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Skyjack SJ3220 Service Manual

Skyjack SJ3220
177 pages
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SERVICE
MANUAL
DC ELECTRIC SCISSORS
223198ABA
August 2020
ANSI/CSA, CE, AS, KC
SJ3220, SJ3226, SJ4720, SJ4726, SJ4732

Table of Contents

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Skyjack SJ3220 Specifications

General IconGeneral
BrandSkyjack
ModelSJ3220
CategoryScissor Lifts
LanguageEnglish

Summary

Scheduled Maintenance

Read and Heed

General information about equipment, policies, and optional accessories.

Maintenance and Inspection Schedule

Details on maintenance schedules, owner's records, and replacement parts.

Owner’s Annual Inspection Record

Requirements and usage of the owner's annual inspection record.

Replacement Parts

Guidelines for using original replacement parts and their importance for safety.

Maintenance and Service Safety Tips

Safety precautions and best practices for maintenance personnel.

Hydraulic System & Component Maintenance and Repair

Points to consider when working on the hydraulic system for maintenance and repair.

Maintenance Hints

Simple, effective maintenance procedures for hydraulic system performance.

About this Section

Overview of the section's content and references to detailed procedures.

Maintenance Instructions

Guidelines on inspection frequencies and procedures for MEWP maintenance.

Owner’s Annual Inspection Record

Information and table for recording annual MEWP inspections.

Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist

Checklist for inspection types, detailing items and schedules.

General Inspections

Sequence and details for performing general visual inspections of the MEWP.

Service Bulletins (B)

Guidance on checking for and applying service bulletins for updates.

Annual Inspections (B)

Procedure to review the machine's service record for previous maintenance.

Labels (B)

Verify label location, condition, and readability as per the operation manual.

Pothole Protection Limit Switches(B)

Inspect switches for attachment, damage, and obstruction.

Base Inspection

Detailed inspection points for the MEWP base, including safety features.

Scissors Inspection

Procedures for inspecting the scissor assembly, sliders, rollers, and lift cylinders.

Platform Inspection

Inspection steps for platform components like railings, gate, and control console.

Function Tests

Importance and procedure for conducting function tests before putting the MEWP into service.

Maintenance Tables and Diagrams

Standard Hose Numbering System

Explanation and chart for the standard numbering system used for hydraulic hoses.

Torque Specifications for Fasteners (US)

Table detailing torque specifications for various US standard fasteners.

Torque Specifications for Fasteners (Metric)

Table providing torque specifications for metric standard fasteners.

Torque Specifications for Hydraulic Couplings & Hoses

Torque values for hydraulic couplings and hoses based on size and type.

Specifications & Features - ANSI/CSA

Technical specifications and features for MEWPs compliant with ANSI/CSA standards.

Specifications & Features - ANSI/CSA Powerdeck and ACPP

Specs for MEWPs with Powerdeck and ACPP options, ANSI/CSA compliant.

Specifications & Features - CE

CE-compliant specifications and features for various MEWP models.

Specifications & Features - AS

Australian Standards (AS) compliant specifications and features for MEWPs.

Specifications & Features - KC

Korean Certification (KC) compliant specifications and features for MEWPs.

Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA

Table detailing maximum platform capacities under ANSI/CSA guidelines.

Maximum Platform Capacities (Evenly Distributed) - CE/AS/KC

Maximum platform capacities for CE, AS, and KC standards.

Floor Loading Pressure (ANSI/CSA)

Data on MEWP floor loading pressure according to ANSI/CSA standards.

Floor Loading Pressure (CE)

Floor loading pressure specifications for CE-compliant MEWPs.

Floor Loading Pressure (AS)

Floor loading pressure information for MEWPs meeting AS standards.

Floor Loading Pressure (KC)

Floor loading pressure data for MEWPs certified by KC.

Torque Specifications

General torque specifications for various components and fasteners.

System Component Identification and Schematics

Electrical Symbol Chart

Chart defining common electrical symbols used in schematics.

Hydraulic Symbol Chart

Chart illustrating standard hydraulic symbols used in diagrams.

Wire Number and Color Code

Reference table for wire numbers and their corresponding color codes.

Hydraulic Parts List

List of hydraulic components with index numbers and Skyjack part numbers.

Electrical Parts List

List of electrical components with index numbers and Skyjack part numbers.

Drive Manifold MB2 - SJ3220/26 & SJ4726/32 (ANSI/CSA)

Schematic of the drive manifold MB2 for specific models under ANSI/CSA.

Drive Manifold MB2 - SJ3220/26 (CE, AS & KC)

Schematic of the drive manifold MB2 for specific models under CE, AS, KC.

Drive Manifold MB2 - SJ4720/26/32 (CE, AS & KC)

Schematic of the drive manifold MB2 for SJ4720/26/32 models under CE, AS, KC.

Brake Manifold MB6 - SJ4720/26/32 (CE, AS & KC)

Schematic of the brake manifold MB6 for specific models under CE, AS, KC.

Single Lift Cylinder Manifold MB5 - SJ3220, SJ4720

Schematic of the single lift cylinder manifold MB5 for SJ3220 and SJ4720.

Dual Lift Cylinder Manifold MB3 & MB4 - SJ3226, SJ4726/32

Schematic of dual lift cylinder manifolds MB3 and MB4 for SJ3226, SJ4726/32.

Powerdeck Manifold MB1 - SJ3220, SJ4720

Schematic of the powerdeck manifold MB1 for SJ3220 and SJ4720 models.

Platform Control Box Wiring

Wiring diagram for the platform control box.

Platform Control Box Wiring - SGLE

Specific wiring diagram for the SGLE platform control box.

Platform Control Box Wiring - ACPP

Wiring diagram for the ACPP platform control box.

Base to Platform Control Cable

Diagram illustrating the wiring of the base to platform control cable.

Base Control Wiring

Wiring schematic for the base control system.

Base Control Wiring - ACPP

Wiring diagram for the base control system with ACPP option.

Emergency Lowering Switch Wiring

Wiring diagram for the emergency lowering switch.

Limit Switch Wiring

Wiring diagrams for limit switches on the hydraulic and battery tray sides.

Limit Switch Wiring - Anti-Overrising Posts (KC Only)

Wiring for anti-overrising posts limit switches, specific to KC models.

Anti-Overrising Harnesses (KC Only)

Diagrams for anti-overrising harnesses for KC models, covering platform and scissor.

Electrical Harnesses

Diagrams for various electrical harnesses including holding valve and transducer.

Powerdeck Harnesses

Wiring diagrams for powerdeck control boxes and related harnesses.

Interlocks Harness (ANSI/CSA ACPP)

Wiring diagram for interlocks harness on ANSI/CSA ACPP models.

Outdoor Switch Wiring and Harness (SJ3226 ANSI/CSA Only)

Wiring and harness details for outdoor switches on SJ3226 ANSI/CSA models.

Main Manifold MB1

Schematic of the main manifold MB1, showing component locations and connections.

Hydraulic Schematics - SJ3220/26 ANSI/CSA

Hydraulic schematic for SJ3220/26 models under ANSI/CSA standards.

Hydraulic Schematics - SJ3220/26 CE

Hydraulic schematic for SJ3220/26 models compliant with CE standards.

Hydraulic Schematics - SJ3220/26 AS/KC

Hydraulic schematic for SJ3220/26 models meeting AS/KC standards.

Hydraulic Schematics - SJ4720/26/32 ANSI/CSA

Hydraulic schematic for SJ4720/26/32 models under ANSI/CSA standards.

Hydraulic Schematics - SJ4720/26/32 CE

Hydraulic schematic for SJ4720/26/32 models compliant with CE standards.

Hydraulic Schematics - SJ4720/26/32 AS/KC

Hydraulic schematic for SJ4720/26/32 models meeting AS/KC standards.

Telematics Harness

Wiring diagram for the telematics harness.

Electrical Schematic - SJ3220, SJ4726/32 - All Option (ANSI/CSA)

Electrical schematic for SJ3220, SJ4726/32 with all options, ANSI/CSA.

Electrical Schematic - SJ3226 - All Option (ANSI/CSA)

Electrical schematic for SJ3226 with all options, ANSI/CSA compliant.

Electrical Schematic - All Option (CE)

Electrical schematic for all options compliant with CE standards.

Electrical Schematic - All Option (AS)

Electrical schematic for all options compliant with AS standards.

Electrical Schematic - All Option (KC)

Electrical schematic for all options compliant with KC standards.

Electrical Schematic - SJ4726 - ACPP

Electrical schematic for SJ4726 with ACPP option.

Main Harness - SJ3220/26

Wiring diagram for the main harness of SJ3220/26 models.

Main Harness - SJ4720/26/32

Wiring diagram for the main harness of SJ4720/26/32 models.

Troubleshooting Information

Introduction

Overview of the troubleshooting section, explaining its structure and approach.

Electrical System

Troubleshooting steps for various electrical system issues.

All Controls Inoperative

Troubleshooting steps for when all controls are not functioning.

All Controls Except for Down Function Inoperative

Troubleshooting when controls work, but the down function fails.

All Controls Inoperative From Base Control Console

Troubleshooting when controls are inoperative from the base console.

No Up Function from Base Control Console

Troubleshooting steps for when the up function fails from the base console.

No Down Function from Base Control Console

Troubleshooting steps for when the down function fails from the base console.

No Emergency Down Function from Base Control Console*

Troubleshooting for the lack of emergency down function from the base console.

All Controls Inoperative From Platform Control Console

Troubleshooting for inoperative controls from the platform console.

No Up Function from Platform Controls (ANSI/CSA, CE, and AS)

Troubleshooting for no up function from platform controls (ANSI/CSA, CE, AS).

No Up Function from Platform Controls (KC)

Troubleshooting for no up function from platform controls on KC models.

No Down Function from Platform Controls

Troubleshooting steps for when the down function fails from platform controls.

Right Steer Inoperative

Troubleshooting procedures for a non-functional right steer function.

Left Steer Inoperative

Troubleshooting steps for a non-functional left steer function.

Forward Drive Function Inoperative

Troubleshooting procedures for when the forward drive function is inoperative.

Reverse Drive Function Inoperative

Troubleshooting steps for when the reverse drive function is inoperative.

No Drive or Steer when Platform Elevated

Troubleshooting for the absence of drive or steer when the platform is elevated.

High/Low Torque Inoperative

Troubleshooting for the high/low torque function being inoperative.

Pressure Transducer PT1 Inoperative

Troubleshooting steps when the pressure transducer PT1 is inoperative.

Angle Transducers AT1 and/or AT2 Inoperative

Troubleshooting for inoperative angle transducers AT1 and/or AT2.

Power Deck Inoperative (if Option is installed)

Troubleshooting steps for an inoperative power deck option.

Hydraulic System

Troubleshooting steps for various hydraulic system issues.

All Functions Inoperative

Troubleshooting steps when all hydraulic functions are inoperative.

All System Sluggish

Troubleshooting for a sluggish hydraulic system performance.

Platform Drifts Down

Troubleshooting steps for the platform drifting down unexpectedly.

Platform Lifts Slowly

Troubleshooting for slow platform lifting performance.

Platform Does Not Lift

Troubleshooting steps when the platform fails to lift.

Platform Will Not Lower

Troubleshooting for the platform's inability to lower.

Platform Drives Slow

Troubleshooting steps for slow platform driving speed.

Platform Will Not Drive in Forward or Reverse

Troubleshooting for the platform's inability to drive forward or reverse.

Brake(s) will not Release (Pin Brakes)

Troubleshooting steps for pin brakes failing to release.

Brake(s) will not Release (Wet Brakes)

Troubleshooting for wet brakes failing to release.

MEWP will not hold on a Grade (Wet Brakes)

Troubleshooting when the MEWP cannot hold on a grade with wet brakes.

Platform does not Steer

Troubleshooting steps for the platform's inability to steer.

High/Low Torque Inoperative

Troubleshooting for the high/low torque function being inoperative.

Platform Power Deck Inoperative (if option installed)

Troubleshooting for an inoperative power deck option.

Procedures

General

General information on using and applying servicing and maintenance procedures.

Safety and Workmanship

Emphasizes safety and proper practices during maintenance operations.

Platform

Procedures related to the platform of the MEWP.

Single Axis Joystick

Details on the single axis joystick, including wiring, specifications, and output graph.

Gate Spring Hinge Adjustment

Procedure for adjusting the tension of the gate spring hinges.

Railing Maintenance and Repair

Guidelines for maintaining and repairing MEWP railings and guardrails.

Base

Procedures related to the base of the MEWP.

System Relief Pressure Adjustment

Procedure for adjusting the system relief pressure on the main manifold.

Pothole Compression Rod Replacement

Instructions for replacing and adjusting the pothole compression rod.

Pothole Limit Switches (LS1 & LS2) Replacement and Adjustment

Steps for replacing and adjusting pothole limit switches LS1 and LS2.

Pothole Bar Replacement/Removal for Servicing

Procedure for replacing or removing pothole bars for servicing.

Tightening and Torque Recommendations for Hydraulic Couplings and Hoses

Guidelines for tightening hydraulic couplings and hoses with torque recommendations.

Integrated Hub Wheel Removal and Installation

Step-by-step guide for removing and installing integrated hub wheels.

Battery Maintenance

Procedures for servicing and charging the MEWP battery.

Charger Maintenance

Information on maintaining the battery charger and understanding its indicator states.

Skycoded Module

Procedures and information related to the Skycoded control module.

Skycoded Control Module (CM1)

Overview of the Skycoded Control Module (CM1) and its functions.

Calibration and Diagnostic Tool Key Functions

Explanation of key functions for calibration and diagnostic tool usage.

Diagnostics, Help Messages and Flash Codes

Information on interpreting diagnostic messages, help messages, and flash codes.

Override Mode Procedure

Procedure for placing the Control Module CM1 into override mode for service.

Initial Set-up and Change Defaults Procedure

Steps for initial setup and changing default settings after replacing the control module.

Access Levels Procedure

Procedure for accessing different levels of settings and adjustments on the Skycoded module.

Calibrate Level Procedure

Procedure to calibrate the integral tilt sensor of the Control Module CM1.

Calibrate Load Procedure

Procedure for calibrating the platform load estimation using lift cylinder pressure.

Language Setting Procedure

Steps to change the language displayed on the Skycoded display panel.

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