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SJ 4620
Skyjack SJ 4620 Service Manual
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SK
YJACK, Page 35
SJIII Conventional Series
143911
A
B
C
D
E
F
G
H
V
Z
Y
X
W
3.24b Electrical Schematic (ANSI/CSA - Equipped with all options)
M146624AC
LIMIT SWITCHES N.C.H.O.
POTHOLE PROTECTION
72
LS4
71
LS5
19
BREAKER
15A CIRCUIT
HORN
POWER ON LED
LOW VOL
T
AGE
PROTECTION
8A
NCHO
ENABLE
S7-6
02
59A
59
RST2
60
02
LED-1
LIGHT
POWER ON/LSS
36
37
CB2
3A
03
CB1
02
00
49
GREEN/WHITE
5A
EMERGENCY
S28
SWITCH
STOP
7A
S10
KEY SWITCH
IDLE/PL
TF/BASE
(IN IDLE POSITION)
8C
07
10E
17B
17B
LS1A
LS1B
18
71
24V
GREEN/BLACK
RED
21B
07
ORANGE
13
49
BLACK
14
10E
CRD2
CRD1
CRD3
WHITE
LS6
71
02
D21B-2
D17-1
RED/BLACK
ORANGE/BLACK
18
59
D21B-1
WHITE/BLACK
BLUE
BLACK/WHITE
17
16
D16
15
D15
D17
23
D23
BLUE/BLACK
24
D24
HOLDING VAL
VE
00
FL
-22
13
22
29
FLASHER
FL
-29
DCM1
M
02
00
DO2-1
13
2H-13-1
2H-13
2H-13-2
3
BATTERY
P
ACK
1
CHARGER
2
6
PUMP MOTOR
5
4
7
15A CIRCUIT
8
BREAKER
OPTION
FLASHING LIGHT
11
9
10
SINGLE CYLINDER
HOLDING VAL
VE
DOWN SOLENOID
12
13
3H-17A
28CR
14A
D14A
14
D14E
LS3
D14E-1
14E
13
19
19
D21A
19
D21-1
TS1
28
02
19
TT
D28A
28A
29
19A
D19A
19A
BP
-29
3H-14A
29
DO2-2
19A
02
02
CAP1
02
19A
2H-18A
3H-18A-1
D17C
D21
18A
21
59
21A
D17C-1
17CR
17
02
17C
21CCR
21C
RST3
3H-18A-2
18A
02
4H-16
DO2-3
4H-15
DO2-4
DO2-5
4H-23
HOURMETER
19
UP SOLENOID
15
BEEPER
16
TWO CYLINDERS
14
0.47uF CAP
ACITOR
MOTOR CONTACTOR
17
18
TIL
T SWITCH
TIL
T RELA
Y
20
21
SPEED A SOLENOID
23
DIFF
. SOLENOID
24
22
SPEED B SOLENOID
PROPORTIONAL
25
26
RELA
Y
27
PROPORTIONAL
SOLENOID
29
28
FORWARD SOLENOID
32
REVERSE SOLENOID
30
TRANSFER RELA
Y
31
RIGHT SOLENOID
33
34
17A
DO2-6
4H-24
LEFT SOLENOID
BRAKE SOLENOID
35
D13
CUTOUT RELA
Y
C1
MOTOR
CONTACTOR
S1
MAIN
DISCONNECT
B1
6V
BATTERY
B2 6V
BATTERY
B3 6V
BATTERY
F1
300A
FUSE
B4 6V
BATTERY
END OF STROKE
LIMIT SWITCH N.C.
H1
HORN
S2
UP/DOWN
SWITCH
DRIVE OVERRIDE
LIMIT SWITCH N.C.
HIGH SPEED
LIMIT SWITCHES N.C.
RED/WHITE
7A
05
BLUE/WHITE
8C
GREEN
7A
OUTPUT
NUETRAL
S7-1
8C
8C
07
24
D15-1
D16-1
16
23
B
S7-3
LEFT
S7-2
REV/DN
12B
RIGHT
23
24
15
59
18
02
A
59
60
13
14
02
V
INDICATOR
BCI
RST1
2.7K OHMS
00
PWM
JOYSTICK
S7
08
SWITCH
HORN
S8
BATTERY CHARGE
07
7A
49
21B
STOP
EMERGENCY
S4
D27
D26
21B
RETRACT SOLENOID
08
7A
NOHC
A
B
NOHC
NO
7B
NCHO
NCHO
08
JOYSTICK PCB
LIFT/DRV LOW/DRV HI
(IN LIFT POSITION)
NOHC
08
S3
09
02
LED-2
POWER ON LIGHT
7A
BASE
24V CHARGER
L1CR
CHARGER
BC
110 VAC
LINE VOL
TAGE
09
S12
9A
EXT
S11
27
RET
SWITCH
EXTEND/
RETRACT
26
SWITCH
ENABLE
4H-26
4H-27
EXTEND SOLENOID
POWERED PLATFORM OPTION
CONTROL BOX
16
15
18
14
13
12B
A
B
8A
08
02
02
02
FWD/UP
ENABLE
08
49
60
2H-59
NCHO
NO
NCHO
07
5A
AC
Serial Breakdown
Reference Chart
Model
Serial Number
SJ3 3220
60002137 & below
SJ3 3226
27006058 & below
SJ3 46XX
70006693 & below
77
79
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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