 1 20 20 le n n 18 n HOLIMS SOHO M ica fom MOTD GION310 foo 05 1 T Ze vel 4 n NIWA 2 08 92 1840 iu m MS 1 r ve ve oL 0 MOTO 1 09 92 18901 0 00 05 HOLIMS AATWA 3NvdOHd 1 aunss3ud 7 7 6 to 14 a x AWA SVO Y3LIWHNOH HOLOVLNOO Too vee vee vee vee 1 ve 0L 0L 16 m TE 4 dd T
69. be completed at a later time If a calibration phase has been successfully completed a REDO message is displayed REDO DYNAMIC NO REDO LOADED NO REDO EMPTY NO 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 to YES then press ENTER SKYJACK Page 28 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance 5 4 8 Curve Group Codes Chart Model Number of Extension Decks 7027 7127 1 Manual Extension Deck 7027 7127 1 Powered Extension Deck 7135 1 Manual Extension Deck 7135 1 Powered Extension Deck 8831 No Extension Deck 8831 1 Manual Extension Deck 8831 1 Powered Extension Deck 8831 2 Manual Extension Decks 8831 2 Powered Extension Decks 8841 No Extension Deck 8841 1 Manual Extension Deck 8841 1 Powered Extension Deck 8841 2 Manual Extension Decks 8841 2 Powered Extension Decks 9250 No Extension Deck 9250 1 Powered Extension Deck 9250 2 Powered Extension Decks 6832RT 1 Manual Extension Deck 6826RT 1 Manual Extension Deck 60403AC SJRT Compact Series SKYJACK Page 29 Engine Powered 143899 SKYVACK Reliable lift solutions by people who care www skyjack com
70. m NMOG 1331 SENE m E UNG gi ase 7 Y399HLNO 1 8600 an nee 1431 Vk 8 T 26 20 96 Ld 5 i zo TASiOinv 6 Sed 02 a SONNO y TA m 5 LOVHISHOLNY 6 9 29 64 a NaS 6 OSE TOU TETTE EE 5 XOVISISIHAA 556 OSE X ase NI NMOHS 26 21 VOL voL ose Ose u3o5iuino 1431 965 NMOG 1441 16 e VOL ose 996 LHOIH 06 Zd v99 Veg voi 9951 LHO P 68 V29 m 4 i 1491 NMOGQHV3Hld3 88 veo vol vo 8951 LN 8 8 99 0136010 ATIVAHON 59 SSHOLIMS NMOG ru 98 6 29 82 82 100109 T 58 Died 1491 98 bpd 4 8z 8 4 m Y 28 92 as Y 1497 18 1331 08 n vL
71. 102853 137793 137788 137783 137782 137781 137795 137791 137785 137783 137781 137790 137795 132537 122869 122877 122877 122869 122869 122869 122872 137792 137786 137782 137781 102853 127132 133762 SKYJACK 10 Service and Maintenance 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Section System Component Identification and Schematics 3 4 Electrical Parts List Continued Skyjack Parts list continued from the previous page LIMIT SWITCH Front right outrigger up LIMIT SWITCH Rear right outrigger up LIMIT SWITCH Rear left outrigger up LIMIT SWITCH Front left outrigger down LIMIT SWITCH Front right outrigger down LIMIT SWITCH Rear right outrigger down LIMIT SWITCH Rear left outrigger down MODULE Outrigger Auto Level Control SWITCH Oil pressure TRANSDUCER Pressure 3000 psi CE SWITCH Main power disconnect N O CONTACT BLOCK Up down switch SWITCH ASSEMBLY Lift Drive Low Drive HEAD Switch Selector 3 Way SWITCH Base Assembly BLOCK N C Contact BLOCK N O Contact LATCH Mounting SWITCH ASSEMBLY Emergency stop HEAD Switch Illuminated Emergency Stop Red SWITCH Base Assembly SWITCH LED Block Red BLOCK N C Contact LATCH Mounting SWITCH BASE ASSEMBLY NC LED Red Base controls SWITCH ASSEMBLY Emergency stop CONTROLL
72. 6 GLOW PLUG TIMER GPT PIN 1 NU PIN 2 NIU PIN 3 02 WHITE PIN 4 91A RED PIN 5 32A GREEN BLACK PIN 6 90 RED PIN 87a NIU 103 91A DIESEL VALVE PULLIN RELAY PIN 30 57 BLACK WHITE PIN 87a 57A BLACK WHITE PIN 85 3A BLUE PIN 86 2B BLACK RED 2 PINg7 NU 24 g 30 Jf GLOW PLUG RELAY 108 PIN 30 103 RED 10 GA PIN 87 91A RED 10 GA PIN 85 31 RED WHITE PIN 86 02 WHITE M137884AH SJRT Compact Series Engine Powered 143899 Print View This Page Parts List 3 15 Outrigger Optional Harness Diagram TTTTTTTT OUTRIGGER ELECTRIC PANEL PIN 1 28A GREENMHITE PIN 2 17A BLUEJBLACK ANSI CSA 17B BLUE BLACK CE PIN 3 86A ORANGE BLACKIWHITE PING 10MBLUEMWHITE LLLI _ PIN 5 09 ORANGE 2 PIN 6 44 RED
73. A reading of OV or 5V is probably due to a wiring problem SJRT Compact Series SKYJACK Page 33 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Load Sensing System CE 4 3 27 Flash Code F30 Bad Heights 1 This message indicates that the recorded heights are not increasing during either STATIC lift or are not decreasing during either STATIC lower may be possible to cause this problem by repeatedly opening and closing the UP or DOWN switch during the STATIC phases 4 3 28 Flash Code F31 Reject Curve 1 The DYNAMIC pressure curve is unacceptable An initial pressure peak when the platform lifted cannot be found between 0 and 15 height Check the pressure sensor and lift cylinder hydraulics 4 3 29 Flash Code F32 Reject Curve 1 The DYNAMIC pressure curve is unacceptable There should be lowest pressure about halfway through the lift i e near 5096 height the lowest pressure measured is at too low a height Check the pressure sensor and lift cylinder hydraulics 4 3 30 Flash Code F33 Reject Curve 1 The DYNAMIC pressure curve is unacceptable There should be a lowest pressure about halfway through the lift i e near 5096 height the lowest pressure measured is at too high a height Check the pressure sensor and lift cylinder hydraulics 4 3 31 Flash Code F34 Reject Curve 1 The DYNAMIC pressure curve is unacceptable There is not enough difference betwee
74. BLACK En PIN 1 BLACK PIN 2 BLACK WHITE dues FINE PIN 2 BLACK WHITE PIN 3 BLUE ine PIN 3 BLUE PIN 4 BROWN PIN 4 BROWN BACK VIEW MALE BACK VIEW MALE RIGHT FRONT OUTRIGGER PIN 1 BLACK 10A PIN 2 WHITE 664 BACK VIEW FEMALE PIN 3 GREEN 63 4 RED 62 BACKVIEW FEMAL LEFT FRONT OUTRIGGER PIN 1 BLACK 10A PIN 2 WHITE 65A PIN 3 GREEN 62 PIN 4 RED 36 SN IK 1o 4 L l 11 O R DOWN SWITCH NC BLACK amp BLACK WHITE O R DOWN SWITCH NC BLACK amp BLACK WHITE LEFT FRONT OUTRIGGER SECTION VIEW RIGHT FRONT OUTRIGGER SECTION VIEW SHOWN IN THE RETRACTED STATE SHOWN IN THE RETRACTED STATE SIXTEEN PIN CONNECTOR PLUG LEFT FRONT OUTRIGGER PCB ON ELECTRICAL PANEL PIN 1 61 PIN 9 10 BLACK 2x PIN 2 62 GREEN 10 10A BLACK 2x PIN 3 62 RED PIN 11 10A BLACK 2x E 4 63 GREEN 12 10A BLACK 2x 5 PIN 5 63 RED PIN 13 10 GREEN A PIN 6 64 GREEN 14 N U RIGHT REAR PIN 7 64 RED PIN 15 N U PIN 8 N U PIN 16 65 GREEN BLACK LEFT REAR TO CONTROL MODULE _ KENN E N 65 GREEN BLACK O R UP SWITCH NO BLUE amp BROWN 2 65A WHITE am N PIN 3 66A WHITE o PIN 4 67 WHITE PIN 1 BLACK B P PIN 5 68A WHITE PIN 2 BLACK WHITE PIN 6 N U PIN 3 BLUE O R UP SWITCH NO BLUE amp BROWN PIN4 BROWN BACK VIEW MALE BACK VIEW MALE 3 fo 2 PIN1
75. Electrical Schematic ANSI CSA All Option With Kubota Diesel 33 3 226 Electrical Schematic ANSI CSA All Option With Kubota Diesel 34 3 23a Electrical Schematic CE Option With Kubota Diesel 35 3 23b Electrical Schematic CE All Option With Kubota Diesel Engine 36 SJRT Compact Series SKYJACK Page 1 Engine Powered 143899 Section System Component Identification and Schematics E 4 LINE CROSSING LINE JOINED HYDRAULIC TANK HYDRAULIC FILTER WITH BYPASS ELECTRIC MOTOR ENGINE FIXED DISPLACEMENT PUMP THREE POSITION FOUR WAY PROPORTIONAL SERIES PARALLEL HYDRAULIC MOTOR TWO POSITION TWO WAY NORMALLY OPEN PRESSURE TRANSDUCER SERVO SJRT Compact Series Engine Powered 143899 Service and Maintenance 3 1 Hydraulic Symbol Chart VARIABLE DISPLACEMENT PUMP HAND PUMP RELIEF VALVE PRESSURE REDUCING VALVE FIXED ORIFICE ADJUSTABLE FLOW CONTROL CHECK VALVE OIL COOLER TWO POSITION TWO WAY NORMALLY CLOSED TWO POSITION THREE WAY MAIN LINES 0000 JUICK DISCONNECT SHUTTLE VALV ACCUMULATOR GAS CHARGED CUSHION CYLINDER PRESSURE SWITCH MOTION CONTROL VALVE FLOW DIVIDER COMBINER COU
76. FLASHING LIGHT 22 GREEN PN8 02WHTE D 29 BLACK ON PN TEBAK 7 MAN BATTERY n MANIFOLD HARNESS FIN 10 38A YELLOW Bi 2 2 02 WHTE 17A BLUERED EUIS GREEN PIN 12 36 YELLOW 13 ORANGE 18B RED BLACK 03 BLUE 14GA y 0 Q1 0 14A BLACK 20 BLACK WHITE RED TO ENGINE HARNESS 15A BLUE 23 BLACKWHITE PIN NU dLO BP 29 158 24 BLUE BLACK PIN 2 GREENMHITE ms 16A WHTEBLACK 30 BROWN mE n ee pee il 02 WIE j TO ENGINE 16B WHITERED 860 ORANGE BLACK WHITE m Fr 5 m B E EE PIN 4 32A GREEN BLACK MAIN Eu M ILI PINS 2A BLACK RED asa A BUCK DISCONNECT CO lt 40 02 BLACK BACK VIEW DEUTSCH 0 PING 37 BLUE WHITE SWITCH 91 09 RED FEMALE 40 20000 00000 Key CDD CC CO C CO COO CO CO J PINT 3A BLUE OUTRIGGER 2 PINS 31 REDWHITE T LIMIT SWITCHES BACKVIEW O gt 2 2 REDIBLACK 18 5 05 WHITERED ORANGEIBLACK 19 ta 06 WHITE BLACKIRED BACKWHTERED amp RED Z Tm BLACKWHITE 23 CO CO 07 REDGREEN BACK VIEW BLUE BLACK 24 0 BLACKIRED 2 REDWHITE 31 48 F 09 ORANGERED 1 OUTR CTRL MODULE CRD3 GREENIBLACK 2 CO CO 10 BLUEMHITE 0 P
77. Input indicating that the RIGHT FRONT outrigger is in contact with the ground Input indicating that the LEFT FRONT outrigger is in contact with the ground Input for AUTO LEVEL function to extend the outriggers to level the machine P2 6 79Green Input for AUTO RETRACT function to retract the outriggers until the switch is released Outrigger Light on Outrigger Control Box P2 8 65 STABLE output to indicate that all outriggers are in contact with the ground P2 9 28Green TILT output to indicate that the machine is level ANSI CSA only Negative Input Main Power Input 78 Black White Output used to extend the LEFT REAR outrigger 71 Blue Black Output used to extend the RIGHT REAR outrigger 76 Red Black Output used to extend the RIGHT FRONT outrigger PIN WIRE WIRE FUNCTION COLOUR Output used to extend the LEFT FRONT outrigger P4 Output used to retract the LEFT REAR outrigger Output used to retract the RIGHT REAR outrigger Output used to retract the RIGHT FRONT outrigger Output used to retract the LEFT FRONT outrigger 35C White Black Power input for outriggers 60401AC SKYJACK Page 16 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance Load Sensing System CE 5 4 1 Control Module Pin Reference Chart 3 QUO GOVO qua
78. MIDDLE SECTION 88 E E MO 1 8A 15 1 mE 1 2 a 08 08 7100 09 99 08 13 3 514 HR 3 49 3 8 3 4 53 LIFT DRIVE SELECTOR TOP SECTION 16 S14 THROTTLE S13 CHOKE GLOW 54 EMERGENCY STOP s in 1 2 C N 1 6 14 2 B 0p 3 4 60 z LED 1 02 11718 5 10 344 41 108 all 52 2 3 08 5 10 X BACK VIEW LL MALE p 15 BLUE O CO CONTROL BOX HARNESS PIN FUNCTION JOYSTICK HARNESS ORANGE GEN G 24 BLUE BLACK PIN 1 LEFT 24 WHITE RED ORANGE CO C GREEN 8 08 BLUE PIN2 JOYSTICK VS 08 WHITE BLACK 0 BLUE RED 2 C 10 BLUE WHITE a pS 1 4 Mawcm 5 fry Ee 2 08 BLACKRED O 24 6 6 6 6 5 7 RED GREEN 75 BLACK WHITE 3 H 08B BROWN RED PIN 5 STEERING VS 088 WHITE GREEN 07 RED 217 OO BLACK WHITE RED 20 Be 70702075052 50 27 52 PURPLE WHITE PIN 6 REVERSE DOWN GREY Em IJ WHTEBRAK RED C o mus E et 19 ORANGE BLACK PIN 7 2nd SPEED 19 BROWN 185 05 WHITE RED CO RED BLACK 18 9 PIN 8 ENABLE VS BA WHITEIBLUE CO C FEP WHTE BLACK 16 EE us gl 18 RED BLACK PIN
79. P3 4 SHORT SUPPLY 60405AA Reading the Codes In order to read the fault codes a sequence of pauses and flashes can be seen on the LED mounted on the GP102 module The codes are continuously displayed by the LED until the fault is cleared the GP102 reset and no longer detects the fault or idle timeout becomes active The sequence is as follows 1 Quarter second flashes followed by quarter second pauses indicate the first digit 2 A1 5 second pause 3 Quarter second flashes followed by quarter second pauses indicate the second digit 4 A4second pause Repeat steps 1 4 Since the GP102 only reports one error only one code can be read from the LED per instance Ifthe error is cleared and another error is present it will then be presented SKYJACK Page 18 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance 5 4 3 LED Error Codes Code Breakdown Chart Diagnostic sequence dependant on LED flash code No Last Caldate Load Not Calibrated Height Not Calibration An EZcal is required Waiting For Neutral Drive Lift Inputs Faulty Up Down Select Inputs Active Together EMS Inputs Faulty Check inputs on P2 pins 1 2 3 4 5 6 7 8 P3 4 Short To Supply P3 4 Short To Supply P3 6 Short To Supply 46 Disconnect plug If fault clears there is a problem with the wiring from P3 4 or P3 6 to the rest of the vehi
80. ast LT ver val T 1 4 9 v v gt el zoa 9 25 4 J 91 vol vol vol rr zio 1 027714 H eveia Si ama Si v v E 48 4 J 4 vst vol gt ol zoa OHON 4 8 891 4 7 ve 14 gt 88 s ve q 80 a tysta sza gt ezoa 4 4 vz xovig ama vz gt 8 41457 4S 4 l n ez aia Y 2 25 4 zo 1 t a gt 4 318vN3 6r T 2 200 4 4 J 148 m m vb QNNM r 4 N 4 02 oos vr vol voL ON 02 0 l 951 80 4 Ue 9 8 Vor N3dO XTIVIWHON 4 J HOLIMS vy 100100 SAIC HOIH voz gt 9 4 4 4 80 vse 60 60 60 t TE ON coe vel vel vi ovia m v 62 49 4 4 4 62 val o 4 v
81. gt Q33dS 89659 t 318VN3 5 t 9 4 1 28 oon Ning dis peii 20 r 4 4 GION310S INYA F ooz 0 02 0 0 02 551 z z 80 1 6 4 LNOLNO IH NOLLWASTS se 4 28 vog vog 110109 3AIBQ t Voz t gt TaTi3uvd salu3s i 5 ae 4 4 4 80 vse eod 60 G3u 39NvHO 60 60 PI 200 5 T SEINE wl INYA 131 62 49 W ve 4 TT 62 ud val vL ovi8 vL vi Noudo 86 4 2 osa Y AV134 TVWS 1 el i 62714 18 MG 4 ie NOLLISOd 14 NI 62 62 1H9I19NIHSV 1H ABOIMT os NHOH D 6v 6 6v T LL 6 al NHOH 4 tl 85 ONTO Ydadwnr LHON A XO8 10H1NOO
82. or 4H 78 down to pin 2 on connector CN21 at the outrigger board Check continuity Replace if defective 4 1 43 Individual Outrigger Functions Inoperative Auto Level 1 Loose or broken wire 71 75 depending on function not working at outrigger control module plug P4 pins 1 8 Check connections of outrigger functions not working refer to Section 5 for pin reference chart Replace if defective 2 No output from outrigger control module OCM1 at plug P4 pins 1 8 Turn off power to reset the outrigger control module Turn power back on and retest If problem persists replace outrigger control module 4 1 44 Auto Level Inoperative 1 Loose or broken wire 35D from outrigger enable switch S9A to auto mode outrigger switch S24 Check continuity Replace if defective 2 Defective auto mode outrigger switch 24 Check switch Replace if defective 3 Loose or broken wire 10A at pin P2 12 on outrigger control module OCM1 Check for power at P2 12 If no voltage present check continuity of wire Replace if defective 4 Loose or broken wire 44 at pin P2 10 on outrigger control module OCM1 Check for power at P2 10 If no voltage present check continuity of wire Replace if defective 5 Loose or broken wire 02 at pin P2 11 on outrigger control module OCM1 Check for ground at P2 11 If no ground present check continuity of wire Replace if defective 6 Loose or broken wire 70 from auto mode outrigger switch S24 to
83. service life of the aerial platform SKYJACK Page 20 SJRT Compact Series Engine Powered 143899 Section 1 Scheduled Maintenance Service and Maintenance Inspections Muffler and Exhaust Base Control Console Tilt Sensor Engine Air Filter Disconnect Switch Radiator Hydraulic Pump Fuel Shut off Battery e Fuel Leaks Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury N DANGER Engine fuels are combustible Inspect the aerial platform in an open well ven tilated area away from heaters sparks and flames Always have an approved fire extinguisher within easy reach Perform a visual inspection around the following areas e hoses and fittings e fuel pump fuel filter SJRT Compact Series SKYJACK Page 21 Engine Powered 143899 Service and Maintenance Inspections Section 1 Scheduled Maintenance Gear Type Hydraulic Flow Divider Oil Filter Oil Level Gauge JONE es Fuel Level x Gauge Manifold 6 Hydraulic Tank Fuel Tank 2 8 6Hydraulic Fuel Compartment Fuel Leaks Ensure compartment latch is secure and Failure to detect and correct fuel leaks will proper working order result in an unsafe condition An exp
84. 00 from pack 2 wire connector to engine ground Check continuity Replace if defective Loose or broken wire 00 from engine ground to crank position sensor Check continuity Replace if defective Loose or broken wire 37 from ignition control module ICM1 to crank position sensor CPS1 Check continuity Replace if defective Defective ignition control module ICM1 Refer to section 5 of this manual for Ohm specifications Replace if defective Defective crank position sensor CPS1 Refer to section 5 of this manual for Ohm specifications Replace if defective Loose or broken wire 37 from engine harness plug to fuel select switch S33 Check continuity Replace if defective Defective fuel switch S33 Check switch Replace if defective While in gasoline loose or broken wire 11 from fuel select switch S33 to fuel pump FP11 or gas valve 20 11 Check continuity Replace if defective While in propane loose or broken wire 50 from fuel select switch S33 to fuel lockoff 2P 50 1 or propane lockoff 2P 50 2 Check continuity Replace if defective Loose or broken wire 00 from engine ground to propane lockoff 2P 50 1 or 2P 50 2 propane or to gasoline 2G 11 or fuel pump FP11 gasoline Check continuity Replace if defective Defective propane lockoff 2P 50 1 or 2P 50 2 propane or gas valve 2G 11 or fuel pump FP11 gasoline Check lockoffs valve or pump Replace if defective 4 1 8 Glow Plugs Inoperative from Engine Con
85. 1 5 to 6 0 infinity SKYJACK Page 6 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Engine Powered 143899 SJRT Compact Series co CN 1 1 m i2 ace air 2 HE TE azir HL Wea 9 n ms 71 AN ud 05 S x Yol vol LE 101 ed oc 8 B8 s gt jo V E 9 9210 00 29 8 11 oc 00 Dd 9 im 7 EN C 5 3 1 Auto Leveling Outrigger PC Board Layout Service and Maintena
86. 2 PIN 11 77 BLUE BLACK PIN 11 02 WHITE 2x 2517 PIN 12 78 BLACK WHITE PIN 12 10A BLACK 189 PIN 13 79 GREEN LEFT REAR OUTRIGGER PIN 14 35C WHITE PIN 1 BLACK PIN 2 WHITE 684 PIN 15 350 GREEN PIN 3 GREEN 104 PIN 4 RED 64 SJRT Compact Series SKYJACK Page 25 Engine Powered 143899 WIRE 86ACR HYDRAULIC GENERATOR STOP RELAY W3 W4 W2 W9 PIN 85 86A ORANGE BLACK WHITE PIN 86 02 WHITE PIN 30 85 ORANGE BLACK WHITE PIN 87a 86B ORANGE BLACK WHITE PIN87 N U WIRE 86BCR HYDRAULIC GENERATOR LATCHING RELAY W9 W5 Wi W2 PIN 85 968 ORANGE BLACK WHITE PIN 86 2A ORANGE BLACK PIN 30 09 ORANGE PIN 87a NU PIN87 86C ORANGE BLACK WHITE WIRE 86ACR HYDRAULIC GENERATOR RELAY W2 W4 W7 W8 WIRE HYDRAULIC GENERATOR 12 CONNECTOR PLUG SKYJACK Page 26 PIN 85 860 ORANGE BLACK WHITE PIN 86 02 WHITE PIN 30 43 RED BLACK PIN 87a 43A RED WHITE PIN 87 86D ORANGE BLACK WHITE PIN 1 09 ORANGE PIN 2 85 ORANGE BLACK WHITE PIN 3 86 ORANGE BLACKIWHITE PIN 4 02 WHITE PIN 5 2A ORANGE BLACK PIN 6 09 ORANGE PIN 7 14 DIODE PIN 8 17 BLUE BLACK PIN 9 43 RED BLACK PIN 10 43A RED WHITE PIN 11 86 ORANGE BLACK WHITE PIN 12 86D ORANGE BLACKMHITE 3 16 Hydraulic Generator Electrical Panel Assembly 86ACR 86BCR 86CCR 14CR
87. 3 Use the ladder to dismount from platform SJRT Compact Series SKYJACK Page 23 Engine Powered 143899 Service and Maintenance Inspections Lift Cylinder Scissor Assembly 2 8 8 Lifting Mechanism 1 Raise the platform until there is adequate clearance to swing down the maintenance support Maintenance Support Ensure maintenance support is properly secured and shows no visible damage Scissor Assembly Ensure scissor assembly shows no visible damage and no signs of deformation in weldments Ensure all pins are properly secured Ensure cables and wires are properly routed and shows no signs of wear and or physical damage Scissor Bumpers Ensure bumpers are secure and shows no sign of visible damage SKYJACK Page 24 Section 1 Scheduled Maintenance Maintenance Support Scissor Bumper Roller Rollers Ensure rollers are secure and there is no visible damage Ensure rollers path of travel are free from dirt and obstructions Lift Cylinder s Ensure each lift cylinder is properly secured there are no loose or missing parts and there is no evidence of damage Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Raise the platform until there is adequate clearance to swing up the maintenance support into storage bracket Fully lower the platform SJRT Compact Series Engine Powered 14389
88. 5 5 1 4 Wheel Reinstallation and Torquing Procedure 00 2 1 4 2 2 1 6 6 nennen nnn nnn nennen nr 5 Engine 5 2 1 Kubota Dual Fuel DF972 Resistance 6 Options 5 3 1 Aulo Leyeling Outrigger Board RE nes aS drink nro E rn iai 8 nos Outrigger Mechanical Limit Swit h YVIFIDDLs irse rta rioreldoaeL eii sa _ _ _ abr Ran iP 9 5 3 3 Auto Leveling Outrigger Settings and Error 10 5 3 4 Auto Leveling Outrigger Error Code nnn nnna nnn nnns nn nnns 11 5 3 5 Hand Held Calibration Diagnostic Tool Key 12 2 08 Outrigger Control Module Ins Pub gt 13 5 3 7 Auto Leveling Outrigger Control Module Pin Reference 16 SJRT Compact Series SKYJACK Page 1 Engine Powered 143899 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 Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanic
89. 998 1 80098 ve 58 88 rer 19 t 1 HONS 998 60 60 GIONSIOS y 1 i 9 608 gt 4 28 HOLVHANS9 98 Sona 69 assa Aviad 89 Vez 1 NOLLdO 19 AVI3H 318VN3 ve d 95 gt asia gt szoa 99 bd 4 GION310S IMYA HSTIOWLNOO 981 gt sia agus dus EL 4 948 pu eos zm p _ n 91 Xov18 31IHM 91 8 8 gt el zoa 9 5 26 Y L HY val val 2 voL h zizoa 18 GION310S 0 HE 4 4 St ama SL Y Y 18 01 20d avva 8 t Me 991 ast z wsid L vsia vea 88 sT ve ve 80 x t 20 4 4 4 mm gt z gt ezoa 1491 48 9r GION310S INYA SNIU331S 1HOlH 2 48 t 1 31IHM 20 80 t 8008 27 t t
90. ALLVO3N gt lt 5 lt 8 5 Serial Breakdown Reference Chart SKYJACK Page 36 4 TROUBLESHOOTING INFORMATION Table of Contents E Lecta y RTT TTC iuw eC ee 4 Electrical System dite tl TIE gt 5 4 1 3 All Functions Inoperative Machines Equipped with Load Sensing System 6 4 1 4 Functions Inoperative from The Platform __ 6 4 1 5 Engine Will Not Crank from Platform or Base Control 6 4 1 6 Engine Cranks But Will Not Start Kubota 7 4 1 7 Engine Cranks But Will Not Start Kubota Dual 7 4 1 8 Glow Plugs Inoperative from Engine Controls or Platform Diesel 8 4 1 9 Choke Inoperative from Engine Controls or Platform Kubota Dual 9 0 9 4 1 11 High Throttle On Demand Inoperative Kubota Dual 10 4 1 12 Drive and Steer Inoperative Machines without outriggers option 10 4 1 13 Drive and Steer Inoperative Machines with
91. Assembly e BLOCK Spring Contact LATCH Mounting SWITCH Front left outrigger up down toggle SWITCH Front left outrigger rocker SWITCH Front right outrigger up down toggle SWITCH Front right outrigger rocker SWITCH Rear right outrigger up down toggle SWITCH Rear right outrigger rocker SWITCH Rear left outrigger up down toggle SWITCH Rear left outrigger rocker SWITCH Auto Level Outrigger SWITCH Engine Glow Plug SWITCH Engine start push button SWITCH Fuel select SWITCH Engine temperature TILT SWITCH HOUR METER COIL 12 Volt lowering valve ANSI CSA COIL 12 Volt lowering valve CE COIL 12 Volt lower lift cylinder holding valve ANSI CSA COIL 12 Volt upper lift cylinder holding valve ANSI CSA COIL 12 Volt lower lift cylinder holding valve CE COIL 12 Volt upper lift cylinder holding valve CE COIL 12 Volt large pump dump valve ANSI CSA COIL 12 Volt large pump dump valve CE COIL 12 Volt holding outrigger valve COIL 12 Volt small pump dump valve ANSI CSA COIL 12 Volt small pump dump valve CE COIL 12 Volt hydraulic generator SOLENOID Propane lockoff valve vaporizer Kubota Dual Fuel Engine COIL 12 Volt lift valve COIL 12 Volt brake valve COIL Reverse drive valve COIL Parallel reverse drive valve COIL Forward drive valve COIL Parallel forward drive valve COIL 12 Volt series parallel drive COIL Right steer valve Parts list continued on the following p
92. Check continuity Replace if defective Loose or broken wire 28 from base terminal TB1 to outrigger connector CN14 at pin 7 Check continuity Replace if defective Loose or broken jumper wire from 28 to 28A on outrigger connector CN14 between pin 1 and pin 7 Check continuity Replace if defective Loose or broken wire 28A from outrigger connector CN14 at pin 1 to base terminal block TB1 Check continuity Replace if defective 4 1 13 Drive and Steer Inoperative Machines with outriggers option 1 Outriggers fully retracted Fully retract outrigger cylinders 2 Lift Drive select switch S3 in lift position Turn switch to Drive position 3 Defective contacts on lift drive select switch between wire 8A and wire 8B Check continuity through contact Replace if defective 4 Loose or broken wire 08 from lift drive select switch S3 to controller enable switch S7 7 Check continuity Replace if defective 5 Defective controller enable switch 57 7 Check switch Replace if defective 6 Loose or broken wire 8A from controller enable relay 8CCR to speed steer and direction switches 57 1 to 57 6 Check continuity Replace if defective 7 Loose or broken wire 8C from controller enable switch S7 7 to controller enable relay 8CCR Check continuity Replace if defective 8 Defective controller enable relay 8CCR Check continuity Replace if defective 9 Loose or broken wire 02 from controller enable re
93. Drive select switch S3 in low drive position Select high drive position on lift drive select switch 2 Defective contacts lift drive select switch S3 between wire 08 and wire 20 Check continuity through contact Replace if defective 3 Loose or broken wire 20 from lift drive select switch S3 to relay 20CR Check continuity Replace if defective 4 Loose or broken wire 02 from relay 20CR to base terminal block TB1 Check continuity Replace if defective 5 Defective relay 20 Check relay Replace if defective 6 Loose or broken wire 44 from base terminal block TB1 to relay 20CR Check continuity Replace if defective 7 Loose or broken wire 20A from relay 20CR to relay 20ACH1 Check continuity Replace if defective 8 Loose or broken wire 20 from relay 20ACR1 to series parallel valve coil 4H 20A Check continuity Replace if defective 9 Loose or broken wire 02 from series parallel valve coil 4H 20A to base terminal block TB1 Check continuity Replace if defective 10 Defective series parallel valve coil 4H 20A Check coil Replace if defective 11 Loose or broken wire 02 from relay 20ACHR1 to base terminal block forward drive only Check continuity Replace if defective 12 Defective relay 20ACR1 forward drive only Check relay Replace if defective 13 Loose or broken wire 20A from relay 20CR to relay 20ACR2 reverse drive only Check continuity Replace if defective
94. Flash Code F04 Tilted 1 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 4 3 5 Flash Code F05 Bad Height 1 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 between 1 0V and 4 0V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem 4 3 6 Flash Code F06 Check Elev 1 This message is given if the elevation switch P2 10 is open at the start of calibration when the operator has confirmed the PLATFORM DOWN question Ifthe platform is down check the elevation switch wiring 4 3 7 Flash Code F08 Check Elev 1 This message is given if the elevation switch P2 10 is closed at the end of the DYNAMIC lift when the platform should be fully raised This message would occur if the UP switch was accidentally opened near the start of the DYNAMIC lift If the platform is fully raised check the elevation switch wiring 4 3 8 Flash Code F09 Bad Height 1 This message is given if the height sensor output P4 3 is out of range at the start of the DYNAMIC lift The height sensor output must be between 1 0V and 4 0V Check DIAGNOSTICS SENSORS to see the output 4 3 9 Flash Code F10 Bad Height 1 This message is given if the height sensor output P4 3 is out of range at the e
95. GION31OS GION31OS 3NVA SVO YOLOVINOD 31 18 3NION3 1903 GION310S HOIH GION31OS 5705 NOLLINOI 310GOW 1OH1NOO NOLLINDI 6s 85 48 95 99 vS es 29 19 08 6v 8v 2 9v Sb vv v ev Ov 68 86 15 96 s ve 18 08 62 42 92 52 vc be 02 6 8 Zt 9L St bh LL ALVO3N u3dwnr d ON A 1 82 vol HOLIMS uds he isi 4 geld gt 4 881 H2 a81 vel 8i SIS t aue m 4 946 891
96. LNOH4 125 T 61 200 001 TO 1NOU LEN E XOv18 35NVHO s L NO 1 20 mr ase 66 4 D ux 3ONVUO lt L LNOUS 1321 lt lt ozs 86 20 46 20 96 Ld voz voz 99 S6 OL 13431 010v 04 988 v6 9 64 LOWHISY 61 6L vos s6 6 056 y YI99IHLNO ose ose XOV18 31IHM Ose Ose a ase NI NMOHS 26 vol Ose ose 1431 66 16 red 9 NMOG 1331 ose jose 1NOH4 06 we 2 7 ONITISAST OLAV HLIM ES 9 NOILdO 95 1 0 27 1961 1431 uan 88 v89 VOL 8951 1 48 8 99 59 NMOG 98 6 82 2 98 Oled cvy avaya 7 V 98 1 NMOG LNOHS 28 6545 9
97. Level Select the Tilt Setups Calibrate Level from the menu and press the ENTER button The display will show Calibrate Level Yes Enter No ESC Select the Yes from the menu by press the ENTER button The display will show Calibrate Level Tilt 0 0 0 0 Select the ESCAPE from the menu once The display will show Tilt Setups Calibrate Level Select the ESCAPE from the menu once again The display will show Setups Setups By using Left Right buttons select the Load Setups from the menu and press the ENTER button 21 The display will show Load Setups Calibrate Load Select the Load Setups Calibrate Load from the menu and press the ENTER button 22 Atthis point elevate the aerial platform at full height check the harness and making sure it is not stretched tight then lower down the platform 23 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 24 The display will show Calibrate Loaded Empty Asking for confirmation that the platform is empty Check that the platform is empty 25 Byusing the Up Down buttons enter the Yes followed by pressing the ENTER button 26 The display will show Calibrate Load Please Lift Waiting for the lift switch to be activated 27 Hold the lift switch and keep holding it
98. Load Weight kg m Ib Ib kg psi kPa psf 6400 2903 2560 1161 157 4 1085 1007 6826 8730 3960 3492 1584 175 41 1209 1373 7661 3475 3064 1390 165 59 1142 1205 9235 4189 3605 1635 181 36 1250 1452 60442AE ANSI Total aerial platform weight with no options max aerial platform weight all options full capacity 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 than 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 Table 2 2b Floor Loading Pressure CE Total Machine Load Total Machine Weight Ib kg Ib kPa psi kg m psf 2903 6400 1161 2560 1085 157 4 1007 6826 3960 8730 1584 3492 1209 175 41 1373 3475 7661 1390 3064 1142 165 59 1205 4189 9235 1635 3605 1250 181 36 1452 60442AE CE 7 Total machine weight with no options max Machine weight all options full capacity xk LCP Locally Concentrated Pressure is a measure of how
99. Powered 4 NMOG NOUS 1331 a SL En SL Na 81 20 1331 GION310S 991 110 HE LNOUS 1321 om Ol 2 20 SLIHM 20 60 9921 100 801 Led 69 voz voz zo 201 04 4 oz 11901 dn tv lOovul3H OLNY 901 9 62 64 64 ves 318VN3 1 901 6 OSE m Ose 956 ose ase NOILISOd Q319Vu13H ose NI NMOHS SH399IH1nO voL 31gvN3 vor ose auuwama ose 1331 ves NMOG 1437 01 ose jose 9 v99 vor uvau SNITI3A31 OLNY Zd 95 1 0 NMOG LOL eed v49 VIS VOL uvau 1331 1441 001 Led v89 1 8957 LNOYS ZOL 99 141 66 8 99 N3dO 36010 59 SSHOLMS NMOG 3991 110 86 6 Zd N N 100109 SAG 76 02 by NMO
100. SJRT Compact Series SKYJACK Page 19 Engine Powered 143899 Service and Maintenance Inspections Section 1 Scheduled Maintenance Muffler and Exhaust Base Control Console Tilt Sensor Engine Air Filter Main Power Disconnect Switch Radiator Hydraulic Pump Fuel Shut off Battery walle Hydraulic Pump WARNING Ensure there are no loose or missing parts and there is no visible damage Beware of hot engine components Ensure all bolts are properly tightened Check oil level on dipstick Ensure all fittings and hoses are properly Oil level should be in the safe zone Add tightened and there is no evidence of oil as needed hydraulic leakage e Fuel Shut off Valve Radiator Ensure there are no loose or missing Ensure radiator is secure parts and there is no visible damage Ensure there are no loose or missing Engine Air Filter parts and there is no visible damage Ensure there are no loose or missing parts and there is no visible damage Check coolant level and add as needed e Muffler and Exhaust Ensure muffler and exhaust system are properly secured with no evidence of damage Engine Pivot Tray Ensure there are no loose or missing parts and no visible damage to the engine pivot tray Ensure that both tray securing bolts are in place Engine Oil Level Maintaining the engine components is essential to good performance and
101. SKYJACK Page 10 SJRT Compact Series Engine Powered e Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 4 Rough Terrain Scissor Fluids Continued ENGINE OIL Engine Type Qty i Recommended Equivalent Kubota D902 Liters Gallons Viscosity API Service Designation Kubota D1105 10W30 API Service Designation CG 4 Kubota DF972 Engine Oil SAE 10W 30 CF 4 CF CD SH Nissan A15 6 16 1 6 10W30 API Service Designation SF CC All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water ENGINE COOLANT Qty Qty lant T Component Type Liters Gallons Coolant Type Kubota D902 KubotaDit05 D1105 Anti freeze Water Kne Kubota DF972 8065 15 11 4 3 01 1 6 Extended life anti freeze Water All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water ENGINE FUEL Tank Gasoline Liquid Propane Model Qty Qty Kubota 0902 Kubtoa 01105 Kubota DF972 GM 1 6 Nissan A15 Liters Gallons SJRT 68xx 8688 2295 SJRT 7127 _ RT 7127 v N A pu RT 7135 80 48 21 26 8243 SJRT 8850 8850 N A v 8831 49 21 SJRT 8841 8841 9241 64 35 9250 9250 fuel capacity quantities are standard lit
102. St ama 5 St v v GIONSTOS 25 asuna 09 T VAa GION3OS IMYA 69 7 1 ast ysr Si 1 ER va ve 80 GION3 OS IMYA 86 ONIH33IS 1331 Vim xovis ama vz vz GION310 IMYA sod 1331 45 48 18 1HOlH Ss yasia LHOIH 2 25 95 20 20 08 80 gt 4008 t GION310S INVA 59 7 Versus 9 MOLLSAOL 6 6L 6L 6 GION310S MVA G bed va m m vv T GION3 IOS zs Vis 631 36 vOZ Ht AYBH i ON Tarmuvd saiu3s 02 02 02 02 957 80 100119 08 7 GdS IH NOLLVA3 T3 SE vol WY gy 531335 voz bb edovoc 095010 9v HOLIMS 9 5 1 vse eod 60 60 60 vi NIL INWA 14171
103. Start Lowering Pushbutton Valve 4 Horn Pushbutton Stop Main Manifold Button WARNING Test Platform Raising Lowering Ensure that you maintain three points of WARNING contact when using the ladder to mount dismount platform Be aware of overhead obstructions or other possible hazards around the aerial 3 Use the ladder of aerial platform to access platform when lifting platform A 1 Select lift torque drive switch to Ev lift 4 Close the gate position 5 On platform control console pull out h emergency stop button 2 Activate and hold x enable trigger switch Emergency stop 3 Pushor pull controller handle until desired height is reached Result Platform raising and lowering functions should operate 1 Ensure engine is running 2 Pushin emergency stop button Result Engine should shut down and Test Steering aerial platform functions should not operate 1 Ensure engine is running Test Enable Trigger Switch 2 Pressrocker switch on top of controller to e X 1 left and 1 right Result Steer wheels should turn left and 1 Ensure engine is running right 2 Without activating 57 enable trigger switch attempt to activate any platform function Result All platform functions s
104. Stop Button 2 Use the ladder to dismount from platform On control console slowly raise the platform Result When platform reaches an appropriate height a warning signal should sound and platform stop raising as lift and drive controls should be disabled SJRT Compact Series Engine Powered 143899 Section 1 Scheduled Maintenance Emergency Stop Button Platform Engine Base Key Switch Emergency Lowering Base Control Console Valve Main Power Disconnect Function Tests Free wheeling Brake Hand 27 Pump Brake Auto Reset Valve Switch 1 2 2 Base Control Console 2 9 1Test Main Power Disconnect Switch 1 ln engine compartment turn power disconnect switch to off position Result Aerial platform functions should not operate 2 9 2Base Con
105. VALVE GREY HIRSHMAN PIN 1 15A BLUE __ HOLDING VALVE UPPER PIN 2 02 WHITE E HOLDING VALVE LOWER PIN 1 13 BLACK 13 9 PN1 13BLAOK PIN 2 02 WHITE E K d H PIN2 02WHTE wE W ot M139827AB SJRT Compact Series SKYJACK Page 19 Engine Powered 143899 ELECTRIC PANEL 13 WIRES 02 WHITE 138 ORANGE 14A BLACK 15A BLUE 15B BLUE YELLOW 16A WHITE BLACK 168 WHITE RED 17B BLUE RED 18C RED BLACK 20A BLACK WHITE RED 23 BLACK WHITE 24 BLUE BLACK 30 BROWN LEFT STEER VALVE GREY HIRSHMAN PIN 1 24 BLUE BLACK PIN 2 02 WHITE a INSERT ORIENTATION BOTTOM VIEW RIGHT STEER VALVE BLACK HIRSHMAN PIN 1 23 BLACK WHITE PIN 2 02 WHITE 3 11 Main Manifold Harness Wiring Diagram SMALL PUMP DUMP VALVE 18C RED BLACK 02 WHITE LIFT VALVE 14A BLACK 02 WHITE SKYJACK Page 20 LOWERING VALVE 13B ORANGE 02 WHITE SPLICE 1 LARGE PUMP DUMP VALVE 178 BLUE RED 02 WHITE HIGH SPEED VALVE 208 BLACKREDMHITE 02 WHITE co PARALLEL FOR
106. aerial platform if it is not on 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 absolutely 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 elevated Af ter elevation the drive function must not be activated Elevated driving must only be done on a firm level sur face DO NOT ascend or descend a grade when elevated When fuly lowered ascending or descending only grades up to rated maximum listed in Table 2 1 are permissible DO NOT operate on surfaces not capable of holding the weight of the aerial platform including the rated load e g covers drains and trenches SKYJACK Page 10 SJRT Compact Series Engine Powered 143899 Operator s Responsibility for Maintenance Service and Maintenance Safety Precautions Continued Know and understand the safety precautions before going on to next section DO NOT operate an aerial platform that has ladders scaffolding or other devices mounted on it to increase its size or work height It is DO NOT lower the platform prohibited unless the area b
107. down at pin 8 down on connector 21 at outrigger board to valve coil 4H 71 up or 4H 75 down Check continuity Replace if defective 5 Loose or broken wire 02 from valve coil 4H 71 up or 4H 75 down to pin 2 on connector CN21 at the outrigger board Check continuity Replace if defective 4 1 40 Right Front Outrigger Inoperative Manually 1 Defective right front outrigger switch 521 at platform control console 521 at base control console Check switch Replace if defective 2 Loose or broken wire 72 up from outrigger control console to pin 8 up on connector 20 at outrigger board or wire 76 down to pin 9 down Check continuity Replace if defective 3 Open diode D72 up or D76 down on outrigger board Check diode Replace if defective 4 Loose or broken wire 72 up at pin 9 up or wire 76 down at pin 10 down on connector 21 at outrigger board to valve coil 4H 72 up or 4H 76 down Check continuity Replace if defective 5 Loose or broken wire 02 from valve coil 4H 72 up or 4H 76 down to pin 2 on connector CN21 at the outrigger board Check continuity Replace if defective 4 1 41 Right Rear Outriggers Inoperative Manually 1 Defective right rear outrigger switch 522 at platform control console or 822A at base control console Check switch Replace if defective 2 Loose or broken wire 73 up from outrigger control console to pin 3 up on connector 20 at out
108. each wheel fastener is torqued to 805 ft lb All fasteners must be torqued using the tightening sequence below 1 G 6 5 2 Q Diagram 5 1 3 Wheel Torque Sequence 5 1 4 Wheel Reinstallation and Torquing Procedure When a Wheel Tire Assembly has been removed or replaced it will be necessary to follow the procedure below to ensure proper installation 1 Inspect wheel fastener threads for damage and defects Replace if defective Clean the mounting surfaces of hub and the wheel rim of debris rust excess paint etc Mount wheel on the hub centering mounting holes on the wheel studs or bolt holes Use appropriate lifting device as required Install wheel nuts or wheel bolts and hand tighten to center the rim Tighten nuts or bolts to approximately 50 ft lb torque using the tightening sequence in procedure 5 1 3 Tighten to 80 ft lb using the same sequence Repeat the torque sequence to confirm that none have changed from 80 ft lb If any are found below 80 ft Ib repeat complete sequence until there is no change in torque values If possible drive the machine prior to checking torques Check torque values after 8 hours of operation and then at weekly intervals 2 Again confirm that each wheel fastener is torqued to the specified tolerance Re torque as necessary until all fasteners are properly torqued SJRT Compact Series Engine Powered 143899 SKYJACK Page 5 Service and Maint
109. gt gt FLOW CONTROL RELIEF valve i lt m 7 59 WO m 16A 15A e J TRE 1 PARALLEL VALVE VALVE VALVE VALVE VALVE rp DRIVE DRIVE REVERSE HOLDING RETRACT RETRACT RETRACT RETRACT VALVE VALVE DRIVE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER ANSIICSA T VALVE Bias LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR 2817806 64 4H 71 4H 72 4H 73 4H 74 DON T n BRAKE VALVE CHECK IN K VALVE VALVE __ Snel en gt 4H 20 19 BN CHECK SERIES PARALLEL lt M COUNTERBALANCE LOWERING VALVE VALVE VALVE SYSTEM ORIFICE Q RELIEF 0 106 6826RT yc BRAKE r 4 VANE 00 089 6832RT ORIFICE CBI TA 5 1 00028 L COUNTERBALANCE 9 VALVE 8 OUTRIGGER MANIFOLD BLOCK 20188 ANSICSA noon 9 26480 CE LN SMALL PUMP DUMP 4 5 I 5 AUXILIARY 1 180 SM TANK DRAN MB1 68XXRT MAIN MANIFOLD PUMP PUMP 1 i Fi E LARGE SMALL dcus ARES CR s SR dax E De Mic N Conr da Ed a E Cuius m UC AM eMe uae dM E Ee E Eg ER Cu Gud Casa REM utc
110. if defective Loose or broken wire 860 from relay 86CCR to generator valve coil 2H 86D Check continuity Replace if defective Loose or broken wire 02 from base terminal block to generator valve coil 2H 86D Check continuity Replace if defective Defective generator valve coil 2H 86D Check coil Replace if defective Open diode D86D Check diode Replace if defective Loose or broken wire 17A from diode D86D to base terminal block TB1 Check continuity Replace if defective 4 1 33 Hydraulic Generator will not Shut Off from Generator Switch 1 Defective generator switch 512 Check switch Replace if defective 2 Loose or broken wire 86 from generator switch 512 to diode D86 Check continuity Replace if defective SJRT Compact Series SKYJACK Page 21 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 3 Open diode 086 Check diode Replace if defective 4 Defective relay 86ACR Check relay Replace if defective 5 Loose or broken wire 02 from base terminal block to relay 86ACR Check continuity Replace if defective 4 1 34 All Outriggers Inoperative Auto Level and Manual WARNING Scissors lift must be below high speed limit switch for outriggers to function NOTE For the outriggers to function the upper control box must be in the lift position and the scissor stack stowed or fully retracted Lo
111. message is displayed while the platform is being lowered to the next measurement height when an EMPTY platform is being calibrated Lowering This message is displayed while the platform is being lowered during HEIGHT only calibration Measuring This message is displayed when the platform is stopped during calibration when the GP102 takes a measurement 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 Platform Down This message is prompting for confirmation that the platform is fully lowered If necessary the DOWN switch can be activated to lower the platform Press ENTER to confirm when the platform is fully lowered Platform Empty This message is prompting for confirmation that the platform is completely empty Press ENTER to confirm if the platform is empty Platform Loaded This message is prompting for confirmation that the platform is loaded to rated load Press ENTER to confirm if the platform is loaded Please Lift This message is prompting for the platform to be raised The UP switch should be closed Please Lower This message is prompting for the platform to be lowered The DOWN switch should be closed Please
112. 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 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 disassembled in spotlessly clean surroundings During disassembly pay particular attention to the identification of parts to assure proper reassembly Clean all metal parts in a clean mineral oil solvent Be sure to thoroughly clean all internal passages After the parts have been dried thoroughly lay them on a clean lint free surface for inspection 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
113. outriggers are fully retracted 2 Ensure path of intended motion is clear SJRT Compact Series SKYJACK Page 29 Engine Powered 143899 Function Tests Section 1 Scheduled Maintenance Drive Steer Enable Trigger Switch Rocker Switch Drive Steer Torque Switch Low High Speed Range Switch Horn Pushbutton Glow Plug Choke Pushbutton Engine Start Pushbutton Lift Enable Pushbutton Test Driving Low High Throttle Switch Operation Light Raise Off Lower Switch Off Lift Drive Key Switch Emergency Stop Button Test Brake 1 Ensure path of intended motion is clear AN WARNING Brake will engage instantly when 2 Activate and hold enable trigger controller handle is released causing switch aerial platform to stop immediately E oll Slowly move controller fully forward Ensure path of intended motion is clear and then return handle to center position Result Aerial platform should move in Activate and hold d enable trigger forward direction and then come to a switch stop 1 Drive aerial platform Si forward Test 4 Slowly move controller fully brake by releasing controller handle backward and then return handle to center position Result Aerial platform should move reverse direction and then come to a Stop SKYJACK Page 30 Result Aerial platform should come
114. outriggers option 11 OES Ti NOL RESA eaa 12 4140 Steer HOM 12 ITI TL TI IU TIME 12 41 17 Reverse Drive 13 Fanaa Ue TODA _ 13 4 1 19 First Drive Speed and Steering 2 4 2004 0 00 14 414 20 Second Drive Speed BEL CREE PIE 14 4141 Third Drive Speed WRIT OVS E VERDI B US 16 414 22 High Drive 16 4 1528 Up Circuit inoperative TOI PIBEIOITL e 17 4 1 24 Up Circuit Inoperative from Base Control 888 17 4 1 25 Up Circuit Inoperative from Platform or Base Control Console without Outriggers 17 4 1 26 Platform will Not Lift from Platform or Base Control Console with Outriggers Retracted Lift Operates 17 4 1 27 Platform will Not Lift from Platform or Base Control Console with Outriggers Extended
115. relay 10CR2 to relay 10CR1 Check continuity Replace if defective Loose or broken wire 3A from base terminal block TB1 to relay 32CR1 Check continuity Replace if defective Defective relay 32CR1 Check relay Replace if defective Loose or broken wire 43 from relay 32CR1 to relay 34ACR Check continuity Replace if defective Loose or broken wire 34B from relay 34ACR to relay 33CR Check continuity Replace if defective 4 1 11 High Throttle On Demand Inoperative Kubota Dual Fuel NOTE If machine is in drive mode and is elevated above high speed limit switch high throttle is inoperative Throttle switch S14 in low throttle position Select high throttle position on switch Open or defective diode D17A or D18B Check diodes Replace if defective Loose or broken wire 33 from terminal block TB1 to power on demand relay 33CR Check continuity Replace if defective Loose or broken wire 02 from terminal block TB1 to power on demand relay 33CR Check continuity Replace if defective Defective power on demand relay 33CR Check relay Replace if defective Loose or broken wire 34C from power on demand relay 33CR to high throttle solenoid HTS 34C Check continuity Replace if defective Defective high throttle solenoid HTS 34C Check solenoid Replace if defective NOTE If the above does not repair the high throttle on demand refer to high throttle inoperative in this section 4 1 12 Drive and S
116. state of outrigger control box light Displays state of stable all legs touching the ground output Displays state of tilt Displays state of left rear outrigger extend valve Displays state of right rear outrigger extend valve Displays state of right front outrigger extend valve Displays state of left front outrigger extend valve Displays state of left rear outrigger retract valve Displays state of right rear outrigger retract valve Displays state of right front outrigger retract valve Displays state of left front outrigger retract valve Displays the voltage to the outrigger valve can only be seen when operating in auto level or retract DIAGNOSTIC LOG MENU OPTIONS MAX BATTERY OCM1 version EZcal version Displays maximum recorded battery supply voltage Displays part number and software version of GP106 Displays software version of EZcal ACCESS LEVEL MENU OPTIONS CODE xxxx ACCESS LEVEL 3 allows viewing only ACCESS LEVEL 2 allows setup 1 ADJUSTMENTS MENU OPTIONS factory set not adjustable Xtilt TRIP Ytilt TRIP TILT ENTRY TILT EXIT Xlevel TRIP Ylevel TRIP Displays the tilt trip point in the X orientation Displays the tilt trip point in the Y orientation Displays the tilt delay time Displays the tilt delay time Displays the tilt trip point in the X orientation during the auto level function Displays the tilt trip point in the Y orientation which applies during t
117. the recorded height where the switch opened F17 High Elev open This message is given if the elevation switch P210 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 F18 Low Elev close This message is given if the elevation switch P210 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 F19 High Elev close This message is given if the elevation switch P210 closed during lower at a too high height above 25 Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened F20 Height gt 0 This message occurs if the platform height is not 096 after the platform has been fully lowered at the end of calibration The platform must return to the same height each time it is fully lowered Check DIAGNOSTICS SYSTEM to check the height F28 Bad Height This message indicates a problem with the height sensor output during calibration The height sensor output must be between 0 9V and 4 1V during calibration and between 0 4 and 4 6v during normal operation Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem F42 Low Pressure This message indicates that the pressure is too low 0 5V or less when the
118. to Table 2 1 Ensure wheels are aligned and true vertically and horizontally SJRT Compact Series SKYJACK Page 25 Engine Powered 143899 Service and Maintenance Inspections Section 1 Scheduled Maintenance Overhead View Steer Cylinder Base i Assembly Weldment Splitter Manifold Wheel Tire Assembly Emergency Lowering Access Rod To safeguard maximum stability achieve optimum Tie Rod aerial platform handling and minimize tire wear Ensure there are no loose or missing it is essential to maintain proper pressure in parts tie rod end studs are locked and air filled tires there is no visible damage Check each tire with air pressure gauge is dih 5 Ensure rod 15 properly secured and there is no visible damage Refer to Table 2 1 for wheel tire specifications Ladder Steer Cylinder Assembly Sis 2 missing Ensure steer cylinder assembly is properly a secured there loose or missing e Outriggers
119. until the platform is fully elevated SKYJACK Page 26 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance 28 29 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 30 When the platform reaches full height release the lift switch 31 The display will briefly show TOTAL DATA 04 to indicate the number of measurements taken 32 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 33 Hold the lower switch and keep holding it until the platform is fully lowered 34 When the system detects the lower switch closed the display will show Calibrate Load Lower Empty 35 After a delay the system will stop the platform lowering and will take height amp pressure measurements the
120. 1 Scheduled Maintenance Service and Maintenance Inspections Manuals Platform Control Console gt fi Platform Railing T fOI Platform Assembly 77 CETT A 7 2 8 7Platform Assembly AC Outlet on Platform Ensure outlet has no visible damage and WARNING free from dirt or obstructions Ensure that you maintain three points of Manuals contact to mount dismount platform Ensure a copy of operating manual manual of responsibilities and ANSI CSA certificate 1 Use the ladder of aerial platform to platform are enclosed in manual storage box 2 Close the gate Check to be sure manual storage box is present and in good condition Ensure there are no loose or missing Ensure manuals are legible and in good parts and there is no visible damage eae g g condition Ensure all fasteners are securely in Always return manuals to the manual place storage box after use Ensure all railings are properly positioned Platform Control Console and secured Ensure all switches and controller are Ensure gate is in good working order returned to neutral and are properly secured e Lanyard Attachment Anchors Ensure attachment rings are secure and Ensure there are no loose or missing no visible damage parts and there is no visible damage WARNING Ensure that you maintain three points of contact to mount dismount platform
121. 1 2 Winching and Towing Procedures and This section provides the operator with procedures about towing and winching and on how to manually Parking Brake System release the parking brake WARNING Ensure platform is fully lowered before winching or towing Sudden motion could cause the aerial platform to become unstable Death or serious injury could result N WARNING In emergency situations where machine functions are not available and lowering is impeded by an obstacle the utmost care must be taken to move the machine far enough to clear the obstacle In such cas es operation must be extremely smooth with no sudden movements and must not exceed a speed of 2 sec When pushing towing or winching do not exceed 2 mph 3 2 km h Do not push tow or winch vehicle on to a slope or brake the towing vehicle rapidly Do not pull the aerial platform down an incline towards a winch To Release the Free Wheeling Valve 1 Make sure that the aerial platform is on level ground Chock or block the wheels to keep aerial platform from rolling Diagram 5 1 1 Free Wheeling Valve Free Wheeling Valve Turning the valve knob counterclockwise item 1 to a fully opened position allows fluid to flow through the wheel motors thus providing free wheeling WARNING The free wheeling valve must be closed tightly clockwise for normal operation To Release the Parking Brakes Manually WARNING D
122. 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 13 14 15 16 17 18 19 20 21 22 23 24 25 Loose broken wire 02 from relay 32CR2 to base terminal block TB 1 Check continuity Replace if defective Ground not getting through N C set of contacts on relay 10CR2 to relay 32CR2 Check continuity through contacts Replace if defective Loose or broken wire 3A from relay 10BC2 to relay 32CR1 Check continuity Replace if defective Loose or broken wire 32A from relay 32CR1 to engine harness Check continuity Replace if defective Loose or broken wire 32 from relay 32CR2 to relay 32CR1 Check continuity Replace if defective Loose or broken wire 41 from relay 32CR2 to relay 32CR1 Check continuity Replace if defective Defective relay 32CR1 Check relay Replace if defective Loose or broken wire 32A from engine harness to starter contactor 32ACR Check continuity Replace if defective Defective starter contactor 32ACR Check contactor Replace if defective Loose or broken wire 00 from starter contactor 32ACR to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 103 from main power disconnect 51 to starter contactor 32ACR Check continuity Replace if defective Loose or broken wire 57 from starter contactor 32ACR to starter motor Check continuity Replace if defective Defe
123. 2 t 18 18 7 Tez sza Y 09 Sd Se 7 9 7 a v 84 du zl za dniNOH414m 2 Sd le iz 318vN3 94 s d di c dn mE sz 2 4 4 vi an az 1381 1HOlH HV3H 1HOlH 1431 396 996 as veeS vies 5 60 2 60 7 dn NI NMOHS SH399IH1nO 1NOH4 1NOH4 1381 1H5lH 1HOlH 14m 02 1 AR 4 3 18VN3 19 ied 9 29 9 v9 vor 99191 0 099 1957 2951 2957 7957 4 89 t 59 ATIVAHON SSHOLIMS 89 Vel 2277 227 vor vor t saw 29 2 A SIONS ONION 24 1 22 vor 8c 8c 99 Y dd 88 WW HH di 99 20 v9 4 vid AVIS 4018 HOlvH3N3O 69 t ves 1 10 1 AV134 ONIHOLVI 60 HOlvH3N3O 99
124. 9 Section 1 Scheduled Maintenance Service and Maintenance Inspections Overhead View Steer Cylinder Base Assembly Weldment Splitter Manifold Wheel Tire Assembly Emergency Lowering Access Rod 2 8 9Base N WARNING Base Weldment An over inflated tire can explode and Ensure there are no visible cracks in may cause death or serious injury welds or structure and there are no signs of deformation Check all tire treads and sidewalls for cuts cracks punctures and unusual Wheel Tire Assembly wear The aerial platform is either equipped with air tires or foam filled tires Tire and or wheel Check each wheel for damage and failure could result in an aerial platform cracked welds tipover Component damage may also result if problems are not discovered and repaired in a timely fashion Check each lug nut for proper torque to ensure none are loose Check wheel motor assembly for loose AN WARNING or missing parts and signs of visible damage Air filled tires are not permitted on some models Refer
125. 9 3rd SPEED 18 RED BLACK S amp 9 m GROUND GREEN BLACK WHITE REFERENCE MALE QDC 2nd 3rd SPD V 8B PURPLE M137799AD SKYJACK Page 16 SJRT Compact Series Engine Powered 143899 Print View This Page Parts List 3 8 Outrigger Hydraulic Generator Control Console Wiring V rf lt 2 TO HYDRAULIC GENERATOR SWITCH PIN 1 86 WHITE TO AUTO OUTRIGGER SWITCH ipte PIN 1 79 GREEN PN 2 80 PURPLENHITE 45514452 PIN 3 70 GREEN BLACK 8 TO OUTRIGGER ENABLE SWITCH Q Cm PIN 1 36D PURPLE WHITE B 88 02 PIN 2 950 x3 ee I Tle TO OUTRIGGER LIGHT BLUE WHITE amp GREENMHITE 70A RED WHITE PIN 3 35D PURPLEIMHITE WHITE X P Q i HYDRAULIC GENERATOR CONTROL CABLE T TJ T Quum Y OUTRIGGER CONTROL CABLE SJRT Compact Series SKYJACK Page 17 Engine Powered 143899 3 9 Scissor Arm Control Cable Print View This Page Parts List B OE a RED BLACK WHITE ORANGE GREEN 60 O 0 0 00 0 0 OO 0 O 0
126. ACK 02 WHITE T TE LEFT STEER VALVE GREY HIRSHMAN PIN 1 24 BLUE BLACK E PIN 2 02 WHITE RIGHT STEER VALVE BLACK HIRSHMAN PIN 1 23 BLACKWHITE PIN 2 02 WHITE 5 p HIGH SPEED VALVE HYDRAULIC GENERATOR 208 BLACK RED WHITE 860 ORANGE BLACKIWHITE 02 WHITE PARALLELFORWARD VALVE 00 WHITE BLACK HIRSHMAN zc Ms PIN 1 168 WHITE RED INSERT ORIENTATION LOWERING VALVE PIN 2 02 WHITE BOTTOM VIEW 2 ME PARALLEL REVERSE VALVE 14A BLACK une 1 GREY HIRSHMAN PIN 1 158 eH PIN 2 02 WHITE PARALLEL REVERSE VALVE X GREY HIRSHMAN s PIN 158 BLUE YELLOW LARGE PUMP DUMP VALVE BRAKE Feen vaye PNe DP WHITE TO ELECTRIC PANEL 14 WIRES 17A BLUE RED ws 30 BROWN 02 WHITE 17A BLUEIRED ANSI CSA 178 BLUE RED CE 02 WHITE LA cy UTE 13 ORANGE ANSI CSA 138 ORANGE 18B RED BLACK ANSIICSA 18C RED BLACK CE a l 2 fal dr 57 CE 20A BLACK WHITE RED r FORWARD VALVE 14A BLACK 23 BLACK WHITE 8 BLACK HIRSHMAN 24 BLUE BLACK Hy PIN 1 16A WHITE BLACK 30 BROWN SERIES PARALLEL VALVE PIN 2 02 WHITE 16A WHITE BLACK 86D ORANGE BLACK WHITE 20A BLACK RED WHITE 168 WHITE RED 204 02 WHITE QT M M M eee ERES INSERT ORIENTATION Y 1 J 4 BOTTOM VIEW HOLDING VALVE 8 13 ORANGE 02 WHITE REVERSE
127. ACK Page 12 SJRT Compact Series Engine Powered 143899 Operator s Responsibility for Maintenance Service and 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 Itis 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 work platform and must not be used without manufacturer s consent Use only original filled tires for models which must be so equipped Consult factory All replacement tires must be of the same size and load rating as original equipment to maintain safety and stability of the work platform Consult factory WARNING Any unit that is damaged or not operat ing properly must be immediately tagged and removed from service
128. BLACK PIN 2 BLACK WHITE 4 PIN 4 BROWN RIGHT REAR OUTRIGGER PIN 1 BLACK 10A BACK VIEW FEMALE LEFT REAR OUTRIGGER 2 FAGA MEW FEMALE PIN 1 BLACK 10A PIN 4 RED 63 PIN 2 WHITE 68A PIN 3 GREEN 10A PIN 4 RED 64 NS CGH H E DOWN SWITCH NC BLACK 8 BLACK WHITE O R DOWN SWITCH NC BLACK amp BLACK WHITE rj 9 LEFT REAR OUTRIGGER SECTION VIEW RIGHT REAR OUTRIGGER SECTION VIEW SHOWN IN THE RETRACTED STATE SHOWN IN THE RETRACTED STATE BE 1 SJRT Compact Series SKYJACK Page 9 Engine Powered 143899 A Service and Maintenance Section 5 Procedures OOOO 5 3 3 Auto Leveling Outrigger Settings and Error Codes Reading the Codes In order to read the fault codes a sequence of pauses and flashes can be seen on the LED mounted on the outrigger control module The codes are continuously displayed by the LED until the fault is cleared the outrigger control module is reset and no longer detects the fault or idle timeout becomes active The sequence is as follows 1 Half second flashes followed by half second pauses indicate the first digit 2 A2 5 second pause 3 Half second flashes followed by half second pauses indicate the second digit 4 A 5 second pause Repeat steps 1 4 Since the outrigger control module only reports one error only one code can be read from the LED per instance If the error is cleared and anot
129. CK Outrigger MANIFOLD BLOCK Hydraulic generator ORIFICE 0 067 diameter ORIFICE Lowering 0 106 ORIFICE Lowering 0 089 ORIFICE Lowering 0 106 ORIFICE Lowering 0 089 ORIFICE Brake 0 028 PUMP Dual hydraulic 0 671 0 366 TRANSDUCER Pressure CE VALVE System relief VALVE Lift relief VALVE Relief VALVE Relief VALVE Drive relief VALVE Emergency lowering VALVE Freewheel VALVE Brake auto reset Model 6826 Model 6832 Model 6826 Model 6832 SJRT Compact Series Engine Powered 143899 Service and Maintenance Section 3 System Component Identification and Schematics CONTROL B Skyjack EE SEN 127035 127131 127131 127035 127035 127035 127035 127035 127035 127131 127035 127035 127035 127035 127035 127035 127035 127035 127035 127035 127035 127035 127035 127035 ee a II II Il lh 3 4 Electrical Parts List SUPPLY B Common GROUND B N NORMALLY NORMALLY CLOSED OPEN CONTACT CONTACT Description ENABLE RELAY RELAY 12 Volt outrigger enable RELAY 12 Volt outrigger enable proof RELAY 12 Volt 40 Amp main power RELAY 12 40 Amp RELAY 12 40 Amp RELAY 12 Volt 40 Amp reverse drive RELAY 12 Volt 40 Amp forward drive RELAY 12 Volt 40 Amp small pump RELA
130. Check diode Replace if defective 4 1 5 Engine Will Not Crank from Platform or Base Control Console 1 Loose or broken wire 8 from horn switch 58 to start switch 515 Platform only Check continuity Replace if defective 2 Defective start switch 515 Platform only Check switch Replace if defective 3 Loose or broken wire 32 from start switch 515 to base start switch S32 Platform only Check continuity Replace if defective 4 Loose or broken wire 10E from key switch S10 to base terminal block TB 1 Base only Check continuity Replace if defective 5 Defective key switch S10 Base only Check switch Replace if defective 6 Open or defective diode D10E Base only Check diode Replace if defective 7 Loose or broken wire 10B from base terminal block TB 1 to base choke glow plug switch S31 only Check continuity Replace if defective 8 Loose or broken wire 10B from base choke glow plug switch S31 to base start switch S32 Base only Check continuity Replace if defective 9 Defective base start switch S32 Base only Check switch Replace if defective 10 Loose or broken wire 32 from base start switch 532 to relay 32CR2 Check continuity Replace if defective 11 Defective relay 32CR2 Check relay Replace if defective 12 Loose or broken jumper wire 41 on relay 32CR2 Check continuity Replace if defective SKYJACK Page 6 SJRT Compact Series Engine Powered
131. DIBLACK PIN 1 77 BLUE BLACK PIN 87a NIU PIN 12 36 YELLOW PIN 2 62 GREEN OUTRIGGER LIMIT SWITCHES CN22 T PIN 3 78 BLACKWHITE PIN2 02 WHITE PIN 2 02 WHITE PN 2 02 WHITE PN2 02 WHITE PIN 3 62 RED i PIN 4 77 BLUEIBLACK 60 eee PN4 73BLUE e ELECTRIC PANEL CN14 PIN 4 63 GREEN PIN 5 74 BLACK x2 1 1 Ti I PIN 5 77 BLUEIBLACK a PIN S 63 RED A 6 71 ORANGE 62 aa EI el PIN 6 74 BLACK l PIN 6 64 GREEN ojere p PIN 7 75 ORANGEIBLACK ho PIN7 71 ORANGE CY CY 4 PIN 7 64 RED PIN 8 72 RED 0 PIN 8 75 ORANGE BLACK eser PIN 8 NIU PIN 9 76 RED BLACK x2 PIN 9 72 RED PIN 9 10A BLACK 2x _ PIN 10 76 RED BLACK PIN 10 10A BLACK D SOL Hi OOO PIN 14 N U TOCONTROLMODULE TO LIMIT SWITCHES PIN 15 N U PIN 1 65 GREEN BLACK PIN 1 65 GREEN BLACK in
132. ER ASSEMBLY Drive steer e SWITCH W ACTUATOR 2nd Speed SWITCH Right steer SWITCH Left steer SWITCH W ACTUATOR Reverse drive SWITCH W ACTUATOR Forward drive SWITCH W ACTUATOR 3rd Speed SWITCH Joystick Enable SWITCH ASSEMBLY Horn e HEAD Switch Push Button Black SWITCH Base Assembly BLOCK N O Spring Contact e LATCH Mounting SWITCH Outrigger Enable SWITCH Outrigger enable N O CONTACT BLOCK Platform idle base switch Base controls Parts list continued on the following page SJRT Compact Series Engine Powered 143899 Section System Component Identification and Schematics Service and Maintenance 3 4 Electrical Parts List Continued Skyjack SJRT Compact Series 137794 137786 137782 137781 137792 137786 137782 137781 102853 127132 102853 127132 102853 127132 102853 127132 102853 102692 102692 115747 113400 146661 103336 103613 103613 103613 103613 103613 103613 106272 106272 106272 103613 103613 103613 125793 106272 103613 128321 128321 128321 128321 137513 128321 Engine Powered 143899 Parts list continued from the previous page SWITCH ASSEMBLY Low High Throttle Select HEAD Switch Selector 2 Way e SWITCH Base Assembly BLOCK Spring Contact LATCH Mounting SWITCH ASSEMBLY Start e HEAD Switch Push Button Black e SWITCH Base
133. ElevDown value shows the recorded height where the switch opened SKYJACK Page 32 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Load Sensing System 4 3 18 Flash Code F19 High Elev close 1 This message is given if the elevation switch P2 10 closed during lower at a too high height above 25 When the switch is closed overload detection is normally disabled but if the switch closes above 25 the platform is too high to allow disabled overload Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened 4 3 19 Flash Code F20 Height lt gt 0 1 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 4 3 20 Flash Code F21 Height lt gt 0 1 This message occurs if the platform height is not 0 before the platform is raised during either STATIC lift The platform must be at 0 height when it is fully lowered Check DIAGNOSTICS SYSTEM to check the height 4 3 21 Flash Code F22 Height lt gt 100 1 This message occurs if the platform height is not 100 after the platform has been fully raised during either STATIC lift The platform must return to the same height each time it is fully raised Check DIAGNO
134. G 96 bd 5 i wv HV3H1HOIH abd LL 76 92 4 1331 6 64 sza Y dnuvauidxi 26 v4 gt 4 Y e dnuvauiHoM 16 94d i ga e INOS LHO9IH 06 4 lt 4 22 INOtH 1331 68 14 LWOO in ua azir ind NO 88 M 4 4 L 18 865 14 9 8 M CT ose os ase T 84 44 92 SZ 1397 uv3H HV3H LNOWS 1437 356 VEES Veces 125 028 L u3ooidino 60 Avi3HdOOUd L 60 2806 v8 vL NOILISOd Q310vul3H vL ger 1 9 NI NMOHS 1NOH3 INOUS uvau 4919 1431 1HOlH 13 NN u3ooriuino 19 95 29 9 9 voL vol 9 1951 2951 2957 7957 i AVISHTIBVN3 yg 4 1 J 13r 95 1 0 59 435010 NadO ATIVWHON SSHOLIMS 08 VeL 247 Woe voL vo
135. H Ove Ove ave ver ve 2 gt 007 vi6 ve 50 0 4 4 ae 50 G3U 31IHM 50 o 20 vee NO eo 4 4 301 s e 20 20 so SO 10 20 80 13931 HOLIMS LL HOLIMS 4018 zs M AON3OH3Ia 4018 3701 asva XO8 vS AONSOH3INS HOLIMS A3 95 015 BN M137327AL SKYJACK Page 35 SJRT Compact Series Engine Powered 143899 View Parts List Print This Page AB 3 23b Electrical Schematic CE All Option With Kubota Diesel Engine BE F 3 203 868 J 10H J 143899 u355iu1no m 4 NMOG 1431 x 82 82 t v 0088105 HADDIN 6 1431 y vL vL yowa vL avay 4 NMOG LHOIY m m LN GION3108 J an ase SLL Ve E Py M137327AN SJRT Compact Series gt GIONS1OS H3OOlHIDO 1 V NMOG 1NOH3 1HOIH nom 02 5 GION310S eu 1 V HOI 1 Z Hv 21 Engine
136. IN 1 10A BLACK O CO 10 BLUERED naio 8167 NO OUTRIGGER JUMPER PLUG UP RELAY JUMPER NO HYDA GEN JUMPER PLUG PIN 2 28 GREEN GREEN 49 8 E 13 ORANGE PINS 02 WHITE 5 olololololololo olololololololol PN1 amp T GRNRED 28 28A BLACK 14 144 PIN 9 amp 10 RED 43 43A PN 4 44 RED J ORANGEIGREEN 60 481 O E Back aaia REDIBLACKWHITE NOTUSED 21 O CO 05 BLUE GROUND GREENBLACKWHITE TO 0 146124 SJRT Compact Series SKYJACK Page 29 Engine Powered 143899 A Print View This Page Parts List 3 19 Electrical Panel Wiring Diagram CE 8B e D 168 gt
137. LK WHT FROM MAIN MANIFOLD HARNESS 146108 SJRT Compact Series Engine Powered 143899 Print V lew This Page Parts List 3 17 Electrical Panel Wiring Diagram Terminal Block Details ____ BE 00000000009 HDC s m 7 fae EOC 1 4 55 L JL JL JE JL JE jE yj IE E L 1 N 4 1 NOK 5 2 A ANSI CSA Models 2 Q2 ome 05 ome 2 0 p LO LO T NUN E Q Q at 5 I O9 g SJRT Compact Series SKYJACK Page 27 Engine Powered 143899 Models x apo 2 e OOO M13 View This Page Parts List 3 18 Electrical Panel Wiring Diagram ANSI CSA A BE 6 40D A H N gt
138. MODELS 5 6826RT SJ 6832RT Service Manual Compact Rough Terrain Scissors Part No 143899AD February 2014 This manual is based on Serial Number s SJ 68XXRT 37 002 164 to 37 002 787 Please refer to the website www skyjack com for older Serial Numbers Skyjack Service Center 3451 Swenson Ave St Charles Illinois 60174 USA Phone 630 262 0005 Toll Free 1 800 275 9522 Fax 630 262 0006 Email service dskyjack com Parts North America Toll Free 1 800 965 4626 Toll Free Fax 1 888 782 4825 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 amp Service Europe Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry Shropshire SY10 8NN UK Phone 44 1691 676 235 Fax 44 1691 676 238 E mail info askyjackeurope co uk Skyjack Brasil Alameda J piter 710 Loteamento American Park Empresarial Indaiatuba SP Brasil 13347 653 Tel 55 19 3936 0132 SERVICE AND MAINTENANCE Table of Contents Section 1 Scheduled Maintenance Table of Contents Section 2 Maintenance Tables Table of Contents Section 3 Schematics Table of Contents Section 4 Troubleshooting Table of Contents Section 5 Procedures Table of Contents SJRT Compact Series SKYJACK Page 3 Engine Powered 143899 Service and Maintenance Operator s Responsib
139. N310S LNOYS 1331 GION3TOS H399lHLnO LNOYS 1331 99 0 13431 OLNY 19v4134 OLNY 1 83 1331 1NOH4 HV3U 1331 1 Iu LNOLND HOIH NMOG 1331 NMOG LNOYS 1331 dn uv3u 1331 dn LNOH4 LNOYS 1331 10 YADOINLNO Aviad 141 0 Av 3H JI9YNI 99 1 14 991 1 10 GION310S 9 1 4016 HOJVH3N39 9 BHOLIVH3N39 GION31OS HOLVH3N39 HOAH GIONGIOS 3ATVA dWnd TIVWS GIONGIOS IMYA 19 GIONS10S 3ATVA GIONS10S IMYA 3 vuga 3SH3A3H GIONG3IOS 3ATVA GION3IOS 5 3ATVA 15 1331 GION310S 3ATVA 15 105 IMYA 9
140. NTER BALANCE VALVE VALVE COIL TWO POSITION THREE WAY THREE POSITION FOUR WAY CLOSED CENTER CLOSED PORT PILOT LINES ERI E VELOCITY FUSE SINGLE ACTING CYLINDER DOUBLE ACTING CYLINDER DOUBLE ACTING DOUBLE RODDED SPRING APPLIED HYDRAULIC RELEASED CYLINDER ROTARY ACTUATOR CLOSED CENTER OPEN PORT VARIABLE DISPLACEMENT HYDRAULIC MOTOR SKYJACK Page 3 Service and Maintenance 3 2 Electrical Symbol Chart WIRE CROSSING m HOURMETER WIRES JOINED LIGHT KEY SWITCH FOOT SWITCH HYDRAULIC BATTERY VALVE COIL CIRCUIT BREAKER TOGGLE SWITCH PROPORTIONAL HYDRAULIC VALVE COIL ELECTRIC MOTOR BATTERY CHARGE INDICATOR CAM OPERATED LIMIT SWITCH EMERGENCY STOP BUTTON RESISTOR POTENTIOMETER LEVEL SENSOR DOUBLE POLE SINGLE THROW SINGLE POLE SINGLE THROWN RELAY DOUBLE POLE DOUBLE THROW RELAY SINGLE POLE DOUBLE THROW RELAY RELAY TRIPLE POLE DOUBLE THROW RELAY TEMPERATURE SWITCH SKYJACK Page 4 DIODE TRANSISTOR Section 3 System Component Identification and Schematics ANGLE TRANSDUCER PRESSURE TRANSDUCER LIMIT SWITCH 0 LIMIT SWITCH N O HELD CLOSED LIMIT SWITCH LIMIT SWITCH N C HELD OPEN SILICON CONTROLLED RECTIFIER PROXIMITY SWITCH PNP TRANSISTOR NPN TRANSISTOR PRESSURE VACUUM SWITCH SJRT Compact Series Engi
141. OUTRIGGER C LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR L J C9 C10 Ci C12 MANIFOLD BLOCK STEERING yc i NR is ies VALVE VALVE VALVE VALVE FLOW CUSHION Q4 CHECK H CHECK Q CHECK H CHECK CYLINDER 10 DIVIDER P A LOWERING HYDRAULIC ORIFICE H DISCONNECT ______ NT E uz d TERI STEER B P C BRAKE FD A FD B FD C M A M B M C M D 1 1 P B L AUXILIARY Ww PRESSURE PORT 1 v HP2 2 9 HYD 2H 86D EMERGENCY 5 a GENERATOR ue FREEWHEEL SANDWICH MANIFOLD GENERATOR IE T VALVE BLOCK VALVE MES VALVE VALVE VALVE VALVE ___ _ Y W 2H 20B HYDRAULIC I A MN 92 0 HIGH SPEED Kj EXTEND Kj EXTEND Kj 26 GENERATOR H A VALVE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR GM1 GENERATOR OPTION 5 RIGHT STEER 59 4H 75 DER 4H 76 K 4H 77 4H 78 MOTOR WITH 2H 13 ANSI CSA VALVE 4H 16B 2438 CE V6 A PARALLEL i ADJUSTABLE id LOWERING AUTO FORWARD T B T B T B T B PEE LIFT VALVE RESET gt
142. RED CO COO EF RED BLACK 18 02 WHITE O O FP WHITE BLACK 16 GROUND GREEN BLACK WHITE MALE X BACK VIEW O O mda WHITE BLACK 16 O E 00 WHITE RED BLACK 18 CO CO 05 WHITEIRED ORANGE BLACK 19 CO 05 WHITE BLACK RED BLACKWHITEIRED 20 Q7 RED BLACKWHITE 23 07 RED GREEN BLUE BLACK 24 CO CO e 08 BLACK RED REDMHITE 31 O CO 5 09 ORANGE RED GREEN BLACK 32 e 10 BLUEMHITE GREENWHITE CO CO e 10 BLUERED GREEN 49 757 O EE 13 ORANGE ORANGE GREEN 60 87 CO 4 BLACK RED BLACKWHITE NOT USED x Es 15 BLUE GROUND 00 7 10 FEMALE M137356AB SJRT Compact Series Engine Powered 143899 Print View This Page Parts List 3 10 Main Manifold Harness Wiring Diagram ANSI CSA EE F 28G8 amp J SMALL PUMP DUMP VALVE 188 RED BL
143. RMETER 42 10 15A 16 17 20A 168 158 13 10 2A 10 2 8 02 15 02 16 02 17 02 19 02 20 02 5 02 5 02 99 02 02 10A 10A 21 44 44 16A 15A 13 4 4 CIRCUIT BREAKER 28ACR1 28ACR2 28ECR1 28ECR2 28ECR3 32CR1 32CR2 33CR 34ACR 35CR 35ACR CBI 18A 17 18B 17A 13A 3A 348 4 10A 34 34 09 02 S 02 B 102 3 02 codi 32 4 83 02 8 gt 26 0 8 0 EMERGENCY STOP 188 m e EN 2 E JE A bs 4A z CIRCUIT BREAKER _ LEGEND C MAIN MANIFOLD HARNESS 1 ____ POWER ON ENGINE HARNESS LED 2 0 PLATFORM CONTROL BOX 221 e i i i Bg Be OUTR GEN HARNESS GLOW PLUG START SWITCH N NO TETH E EB 932 26 ta HIGH SPEED LMT SWITCH pe O O 212 CONTROLMODULE E Refer to P PR UR Terminal Strip x i for details S E P E Q INO KEY SWITCH 7 510 HORN z 02 WHITE UP DOWN X 49 BLACK JIO SWITCH 52 E _ 4 ee 15 8 8 02 5 05 07 18 10 09 0 13 2 24 49 60 HIGH SPEED LIMIT SWITCH e
144. STICS SYSTEM to check the height 4 3 22 Flash Code F23 Height lt gt 100 1 This message occurs if the platform height is not 100 before the platform is lowered during either STATIC lift The platform must be at 100 height when it is fully raised Check DIAGNOSTICS SYSTEM to check the height 4 3 23 Flash Code F24 Too Many 1 This message occurs if too many static measurements are taken during either STATIC lift or lower likely that there is a problem with the lift cylinder pressure the GP102 should only need about 10 measurements for most vehicles The SETUPS HEIGHT SETUPS MIN LIFT time could be increased to force a longer time between static measurements but this should not be necessary 4 3 24 Flash Code F25 Check Elev 1 This message indicates a problem with the elevation switch P2 10 during the STATIC phases The switch is either staying closed to a higher height or staying open to a lower height than that recorded during the DYNAMIC phase 4 3 25 Flash Code F26 Check Elev 1 This message indicates a problem with the elevation switch P2 10 during the STATIC phases The switch is opening or closing at a different height than that recorded during the DYNAMIC phase 4 3 26 Flash Code F27 Bad Height 1 This message indicates a problem with the height sensor output P4 3 during the STATIC phases The height sensor output must be between 1 0V and 4 0V at all times Check DIAGNOSTICS SENSORS to see the output
145. Stuck or defective hydraulic generator valve 2H 86D Check valve Repair or replace if defective 2 Misadjusted or defective flow control valve FC1 Adjust valve Replace if defective 3 Stuck or defective large pump dump valve 2 17 Check valve Repair or replace if defective 4 Defective hydraulic generator hydraulic motor GM1 Check motor Repair or replace if defective 4 2 15 Outriggers Inoperative 1 Stuck or defective outrigger holding valve 2H 17C Check valve Repair or replace if defective 4 2 16 Left Front Outriggers Inoperative 1 Stuck or defective retract valve 4H 71 or extend valve 4H 75 Clean valve Replace if defective 2 Stuck or defective check valve CV7 Check valve Replace if defective 3 Bypassing outrigger cylinder C9 Repack cylinder Replace if defective 4 2 17 Right Front Outriggers Inoperative 1 Stuck or defective retract valve 4H 72 or extend valve 4H 76 Clean valve Replace if defective 2 Stuck or defective check valve CV8 Check valve Replace if defective 3 Bypassing outrigger cylinder C10 Repack cylinder Replace if defective 4 2 18 Right Rear Outriggers Inoperative 1 Stuck or defective retract valve 4H 73 or extend valve 4H 77 Clean valve Replace if defective 2 Stuck or defective check valve CV9 Check valve Replace if defective 3 Bypassing outrigger cylinder C11 Repack cylinder Replace if defective 4 2 19 Left Rear Outriggers I
146. UTRIGGERS Ir 4 SKYJACK Page 30 SJRT Compact Series Engine Powered A 143899 View Parts List Print This Page 3 20 Electrical Schematic ANSI CSA No Option With Kubota Dual Fuel Engine ____ BE 686 1 39uv1 AV HU dnd 5 GIONS10S 3ATVA dnd GIONG IOS 3 ATIVA T3TIVuvd AV THH GION3 1OS INVA GION310S CGION310S 3Su3A3H GION3T1OS INVA 3su3Aau T T1Vuvd GIONG IOS 3ATVA ONIH33IS 1331 GION3 1OS INWA ONIH33LS GION3 OS 3ATVA 93395 39uv1 5 INVA dnd 9 CGION3T1OS INYA ariuvd saluas 1 01 0 46 IH NOLLVA3T3 Ta3ruvd saiuas 1371139 531935 318VN3 SILLOYHL GION31OS 141 GIONS10S NIHIMOT NIV GION310S SNIGIOH GION31OS SATIVA H3MOd NIVIA JILLOHHL 18915 V SZ AZL 73 18 3NION3 GION31OS HOLIMS 3univu3dWal
147. WARD VALVE BLACK HIRSHMAN PIN 1 168 WHITE RED PIN 2 02 WHITE INSERT ORIENTATION BOTTOM VIEW PARALLEL REVERSE VALVE GREY HIRSHMAN PIN 1 158 BLUE YELLOW PIN 2 02 WHITE BRAKE FEED VALVE 30 BROWN 02 WHITE SERIES PARALLEL VALVE 20A BLACK RED WHITE 02 WHITE Print This Page 13 BLACK 02 WHITE HOLDING VALVE 138 ORANGE 02 WHITE HOLDING VALVE LOWER PIN 1 13 BLACK PIN 2 02 WHITE HOLDING VALVE UPPER PIN 1 13 BLACK PIN 2 02 WHITE View Parts List FORWARD VALVE BLACK HIRSHMAN PIN 1 16A WHITE BLACK PIN 2 02 WHITE amp INSERT ORIENTATION BOTTOM VIEW V REVERSE VALVE GREY HIRSHMAN PIN 1 15A BLUE PIN 2 02 WHITE M139828AB_M139647AA SJRT Compact Series Engine Powered 143899 3 12 Load Sensing Harnesses LIGHT BEEPER HARNESS Print View This Page Parts List 1 2 686 HY SJRT Compact Series Engine Powered 143899 a 22 BLACK CONTROL MODULE P3 02 WHITE CONTROL MODULE P3 5 29 GREEN TO CONTROL MODULE P3 2
148. Wait This message indicates that the GP102 is busy the delay will be short no more than 5s Total Data This message is displayed at the end of each phase to confirm the number of measurements recorded by the GP102 SKYJACK Page 24 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance 5 4 7 Control Module Load Calibration Procedure 1 Move the aerial platform to a test area where the platform can be elevated to its maximum working height and reach 2 Ensure the aerial platform is parked on a firm level surface IMPORTANT Each phase must be completed before the next phase can be carried out All phases must be completed before the aerial platform can be operated IMPORTANT Always follow the instructions of the Calibration instrument 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 7 Connect the Easy Cal tool to the P1 connector on the CONTROL MODULE 8 The display will show Help Press Enter By using Left Right buttons select the Access Level
149. Y 12 Volt outrigger lift disable RELAY 12 Volt 40 Amp large pump RELAY 12 Volt 40 Amp series parallel drive RELAY 12 Volt 40 Amp series parallel RELAY 12 Volt 40 Amp series parallel HELAY 12 Volt 40 Amp small pump dump enable RELAY 12 Volt 40 Amp large pump dump enable RELAY 12 Volt 40 Amp down enable CE RELAY 12 Volt 40 Amp small pump dump auxiliary enable CE RELAY 12 Volt 40 Amp large pump dump auxiliary enable CE auxiliary down enable CE RELAY 12 Volt 40 Amp RELAY 12 Volt 40 Amp glow plug CONTACTOR Engine start RELAY 12 Volt 40 Amp RELAY 12 40 Amp engine start Parts list continued on the following page SKYJACK Page 8 SJRT Compact Series Engine Powered 143899 127035 127035 127035 127035 127131 127131 127035 127035 127035 130440 103295 103056 117967 137919 137919 136172 137355 137356 137363 137354 103007 102921 KUBOTA 128595 138091 121476 103743 136119 133133 137868 146652 103007 136121 137857 136101 136106 136106 138094 137785 137785 122010 138060 Section System Component Identification and Schematics 1 II ILI ILIA ll lll gt JJ Service and Maintenance 3 4 Electrical Parts List Continued Skyjack Parts list continued from previous page RELAY Power on d
150. You as a careful operator are the best insurance against an accident Therefore proper usage of this aerial platform is mandatory The following pages of this manual should be read and understood completely before operating the aerial platform Common sense dictates the use of protective clothing when working on or near machinery Use appropriate safety devices to protect your eyes ears hands feet and body Any modifications from the original design are strictly forbidden without written permission from SKYJACK Electrocution Hazard This aerial platform is not electrically insulated Maintain a Minimum Safe Approach Distance MSAD from energized power lines and parts as listed below The operator must allow for the platform to sway rock or sag This aerial platform does not provide protection from contact with or proximity to an electrically charged conductor DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS DANGER Avoid Power Lines Minimum Safe Approach Distance ANSI SIA A92 6 2006 CE Guidance Note Phase to Phase Feet 0 to 300V Avoid Contact eee Adhere strictly to the governmental rulings Over 50KV to 200 cable i and regulations applicable your country Over 200KV to 350KV Over 350KV to 500KV Over 500 to 750KV Over 750KV to 1000KV 45 FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY
151. _ _ 7 NENNEN nen eae 7 ENTE T 7 7 ASEE OTA 8 Operator Salely Mo MNT TS TT EEE EENAA EITEN EN ATEN EES 9 E EE E E 9 E F cet co A E N EN A 10 Maintenance and Inspection 0 GE TN 13 Owner s Annual Inspection Record La 13 FEPIBEBDORET MEER UHR RAUS AT 13 Maintenance and Service Safety 13 Hydraulic System amp Component Maintenance and 14 Vip siis NETT TTE TO 14 Service and Maintenance Pr Mig mee ETT RI 15 O 15 D Emm 15 Kamienice eii RET 15 Schedule Maintenance Inspections Scheduled Mamtenance 18 AEN Qc CIEL o TR Dre er Tables LI Owners Annual iin tert MTM 16 1 2 FER UE 17 SJRT Compact Series SKYJACK Page 5 Engine Powered 143899 Operator s Respon
152. a 2 AMG MOT 141 uaHsvid eld 25 4 NHOH 106 T N3349 6 80 WY GION310S SATA E NHOH NIVIA ei 85 GIONSI0S gz iv 3AYA ONIGIOH LHO p 10H1NOO A 4 GIONSIOS gt 0L e 09 09 09 00 5 521 FD SWHO D NOLdOH31H3ANI 92 ur E Avi3HH3MOd NIN 92 901 80 80 e 7 uj 4 AATOMI 259 T ey we ve T 80 H IH MOT NS 915 T 2 ze ze 80 LUVLS SIS N lz NM 4 61 85 189 0 006 ZL tey a la asni m 2 HOLVNHALIY 9i ul n ee HOlOWCH dl NIV H31HVIS 901 vi 4 4 20 20 oL 0L n 2800 4 7 Tz le 7 n n 80 HOLIMS HOHO Les els 1 ve ve w y HOLIMS reao 15 ot MS 2 inr 1 az ve oL MOTO 1641 18901
153. a 4 V a e pt 12 4 St ama Si St Y zoa 25 2 J voL 4 ast TT SL 98 lt 1 ve ve x IA 6 PAL 1491 45 4 4 3LIHWMOV18 ez Yas a 1HOlB 2 25 4 20 zo 20 08 74 80 2200 HN goz 4 9204 46 4 IP vit m m vy gt VOz Hv 551 41 5 4 p vol i zuovoz 2 Ms E 038010 ATIVWHON D HOLIMS t 4 60 S v 110109 JAHA HOIH 60 60 7 20 3aiB83AO Vt vel d voL vol EUN ax 4 ase vol voL SHON 8 2 vL vL 62 98 4 x i Dn i y 5218 P do p B d Po POP P d Pod m a T NOILISOd 1 a n lt M 1 IH
154. age SKYJACK Page 11 Service and Maintenance Section 3 System Component Identification and Schematics 3 4 Electrical Parts List Continued Skyjack Parts list continued from previous page 128321 128321 128321 128321 128321 128321 128321 128321 128321 COIL Left steer valve COIL 12 Volt front left retract outrigger COIL 12 Volt front right retract outrigger COIL 12 Volt rear right retract outrigger COIL 12 Volt rear left retract outrigger COIL 12 Volt front left extend outrigger COIL 12 Volt front right extend outrigger COIL 12 Volt rear right extend outrigger COIL 12 Volt rear left extend outrigger 1 I Ill ll SKYJACK Page 12 SJRT Compact Series Engine Powered 143899 Print View This Page Parts List 3 5 Hydraulic Schematic
155. air or replace if defective 4 Defective drive motor M1 M2 or MA Check motor Repair or replace if defective 5 Free wheeling valve V2 open or defective Close valve Repair or replace if defective 6 Stuck or defective high speed valve 2H 20B Check valve Repair or replace if defective 7 Cushion cylinder C8 bypassing internally Check cylinder Repair or replace if defective SJRT Compact Series SKYJACK Page 27 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Hydraulic System Continued 4 2 6 Drive Sluggish 1 Stuck open or defective valve CV3 CV4 CV5 or 6 Check valve Replace if defective 2 Drive relief valve R5 set too low Refer to Section 5 of this manual for setup procedure 3 Defective flow divider FD1 Check flow divider Replace if defective 4 2 7 Reverse Drive Inoperative 1 Stuck or defective drive valve 4 15 Check valve Repair or replace if defective 4 2 8 Forward Drive Inoperative 1 Stuck or defective drive valve 4H 16A Check valve Repair or replace if defective 4 2 9 Drive Inoperative When in Low Drive 1 Stuck or defective parallel counterbalance valve CB2 Check valve Replace if defective 2 Stuck or defective parallel forward drive valve 4H 16B or parallel reverse valve 4H 15B Check valve Replace if defective 4 2 10 Drive Inoperative When in High Drive 1 Stuck or defective series parallel val
156. al 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 Base 5 1 1 System Lift and Pressure Adjustment All adjustments must be made with a calibrated hydraulic gauge Refer to the serial number nameplate located on the rear of the machine for system and lift pressure values System Relief Pressure Adjustment 1 Locate right steer hydraulic line at main manifold Refer to Hydraulic Manifold Component and Port Identification found in Section 3 for location 2 Tee in a calibrated 3000 psi gauge into the right steer line 3 Remove operator s control box from guardrail and disconnect it from scissors control cable 4 Locate electrical panel cable plug in the hydraulic electric cabinet 5 Disconnect scissors control cable and connect operator s control box cable 6 At main manifold loosen locknut on system relief valve R1 Refer to Hydraulic Manifold Component and Port Identification found in Section 3 for location 7 Select drive position with lift drive select switch on platform control console 8 Engage steer right with rocker switch of the controller handle and hold 9 Observe reading on pressure gauge Adjust system relief valve R1 to the pressure listed on the serial number nameplate NOTE Turning the stem on the relief valve clockwise increases pressure Turning the stem counter clockwise decreases pr
157. and is elevated above high speed limit switch high throttle is inoperative Loose or broken wire 08 from lift drive select switch S3 to low high throttle switch 514 Check continuity Replace if defective 2 Defective low high throttle switch 514 Check switch Replace if defective 3 Loose or broken wire 34 from low high throttle switch 14 to relay 35ACR Check continuity Replace if defective 4 Open diode 009 when in lift only Check diode Replace if defective 5 Open diode D44 2 when in drive only Check diode Replace if defective 6 Loose or broken wire 35A from base terminal block TB 1 to relay 35ACR Check continuity Replace if defective 7 Defective relay 35ACR Check relay Replace if defective 8 Loose or broken wire 02 from relay 35ACR to terminal block TB1 Check continuity Replace if defective SJRT Compact Series SKYJACK Page 9 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 9 10 11 12 13 14 15 16 17 Loose or broken wire 34 from relay to relay 34ACR Check continuity Replace if defective Defective relay 34ACR Check relay Replace if defective Loose or broken wire 42 from relay 34ACR to relay 10CR2 Check continuity Replace if defective Defective relay 10CR2 Check relay Replace if defective Loose or broken wire 2A from
158. annot read tilt sensor 2 Defective outrigger control module 2 Replace eee NNNM controlled 1 1 Error occured while self diagnosing the 1 Turn off power to reset the outrigger control module Turn power hardware fail safe back on and see if the code has cleared If problem persists replace outrigger control module 2 Power wire 70 or 79 when 1 module 10A at pin P2 12 at outrigger control module 1 Startup error occurred while self 1 Turn off power to reset the outrigger control module Turn power diagnosing back on and see if the code has cleared If problem persists replace outrigger control module 1 Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module 1 Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module 1 Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module 1 Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module 1 Internal failure of OCM1 1 Turn off power to reset th
159. apacity label for additional information and for models equipped with options SJRT Compact Series SKYJACK Page 9 Engine Powered 143899 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 4 Rough Terrain Scissor Fluids AXLE Recommended Equivalent 0 634 Gear Oil 80W 90 GL5 Front Rear Axle Type Chevron Gear Lubricant Delo ESI 80W 90 Caltex Gear Lubricant ESI 80W 90 Cushman Rear 1 0 264 Gear ESI 80W 90 Caltex RPM Borate EP 80W 90 Texaco Star Gear Lubricant 80W 90 All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water CENTER DRIVE OIL P Qty Qty ter D alent Oil Center Drive Type Liters Gallons Oil Type mmen quivalent Oi Gear 80w 90 GL5 J All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water HYDRAULIC OIL Qty Qty Liters Gallons SJRT 68XX 86 88 22 95 5 71277 RT 7127 eat RT 7135 80 48 21 26 SJR 8243 8243 SS 8850 Oil Type ae 8831 ATF Dexron 111 8841 8841 75 71 ien 8831E 8841E ae 9241 67 38 SJRT 9250 9250 fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water
160. 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 SJRT Compact Series Engine Powered 143899 SKYJACK Page 15 Service and Maintenance Inspections Section 1 Scheduled Maintenance Table 1 1 Owner s Annual Inspection Record Model Number Serial Number Recording Date Owner s Inspected R ecording 1 2 3 4 5 7 Year 60564AA As described earlier in this section this decal is located on the control compartment cowling It must be completed after an annual inspection has been completed Do not use the aerial platform if an inspection has not been recorded in the last 13 months SKYJACK Page 16 SJRT Compact Series Engine Powered 143899 Section 1 Scheduled Maintenance Service and Maintenance Inspections Table 1 2 MAINTENANCE AND INSPECTION CHECKLIST Serial Number Model Hourmeter Reading Date Time Name Printed Signature Each item shall be inspected using the the appropriate section of the Sk
161. ch Operation Light Torque Switch Ci 0 Low High Speed Range Switch SC I Horn Pushbutton Raise Off Lower Switch 1 Glow Plug Choke Pushbutton Off Lift Drive Key Switch Engine Start Pushbutton Emergency Stop B Lift Enable Aen Pushbutton Test Platform Raising Lowering 3 Select off lift drive key switch to drive position IV WARNING Be aware of overhead obstructions 4 Without activating C4 enable trigger or other possible hazards around the switch attempt to drive and steer the aerial aerial platform when lifting platform Result Drive and steer functions should 1 Pressandhold enable pushbutton not operate then select and hold raise off lower Test Steering switch to 5 raise position and raise the platform to an approximate height of 1 Activate and hold enable trigger switch 1 ft 30 5 cm Release switch to stop and then press rocker switch on top of Result Platform should rise ds au controller to 4 left and 7 2 Pressandhold lift enable pushbutton right then select and hold raise off lower switch Result Steer wheels should turn left and to E lower position and lower the right platform fully Release switch to stop Result Platform should lower Test Horn Test Enable Trigger Switch 1 Push horn pushbutton Result Horn should sound 1 Ensure
162. cific 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 SKYJACK Page 4 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System 4 1 1 All Controls Inoperative 1 2 10 11 12 13 14 15 16 17 18 Battery disconnected or discharged Reconnect battery Recharge if discharged Loose or dirty battery cables Clean and tighten battery cables Defective main fuse F1 300Amp Check fuse Replace if defective Open or defective main power disconnect switch 51 Close switch Replace if defective Loose or broken wire 03 from main power disconnect switch 51 to circuit breaker CB1 Check continuity Replace if defective Tripped or defective circuit breaker CB1 Reset breaker Check for defective wiring Replace breaker if defective Loose or broken wire 3A from breaker CB1 to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 3A from base terminal block TB 1 to base emergency stop switch S6 Check continuity Replace if defective Defective base emergency stop switch 56 Che
163. ck switch Replace if defective Loose or broken wire 5 from base emergency stop switch 56 to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 5 from base terminal block TB 1 to key switch 510 Check continuity Replace if defective Defective key switch S10 Check switch Replace if defective Loose or broken wire 7 from key switch 510 to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 7 from base terminal block TB 1 to platform emergency stop switch S4 Check continuity Replace if defective Defective platform emergency stop switch S4 Check switch Replace if defective Loose or broken wire 10 from platform emergency stop switch S4 to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 10 from base terminal block TB 1 to key switch 510 Check continuity Replace if defective Defective key switch S10 Check switch Replace if defective 4 1 2 No Power To Platform 1 Open or defective key switch 510 Check switch Replace if defective 2 Loose or broken wire 07 from key switch 10 to base terminal block TB 1 Check continuity Replace if defective 3 Loose or broken wire 07 from base terminal block TB 1 to platform emergency stop switch 54 Check continuity Replace if defective 4 Open defective platform emergency stop switch 54 Check switch Replace if defective SJRT Compact Ser
164. cle Armguard Active Elevation Switch Shifted Elevation Switch Stuck If the 23 flash code is triggered by armguard it will occur once then clean This is not a true fault but just an indica tion of the reason for the vehicle stop If the 21 or 22 flash code is triggered by a fault with the elevation switch it will not clear Check that the elevation switch correctly opens closes when the platform is raised lowered P3 4 Short To OV P3 6 Short To OV Disconnect plug If fault clears there is a wiring fault from P3 4 or P3 6 to the rest of the vehicle Invalid Load Check Sensors Check the voltage out of the pressure transducer into P4 2 It should be between 0 5 zero pressure and 4 5V maximum pressure and should vary as the platform load amp position varies O1 Waiting For B 2 12 B Supply Too Low 4 1 Or P5 1 Short To OV Check that the battery voltage is not too low Verify battery voltage on P2 12 Disconnect plug if the fault clears there is a wiring fault from P4 1 to the rest of the vehicle SJRT Compact Series SKYJACK Page 19 Engine Powered 143899 Service and Maintenance Section 5 Procedures 5 4 4 LED Error Codes Code Breakdown Chart Continued 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 ve
165. ctive starter motor Check motor Repair or replace if defective 4 1 6 Engine Cranks But Will Not Start Kubota Diesel 1 5 6 Open diode D32A from engine start switch 532 to glow plug switch S31 Diode located Engine harness Refer to Engine wiring diagram Diesel Fuel System Check diode Replace if defective Loose or broken wire 37 from engine harness to diesel valve solenoid 2D37 Check continuity Replace if defective Loose or broken wire 57 from starter contactor 32ACR to diesel valve solenoid 2D37 Check continuity Replace if defective Defective fuel valve solenoid 2D37 Check solenoid Replace if defective Defective glow plugs Check glow plugs Repair if necessary Defective glow plug timer GPT1 Check timer Replace if defective Defective glow plug relay 31 Check relay Replace if defective 4 1 7 Engine Cranks But Will Not Start Kubota Dual Fuel 1 Open or defective diode D57 Diode located in Engine harness Refer to Engine wiring diagram Dual Fuel System Check diode Replace if defective 2 Loose or broken wire 37 from engine harness plug to coil pack 2 wire connector Check continuity Replace if defective SJRT Compact Series SKYJACK 7 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 3 4 5 10 12 13 Loose broken wire
166. cy lowering valve to fully lower the platform Result The platform should lower 4 To restore normal operation depress and 3 turn holding valve manual override knobs clockwise Ensure path of intended motion is clear Release the brake manually Turn free wheeling valve knob counterclockwise to a fully opened position and attempt to push pull the aerial platform Result Aerial platform should move Turn free wheeling valve knob clockwise to a fully closed position for normal operation Heengage the brake Platform Control Console Ensure base emergency stop button is pulled out Ensure main power disconnect switch is in on position Select platform engine base key switch to JA platform position and remove key SKYJACK Page 34 a SJRT Compact Series Engine Powered 143899 Section 1 Scheduled Maintenance Function Tests Enable Trigger Low High Throttle Switch Switch Drive Lift Steer Controller Choke Dual Fuel 10 Glow Plug Diesel Lift Torque Drive M Pushibutt n JTO Switch Brake Auto Brake 4 4 gt m gt N Reset Valve Pump Emergency Engine
167. e INOH3 1391 86 20 31IHM 26 20 3991 110 96 02 13 41 OLN 56 Sed 04 lovuldu OLNY 76 9 64 318VN3 9 1 6 6 OSE NOLLISOd ose Xov18 3LIHM NI NMOHS SY3D9IHLNO uod 9 Qe vol ose ves 16 54 PF ose _____________ _ __ ONrTISAS 68 Y3DDIHLNO L437 141 28 8 59 N3dO 0358010 ATIVWHON S3HOLIMS NMOG H399IH1nO LNOLND H9IH 01 24 vv 1331 78 84 NMOG 8 eid 22 NMOG LNOYS 28 92 NMOG 1NOHJ 1331 18 5 1331 08 Std 2 LHOIW 64 9 vd 64 i _ YOL ved v99 zed 29 bed dnlNOHd1HOld 22 dniNOHdld31 2 Bd 14 i 318VN3 99 110 865 310n0OW 1OHLNOO 92 141 uxoouino 5 1481 1HOlH 1HOlH LNOWS 1J311NOu4 396
168. e Scope of this Manual a This manual applies to the ANSI SIA CSA and CE versions of the Mid Size and Full Size Rough Terrain aerial platform models listed on Table 2 1 Equipment identified with ANSI meets the ANSI SIA A92 6 2006 standard Equipment identified with CSA meets the CSA B354 2 01 standard Equipment identified with CE meets the requirements for the European countries i e Machinery Directive 98 37 EC and or 89 392 EE EMC Directive 89 336 EEC Directive 2000 14 EC and the corresponding EN standards b CSA Canada and CE Europe Operators are required to conform to national territorial provincial and local health and safety regulations applicable to the operation of this aerial platform c ANSI SIA United States Operators are required by the current ANSI SIA A92 6 standards to read and understand their responsibilities in the manual of responsibilities before they use or operate this aerial platform SKYJACK Page 8 SJRT Compact Series Engine Powered 143899 Operator s Responsibility for Maintenance Service and 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
169. e 1 This message indicates that the pressure is too low 0 5V or less at a STATIC measurement point This message would occur if the pressure sensor was disconnected or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure SKYJACK Page 34 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Load Sensing System CE 4 3 36 Flash Code F45 High Pressure 1 This message indicates that the pressure is too high 4 5V or more at a STATIC measurement point This message would occur if the wrong pressure sensor was fitted or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure 4 3 37 Flash Code F46 Check Elev 1 This message indicates that the elevation switch opened more than once during the DYNAMIC lift 4 3 38 Flash Code F47 Check Elev 1 This message indicates that the elevation switch closed more than once during the DYNAMIC lower SJRT Compact Series SKYJACK Page 35 Engine Powered 143899 PROCEDURES Table of Contents 3 iie icing TRENT TITEL 3 Base 5 1 1 System LIN and Pressure Si 3 5 1 2 Winching and Towing Procedures and Parking Brake System 4 5 1 3 Wheel Bolt Nut Inspection and Torquing
170. e carried out in ground mode Not Stopped This message is given if any function switch is closed Check DIAGNOSTICS SWITCHES to see which function switch is closed 04 Tilted This message is given if the machine is tilted Calibration must be carried out with the machine level If the machine is level use the SETUPS TILT SETUPS to set the GP102 level 5 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 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 F06 Check Elev This message is given if the elevation switch P210 is open at the start of calibration when the operator has confirmed the PLATFORM DOWN question If the platform is down check the elevation switch wiring 08 Check Elev This message is given if the elevation switch P2 10 is closed at the end of calibration when the platform should be fully raised This message would occur if the UP switch was accidentally opened near the start of the lift If the platform is fully raised check the elevation switch wiring 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 between 0 9V and 4 1V Check DIAGNOSTICS SENSORS to see the output F10 Bad Height This mes
171. e outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module 1 Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module 1 Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module 1 Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module 60416AB 6 6 7 8 7 6 SKYJACK Page 24 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 39 Left Front Outrigger Inoperative Manually 1 Defective left front outrigger switch S20 at platform control console or S20A at base control console Check switch Replace if defective 2 Loose or broken wire 71 up from outrigger control console to pin 6 up on connector CN20 at outrigger board or wire 75 down to pin 7 down Check continuity Replace if defective 3 Open diode 71 up D75 down on outrigger board Check diode Replace if defective 4 Loose or broken wire 71 up at pin 7 up or pin 75
172. e ve 50 S0 09 2001 1001 00 50 50 OL 1Hon 14VHSXNVHO e NO 4304 1540 y 00 m 4 wor 48 ky 30 NE s 10 20 4 ve 90 50 2 20 20 80 da 7 LL HOLIMS NMOG dn 3015 zs c 3NION3 v1Og n 3018 asva 10H1NOO 25 AON3OH3W3 HOLIMS 95 018 Nom M137324AG SKYJACK Page 31 SJRT Compact Series Engine Powered 143899 View Parts List Print This Page 3 21 Electrical Schematic ANSI CSA Option With Kubota Dual Fuel Engine gt j E Jj sx 1 143899 M137325AL Engine Powered SJRT Compact Series
173. elect the Change Defaults from the menu and press the ENTER button 10 The display will show Defaults 0 Custom By using Up Down buttons select the Defaults Code Setting for your Model For Default Code Refer to Table 5 3 from the menu and press the ENTER button and followed by ESCAPE button 11 display will show Setups Change Defaults By using Left Right buttons select the Calibrate Level from the menu and press the ENTER 12 The display will show Calibrate Level Yes Enter No Select the Yes from the menu by press the ENTER button 13 The display will show Calibrate Level Tilt 0 0 0 0 Select the ESCAPE from the menu once 14 The display will show Setups Calibrate Level Select the ESCAPE from the menu once again 15 The Calibration procedure is complete unplug and remove the EZ Cal 16 Close the hydraulic electric cabinet SJRT Compact Series SKYJACK Page 15 Engine Powered 143899 Service and Maintenance Section 5 Procedures 5 3 7 Auto Leveling Outrigger Control Module Pin Reference Chart 2 DOS DOG DOG NOG DOG NOA U AVOA GP106 Control Module PLUG The Calibration Connection Input indicating that the LEFT REAR outrigger is in contact with the ground Input indicating that the RIGHT REAR outrigger is in contact with the ground
174. elevation switch opens during calibration Check DIAGNOSTICS SENSORS to check the pressure F43 High Pressure This message indicates that the pressure is too high 4 5V or more when the elevation switch opens during calibration Check DIAGNOSTICS SENSORS to check the pressure SKYJACK Page 22 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance 44 Low Pressure This message indicates that the pressure is too low 0 5V or less at a measurement point Check DIAGNOSTICS SENSORS to check the pressure F45 High Pressure This message indicates that the pressure is too high 4 5V or more at a measurement point Check DIAGNOSTICS SENSORS to check the pressure F46 Check Elev This message indicates that the elevation switch opened more than once during calibration lifting F47 Check Elev This message indicates that the elevation switch closed more than once during calibration lowering F48 Bad Pressure This message is given if the pressure sensor output P4 2 is out of range at the start of calibration The height sensor output must be between 0 5V and 4 5V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem F52 Too Few This message indicates that not enough measurements were recorded during calibration lifting or lowering F98 Out of Range This message indicates that the fine tune
175. elow is clear of personnel and obstructions DO NOT exert side forces A ENSURE that there are no aerial platform while elevated personnel or obstructions in the path of travel including blind spots DO NOT use the aerial platform as a crane It is prohibited gZ BE AWARE of blind spots when operating the aerial platform DO NOT sit stand or climb on the guardrails It is prohibited STUNT driving and horseplay are prohibited DO NOT climb on scissor arm assemblv It is ENSURE ALL tires are in good condition and lug prohibited nuts are properly tightened DO NOT alter or disable limit switches or other safety devices AWARE of overhead DO NOT use the aerial platform without obstructions or other possible guardrails locking pins and the entry gate chain hazards around the aerial bar in place platform when driving or lifting e DO NOT raise the platform while the aerial platform is on a truck fork lift or other device or vehicle e AWARE crushing hazards Keep all body parts inside platform guardrail SJRT Compact Series SKYJACK Page 11 Engine Powe
176. emand RELAY 12 Volt 40 Amp throttle RELAY 12 Volt 40 Amp throttle enable RELAY 12 Volt 40 Amp elevation high speed cutout RELAY 12 Volt 40 Amp outrigger drive enable RELAY 12 Volt outrigger lift enable RELAY 12 Volt 40 Amp hydraulic generator stop RELAY 12 Volt 40 Amp hydraulic generator latching RELAY 12 Volt 40 Amp hydraulic generator SOLENOID Gas shutoff Kubota Dual Fuel Engine TRANSDUCER Angle CE BATTERY 12 Volt WET BEEPER 7 5 16 VDC ANSI CSA BEEPER XL 600 9 28 VDC CE CIRCUIT BREAKER 25 Amp CIRCUIT BREAKER 25 Amp SENSOR Cranshaft position CABLE ASSEMBLY Control box CABLE ASSEMBLY Scissor arm Model 6826 CABLE ASSEMBLY Scissor arm Model 6832 CABLE ASSEMBLY Electrical panel SOLENOID Choke DIODE PLUG Engine glow FUSE 300 Amp FUSE 125 Amp Electrical inverter option FLASHING LIGHT FLASHER PUMP Electric fuel GLOW PLUG INDICATOR LIGHT GLOW PLUG TIMER HORN 12 Volt SOLENOID High throttle MODULE Igniter control ALTERNATOR Kubota DF902 ALTERNATOR Kubota DF972 COIL Ignition COIL Ignition INVERTER 125 Amp LIGHT Power on LIGHT Power on Base controls LIMIT SWITCH High drive cutout tilt override LIMIT SWITCH Front left outrigger up Parts list continued on the following page SJRT Compact Series Engine Powered 143899 SKYJACK Page 9 138060 138060 138060 138059 138059 138059 138059 132804 102838 134432 119726
177. enance Inspection every year Refer to Section 1 0 of this manual D Perform Scheduled Maintenance Inspection every 2 years Refer to Section 1 0 of this manual Perform scheduled inspection every three months or 150 hours T Refer to Skyjack s webiste www skyjack com for latest service bulletins prior to performing quarterly or yearly inspection Note Make copy of this page or visit the Skyjack web site www skyjack com for a printable copy SJRT Compact Series Engine Powered 143899 SKYJACK 17 A Service and Maintenance Inspections Section 1 Scheduled Maintenance Platform Control Scissor Assembly Platform Assembly Limit Switch Outriggers 1 1 Scheduled Maintenance Inspections Perform a visual inspection around the following Begin the scheduled maintenance inspections by areas checking each item in sequence for the conditions listed in this section e hydraulic tank filter fittings hoses emergency power unit if equipped and base surfaces AN WARNING e engine compartment fittings hoses main 5 pump filter To avoid injury do not operate an aerial e hydraulic cylinders platform until all malfunctions have been all hydraulic manifolds corrected e underside of the base e ground area under the aerial platform N WARNING e To avoid possible injury ensure aerial platform power is off during your visual a
178. enance Section 5 Procedures Engine 5 2 1 Kubota Dual Fuel DF972 Resistance Checks Resistance of Pick Up Sensor 1 Disconnect the connector 2 Measure the resistance with the ohmmeter 3 If the resistance is not within the factory specifications replace it Factory Spec A 1 85 to 2 45 at 20 C Resistance of Ignition Coil 1 Disconnect the connector B E 2 2 Measure the resistance with ohmmeter 3 If the resistance is not within the factory specifications replace it Resist Factory 8 1 87 to 2 530 at 20 C esistance Factory Spec 104 to 15 60 at 20 C A Terminal C High Tension Cord B Terminal Resistance of Ignitor Disconnect the connector 2 Measure the resistance with an ohmmeter 3 If the resistance is not within the factory specifications replace it omo Important To replace the ignitor with a service part make sure the ignitor has the same part cord No ID mark as the old one See the information label 1 Ignitor Check Chart Negative s C Positive 0 33 to 1 3 1 8 to 7 3 10to 40kQ 03310 1 3 EE 1 5 to 6 0 infinity infinity infinity infinity infinity infinity infinity infinity infinity 60434 minimum minimum minimum minimum y minimum minimum minimum minimum y 2 megohm 2megohm 2megohm infinit minimum minimum minimum minimum y infinity 1 8 to 7 3
179. er or US gallons liquid Use distilled water and 50 50 mix of anti freeze water SJRT Compact Series Engine Powered 143899 SKYJACK Page 11 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 5 Torque Specifications Hydraulic drive motor castle nut 350 DJ Directional valve mounting bolts 28 32 Ibf in Wheel mounting bolts 135 145 Ibf ft Center drive sprocket mounting bolts 110 115 Ibf ft 242 LOCTITE Hydraulic drive motor mounting bolts 120 Ibf ft 242 LOCTITE Positive battery post cable fuse nut 90 Ib in Cartridge Lbf ft max Torque All coils Lbf ft max 4105 48 to 60 5 42 to 6 78 Newton meter Nm Pound force foot Ibf ft Pound force inch Ibf in 6002 SKYJACK Page 12 SJRT Compact Series Engine Powered 143899 Section 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS Table of Contents Charts sre M 3 T ei NE T 4 Pe Hydraul Pals LIBE 5 Parts List Farne LIST e 8 15 eer eee Tm 13 Diagrams and Schematics 3 6 Hydraulic Manifolds And Ports SE Nave RUE 14 65 BO Vu A Ets ETT 16 3 8 Outrigger Hydraulic Gene
180. essure 10 Release steer switch and retighten locknut on system relief valve R1 11 Remove gauge from steer line Lift Pressure Adjustment WARNING Fully lower the platform 1 Locatethe lift line coming out of the main manifold Refer to Hydraulic Manifold Component and Port Identification found in Section 3 for location 2 Open manual lowering valve with platform fully lowered Remove lift line from main manifold 3 Install a 3000 psi gauge into the lift line port fitting on the main manifold Plug the lift line going to the lift cylinders 4 Loosen locknut on lift relief valve R2 Refer to Hydraulic Manifold Component and Port Identification found in Section 3 for location 5 Close the manual lowering valve 6 At base controls in hydraulic electric cabinet depress and hold the up pushbutton 7 Observe reading on pressure gauge Adjust lift relief valve R2 to the pressure listed on the serial number nameplate NOTE Turning the stem on the relief valve clockwise increases pressure Turning the stem counter clockwise decreases pressure 8 Release the up pushbutton and retighten locknut on lift relief valve R2 9 Remove gauge from lift line port fitting and reinstall the lift line WARNING Ensure machine does not lift more than rated load SJRT Compact Series Engine Powered 143899 SKYJACK Page 3 Service and Maintenance Section 5 Procedures 5
181. g if everything is OK or if there is an error code see LED Error Codes Table 5 3 DIAGNOSTIC MENU OPTIONS SYSTEM Select this menu to see general OCM1 system information SWITCHES Select this menu to see switch input status OUTPUTS Select this menu to see OCM 1 output status LOG Select this menu to see logged information DIAGNOSTIC SYSTEM MENU OPTIONS OUTRIGGERS Displays various status during the auto level function TILT Displays vehicle tilt in X and Y orientations measured by integral sensor TILTED Displays whether vehicle is tilted YES or NO BATTERY Displays battery supply voltage on P2 12 DIAGNOSTIC SWITCHES MENU OPTIONS LR P2 1 High when the left rear outrigger is in contact with the ground RR P2 2 High when the right rear outrigger is in contact with the ground RF P2 3 High when the right front outrigger is in contact with the ground LF P2 4 High when the left front outrigger is in contact with the ground EXTEND P2 5 High to activate the auto level function RETRACT P2 6 X High to activate the auto retract function ELEV P2 10 High when the scissor stack is stowed elevated input indicates that the vehicle is stowed SJRT Compact Series SKYJACK Page 13 Engine Powered 143899 Service and Maintenance Section 5 Procedures DIAGNOSTIC OUTPUTS MENU OPTIONS LAMP P2 7 STABLE P2 8 TILT P2 9 LRe P4 1 RRe P4 2 RFe P4 3 LFe P4 4 LRr P4 5 RRr P4 6 RFr P4 7 LFr P4 8 P4 9 MON Displays
182. h throttle switch to C7 low throttle position CAUTION Do not start the engine in the high throttle position 9 To start the engine e f ANSI CSA dual fuel engine is cold depress and hold choke pushbutton if equipped with engine start pushbutton to start the engine f diesel engine 15 cold select and hold glow plug pushbutton for 15 to 20 seconds or until indicator light goes 2 off Depress and hold pushbutton to start the engine engine start Section 1 Scheduled Maintenance Rocker Switch Drive Steer Low High Throttle Switch SA Operation Light 52 Raise Off Lower Switch Off Lift Drive Key Switch Emergency Stop Button If engine is not cold depress and hold TOL engine start pushbutton to start the engine Test Emergency Stop 1 Push in emergency stop button Result Engine should shut down and aerial platform functions should not operate Test Lift Enable 1 Pull out emergency stop button 2 Restart the engine 3 Select and hold raise off lower switch to T 17 2 raise position without pressing lift VY enable pushbutton Result Platform should not rise SKYJACK Page 28 SJRT Compact Series Engine Powered 143899 Section 1 Scheduled Maintenance Function Tests Drive Steer Enable Trigger Switch ocker Switch Drive Steer Controller Low High Throttle Swit
183. hard the machine presses on the areas in direct contact with the floor The floor covering tile carpet etc must be able to withstand more than the indicated values above OUP Overall Uniform Pressure is a measure of the average load the machine 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 6 SJRT Compact Series Engine Powered 143899 Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 2 Floor Loading Pressure AS Extension Number of Number of Capacity Occupants Capacity Occupants One Extension One Extension 60441AC AS NOTE Occupants and materials are not to exceed rated load Refer to capacity label for additional information and for models equipped with options SJRT Compact Series SKYJACK Page 7 Engine Powered 143899 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 3a Maximum Platform Capacities Evenly Distributed ANSI CSA Total Machine Weight Extension Number of Capacity Number of C Occupants Occupants 6826 4 300 Ib 136 kg 1 Platform One Extensi
184. he auto level function MACHINE SETUP MENU OPTIONS factory set not adjustable DEFAULTS Allows all adjustments amp machine settings to be set to defaults WARNING all GP106 settings will be changed use with caution CALIBRATE LEVEL Allows levelling of the integral tilt sensor of the GP106 when the vehicle is TILT MODE TILT FILTER Xlevel TARGET Ylevel TARGET tilt SLACK positioned on level ground see Appendix Four Allows configuration of the GP106 tilt output P2 9 1 output turns on to light lamp when tilted 2 output turns off to cutout functions when tilted 3 output turns off to cutout functions when tilted AND elevated Displays the filter applied to the tilt measurements during the auto level function used to minimize the effect of vehicle vibrations on the tilt measurement Displays the tilt in the X orientation at which the auto level function will complete Displays the tilt in the Y orientation at which the auto level function will complete Displays the amount of vehicle tilt exceeding the Xtilt TARGET and or Ytilt TARGET in which the auto level function will not attempt to level EXAMPLE Xtilt TARGET 0 3 TARGET 0 7 tilt SLACK 0 5 If machine is tilted to 1 0 in the X and Y orientations the auto level function will attempt to level the X orientation 0 3 0 5 1 0 but will not attempt to level the Y orientation 0 7 0 5 gt 1 0 RANGE 0 0 to 1 0 default 0 3
185. her error is present it will then be presented LED ERROR CODES 60402AA SKYJACK Page 10 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance 5 3 4 Auto Leveling Outrigger Error Code Breakdown RELEASE OUTRIGGER DEMAND 5 5 Check inputs on P2 pins 5 amp 6 the auto level or auto retract input is active at power on or when it is not allowed to carry out the function OUTRIGGERS CANNOT BE MOVED 1 2 Check input on P2 pin 10 auto level or auto retract has been requested but the platform is D lt RV e NOT FULLY LEVEL 2 1 The outrigger legs are all down touching ground but the platform is fully level OUTRIGGERS NOT HOME 2 2 The outrigger legs are not all down touching the ground and also are not all home fully retracted B SUPPLY TOO LOW CHECK OUTRIGGER SUPPLY P4 9 Check that the battery voltage is not too low VEHICLE TILTED These is not a true fault move the vehicle to level ground a NO TESTING HWFS 7 8 STARTUP 7 7 These are not true faults unless they do not clear the start up tests should only occur for a short time OUTRIGGERS MANUALLY CONTROLLED 6 6 This is not a true fault the outriggers are being manually operated one or more outrigger legs on P4 pins 1 8 is high when the outrigger control module is not active CANNOT LEVEL BAD TILT SENSOR
186. hicle to level ground Check the voltage out of the height transducer into P4 3 It should be between 4V and 4 6V and should vary as the platform position varies Testing HWFS 78 Start Up 71 These not true faults unless they not clear start up tests should only occur for a short time Overload Functions Disabled Factory Override 67 These are not true faults the GP102 has been configured to suppress overload functionality Idle Timeout Active Always Off Fault Bad Tilt Sensor Fault Bad HWFS Fault Bad Slave Analogs Fault Bad Strain Monitors Fault Bad Slave Micro Fault HWFS Stalledi 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 20 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance 5 4 6 Control Module Load Calibration Code Messages amp Definitions During calibration the following failure message may appear Refer to 5 3 5 for hand held calibration diagnostic tool key functions 01 Check HWFS This message is given if the GP102 startup tests have not completed Check HELP message for more information 02 Not Ground Mode This message is given if the machine is not in ground mode P2 2 must be high Calibration can only b
187. hould not operate SJRT Compact Series SKYJACK Page 35 Engine Powered 143899 Section 2 MAINTENANCE TABLES AND DIAGRAMS Table of Contents Tables 2 1a Specifications and Features 5 2 PAD POA N d 210 Specifications and Features RITU T NT 4 2 dro tix c T E 6 220 NNI RENE 6 220 Loan Freee A 7 2 3a Maximum Platform Capacities Evenly Distributed 8 2 36 Maximum Platform Capacities Evenly Distributed 8 2 Maximum Platform Capacities Evenly Distributed 9 dali m m m 10 20 12 SJRT Compact Series SKYJACK Page 1 Engine Powered 143899 Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 1a Specifications and Features ANSI CSA Compact RT s Model 6826 6832 With Outriggers 7500 Ib 3656 kg ___ _ With Outriggers 4 LL
188. ies SKYJACK Page 5 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 1 3 All Functions Inoperative Machines Equipped with Load Sensing System CE 1 Loose or broken wire 10A from base terminal block TB1 to control module CM1 at pin P2 12 Check for 12 Volts at P2 12 If no voltage present check wire continuity Replace if defective 2 Loose or broken wire 02 from control module CM1 at pin P2 11 to base terminal block 1 Check continuity Replace if defective 3 Loose or broken wire 28E from control module CM1 at pin 3 6 to 28ECR1 small pump dump auxiliary enable relay and 28ECR2 large pump dump auxiliary enable relay and 28ECR3 auxiliary down enable relay Check for 12 Volts at P3 6 If voltage present check for 12 Volts at wire 28 at 28ECR1 28ECR2 and 28ECR3 relays If voltage present check operation of relays If no voltage present check wire continuity Replace if defective 4 Defective pressure transducer PT1 or angle transducer AT1 or related wiring Refer to transducer troubleshooting charts 4 1 4 All Functions Inoperative from The Platform 1 Open defective emergency stop switch S4 Check switch Replace if defective 2 Loose or broken wire 08 from platform emergency stop switch S4 to base terminal block TB 1 Check continuity Replace if defective 3 Open diode 008 at base terminal block TB 1
189. if defective SKYJACK Page 12 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 5 6 Defective steer valve 4H 24 Check coil Replace if defective Loose or broken wire 02 from steer left valve coil 4H 24 to base terminal block TB1 Check continuity Replace if defective Open diode D24 Check diode Replace if defective 4 1 17 Reverse Drive Inoperative 1 2 10 11 12 13 14 15 Defective reverse switch 57 4 controller 57 Check switch Replace if defective Defective controller 57 Check controller Replace if defective Loose or broken wire A from reverse switch S7 4 to contacts on Lift Drive select switch between wire A and wire 15 Check continuity Replace if defective Loose or broken wire 15 from Lift Drive select switch to relay 15CR Check continuity Replace if defective Defective relay 15CR Check relay Replace if defective Loose or broken wire 02 from relay 15CR to base terminal block Check continuity Replace if defective Loose or broken wire 10A from base terminal block to relay 15CR Check continuity Replace if defective Loose or broken wire 15A from relay 15CR to reverse valve coil 4H 15A Check continuity Replace if defective Loose or broken wire 02 from reverse valve coil to base terminal block TB1 Check co
190. il level low Refill tank to proper level Defective pump 1 Check pump Repair or replace if defective Broken engine to pump coupler Check coupler Replace if defective Relief valve R1 open Check valve Replace if defective 4 2 2 Steering Inoperative 1 2 Stuck or defective steer right valve 4H 23A or steer valve 4 24 Check valves Replace if defective Steer cylinder C7 damaged or bypassing internally Check cylinder Repair or replace if defective 4 2 3 Lift Steer and First Drive Speed Inoperative T 2 3 Small pump dump valve 2H 18B stuck open Check valve Repair or replace if defective Worn or defective small pump section of pump P1 Check pump Repair or replace if defective Check valve CV1 or CV2 stuck Check valves Clean or replace if defective 4 2 4 Second Drive Speed Inoperative 1 2 3 Large pump dump valve 2H 17A stuck open Check valve Repair or replace if defective Worn or defective large pump section of pump 1 Check pump Repair or replace if defective Check valve CV1 or CV2 stuck Check valves Clean or replace if defective 4 2 5 Drive Inoperative T Stuck or defective drive reverse valve 4H 15A or drive forward valve 4H 16A Check valves Repair or replace if defective 2 Defective drive relief valve R5 Check valve Replace if defective 3 Stuck or defective main counterbalance valve CB1 Check valve Rep
191. ility for 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 V DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices IMPORTANT IMPORTANT indicates a procedure essential for safe operation and which If not followed may result in a malfunction or damage to the aerial platform SKYJACK Page 4 SJRT Compact Series Engine Powered 143899 Section 1 SCHEDULE MAINTENANCE Table of Contents Operator s Responsibility for Maintenance Pt a ue E 7 ele Pa r NEIN Iri 7 B TIT TIT IMMERHIN 7 tae EE E a a eso os ew E _ ____ _
192. inuity Replace if defective 4 1 14 Brakes Will Not Release 1 2 3 Loose or broken wire 30 from base terminal block TB1 to brake valve coil 3H 30 Check continuity Replace if defective Defective brake valve coil 3H 30 Check continuity through coil Replace if defective Loose or broken wire 02 from brake valve 3H 30 to base terminal block TB1 Check continuity Replace if defective 4 1 15 Steer Right Inoperative 1 2 3 4 6 Defective steer right switch 57 2 in controller 57 Check switch Replace if defective Loose or broken wire 23 from steer right switch S7 2 to base terminal block TB1 Check continuity Replace if defective Loose or broken wire 23 from base terminal block 1 to steer right valve 4H 23 Check continuity Replace if defective Defective steer right valve coil 4H 23 Check coil Replace if defective Loose or broken wire 02 from steer right valve coil 4H 23 to base terminal block TB1 Check continuity Replace if defective Open diode D23 Check diode Replace if defective 4 1 16 Steer Left Inoperative 1 Defective steer left switch S7 3 in controller S7 Check switch Replace if defective 2 Loose or broken wire 24 from steer left switch S7 3 to base terminal block TB1 Check continuity Replace if defective 3 Loose or broken wire 24 from base terminal block TB1 to steer left valve coil 4H 24 Check continuity Replace
193. l block to high drive tilt override limit switch LS5 Check continuity Replace if defective 7 Misadjusted or defective high drive tilt override limit switch LS5 Adjust switch Replace if defective 8 Loose or broken wire 35 from high drive tilt override limit switch LS5 to relay 35CR Check continuity Replace if defective 9 Loose or broken wire 02 from relay 35CR to base terminal block Check continuity Replace if defective 10 Defective relay 35CR Check relay Replace if defective 11 Loose or broken wire 10A from base terminal block TB1 to relay 35CR Check continuity Replace if defective 12 Loose or broken wire 44 from relay 35CR to base terminal block TB1 Check continuity Replace if defective 13 Loose or broken wire 44 from base terminal block TB1 to relay 19 Check continuity Replace if defective 14 Loose or broken wire 17 from relay 19CR to relay 17CR Check continuity Replace if defective 15 Defective relay 17CR Check relay Replace if defective 16 Loose or broken wire 02 from relay 17CR to base terminal block TB1 Check continuity Replace if defective 17 Loose or broken wire 17 from relay 17CR to relay 28ACR2 Check continuity Replace if defective 18 Loose or broken wire 17A from relay 28ACR to base terminal block TB1 ANSI CSA Check continuity Replace if defective 19 Defective relay 28ACR2 Check relay Replace if defective 20 Loose or broken wire 17A from
194. lay 8CCR to controller harness Check continuity Replace if defective SJRT Compact Series SKYJACK Page 11 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 10 12 13 14 15 16 17 Loose broken wire 10A from base terminal block TB1 to outrigger control module OCM1 at pin p2 12 Check continuity Replace if defective Loose or broken wire 28 from outrigger control module 1 at pin P2 9 to outrigger connector CN14 at pin 7 Check continuity Replace if defective Left rear outrigger limit switch LS64 is out of adjustment or defective Check continuity through switch Adjust switch if out of adjustment Replace if defective Right rear outrigger limit switch LS63 is out of adjustment or defective Check continuity through switch Adjust switch if out of adjustment Replace if defective Right front outrigger limit switch LS62 is out of adjustment or defective Check continuity through switch Adjust switch if out of adjustment Replace if defective Left front outrigger limit switch LS61 is out of adjustment or defective Check continuity through switch Adjust switch if out of adjustment Replace if defective Defective drive enable relay 61CR Check relay Replace if defective Loose or broken wire 28A from pin 1 on connector 14 at the outrigger board to terminal block TB1 Check cont
195. ll Outriggers Inoperative Auto Level only Led Power Indicator Light at Outrigger Control Module OCM1 Flashing Flash Code Probable Cause Remedy 1 Outriggers are all up and machine is 1 Level the machine tilted 1 Machine is elevated 1 Lower the scissor stack below high speed limit switch 1 2 2 Loose or broken wire 35 2 Check for input voltage on wire 35 at pin P2 10 of the outrigger control module OCM1 Replace if defective 1 At least one outrigger is not fully 1 Fully retract all outriggers retracted 2 Defective outrigger rod limit switch 1561 1562 LS63 1564 or wiring 3 Defective diode D36 on outrigger board 2 1 1 Outriggers all down the machine 1 Move machine to less sloped terrain if it will not lift is not fully level 1 Power on wire 70 or 79 at power on 1 Check for power on wire 70 or 79 at P2 5 or P2 6 of the outrigger control module Replace defective component 2 2 2 Replace defective or damaged switch es wiring 3 Check for continuity Replace if defective 5 5 2 Check for power on wire 70 or 79 while manually operating an outrigger manually operating outriggers Low or no voltage on wire 35c 1 Check battery and charging system to ensure minimum 9 volts 5 2 2 Loose or broken wire on 35c 2 Check for input voltage on wire 35c at pin P4 9 of outrigger control module 1 1 Outrigger control module c
196. losion or fuel fire may cause death or serious injury Hydraulic Tank y dai Ensure hydraulic filler cap is secure IV DANGER Ensure tank shows no visible damage and no evidence of hydraulic leakage Engine fuels are combustible Inspect the aerial platform in an open well ven e Hydraulic tilated area away from heaters sparks Ensure platform is fully lowered and then and flames Always have an approved visually inspect the sight gauge located fire extinguisher within easy reach on the side of the hydraulic oil tank 2 Perform visual inspection around the following The hydraulic oil level should be at or slightly above the top mark of the sight fuel tank glass e hoses and fittings Hydraulic Return Filter Ensure filter element is secure Main Manifold Ensure all fittings and hoses are properly Ensure there are no signs of leakage or tightened and there is no evidence of visible damage hydraulic leakage e Fuel Tank Ensure there are no loose wires or missing fasteners IMPORTANT uu Before using your aerial platform ensure GearType Flow Divider there is enough fuel for expected use Ensure there no loose or missing parts and there is no visible damage Ensure fuel filler cap is secure Ensure tank shows no visible damage and no evidence of fuel leakage SKYJACK Page 22 SJRT Compact Series Engine Powered 143899 Section
197. lowing 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 change of oil The presence of metal particles also may indicate the possibility of imminent component failure A very small amount of fine particles is normal All containers and funnels used in handling hydraulic oil must be absolutely clean Use a funnel when necessary for filling the hydraulic oil reservoir and fill the reservoir only through the filter opening The use
198. must be between 1 0V and 4 0V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem 4 3 14 Flash Code F15 Check Elev 1 This message is given if the elevation switch P2 10 is open when the platform has been fully lowered after the DYNAMIC lift This message would occur if the DOWN switch was accidentally opened before the platform was fully lowered Ifthe platform is fully lowered check the elevation switch 4 3 15 Flash Code F16 Low Elev open 1 This message is given if the elevation switch P2 10 opened during lift at a too low height below 5 If it opens below 5 the pressure is probably too unpredictable to allow reliable detection of an overloaded platform when initially raised Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened 4 3 16 Flash Code F17 High Elev open 1 This message is given if the elevation switch P2 10 opened during lift at a too high height above 2596 lf it opens above 25 the platform is too high when the overloaded platform is detected Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened 4 3 17 Flash Code F18 Low Elev close 1 This message is given if the elevation switch P2 10 closed during lower at a too low height below 5 If it closes below 5 height sensor fault detection is compromised Check CALIBRATIONS HEIGHT CALS the
199. n the initial pressure peak and the minimum pressure Check the pressure sensor and lift cylinder hydraulics 4 3 32 Flash Code F40 Reject Delta 1 This message indicates that there is not enough difference between the loaded amp empty pressure This message could also occur if the wrong pressure sensor was fitted e g a 5000psi sensor when a 2000psi one is needed This message could occur if the platform were not properly loaded during the STATIC LOADED phase or if the platform were not properly empty during the STATIC EMPTY phase Check CALIBRATIONS HEIGHT CALS the Height indicates the first height at which there was insufficient difference and the Up and Down values show the loaded pressure first and the difference between loaded and empty pressure second 4 3 33 Flash Code F42 Low Pressure 1 This message indicates that the pressure is too low 0 5V or less when the elevation switch opens during the DYNAMIC lift This message would occur if the pressure sensor was disconnected or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure 4 3 34 Flash Code F43 High Pressure 1 This message indicates that the pressure is too high 4 5V or more when the elevation switch opens during the DYNAMIC lift This message would occur if the pressure sensor was disconnected or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure 4 3 35 Flash Code F44 Low Pressur
200. nce Options SKYJACK Page 8 Section 5 Procedures Service and Maintenance 5 3 2 Outrigger Mechanical Limit Switch Wiring Diagram Are O R UP SWITCH NO BLUE BROWN O R UP SWITCH NO BLUE BROWN PIN 1
201. nd daily maintenance inspections 1 1 1 Labels Refer to the labels section in this manual and determine that all labels are in place and are legible Electrical Maintaining the electrical components is essential to good performance and service life of the aerial platform 1 1 2 Limit Switches Detecting limit switch malfunction is essential to safe aerial platform operation Ensure limit switches are properly secured with no signs of visible damage and i movement is n r Inspect the following areas for chafed corroded OVEMENLIS and loose wires base to platform cables and wiring harness e engine compartment electrical panel e engine wiring harness e hydraulic electrical wiring harnesses Visually inspect all limit switch located inside the scissor arms and the outrigger assemblies for the following broken or missing actuator arm e missing fasteners e loose wirin Hydraulic 9 Maintaining the hydraulic components is essential to good performance and service life of the aerial platform SKYJACK Page 18 SJRT Compact Series Engine Powered 143899 Section 1 Scheduled Maintenance Service and Maintenance Inspections Muffler and Exhaust Base Control Console Tilt Sensor Engine Air Filter Disconnect Switch Radiator Hydraulic Pump Fuel Shut off Battery 1 1 4 Engine Componen
202. nd of the DYNAMIC lift The height sensor output must be between 1 0V and 4 0V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem 4 3 10 Flash Code F11 Not Up 1 This message occurs at the start of the DYNAMIC lift if the operator selects a function other than UP Select the UP function SJRT Compact Series SKYJACK Page 31 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Load Sensing System CE 4 3 11 Flash Code F12 Too Many 1 This message occurs if the DYNAMIC lift takes too long This message could occur if the UP switch was not released at the end of the dynamic lift Ifthe machine takes more than two minutes to lift the GP102 may need modification to avoid this problem 4 3 12 Flash Code F13 Low Height Range 1 This message occurs at the end of the DYNAMIC lift 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 This message would occur if the UP switch was accidentally opened near the start of the DYNAMIC lift If the platform is fully raised check the elevation switch wiring 4 3 13 Flash Code F14 Bad Height 1 This message occurs if the height sensor output P4 3 is out of range during the DYNAMIC lift The height sensor output
203. ne Powered 143899 Section System Component Identification and Schematics Service and Maintenance 3 3 Hydraulic Schematic Parts List Skyjack Tie tie om _ _______ 120989 CYLINDER Lower lift 120989 CYLINDER Upper lift 135896 CYLINDER Steer 107752 CYLINDER Cushion 132694 CYLINDER Outrigger left front 132694 CYLINDER Outrigger left front 132694 CYLINDER Outrigger left front 132694 CYLINDER Outrigger left front 137181 VALVE Main counterbalance 137181 VALVE Parallel counterbalance 104624 VALVE Check 104624 VALVE Check 104624 VALVE Pilot check 104624 VALVE Pilot check 104624 VALVE Pilot check 104624 VALVE Pilot check 104115 VALVE Pilot check 104115 VALVE Pilot check 104115 VALVE Pilot check 104115 VALVE Pilot check 136405 FILTER ASSEMBLY 137185 VALVE Flow divider 110652 PUMP Brake hand 103655 VALVE Lowering ANSI CSA 107269 VALVE Holding lower cylinder ANSI CSA 107269 VALVE Holding upper cylinder ANSI CSA 103655 VALVE Lowering CE 107269 VALVE Holding lower cylinder CE 107269 VALVE Holding upper cylinder CE 114365 VALVE Large pump dump ANSI CSA 114365 VALVE Large pump dump CE 103655 VALVE Holding outrigger 103656 VALVE Small pump dump ANSI CSA 103656 VALVE Small pump dump CE 111937 VALVE High speed 103655 VALVE Hydraulic generator 106273 VALVE Lift 103623 VALVE Brake 139256 VALVE Reverse drive 128318 VALVE Parallel reverse dri
204. ngine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information 4 1 41 4 1 42 4 1 43 4 1 44 4 1 45 Table of Contents Continued Right Rear Outriggers Inoperative 25 Left Rear Outriggers Inoperative 25 Individual Outrigger Functions Inoperative Auto Level 26 26 Auto All Up atii nb T DE T TUM 26 Hydraulic System Funcions ld po REPE esses IESU E sta eens AUR Pub AUR STE GER ia i eas eee 27 ENER 27 4 2 3 Lift Steer and First Drive Speed 4 27 4 2 4 Second Drive eee eine heen erin 27 RN RETURN 27 N AE E E EEE R 28 4 2 7 Reverse Drive gt MER IR CFR IA DU Qd 28 28 429 Drive Inoperative When LOW 28 42410 Drive 1 When in High DV Gi 28 A211 Brakes E n AE A aie aai 28 Up GCU dieti ieina E 28 Doi Iu 29 4 2 14 Hydra
205. noperative 1 Stuck or defective retract valve 4H 74 or extend valve 4H 78 Clean valve Replace if defective SJRT Compact Series SKYJACK Page 29 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Hydraulic System Continued 2 Stuck or defective check valve CV10 Check valve Replace if defective 3 Bypassing outrigger cylinder C12 Repack cylinder Replace if defective 4 2 20 Outriggers Drift In 1 Defective check valve left front CV7 right front CV8 right rear CV9 or left rear CV10 Clean valve Replace if defective 2 Outriggers cylinder bypassing left front C9 right front C10 right rear C11 or left rear C12 Repack cylinder Replace if defective SKYJACK Page 30 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Load Sensing System CE Load Sense System Flash Codes 4 3 1 Flash Code F01 Check HWFS 1 This message is given if the GP102 startup tests have not completed Check HELP message for more information 4 3 2 Flash Code 02 Not Ground Mode 1 This message is given if the machine is not in ground mode P2 2 must be high Calibration can only be carried out in ground mode 4 3 3 Flash Code F03 Not Stopped 1 This message is given if the machine is not in ground mode P2 2 must be high Check DIAGNOSTICS SWITCHES to see which function switch is closed 4 3 4
206. ntinuity Replace if defective Loose or broken wire 15A from base terminal block TB1 to relay 20ACRe In parallel drive only Check continuity Replace if defective Defective relay 20 2 in parallel drive only Check relay Replace if defective Loose or broken wire 15B from relay 20ACR2 to parallel reverse valve 4H 15B in parallel drive only Check continuity Replace if defective Loose or broken wire 02 from base terminal block TB1 to parallel reverse valve coil 4H 15B in parallel drive only Check continuity Replace if defective Defective parallel reverse valve coil 4H 15B in parallel drive only Check coil Replace if defective Open diode D15A 1 or D15A 2 Check diodes Replace if defective 4 1 18 Forward Drive Inoperative 1 Defective forward switch S7 5 in controller 57 Check switch Replace if defective 2 Defective controller 57 Check controller Replace if defective 3 Loose or broken wire B from forward switch S7 5 to contacts on lift drive select switch between wire B and wire 16 Check continuity Replace if defective SJRT Compact Series SKYJACK Page 13 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 9 6 10 11 12 13 14 15 Loose or broken wire 16 from lift drive select switch to relay 16 Check continuity Replace if defective Defective
207. o Outriggers 2900 kg 3475 kg With Outriggers 3305 kg 3655 kg 1 73 m 1 73 m No Outriggers 2 71 m 2 71 m With Outriggers 3 34 m 3 34 m Length Platform Size 1 4mx2 5m 1 4mx2 5m 11 6 m Platform Elevated Platform Lowered Normal Drive 6 3 km h 6 3 km h Elevated Drive 0 63 km h 0 63 km h Lift Rated Load 36 sec 39 sec Lower Rated Load 36 sec 36 sec 9 8 m 8 0 m 8 0 m o 3 Kubota Diesel 3500 High Throttle 2050 Low Throttle Kubota Dual Fuel 3500 High Throttle 2050 Low Throttle Foam filled OTR Outrigger 26 x 12 N A Engine Sound Pressure 96 dB A 60440AD AS Gradeability Torque Equivalent To Weights are approximate refer to serial nameplate for specific weight SKYJACK Page 4 SJRT Compact Series Engine Powered 143899 Section 2 Maintenance Tables and Diagrams Service and Maintenance Floor Loading Pressure Locally Concentrated Pressure LCP Foot Print Area Length x Width LCP Weight of Aerial Platform Capacity Foot Print Area x 4 Tires Width A 2 5 NR Diameter Overall Uniform Pressure OUP Base Area Length x Width Weight of Aerial Platform Capacity
208. o not manually disengage the park ing brakes if the aerial platform is on a slope Diagram 5 1 2 Disc Brakes System Parking Brakes The brakes must be manually disen gaged for pushing towing or winching 1 7 Make sure that the aerial platform is on level ground Chock or block the wheels to keep aerial platform from rolling Turn emergency main power disconnect switch to off position Locate brake hand pump and brake auto reset valve at main manifold in hydraulic fuel cabinet Push in brake auto reset valve item 1 Grasp the red hand pump item 2 and rapidly depress until firm resistance is felt The brakes are now released Remove the wheel chocks or blocks then push tow or winch the aerial platform to the desired location WARNING The parking brake MUST be re engaged immediately after reaching the desired location Position the machine on a firm and level surface Chock or block the wheels to prevent the aerial platform from rolling Re engage the parking brakes by pulling out the black brake valve plunger SKYJACK Page 4 SJRT Compact Series Engine Powered 143899 Section 5 Procedures Service and Maintenance 5 1 3 Wheel Bolt Nut Inspection and Torquing Procedure It is necessary to check the torque on all wheel nuts and wheel bolts at pre delivery after 8 hours of operation and at weekly intervals using the following procedure 1 Confirm that
209. on 60441AC ANSI NOTE Occupants and materials are not to exceed rated load Refer to capacity label for additional information and for models equipped with options Table 2 3b Maximum Platform Capacities Evenly Distributed CE Extension Number of Canacit Number of Occupants Occupants One Extension Capacity One Extension NOTE Occupants and materials are not to exceed rated load Refer to capacity label for additional information and for models equipped with options 60441AB CE BEAUFORT Wind Speed SCALE m s 34 54 125 194 11 5 17 75 5 494 006 branches sway Ground Conditions mph 12 0 Papers and thin branches move flags wave 80 108 28 8 38 9 2625 35 5 18 2425 Shrubs with leaves start swaying Wave crests are apparent in ponds or swamps 108 139 289 500 35 5 455 245 34 Tree branches move Power lines whistle It is difficult to open an umbrella 139 172 500 619 455 655 3138 5 Min trees sway It is difficult to walk against the 60338AC SKYJACK Page 8 SJRT Compact Series Engine Powered Q 143899 Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 3c Maximum Platform Capacities Evenly Distributed AS Extension Number of Number of Capacity Occupants Capacity Occupants One Extension One Extension 60441 AC AS NOTE Occupants and materials are not to exceed rated load Refer to c
210. ontinuity Replace if defective Defective down enable relay 28CR or auxiliary down enable relay 28ECR3 Check relay Replace if defective Loose or broken wire 28 from control module CM1 at pin P3 4 to down enable relay 28CR Check continuity Replace if defective Loose or broken wire 28E from control module CM1 at pin P3 6 to auxiliary down enable relay 28ECR3 Check continuity Replace if defective Loose or broken wire 13 from base terminal block to down enable relay 28 Check continuity Replace if defective Loose or broken wire 13 from base terminal block to control module CM1 at pin P2 4 Check continuity Replace if defective Loose or broken wire 13A from auxiliary down enable relay 28ECR3 to down enable relay 28CR Check continuity Replace if defective Loose or broken wire 13B from auxiliary down enable relay 28CR3 to lowering valve 2H 13B or holding valve 2H 13B 1 and 2H 13B 2 Check continuity Replace if defective Loose or broken wire 02 from base terminal block TB1 to lowering valve 2H 13B or holding valve 2H 13B 1 and 2H 13B 2 Check continuity Replace if defective 10 Defective lowering valve coil 2H 13B or holding valve 2H 13B 1 and 2H 13B 2 Check Coil Replace if defective SKYJACK Page 20 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 32 Hydraulic Generator Inope
211. ose or broken wire 44 from base terminal block TB1 to pin 6 on connector CN14 on outrigger board Check for continuity Replace if defective No power at wire 9 at pin 5 on connector CN14 on outrigger board f no power is present check for continuity on wire 9 back to the main terminal block TB1 Replace if defective Defective relay 9CR2 or 9CR3 on outrigger board Check relays Replace if defective Open diode D17C 1 on outrigger board Check diode Replace if defective Defective relay 17DCR on outrigger board Check relay Replace if defective Open or defective fuse jumper J17E on outrigger board Check fuse Replace if defective Loose or broken wire 17A from pin 2 on connector CN14 on outrigger board to terminal block TB1 Check for continuity Replace if defective Loose or broken wire 17C at pin 1 or wire 02 at pin 2 on connector CN21 on outrigger board to outrigger holding valve coil 2H 17C Check for continuity Replace if defective Defective outrigger holding valve coil 2H 17C Check coil Replace if defective 4 1 35 All Outriggers Inoperative Auto Level and Manual from Platform Controls 1 Loose or broken wires 35C at pin 1 on connector CN20 on outrigger board through outrigger cables and plugs to the outrigger enable switch 5 in the control box Check for continuity Replace if defective 2 Loose broken wire 35D from outrigger enable switch S9A to pin 5 on the outrigger con
212. parts alll fittings and hoses are properly Ensure there are no loose or missing tightened and there is no evidence of parts and there is no visible damage hydraulic leakage Splitter Manifold Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage SKYJACK Page 26 SJRT Compact Series Engine Powered 143899 Section 1 Scheduled Maintenance Drive Steer Enable Trigger Switch EA C Torque Switch Low High Speed Range Switch Horn Pushbutton Glow Plug Choke Pushbutton Engine Start Pushbutton Lift Enable Pushbutton 1 2 Function Tests Function tests are designed to discover any malfunctions before aerial platform is put into service The operator must understand and follow step by step instructions to test all aerial platform functions WARNING Never use a malfunctioning aerial platform If malfunctions are discovered aerial platform must be tagged and placed out of service Repairs to aerial platform may only be made by a qualified service technician After repairs are completed operator must perform a 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 Platform Control Console 1 main power disconnect switch
213. pin 4 on connector CN14 at the outrigger board Check continuity Replace if defective SJRT Compact Series SKYJACK Page 17 Engine Powered 143899 Service and Maintenance Electrical System Continued 3 4 10 11 12 13 14 15 16 Loose broken wire 10A from outrigger board to outrigger limit switch 1564 Check continuity Replace if defective Defective outrigger limit switch LS64 Check switch Replace if defective Loose or broken wire 64 from outrigger limit switch LS64 to outrigger board Check continuity Replace if defective Loose or broken wire 64 from outrigger board to outrigger limit switch 1563 Check continuity Replace if defective Defective outrigger limit switch LS63 Check continuity Replace if defective Loose or broken wire 63 from outrigger limit switch LS63 to outrigger board Check continuity Replace if defective Loose or broken wire 63 from outrigger board to outrigger limit switch 1562 Check continuity Replace if defective Defective Limit Switch 1562 Check switch Replace if defective Loose or broken wire 62 from outrigger limit switch LS62 to outrigger board Check continuity Replace if defective Loose or broken wire 62 from outrigger board to outrigger limit switch LS61 Check continuity Replace if defective Defective outrigger limit switch LS61 Check switch Replace if defective Loose or broken
214. pin P2 5 on outrigger control module Check continuity Replace if defective 7 For additional information refer to sections 4 amp 5 Outrigger Control Module Troubleshooting 4 1 45 Auto All Up Inoperative Retract 1 Loose or broken wire 35D from outrigger enable switch S9A to auto mode outrigger switch S24 Check continuity Replace if defective 2 Defective auto mode outrigger switch 24 Check switch Replace if defective 3 Loose or broken wire 10A at pin P2 12 on outrigger control module OCM1 Check for power at P2 12 If no voltage present check continuity of wire Replace if defective 4 Loose or broken wire 44 at pin P2 12 on outrigger control module OCM1 Check for power at P2 10 If no voltage present check continuity of wire Replace if defective 5 Loose or broken wire 02 at P2 11 on outrigger control module OCM1 Check for ground at P2 11 If no ground present check continuity of wire Replace if defective 6 Loose or broken wire 79 from auto mode outrigger switch S24 to pin P2 6 on outrigger control module Check continuity Replace if defective 7 For additional information refer to section 5 Outrigger Control Module SKYJACK Page 26 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Hydraulic System 4 2 1 All Functions Inoperative 1 2 3 4 Hydraulic o
215. rative 1 2 10 11 12 13 14 15 16 17 18 19 20 Key switch 53 drive position Turn switch to lift position Loose or broken wire 9 from base terminal block TB1 to generator relay 86BCR Check continuity Replace if defective Loose or broken wire 9 from generator relay 86BCR to generator switch 12 Check continuity Replace if defective Defective generator switch 12 Check switch Replace if defective Loose or broken wire 85 from generator switch S12 to generator relay 86ACR Check continuity Replace if defective Loose or broken wire 86B from generator relay 86ACR to generator relay 86BCR Check continuity Replace if defective Defective relay 86ACR Check relay Replace if defective Defective relay 86BCR Check relay Replace if defective Loose or broken wire 2A from hour meter to relay 86BCR Check continuity Replace if defective Loose or broken wire 86C from generator relay 86BCR to generator relay 86CCR Check continuity Replace if defective Open diode D86C Check diode Replace if defective Loose or broken wire 85 from diode D86C to relay 86ACR Check continuity Replace if defective Loose or broken wire 02 from base terminal block TB1 to relay 86CCR Check continuity Replace if defective Defective relay 86CCR Check Replace if defective Loose or broken wire 43 from relay 32CR1 to relay 86CCR Check continuity Replace
216. rator Control Console 17 39 obuia bnt mue 18 3 10 Main Manifold Harness Wiring Diagram 19 3 11 Main Manifold Harness Wiring Diagram 20 2 E I M I NE 21 3 13 Engine Wiring Diagram Dual Fuel System Kubota 22 3 14a Engine Wiring Diagram Diesel Fuel System Kubota 23 3 14b Engine Wiring Diagram Diesel Fuel System Kubota 24 3 15 Outrigger Optional NR 25 3 16 Hydraulic Generator Electrical Panel 26 3 17 Electrical Panel Wiring Diagram Terminal Block Details 27 3 18 Electrical Panel Wiring Diagram ANSI CSA ud uda qo RR ct Da 29 3 19 5 PATI Winnog Diagram 191 30 3 20 Electrical Schematic ANSI CSA No Option With Kubota Dual Fuel Engine 31 3 21 Electrical Schematic ANSI CSA Option With Kubota Dual Fuel Engine 32 3 22a
217. red 143899 Service and Maintenance Operator s Responsibility for Maintenance Fall 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 distrib uted 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 an other object to steady the platform DO NOT place materials on the guardrails or ma terials that exceed the confines of the guardrails unless approved by Skyjack Protection As per the ANSI A92 6 2006 standard The guard rail system of the aerial platform provides fall pro tection If occupant s of the platform are required to wear personal fall protection equipment PFPE occupants shall comply with instructions provided by the aerial platform manufacturer remanufac turer regarding anchorage s If additional fall protection is required an em ployer or the authority having jurisdiction Skyjack recommends the use of a fall restraint system to keep an occupant within the confines of the plat form and thus not expose the occupant to any fall hazard requiring a fall arrest All personal fall protection equipment must com ply with applicable governmental regulations and must be inspected and used in accordance with the manufactu
218. red 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 7 Loose broken wire 02 from base terminal block TB1 to lowering valve 2 13 holding valve 2 13 1 and 2H 13 2 Check continuity Replace if defective Defective lowering valve coil 2H 13 or holding valve 2H 13 1 and 2H 13 2 Check Coil Replace if defective 4 1 30 Down Circuit Inoperative from Base 1 2 3 Loose or broken wire 10E from base terminal block TB1 to base up down switch 52 Check continuity Replace if defective Loose or broken wire 13 from base up down switch S2 to base terminal block TB1 Check continuity Replace if defective Defective base up down switch 52 Check switch Replace if defective Loose or broken wire 13 from base terminal block TB1 to lowering valve 2H 13 or holding valve 2H 13 1 and 2H 13 2 ANSI CSA Check continuity Replace if defective Loose or broken wire 02 from base terminal block TB1 to lowering valve 2H 13 or holding valve 2H 13 1 and 2H 13 2 ANSI CSA Check continuity Replace if defective Defective lowering valve coil 2H 13 or holding valve 2H 13 1 and 2H 13 2 ANSI CSA Check Coil Replace if defective 4 1 31 No Down Function Additional for machines with Load Sensing System CE 1 Loose or broken wire 02 from base terminal strip TB1 to down enable relay 28CR auxiliary down enable relay 28ECR3 Check c
219. relay 16CR Check relay Replace if defective Loose or broken wire 02 from relay 16CR to base terminal block Check continuity Replace if defective Loose or broken wire 10A from base terminal block to relay 16CR Check continuity Replace if defective Loose or broken wire 16A from relay 16CR to forward valve coil 4H 16A Check continuity Replace if defective Loose or broken wire 02 from forward valve coil to base terminal block TB1 Check continuity Replace if defective Loose or broken wire 16A from base terminal block TB1 to relay 20ACR1 in parallel drive only Check continuity Replace if defective Defective relay 20ACHR1 in parallel drive only Check relay Replace if defective Loose or broken wire 16B from relay 20ACHR1 to parallel forward valve coil 4H 16B in parallel drive only Check continuity Replace if defective Loose or broken wire 02 from base terminal block TB1 to parallel forward valve coil 4H 16B in parallel drive only Check continuity Replace if defective Defective parallel forward valve coil 4H 16B in parallel drive only Check coil Replace if defective Open diode D16A 1 or D16A 2 Check diodes Replace if defective 4 1 19 First Drive Speed and Steering Inoperative 1 2 3 4 7 8 9 Loose or broken wire 21 from base terminal block TB1 to relay 17CR Check continuity Replace if defective Defective relay 17CR Check relay Replace if defective
220. relay 28ACR2 to relay 28ECR2 Check continuity Replace if defective 21 Defective relay 28bECR2 CE Check relay Replace if defective 22 Loose or broken wire 17B from relay 28ECR2 to base terminal block TB1 CE Check continuity Replace if defective 23 Loose or broken wire 17A from base terminal block TB1 to large pump dump valve coil 2H 17A ANSI CSA Check continuity Replace if defective 24 Loose or broken wire 17 from base terminal block TB1 to large pump dump valve coil 2H 17B CE Check continuity Replace if defective SJRT Compact Series SKYJACK Page 15 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 25 Loose or broken wire 02 from large pump dump valve coil 2H 17A ANSI CSA or 2H 17B CE to base terminal block TB1 Check continuity Replace if defective 26 Defective large pump dump valve coil 2H 17A ANSI CSA or 2H 17B CE Check coil Replace if defective 4 1 21 Third Drive Speed Inoperative 1 Defective third speed switch 57 6 in controller 57 Check switch Replace if defective 2 Defective controller S7 Check controller Replace if defective 3 Loose or broken wire 18 from third speed switch 57 6 to diode D18 at base terminal block TB1 Check continuity Replace if defective 4 Defective diode D18 Check diode Replace if defective 4 1 22 High Drive Speed Inoperative 1 Lift
221. rer s recommendations All personal fall protection equipment must be at tached only to approved anchorage points within the platform of the aerial platform WARNING Entering and exiting the aerial platform should only be done using the 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 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 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 result 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 SKYJ
222. rigger board or wire 77 down to pin 4 down Check continuity Replace if defective 3 Open diode D73 up or D77 down on outrigger board Check diode Replace if defective 4 Loose or broken wire 73 up at pin 4 up or wire 77 down at pin 5 down on connector CN21 at outrigger board to valve coil 4H 73 up or 4H 77 down Check continuity Replace if defective 5 Loose or broken wire 02 from valve coil 4H 73 up or 4H 77 down to pin 2 on connector CN21 at the outrigger board Check continuity Replace if defective 4 1 42 Left Rear Outriggers Inoperative Manually 1 Defective left rear outrigger switch 523 at platform control console or S23A at base control console Check switch Replace if defective 2 Loose or broken wire 74 up from outrigger control console to pin 5 up on connector CN20 at outrigger board or 78 down from pin 2 down Check continuity Replace if defective 3 Open diode D74 up or D78 down on outrigger board Check diode Replace if defective SJRT Compact Series SKYJACK Page 25 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 Loose or broken wire 74 up at pin 6 up or wire 78 down at pin 3 down on connector CN21 at outrigger board to valve coil 4H 74 up or 4H 78 down Check continuity Replace if defective 5 Loose or broken wire 02 from valve coil 4H 74 up
223. rm Kubota Dual Fuel T 2 3 10 11 12 13 Loose or broken wire 8 from start switch 515 to choke switch 13 Platform only Check continuity Replace if defective Defective choke switch 13 Platform only Check switch Replace if defective Loose or broken wire 31 from choke switch 513 to base choke switch 531 Platform only Check continuity Replace if defective Loose or broken wire 10B from base terminal block TB 1 to base choke switch S31 Base only Check continuity Replace if defective Defective base choke switch S31 Base only Check switch Replace if defective Loose or broken wire 31 from base choke switch 531 to engine harness Check continuity Replace if defective Loose or broken wire 31 from engine harness to relay 31CR Check continuity Replace if defective Loose or broken wire 02 from engine harness to relay 31CR Check continuity Replace if defective Loose or broken wire 3A from engine harness to relay 31CR Check continuity Replace if defective Defective relay 31CR Check relay Replace if defective Loose or broken wire 31A from relay 31CR to choke solenoid CS 31A Check continuity Replace if defective Loose or broken wire 02 from engine harness to choke solenoid CS 31A Check continuity Replace if defective Defective choke solenoid CS 31A Check solenoid Replace if defective 4 1 10 High Throttle Inoperative NOTE If machine is in drive mode
224. rm raise off lower switch ensure area around scissor 15 clear then continue lowering the platform Lower the platform fully e Test Powerdeck Enable If Equipped 1 Select and hold extend retract switch to EM extend position without selecting S enable switch Result Platform should not extend SJRT Compact Series Engine Powered 143899 SKYJACK Page 31 Function Tests Drive Steer Enable Trigger Switch Torque Switch Low High Speed Range Switch Horn Pushbutton Glow Plug Choke Pushbutton Engine Start Pushbutton Lift Enable Pushbutton Test Extension Platform s If Equipped 1 Extend each extension platform to about 1 ft 30 5 cm Result Each extension platform should extend 2 Retract each extension platform fully Result Each extension platform should fully retract e Test Tilt Sensor If Equipped N WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting WARNING Ensure that there are no personnel or obstructions in the path of travel including blind spots 1 Move the aerial platform on to a slope greater than 4 5 SKYJACK Page 32 Section 1 Scheduled Maintenance Rocker Switch Drive Steer Low High Throttle Switch SD Operation Light 52 Raise Off Lower Switch Off Lift Drive Key Switch Emergency
225. sage 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 F11 Not Up This message occurs at the start of calibration if the operator selects a function other than UP SJRT Compact Series SKYJACK Page 21 Engine Powered 143899 Service and Maintenance Section 5 Procedures F13 Low Height Range This message occurs at the end of calibration if the height sensor output did not change sufficiently to give a reasonably accurate platform height estimate DIAGNOSTICS SENSORS can be used to check the height sensor output P43 when the platform is fully lowered and fully raised a difference of at least 1V is to be expected This message could occur if the UP switch was accidentally opened too early when the platform is not fully raised F15 Check Elev This message is given if the elevation switch P2 10 is open when the platform has been fully lowered at the end of calibration This message would occur if the DOWN switch was accidentally opened before the platform was fully lowered If the platform is fully lowered check the elevation switch 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
226. sibility for Maintenance Service and Maintenance SKYJACK is continuously improving and expanding product features on its equipment therefore specifications and dimensions are subject to change without notice Aerial Platform Definition A mobile device that has an adjustable position platform supported from ground level by a structure Purpose of Equipment The SKYJACK Rough Terrain s mid and full size 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 It can be driven over uneven terrain only when the platform is fully lowered Manuals Operating The operating manual is considered a fundamental part of the aerial platform It is a very important way to communicate necessary safety information to users and operators A complete and legible copy of this manual must be kept in the provided weather resistant storage compartment on the aerial platform at all times Service amp Maintenance The purpose of this is to provide the customer with the servicing and maintenance procedures essential for the promotion of proper machine operation for its intended purpose All information in this manual should be read and understood before any attempt is made to service the machine The updated copy of the manuals are found on the company s website w
227. t N WARNING Ensure compartment latch is secure and in proper working order Battery acid is extremely corrosive Wear proper eye and facial protection as well as appropriate protective clothing If contact occurs immediately flush with Main Power Disconnect Switch Turn main power disconnect switch to off position cold water and seek medical attention Ensure all cables are secure and switch is in proper working condition 1 Check battery case for damage Base Control Switches 2 Clean battery terminals and cable ends Ensure there are no signs of visible thoroughly with a terminal cleaning tool or damage and all switches are in their wire brush neutral positions Tilt Sensor 3 Ensure all battery connections are tight Ensure tilt sensor is properly secure and there is no visible damage 4 l fapplicable check battery fluid level If plates are not covered by at least 1 2 13 mm Battery of solution add distilled or demineralized Proper battery condition is essential to water good performance and operational safety Improper fluid levels or damaged cables and 5 Replace battery if damaged or incapable of connections can result in component damage holding a lasting charge and hazardous conditions IN WARNING AN WARNING Use original or manufacturer approved Explosion hazard Keep flames and parts and components for the aerial sparks away Do not smoke near bat platform teries
228. teer Inoperative Machines without outriggers option 1 Lift Drive select switch S3 in lift position Turn switch to Drive position 2 Defective contacts on lift drive select switch between wire 78A and wire 8B Check continuity through contact Replace if defective SKYJACK Page 10 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 3 4 9 10 11 12 13 14 Loose or broken wire 08 from Lift Drive select switch 53 to controller enable switch 57 7 Check continuity Replace if defective Defective controller enable switch 57 7 Check switch Replace if defective Loose or broken wire 8A from controller enable relay 8CCR to speed steer and direction switches 97 1 to S7 6 Check continuity Replace if defective Loose or broken wire 8C from controller enable switch S7 7 to controller enable relay 8CCR Check continuity Replace if defective Defective controller enable relay 8CCR Check continuity Replace if defective Loose or broken wire 02 from controller enable relay 8CCR to controller harness Check continuity Replace if defective Loose or broken wire 10A from base terminal block to tilt switch TS1 Check continuity Replace if defective Defective tilt switch TS1 Check tilt switch Replace if defective Loose or broken wire 28 from tilt switch TS1 to terminal block TB1
229. tive Open diode D14E 1 Check diode Replace if defective Loose or broken wire 10E from base terminal block to control module CM1 at pin P2 2 CE Check continuity Replace if defective 4 1 25 Up Circuit Inoperative from Platform or Base Control Console without Outriggers 1 Loose or broken wire 14 from base terminal block TB1 to up relay jumper between wire 14 and 14 Check continuity Replace if defective Loose or broken up relay jumper wire between wires 14 and 14A Check continuity Replace if defective Loose or broken wire 14A from up relay jumper to base terminal block TB1 Check continuity Replace if defective Loose or broken wire 14 from base terminal block to control module CM1 at pin P2 3 Check continuity Replace if defective Loose or broken wire 14A from base terminal block 1 to lift valve coil 14 Check continuity Replace if defective Loose or broken wire 02 from lift valve coil 3H 14A to base terminal block TB1 Check continuity Replace if defective Defective lift valve coil 14 Check coil Replace if defective Defective diode D14A 1 Check diode Replace if defective 4 1 26 Platform will Not Lift from Platform or Base Control Console with Outriggers 1 Retracted Lift Operates Correctly with Outriggers Extended Outriggers not fully retracted Fully retract outrigger cylinders 2 Loose or broken wire 10A from base terminal block TB1 to
230. to position on 2 On base control console pull out stop button OG Function Tests Rocker Switch Drive Steer Low High Throttle Switch Operation Light Raise Off Lower Switch Off Lift Drive Key Switch Emergency Stop Button For CE select off platform base key switch to JA platform position On engine control console select off on start switch to on position For ANSI CSA with dual fuel engine select fuel 2 supply by moving fuel switch to either gasoline liquid propane gas position WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform Use the ladder of aerial platform to access platform Close the gate On platform control console insert key into off lift gt drive key switch and select Ej lift position Pull out emergency stop button A beeping sound should be audible and light should come on SJRT Compact Series Engine Powered SKYJACK Page 27 143899 Function Tests Drive Steer Enable Trigger Switch Torque Switch Low High Speed Range Switch Horn Pushbutton Glow Plug Choke Pushbutton Engine Start Pushbutton Lift Enable Pushbutton WARNING If beeping sound is not audible and light does not come on aerial platform must be tagged and placed out of service 8 Select low hig
231. trol 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 On platform control console pull out emergency stop button 4 Select low high throttle switch to low throttle position 5 Use the ladder to dismount from platform Ek Main Manifold Test Platform Engine Base Key Switch WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting 1 Pull out base emergency stop button 2 Insert key into platform engine base key switch select amp engine position and attempt to start engine Result Engine should not start 3 With key inserted into platform engine base key switch select base position and attempt to start engine Result Engine should start Test Emergency Stop 1 Push in base 16 emergency stop button Result Engine should shut down and aerial platform functions should not operate 2 Pulloutbase emergency stop button and restart engine 6 Turn main power disconnect switch to l on position SJRT Compact Series Engine Powered SKYJACK Page 33 143899 Function Tests Section 1 Scheduled Maintenance Emergency Stop Button
232. trol console plug Check for continuity Replace if defective 3 Defective outrigger enable switch 5 Check switch Replace if defective SKYJACK Page 22 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 36 All Outriggers Inoperative Base Controls only 1 Defective outrigger enable switch S9B Check switch Replace if defective 4 1 37 All Outriggers Inoperative Auto Level only 1 Led Power Indicator Light at Outrigger Control Module 1 Not On Constant Loose or broken wire 10A at pin 1 of the tilt switch connector to pin P2 12 on the outrigger control module OCM1 Check for continuity Replace if defective 2 Loose or broken wire 10A at pin 1 of the tilt switch connector to base terminal block TB1 Check for continuity Replace if defective 3 Loose or broken wire 02 at pin 3 of the tilt switch connector to pin P2 11 on the outrigger control module OCM1 Check for continuity Replace if defective 4 Loose or broken wire 02 at pin 3 of the tilt switch connector to base terminal block TB1 Check for continuity Replace if defective 5 Defective outrigger control module OCM1 Replace SJRT Compact Series SKYJACK Page 23 Engine Powered 143899 Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 1 38 A
233. trols or Platform Diesel Models 1 Loose or broken wire 8 from start switch 515 to glow plug switch 513 Platform only Check continuity Replace if defective 2 Defective glow plug switch 13 Platform only Check switch Replace if defective 3 Loose or broken wire 31 from glow plug switch 513 to base glow plug switch 531 Platform only Check continuity Replace if defective 4 Loose or broken wire 10B from base terminal block TB 1 to base glow plug switch 531 Base only Check continuity Replace if defective 5 Defective base glow plug switch S31 Base only Check switch Replace if defective 6 Loose or broken wire 31 from glow plug switch S31 to glow plug relay 31CR Check continuity Replace if defective 7 Loose or broken wire 02 from glow plug relay 31CR to base terminal block TB1 Check continuity Replace if defective 8 Loose or broken wire 103 from engine starter to relay 31CR Check continuity Replace if defective 9 Loose or broken wire 91A from relay 31CR to engine glow plugs EGP1 Check continuity Replace if defective 10 Defective glow plug relay 31CR Check relay Replace if defective 11 Defective glow plugs Check glow plugs Replace if defective SKYJACK Page 8 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 9 Choke Inoperative from Engine Controls or Platfo
234. ulic Generator LITT TUTTI 29 pes cpu 29 LER Fon ii RIT UU DIM 29 4 2 17 Right Front Outriggers Inoperative 29 4 2 18 Right Rear Outriggers 29 42 49 Len Rear Outriggers sucus is DI PH EAS 29 es 30 Load Sensing System Load Sense 31 Faon T I Mm 31 Not Ground MOOG NA 31 31 FOR TRE 31 toS 31 45 FUG EIO DNE Ew ORNA I dA 31 tor a aterert 31 ode FOO 31 31 tO TERRENT 31 FOr AREF 32 Flash Low FSi RANGO
235. until proper repairs are completed Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this aerial platform All maintenance and service procedures should be performed in a well lighted and well ventilated area Anyone operating or servicing this aerial platform must read and completely understand all operating instructions and safety hazards in this manual and operating manual All tools supports and lifting equipment to be used must be of proper rated load and in good working order before any service work begins Work area should be kept clean and free of debris to avoid contaminating components while servicing All service personnel must be familiar with employer and governmental regulations that apply to servicing this type of equipment Keep sparks and flames away from all flammable or combustible materials Properly dispose of all waste material such as lubricants rags and old parts according to the 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 SJRT Compact Series Engine Powered 143899 SKYJACK Page 13 Service and Maintenance Operator s Responsibility for Maintenance Hydraulic System amp Component Maintenance and Repair The fol
236. ve 139256 VALVE Forward drive 128318 VALVE Parallel forward drive Parts list continued on following page SJRT Compact Series SKYJACK Page 5 Engine Powered 143899 139351 128318 128318 128318 128318 128318 128318 128318 128318 128318 128318 137479 137479 137480 137480 137125 139450 106688 108778 139830 139450 111970 146109 105281 137510 137509 137510 137509 137508 114201 134432 104534 104534 106557 106557 104534 107271 137182 113752 SKYJACK Page 6 Service and Maintenance c c cl c Section System Component Identification and Schematics 3 3 Hydraulic Schematic Parts List Continued Skyjack Parts list continued from previous page VALVE Series parallel VALVE Right steer VALVE Left steer VALVE Retract outrigger left front VALVE Retract outrigger right front VALVE Retract outrigger right rear VALVE Retract outrigger left rear VALVE Extend outrigger left front VALVE Extend outrigger right front VALVE Extend outrigger right rear VALVE Extend outrigger left rear MOTOR Front left MOTOR Front right MOTOR Rear right MOTOR Rear left MANIFOLD BLOCK Main MANIFOLD BLOCK Splitter MANIFOLD BLOCK Lower holding valve MANIFOLD BLOCK Upper holding valve MANIFOLD BLOCK Sandwich MANIFOLD BLOCK Splitter MANIFOLD BLO
237. ve 4H 20A Check valve Replace if defective 2 Stuck or defective main counterbalance valve CB1 Check valve Replace if defective 4 2 11 Brakes Will Not Release 1 Stuck or defective brake valve 3H 30 Check valve Repair or replace if defective 2 Stuck or defective auto reset valve V6 Check valve Repair or replace if defective 4 2 12 Up Circuit Inoperative 1 Stuck or defective lift valve 3H 14A Check valve Repair or replace if defective 2 Misadjusted or defective lift relief valve R2 Adjust valve Replace if defective 3 Stuck or defective lowering valve 2H 13 Check valve Repair or replace if defective 4 Stuck or defective manual lowering valve V1 Check valve Repair or replace if defective 5 Open manual override on holding valve 2H13 1 or 2H13 2 Depress and turn manual override clockwise to close Replace if defective 6 Stuck holding valve 2H13 1 or 2H13 2 Check valves Repair or replace if defective SKYJACK Page 28 SJRT Compact Series Engine Powered 143899 Section 4 Troubleshooting Information Service and Maintenance Hydraulic System Continued 4 2 13 Down Circuit Inoperative 1 Stuck or defective lowering valve 2H 13 Check valve Repair or replace if defective 2 Stuck holding valve 2H13 1 or 2H13 2 Check valves Repair or replace if defective 3 Plugged lowering orifice O1 Clean or replace orifice 4 2 14 Hydraulic Generator Inoperative 1
238. wire 61 from outrigger limit switch LS61 to outrigger board Check continuity Replace if defective Open diode D36 on outrigger board Check diode Replace if defective Open diode D36 1 at pin 1 on CN22 on outrigger board Check diode Replace if defective Section 4 Troubleshooting Information 4 1 27 Platform will Not Lift from Platform or Base Control Console with Outriggers 1 2 Extended Outriggers not extended enough Extend outriggers to take weight off tires refer to operator section Loose or broken wire 10A from base terminal block TB1 to pin 4 on connector CN14 at the outrigger board Check continuity Replace if defective Loose or broken wire 10A from outrigger board to outrigger limit switch LS68 Check continuity Replace if defective Defective outrigger limit switch LS68 Check switch Replace if defective Loose or broken wire 68A from outrigger limit switch LS68 to outrigger board Check continuity Replace if defective Loose or broken wire 10A from outrigger board to outrigger limit switch LS67 Check continuity Replace if defective Defective outrigger limit switch 1567 Check switch Replace if defective Loose or broken wire 67A from outrigger limit switch LS67 to outrigger board Check continuity Replace if defective Loose or broken wire 10A from outrigger board to outrigger limit switch LS66 Check continuity Replace if defective SKYJACK Page 18
239. ww skyjack com Operator The operator must read and completely understand both this operating manual and the safety panel label located on the platform and all other warnings in this manual and on the aerial platform Compare the labels on the aerial platform with the labels found within this manual If any labels are damaged or missing replace them immediately Service Policy and Warranty SKYJACK warrants each new SJRT series work platform to be free of defective parts and workmanship for the first 24 months Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor Contact the SKYJACK Service Department for warranty statement extensions or exclusions Optional Accessories The SKYJACK aerial platform is designed to accept a variety of optional accessories These are listed under Standard and Optional Features in Table 2 1 of the operating manual Operating instructions for these options if equipped are located in section 2 of the operating manual For non standard components or systems contact the SKYJACK Service Department at North America amp Asia Europe 2 800 275 9522 2 44 1691 676 235 630 262 0006 44 1691 676 239 Include the model and serial number for each applicable aerial platform SJRT Compact Series SKYJACK 7 Engine Powered 143899 Service and Maintenance Operator s Responsibility for Maintenanc
240. y Replace if defective Loose or broken wire 02 from base terminal block TB1 to outrigger generator harness connector Check continuity Replace if defective Loose or broken wire 14 from base terminal block to control module CM1 at pin P2 3 Check continuity Replace if defective Defective up relay 14CR Check relay Replace if defective Loose or broken wire 36A from 10 on connector CN14 to up relay 14CR Check continuity Replace if defective Loose or broken wire 14A from up relay 14CR to base terminal block TB1 Check continuity Replace if defective 4 1 29 Down Circuit Inoperative from Platform 1 Lift Drive select switch 53 in drive position Select lift on lift drive select switch 2 Defective reverse switch S7 4 on controller 57 Check continuity through switch Replace if defective 3 Loose or broken wire A from reverse switch S7 4 to contact on lift drive select switch S3 Check continuity Replace if defective 4 Defective contact on lift drive select switch S3 between wire A and wire 13 Check continuity through contact Replace if defective 5 Loose or broken wire 13 from lift drive select switch S3 to base terminal block TB1 Check continuity Replace if defective 6 Loose or broken wire 13 from base terminal block TB1 to lowering valve 2H 13 or holding valve 2H 13 1 and 2H 13 2 Check continuity Replace if defective SJRT Compact Series SKYJACK Page 19 Engine Powe
241. y scheduled maintenance inspection procedure refer to service bulletins found in our web site www skyjack com for updates related to service and maintenance of this aerial platform Maintenance and Inspection Death or injury can result if the aerial platform is not kept in good working order Inspection and maintenance should be performed by competent personnel who are trained and qualified on maintenance of this aerial platform WARNING Failure to perform each procedure as pre sented and scheduled may cause death serious injury or substantial damage NOTE Preventive maintenance is the easiest and least expensive type of maintenance e Unless otherwise specified perform each maintenance procedure with the aerial platform in the following configuration Aerial platform parked on a flat and level surface Disconnect the battery by turning the main power disconnect switch to the OFF position Repair any damaged or malfunction components before operating aerial platform e Keep records on all inspections Maintenance Instructions This manual consists of four schedules to be done for maintaining on an aerial platform Inspection schedule frequency is shown below Inspection Schedule Daily A Frequently A B Annually A B C Bi annually A B C D e Make copies of the maintenance and inspection checklist to be used for each inspection e Check the schedule on the checklist for the type of inspection to
242. yjack service manual As each item is inspected write the apropriate grade in the box INSPECTION FREQUENCY DAILY PASS LJ FREQUENTLY F FAIL LJ ANNUALLY R REPAIRED BI ANNUALLY Schedule Schedule Maintenance nspections B B B C B B B Labels Limit Switches gt Emergency Lowering Access If Equipped Electrical and Control Components Main Power Disconnect Switch Base Control Switches Battery Manifolds Electrical Panel Tilt Sensor Equipped Load Tilt Sensor CE m 5 5 o F d a Engine Control Console Radiator Muffler and Exhaust Engine Tray Hydraulic Pump Engine Air Filter Engine Oil Level Engine Fuel Filter 2 0 0 5 5 lt Hydraulic Tank Hydraulic Oil 9 3 3 3 5 lt Lanyard Attachment Anchors AC Outlet on Platform Platform Control Console Powered Extension Control Console Equipped 2 2 y 3 Scissor Guards Equipped Sliders Maintenance Support Scissor Assembly Scissor Bumpers Lift Cylinder s I nspection Schedule Frequently t Annuallyt Bi annuallyt A B C D 9

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