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SJ12 E
Skyjack SJ12 E Service Manual
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This manual is for MEWP
s with serial numbers:
SJ12 E, S
J16 E, SJ20 E:
A601 000 906 - A601 999 999
Pl
ease ref
er to the website (
www.skyjack.c
om
) for
cont
act information, other serial number
s, the most
r
ecent technical manuals, and USB softwar
e.
1
3
Table of Contents
Table of Contents
5
Section 1 - Scheduled Maintenance
9
Read and Heed
9
Mobile Elevating Work Platform (MEWP) Definition
9
Purpose of Equipment
9
Use of Equipment
9
Manual
9
Service Policy and Warranty
9
Operator Safety Reminders, Warnings and Precautions
9
Maintenance and Inspection Schedule
10
Owner's Annual Inspection Record
10
Replacement Parts
10
Maintenance and Service Safety Tips
10
Hydraulic System & Component Maintenance and Repair
11
Maintenance Hints
11
About this Section
12
Service Bulletins
12
Maintenance and Inspection
12
Maintenance Instructions
12
Owner's Annual Inspection Record
13
Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist
14
Visual and Daily Maintenance Inspections
15
Labels
15
Electrical
15
Limit Switches, B
15
Hydraulic
15
Base
16
Wheel/Tire Assembly
16
Platform Assembly
18
Hydraulic/Electrical Compartment
19
Lift Mechanism
21
10 Optional Equipment
21
Section 2 - Maintenance Tables and Diagrams
23
Standard Hose Numbering System
23
Torque Specifications for Fasteners (US Imperial)
25
Torque Specifications for Fasteners (Metric)
26
Torque Specifications for Hydraulic Couplings & Hoses
27
Specifications (ANSI/CSA) - S/N A601001639 and above
28
Specifications (ANSI/CSA) - S/N A601001638 and below
29
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
Environment
33
Floor Loading Capacity (ANSI/CSA)
34
Floor Loading Capacity (AS/CE)
35
Torque Specifications
36
Section 3 - System Component Identification and Schematics
37
Electrical Symbol Chart
38
Hydraulic Symbol Chart
39
Wire Number and Color Code
40
Hydraulic Parts List
41
Electrical Parts List
42
Hydraulic Connections
43
Platform Control Box Wiring
44
Platform Control Cable Wiring
45
Platform Control Box Wiring - SGLE
46
Platform Control Cable Wiring - SGLE
47
Beeper
48
Base Limit Switch
48
Platform Limit Switches
48
Motor and Controller Connections
49
Mast Cable (SJ12 E)
50
Mast Cable (SJ16 E)
51
Mast Cable (SJ20 E)
52
Elevate Telematics Harness
53
Battery Management System Harness
54
Major Component Identification
55
Hydraulic Schematic
56
Base Control Wiring
57
Main Harness - ZAPI a
58
Main Harness Wiring - ZAPI a
59
Main Harness - ZAPI B
60
Electrical Schematic
61
Section 4 - Troubleshooting Information
63
Introduction
63
Electrical System
64
All Controls Inoperative
64
No Lift or Steer Functions
65
No Lift from Base or Platform
66
No Lower from Base or Platform
66
No Lift from Base Controls
66
No Lower from Base Controls
66
No Functions from Platform Controls
67
No Lift/Lower from Platforms Controls
67
No Steer Left
67
10 No Steer Right
67
11 No Drive
68
Hydraulic System
69
All Hydraulic Controls Inoperative (no Lift or Steer Functions)
69
No Lift Function
69
No Lower Function
69
No Steer Left And/Or Right
69
Section 5 - Procedures
71
General
71
Safety and Workmanship
71
Diagnostic Switch
71
Platform
72
Remove the Platform
72
Install the Platform
74
Replace the Load Cells
76
Railing Maintenance and Repair
78
Mast
79
Lubricate the Mast
79
Remove the Lift Cylinder
80
Install the Lift Cylinder
81
Remove the Mast and Lift Cylinder Together
82
Install the Mast and Lift Cylinder Together
84
Replace the Mast Wear Pads
87
Hydraulic System
100
System Pressure Adjustment
100
Lift Pressure Adjustment
102
Tilt Switch
104
Level the MEWP
104
Replace the Tilt Switch
105
Program the Tilt Switch
106
Tilt Switch Operation
107
Pin Charts
108
ZAPI Controller Pin Chart
108
Joystick 32-Pin Connector Chart
111
Display Module
112
Calibration and Diagnostic Tool Key Functions
112
Display Module Error Codes
125
Tester Menu - Master Uc
143
Tester Menu - Slave Uc
148
Set the Access Level
152
Set the Language
152
Set the Machine Type
152
Set the Region
153
Set the Battery Type
153
10 Select the Console
153
11 Tilt Sensor Calibration
154
12 Nominal Weight Calibration
155
13 Partial Weight Calibration
156
Batteries
157
Service the Batteries
157
Battery Charger
157
Charger Maintenance
157
Charger Profiles
158
Charger Troubleshooting
159
Charger Fault Codes
159
Charger Error Codes
160
Wheels
164
Remove the Front Wheel
164
Install the Front Wheel
164
Remove the Rear Wheel
165
Prepare the New Rear Wheel
166
Install the Rear Wheel
167
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Skyjack SJ12 E Specifications
General
Brand
Skyjack
Model
SJ12 E
Category
Lifting Systems
Language
English
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