Skyjack SJ16 - Page 143

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Table of Contents5
Section 1 - Scheduled Maintenance11
Read and Heed11
Mobile Elevating Work Platform (MEWP) Definition11
Purpose of Equipment11
Use of Equipment11
Service Policy and Warranty11
Ownership of MEWP11
Optional Equipment11
Maintenance and Inspection Schedule12
Owner's Annual Inspection Record12
Replacement Parts12
Maintenance and Service Safety Tips12
Hydraulic System & Component Maintenance and Repair13
Maintenance Hints14
About this Section15
Owner's Annual Inspection Record16
Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist17
General Inspections18
Service Bulletins18
Annual Inspection18
Labels18
Limit Switches18
Base Inspections19
Mast Inspections23
Platform Inspections24
Function Tests25
Section 2 - Maintenance Tables and Diagrams27
Standard Hose Numbering System27
Specifications and Features - ANSI/CSA29
Specifications and Features - CE, as30
Maximum Platform Capacities (Evenly Distributed) ANSI/CSA31
Maximum Platform Capacities (Evenly Distributed) CE,AS31
Floor Loading Pressure ANSI/CSA32
Floor Loading Pressure - CE, as33
Torque Specifications35
Torque Specifications for Fasteners (Imperial)36
Torque Specifications for Fasteners (Metric)37
Torque Specifications for Hydraulic Couplings & Hoses38
Section 3 - System Component Identification and Schematics39
Electrical Symbol Chart40
Hydraulic Symbol Chart41
Wire Number and Color Code42
Hydraulic Component Parts List43
Electrical Component Parts List44
Cylinders and Port Identifications46
Wheel Brake and Port Identifications47
Powerpack and Port Identifications48
Platform Control Box Wiring49
Platform Control Box Wiring - SGLE50
Platform Control Box Cable51
Platform Control Box Cable - SGLE52
Terminal Strip53
Brake and Main Manifold and Hydraulic Identifications54
Disc Brake Kits and Torque Specifications55
Hydraulic Schematic56
Base Control Wiring Diagram57
Base Control Wiring Diagram58
Main Electrical Harness59
Main Electrical Harness60
Mast Control Cable61
Limit Switches62
Electrical Schematic (ANSI/CSA)63
Electrical Schematic (CE)64
Electrical Schematic (AS)65
Elevate Telematics Harness66
Section 4 - Troubleshooting Information67
Introduction67
Electrical System Troubleshooting69
All Controls Inoperative69
All Controls Except for down Function Inoperative71
All Controls Inoperative from Base Control Console72
No up Function from Base Control Console72
Up Function Slow from Base Control Console73
No down Function from Base Control Console74
All Controls Inoperative from Platform Control Console74
No up Function from Platform Controls75
Up Function Slow from Platform Control Console76
10 No down Function from Platform Controls77
11 Pothole Bars will Not Retract77
12 Steer Only Inoperative78
13 Right Steer Inoperative78
14 Left Steer Inoperative79
15 No Drive Forward or Reverse80
16 Brake will Not Release81
17 No Elevated Drive81
18 Work Platform Drives in Slow Speed Only81
19 Forward Drive Function Inoperative82
20 Reverse Drive Function Inoperative83
21 Two or more Functions at One Time83
Hydraulic System Troubleshooting84
All Functions Inoperative84
All System Sluggish84
Platform Drifts down84
Platform Lifts Slowly84
Platform Does Not Lift84
Platform will Not Lower85
Pothole Bars will Not Retract85
Platform Drives Slow85
Platform will Not Drive in Forward85
10 Platform will Not Drive in Reverse85
11 Brake(S) will Not Release85
12 Platform Does Not Steer86
13 Platform Steers very Slowly86
Section 5 - Procedures87
General87
Safety and Workmanship87
Electrical System Adjustments87
Electrical System87
Resistor - Voltage Divider87
Troubleshooting - Diagnostic Switch88
Tilt Switch Orientation88
Hydraulic System Adjustments89
System Relief Pressure Adjustment89
Lift Pressure Adjustment89
Steer Relief Pressure Adjustment90
Electronic Tilt Switch Setup Procedure91
Tilt Switch Replacement91
Reprogramming Existing Tilt Switch93
Test and Verify Tilt Circuit94
Wheel Reinstallation and Torquing Procedure95
Battery Maintenance98
Charger Maintenance98
Charger Profiles99
Charger Troubleshooting100
Charger Error Codes101
Pothole Limit Switch(LS2) Replacement and Adjustment105
Mast Lubrication Procedure106
Outside Mast Lubrication106
Inner Wear Pads Lubrication107
Chains and Rollers Lubrication107
Mast Roller Inspection/Maintenance108
Roller Operation Inspection108
Mast Chain Visual Inspection109
Chain Thorough Examination110
Condition Inspection Table110
Mast Disassembly Procedure111
Extending Platform Removal111
Mast Section 5 Removal (SJ16 Only)113
Mast Section 4 Removal114
Mast Section 3 Removal116
Mast Section 2 Removal118
Mast Section 1 Removal120
Mast Roller Replacement122
Mast Assembly Procedure123
Mast Section 1 Installation123
Mast Section 2 Installation124
Mast Section 3 Installation125
Mast Section 4 Installation127
Mast Section 5 Installation (SJ16 Only)129
Extending Platform Installation130
Lift Cylinder Replacement132
Extending Platform Removal132
Mast Assembly Removal132
Lift Cylinder Removal135
Lift Cylinder Installation136
Mast Assembly Installation137
Railing Maintenance and Repair140

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