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Skyjack
Lifting Systems
SJ12
Service Manual
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Skyjack SJ12 - Page 2
143 pages
Manual
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This manual is for MEWP
s with serial numbers:
SJ12 & S
J16:
A600 000 001 - A600 999 999
Pl
ease r
efer t
o the website (
www.skyjack.c
om
) for
cont
act information, other serial number
s, the most
r
ec
ent technical manuals, and USB softwar
e.
1
3
Table of Contents
Main Page
Table of Contents
5
Section 1 - Scheduled Maintenance
11
Read and Heed
11
Mobile Elevating Work Platform (MEWP) Definition
11
Purpose of Equipment
11
Use of Equipment
11
Service Policy and Warranty
11
Ownership of MEWP
11
Optional Equipment
11
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
14
About this Section
15
Owner's Annual Inspection Record
16
Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist
17
General Inspections
18
Service Bulletins
18
Annual Inspection
18
Labels
18
Limit Switches
18
Base Inspections
19
Mast Inspections
23
Platform Inspections
24
Function Tests
25
Section 2 - Maintenance Tables and Diagrams
27
Standard Hose Numbering System
27
Specifications and Features - ANSI/CSA
29
Specifications and Features - CE, as
30
Maximum Platform Capacities (Evenly Distributed) ANSI/CSA
31
Maximum Platform Capacities (Evenly Distributed) CE,AS
31
Floor Loading Pressure ANSI/CSA
32
Floor Loading Pressure - CE, as
33
Torque Specifications
35
Torque Specifications for Fasteners (Imperial)
36
Torque Specifications for Fasteners (Metric)
37
Torque Specifications for Hydraulic Couplings & Hoses
38
Section 3 - System Component Identification and Schematics
39
Electrical Symbol Chart
40
Hydraulic Symbol Chart
41
Wire Number and Color Code
42
Hydraulic Component Parts List
43
Electrical Component Parts List
44
Cylinders and Port Identifications
46
Wheel Brake and Port Identifications
47
Powerpack and Port Identifications
48
Platform Control Box Wiring
49
Platform Control Box Wiring - SGLE
50
Platform Control Box Cable
51
Platform Control Box Cable - SGLE
52
Terminal Strip
53
Brake and Main Manifold and Hydraulic Identifications
54
Disc Brake Kits and Torque Specifications
55
Hydraulic Schematic
56
Base Control Wiring Diagram
57
Base Control Wiring Diagram
58
Main Electrical Harness
59
Main Electrical Harness
60
Mast Control Cable
61
Limit Switches
62
Electrical Schematic (ANSI/CSA)
63
Electrical Schematic (CE)
64
Electrical Schematic (AS)
65
Elevate Telematics Harness
66
Section 4 - Troubleshooting Information
67
Introduction
67
Electrical System Troubleshooting
69
All Controls Inoperative
69
All Controls Except for down Function Inoperative
71
All Controls Inoperative from Base Control Console
72
No up Function from Base Control Console
72
Up Function Slow from Base Control Console
73
No down Function from Base Control Console
74
All Controls Inoperative from Platform Control Console
74
No up Function from Platform Controls
75
Up Function Slow from Platform Control Console
76
10 No down Function from Platform Controls
77
11 Pothole Bars will Not Retract
77
12 Steer Only Inoperative
78
13 Right Steer Inoperative
78
14 Left Steer Inoperative
79
15 No Drive Forward or Reverse
80
16 Brake will Not Release
81
17 No Elevated Drive
81
18 Work Platform Drives in Slow Speed Only
81
19 Forward Drive Function Inoperative
82
20 Reverse Drive Function Inoperative
83
21 Two or more Functions at One Time
83
Hydraulic System Troubleshooting
84
All Functions Inoperative
84
All System Sluggish
84
Platform Drifts down
84
Platform Lifts Slowly
84
Platform Does Not Lift
84
Platform will Not Lower
85
Pothole Bars will Not Retract
85
Platform Drives Slow
85
Platform will Not Drive in Forward
85
10 Platform will Not Drive in Reverse
85
11 Brake(S) will Not Release
85
12 Platform Does Not Steer
86
13 Platform Steers very Slowly
86
Section 5 - Procedures
87
General
87
Safety and Workmanship
87
Electrical System Adjustments
87
Electrical System
87
Resistor - Voltage Divider
87
Troubleshooting - Diagnostic Switch
88
Tilt Switch Orientation
88
Hydraulic System Adjustments
89
System Relief Pressure Adjustment
89
Lift Pressure Adjustment
89
Steer Relief Pressure Adjustment
90
Electronic Tilt Switch Setup Procedure
91
Tilt Switch Replacement
91
Reprogramming Existing Tilt Switch
93
Test and Verify Tilt Circuit
94
Wheel Reinstallation and Torquing Procedure
95
Battery Maintenance
98
Charger Maintenance
98
Charger Profiles
99
Charger Troubleshooting
100
Charger Error Codes
101
Pothole Limit Switch(LS2) Replacement and Adjustment
105
Mast Lubrication Procedure
106
Outside Mast Lubrication
106
Inner Wear Pads Lubrication
107
Chains and Rollers Lubrication
107
Mast Roller Inspection/Maintenance
108
Roller Operation Inspection
108
Mast Chain Visual Inspection
109
Chain Thorough Examination
110
Condition Inspection Table
110
Mast Disassembly Procedure
111
Extending Platform Removal
111
Mast Section 5 Removal (SJ16 Only)
113
Mast Section 4 Removal
114
Mast Section 3 Removal
116
Mast Section 2 Removal
118
Mast Section 1 Removal
120
Mast Roller Replacement
122
Mast Assembly Procedure
123
Mast Section 1 Installation
123
Mast Section 2 Installation
124
Mast Section 3 Installation
125
Mast Section 4 Installation
127
Mast Section 5 Installation (SJ16 Only)
129
Extending Platform Installation
130
Lift Cylinder Replacement
132
Extending Platform Removal
132
Mast Assembly Removal
132
Lift Cylinder Removal
135
Lift Cylinder Installation
136
Mast Assembly Installation
137
Railing Maintenance and Repair
140
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