Skyjack SJ 3215 Service Manual
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Skyjack SJ 3215 Service Manual

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See also: Operating Manual
MODELS
SJ 3215 SJ 3219
Service Manual
SJIII Compact Series
Part No. 143909AD
November 2013

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Summary of Contents for Skyjack SJ 3215

  • Page 1 MODELS SJ 3215 SJ 3219 Service Manual SJIII Compact Series Part No. 143909AD November 2013...
  • Page 2 Alameda Júpiter, 710 Toll Free Fax: 1-888-782-4825 Loteamento American Park Empresarial E-mail: parts@skyjack.com Indaiatuba, SP, Brasil 13347-653 Tel: +55 19 3936 0132 Skyjack Australia Pty Ltd. 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel: +61 (0) 28786 3200...
  • Page 3 Section 1 - Scheduled Maintenance Inspections Table of Contents Section 2 - Maintenance Tables Table of Contents Section 3 - Schematics Table of Contents Section 4 - Troubleshooting Table of Contents Section 5 - Procedures Table of Contents SJIII Series SKYJACK, Page 3...
  • Page 4 It may also be used to alert against unsafe practices. impORTANT IMPORTANT indicates a procedure) essential for safe operation and which, if not followed, may result in a malfunction or damage to the aerial platform. SKYJACK, Page 4 SJIII Series...

  • Page 5: Table Of Contents

    Service and Maintenance About this Section ..............................15 Service Bulletins .................................15 Maintenance and Inspection .............................15 Maintenance Instructions ............................15 Scheduled Maintenance Scheduled Maintenance Inspections ......................18 Function Tests..............................25 Tables Owner’s Annual Inspection Record ........................16 Maintenance and Inspection Checklist ......................17 SJIII Series SKYJACK, Page 5...

  • Page 6: Aerial Platform Definition

    SKYJACK warrants each new SJIII Series work platform to be free of defective parts and workmanship for the first 24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor.

  • Page 7: Scope Of This Manual

    ANSI/SIA (United States) Operators are required by the current ANSI/SIA A92.6 standards to read and understand their responsibilities in the manual of responsibilities before they use or operate this aerial platform. SKYJACK, Page 8 SJIII Series...

  • Page 8: Operator Safety Reminders

    Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety devices to protect your eyes, ears, hands, feet and body. Any modifications from the original design are strictly forbidden without written permission from SKYJACK Inc. Electrocution Hazard This aerial platform is not electrically insulated.

  • Page 9: Safety Precautions

    When • DO NOT raise the aerial plat- fully lowered, ascending or form in windy or gusty condi- descending, only grades up tions. to rated maximum listed in Tables 2-3 are permissible. SKYJACK, Page 10 SJIII Series...
  • Page 10 • DO NOT use the aerial platform without guardrails, obstructions or other possible locking pins and the entry gate in place. hazards around the aerial platform when driving or lifting. SJIII Series SKYJACK, Page 11...
  • Page 11 If additional fall protection is required, by an employer or • has been damaged or appears to have worn or the authority having jurisdiction, Skyjack recommends missing parts. the use of a fall restraint system to keep an occupant •...

  • Page 12: Maintenance And Inspection Schedule

    Consult SKYJACK’s Service Department for optional tires specifications and installation. Before attempting any repair work, turn Battery Disconnect Switch to the “OFF” position.

  • Page 13: Hydraulic System & Component Maintenance And Repair

    The sample should be analyzed Keep all connections tight. by a qualified lubrication specialist to determine if it is suitable for continued use. SKYJACK, Page 14 SJIII Series...

  • Page 14: Service And Maintenance

    - Aerial platform parked on a flat and level surface - Disconnect the battery by turning the main power disconnect switch to the “OFF” position. • Repair any damaged or malfunction components before operating aerial platform. • Keep records on all inspections. SJIII Series SKYJACK, Page 15...

  • Page 15: Owner's Annual Inspection Record

    As described earlier in this section, this decal is located on the control compartment cowling. It must be completed after an annual inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 13 months. SKYJACK, Page 16 SJIII Series...

  • Page 16: Schedule Maintenance Inspections

    † - Refer to Skyjack's website @ www.skyjack.com for latest service bulletins porior to performing quarterly or yearly inspection. Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy. SJIII Series SKYJACK, Page 17...

  • Page 17: Scheduled Maintenance Inspections

    Visually inspect all limit switch located inside the scissor loose wires: arms and the outrigger assemblies for the following: • base to platform cables and wiring harness • broken or missing actuator arm • battery tray wiring harnesses • missing fasteners • hydraulic/electrical wiring harnesses • loose wiring SKYJACK, Page 18 SJIII Series...
  • Page 18 Ensure there are no loose or missing parts and there is no visible damage. • Brakes Ensure there are no loose or missing parts and there is no visible damage. Ensure tabs are not locked. SJIII Series SKYJACK, Page 19...
  • Page 19 5. Replace battery if damaged or incapable wARNiNG of holding a lasting charge. Explosion hazard. Keep flames and sparks away. Do not smoke wARNiNG near batteries. Use original or manufacturer-approved parts and components for the aerial platform. SKYJACK, Page 20 SJIII Series...
  • Page 20 Check each lug nut for proper torque to ensure none are loose. Check wheel motor assembly for loose or missing parts and signs of visible damage. Ensure wheels are aligned and true vertically and horizontally. SJIII Series SKYJACK, Page 21...
  • Page 21 For hydraulic oil replacement procedure, Ensure rod is properly secured and there refer to section 5. is no visible damage. • Hydraulic Pump and Motor Ensure there are no loose or missing parts and there is no visible damage. SKYJACK, Page 22 SJIII Series...
  • Page 22 Ensure gate is in good working order. • Lanyard Attachment Anchors Ensure attachment rings are secure and no visible damage. • AC Outlet on Platform Ensure outlet has no visible damage and free from dirt or obstructions. SJIII Series SKYJACK, Page 23...
  • Page 23 Fully lower the platform. weldments. Ensure all pins are properly secured. Ensure cables and wires are properly routed and shows no signs of wear and/ or physical damage. SKYJACK, Page 24 SJIII Series...

  • Page 24: Function Tests

    Section 2.10 - Start Operation of the operating manual. 1.2-1 Test Main Power Disconnect Switch At rear of the base, turn main power disconnect switch to “ ” off position. Result: Aerial platform functions should not operate. SJIII Series SKYJACK, Page 25...
  • Page 25 Result: Platform raising and lowering functions should not operate. 2. Select off/platform/base key switch to “ ” platform position. Attempt to raise or lower the platform. Result: Platform raising and lowering functions should not operate. SKYJACK, Page 26 SJIII Series...
  • Page 26 4. Turn free-wheeling valve knob clockwise Result: The platform should lower. to a fully closed position for normal operation. 4. To restore normal operation, depress and turn holding valve manual override knobs 5. Reengage the brake. clockwise. SJIII Series SKYJACK, Page 27...
  • Page 27 Result: All platform functions should not contact when using the ladder to mount/ operate. dismount platform. Use the ladder of aerial platform to access platform. Close the gate. On platform control console, pull out “ ”emergency stop button. SKYJACK, Page 28 SJIII Series...
  • Page 28 Result: Aerial platform should move in 3. Press rocker switch on top of controller reverse direction, and then come to a stop. handle to “ ” left and “ ” right. Result: Steer wheels should turn left and right. SJIII Series SKYJACK, Page 29...
  • Page 29 ” lift position. 4. Drive aerial platform “ ” forward and then “ ” backward. Test brake again 2. Activate and hold “ ” enable trigger by releasing “ ” enable trigger switch switch. only. SKYJACK, Page 30 SJIII Series...
  • Page 30 Result: Aerial platform should not move forward or backward. 1. Push “ ” horn pushbutton. Result: Horn should sound. 5. Repeat the steps above with block placed under battery tray. Result: Aerial platform should not move forward or backward. SJIII Series SKYJACK, Page 31...
  • Page 31 Ensure that there are no personnel or obstructions in the path of travel, including blind spots. 1. Move the aerial platform on to a slope not greater than 4.5°. SKYJACK, Page 32 SJIII Series...

  • Page 32: Table Of Contents

    2.2c Floor Loading Pressure (AS) ...........................11 2.3a Maximum Platform Capacities (Evenly Distributed) (ANSI/CSA) ..............12 2.3b Maximum Platform Capacities (Evenly Distributed) (CE) ................13 2.3c Maximum Platform Capacities (Evenly Distributed) (AS) ................14 Torque Specifications ............................15 Scissors Fluids - Hydraulic Oil ........................16 SJIII Series SKYJACK, Page 1...
  • Page 33 Tank Capacity 10.9 L 30 L 162AB * Weight with standard 3' (0.9 m) or 4' (1.2 m) extension platform. Refer to nameplate for aerial platforms with 5' (1.5 m) or 6' (1.8 m) extension platform. SKYJACK, Page 2 SJIII Series...
  • Page 34 Hydraulic Oil ATF Dexron III Type 7.93 gal. Tank Capacity 30 L 163AC Weight with standard 3' (0.9 m) or 4' (1.2 m) extension platform. Refer to serial nameplate for specific applications. Fill hardness: 55 Durometer SJIII Series SKYJACK, Page 3...
  • Page 35 ATF Dexron III ATF Dexron III Type 10.9 L 30 L Tank Capacity 60156AL-CE-1-R-S * Weight with standard 0.9 m extension platform. (Refer to nameplate for aerial platforms with 1.5 m or 1.8 m extension platform.) SKYJACK, Page 4 SJIII Series...
  • Page 36 16 x 5 x 12 Tires (Solid Rubber) Hydraulic Oil ATF Dexron III Type Tank Capacity 30 L 60156AL-CE-2-R-S † Weight with standard 0.9m extension platform. Refer to serial nameplate for specific applications. Fill hardness: 55 Durometer SJIII Series SKYJACK, Page 5...
  • Page 37 ATF Dexron III Type 10.9 L 30 L Tank Capacity 60156AJ-AS-1-S * Weight with standard 0.9 m or 1.2 m extension platform. Refer to nameplate for aerial platforms with 1.5 m or 1.8 m extension platform. SKYJACK, Page 6 SJIII Series...
  • Page 38 16 x 5 x 12 Tires (Solid Rubber) Hydraulic Oil ATF Dexron III Type 30 L Tank Capacity 60156AJ-AS-2-S † Weight with standard 0.9m extension platform. Refer to serial nameplate for specific applications. Fill hardness: 55 Durometer SJIII Series SKYJACK, Page 7...
  • Page 39 Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability. Therefore, replace tires only with the exact original Skyjack-approved type. Failure to operate with matched approved tires in good condition may result in death or serious injury.
  • Page 40 NOTE: The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or architect for that particular structure. SJIII Series SKYJACK, Page 9...
  • Page 41 NOTE: The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or architect for that particular structure. SKYJACK, Page 10 SJIII Series...
  • Page 42 NOTE: The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or architect for that particular structure. SJIII Series SKYJACK, Page 11...
  • Page 43 12.5 m/s 700 lb. 250 lb. 28 mph 4632 2 Persons 1 Person 2.5 x 4.5 318 kg 113 kg 12.5 m/s 165AB NOTE: Overall Capacity - Occupants and materials not to exceed rated load SKYJACK, Page 12 SJIII Series...
  • Page 44 The aerial is equipped with a Load Sensing System. Do not exceed the rated capacity of the aerial platform. Failure to avoid this will prevent operation of all normal controls/functions of the aerial platform. To resume normal operation remove the additional loads. SJIII Series SKYJACK, Page 13...
  • Page 45 136 kg 1 Person 4632 12.5 317 kg 2 Persons 113 kg 1 Person 60315AG-AS-S SJIII3226 shall have extension retracted when used outdoor. NOTE: Overall Capacity - Occupants and materials not to exceed rated load SKYJACK, Page 14 SJIII Series...
  • Page 46 Size Torque Ft-lb (max) In-lb (max) Nm (max) 4.07 13.56 20.34 20.34 33.90 33.90 40.68 47.46 Newton-meter = Nm Foot-pound = ft-lb Inch-pound = in-lb Additional Torque Specifications may be found in Section 3. 60056AF SJIII Series SKYJACK, Page 15...
  • Page 47 Electrical Schematic (ANSI/CSA EE Rated - equipped with no options) ............32 3.24b Electrical Schematic (ANSI/CSA EE Rated - equipped with no options) ............33 3.25b Electrical Schematic (ANSI/CSA EE Rated - equipped with all options) .............34 SJIII Compact Series SKYJACK, Page 1 143909...

  • Page 48: Electrical Symbol Chart

    SINGLE POLE VACUUM POTENTIOMETER SINGLE THROWN LEVEL SENSOR SWITCH RELAY DOUBLE POLE TEMPERATURE SINGLE POLE DOUBLE POLE DOUBLE THROW SWITCH DOUBLE THROW SINGLE THROW RELAY RELAY RELAY TRIPLE POLE RHEOSTAT DIODE DOUBLE THROW RELAY SJIII Compact Series SKYJACK, Page 3 143909...

  • Page 49: Hydraulic Symbol Chart

    THREE POSITION THREE POSITION TWO POSITION TWO POSITION FOUR WAY FOUR WAY TWO WAY THREE WAY VALVE CLOSED CENTER PROPORTIONAL NORMALLY CLOSED PORT OPEN VALVE PRESSURE PILOT LINES Dashed MAIN LINES Solid TRANSDUCER SERVO SKYJACK, Page 4 SJIII Compact Series 143909...

  • Page 50: Wire Number And Color Code

    This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red. SJIII Compact Series SKYJACK, Page 5 143909...

  • Page 51: Hydraulic Manifold And Port Identifications

    4H-16 Forward Drive Valve Counterbalance Valve 4H-15 Reverse Drive Valve 2H-25 Cushion Valve 4H-24 Left Steering Valve 3H-17 Brake Valve 4h-23 Right Steering Valve To Proportional Valve System Relief Valve M10414AA M10561AC_1 M10589AA SKYJACK, Page 6 SJIII Compact Series 143909...
  • Page 52 147661 PUMP , Hydraulic 134431 TRANSDUCER, Pressure (2000 psi) (Model 3215) 134432 TRANSDUCER, Pressure (3000 psi) (Model 3219) 104534 VALVE, Relief (System) 104534 VALVE, Relief (Lift) 107271 VALVE (Emergency lowering) 103136 VALVE (Free-wheeling) SJIII Compact Series SKYJACK, Page 7 143909...

  • Page 53: Electrical Component Parts List

    COIL, 24 Volt (Reverse drive spool valve) (Hytos) (If equipped) 4H-16 153335 COIL, 24 Volt (Forward drive spool valve) (Hytos) 128320 COIL, 24 Volt (Forward drive spool valve) (Hytos) (If equipped) Parts list continued on the following page. SKYJACK, Page 8 SJIII Compact Series 143909...
  • Page 54 SWITCH, Main power disconnect 147054 N.O. CONTACT (Raise/Lower) 147053 N.C. CONTACT (Lift/Drive) 147054 N.O. CONTACT (Lift/Drive) (without powered extension platform) N.O. CONTACT (Lift/Drive) (with powered extension platform) Parts list continued on the following page. SJIII Compact Series SKYJACK, Page 9 143909...
  • Page 55 S7-6 122872 SWITCH, Enable pushbutton 147054 N.O. CONTACT (Horn) 147053 N.C. CONTACT (Off/Platform) 147054 N.O. CONTACT (Base) 147053 N.C. CONTACT (Emergency stop) (Base control console) 146658 TILT SWITCH 103336 HOURMETER - Purchase locally. SKYJACK, Page 10 SJIII Compact Series 143909...
  • Page 56 08 BLUE WHITE/BLACK GREY PIN 6 - REV/DOWN PURPLE/WHITE BLUE PIN 7 - PWM 59 ORANGE/BLACK BLACK PIN 8 - GND 02 WHITE PIN 9 - ENABLE VS+ 8A BLUE WHITE/ BLUE M156881AA SJIII Compact Series SKYJACK, Page 11 143909...
  • Page 57 PIN 6 - REV/DOWN PURPLE/WHITE GREY JOYSTICK HARNESS BLUE PIN 7 - PWM 59 ORANGE/BLACK BLACK PIN 8 - GND 02 WHITE PIN 9 - ENABLE VS+ 8A BLUE WHITE/ BLUE CRD1 M146621AB SKYJACK, Page 12 SJIII Compact Series 143909...

  • Page 58: Base Control Console Diagram

    PIN 3 - 13 (ORANGE) PIN 4 - 14E (BLACK) PIN 5 - 10E (BLUE/BLACK) PIN 6 - 8C (BLUE/WHITE) PIN 7 - 7A (GREEN) PIN 8 - 02 (WHITE) BACK VIEW M149686AA_S3 SJIII Compact Series SKYJACK, Page 13 143909...

  • Page 59: Scissor Arm Control Cable

    (23) BLACK WHITE (24) BLUE BLACK BLUE WHITE (8C) (OPT) GREEN BLACK RED (07) (59) ORANGE BLACK BLACK (14) (18) RED BLACK ORANGE (13) BLUE (15) (16) WHITE BLACK WHITE (02) (NOT USED) M146650AB_S3 SKYJACK, Page 14 SJIII Compact Series 143909...

  • Page 60: Electrical Inverter Schematic & Panel Diagram (Ansi/Csa - Equipped With Timer Cutout Relay)

    CUSHION SOLENOID LS1B RST3 RED/BLACK 21ACR PROPORTIONAL RELAY HIGH SPEED LOW VOLTAGE MM147370AD1 M149724AA LIMIT SWITCHES N.C. RST2 PROTECTION SJIII Compact Series D17-1 SKYJACK, Page 15 2H-59 ORANGE/BLACK PROPORTIONAL 143909 SOLENOID 17CR1 TRANSFER RELAY 4H-15 BLUE REVERSE SOLENOID DO2-2 3H-17...

  • Page 61: Hydraulic Schematic (Model 3215)

    DISCONNECT MAIN MANIFOLD BLOCK BRAKE ORIFICE CUSHION RETURN CUSHION .051 DIA. 2H-25 ORIFICE FILTER VALVE LOWERING EMERGENCY .040 DIA. CUSHION BLOCK VALVE LOWERING VALVE BLOCK VALVE C4 BRAKE CYLINDER PUMP HYDRAULIC TANK M149792AA SJIII Compact Series SKYJACK, Page 17 143909...

  • Page 62: Hydraulic Schematic (Model 3219)

    DISCONNECT MAIN MANIFOLD BLOCK BRAKE ORIFICE CUSHION RETURN CUSHION .051 DIA. ORIFICE 2H-25 FILTER VALVE LOWERING EMERGENCY CUSHION .040 DIA. BLOCK VALVE LOWERING VALVE BLOCK VALVE C4 BRAKE CYLINDER PUMP HYDRAULIC TANK M138023AA SKYJACK, Page 18 SJIII Compact Series 143909...

  • Page 63: Main Manifold Harness And Holding Valve Harness (Ansi/Csa)

    24 - BLUE/BLACK MOTOR (-) 25 - ORANGE/GREEN 00 - WHITE 59 - ORANGE/BLACK (14 AWG) SPLICE #1 BRAKE VALVE PROPORTIONAL VALVE 17 - BLUE/RED 59 - ORANGE/BLACK 02 - WHITE 02 - WHITE M147331AB_S3 SJIII Compact Series SKYJACK, Page 19 143909...

  • Page 64: Main Manifold Harness And Holding Valve Harness (Ce)

    25 - ORANGE/GREEN 02 - WHITE MOTOR (-) 59 - ORANGE/BLACK 00 - GREEN/YELLOW SPLICE #1 (14 AWG) BRAKE VALVE PROPORTIONAL VALVE 17 - BLUE/RED 59 - ORANGE/BLACK 02 - WHITE 02 - WHITE M147332AA_S3 SKYJACK, Page 20 SJIII Compact Series 143909...

  • Page 65: Electrical Panel Diagram (Ansi/Csa)

    PIN 3 - 02 (WHITE) HORN/FLASHING LIGHT TO MAIN DISCONNECT SWITCH PIN 4 - N/U TO (+) AT MOTOR TO FLASHING LIGHT 02 - WHITE 22 - GREEN TO HORN 02 - WHITE 49 - BLACK M149649AA2 SJIII Compact Series SKYJACK, Page 21 143909...

  • Page 66: Electrical Panel Diagram (Ce)

    7A - RED 10E - BLACK/WHITE 13 - ORANGE 14 - BLACK 15 - BLUE 16 - WHITE/BLACK HORN 18B - RED/BLACK 02 - WHITE N/U - BLUE/BLACK 49 - BLACK N/U - ORANGE/BLACK M149689AA2 SKYJACK, Page 22 SJIII Compact Series 143909...

  • Page 67: Electrical Panel Diagram (Ansi/Csa Ee Rated)

    GREEN/BLACK (18) RED BLACK ORANGE (13) TILT SWITCH RED/WHITE (16) WHITE BLACK BLUE (15) 22 02 TO HORN (NOT USED) WHITE (02) HORN/FLASHING LIGHT 02 - WHITE 49 - BLACK BACK VIEW M147957AA SJIII Compact Series SKYJACK, Page 23 143909...

  • Page 68: Limit Swtich Assemblies Diagram

    PIN 8 - 71 (BLACK/WHITE) BLUE BLACK/WHITE PIN 4 - N/U PIN 8 - 71 (BLACK/WHITE) BLUE BLACK/WHITE BROWN BLACK BROWN BLACK BLUE BLACK/WHITE BLUE BLACK/WHITE ANSI/CSA - Model 3219 CE - Model 3219 M141511AB_S3 SKYJACK, Page 24 SJIII Compact Series 143909...

  • Page 69: Horn/Tilt Switch/Flashing Light Diagram

    FLASHING LIGHT HORN/FLASHING LIGHT HARNESS BLACK - 22 FROM ELEC. PANEL WHITE - 02 (ANSI - FEM. TERM.) WHITE - 02 (CE - RING TERM.) 02 - WHITE 22 - GREEN HORN M146648AA_S3a SJIII Compact Series SKYJACK, Page 25 143909...

  • Page 70: Control Module And Beeper Diagram (Ce)

    PIN 1 - 22 BLACK PIN 2 - 29 GREEN TO GROUND PIN 3 - 60 GREEN PIN 4 - 28 BLACK PIN 5 - 02 WHITE TO ELECTRICAL PANEL PIN 6 - 28E WHITE M130612AE SKYJACK, Page 26 SJIII Compact Series 143909...

  • Page 71: Electrical Schematic (Ansi/Csa - Equipped With No Options)

    NUETRAL 3H-17 BRAKE SOLENOID FWD/UP WHITE/BLACK 4H-16 FORWARD SOLENOID DO2-3 S7-6 ENABLE 17CR ENABLE STEER RELAY BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-4 D23-1 RIGHT S7-3 D24-1 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-5 M147371AC SJIII Compact Series SKYJACK, Page 27 143909...

  • Page 72: Electrical Schematic (Ansi/Csa - Equipped With No Options)

    BRAKE SOLENOID D16-1 4H-16 WHITE/BLACK FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-3 ENABLE 17CR ENABLE STEER RELAY NCHO 4H-23 BLACK/WHITE RIGHT SOLENOID S7-2 DO2-4 D23-1 RIGHT S7-3 LEFT D24-1 4H-24 BLUE/BLACK LEFT SOLENOID DO2-5 M147371AB SKYJACK, Page 28 SJIII Compact Series 143909...

  • Page 73: Electrical Schematic [Ansi/Csa & Ee Rated - Equipped With All Options]

    NUETRAL 3H-17 BRAKE SOLENOID FWD/UP WHITE/BLACK 4H-16 FORWARD SOLENOID S7-6 DO2-3 ENABLE 17CR ENABLE STEER RELAY BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-4 D23-1 RIGHT S7-3 D24-1 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-5 M147370AD SJIII Compact Series SKYJACK, Page 29 143909...

  • Page 74: Electrical Schematic (Ansi/Csa - Equipped With All Options)

    BRAKE SOLENOID D16-1 WHITE/BLACK 4H-16 FWD/UP FORWARD SOLENOID NCHO DO2-3 S7-6 ENABLE 17CR ENABLE STEER RELAY NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-4 D23-1 RIGHT S7-3 D24-1 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-5 M147370AB SKYJACK, Page 30 SJIII Compact Series 143909...

  • Page 75: Electrical Schematic (Ce - Equipped With All Options)

    DO2-8 D16-1 4H-16 WHITE/BLACK FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-9 ENABLE 17CR ENABLE STEER RELAY NCHO 4H-23 BLACK/WHITE RIGHT SOLENOID S7-2 DO2-10 D23-1 RIGHT S7-3 LEFT D24-1 4H-24 BLUE/BLACK LEFT SOLENOID DO2-11 M147810AA SJIII Compact Series SKYJACK, Page 31 143909...

  • Page 76: Electrical Schematic (Ansi/Csa Ee Rated - Equipped With No Options)

    NUETRAL 3H-17 BRAKE SOLENOID 4H-16 FWD/UP WHITE/BLACK FORWARD SOLENOID S7-6 DO2-3 ENABLE 17CR ENABLE STEER RELAY 4H-23 BLACK/WHITE RIGHT SOLENOID S7-2 DO2-4 D23-1 RIGHT S7-3 LEFT D24-1 4H-24 BLUE/BLACK LEFT SOLENOID DO2-5 M149688AB SKYJACK, Page 32 SJIII Compact Series 143909...

  • Page 77: Electrical Schematic (Ansi/Csa Ee Rated - Equipped With No Options)

    BRAKE SOLENOID D16-1 WHITE/BLACK 4H-16 FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-3 ENABLE 17CR ENABLE STEER RELAY NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-4 D23-1 RIGHT S7-3 LEFT D24-1 4H-24 BLUE/BLACK LEFT SOLENOID DO2-5 M149688AA1 SJIII Compact Series SKYJACK, Page 33 143909...

  • Page 78: Electrical Schematic (Ansi/Csa Ee Rated - Equipped With All Options)

    BRAKE SOLENOID D16-1 WHITE/BLACK 4H-16 FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-3 ENABLE 17CR ENABLE STEER RELAY NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID DO2-4 S7-2 D23-1 RIGHT S7-3 LEFT D24-1 BLUE/BLACK 4H-24 LEFT SOLENOID DO2-5 M149867AA SKYJACK, Page 34 SJIII Compact Series 143909...
  • Page 79 Platform will not Lower ..........................12 4.2-7 Platform Lowers Slowly ..........................12 4.2-8 Platform Drives Slow .............................12 4.2-9 Platform will not Drive in Forward or Reverse ....................12 4.2-10 Brake(s) will not Release ..........................13 4.2-11 Platform does not Steer ..........................13 SJIII Compact Series SKYJACK, Page 1 143909...

  • Page 80: Introduction

    The content of this section is separated into “probable cause” and “remedy.” The information preceded by a num- ber represents the “probable cause.” The following line, noted by a dash represents the “remedy” to the “probable cause” directly above it. See example below for clarification. 1. Probable Cause Remedy SJIII Compact Series SKYJACK, Page 3 143909...

  • Page 81: Electrical System

    2. Loose or broken wire #02 from base terminal block to proportional valve 2H-59. Check continuity. Replace if defective. 3. Defective proportional valve coil. Check coil for resistance. Reading should be 19 ohms. Replace if defective. SKYJACK, Page 4 SJIII Compact Series 143909...

  • Page 82: All Controls Inoperative From Base Control Console

    5. Loose or broken wire #19 from base terminal block to Aux. tilt relay 28ECR1. Check continuity. Replace if defective. 6. Loose or broken wire #19A from Aux. tilt relay 28ECR1 to tilt relay 28CR1. Check continuity. Replace if defective. SJIII Compact Series SKYJACK, Page 5 143909...

  • Page 83: No Down Or Reverse Only Function From Platform Controls

    Check continuity. Replace if defective. 10. Defective tilt relay 28CR (ANSI/CSA). Check relay. Replace if defective. 11. Loose or broken wire #19A from tilt relay 28CR to pump motor contactor (ANSI/CSA). Check continuity. Replace if defective. SKYJACK, Page 6 SJIII Compact Series 143909...

  • Page 84: No Down Function From Platform Or Base Control Console (Ansi/Csa Only)

    4.1-11 No Up Function from Base Control Console 1. Defective up/down switch S2. Check switch. Replace if defective. 2. Loose or broken wire #14E from up/down switch S2 to base terminal switch. Check continuity. Replace if defective. SJIII Compact Series SKYJACK, Page 7 143909...

  • Page 85: 12 No Down Function From Base Control Console

    4. Loose or broken wire #59 from 17CR steer relay to base terminal block TB1. Check continuity. Replace if defective. 4.1-17 Drive Only Inoperative 1. Open diode D17. Check diode. Replace if defective. SKYJACK, Page 8 SJIII Compact Series 143909...

  • Page 86: 18 No Drive Or Steer When Platform Fully Lowered

    5. Defective low voltage protection resistor RST3. Check resistor. Replace if defective. 6. Loose or broken wire #21A from low voltage protection resistor RST3 to proportional relay 21ACR. Check continuity. Replace if defective. SJIII Compact Series SKYJACK, Page 9 143909...

  • Page 87: 22 Forward Drive Function Inoperative

    4. Loose or broken wire #02 from brake valve coil 3H-17 to base terminal block. Check continuity. Replace if defective. 4.1-25 Two or more Functions at one time 1. Shorted diode. Check continuity of all diodes. Replace if defective. SKYJACK, Page 10 SJIII Compact Series 143909...

  • Page 88: Hydraulic System

    4. Up valve 3H-14 defective or is sticking. Check valve. Replace if defective. 5. Plugged deceleration valve 2H-13A (Model 3215 ANSI/CSA) or 2H-13C (Model 3215 CE). Clear obstruction from valve. Replace if defective. SJIII Compact Series SKYJACK, Page 11 143909...

  • Page 89: Platform Will Not Lower

    Close Valve. Replace if defective. 2. Forward drive valve 4H-16 or reverse drive valve 4H-15 defective or is sticking. Clean Valve. Replace if defective. 3. Counterbalance valve CB1 defective or is plugged. Clean Valve. Replace if defective. SKYJACK, Page 12 SJIII Compact Series 143909...

  • Page 90: 10 Brake(S) Will Not Release

    Clean valve. Replace if defective. 2. Steer cylinder C3 seals leaking. Rebuild cylinder(s). Replace if damaged. 3. Mechanical binding in king pins. Check for binding. Repair as needed. 4. Orifices 05 plugged. Clean Orifices, and reinstall. SJIII Compact Series SKYJACK, Page 13 143909...
  • Page 91 5.3-3 LED Error Codes - Code Breakdown Chart ....................13 5.3-4 Hand Held Calibration/Diagnostic Tool Key Functions ...................15 5.3-5 Control Module Load Calibration - Code Messages & Definitions ..............16 5.3-6 Control Module Load Calibration Procedure ....................20 5.3-7 Curve/Group Codes Chart ..........................24 SJIII Series SKYJACK, Page 1...

  • Page 92: Service And Maintenance

    The following adjustments affect function response, or speed. There may be some interaction between adjustments, making it necessary to repeat the adjustment in order to achieve the desired response. SJIII Series SKYJACK, Page 3...

  • Page 93: Oem Controller Troubleshooting

    A. Perform “Maxout” adjustment procedures. Trimpots should be sealed with nail polish The function speed remains constant regardless or enamel based paint. of the degree of handle deflection. A. Perform “Maxout” adjustment procedures. wARNiNG Do not use RTV silicone. SKYJACK, Page 4 SJIII Series...

  • Page 94: Oem Controller Switch Wiring

    (STEER RIGHT) STEER COMMON WHT/GRN SINGLE DOT (STEER LEFT) STEER RIGHT STEER LEFT WHT/RED ENABLE OUT WHT/BLU +24V INPUT WHT/BLK ENABLE 15589 PCB (+24V INPUT) WHT/BLK PWD OUT (A) (ENABLE) WHT/YEL GROUND (-) FORWARD/UP REVERSE/DOWN CONNECTOR SJIII Series SKYJACK, Page 5...

  • Page 95: Base

    Release steer switch and tighten the locknut. NOTE Remove the gauge from system pressure test Pressure setting may vary as aerial platform port. components wear. The lift pressure should be set for rated load only. SKYJACK, Page 6 SJIII Series...

  • Page 96: Electronic Tilt Switch Setup Procedure

    . NOTE Results: The switch Red LED The tilt circuit is only powered when Green LED is ready for normal activating a function. operation. SJIII Series SKYJACK, Page 7...
  • Page 97 Remove jumper wire between #7 and #19 from terminal block. Reattach all wires #02 to motor contactor. Reinstall any covers that was removed. Remove chock or wheel blocks. Proceed to Test and Verify Tilt Circuit. SKYJACK, Page 8 SJIII Series...

  • Page 98: Reprogramming Existing Tilt Switch

    LED will turn on solid for 2 seconds. Red LED Red LED Green LED Green LED Red LED Red LED Green LED Green LED Results: The switch is verifying the new zero position. SJIII Series SKYJACK, Page 9...

  • Page 99: Test And Verify Tilt Circuit

    Red LED specified degrees out from the zero/ home position. On together, no blinking when Green & Red LED fault detected. Tilt Circuit Test Refer to section 2 for test tilt sensor procedure. SKYJACK, Page 10 SJIII Series...

  • Page 100: Load Sensing System - Ce

    Not Used Not Used Not Used 910 Black Positive Signal To Angle Transducer 900 White Negative Signal To Angle Transducer 902 White Negative Signal To Pressure Transducer 910A Black Positive Signal To Pressure Transducer M60303AG SJIII Series SKYJACK, Page 11...

  • Page 101: Led Error Codes - Quick Reference Chart

    4. A 4 second pause. Repeat steps 1-4 Since the GP102 only reports one error, only one code can be read from the LED per instance. If the error is cleared and another error is present, it will then be presented. SKYJACK, Page 12 SJIII Series...

  • Page 102: Led Error Codes - Code Breakdown Chart

    Check that the battery voltage is not too low. Verify battery voltage on P2-12. Disconnect plug P4 – if the fault clears there is a wiring fault from P4-1 to the rest of the vehicle. SJIII Series SKYJACK, Page 13...
  • Page 103 Action a function to clear the idle timeout if it occurred. Ensure the GP102 is correctly mounted – incorrect mounting can cause the “bad tilt sensor” diagnostic to occur. Otherwise there may be an internal problem with the GP102. SKYJACK, Page 14 SJIII Series...

  • Page 104: Hand Held Calibration/Diagnostic Tool Key Functions

    Read all instructions closely before attempting each phase or the calibration procedure. Symbol Key Function ESC/ENTER Buttons To move back and forth between menu and sub-menu LEFT/RIGHT Buttons Select menus and setting to be adjusted UP?DOWN BUTTONS Adjust setting values SJIII Series SKYJACK, Page 15...

  • Page 105: Control Module Load Calibration - Code Messages & Definitions

    Check DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem. Code F11: Not Up This message occurs at the start of calibration if the operator selects a function other than UP . Select the UP function. SKYJACK, Page 16 SJIII Series...
  • Page 106 0.9V and 4.1V, during calibration; and between 0.4V and 4.6V, during normal operation. Check DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem. SJIII Series SKYJACK, Page 17...
  • Page 107 This message is prompting for confirmation that the platform is loaded to rated load Press ENTER to confirm if the platform is loaded. Please Lift This message is prompting for the platform to be raised. The UP switch should be closed. SKYJACK, Page 18 SJIII Series...
  • Page 108 The last calibrate date can be viewed in DIAGNOSTICS / LOG. Press LEFT & RIGHT to select the flashing digits. Press UP & DOWN to change the flashing digits. Press ENTER when the entry is complete. IMPORTANT: The date 00/00/00 is not allowed! Finished This message confirms that calibration is complete and successful. SJIII Series SKYJACK, Page 19...

  • Page 109: Control Module Load Calibration Procedure

    The jumper connection must be connected between the contractor (wire #19B) and the lift coil (instead of the black wire #14) Contactor Main Manifold JUMPER, Insulated Alligator Clip Wire #19B Coil Black wire #14 Lift Valve Connect the Easy-Cal tool to the P1 connector on the CONTROL MODULE. SKYJACK, Page 20 SJIII Series...
  • Page 110 The display will show “Help: Press Enter”. By using Left/Right buttons, select the “Access Level ( ? )” from the menu and press the ENTER button. Contact Skyjack Service Department at: (44) 1691-676 236 for your Access Level Code Number.
  • Page 111 38. The display will show “Calibrate Load: Caldate: mm/dd/yy”. It is recommended that the current date be entered here to provide easy taking of the data of last calibration. The current date must be entered using the LEFT/RIGHT and UP/DOWN buttons. SKYJACK, Page 22 SJIII Series...
  • Page 112 If the phase does not need to be repeated, just press ENTER to move on. If the phase does need to be repeated, press UP or DOWN to change “NO” to “YES” then press ENTER. SJIII Series SKYJACK, Page 23...
  • Page 113 1 Powered Extension Platform 3226 1 Manual Extension Platform 4620 1 Manual Extension Platform 4620 1 Powered Extension Platform 4626 1 Manual Extension Platform 4626 1 Powered Extension Platform 4632 1 Manual Extension Platform 60404AE_SJ3D SKYJACK, Page 24 SJIII Series...
  • Page 114 Reliable lift solutions by people who care. www.skyjack.com...

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Sj 3219

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