Skyjack SJ12 E

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This manual is for MEWPs with serial numbers:

SJ12 E, SJ16 E, SJ20 E: A601 000 906 - A601 999 999

Please refer to the website (www.skyjack.com) for

contact information, other serial numbers, the most

recent technical manuals, and USB software.

Main Page

Table of Contents5
Section 1 - Scheduled Maintenance9
Read and Heed9
Mobile Elevating Work Platform (MEWP) Definition9
Purpose of Equipment9
Use of Equipment9
Manual9
Service Policy and Warranty9
Operator Safety Reminders, Warnings and Precautions9
Maintenance and Inspection Schedule10
Owner's Annual Inspection Record10
Replacement Parts10
Maintenance and Service Safety Tips10
Hydraulic System & Component Maintenance and Repair11
Maintenance Hints11
About this Section12
Service Bulletins12
Maintenance and Inspection12
Maintenance Instructions12
Owner's Annual Inspection Record13
Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist14
Visual and Daily Maintenance Inspections15
Labels15
Electrical15
Limit Switches, B15
Hydraulic15
Base16
Wheel/Tire Assembly16
Platform Assembly18
Hydraulic/Electrical Compartment19
Lift Mechanism21
10 Optional Equipment21
Section 2 - Maintenance Tables and Diagrams23
Standard Hose Numbering System23
Torque Specifications for Fasteners (US Imperial)25
Torque Specifications for Fasteners (Metric)26
Torque Specifications for Hydraulic Couplings & Hoses27
Specifications (ANSI/CSA) - S/N A601001639 and above28
Specifications (ANSI/CSA) - S/N A601001638 and below29
Specifications (CE)30
Specifications (AS)31
Maximum Platform Capacities (Evenly Distributed) (ANSI/CSA)32
Maximum Platform Capacities (Evenly Distributed) (CE)32
Maximum Platform Capacities (Evenly Distributed) (AS)32
Environment33
Floor Loading Capacity (ANSI/CSA)34
Floor Loading Capacity (AS/CE)35
Torque Specifications36
Section 3 - System Component Identification and Schematics37
Electrical Symbol Chart38
Hydraulic Symbol Chart39
Wire Number and Color Code40
Hydraulic Parts List41
Electrical Parts List42
Hydraulic Connections43
Platform Control Box Wiring44
Platform Control Cable Wiring45
Platform Control Box Wiring - SGLE46
Platform Control Cable Wiring - SGLE47
Beeper48
Base Limit Switch48
Platform Limit Switches48
Motor and Controller Connections49
Mast Cable (SJ12 E)50
Mast Cable (SJ16 E)51
Mast Cable (SJ20 E)52
Elevate Telematics Harness53
Battery Management System Harness54
Major Component Identification55
Hydraulic Schematic56
Base Control Wiring57
Main Harness - ZAPI a58
Main Harness Wiring - ZAPI a59
Main Harness - ZAPI B60
Electrical Schematic61
Section 4 - Troubleshooting Information63
Introduction63
Electrical System64
All Controls Inoperative64
No Lift or Steer Functions65
No Lift from Base or Platform66
No Lower from Base or Platform66
No Lift from Base Controls66
No Lower from Base Controls66
No Functions from Platform Controls67
No Lift/Lower from Platforms Controls67
No Steer Left67
10 No Steer Right67
11 No Drive68
Hydraulic System69
All Hydraulic Controls Inoperative (no Lift or Steer Functions)69
No Lift Function69
No Lower Function69
No Steer Left And/Or Right69
Section 5 - Procedures71
General71
Safety and Workmanship71
Diagnostic Switch71
Platform72
Remove the Platform72
Install the Platform74
Replace the Load Cells76
Railing Maintenance and Repair78
Mast79
Lubricate the Mast79
Remove the Lift Cylinder80
Install the Lift Cylinder81
Remove the Mast and Lift Cylinder Together82
Install the Mast and Lift Cylinder Together84
Replace the Mast Wear Pads87
Hydraulic System100
System Pressure Adjustment100
Lift Pressure Adjustment102
Tilt Switch104
Level the MEWP104
Replace the Tilt Switch105
Program the Tilt Switch106
Tilt Switch Operation107
Pin Charts108
ZAPI Controller Pin Chart108
Joystick 32-Pin Connector Chart111
Display Module112
Calibration and Diagnostic Tool Key Functions112
Display Module Error Codes125
Tester Menu - Master Uc143
Tester Menu - Slave Uc148
Set the Access Level152
Set the Language152
Set the Machine Type152
Set the Region153
Set the Battery Type153
10 Select the Console153
11 Tilt Sensor Calibration154
12 Nominal Weight Calibration155
13 Partial Weight Calibration156
Batteries157
Service the Batteries157
Battery Charger157
Charger Maintenance157
Charger Profiles158
Charger Troubleshooting159
Charger Fault Codes159
Charger Error Codes160
Wheels164
Remove the Front Wheel164
Install the Front Wheel164
Remove the Rear Wheel165
Prepare the New Rear Wheel166
Install the Rear Wheel167

Skyjack SJ12 E - Page 2

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