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MODEL 3220 3226 4620 4626 4632 ervice Manual JIII Conventional eries art No. 143911A March 2018...
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CE & AS JIII 3320 60,001,523 TO 60,002,031 JIII 3226 27,004,500 TO 27,005,500 JIII 46xx 70,004,720 TO 70,006,052 Please refer to the website (www.skyjack.com) for older erial Numbers. Skyjack Service Center Parts & Service (Europe) Unit 1 Maes Y Clawdd 3451 wenson Ave.
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ERVICE AND MAINTENANCE Table of Contents ection 1 - cheduled Maintenance Inspections able of Contents ection 2 - Maintenance Tables able of Contents ection 3 - chematics able of Contents ection 4 - Troubleshooting able of Contents ection 5 - Procedures able of Contents JIII eries KYJACK, Page 3...
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Operator’s Responsibility for Maintenance ection 1 - cheduled Maintenance he Safety Alert Symbol identifies important safety messages on aerial platforms, safety This afety Alert ymbol means attention! signs in manuals or elsewhere. When you see this symbol, be alert to the possibility of Become alert! Your safety is involved.
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.
Operator’s Responsibility for Maintenance ection 1 - cheduled Maintenance cope of this Manual This manual applies to the ANSI/SIA, CSA and CE versions of the SJIII Series aerial platform models listed able 2.1. - Equipment identified with “ANSI” meets the ANSI SIA-A92.6-2006 standard. - Equipment identified with “CSA”...
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 his aerial platform is not electrically insulated.
Operator’s Responsibility for Maintenance ection 1 - cheduled Maintenance afety Precautions Know and understand the safety precautions before going on to next section. wARNiNG Failure to heed the following safety O NOT increase the lateral precautions could result in tip over, surface area of the platform.
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ection 1 - cheduled Maintenance Operator’s Responsibility for Maintenance afety Precautions (Continued) Know and understand the safety precautions before going on to next section. O NOT operate on surfaces not capable of O NOT raise the aerial platform holding the weight of the aerial platform including while the aerial platform is on a the rated load, e.g.
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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...
Consult SKYJACK’s Service Department for optional tires specifications and installation. Before attempting any repair work, turn Battery Disconnect Switch to the “OFF” position.
Operator’s Responsibility for Maintenance ection 1 - cheduled Maintenance Hydraulic ystem & Component Oil change intervals will depend on the care used in keeping the oil clean, and the Maintenance and Repair operating conditions. Dirt and/or moisture he following points should be kept in mind when cotamination will dictate that the oil should working on the hydraulic system or any component: be changed more often.
ection 1 - cheduled Maintenance ervice and Maintenance About this ection Maintenance Instructions his section contains the maintenance and inspection his manual consists of four schedules to be done for schedule that is to be performed. maintaining on an aerial platform. Inspection schedule frequency is shown below: References are made to the procedures in Section 5 that outline detailed step-by-step instructions for checks...
ervice and Maintenance ection 1 - cheduled Maintenance Table 1.1 Owner’s Annual Inspection Record Model Number: ____________________________ Serial Number: ____________________________ ecording Date ecording Year # Owner’s Name Inspected 05 4AA 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.
† - 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. JIII eries KYJACK, Page 17...
ervice and Maintenance ection 1 - cheduled Maintenance High Speed Limit Switch High Speed Limit Switch Pothole Protection Limit Switch cheduled Maintenance Inspections Hydraulic Maintaining the hydraulic components is essential Begin the scheduled maintenance inspections by to good performance and service life of the aerial checking each item in sequence for the conditions listed platform.
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ection 1 - cheduled Maintenance ervice and Maintenance Conventional Compact Ladder (Back View) 110V Outlet Receptacle Free-wheeling Valve Emergency Main Brakes Power Ladder Disconnect Base Switch Control Console 110V Outlet Receptacle Free-wheeling Valve Compact Brakes (Back View) 1.1-3 Entrance ide AC Outlet Receptacle Ensure receptacle is free from dirt and Main Power Disconnect witch...
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ervice and Maintenance ection 1 - cheduled Maintenance Conventional Compact Battery Battery Charger Battery Charger Hydraulic/Electric Battery Fuse Box Battery ray Battery ray Pothole Protection Device 1.1-4 Battery Tray ide wARNiNG Battery acid is extremely corrosive Pothole Protection Device - Wear proper eye and facial protec- Ensure mechanisms have no sign of tion as well as appropriate protective visible damage and are free from dirt and...
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ection 1 - cheduled Maintenance ervice and Maintenance Conventional Wheel/ ire Steer Cylinder Wheel/ ire Greasing Point Wheel Motor ie Rod teer Cylinder Assembly Tie Rod (Conventionals) Ensure steer cylinder assembly is Ensure there are no loose or missing properly secured and there are no loose parts, tie rod end studs are locked and or missing parts.
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ervice and Maintenance ection 1 - cheduled Maintenance Compact ilt Sensor Emergency Lowering Greasing Point Access Rod Electrical Panel Hydraulic/Electric Main Manifold Greasing Point Hydraulic ank 1.1-5 Hydraulic/Electric Tray ide Electrical Panel Ensure tray latch is secure and in proper Ensure panel is properly secured and working order.
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ection 1 - cheduled Maintenance ervice and Maintenance Platform Control Console Platform Railing Manual Storage Lanyard Attachment Anchor Platform Assembly 1.1-6 Platform Assembly Platform Control Console Ensure all switches and controller are returned to neutral and are properly wARNiNG secured. Ensure that you maintain three points of Ensure there are no loose or missing contact to mount/dismount platform.
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ervice and Maintenance ection 1 - cheduled Maintenance Maintenance Support Lift Cylinder Scissor Bumper Scissor Assembly Roller Powered Extension Control Console cissor Bumpers (If Equipped) Ensure bumpers are secure and shows Ensure all switches are returned to no sign of visible damage. neutral and are properly secured.
ection 1 - cheduled Maintenance Function Tests Conventional Compact (Back View) (Back View) Free-wheeling Valve Lower/ Lower/ Neutral/Raise Neutral/Raise Switch Switch Emergency Stop Platform/Off/Base Emergency Stop Button Key Switch Button 1.2 Function Tests 1.2-2 Base Control Console Function tests are designed to discover any malfunctions before aerial platform is put into service.
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Function Tests ection 1 - cheduled Maintenance Conventional Compact (Back View) (Back View) Free-wheeling Valve Platform Platform Raise/Lower Raise/Lower Switch Switch Emergency Stop Platform/Off/Base Emergency Stop Button Key Switch Button Test Base Emergency top 3. Select and hold off/platform/base key switch to “...
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ection 1 - cheduled Maintenance Function Tests Conventional Compact (Back View) (Back View) Free-wheeling Valve Lower/ Lower/ Neutral/Raise Neutral/Raise Switch Switch Emergency Stop Platform/Off/Base Emergency Stop Button Key Switch Button Test Emergency Lowering Test Free-wheeling 1. Raise the platform. 1. Ensure path of intended motion is clear. 2.
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ection 1 - cheduled Maintenance Function Tests Conventional Compact Pothole Protection Pothole Protection Device Device 3. Push controller handle and raise the Test Pothole ensor platform to an approximate height of 1 ft. (30.5 cm). wARNiNG Result: Platform should rise. Ensure that you maintain three points of contact to mount/dismount plat- 4.
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Function Tests ection 1 - cheduled Maintenance Conventional Compact Pothole Protection Pothole Protection Device Device Test Elevated Drive peed 2. Use the ladder to dismount from platform. wARNiNG 3. On base control console, slowly raise the Be aware of overhead obstructions platform.
ection 2 mAiNTENANCE TABlEs AN iAGRAms Table of Contents Tables 2.1a Specifications and Features (ANSI/CSA) ......................2 2.1b Specifications and Features (CE) ........................4 2.1c Specifications and Features (AS) ........................6 2.2a Floor Loading Pressure (ANSI/CSA) .........................9 2.2b Floor Loading Pressure (CE) ..........................10 2.2c Floor Loading Pressure (AS) ...........................11 2.3a Maximum Platform Capacities (Evenly Distributed) (ANSI/CSA) ..............12 2.3b...
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ervice and Maintenance ection 2 - Maintenance Tables and Diagrams Table 2.1a pecifications and Features (AN I/C A) ODEL 3215 3219 3220 3226 400 lb. 580 lb. 3510 lb. 4135 lb. Weight * 1089 kg 1170 kg 159 kg 1876 kg 3 "...
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ection 2 - Maintenance Tables and Diagrams ervice and Maintenance Table 2.1a pecifications and Features (AN I/C A) (Continued) ODEL 4620 4626 4632 100 lb. 700 lb. 5075 lb. Weight * 1860 kg 2132 kg 2302 kg 6" Overall width 1.17 m 91"...
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ervice and Maintenance ection 2 - Maintenance Tables and Diagrams Table 2.1b pecifications and Features (CE) ODEL 3215 3219 3220 3226 eight * 1090 kg 1170 kg 1542 kg 1896 kg 0.81 m 0.81 m idth 1.78 m 2.3 m Length 0.66 x 1.63 m 0.71 x 2.1 m...
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ection 2 - Maintenance Tables and Diagrams ervice and Maintenance Table 2.1b pecifications and Features (CE) (Continued) ODEL 4620 4626 4632 † 860 kg 2 30 kg 2300 kg eight . 7 m idth 2.3 m Length .07 x 2. Platform Size Height orking Height...
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ervice and Maintenance ection 2 - Maintenance Tables and Diagrams Table 2.1c pecifications and Features (A ) ODEL 3215 3219 3220 3226 eight * 1090 kg 1170 kg 1583 kg 1864 kg 0.81 m 0.84 m idth 1.78 m 2.32 m Length 0.66 x 1.57 m 0.71 x 2.13 m...
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ection 2 - Maintenance Tables and Diagrams ervice and Maintenance Table 2.1c pecifications and Features (A ) (Continued) ODEL 4620 4626 4632 † 860 kg 2 30 kg 2300 kg eight . 7 m idth 2.3 m Length .07 x 2. Platform Size Height orking...
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ervice and Maintenance ection 2 - Maintenance Tables and Diagrams Floor Loading Pressure Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP): Foot Print Area = Length x Width Base Area = Length x Width Weight of Aerial Platform + Capacity Weight of Aerial Platform + Capacity LCP = 0.4 X OUP =...
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ection 2 - Maintenance Tables and Diagrams ervice and Maintenance Table 2.2a Floor Loading Pressure (AN I/C A) Total Aerial Platform Load Total Aerial Platform Weight Wheel LCP** OUP** ODEL (kN/m (kN/m 2400 1089 689.48 7.66 3215 3000 1361 1200 758.42 9.58 2580...
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ervice and Maintenance ection 2 - Maintenance Tables and Diagrams Table 2.2b Floor Loading Pressure (CE) Total Aerial Total Aerial Platform Load Platform MODEL heel LCP** OUP** eight KPa (kN/m KPa (kN/m 1089 689.5 3215 1361 758.5 1170 689.5 3219 1420 758.5 10.0...
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ection 2 - Maintenance Tables and Diagrams ervice and Maintenance Table 2.2c Floor Loading Pressure (A ) Total Aerial Total Aerial Platform Load Platform MODEL heel LCP** OUP** eight KPa (kN/m KPa (kN/m 1089 689.5 3215 1361 758.5 1170 689.5 3219 1420 758.5...
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ervice and Maintenance ection 2 - Maintenance Tables and Diagrams Table 2.3a Maximum Platform Capacities (Evenly Distributed) (AN I/C A) aximum Tilt anual Extension Platform Powered Extension Platform ODEL Wind Cutout Total Capacity Extension Capacity Total Capacity Extension Capacity Speed Setting 00 lb.
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ection 2 - Maintenance Tables and Diagrams ervice and Maintenance Table 2.3b Maximum Platform Capacities (Evenly Distributed) (CE) Maximum Manual Extension Platform Powered Extension Platform MODEL Wind Cutout otal Capacity Extension Capacity otal Capacity Extension Capacity Speed Setting 7 kg Persons 113 kg 1 Person...
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ervice and Maintenance ection 2 - Maintenance Tables and Diagrams Table 2.3c Maximum Platform Capacities (Evenly Distributed) (A ) ax. Side anual Extension Platform Powered Extension Platform ODEL Force Wind Total Capacity Extension Capacity Total Capacity Extension Capacity (m/s) 227 kg 2 Persons 113 kg 3215...
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section 3 sysTEm COmpONENT i ENifiCATiON AN sChEmATiCs Table of Contents Charts Electrical Symbol Chart ..........................3 Hydraulic Symbol Chart ..........................4 Wire Number and Color Code ........................5 Parts List Hydraulic Manifold and Port Identifications ....................6 Hydraulic Schematic Parts List ........................7 Electrical Components Parts List ........................10 Diagrams and chematics 3.7a Platform Control Console Diagram (with oggle Switch) ................13...
ervice and Maintenance ection 3 - ystem Component Identification and chematics 3.2 Hydraulic ymbol Chart VARIAB E DISP ACEMENT SHUTT E VA VE VE OCITY FUSE INE CROSSING PUMP ACCUMU ATOR, SING E ACTING INE JOINED HAND PUMP GAS CHARGED CY INDER HYDRAU IC CUSHION...
ection 3 - ystem Component Identification and chematics ervice and Maintenance 3.3 Wire Number and Color Code WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE COLOR COLOR COLOR COLOR COLOR ORG/BLU YEL/WH ORG/BRN GRN SHLD WH /RED YEL/ORG GREY BLK SHLD BLU/PINK...
ervice and Maintenance ection 3 - ystem Component Identification and chematics 3.4 Hydraulic Manifold and Port Identifications 2H-59B 2H-18A If equipped Proportional Valve Differential Valve To Main Manifold (Internal Compensator Valve) 3H-18A-2 peed Valve B To Main Manifold Flow Divier/Combiner Valve To Pump Auto Reset Valve...
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ection 3 - ystem Component Identification and chematics ervice and Maintenance 3.5 Hydraulic chematic Parts List Index kyjack Qty. Description Part No. 2H-13 103655 VALVE, Control (Lowering) (AN I/C A) 2H-13B 103655 VALVE, Control (Lowering) (CE) 2H-13-1 107269 VALVE, Control (Holding) (AN I/C A) 2H-13B-1 107269...
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ervice and Maintenance ection 3 - ystem Component Identification and chematics 3.5 Hydraulic chematic Parts List (Continued) Index kyjack Qty. Description Part No. Parts list continued from the following page. 132748 BLOCK, Manifold (Proportional control) 105530 ORIFICE (0.081” diameter) (Lowering) (Model 4632) 122213 ORIFICE (0.073”...
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ervice and Maintenance ection 3 - ystem Component Identification and chematics 3.6 Electrical Components Parts List UPPLY (B+) (Common) CONTROL (B+) GROUND (B-) NORMALLY NORMALLY CLO ED OPEN CONTACT CONTACT Index kyjack Qty. Description Part No. 17CR 108589 RELAY, 24 Volt ( ransfer) 21ACR 108589 RELAY, 24 Volt (Proportional)
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ection 3 - ystem Component Identification and chematics ervice and Maintenance 3.6 Electrical Component Parts List Index kyjack Qty. Description Part No. Parts list continued from the following page. 4H-23 153335 COIL, 24 Volt (Right steer spool valve) (Hytos) 128320 COIL, 24 Volt (Right steer spool valve) (Hytos) (if equipped) 4H-24 153335...
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ervice and Maintenance ection 3 - ystem Component Identification and chematics 3.6 Electrical Component Parts List (Continued) Index kyjack Qty. Description Part No. Parts list continued from the following page. 119725 SWI CH, Main power disconnect 147054 N.O. CON AC (Raise/Lower) 147053 N.C.
ection 3 - ystem Component Identification and chematics ervice and Maintenance 3.9 Power Extension Platform Control Console and Harness EXTENSION PLATFORM CONTROL CONSOLE WHITE BLACK GREEN TO POWER CONTROL CONSOLE BACK VIEW W/ALL FUNCTION CUTOUT MALE 1 BLACK (27) 2 WHITE ( 8) 3 GREEN (26) 4 (N/U) TO POWER CONTROL CONSOLE...
ervice and Maintenance ection 3 - ystem Component Identification and chematics 3.10 Base Control Console Diagram 2 - UP WITCH 10 - IDLE W N.O. CONTACT N.C. CONTACT PIN 3 - 10E WHITE/BLACK (X2) PIN 1 - 5A PURPLE/WHITE PIN 4 - 14E BLACK PIN 2 - 07 RED (X2) 2 - DOWN WITCH 10 - BA E W...
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ection 3 - ystem Component Identification and chematics ervice and Maintenance 3.11 cissor Arm Control Cable CONTROL CABLE OPTIONS EUROPE WIRE COLOUR WIRE NUMBER WIRE NUMBER GREEN/BLACK RED/WHITE BACK VIEW FRONT VIEW TO ELECTRIC PANEL CONTROL CABLE MALE (7A) GREEN RED WHITE (OPT) (4 ) GREEN WHITE BLACK WHITE (23)
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3.12 Hydraulic chematic (Models 322x) C4 BRAKE C4 BRAKE CYLINDER CYLINDER RIGHT DRIVE BRAKE M T R RIFICE Ø.040 EMERGENCY UPPER LIFT L WERING CYLINDER RIFICE 3226 2H-18A Ø.067 DIFFERENTIAL REAR DRIVE VALVE MANIF LD BL CK 4H-27 2H-13-2 C5 P.DECK DIFFERENTIAL RETRACT RELIEF VALVE...
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3.13 Hydraulic chematic (Models 46xx) RIGHT DRIVE AUTO RESET UPPER LIFT OTOR/BRAKE VALVE E ERGENCY CASE DRAIN CYLINDER LOWERING 3226/4626/4632 ORIFICE HAND PU P Ø.067 REAR DRIVE 2H-18A ANIFOLD BLOCK DIFFERENTIAL DIFFERENTIAL 2H-13-2 (ANSI/CSA) 2H-13B-2 (CE) ORIFICE Ø.040 VALVE HOLDING VALVE BRAKE RELEASE HOLDING VALVE ANIFOLD BLOCK...
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3.14 Main Manifold Harness and Holding Valve Harness (AN I/C A & EE Rated) HOLDING VALVE HARNESS - MODEL XX20 HOLDING VALVE PIN - 3 BLACK 3 - BLACK PIN 2 - 02 WHITE 02 - WHITE INSERT ORIENTATION BOTTOM VIEW FORWARD VALVE RIGHT STEER VALVE HOLDING VALVE HARNESS - MODEL XX26 / XX32...
3.17 Electrical Panel Diagram (CE) TO LOWER BASE BOX LEGEND: IN 1 - 07 (RED) IN 5 - 10E (BLUE/BLACK) (CE) TO JOYSTICK BOX TO LOWER KEYSWITCH BOX IN 2 - 05 (GREEN/BLACK) IN 6 - 8C (BLUE/WHITE) IN 3 - 13 (ORANGE) IN 7 - 7A (GREEN) TO TERMINAL BLOCK TO TILT SWITCH...
3.19 Harnesses Diagram CONTROL MODULE HARNESSES HORN/FLASHING LIGHT HARNESS TO FLASHING LIGHT 0 - WHITE - GREEN FROM ELECTRIC PANEL TO CONTROL MODULE - P3 8 BLACK PIN 3 - 60 GREEN 8E WHITE PIN 4 - 8 BLACK 60 GREEN PIN 6 - 8E WHITE TO HORN TO ELECTRIC PANEL...
3.22 Control Module and Beeper Diagram (CE) OVERLOAD SENSING MODULE (CE) 1-S LEVEL INSIDE SCISSOR BEEPER 29 - RED (+) 02 - BLUE (-) N/U - BLACK (-) CONNEC GROUND WIRES O CON ROL MODULE - P4 PIN 1 - N/U O PRESSURE RANSDUCER PIN 2 - 60A GREEN PIN 1 - 910A BLACK...
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3.23a Electrical chematic (AN I/C A - Equipped with no options) erial Breakdown 110 VAC LINE VOLTAGE Reference Chart Model erial Number 24V CHARGER SJ3 3220 60002138 & above L1CR CHARGER CUTOUT RELAY SJ3 3226 27006059 & above CHARGER SJ3 46XX 70006694 &...
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3.23b Electrical chematic (AN I/C A - Equipped with no options) 110 VAC erial Breakdown LINE VOLTAGE Reference Chart Model erial Number 24V CHARGER L1CR SJ3 3220 60002137 & below CHARGER CUTOUT RELAY SJ3 3226 27006058 & below CHARGER SJ3 46XX 70006693 &...
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3.24a Electrical chematic (AN I/C A - Equipped with all options) erial Breakdown 110 VAC Reference Chart LINE VOLTAGE CONTROL BOX BASE Model erial Number OWERED LATFORM O TION 24V CHARGER SJ3 3220 60002138 & above EXTEND/ ENABLE EXTEND SOLENOID RETRACT L1CR SWITCH...
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3.24b Electrical chematic (AN I/C A - Equipped with all options) 110 VAC erial Breakdown INE VO TAGE CONTRO BOX BASE Reference Chart POWERED P ATFORM OPTION Model erial Number 24V CHARGER EXTEND/ ENAB E EXTEND SO ENOID RETRACT SWITCH SJ3 3220 60002137 &...
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3.25a Electrical chematic (Models 322x CE - Equipped with all options) erial Breakdown 110 VAC Reference Chart LINE VOLTAGE CONTROL OX Model erial Number POWERED PLATFORM OPTION 24V CHARGER EXTEND/ SJ3 3220 60002138 & above ENA LE EXTEND SOLENOID RETRACT SWITCH L1CR SWITCH...
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3.25b Electrical chematic (Models 322x CE - Equipped with all options) erial Breakdown 110 VAC Reference Chart INE VO TAGE CONTRO BOX BASE Model erial Number POWERED P ATFORM OPTION 24V CHARGER EXTEND/ SJ3 3220 60002137 & below ENAB E EXTEND SO ENOID RETRACT SWITCH...
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3.26a Electrical chematic (Models 46xx CE - Equipped with all options) erial Breakdown 110 VAC LINE VOLTAGE Reference Chart CONTROL BOX BASE POWERE PLATFORM OPTION Model erial Number 24V CHARGER EXTEN / ENABLE EXTEN SOLENOI RETRACT SWITCH SJ3 46XX 70006694 & above L1CR SWITCH CHARGER...
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3.26b Electrical chematic (Models 46xx CE - Equipped with all options) erial Breakdown 110 VAC LINE VOLTAGE Reference Chart CONTROL BOX BASE POWERE PLATFORM OPTION Model erial Number 24V CHARGER EXTEN / ENABLE EXTEN SOLENOI RETRACT SWITCH L1CR SJ3 46XX 70006693 &...
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3.27a Electrical chematic (AN I/C A EE Rated - Equipped with no options) erial Breakdown 110 VAC Reference Chart LINE VOLTAGE Model erial Number 24V CHARGER SJ3 3220 60002138 & above 110 VAC CHARGER SJ3 3226 27006059 & above B4 6V B3 6V B2 6V SJ3 46XX...
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3.27b Electrical chematic (AN I/C A EE Rated - Equipped with no options) erial Breakdown 110 VAC LINE VOLTAGE Reference Chart 24V CHARGER Model erial Number 110 VAC SJ3 3220 60002137 & below CHARGER SJ3 3226 27006058 & below B4 6V B3 6V B2 6V BATTERY...
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3.28a Electrical chematic (AN I/C A EE Rated - Equipped with all options) erial Breakdown CON ROL BOX BASE Reference Chart 110 VAC POWERED PLA FORM OP ION LINE VOL AGE Model erial Number 24V CHARGER EX END/ ENABLE EX END SOLENOID RE RAC SWI CH SWI CH...
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3.28b Electrical chematic (AN I/C A EE Rated - Equipped with all options) CON ROL BOX BASE erial Breakdown 110 VAC POWERED PLA FORM OP ION LINE VOL AGE Reference Chart 24V CHARGER EX END/ ENABLE EX END SOLENOID RE RAC Model erial Number SWI CH...
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ection 4 TROUBlEshOOTiNG iNfORmATiON Table of Contents Introduction ..................................3 Electrical ystem 4.1-1 All Controls Inoperative ...........................4 4.1-2 All Controls Except for Down Function Inoperative ..................4 4.1-3 All Controls Inoperative From Base Control Console ..................5 4.1-4 All Controls Inoperative From Platform Control Console ................5 4.1-5 No Drive or Up Function from Platform or Base Controls (CE only) .............6 4.1-6...
ection 4 - Troubleshooting Information ervice and Maintenance Introduction he following pages contain a table of roubleshooting Information for locating and correcting most service trouble which can develop. Careful and accurate analysis of the systems listed in the table of roubleshooting Information will localize the trouble more quickly than any other method.
ection 4 - Troubleshooting Information ervice and Maintenance Electrical ystem (Continued) 2. Contactor C1 defective. Check contactor. Replace if defective. 3. Defective pump motor DCM1. Check motor. Replace if defective. 4. Loose or broken wire #59 from relay 21CCR (AN I/C A) or relay 21ACR (CE) to proportional valve...
ervice and Maintenance ection 4 - Troubleshooting Information Electrical ystem (Continued) 4.1-5 No Drive or Up Function from Platform or Base Controls (CE only) 1. Defective tilt relay 28CR1 or Aux. tilt relay 28ECR1. Check relay. Replace if defective. 2. Loose or broken wire #02 from base terminal block to tilt relay 28CR1 or Aux. tilt relay 28ECR1. Check continuity.
ection 4 - Troubleshooting Information ervice and Maintenance Electrical ystem (Continued) 4.1-16 No Drive or teer when Platform Elevated 1. Pothole protection bars not fully lowered. Clear obstructions. Repair as needed. 2. Loose or broken wire #71 from base terminal block to pothole protection limit switch LS4. Check continuity.
ervice and Maintenance ection 4 - Troubleshooting Information Electrical ystem (Continued) 4.1-19 Forward Drive Function Inoperative 1. Loose or broken wire #16 from lift/drive switch S3 to base terminal block. Check continuity. Replace if defective. 2. Loose or broken wire #16 from base terminal block to forward drive valve coil 4H-16. Check continuity.
ervice and Maintenance ection 4 - Troubleshooting Information Electrical ystem (Continued) 4.1-25 Power Extension Platform will not Extend or Retract 1. Lift/Drive switch S3 not in lift position. Move switch to lift position. 2. Loose or broken wire #09 from lift/drive switch S3 to power extension platform enable switch S12. Check continuity.
ection 4 - Troubleshooting Information ervice and Maintenance Hydraulic ystem 4.2-1 All Function Inoperative 1. Proportional valve 2H-59 defective or is sticking. Check valve. Replace if defective. 2. Pump P1 defective. Check pump. Replace if defective. 4.2-2 Platform Drifts Down 1.
ervice and Maintenance ection 4 - Troubleshooting Information Hydraulic ystem (Continued) CE Machines only 3. Lowering valve 2H-13 defective or is sticking. Clean valve. Replace if defective. 4. Defective holding valve 2H-13B-1 or 2H-13B-2. Clean valve. Replace if defective. 4.2-6 Platform Drives low 1.
ection 4 - Troubleshooting Information ervice and Maintenance Hydraulic ystem (Continued) 4.2-10 Aerial Platform will not hold on a Grade (Machines with Integrals Brakes) 1. Worn or damaged brake discs. Inspect brake discs for wear. Replace if worn or damaged. 2.
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ervice and Maintenance ection 4 - Troubleshooting Information Load ensing ystem - CE 4.3-1 Flash Code F01: Check HWF his message is given if the GP102 startup tests have not completed. Check HELP message for more information. 4.3-2 Flash Code F02: Not Ground Mode his message is given if the machine is not in ground mode (P2-2 must be high).
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ection 4 - Troubleshooting Information ervice and Maintenance Load ensing ystem - CE (Continued) 4.3-11 Flash Code F12: Too Many his message occurs if the DYNAMIC lift takes too long. his message could occur if the UP switch was not released at the end of the dynamic lift. If the machine takes more than two minutes to lift, the GP102 may need modification to avoid this problem.
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ervice and Maintenance ection 4 - Troubleshooting Information Load ensing ystem - CE (Continued) 4.3-18 Flash Code F19: High Elev.close his message is given if the elevation switch (P2-10) closed during lower at a too high height (above 25%). When the switch is closed, overload detection is normally disabled but if the switch closes above 25%, the platform is too high to allow disabled overload.
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ection 4 - Troubleshooting Information ervice and Maintenance Load ensing ystem - CE (Continued) 4.3-26 Flash Code F27:Bad Height his message indicates a problem with the height sensor output (P4-3) during the S A IC phases. he height sensor output must be between 1.0V and 4.0V at all times. Check DIAGNOS ICS / SENSORS to see the output.
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ervice and Maintenance ection 4 - Troubleshooting Information Load ensing ystem - CE (Continued) 4.3-33 Flash Code F42:Low Pressure his message indicates that the pressure is too low (0.5V or less) when the elevation switch opens during the DYNAMIC lift. his message would occur if the pressure sensor was disconnected, or if there were some other wiring error.
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section 5 pROCE UREs Table of Contents ervice and Maintenance General ..................................3 Safety and Workmanship .............................3 Platform 5.1-1 OEM Controller Electronics Information ......................3 5.1-2 OEM Controller roubleshooting ........................4 5.1-3 OEM Controller switch wiring ..........................5 Base 5.2-1 System Relief Pressure Adjustment ........................6 5.2-2 Lift Pressure Adjustment ...........................6 5.2-3 Electronic ilt Switch Setup Procedure ......................7 ilt Switch Replacement ............................7...
ection 5 - Procedures ervice and Maintenance General “Threshold” Adjustments Adjust the initial current flow or duty cycle, affecting he following information is provided to assist you in the function response or speed when the handle is the use and application of servicing and maintenance first moved from the off position.
ervice and Maintenance ection 5 - Procedures 5.1-2 OEM Controller Troubleshooting IR Option Function speed reacts too slowly or too quickly in relation to handle deflection. Problem he function will not operate when the handle is A. Check “IRS” (Ramp) trimpot adjustment. moved.
ervice and Maintenance ection 5 - Procedures Base 5.2-2 Lift Pressure Adjustment 5.2-1 ystem Relief Pressure Adjustment NOTE Locate the system pressure quick disconnect port Adequate area to raise the platform to full on the main manifold. height is required for the following steps. Install a calibrated 5000 psi gauge to the system pressure quick disconnect port.
ection 5 - Procedures ervice and Maintenance Disconnect all wires #02 from motor contactor. 5.2-3 Electronic Tilt witch etup Procedure he following information is supplied for replacement Install jumper wire between #7 and #19 to or reprogramming of the electronic tilt switch. Also terminal strip.
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ervice and Maintenance ection 5 - Procedures urn main disconnect switch to “ ” off position. 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 est and Verify ilt Circuit.
ection 5 - Procedures ervice and Maintenance Reprogramming Existing Tilt witch Reprogram the Tilt witch Press and hold the set Set up button is located on this up button for 3 seconds. Light Indicators face next to harness ed LED Results: Both LEDs will Green LED be OFF.
ervice and Maintenance ection 5 - Procedures g r e e n L E D Test and Verify Tilt Circuit w i l l t u r n o n s o l i d . Set up button is located on this he switch Results: ed LED...
ection 5 - Procedures ervice and Maintenance Load ensing ystem - CE 5.3-1 Control Module Pin Reference Chart WIRE # WIRE FUNCTION AND COLOUR The Calibration Connection Not Used Not Used 10E Black/White Input Power From Base Terminal Strip To Confirm Lower Control Is Selected 14 Black Raise Platform Input 13 Orange...
ervice and Maintenance ection 5 - Procedures 5.3-2 LED Error Codes - Quick Reference Chart LED indication ELP Message Steady on V RYTHING OK Steady on IN GROUND MOD ! OV RLOAD FUNCTIONS DISABL D! V HICL TILT D V HICL OV RLOAD D WAITING FOR B+ ON P2-12 ARMGUARD ACTIV ! TOO HIGH - DRIV PR V NT D...
ection 5 - Procedures ervice and Maintenance 5.3-3 LED Error Codes - Code Breakdown Chart Diagnostic sequence dependant on LED flash code: No Last Caldate Load Not Calibrated Height Not Calibration An EZcal is required! Waiting For Neutral Drive/Lift Inputs Faulty! Up/Down Select Inputs Active ogether EMS Inputs Faulty! Check inputs on P2 pins 1,2,3,4,5,6,7,8.
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ervice and Maintenance ection 5 - Procedures 5.3-3 LED Error Codes - Code Breakdown Chart (Continued) Vehicle ilted Vehicle Overloaded oo High - Drive Prevented oo High - Lift Up Prevented hese are not true faults but an indication that vehicle movement is prevented. Remove excessive load from the platform.
ection 5 - Procedures ervice and Maintenance 5.3-4 Hand Held Calibration/Diagnostic Tool Key Functions wARNiNG Only trained and authorized personnel shall be permitted to service and aerial platform. wARNiNG Read all instructions closely before attempting each phase or the calibration procedure. ymbol Key Function E C/ENTER Buttons...
ervice and Maintenance ection 5 - Procedures 5.3-5 Control Module Load Calibration - Code Messages & Definitions During calibration the following failure message may appear: Code F01: Check HWF his message is given if the GP102 startup tests have not completed. Check HELP message for more information.
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ection 5 - Procedures ervice and Maintenance Code F13: Low Height Range his message occurs at the end of calibration if the height sensor output did not change sufficiently to give a reasonably accurate platform height estimate. his message could occur if the UP switch was accidentally opened too early (when the platform is not fully raised).
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ervice and Maintenance ection 5 - Procedures Code F42: Low Pressure his message indicates that the pressure is too low (0.5V or less) when the elevation switch opens during calibration. Check DIAGNOS ICS / SENSORS to check the pressure. Code F43: High Pressure his message indicates that the pressure is too high (4.5V or more) when the elevation switch opens during calibration.
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ection 5 - Procedures ervice and Maintenance Please Lower his message is prompting for the platform to be lowered. he DOWN switch should be closed. Lift Empty his message is displayed while the platform is being raised to the next measurement height, when an EMP Y platform is being calibrated.
ervice and Maintenance ection 5 - Procedures 5.3-6 Control Module Load Calibration Procedure Move the aerial platform to a test area where the platform can be elevated to its maximum working height and reach. Ensure the aerial platform is parked on a firm, level surface. impORTANT Each phase must be completed before the next phase can be carried out.
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ection 5 - Procedures ervice and Maintenance he display will show “Help: Press Enter”. By using Left/Right buttons, select the “Access Level ( ? )” from the menu and press the ENTER button. Contact kyjack ervice Department at: (44) 1691-676 236 for your Access Level Code Number. he display will show “Access Level Code (xxxx)”.
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ervice and Maintenance ection 5 - Procedures he display will show “Calibrate: Loaded Empty? No”. Asking for confirmation that the platform is empty? Check that the platform is empty 25. By using the Up/Down buttons, enter the “Yes” followed by pressing the ENTER button. he display will show “Calibrate Load: Please Lift..”.
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ection 5 - Procedures ervice and Maintenance 39. Press EN ER to complete date entry (the system will store it). he display will show “Calibrate Load” option. 41. Press the ESC button to exit the “Calibrate Load” option. 42. Remove the jumper wire and re-connect the black wire #14 to the coil removed earlier. 43.
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