Skyjack SJ 3220 Service Manual
  1. Manuals
  2. Brands
  3. Skyjack Manuals
  4. Lifting Systems
  5. SJ 3220
  6. Service manual

Skyjack SJ 3220 Service Manual

Sjiii conventional series
Hide thumbs Also See for SJ 3220:
Table of Contents

Advertisement

Quick Links

See also: Operating Manual
MODELS
SJ 3220 SJ 3226 SJ 4620 SJ 4626 SJ 4632
Service Manual
SJIII Conventional Series
Part No. 143911AD
November 2013

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SJ 3220 and is the answer not in the manual?

Questions and answers

Related Manuals for Skyjack SJ 3220

Summary of Contents for Skyjack SJ 3220

  • Page 1 MODELS SJ 3220 SJ 3226 SJ 4620 SJ 4626 SJ 4632 Service Manual SJIII Conventional Series Part No. 143911AD November 2013...
  • Page 2 CE & AS SJIII 3320 60,001,523 TO 60,002,031 SJIII 3226 27,004,500 TO 27,005,500 SJIII 46xx 70,004,720 TO 70,006,052 Please refer to the website (www.skyjack.com) for older Serial Numbers. Skyjack Service Center Parts & Service (Europe) Unit 1 Maes Y Clawdd 3451 Swenson Ave.
  • 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) ............41 3.28a Electrical Schematic (ANSI/CSA EE Rated - Equipped with all options) .............42 3.28b Electrical Schematic (ANSI/CSA EE Rated - Equipped with all options) .............43 SJIII Conventional Series SKYJACK, Page 1 143911...

  • 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 Conventional Series SKYJACK, Page 3 143911...

  • 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 Conventional Series 143911...

  • 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 Conventional Series SKYJACK, Page 5 143911...

  • Page 51: Hydraulic Manifold And Port Identifications

    4H-16 (If equipped) Forward Valve Lift Relief Valve 2H-13 Relief Valve Lowering Valve 4H-23 4H-15 Right Steer Valve Reverse Drive Valve 4H-24 Quick Disconnect Left Steer Valve (If equipped) System Relief Valve M138117AA_S3 SKYJACK, Page 6 SJIII Conventional Series 143911...
  • Page 52 BLOCK, Manifold (Holding valve) (Models 3226/4626/4632 CE) 108195 BLOCK, Manifold (Rear drive) BLOCK, Manifold (Powered extension platform - part of cylinder weldment) 146563 BLOCK, Manifold (Brake release) (Models 46xx) Parts list continued on the following page. SJIII Conventional Series SKYJACK, Page 7 143911...
  • Page 53 (Model 4620 CE) 104534 VALVE, Relief (System) 104534 VALVE, Relief (Lift) 106557 VALVE, Relief (Holding valve) (Models 3226/4626/4632) 107271 VALVE (Emergency lowering) 103136 VALVE (Free-wheeling) 146562 VALVE (Auto reset - brake release) (Models 46xx) SKYJACK, Page 8 SJIII Conventional Series 143911...

  • Page 54: Electrical Components 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 10 SJIII Conventional Series 143911...
  • Page 55 (Models 4620 CE) 134543 TRANSDUCER, Pressure 1250 psi (Models 3226 CE) RST1 119629 RESISTOR, 2.7K ohms RST2 146644 RESISTOR, 25W-30 Ohms RST3 116505 RESISTOR, Low voltage protection Parts list continued on the following page. SJIII Conventional Series SKYJACK, Page 11 143911...
  • Page 56 SWITCH (Powered extension platform enable) 147053 N.C. CONTACT (Emergency stop) (Base control console) 146658 TILT SWITCH (Models 322x ANSI/CSA & EE rated) 146661 TILT SWITCH (Models 46xx ANSI/CSA & EE rated) 103336 HOURMETER SKYJACK, Page 12 SJIII Conventional Series 143911...

  • Page 57: Platform Control Console Diagram (With Toggle Switch)

    08 BLUE WHITE/BLACK GREY PIN 6 - REV/DOWN PURPLE/WHITE PIN 7 - PWM BLUE 59 ORANGE/BLACK BLACK PIN 8 - GND 02 WHITE PIN 9 - ENABLE VS+ 8A BLUE WHITE/ BLUE M156881AA SJIII Conventional Series SKYJACK, Page 13 143911...

  • Page 58: Platform Control Console Diagram (With Rotary Switch)

    JOYSTICK HARNESS PIN 6 - REV/DOWN A PURPLE/WHITE GREY PIN 7 - PWM 59 ORANGE/BLACK BLUE PIN 8 - GND BLACK 02 WHITE CRD1 PIN 9 - ENABLE VS+ 8A BLUE WHITE/BLUE M146621AA SKYJACK, Page 14 SJIII Conventional Series 143911...

  • Page 59: Platform Control Console With Toggle Switch - Powered Extension Platform Modification Diagram

    TO PWR DECK CONTROL BOX PIN 1 - 27 BLACK PIN 2 - 09 WHITE PIN 3 - 26 GREEN PIN 4 - N / U PIN 5 - N / U M156955AA SJIII Conventional Series SKYJACK, Page 15 143911...

  • Page 60: Platform Control Console With Rotary Switch - Powered Extension Platform Modification Diagram

    WHITE BLACK (16) (NOT USED) (02) WHITE TO POWER EXTENSION PLATFORM BACK VIEW SOLENOID VALVES 1.BLACK (27) 2.WHITE (02) 3.GREEN (26) TO POWER EXTENSION PLATFORM CONTROL CONSOLE 1.BLACK (27) 2.WHITE (09) 3.GREEN (26) 4.(N/U) M146620AB SKYJACK, Page 16 SJIII Conventional Series 143911...

  • Page 61: Power Extension Platform Control Console And Harness

    1 BLACK (27) MALE 2 WHITE (08) 3 GREEN (26) 4 (N/U) TO POWER CONTROL CONSOLE BACK VIEW EXTENSION PLATFORM CYLINDER HARNESS MALE 1 BLACK (27) 2 WHITE (02) 3 GREEN (26) 4 (N/U) M115592AI1_S3 SJIII Conventional Series SKYJACK, Page 17 143911...

  • Page 62: Base Control Console Diagram

    PIN 3 - 13 (ORANGE) PIN 4 - 14E (BLACK) PIN 5 - 10E (WHITE/BLACK) (CE) PIN 6 - 8C (BLUE) PIN 7 - 7A (RED/BLACK) PIN 8 - 02 (WHITE) BACK VIEW M149553AA_S3 SKYJACK, Page 18 SJIII Conventional Series 143911...

  • Page 63: 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 SJIII Conventional Series SKYJACK, Page 19 143911...

  • Page 64: Hydraulic Schematic (Models 322X)

    VALVE SYSTEM RELIEF LOWERING ORIFICE VALVE VALVE VALVE SEE REFERENCE TABLE COUNTERBALANCE VALVE DCM1 DC MOTOR V1 EMERGENCY MAIN MANIFOLD BLOCK LOWERING HYDRAULIC LOWERING PUMP VALVE VALVE BLOCK (MANUAL) RETURN FILTER RESERVOIR M132308AD1 SJIII Conventional Series SKYJACK, Page 21 143911...

  • Page 65: Hydraulic Schematic (Models 46Xx)

    SYSTEM RELIEF VALVE COUNTERBALANCE VALVE MB5 P. DECK PRESSURE- VALVE MANIFOLD BLOCK COMPENSATED PROPORTIONAL VALVE MAIN MANIFOLD BLOCK EMERGENCY LOWERING LOWERING VALVE VALVE DCM1 BLOCK (MANUAL) DC MOTOR HYDRAULIC PUMP RETURN FILTER RESERVOIR M137018AD1 SKYJACK, Page 22 SJIII Conventional Series 143911...

  • Page 66: Main Manifold Harness And Holding Valve Harness (Ansi/Csa & Ee Rated)

    PROPORTIONAL VALVE 24 - BLUE/BLACK LIFT VALVE 02 - WHITE 59 - ORANGE/BLACK 59 - ORANGE/BLACK 14 - BLACK 02 - WHITE 02 - WHITE BRAKE VALVE 17A - BLUE/RED 02 - WHITE M146669AA_S3 SJIII Conventional Series SKYJACK, Page 23 143911...

  • Page 67: Main Manifold Harness And Holding Valve Harness (Ce)

    PROPORTIONAL VALVE 24 - BLUE/BLACK LIFT VALVE 02 - WHITE 59 - ORANGE/BLACK 59 - ORANGE/BLACK 14 - BLACK 02 - WHITE 02 - WHITE BRAKE VALVE 17A - BLUE/RED 02 - WHITE M146667AA_S3 SKYJACK, Page 24 SJIII Conventional Series 143911...

  • Page 68: Electrical Panel Diagram (Ansi/Csa)

    19 - BLACK (59) ORANGE BLACK BLACK (14) ORANGE (13) (18) RED BLACK MAIN MANIFOLD (16) WHITE BLACK BLUE (15) (NOT USED) WHITE (02) PLATFORM CONTROL BOX REAR HARNESS TILT SWITCH HORN/FLASHING LIGHT M149583AA SJIII Conventional Series SKYJACK, Page 25 143911...

  • Page 69: Electrical Panel Diagram (Ce)

    (18) RED BLACK ORANGE (13) (16) WHITE BLACK BLUE (15) PLATFORM CONTROL BOX (NOT USED) WHITE (02) REAR HARNESS CONTROL MODULE HORN CONTROL MODULE 28 - BLACK 28E - WHITE 60 - GREEN M147918AA_S3 SKYJACK, Page 26 SJIII Conventional Series 143911...

  • Page 70: Electrical Panel Diagram (Ansi/Csa Ee Rated)

    72 - BROWN 19 - BLUE TO FLASHING LIGHT 02 - WHITE 22 - GREEN MAIN MANIFOLD PLATFORM CONTROL BOX TO HORN 02 - WHITE REAR HARNESS 49 - BLACK TILT SWITCH HORN/FLASHING LIGHT M147790AA_S3 SJIII Conventional Series SKYJACK, Page 27 143911...

  • Page 71: Harnesses Diagram

    PIN 3 - 02 (WHITE) 02 - WHITE TO ELECTRIC PANEL PIN 4 - N/U PIN 1 - 3A BLACK 3A - BLACK PIN 2 - 05 WHITE 05 - WHITE (OPT) - GREEN M146588AA_S3 SKYJACK, Page 28 SJIII Conventional Series 143911...

  • Page 72: Limit Switch Assemblies Diagram

    PIN 3 - 18 (BLACK/WHITE) PIN 7 - 19 (BLACK) PIN 4 - 18A (BLACK) PIN 8 - 71 (BLACK/WHITE) BLUE BLACK/WHITE BROWN BLACK LS1A BLUE BLACK/WHITE ANSI/CSA - MODEL 32xx/46xx EE RATED EXCEPT MODEL 4632 M133664AB SJIII Conventional Series SKYJACK, Page 29 143911...

  • Page 73: Horn/Tilt Switch/Flashing Light Diagram

    BLACK - 22 FLASHING LIGHT WHITE - 02 (ANSI - FEM. TERM.) WHITE - 02 (CE - RING TERM.) HORN/FLASHING LIGHT HARNESS 02 - WHITE FROM ELEC. PANEL 22 - GREEN HORN M146648AA_S3B SKYJACK, Page 30 SJIII Conventional Series 143911...

  • Page 74: 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 SJIII Conventional Series SKYJACK, Page 31 143911...

  • Page 75: Electrical Schematic (Ansi/Csa - Equipped With No Options)

    S7-1 17CR DO2-3 NUETRAL TRANSFER RELAY FWD/UP WHITE/BLACK 4H-16 FORWARD SOLENOID DO2-4 S7-6 ENABLE ENABLE BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-5 RIGHT 3H-17A BRAKE SOLENOID S7-3 LEFT 4H-24 BLUE/BLACK LEFT SOLENOID DO2-6 M146647AC1 SKYJACK, Page 32 SJIII Conventional Series 143911...

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

    NUETRAL TRANSFER RELAY D16-1 4H-16 WHITE/BLACK FWD/UP FORWARD SOLENOID NCHO DO2-4 S7-6 ENABLE ENABLE NCHO 4H-23 BLACK/WHITE RIGHT SOLENOID S7-2 DO2-5 RIGHT 3H-17A BRAKE SOLENOID S7-3 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-6 M146647AB SKYJACK, Page 33 SJIII Conventional Series 143911...

  • Page 77: Electrical Schematic (Ansi/Csa - Equipped With All Options)

    S7-1 17CR DO2-3 NUETRAL TRANSFER RELAY 4H-16 FWD/UP WHITE/BLACK FORWARD SOLENOID DO2-4 S7-6 ENABLE ENABLE BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-5 RIGHT 3H-17A BRAKE SOLENOID S7-3 LEFT 4H-24 BLUE/BLACK LEFT SOLENOID DO2-6 M146624AE1 SJIII Conventional Series SKYJACK, Page 34 143911...

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

    NUETRAL TRANSFER RELAY D16-1 WHITE/BLACK 4H-16 FWD/UP FORWARD SOLENOID NCHO DO2-4 S7-6 ENABLE ENABLE NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-5 RIGHT 3H-17A BRAKE SOLENOID S7-3 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-6 M146624AC SJIII Conventional Series SKYJACK, Page 35 143911...

  • Page 79: Electrical Schematic (Models 322X Ce - Equipped With All Options)

    S7-1 17CR NUETRAL TRANSFER RELAY FWD/UP WHITE/BLACK 4H-16 FORWARD SOLENOID S7-6 DO2-10 ENABLE ENABLE BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-11 RIGHT 3H-17A BRAKE SOLENOID S7-3 DO2-12 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-13 M149743AB SKYJACK, Page 36 SJIII Conventional Series 143911...
  • Page 80 TRANSFER RELAY D16-1 WHITE/BLACK 4H-16 FWD/UP FORWARD SOLENOID S7-6 NCHO DO2-10 ENABLE ENABLE NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-11 RIGHT 3H-17A BRAKE SOLENOID S7-3 DO2-12 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-13 M149743AA SKYJACK, Page 37 SJIII Conventional Series 143911...

  • Page 81: Electrical Schematic (Models 46Xx Ce - Equipped With All Options)

    S7-1 17CR NUETRAL TRANSFER RELAY 4H-16 FWD/UP WHITE/BLACK FORWARD SOLENOID DO2-10 S7-6 ENABLE ENABLE 4H-23 BLACK/WHITE RIGHT SOLENOID DO2-11 S7-2 RIGHT 3H-17A BRAKE SOLENOID S7-3 DO2-12 LEFT 4H-24 BLUE/BLACK LEFT SOLENOID DO2-13 M147346AE SJIII Conventional Series SKYJACK, Page 38 143911...

  • Page 82: Electrical Schematic (Models 46Xx Ce - Equipped With All Options)

    TRANSFER RELAY D16-1 WHITE/BLACK 4H-16 FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-10 ENABLE ENABLE NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-11 RIGHT 3H-17A BRAKE SOLENOID S7-3 DO2-12 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-13 M147346AD SJIII Conventional Series SKYJACK, Page 39 143911...

  • Page 83: Electrical Schematic (Ansi/Csa Ee Rated - Equipped With No Options)

    DO2-3 S7-1 17CR NUETRAL TRANSFER RELAY 4H-16 FWD/UP WHITE/BLACK FORWARD SOLENOID S7-6 DO2-4 ENABLE ENABLE BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-5 RIGHT 3H-17A BRAKE SOLENOID S7-3 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-6 M150851AB-1 SKYJACK, Page 40 SJIII Conventional Series 143911...

  • Page 84: Electrical Schematic (Ansi/Csa Ee Rated - Equipped With No Options)

    NUETRAL TRANSFER RELAY D16-1 4H-16 WHITE/BLACK FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-4 ENABLE ENABLE NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-5 RIGHT 3H-17A BRAKE SOLENOID S7-3 LEFT 4H-24 BLUE/BLACK LEFT SOLENOID DO2-6 M150851AA SKYJACK, Page 41 SJIII Conventional Series 143911...

  • Page 85: Electrical Schematic (Ansi/Csa Ee Rated - Equipped With All Options)

    S7-1 17CR DO2-3 NUETRAL TRANSFER RELAY FWD/UP WHITE/BLACK 4H-16 FORWARD SOLENOID S7-6 DO2-4 ENABLE ENABLE BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-5 RIGHT 3H-17A BRAKE SOLENOID S7-3 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-6 M147978AB-1 SJIII Conventional Series SKYJACK, Page 42 143911...

  • Page 86: Electrical Schematic (Ansi/Csa Ee Rated - Equipped With All Options)

    NUETRAL TRANSFER RELAY D16-1 WHITE/BLACK 4H-16 FWD/UP FORWARD SOLENOID NCHO DO2-4 S7-6 ENABLE ENABLE NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-5 RIGHT 3H-17A BRAKE SOLENOID S7-3 LEFT 4H-24 BLUE/BLACK LEFT SOLENOID DO2-6 M147978AA SJIII Conventional Series SKYJACK, Page 43 143911...
  • Page 87 4.2-10 Aerial Platform will not hold on a Grade (Machines with Integrals Brakes) ..........15 4.2-11 Platform does not Steer ..........................15 4.2-12 All System sluggish ............................15 4.2-13 Power Extension Platform will not Extend or Retract ...................15 4.2-14 High/Low Torque Inoperative ........................15 SJIII Conventional Series SKYJACK, Page 1 143911...
  • Page 88 4.3-33 Flash Code F42:Low Pressure ........................20 4.3-34 Flash Code F43:High Pressure ........................20 4.3-35 Flash Code F44:Low Pressure ........................20 4.3-36 Flash Code F45:High Pressure ........................20 4.3-37 Flash Code F46:Check Elev .........................20 4.3-38 Flash Code F47:Check Elev .........................20 SKYJACK, Page 2 SJIII Conventional Series 143911...

  • Page 89: 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 Conventional Series SKYJACK, Page 3 143911...

  • Page 90: Electrical System

    Check continuity. Replace if defective. 4.1-2 All Controls Except for Down Function Inoperative 1. Loose or broken wire #19A (ANSI/CSA) or wire #19B (CE) from base terminal block TB-1 to contactor Check continuity. Replace if defective. SKYJACK, Page 4 SJIII Conventional Series 143911...

  • Page 91: All Controls Inoperative From Base Control Console

    Check continuity. Replace if defective. 6. Defective joystick enable switch S7-6. Check switch. Replace if defective. 7. Defective joystick neutral switch S7-1. Check switch. Replace if defective. 8. Defective joystick S7. Check joystick. Replace if defective. SJIII Conventional Series SKYJACK, Page 5 143911...

  • Page 92: No Drive Or Up Function From Platform Or Base Controls (Ce Only)

    3. Open diode D14. Check diode. Replace if defective. 4. Open diode D21A (ANSI/CSA) or D21 (CE). Check diode. Replace if defective. 5. Machine not level. (Above high speed limit switch) Use on level surface. SKYJACK, Page 6 SJIII Conventional Series 143911...

  • Page 93: No Down Function From Platform Or Base Control Console (Ansi/Csa Only)

    Check continuity. Replace if defective. 6. Loose or broken wire # 13B from down relay 28CR2 to down valve 2H-13B or holding valve 2H-13B-1 or holding valve 2H-13B-2. Check continuity. Replace if defective. SJIII Conventional Series SKYJACK, Page 7 143911...

  • Page 94: 11 No Up Function From Base Control Console

    Check continuity. Replace if defective. 2. Defective drive override switch LS6. Check switch. Replace if defective. 3. Loose or broken wire #19 from drive override limit switch LS6 to base terminal block. Check continuity. Replace if defective. SKYJACK, Page 8 SJIII Conventional Series 143911...

  • Page 95: 16 No Drive Or Steer When Platform Elevated

    7. Loose or broken wire #02 from proportional relay 21CCR (ANSI/CSA) or 21ACR (CE) to base terminal block. Check continuity. Replace if defective. 8. Proportional controller S7 out of adjustment. Adjust controller. Refer to Section 5, Joystick Adjusting Procedure. SJIII Conventional Series SKYJACK, Page 9 143911...

  • Page 96: 19 Forward Drive Function Inoperative

    1. Open diode D15-1 (reverse) or D16-1 (forward). Check diode. Replace if defective. 2. Loose or broken wire #7B from diodes D15-1 and D16-1 to lift/drive switch S3. Check continuity. Replace if defective. SKYJACK, Page 10 SJIII Conventional Series 143911...

  • Page 97: 23 Right Steer Inoperative

    Check continuity through coil. Replace if defective. 6. Loose or broken wire #02 from steer left valve coil 4H-24 to base terminal block TB-1. Check continuity. Replace if defective. 7. Open diode D24. Check diode. Replace if defective. SJIII Conventional Series SKYJACK, Page 11 143911...

  • Page 98: 25 Power Extension Platform Will Not Extend Or Retract

    5. Loose or broken wire #02 from retract valve coil 4H-27 to platform control box. Check continuity. Replace if defective. 4.1-28 Two or more Functions at one time 1. Shorted Diode. Check continuity of all diodes. Replace if defective. SKYJACK, Page 12 SJIII Conventional Series 143911...

  • Page 99: Hydraulic System

    Down function is not proportionally controlled. ANSI/CSA Machines only 1. Lowering valve 2H-13 defective or is sticking. Clean valve. Replace if defective. 2. Defective holding valve 2H-13-1 or 2H-13-2. Clean valve. Replace if defective. SJIII Conventional Series SKYJACK, Page 13 143911...

  • Page 100: Platform Drives Slow

    Check brake pack will maintain pressure. If pressure is not maintained replace seals. 4. Plugged or defective brake orifice 07. Clear obstruction. Replace if defective. 5. Damaged integral brake in wheel motor. Inspect wheel motor assembly. Repair and replace as necessary. SKYJACK, Page 14 SJIII Conventional Series 143911...

  • Page 101: 10 Aerial Platform Will Not Hold On A Grade (Machines With Integrals Brakes)

    3. Mechanical binding in power extension platform mechanism. Check for binding. Repair as needed. 4.2-14 High/Low Torque Inoperative 1. Stuck speed valve 3H-18A-1. Clean valve. Replace if defective. 2. Stuck speed valve 3H-18A-2. Clean valve. Replace if defective. SJIII Conventional Series SKYJACK, Page 15 143911...
  • Page 102 A reading of 0V or 5V is probably due to a wiring problem. 4.3-10 Flash Code F11: Not Up 1. This message occurs at the start of the DYNAMIC lift if the operator selects a function other than UP . Select the UP function. SKYJACK, Page 16 SJIII Conventional Series 143911...
  • Page 103 1. This message is given if the elevation switch (P2-10) closed during lower at a too low height (below 5%). If it closes below 5%, height sensor fault detection is compromised. Check CALIBRATIONS / HEIGHT CALS; the “ElevDown” value shows the recorded height where the switch opened. SJIII Conventional Series SKYJACK, Page 17 143911...
  • Page 104 4.3-25 Flash Code F26:Check Elev 1. This message indicates a problem with the elevation switch (P2-10) during the STATIC phases. The switch is opening or closing at a different height than that recorded during the DYNAMIC phase. SKYJACK, Page 18 SJIII Conventional Series 143911...
  • Page 105 Check CALIBRATIONS / HEIGHT CALS; the “Height” indicates the first height at which there was insufficient difference and the “Up” and “Down” values show the loaded pressure (first) and the difference between loaded and empty pressure (second). SJIII Conventional Series SKYJACK, Page 19 143911...
  • Page 106 1. This message indicates that the elevation switch opened more than once during the DYNAMIC lift. 4.3-38 Flash Code F47:Check Elev 1. This message indicates that the elevation switch closed more than once during the DYNAMIC lower. SKYJACK, Page 20 SJIII Conventional Series 143911...
  • Page 107 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 108: 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 109: 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 110: 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 111: 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 112: 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 113 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 114: 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 115: 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 116: 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 117: 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 118: 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 119 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 120: 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 121: 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 122 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 123 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 124 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 125: 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 126 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 127 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 128 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 129: Curve/Group Codes Chart

    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 130 Reliable lift solutions by people who care. www.skyjack.com...

This manual is also suitable for:

Sj 4620Sj 3226Sj 4626Sj 4632

Table of Contents

Save PDF