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Skyjack SJ 3220 Service Manual

Skyjack SJ 3220
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Service Manual
SJIII Conventional Series
MODELS SJ 3220 SJ 3226 SJ 4620 SJ 4626 SJ 4632
Part No. 143911AD November 2013

Table of Contents

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Skyjack SJ 3220 Specifications

General IconGeneral
BrandSkyjack
ModelSJ 3220
CategoryBoom Lifts
LanguageEnglish

Summary

Models and Series Information

SJIII Conventional Series Service Manual

Identifies the title and series of the service manual for SJIII conventional models.

Manual Sections Overview

Scheduled Maintenance Inspections

Details scheduled maintenance inspection procedures for the equipment.

Maintenance Tables

Provides maintenance tables and specifications for the equipment.

Schematics and Diagrams

Contains diagrams and schematics of the equipment's systems.

Troubleshooting Information

Offers troubleshooting guidance for common issues.

Procedures

Outlines step-by-step procedures for maintenance and calibration.

Scheduled Maintenance and Operator Responsibilities

Operator Responsibilities

Defines the operator's duties and responsibilities for safe operation.

Manual Scope and Operator Safety

Manual Scope and Applicability

Clarifies the scope and applicability of the manual to different versions.

Safety Reminders and Electrocution Hazards

Operator Safety Reminders

Emphasizes operator responsibilities and safety reminders.

Electrocution Hazard Warnings

Warns about electrocution hazards and safe approach distances.

General Safety Precautions

General Safety Precautions

Provides crucial safety precautions for operating the aerial platform.

Additional Safety Precautions

Additional Safety Precautions

Lists important safety precautions to prevent hazards during operation.

Platform Entry/Exit and Hazard Safety

Platform Entry/Exit and Hazard Safety

Details safety precautions regarding platform entry, exit, and operational hazards.

Maintenance Schedules and Safety Tips

Maintenance and Inspection Schedule

Covers maintenance and inspection schedules, parts, and safety tips.

Hydraulic System Maintenance

Hydraulic System Maintenance

Provides guidance on hydraulic system maintenance and hints for efficiency.

Maintenance and Inspection Procedures

Service and Maintenance Procedures

Explains the maintenance and inspection procedures and schedules.

Service and Maintenance Overview

Scheduled Maintenance Overview

Contains maintenance and inspection schedules for the aerial platform.

Maintenance Schedules and Function Tests

Maintenance and Inspection Checklist

Lists scheduled maintenance inspections and function tests with frequencies.

Scheduled Maintenance Inspections

Scheduled Maintenance Inspections

Details scheduled maintenance inspections for electrical and hydraulic systems.

Entrance Side Maintenance Checks

Entrance Side Maintenance Checks

Covers maintenance checks for the entrance side components.

Battery Tray Side Maintenance Checks

Battery Tray Side Maintenance Checks

Details maintenance checks for the battery tray side components.

Chassis Component Maintenance Checks

Chassis Component Maintenance Checks

Covers maintenance checks for steer cylinder, wheel/tire, tie rod, and greasing points.

Hydraulic/Electric Tray Side Maintenance Checks

Hydraulic/Electric Tray Side Maintenance Checks

Details maintenance checks for hydraulic/electric tray side components.

Platform Assembly Maintenance Checks

Platform Assembly Maintenance Checks

Covers maintenance checks for the platform assembly and its components.

Lifting Mechanism Maintenance Checks

Lifting Mechanism Maintenance Checks

Details maintenance checks for the lifting mechanism and its parts.

Function Tests Overview

Function Tests Overview

Outlines function tests to be performed before putting the aerial platform into service.

Test Main Power Disconnect Switch

Details the procedure to test the main power disconnect switch.

Base Control Console Testing

Describes testing procedures for the base control console.

Base Control Console Function Tests

Test Base Emergency Stop

Details the procedure to test the base emergency stop button.

Test Off/Platform/Base Switch

Outlines testing procedures for the off/platform/base key switch.

Emergency Lowering and Free-wheeling Tests

Test Emergency Lowering

Details the procedure for testing the emergency lowering function.

Test Free-wheeling

Outlines the procedure to test the free-wheeling function.

Platform Control Console Function Tests

Platform Control Console Testing

Details testing procedures for the platform control console functions.

Test Platform Emergency Stop

Describes testing the platform's emergency stop button.

Steering and Driving Function Tests

Test Steering Function

Details the procedure to test the steering function of the platform.

Test Driving Function

Outlines testing the driving functions (forward and reverse).

Brake and Raising/Lowering Function Tests

Test Braking System

Describes testing the platform's braking system.

Test Platform Raising/Lowering

Outlines testing the platform's raising and lowering capabilities.

CE Lowering Warning, Horn, and Pothole Sensor Tests

Test CE Lowering Warning

Details testing the CE lowering warning system.

Test Horn Function

Outlines testing the horn function.

Test Pothole Sensor

Describes testing the pothole protection sensor system.

Elevated Drive Speed and Tilt Sensor Tests

Test Elevated Drive Speed

Details testing the elevated drive speed.

Test ANSI/CSA Tilt Sensor

Outlines testing the ANSI/CSA tilt sensor.

Maintenance Tables and Diagrams Overview

Table of Contents

Lists the contents of Section 2.

Specifications and Features (ANSI/CSA)

ANSI/CSA Specifications and Features

Provides specifications and features for ANSI/CSA models.

Specifications and Features (ANSI/CSA) Continued

ANSI/CSA Specifications and Features (Continued)

Continues specifications and features for ANSI/CSA models.

Specifications and Features (CE)

CE Specifications and Features

Provides specifications and features for CE models.

Specifications and Features (CE) Continued

CE Specifications and Features (Continued)

Continues specifications and features for CE models.

Specifications and Features (AS)

AS Specifications and Features

Provides specifications and features for AS models.

Specifications and Features (AS) Continued

AS Specifications and Features (Continued)

Continues specifications and features for AS models.

Floor Loading Pressure Calculations

Floor Loading Pressure Calculations

Explains floor loading pressure calculations and tire recommendations.

Floor Loading Pressure (ANSI/CSA)

ANSI/CSA Floor Loading Pressure

Presents floor loading pressure data for ANSI/CSA models.

Floor Loading Pressure (CE)

CE Floor Loading Pressure

Provides floor loading pressure data for CE models.

Floor Loading Pressure (AS)

AS Floor Loading Pressure

Presents floor loading pressure data for AS models.

Maximum Platform Capacities (ANSI/CSA)

ANSI/CSA Max Platform Capacities

Details maximum platform capacities for ANSI/CSA models.

Maximum Platform Capacities (CE)

CE Max Platform Capacities

Provides maximum platform capacities and wind speed data for CE models.

Maximum Platform Capacities (AS)

AS Max Platform Capacities

Details maximum platform capacities for AS models.

Torque Specifications

Torque Specifications

Lists torque specifications for various components.

System Component Identification and Schematics

Table of Contents

Lists the contents of Section 3.

Electrical Symbol Chart

Electrical Symbol Chart

Provides an electrical symbol chart for understanding schematics.

Hydraulic Symbol Chart

Hydraulic Symbol Chart

Offers a hydraulic symbol chart for interpreting hydraulic diagrams.

Wire Number and Color Code

Wire Number and Color Code

Details the wire number and color code for electrical diagrams.

Hydraulic Manifold and Port Identifications

Hydraulic Manifold and Port Identifications

Identifies hydraulic manifold and port connections.

Hydraulic Schematic Parts List

Hydraulic Schematic Parts List

Lists hydraulic schematic parts.

Hydraulic Schematic Parts List Continued

Hydraulic Schematic Parts List (Continued)

Continues the list of hydraulic schematic parts.

Electrical Components Parts List

Electrical Components Parts List

Lists electrical components.

Electrical Components Parts List Continued

Electrical Components Parts List (Continued)

Continues the list of electrical components.

Electrical Components Parts List Continued

Electrical Components Parts List (Continued)

Continues the list of electrical components.

Platform Control Console Diagram (Toggle Switch)

Platform Control Console Diagram (Toggle Switch)

Shows the platform control console diagram for toggle switch models.

Platform Control Console Diagram (Rotary Switch)

Platform Control Console Diagram (Rotary Switch)

Displays the platform control console diagram for rotary switch models.

Powered Extension Platform Diagram (Toggle Switch)

Powered Extension Platform Diagram (Toggle Switch)

Illustrates the powered extension platform modification diagram for toggle switch.

Powered Extension Platform Diagram (Rotary Switch)

Powered Extension Platform Diagram (Rotary Switch)

Shows the powered extension platform modification diagram for rotary switch.

Power Extension Platform Console and Harness

Power Extension Platform Console and Harness

Details the power extension platform control console and harness.

Base Control Console Diagram

Base Control Console Diagram

Provides the base control console diagram.

Scissor Arm Control Cable

Scissor Arm Control Cable

Illustrates the scissor arm control cable connections.

Hydraulic Schematic (Models 322x)

Hydraulic Schematic (Models 322x)

Shows the hydraulic schematic for Models 322x.

Hydraulic Schematic (Models 46xx)

Hydraulic Schematic (Models 46xx)

Provides the hydraulic schematic for Models 46xx.

Main Manifold and Holding Valve Harness (ANSI/CSA & EE Rated)

Main Manifold Harness (ANSI/CSA & EE Rated)

Details the main manifold and holding valve harness for ANSI/CSA & EE rated.

Main Manifold and Holding Valve Harness (CE)

Main Manifold Harness (CE)

Shows the main manifold and holding valve harness for CE models.

Electrical Panel Diagram (ANSI/CSA)

Electrical Panel Diagram (ANSI/CSA)

Provides the electrical panel diagram for ANSI/CSA models.

Electrical Panel Diagram (CE)

Electrical Panel Diagram (CE)

Shows the electrical panel diagram for CE models.

Electrical Panel Diagram (ANSI/CSA EE Rated)

Electrical Panel Diagram (ANSI/CSA EE Rated)

Provides the electrical panel diagram for ANSI/CSA EE Rated models.

Harness Diagrams

Harness Diagrams

Illustrates the harness diagrams for various functions.

Limit Switch Assemblies Diagrams

Limit Switch Assemblies Diagrams

Shows limit switch assembly diagrams for different models and ratings.

Horn, Tilt Switch, and Flashing Light Diagrams

Horn, Tilt Switch, Flashing Light Diagrams

Details the horn, tilt switch, and flashing light diagrams.

Control Module and Beeper Diagram (CE)

Control Module and Beeper Diagram (CE)

Provides the control module and beeper diagram for CE models.

Electrical Schematic (ANSI/CSA - No Options)

Electrical Schematic (ANSI/CSA - No Options)

Shows the electrical schematic for ANSI/CSA models without options.

Electrical Schematic (ANSI/CSA - All Options)

Electrical Schematic (ANSI/CSA - All Options)

Provides the electrical schematic for ANSI/CSA models with all options.

Electrical Schematic (322x CE - All Options)

Electrical Schematic (322x CE - All Options)

Shows the electrical schematic for Models 322x CE with all options.

Electrical Schematic (46xx CE - All Options)

Electrical Schematic (46xx CE - All Options)

Provides the electrical schematic for Models 46xx CE with all options.

Electrical Schematic (ANSI/CSA EE Rated - No Options)

Electrical Schematic (ANSI/CSA EE Rated - No Options)

Shows the electrical schematic for ANSI/CSA EE Rated models without options.

Electrical Schematic (ANSI/CSA EE Rated - All Options)

Electrical Schematic (ANSI/CSA EE Rated - All Options)

Provides the electrical schematic for ANSI/CSA EE Rated models with all options.

Troubleshooting Information

Electrical System Troubleshooting

Lists troubleshooting steps for electrical system problems.

Troubleshooting Introduction

Troubleshooting Introduction

Introduces the troubleshooting section and its format.

Electrical System Troubleshooting - Inoperative Controls

Inoperative Controls Troubleshooting

Details troubleshooting steps for inoperative controls and related electrical issues.

Electrical System Troubleshooting - More Inoperative Controls

More Inoperative Controls Troubleshooting

Continues troubleshooting for electrical system problems, including inoperative controls.

Electrical System Troubleshooting - CE Functions and Platform Controls

CE Functions and Platform Controls Troubleshooting

Provides troubleshooting steps for CE-specific drive/up function and platform control issues.

Electrical System Troubleshooting - Tilt and Drive Issues

Tilt and Drive Issues Troubleshooting

Continues troubleshooting for electrical system issues, including tilt and drive problems.

Electrical System Troubleshooting - Lowered Platform Issues

Lowered Platform Issues Troubleshooting

Details troubleshooting for steer and drive inoperability when the platform is lowered.

Electrical System Troubleshooting - Elevated and Slow Drive Issues

Elevated and Slow Drive Issues Troubleshooting

Covers troubleshooting for drive/steer issues when elevated and slow drive speeds.

Electrical System Troubleshooting - Drive, Brake, and Torque

Drive, Brake, Torque Troubleshooting

Provides troubleshooting for forward/reverse drive, brake release, and torque issues.

Electrical System Troubleshooting - Steer and Speed Issues

Steer and Speed Issues Troubleshooting

Details troubleshooting for steer inoperability and drive/lift speed issues.

Electrical System Troubleshooting - Extension Platform Issues

Extension Platform Issues Troubleshooting

Covers troubleshooting for power extension platform issues and multiple functions.

Hydraulic System Troubleshooting - General Issues

General Hydraulic System Troubleshooting

Lists troubleshooting steps for general hydraulic system problems.

Hydraulic System Troubleshooting - Drive and Brake Issues

Drive and Brake Issues Troubleshooting

Continues hydraulic troubleshooting for slow drives, forward/reverse, and brake release.

Hydraulic System Troubleshooting - Other Issues

Other Hydraulic Issues Troubleshooting

Details hydraulic troubleshooting for grades, steering, sluggish systems, and extension issues.

CE Load Sensing System Troubleshooting - Flash Codes F01-F11

Flash Code F01: Check HWFS

Explains Flash Code F01 related to HWFS startup tests.

Flash Code F02: Not Ground Mode

Explains Flash Code F02 for not being in ground mode.

Flash Code F03: Not Stopped

Explains Flash Code F03 when the machine is not stopped.

Flash Code F04: Tilted

Explains Flash Code F04 for a tilted machine.

Flash Code F05: Bad Height

Explains Flash Code F05 for bad height sensor output during calibration.

Flash Code F06: Check Elevation

Explains Flash Code F06 related to the elevation switch.

Flash Code F08: Check Elevation

Explains Flash Code F08 for elevation switch issues during lift.

Flash Code F09: Bad Height

Explains Flash Code F09 for bad height sensor output during lift.

Flash Code F10: Bad Height

Explains Flash Code F10 for bad height sensor output at end of lift.

Flash Code F11: Not Up

Explains Flash Code F11 when UP function is not selected.

CE Load Sensing System Troubleshooting - Flash Codes F12-F18

Flash Code F12: Too Many

Explains Flash Code F12 for excessive DYNAMIC lift time.

Flash Code F13: Low Height Range

Explains Flash Code F13 for low height range estimation.

Flash Code F14: Bad Height

Explains Flash Code F14 for bad height sensor output during DYNAMIC lift.

Flash Code F15: Check Elevation

Explains Flash Code F15 for elevation switch issues after lowering.

Flash Code F16: Low Elevation Open

Explains Flash Code F16 for elevation switch opening at low height during lift.

Flash Code F17: High Elevation Open

Explains Flash Code F17 for elevation switch opening at high height during lift.

Flash Code F18: Low Elevation Close

Explains Flash Code F18 for elevation switch closing at low height during lower.

CE Load Sensing System Troubleshooting - Flash Codes F19-F26

Flash Code F19: High Elevation Close

Explains Flash Code F19 for elevation switch closing at high height during lower.

Flash Code F20: Height Not Zero

Explains Flash Code F20 for incorrect platform height after lowering.

Flash Code F21: Height Not Zero

Explains Flash Code F21 for incorrect platform height before raising.

Flash Code F22: Height Not 100%

Explains Flash Code F22 for incorrect platform height after raising.

Flash Code F23: Height Not 100%

Explains Flash Code F23 for incorrect platform height before lowering.

Flash Code F24: Too Many Measurements

Explains Flash Code F24 for too many static measurements.

Flash Code F25: Check Elevation

Explains Flash Code F25 for elevation switch issues during STATIC phases.

Flash Code F26: Check Elevation

Explains Flash Code F26 for elevation switch issues during STATIC phases.

CE Load Sensing System Troubleshooting - Flash Codes F27-F40

Flash Code F27: Bad Height

Explains Flash Code F27 for bad height sensor output during STATIC phases.

Flash Code F30: Bad Heights

Explains Flash Code F30 for incorrect height progression during STATIC lift/lower.

Flash Code F31: Reject Curve

Explains Flash Code F31 for an unacceptable DYNAMIC pressure curve.

Flash Code F32: Reject Curve

Explains Flash Code F32 for an unacceptable DYNAMIC pressure curve (low pressure point).

Flash Code F33: Reject Curve

Explains Flash Code F33 for an unacceptable DYNAMIC pressure curve (high pressure point).

Flash Code F34: Reject Curve

Explains Flash Code F34 for insufficient pressure difference in DYNAMIC curve.

Flash Code F40: Reject Delta

Explains Flash Code F40 for insufficient pressure difference between loaded/empty.

CE Load Sensing System Troubleshooting - Flash Codes F42-F47

Flash Code F42: Low Pressure

Explains Flash Code F42 for low pressure during DYNAMIC lift.

Flash Code F43: High Pressure

Explains Flash Code F43 for high pressure during DYNAMIC lift.

Flash Code F44: Low Pressure

Explains Flash Code F44 for low pressure at STATIC measurement.

Flash Code F45: High Pressure

Explains Flash Code F45 for high pressure at STATIC measurement.

Flash Code F46: Check Elevation

Explains Flash Code F46 for elevation switch opening multiple times during lift.

Flash Code F47: Check Elevation

Explains Flash Code F47 for elevation switch closing multiple times during lower.

Procedures Overview

Service and Maintenance Procedures

Covers general service and maintenance procedures.

Platform Procedures

Details procedures related to the OEM controller and platform electronics.

Base Procedures

Outlines procedures for base system adjustments and tilt switch setup.

CE Load Sensing System Procedures

Provides procedures for load sensing system calibration and error codes.

General Procedures and Adjustments

General Procedures

Provides general information on using the servicing and maintenance procedures.

Safety and Workmanship Procedures

Emphasizes safety and proper techniques for maintenance.

Platform Controller Electronics

Explains OEM controller electronics and flow control.

Trimpot Adjustment Procedures

Describes trimpot adjustments for output control.

OEM Controller Troubleshooting

OEM Controller Troubleshooting

Provides troubleshooting steps for OEM controller problems.

OEM Controller Switch Wiring

OEM Controller Switch Wiring

Details the wiring connections for the OEM controller switches.

Base Pressure Adjustments

Base Pressure Adjustments

Outlines procedures for system relief and lift pressure adjustments.

Electronic Tilt Switch Setup Procedures

Electronic Tilt Switch Setup

Covers tilt switch replacement, reprogramming, and testing procedures.

Reprogramming Existing Tilt Switch

Reprogramming Tilt Switch

Details the step-by-step process for reprogramming the tilt switch.

Test and Verify Tilt Circuit

Test and Verify Tilt Circuit

Outlines the procedure to test and verify the tilt circuit.

Control Module Pin Reference Chart

Control Module Pin Reference Chart

Provides a pin reference chart for the control module.

LED Error Codes - Quick Reference

LED Error Codes - Quick Reference

Offers a quick reference chart for LED error codes.

LED Error Codes - Code Breakdown

LED Error Codes - Code Breakdown

Provides a breakdown of LED error codes and their meanings.

LED Error Codes - Code Breakdown Continued

LED Error Codes - Code Breakdown (Continued)

Continues the breakdown of LED error codes and their meanings.

Diagnostic Tool Key Functions

Diagnostic Tool Key Functions

Explains the key functions of the calibration and diagnostic tool.

Control Module Load Calibration Codes

Load Calibration Codes & Definitions

Lists and defines code messages for control module load calibration.

Control Module Load Calibration Codes Continued

Load Calibration Codes & Definitions (Continued)

Continues definitions of code messages for load calibration.

Control Module Load Calibration Messages

Load Calibration Messages

Lists and defines messages related to load calibration phases.

Calibration Display Messages

Calibration Display Messages

Defines various messages displayed during calibration.

Control Module Load Calibration Procedure

Load Calibration Procedure

Provides step-by-step instructions for control module load calibration.

Load Calibration Procedure Steps

Load Calibration Procedure Steps

Continues the control module load calibration procedure.

Load Calibration Procedure Continued

Load Calibration Procedure Continued

Continues the control module load calibration procedure.

Load Calibration Procedure Completion

Load Calibration Procedure Completion

Concludes the control module load calibration procedure.

Curve and Group Codes Chart

Curve/Group Codes Chart

Lists curve and group codes for different models and extension platforms.

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