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SJ 4620
Skyjack SJ 4620 Service Manual
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SJIII Conventional Series
143911
SK
YJACK, Page 28
A
B
C
D
E
F
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V
Z
Y
X
W
3.19 Harnesses Diagram
M146588AA_S3
2
1
PIN 1 - 3A BLACK
PIN 2 - 05 WHITE
BACK VIEW
TO ELECTRIC P
ANEL
3A - BLACK
05 - WHITE
(OPT) - GREEN
49
02
TO ELECTRIC P
ANEL
02 - WHITE
22 - GREEN
02 - WHITE
49 - BLACK
TO HORN
02
22
TO FLASHING LIGHT
22 - GREEN
02 - WHITE
49 - BLACK
FROM ELECTRIC P
ANEL
28 BLACK
28E WHITE
60 GREEN
TO CONTROL MODULE - P3
PIN 3 - 60 GREEN
PIN 4 - 28 BLACK
PIN 6 - 28E WHITE
PIN 4 - N/U
TO TIL
T SWIT
CH
PIN 1 - 19 (BLACK)
PIN 2 - 28 (GREEN)
PIN 3 - 02 (WHITE)
DEUTSCH
1
4
3
2
TO ELECTRIC P
ANEL
02 - WHITE
28 - GREEN
19 - BLACK
FROM ELECTRIC P
ANEL
02 - WHITE
7A - RED
10E - BLACK/WHITE
13 - ORANGE
14 - BLACK
15 - BLUE
16 - WHITE/BLACK
18B - RED/BLACK
N/U - BLUE/BLACK
N/U - ORANGE/BLACK
CONTROL MODULE - P2
PIN 1 - N/U
PIN 2 - 10E BLACK/WHITE
PIN 3 - 14 BLACK
PIN 4 - 13 ORANGE
PIN 5 - N/U
PIN 6 - N/U
PIN 7 - 16 WHITE/BLACK
PIN 8 - 15 BLUE
PIN 9 - N/U
PIN 10 - 18B RED/BLACK
PIN 11 - 02 WHITE
PIN 12 - 7A RED
11
10
12
BACK VIEW
3
9
6
2
1
8
7
5
4
49
02
CONTROL MODULE HARNESSES
CHARGER CUTOUT HARNESS
TIL
T SWITCH HARNESS
HORN HARNESS
HORN/FLASHING LIGHT HARNESS
TO ELECTRIC P
ANEL
02 - WHITE
02 - WHITE
49 - BLACK
TO HORN
49 - BLACK
70
72
Table of Contents
1 Section 1 Schedule Maintenance Inspections
5
Table of Contents
5
Aerial Platform Definition
6
Purpose of Equipment
6
Use of Equipment
6
Manuals
6
Operator
6
Service Policy and Warranty
6
Optional Accessories
6
Scope of this Manual
7
Operator Safety Reminders
8
Electrocution Hazard
8
Safety Precautions
9
Maintenance and Inspection Schedule
12
Owner's Annual Inspection Record
12
Replacement Parts
12
Maintenance and Service Safety Tips
12
Hydraulic System & Component Maintenance and Repair
13
Maintenance Hints
13
Service and Maintenance
14
About this Section
14
Service Bulletins
14
Maintenance and Inspection
14
Maintenance Instructions
14
Scheduled Maintenance
14
Owner's Annual Inspection Record
15
Maintenance and Inspection Checklist
16
Schedule Maintenance Inspections
16
Scheduled Maintenance Inspections
17
Function Tests
24
Section 2 Maintenance Tables and Diagrams
32
Table of Contents
32
Tables
32
Section 3 System Component Idenification and Schematics
47
Electrical Symbol Chart
48
Hydraulic Symbol Chart
49
Wire Number and Color Code
50
Hydraulic Manifold and Port Identifications
51
Electrical Components Parts List
54
Platform Control Console Diagram (with Toggle Switch)
57
Platform Control Console Diagram (with Rotary Switch)
58
Platform Control Console with Toggle Switch - Powered Extension Platform Modification Diagram
59
Platform Control Console with Rotary Switch - Powered Extension Platform Modification Diagram
60
Power Extension Platform Control Console and Harness
61
Base Control Console Diagram
62
Scissor Arm Control Cable
63
Hydraulic Schematic (Models 322X)
64
Hydraulic Schematic (Models 46Xx)
65
Main Manifold Harness and Holding Valve Harness (ANSI/CSA & EE Rated)
66
Main Manifold Harness and Holding Valve Harness (CE)
67
Electrical Panel Diagram (ANSI/CSA)
68
Electrical Panel Diagram (CE)
69
Electrical Panel Diagram (ANSI/CSA EE Rated)
70
Harnesses Diagram
71
Limit Switch Assemblies Diagram
72
Horn/Tilt Switch/Flashing Light Diagram
73
Control Module and Beeper Diagram (CE)
74
Electrical Schematic (ANSI/CSA - Equipped with no Options)
75
Electrical Schematic (ANSI/CSA - Equipped with no Options)
76
Electrical Schematic (ANSI/CSA - Equipped with All Options)
77
Electrical Schematic (ANSI/CSA - Equipped with All Options)
78
Electrical Schematic (Models 322X CE - Equipped with All Options)
79
Electrical Schematic (Models 46Xx CE - Equipped with All Options)
81
Electrical Schematic (Models 46Xx CE - Equipped with All Options)
82
Electrical Schematic (ANSI/CSA EE Rated - Equipped with no Options)
83
Electrical Schematic (ANSI/CSA EE Rated - Equipped with no Options)
84
Electrical Schematic (ANSI/CSA EE Rated - Equipped with All Options)
85
Electrical Schematic (ANSI/CSA EE Rated - Equipped with All Options)
86
Section 4 Troubleshooting Information
87
Introduction
89
All Controls Except for down Function Inoperative
90
All Controls Inoperative
90
Electrical System
90
All Controls Inoperative from Base Control Console
91
All Controls Inoperative from Platform Control Console
91
No down or Reverse Only Function from Platform Controls
92
No Drive or up Function from Platform or Base Controls (CE Only)
92
No up Function from Platform or Base Control Console
92
No up or Forward Only Function from Platform Control Console
92
10 No down Function from Platform or Base Control Console (CE Only)
93
No down Function from Platform or Base Control Console (ANSI/CSA Only)
93
11 No up Function from Base Control Console
94
13 Steer Only Inoperative
94
14 Drive Only Inoperative
94
15 No Drive or Steer When Platform Fully Lowered
94
16 No Drive or Steer When Platform Elevated
95
17 Elevated Drive Speed Does Not Activate
95
18 Work Platform Drives in Slow Speed Only
95
19 Forward Drive Function Inoperative
96
20 Reverse Drive Function Inoperative
96
21 Brake will Not Release
96
22 High/Low Torque Inoperative
96
23 Right Steer Inoperative
97
25 Power Extension Platform will Not Extend or Retract
98
26 Power Extension Platform will Not Extend
98
28 Two or more Functions at One Time
98
All Function Inoperative
99
Hydraulic System
99
Platform Does Not Lift
99
Platform Drifts down
99
Platform Lifts Slowly
99
Platform will Not Lower
99
Brake(S) will Not Release
100
Brake(S) will Not Release (Additional for Machines with Integral Brakes)
100
Platform Drives Slow
100
Platform will Not Drive in Forward or Reverse
100
10 Aerial Platform will Not Hold on a Grade (Machines with Integrals Brakes)
101
11 Platform Does Not Steer
101
12 All System Sluggish
101
13 Power Extension Platform will Not Extend or Retract
101
14 High/Low Torque Inoperative
101
Section 5 Procedures
107
General
108
OEM Controller Electronics Information
108
Safety and Workmanship
108
Service and Maintenance
108
OEM Controller Troubleshooting
109
OEM Controller Switch Wiring
110
Base
111
Lift Pressure Adjustment
111
System Relief Pressure Adjustment
111
Electronic Tilt Switch Setup Procedure
112
Tilt Switch Replacement
112
Reprogramming Existing Tilt Switch
114
Test and Verify Tilt Circuit
115
Control Module Pin Reference Chart
116
Load Sensing System - CE
116
LED Error Codes - Quick Reference Chart
117
LED Error Codes - Code Breakdown Chart
118
Hand Held Calibration/Diagnostic Tool Key Functions
120
Control Module Load Calibration - Code Messages & Definitions
121
Control Module Load Calibration Procedure
125
Curve/Group Codes Chart
129
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Skyjack SJ 4620 Specifications
General
Brand
Skyjack
Model
SJ 4620
Category
Boom Lifts
Language
English
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