Page 1 AINTENANCE & PARTS ANUAL 00 275-9522 For Service please call ..............kyjack Inc. ervice Center, 3451 wenson Ave., t. Charles, IL. 60174 ..AX 630 262-0006 00 965-4626 For Parts in North America and Asia please call ........kyjack Inc. Parts Center, 3451 wenson Ave., t. Charles, IL. 60174 ....AX 888 782-4825 44-1691-676 236 For Parts &...
Page 2 RAINING AND UNDERS ANDING OF HE OPERA ION OF BO H S ANDARD AND OP IONAL EQUIPMEN . DO NO USE A WORK PLA FORM HA HAS OP IONS, AL ERA IONS OR MODIFICA IONS NO APPROVED BY SKYJACK. USE HE SERIAL NUMBER OF YOUR MACHINE O DE ERMINE...
Page 3: Table Of Contents
Table of Contents ection - Paragraph Page No. ection 1 - About Your Aerial Platform erial Platform Definition ........................1 Purpose of Equipment ........................1 Use of Equipment ..........................1 Manuals .............................. 1 Operator ............................. 1 Service Policy and Warranty ......................1 Optional ccessories .........................
Page 4 The Safety lert Symbol identifies important safety messages on aerial platforms, safety Th s afety Alert ymbol means attent on! signs in manuals or elsewhere. When you see this symbol, be alert to the possibility of Become alert! Your safety s nvolved. personal injury or death.
Page 5: Ection 1 - About Your Aerial Platform
SKYJACK warrants each new SJIII Ser es work platform to be free of defect ve parts and workmansh p for the f rst 12 months. Any defect ve part w ll be replaced or repa red by your local SKYJACK dealer at no charge for parts or labor.
Page 6: Scope Of This Manual
ection 1 - About Your Aerial Platform cope of this Manual This manual appl es to the ANSI/SIA, CSA and CE vers ons of the SJIII ser es aer al platform models l sted Table 2-1a and Table 2-1b. - Equipment identified w th “ANSI” meets the ANSI SIA-A92.6-1999 standard. - Equipment identified w th “CSA”...
Page 7: Operator Safety Reminders
Common sense d ctates the use of protect ve cloth ng when work ng on or near mach nery. Use appropr ate safety dev ces to protect your eyes, ears, hands, feet and body. Any mod f cat ons from the or g nal des gn are str ctly forb dden w thout wr tten perm ss on from SKYJACK. Electrocution Hazard This aerial platform is not electrically insulated.
Page 8: Safety Precautions
ection 1 - About Your Aerial Platform afety Precautions Know and understand the safety precaut ons before go ng on to next sect on. arning Failure to heed the following safety DO nOT • ncrease the lateral precautions could result in tip over, surface area of the platform.
Page 9 ection 1 - About Your Aerial Platform afety Precautions (Continued) Know and understand the safety precaut ons before go ng on to next sect on. • DO nOT operate on surfaces not capable of • ra se the aer al hold ng the we ght of the aer al platform nclud ng platform wh le...
Page 10 Skyjack. Failure to avoid these hazards could arning result in death or serious injury.
Page 11 ection 2 List of Tables able of Contents able 2.1a Specifications and Features - ANSI/CSA ....................2 able 2.1b Specifications and Features - AS ......................4 able 2.1c Specifications and Features - CE ......................6 able 2.2 Owner’s Annual Inspection Record ......................8 able 2.3a Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA..............9 able 2.3b Maximum Platform Capacities (Evenly Distributed) - AS ...............10 able 2.3c Maximum Platform Capacities (Evenly Distributed) - CE ...............11 able 2.4a Floor Loading Pressure - ANSI/CSA .......................12...
Page 12: Ection 2 - List Of Tables
Section 2 - List of ables able 2.1a Specifications and Features - ANSI/CSA ODEL 3215 3219 3220 3226 400 lb. 580 lb. 3510 lb. 4135 lb. Weight * 1089 kg 1170 kg 159 kg 1876 kg 2" 2" Width 0.81 m 0.81 m 70.0”...
Page 13 Section 2 - List of ables able 2.1a Specifications and Features - ANSI/CSA (Continued) ODEL 4620 4626 4632 6826 6832 100 lb. 700 lb. 5075 lb. 5380 lb. 5680 lb. Weight * 1860 kg 2132 kg 2302 kg 0 kg 2576 kg 6"...
Page 14: Able 2.1B Specifications And Features - As
Section 2 - List of ables able 2.1b Specifications and Features - AS 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 Platform Size Height...
Page 15 Section 2 - List of ables able 2.1b Specifications and Features - AS (Continued) ODEL 4620 4626 4632 6826 6832 † 860 kg 2 30 kg 2300 kg 2440 kg 2700 kg eight . 7 m .73 m idth 2.3 m 2.52 m Length Platform Size...
Page 16: Able 2.1C Specifications And Features - Ce
Section 2 - List of ables able 2.1c Specifications and Features - CE ODEL 3215 3219 3220/3220 3226/3226 1090 kg 1170 kg 1583 kg 1864 kg Weight * 2403 lb. 2580 lb. 3490 lb. 4110 lb. 0.81 m 0.84 m Width 1.9"...
Page 17 Section 2 - List of ables able 2.1c Specifications and Features - CE (Continued) ODEL 4620 4626 4632 6826 6832 860 kg 2 30 kg 2300 kg 2440 kg 2700 kg † Weight 4 0 lb. 4696 lb. 507 lb. 5380 lb.
Page 18: Able 2.2 Owner's Annual Inspection Record
Section 2 - List of ables able 2.2 Owner’s Annual Inspection Record Model Number: ____________________________ Serial Number: ____________________________ Recording Date Recording Year # wner’s Name Inspected By 0141AB As described earlier in this section, this decal is located on the scissor assembly. It must be completed after an annual inspection has been completed.
Page 19: Able 2.3A Maximum Platform Capacities (Evenly Distributed) - Ansi/Csa
Section 2 - List of ables able 2.3a Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA anual Extension Platform Powered Extension Platform ODEL Total Capacity Extension Capacity Total Capacity Extension Capacity 00 lb. 250 lb. 3215 2 Persons 1 Person 272 kg 113 kg 550 lb.
Page 20: Able 2.3B Maximum Platform Capacities (Evenly Distributed) - As
Section 2 - List of ables able 2.3b Maximum Platform Capacities (Evenly Distributed) - AS 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 1 Person 12.5...
Page 21: Able 2.3C Maximum Platform Capacities (Evenly Distributed) - Ce
Section 2 - List of ables able 2.3c Maximum Platform Capacities (Evenly Distributed) - CE anual Extension Platform Powered Extension Platform ODEL Total Capacity Extension Capacity Total Capacity Extension Capacity 7 kg 113 kg 3215 Persons 1 Person 500 lb. 50 lb.
Page 22: Able 2.4A Floor Loading Pressure - Ansi/Csa
Section 2 - List of ables able 2.4a Floor Loading Pressure - ANSI/CSA Tota Aeria P atform Load Tota Aeria P atform Weight Whee LCP** OUP** MODEL (kN/m (kN/m 2400 1089 689.48 7.66 3215 3000 1361 1200 758.42 9.58 2580 1170 1032 689.48...
Page 23 Section 2 - List of ables 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 = OUP = Foot Print Area x 4 ( ires)
Page 24: Able 2.4B Floor Loading Pressure - As
Section 2 - List of ables able 2.4b Floor Loading Pressure - AS Total Aerial Platform Load Total Aerial Platform Weight Wheel LCP** OUP** MODEL ( N/m ( N/m 1089 2400 689.48 7.66 3215 1361 3000 1200 758.42 9.58 1170 2580 1032 689.48...
Page 25 Section 2 - List of ables Floor Loading Pressure Local Concentrated Pressure (LCP): Overall Uniform Pressure (OUP): Foot Print Area = Length x Width Base Area = Length x Width Weight of Machine + Capacity Weight of Machine + Capacity LCP = OUP = Foot Print Area x 4 ( ires)
Page 26: Able 2.4C Floor Loading Pressure - Ce
Section 2 - List of ables able 2.4c Floor Loading Pressure - CE Total Aerial Platform Load Total Aerial Platform Weight Wheel LCP** OUP** MODEL ( N/m ( N/m 1089 2400 689.48 7.66 3215 1361 3000 1200 758.42 9.58 1170 2580 1032 689.48...
Page 27 Section 2 - List of ables 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 = OUP = Foot Print Area x 4 ( ires)
Page 28: Able 2-5A General Maintenance And Inspection Schedule - Ansi/Csa
Section 2 - List of ables General Maintenance Before attempting any repair work, disconnect the battery by turning the emergency main power disconnect switch to off position. Preventive maintenance is the easiest and least expensive type of maintenance. able 2.5a Maintenance and Inspection Schedule - ANSI/CSA 3 months or 3 months or requency...
Page 29: Able 2-5B General Maintenance And Inspection Schedule - As
Section 2 - List of ables General Maintenance Before attempting any repair work, disconnect the battery by turning the main power disconnect switch to off position. Preventive maintenance is the easiest and least expensive type of maintenance. able 2.5b Maintenance and Inspection Schedule - AS 3 months or 3 months or requency...
Page 30: Able 2-5C General Maintenance And Inspection Schedule - Ce
Section 2 - List of ables General Maintenance Before attempting any repair work, disconnect the battery by turning the main power disconnect switch to off position. Preventive maintenance is the easiest and least expensive type of maintenance. able 2.5c Maintenance and Inspection Schedule - CE 3 months or 3 months or requency...
Page 31: Able 2-6A Operator's Checklist - Ansi/Csa
Hourmeter Reading: Operator's Name (Printed): Date: Time: Operator's Signature: Each item shall be inspected using the the appropriate section of the Skyjack operating manual. s each item is inspected, check the appropriate box. - P SS D ILY - F IL...
Page 32: Able 2-6B Operator's Checklist - As
Hourmeter Reading: Operator's Name (Printed): Date: Time: Operator's Signature: Each item shall be inspected using the the appropriate section of the Skyjack operating manual. s each item is inspected, check the appropriate box. - P SS D ILY - F IL...
Page 33: Able 2-6C Operator's Checklist - Ce
Hourmeter Reading: Operator's Name (Printed): Date: Time: Operator's Signature: Each item shall be inspected using the the appropriate section of the Skyjack operating manual. s each item is inspected, check the appropriate box. - P SS D ILY - F IL...
Page 34 ection 3 ystem Component Identification And chematics Table of Contents ymbols & Charts igure 3.1-1. Relay unction Chart ....................... 2 igure 3.1-2. Tilt Switch Usage Chart ......................3 igure 3.1-3. Electrical Symbol Chart ......................4 igure 3.1-4. Hydraulic Symbol Chart ......................5 Hydraulic ystem igure 3.2-1.
Page 35 Figure 3.1-1. Relay Function Chart UPPLY (B+) (Common) CONTROL (B+) GROUND (B-) NORMALLY NORMALLY CLO ED OPEN CONTACT CONTACT 60045AB RELAY NO. RELAY FUNCTION 3BCR LWS MODULE TIME DELAY CUTOUT (CE Models Without Load Sensing) TRANSFER RELAY 2 CCR PROPORTIONAL RELAY (Machines with no options) 28CR TILT SWITCH RELAY 39CR...
Page 36 Figure 3.1-2. ilt Switch Usage Chart AN I Models CE Models Australian Tilt switch Tilt switch erial erial erial (X Axis x Y Axis ) (X Axis x Y Axis ) Tilt switch Numbers Numbers Numbers 24 38 (X Axis x Y Axis ) 24 38 ( .5°...
Page 37 Figure 3.1-3. Electrical Symbol Chart ANGLE KEY SWITCH WIRE CROSSING HOURMETER TRANSDUCER PRESSURE WIRES JOINED LIGHT FOOT SWITCH TRANSDUCER HYDRAULIC LIMIT SWITCH BATTERY TOGGLE SWITCH VALVE COIL N.O. PROPORTIONAL LIMIT SWITCH PUSH BUTTON GROUND HYDRAULIC N.O. HELD VALVE COIL CLOSED LIMIT SWITCH ELECTRIC ROTARY SWITCH...
Page 38 Figure 3.1-4. Hydraulic Symbol Chart VARIABLE DISPLACEMENT LINE CROSSING SHUTTLE VALVE VELOCITY FUSE PUMP ACCUMULATOR, SINGLE ACTING LINE JOINED HAND PUMP GAS CHARGED CYLINDER HYDRAULIC CUSHION DOUBLE ACTING RELIEF VALVE TANK CYLINDER CYLINDER PRESSURE HYDRAULIC DOUBLE ACTING PRESSURE REDUCING FILTER WITH DOUBLE SWITCH VALVE...
Page 39 Figure 3.2-1. Hydraulic Schematic Parts List Index kyjack Qty. Description Part No. 2H- 3A 34822 VALVE, Deceleration 2H- 3 03655 VALVE, Lowering 2H- 3- 06689 VALVE, Holding 2H-25 28 3 VALVE, Cushion 2H-59B 32749 VALVE, Proportional Control Order P/N 115351 for machines with Serial No.
Page 40 Figure 3.2-2a. Hydraulic Schematic (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 3215 151982 to 152201 60545AA erial Breakdown Reference Chart Model Serial Number 3219 236286 to 239960 60546AA efer to following page(s) to locate model, serial number and respective diagram Figure 3.2-2b M129500AE...
Page 41 Figure 3.2-2b. Hydraulic Schematic (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 3215 152202 to 152537 60545AB erial Breakdown Reference Chart Model Serial Number 3219 239961 & Above 60546AB efer to following page(s) to locate model, serial number and respective diagram Figure 3.2-2a Figure 3.2-2c...
Page 42 Figure 3.2-2c. Hydraulic Schematic (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 3215 152538 & Above 50343AC erial Breakdown Reference Chart Model Serial Number 3215 300000 & Above 50343AD efer to following page(s) to locate model, serial number and respective diagram Figure 3.2-2b M136432AC...
Page 43 Figure 3.2- . Hydraulic Manifold Component And Port Identification PROPORTIONAL TO LEFT WHEEL FLOW DIVIDER/ MANIFOLD MOTOR UPPER COMBINER 2H-59B PORT VALVE TO PUMP PROPORTIONAL VALVE TO RIGHT WHEEL MOTOR UPPER PORT TO RETURN TO RIGHT FILTER WHEEL MOTOR LOWER PORT TO LEFT WHEEL TO MAIN MOTOR LOWER...
Page 44 Figure 3.3-1. Electrical Schematic And Diagram Parts List Index kyjack Qty. Description Part No. 10 5 9 RELAY, 24 Volt (Joystick enable switch) 13BCR 10 5 9 RELAY, 24 Volt (LWS time delay cutout) 17CCR 10 5 9 RELAY, 24 Volt - Cushion 17CR1 10 5 9 RELAY, 24 Volt - Brake...
Page 45 Figure 3.3-1. Electrical Schematic And Diagram Parts List (Continued) Index kyjack Qty. Description Part No. Parts list continued from the previous page. 121975 LIMIT SWITCH, High speed LS1A 121975 LIMIT SWITCH, High speed LS1B 121975 LIMIT SWITCH, High speed 122014 LIMIT SWITCH, End of stroke (Option) 125 6 LIMIT SWITCH, Pothole protection...
Page 46 Figure 3.3-2. Electrical Inverter Option: Schematic & Panel Diagram (Without Timer Cut-out Relay) Electrical Schematic 50219AA Electrical Panel Diagram 11198AA ECTION 3, Page 14 JIII eries - The Compacts 118941...
Page 47 Figure 3.3-3a. Electrical Inverter Option: Schematic & Panel Diagram - ANSI/CSA Models (Equipped with Timer Cut-out Relay) (Refer to Serial No. Breakdown Chart) erial Breakdown Reference Chart Model erial Number Electrical Schematic 53077 & Below 32 9 254283 & Below 60508AA Refer to following page(s) to locate model, serial number and respective diagram...
Page 48 Figure 3.3-3b. Electrical Inverter Option: Schematic & Panel Diagram - ANSI/CSA Models (Equipped with imer Cut-out Relay) (Refer to Serial No. Breakdown Chart) erial Breakdown Reference Chart Model erial Number Electrical Schematic 53078 & Above 32 9 254284 & Above 60509AA Refer to following page(s) to locate model, serial number and respective diagram...
Page 49 Figure 3.3-4a. Electrical Inverter Option: Schematic & Panel Diagram - CE with Load Sensing System (Equipped with Timer Cut-out Relay) (Refer to Serial No. Breakdown Chart) Note: For machines equipped with Load Sensing, erial Breakdown Reference Chart refer to the Load Sensing supplement manual Model erial Number 53077 &...
Page 50 Figure 3.3-4b. Electrical Inverter Option: Schematic & Panel Diagram - CE with Load Sensing System (Equipped with imer Cut-out Relay) (Refer to Serial No. Breakdown Chart) Note: For machines equipped with Load Sensing, erial Breakdown Reference Chart refer to the Load Sensing supplement manual Model erial Number 53078 &...
Page 51 Figure 3.4-1. Control Box Diagram - ANSI/CSA Models Equipped With No Options 10562AA JIII eries - The Compacts 118941 ECTION 3, Page 19...
Page 52 Figure 3.4-2. Control Box Diagram - ANSI/CSA (EE-Rated) Models Equipped With No Options 11035AA ECTION 3, Page 20 JIII eries - he Compacts 118941...
Page 53 Figure 3.4-3a. Control Box Diagram - CE Models Equipped With No Options erial Breakdown Reference Chart odel Serial Number 3215 152099 & Below 3219 237786 & Below 10563AA JIII eries - The Compacts 118941 ECTION 3, Page 21...
Page 54 Figure 3.4-3b. Control Box Diagram - CE Models Equipped With No Options erial Breakdown Reference Chart odel Serial Number 3215 152100 & Above 3219 237787 & Above M130574AF ECTION 3, Page 22 JIII eries - he Compacts 118941...
Page 55 Figure 3.5-1a. Electrical Panel Diagram - ANSI/CSA Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model erial Number 1525 7 & Below 50157AB erial Breakdown Reference Chart odel S erial Number All / 00000 & Above 60529AA Refer to following page(s) to locate model, serial number and respective diagram...
Page 56 Figure 3.5-1b. Electrical Panel Diagram - ANSI/CSA Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 1525 8 & Above 50 4 AC erial Breakdown Reference Chart odel S erial Number 00000 &...
Page 57 Figure 3.5-2a. Electrical Panel Diagram - ANSI/CSA Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart erial Breakdown Reference Chart Refer to following page(s) to locate model, serial number and respective diagram Model erial Number odel S erial Number Figure .5-2b...
Page 58 Figure 3.5-2b. Electrical Panel Diagram - ANSI/CSA Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 1525 8 & Above 50 4 AC erial Breakdown Reference Chart odel S erial Number 00000 &...
Page 59 Figure 3.5-3a. Electrical Panel Diagram - ANSI/CSA EE Rated Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model erial Number 1525 7 & Below 50157AB erial Breakdown Reference Chart odel S erial Number All / 00000 &...
Page 60 Figure 3.5-3b. Electrical Panel Diagram - ANSI/CSA EE Rated Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 1525 8 & Above 50 4 AC erial Breakdown Reference Chart odel S erial Number 00000 &...
Page 61 Figure 3.5-4a. Electrical Panel Diagram - CE Models Equipped With All Options Without Load Sensing (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 152099 & Below 2 757 & Below 605 0AA Refer to following page(s) to locate model, serial number and respective diagram Figure .5-4b 50156AB...
Page 62 Figure 3.5-4b. Electrical Panel Diagram - CE Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) Note: For machines equipped with Load Sensing, refer to the erial Breakdown Reference Chart Refer to following page(s) to locate model, serial Load Sensing supplement manual.
Page 63 Figure 3.5-4c. Electrical Panel Diagram - CE Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) Note: For machines equipped with Load Sensing, refer to the erial Breakdown Reference Chart Load Sensing supplement manual. Refer to following page(s) to locate model, serial odel S erial Number number and respective diagram...
Page 64 Figure 3.5-4d. Electrical Panel Diagram - CE Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Note: For machines equipped with Load Sensing, refer to the Load Sensing supplement manual. odel S erial Number 1525 8 to 15 077 00000 &...
Page 65 Figure 3.5-4e. Electrical Panel Diagram - CE Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) Note: For machines equipped with Load Sensing, refer to the erial Breakdown Reference Chart Load Sensing supplement manual. odel S erial Number 15 078 &...
Page 66 Figure 3.6-1a. Electrical Schematic - ANSI/CSA Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel Serial Number 1525 7 & Below 60528AA erial Breakdown Reference Chart odel S erial Number 25 890 & Below 60525AA efer to following page(s) to locate model, serial number and respective diagram...
Page 67 Figure 3.6-1b. Electrical Schematic - ANSI/CSA Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 1525 8 to 15 066 60524AA efer to following page(s) to locate model, serial number and respective diagram Figure 3.6-1a Figure 3.6-1c 50329AA...
Page 68 Figure 3.6-1c. Electrical Schematic - ANSI/CSA Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 00000 & Above 50343AD erial Breakdown Reference Chart odel S erial Number 15 067 & Above 60526AA efer to following page(s) to locate model, serial number and respective diagram...
Page 69 Figure 3.6-1d. Electrical Schematic - ANSI/CSA Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 00000 & Above 50343AE erial Breakdown Reference Chart odel S erial Number 25 891 & Above 60527AA efer to following page(s) to locate model, serial number and respective diagram...
Page 70 Figure 3.6-2a. Electrical Schematic - ANSI/CSA Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel Serial Number 1525 7 & Below 60528AA erial Breakdown Reference Chart odel S erial Number 25 890 & Below 60525AA efer to following page(s) to locate model, serial number and respective diagram...
Page 71 Figure 3.6-2b. Electrical Schematic - ANSI/CSA Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 1525 8 to 15 066 60524AA efer to following page(s) to locate model, serial number and respective diagram Figure 3.6-2a Figure 3.6-2c 50328AA...
Page 72 Figure 3.6-2c. Electrical Schematic - ANSI/CSA Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 00000 & Above 50343AD erial Breakdown Reference Chart odel S erial Number 15 067 & Above 60526AA efer to following page(s) to locate model, serial number and respective diagram...
Page 73 Figure 3.6-2d. Electrical Schematic - ANSI/CSA Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 00000 & Above 50343AE erial Breakdown Reference Chart odel S erial Number 25 891 & Above 60527AA efer to following page(s) to locate model, serial number and respective diagram...
Page 74 Figure 3.6-3a. Electrical Schematic - ANSI/CSA EE Rated Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel Serial Number 1525 7 & Below 60528AA erial Breakdown Reference Chart odel S erial Number 25 890 & Below 60525AA efer to following page(s) to locate model, serial number and respective diagram...
Page 75 Figure 3.6-3b. Electrical Schematic - ANSI/CSA EE Rated Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 1525 8 to 15 066 60524AA efer to following page(s) to locate model, serial number and respective diagram Figure 3.6-3a Figure 3.6-3c...
Page 76 Figure 3.6-3c. Electrical Schematic - ANSI/CSA EE Rated Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 00000 & Above 50343AD erial Breakdown Reference Chart odel S erial Number 15 067 & Above 60526AA efer to following page(s) to locate model, serial number and respective diagram...
Page 77 Figure 3.6-3d. Electrical Schematic - ANSI/CSA EE Rated Models Equipped With No Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 00000 & Above 50343AE erial Breakdown Reference Chart odel S erial Number 25 891 & Above 60527AA efer to following page(s) to locate model, serial number and respective diagram...
Page 78 Figure 3.6-4a. Electrical Schematic - ANSI/CSA EE Rated Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel Serial Number 1525 7 & Below 60528AA erial Breakdown Reference Chart odel S erial Number 25 890 & Below 60525AA efer to following page(s) to locate model, serial number and respective diagram...
Page 79 Figure 3.6-4b. Electrical Schematic - ANSI/CSA EE Rated Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 1525 8 to 15 066 60524AA efer to following page(s) to locate model, serial number and respective diagram Figure 3.6-4a Figure 3.6-4c...
Page 80 Figure 3.6-4c. Electrical Schematic - ANSI/CSA EE Rated Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 00000 & Above 50343AD erial Breakdown Reference Chart odel S erial Number 15 067 & Above 60526AA efer to following page(s) to locate model, serial number and respective diagram...
Page 81 Figure 3.6-4d. Electrical Schematic - ANSI/CSA EE Rated Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 00000 & Above 50343AE erial Breakdown Reference Chart odel S erial Number 25 891 & Above 60527AA efer to following page(s) to locate model, serial number and respective diagram...
Page 82 Figure 3.6-5. Electrical Schematic - CE Models Equipped With No Options Without Load Sensing - (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 152099 & Below 2 757 & Below 605 0AA 10586AD JIII eries - he Compacts 118941 ECTION 3, Page 51...
Page 83 Figure 3.6-6a. Electrical Schematic - CE Models Equipped With All Options Without Load Sensing - (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart odel S erial Number 152099 & Below 2 757 & Below 605 0AA efer to following page(s) to locate model, serial number and respective diagram Figure 3.6-6b 10585AD...
Page 84 Figure 3.6-6b. Electrical Schematic - CE Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) Note: For machines equipped with Load Sensing, refer to the erial Breakdown Reference Chart Load Sensing supplement manual. odel S erial Number 152100 to 1525 7 2 7574 to 25 890 605 5AA efer to following page(s) to locate model, serial...
Page 85 Figure 3.6-6c. Electrical Schematic - CE Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) Note: For machines equipped with Load Sensing, refer to the erial Breakdown Reference Chart Load Sensing supplement manual. odel S erial Number 1525 8 to 15 066 60524AA efer to following page(s) to locate model, serial number and respective diagram...
Page 86 Figure 3.6-6d. Electrical Schematic - CE Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) Note: For machines equipped with Load Sensing, refer to the erial Breakdown Reference Chart Load Sensing supplement manual. odel S erial Number 00000 & Above 50343AD erial Breakdown Reference Chart odel...
Page 87 Figure 3.6-6e. Electrical Schematic - CE Models Equipped With All Options (Refer to Serial Breakdown Reference Chart) Note: For machines equipped with Load Sensing, refer to the erial Breakdown Reference Chart Load Sensing supplement manual. odel S erial Number 00000 & Above 50343AE erial Breakdown Reference Chart odel...
Page 88 ection 4 Troubleshooting Information Table Of Contents Introduction ..............................2 Electrical ystem ............................3 .1-1. All Controls Inoperative ........................3 .1-2. All Controls Inoperative From Platform ....................1-3. Lift And Drive Inoperative From Platform Controls ................1- . No Down Or Reverse Only Function From Platform Controls .............. .1-5.
Page 89: Introduction
Troubleshooting Information - Introduction Introduction he following pages contain a able of roubleshooting information for locating and correcting most service trouble which can develop. Careful inspection and accurate analysis of the systems listed in the able of roubleshooting Information will localize the trouble more quickly than any other method. his manual cannot cover all possible troubles and deficiencies that may occur.
Page 90: Electrical Ystem
Troubleshooting Information - Electrical ystem Probable Cause Remedy 4.1-1. All Controls Inoperative 1. Battery charger plugged into external power source. 1. Disconnect charger cord. 2. Batteries disconnected. 2. Connect batteries. 3. Dirty or loose battery terminals. 3. Clean and tighten connections. 4.
Page 91 Troubleshooting Information - Electrical ystem Probable Cause Remedy 4.1-2. All Controls Inoperative From Platform 1. Loose or broken wire #07 from base terminal block 1. Check continuity. Replace if defective. ( B-1) to platform emergency stop switch (S4). 2. Open or defective platform emergency stop switch 2.
Page 92: No Down Function From Platform Controls (Ce Machines Only)
Troubleshooting Information - Electrical ystem Probable Cause Remedy 4.1-7. No Up Function From Platform Or Base Controls (Machines Equipped With Tilt Cut-out Options) 4.1-6. No Up Function From Platform Or Base Controls 1. Loose or broken wire #14 from base terminal block 1.
Page 93: Lowering Warning System Inoperative (Ce Machines Only)
Troubleshooting Information - Electrical ystem Probable Cause Remedy 4.1-8. Lowering Warning ystem Inoperative (CE Machines Only) 1. Loose or broken wire #10A from base terminal block 1. Check continuity. Replace if defective. terminal block ( B-1) to lowering warning system module (LWS1).
Page 94: Steer Only Inoperative
Troubleshooting Information - Electrical ystem Probable Cause Remedy 4.1-13. teer Only Inoperative 1. Defective relay (17CR). 1. Check relay. Replace if defective. 2. Loose or broken wire #59 from (17CR) steer relay to 2. Check continuity. Replace if defective. base terminal block ( B1). 4.1-14.
Page 95: Forward Drive Function Inoperative
Troubleshooting Information - Electrical ystem Probable Cause Remedy 4.1-18. Work Platform Drives In low peed Only (Continued) 7. Loose or broken wire #2 from proportional relay 7. Check continuity. Replace if defective. (21ACR) to base terminal block ( B-1). 8. Proportional controller (S7) out of adjustment. 8.
Page 96: Hydraulic Ystem
Troubleshooting Information - Hydraulic ystem Probable Cause Remedy 4.2-1. All Functions Inoperative 1. Proportional valve (2H-59B) defective or is sticking. 1. Check valve. Replace if defective. 2. Compensator valve (CMP1) defective or is sticking. 2. Check valve. Replace if defective. 3.
Page 97: Platform Will Not Drive In Forward Or Reverse
Troubleshooting Information - Hydraulic ystem Probable Cause Remedy 4.2-8. Platform Will Not Drive In Forward Or Reverse 1. Open free-wheeling valve (V2). 1. Close Valve. Replace if defective. 2. Forward drive valve (4H-16) or reverse drive valve (4H- 2. Clean Valve. Replace if defective. 15) defective or is sticking.
Page 98 ection 5 Maintenance And ervice Table Of Contents perators Responsibility For Maintenance ....................2 Maintenance And Inspection Schedule ....................... 2 wners Annual Inspection Record ......................2 General Maintenance Hints ......................... 2 Hydraulic System And Component Maintenance And Repair ..............3 General Specifications ..........................
Page 99: Perators Responsibility For Maintenance
Operator’s Responsibility For Maintenance And Inspection Maintenance chedule eath or injury can result if the work platform is not kept The actual operating environment of the work platform in good working order. Inspection and maintenance governs the use of the maintenance schedule. The should be performed by competent personnel who are inspection points covered in the Maintenance and...
Page 100: Hydraulic System And Component Maintenance And Repair
For conditions oil of the proper type and viscosity in the causing oil temperatures below -31°F (-35°C) hydraulic reservoir. and above 122°F (50°C) consult Skyjack, Inc. Keep all connections tight. JIII eries - he Compacts ECTION 5, Page 3...
Page 101 32 sec. (Rated Load) Gradability 12 x 4 x 8 12 x 4 x 8 Tires * Refer to serial number nameplate for specific pressures. Solid Rubber Solid Rubber 60162AB ECTION 5, Page 4 SJIII Series - The Compacts 118941...
Page 102 Table 5-2. Torque pecifications irectional valve mounting bolts 28-32 lbf.in 2.16 – 3.61 Nm Wheel mounting bolts (32XX) 90 lbf.ft 122.02 Nm Wheel motor castle nut (32XX) 200 lbf.ft 271.20 Nm Parking brake cylinder rod nut 35 lbf.ft 47.46 Nm Cartridge Torque Lbf.ft (max)
Page 103: System And Lift Pressure Adjustments
Remove the gauge from the Lift Pressure Test Port. Note: Pressure setting may vary as machine components wear. The lift pressure should be set for rated load only. ECTION 5, Page 6 SJIII Series - The Compacts 118941...
Page 104: Em Joystick Electronics Information
OEM Joystick Electronics Information Flow Control Single coil or solenoid for single direction. The coil has two connections; one is wired to the P .C. Board (A) terminal and the other is wired to (-), or the negative side of the supply voltage. Switches to control directional valves may be provided on the controller.
Page 105: Em Joystick - Troubleshooting Procedures
(OFF) the output will ramp down to off. Ramp time is factory set to 2 seconds, unless otherwise specified. Note: Trimpots should be sealed with nail polish or enamel based paint. DO NOT U E RTV ILICONE ECTION 5, Page 8 SJIII Series - The Compacts 118941...
Page 106 Figure 5-1. OEM Joystick witch Wiring (Without Enable Relay) Wire Chart Color From hite/Red Steer Left Pin #1 hite/Green +24V Steer Common Pin #2 hite Steer Right Pin #3 Yellow Forward/Up (S2-NO) Pin #4 hite/Black +24V Input Pin #5 Gray Reverse/Down (S1-NO) Pin #6 Blue...
Page 107 Figure 5-2. OEM Joystick witch Wiring (Equipped with Enable Relay) Wire Chart Color From hite/Red Steer Left Pin #1 hite/Green +24V Steer Common Pin #2 hite Steer Right Pin #3 Yellow Forward/Up (S2-NO) Pin #4 hite/Black +24V Input Pin #5 Gray Reverse/Down (S1-NO) Pin #6...
Page 108 How To Order Repair Parts number shown in the illustration, followed by a full 1. Address all orders to your local SKYJACK dealer. description based upon the “NOUN FIRS ” method. 2. Specify model and serial number of the work hat is, the noun name of the part is listed first, then the platform (found on the serial number plate).
Page 109: Table Of Contents
Table Of Contents Platform And Related Parts Figure 6.1-1 Entrance Gates And Chains ..................... 4 Figure 6.1-2 Side Railings ..........................6 Figure 6.1-3 Extension Platform Railings ..................... 8 Figure 6.1-4 Slide Rail Assemblies ......................10 Figure 6.1-5 Quick Release Pins ........................ 11 Figure 6.1-6 Main Platforms Assemblies ....................
Page 110 Table Of Contents Hydraulic Tray Assembly igure 6.4-1 Hydraulic/Electric Tray Assembly ..................72 igure 6.4-2 Hydraulic Hose Connections ....................74 igure 6.4-3 Tank Lid Assembly ....................... 75 igure 6.4-4 Motor/Pump Assembly ......................76 igure 6.4-5 Main Manifold Assembly ......................78 igure 6.4-6 Steering Manifold Assembly ....................
Page 111 Figure 6.1-1. Entrance Gates And Chains 10155AA ECTION 6, Page 4 JIII eries - he Compacts 118941...
Page 112 Figure 6.1-1. Entrance Gates And Chains Index kyjack Qty. Description Part No. 106893 CHAIN, Entry (Models 32XX) 106896 • Chain 100297 • LINK, Attaching 100493 • LA CH, Chain Snap 127944 RAIL, Fixed Upper Assembly 106520 • UBE, op Rail 127943 •...
Page 113 Figure 6.1-2. Side Railings 10533AB ECTION 6, Page 6 JIII eries - he Compacts 118941...
Page 114 Figure 6.1-2. Side Railings Index kyjack Qty. Description Part No. 27447 RAILING, Rigid LH 27448 RAILING, Rigid RH 25336 RAILING, Spacer (CE) 27450 KICK PLATE, LH 27437 BOLT, Carriage 5/ 6 - 8 x 2 Grade 5 03984 • NUT, Hex Nylon Lock 5/ 6 - 8 Grade 5 2747 RAILING, Side Bottom LH 27473...
Page 115 Figure 6.1-3. Extension Platform Railings 10534AA ECTION 6, Page 8 JIII eries - he Compacts 118941...
Page 116 Figure 6.1-3. Extension Platform Railings Index kyjack Qty. Description Part No. 103796 MIDRAIL, Extension Deck (Ref.) PIN, Quick Release Large or Small Loop Assembly (For components, refer to Figure 6.1-5) (Ref.) SLIDE RAIL, 3 ft. Assembly (For components, refer to Figure 6.1-4) 106950 PLA E, Extension Deck Rail Retainer 104625...
Page 117 Figure 6.1-4. Slide Rail Assemblies 10572AA Index kyjack Qty. Description Part No. 125480 HANDRAIL, Extension 103550 PLUG, Handrail Slide Plug 103865 BOL , Hex Head 5/16 - 18 x 2 Grade 5 103984 NU , Hex Lock 5/16 - 18 Grade B (Ref.) PIN, Quick Release Large or Small Loop Assembly (For components, refer to Figure 6.1-5)
Page 118 Figure 6.1-5. Quick Release Pins 10168AA Index kyjack Qty. Description Part No. 124548 PIN, Quick Release Large Loop Assembly 100509 • PIN, Quick Release 3/8 DIA x 2 105807 • LANYARD, 6" Plastic Coated 104606 NU , Hex Lock 3/8 - 16 Grade B 103472 WASHER, Flat 3/8 SAE 103873...
Page 119 Figure 6.1-6. Main Platforms Assemblies 10535AB ECTION 6, Page 12 JIII eries - he Compacts 118941...
Page 120 Figure 6.1-6. Main Platforms Assemblies Index kyjack Qty. Description Part No. 27366 WELDMENT, Main Platform SJ3E 30 5/32 9 25455 ROLLER, Wide 25433 BUSHING, Slider 25422 PIN, Roll Out Assembly 2 874 COTTER PIN, /4” x - /2” (Ref.) SAFETY D-RING, Kit (For components, refer to Figure 6.
Page 121 Figure 6.1-7. Extension Platform Assemblies 10669AA ECTION 6, Page 14 JIII eries - he Compacts 118941...
Page 122 Figure 6.1-7. Extension Platform Assemblies Index kyjack Qty. Description Part No. 127382 WELDMEN , Extension Deck 125433 BUSHING, Slider (Ref.) SAFE Y D-RING, Kit (For components, refer to Figure 6.1-8) 121042 S OP , Extension Deck 103984 NU , Hex Nylon Lock 5/16 - 18 Grade 5 300064 BOL , HHCS 5/16 - 18 x 3/4 JIII eries - he Compacts...
Page 123 Figure 6.1-8. Safety D-Ring Assembly Platform xtension Deck Machines Without Optional Locations For Optional Locations For xtension Platform Safety D-Rings Safety D-Rings 10163AA Index kyjack Qty. Description Part No. 125584 SAFE Y D-RING KI 103473 • BOL , Hex head 3/8-16 x 1” grade 5 113122 •...
Page 124 Figure 6.1-9. Latch Assembly 10160AA Index kyjack Qty. Description Part No. (Ref.) 110824 LA CH, Pin Spring Assembly 109377 • PIN, Latch 105312 • GUIDE, Nylon Spring 105307 • PLA E, Gate Latch Release 105310 • PIN, Roll 103107 • SPRING, Compression JIII eries - he Compacts 118941 ECTION 6, Page 17...
Page 125 Figure 6.1-10. Platform AC Outlet 11088AA 11121AA 11121AC ECTION 6, Page 18 JIII eries - he Compacts 118941...
Page 126 Figure 6.1-10. Platform AC Outlet Index kyjack Qty. Description Part No. Ref.) AC OUTLET 110 Volt on PLATFORM (Models 3215) Ref.) AC OUTLET 110 Volt on PLATFORM (Models 3219) Ref.) AC OUTLET 220 Volt on PLATFORM (Model 3215) Ref.) AC OUTLET 220 Volt on PLATFORM (Model 3219) 131999 BOX, GFI Receptacle,...
Page 127 Figure 6.1-11. Operator’s Control Box Assembly - ANSI/CSA EE Rated Models 11161AA ECTION 6, Page 20 JIII eries - he Compacts 118941...
Page 128 • NU , Hex Head #6 - 32 106099 • WASHER, LOCK #6 310624 WELDMEN , Control Box 102754 SWI CH, KEY 114710 RING, Key Skyjack Logo 102769 ON, Emergency Stop 103278 SWI CH, Contact 103100 • BASE, Contact Block 103141 •...
Page 129 Figure 6.1-12A. Operator’s Control Box Assembly - ANSI/CSA Models & CE Models (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Models From Model 3215 115981 152149 AN I/C A Model 3219 236286 239574 Model 3215 115981 152099 Model 3219 236286 237786 Note:...
Page 130 • HEAD, Key Switch 2 Position 103100 • BASE, Block Contact 103141 • SWI CH, N.O. Contact 100149 • WASHER, Switch Mount 114710 RING, Key Skyjack Logo (Ref.) ASSEMBLY, Emergency Stop Switch 102769 • HEAD, Emergency Stop Switch 103100 • BASE, Block Contact 103225 •...
Page 131 Figure 6.1-12A. Operator’s Control Box Assembly - ANSI/CSA Models & CE Models (Continued) (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. Part list continued from the previous page. (Ref) ASSEMBLY, Horn Switch 102851 • HEAD, Push Button Switch 103100 •...
Page 132 Figure 6.1-12B. Operator’s Control Box Assembly - ANSI/CSA Models (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 32 5 52 50 & Above ANSI/CSA 32 9 239575 & Above 32 5 52 00 & Above 32 9 237787 &...
Page 133 Figure 6.1-12B. Operator’s Control Box Assembly - ANSI/CSA Models (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. 29674 CONTROL BOX, Assembly (AN I & C A) 30574 CONTROL BOX, Assembly (CE) 32096 WELDMENT, Control Box (AN I & C A) 30564 WELDMENT, Control Box (CE)
Page 134 • BASE, Block Contact 03225 • SWITCH, N.C. Contact 00 49 • WASHER, Switch Mount 47 0 RING, Key Skyjack Logo 32098 WELDMENT, Control Box Bottom Cover 2327 • SCREW, Hex Hd Self-tapping #8- 8 x /2” 300788 CONNECTOR, Strain Relief...
Page 135 Figure 6.1-13. Proportional Controller Assembly 31 30 11333AA M123994AB_1 M123994AB_2 ECTION 6, Page 30 JIII eries - he Compacts 118941...
Page 136 Figure 6.1-13. Proportional Controller Assembly Index kyjack Qty. Description Part No. 1 3994 CONTROLLER, Enable Joystick Assembly 1 849 • HANDLE, Assembly 1 873 • • LEVER, Trigger 1 87 • • SWITCH, Enable Push Button 1 874 • • CAP , Rubber 13411 •...
Page 137 Figure 6.1-14. Scissor Arm Control Cable Assemblies 10547AA ECTION 6, Page 32 JIII eries - he Compacts 118941...
Page 138 Figure 6.1-14. Scissor Arm Control Cable Assemblies Index kyjack Qty. Description Part No. 310254 CABLE, 3219 Assembly (CE) 310255 CABLE, 3215 Assembly (CE) 129673 CABLE, 3219 Assembly (AN I/C A) 129672 CABLE, 3215 Assembly (AN I/C A) 103573 CONNEC OR, Female 16 Pin 103565 HOUSING, op 102887...
Page 139 Figure 6.2-1. Scissor Arm Assembly, Accessories And Hardware 10552AC ECTION 6, Page 34 JIII eries - he Compacts 118941...
Page 140 Figure 6.2-1. Scissor Arm Assembly, Accessories And Hardware Index kyjack Qty. Description Part No. (Ref.) WELDMEN , Scissor Arm (For components, Refer to Figure 6.2-2) (Ref.) SCISSOR PINS, Bushings and Connecting Hardware (For components, Refer to Figure 6.2-4) (Ref) HARDWARE, Lift Cylinder and Mounting (For Components, Refer to Figure 6.2-8) (Ref.) FLASHING AMBER LIGH , Option...
Page 141 Figure 6.2-2. Scissor Arm Weldments Model 3219 Model 3215 10553AA ECTION 6, Page 36 JIII eries - he Compacts 118941...
Page 142 Figure 6.2-2. Scissor Arm Weldments Index kyjack Qty. Description Part No. 127723 SCISSOR, Entire Assembly Model 3215 127722 SCISSOR, Entire Assembly Model 3219 127556 SCISSOR LEVEL, Inside Cylinder Bottom 127555 SCISSOR LEVEL, Inside Cylinder op 127563 SCISSOR ARMS, Outside 127557 SCISSOR LEVEL, Inside Entire assembly includes connecting hardware, pins, safety bar, and cylinder mounting hardware (cylinders are not included).
Page 143 Figure 6.2-3. Scissor Stack to Base & Main Platform Connecting Hardware op Slider Assembly Main Platform Bracket Mounting Assembly Bottom Slider Assembly End Pin Assembly at Base 11272AA ECTION 6, Page 38 JIII eries - he Compacts 118941...
Page 144 Figure 6.2-3. Scissor Stack to Base & Main Platform Connecting Hardware Index kyjack Qty. Description Part No. 120772 PAD, Slider 120771 BRACKET, Main Platform Slider 127791 SPACER, Slider Tube 100050 BUSHING, Fiberglide 3/4”I.D. x 1” 127799 PIN, Main Platform Slider (Model 3215 only) 127797 PIN, Main Platform Slider...
Page 145 Figure 6.2-4. Scissor Arm Connecting Hardware A - Outside End Pin Assembly B - Inside End Pin Assembly (With Cross Member ube) (Without Cross Member ube) C - Limit Switch Pin Assembly D - Center Pin Assembly 11271AA ECTION 6, Page 40 JIII eries - he Compacts 118941...
Page 146 Figure 6.2-4. Scissor Arm Connecting Hardware Index kyjack Qty. Description Part No. 127759 PIN, Outside Scissor 100050 BUSHING, Fiberglide 3/4”I.D. x 1” 121874 COTTER PIN, 1/4” x 1-1/2” 127561 TUBE, Cross Member 127763 PIN, Inside Scissor 127782 PIN, Limit Switch (Ref.) ASSEMBLY, Limit Switch (For components, refer to Figure 6.2-7)
Page 147 Figure 6.2-5. Platform Air Supply Hose Back View M310053AB Index kyjack Qty. Description Part No. 46 49 FITTING, Male disconnect 07886 CLAMP , Hose 46 50 260” HOSE, Air 3/8” (Model 3215) 300” HOSE, Air 3/8” (Model 3219) 0289 STRAP , Tie 7 02893 STRAP , Tie 0- /2 46 48...
Page 148 Figure 6.2-6. Flashing Amber Light Option 10113AA Index kyjack Qty. Description Part No. 23 78 BRACKET, Flashing Light Cover 20094 • BOLT, # 0 - 32 x 5/8 04003 • NUT, # 0 - 32 04694 • WASHER, # 0 Flat 04 85 •...
Page 149 Figure 6.2-7. Limit Switch Assemblies Scissor Arm 10a 10b 10c 10d 10557AB ECTION 6, Page 44 JIII eries - he Compacts 118941...
Page 150 Figure 6.2-7. Limit Switch Assemblies Scissor Arm Index kyjack Qty. Description Part No. 141507 SWITCH ASS’Y, High Speed/Pothole Limit (AN I/C A Model 3219 with Serial No. 260450 & Above) 121 75 • SWITCH, Drilled Sealed Limit 11 65 • HEATSHRINK, 3/4 Yellow 117582 •...
Page 151 Figure 6.2-7. Limit Switch Assemblies Scissor Arm (Continued) Index kyjack Qty. Description Part No. Part list continued from the previous page. 121 08 BUSHING, Snap 3/4 127 18 GUARD, Limit Switch 127 1 KIT, Hardware 300450 • LOCKNUT, #10-32 UNF Nylon Insert Hex 1200 4 •...
Page 152 Figure 6.2-8. Lift Cylinder Assembly And Mounting Hardware 10140AA ECTION 6, Page 48 JIII eries - he Compacts 118941...
Page 153 Figure 6.2-8. Lift Cylinder Assembly And Mounting Hardware Index kyjack Qty. Description Part No. (Ref.) 130709 CYLINDER, Lift Assembly 110681 • WELDMEN , Barrel 106220 • RING, Piston wear 114646 • ROD, Piston 106223 • O-RING, Gland 106209 • GLAND, Front Head 106219 •...
Page 154 Figure 6.2-9. Holding Valve Assembly 10932AA Index kyjack Qty. Description Part No. 130480 BLOCK ASSEMBLY, Holding Valve 130481 • BLOCK, Manifold 108052 • PLUG, Expander 114578 ING, Elbow (Ref.) HOSE, Lift Cylinder (For Components, Refer to Figure 6.3-3) (Ref.) ASSEMBLY, Lift cylinder (For components, refer to Figure 6.2-8) 103405 BOL , Hex head 5/16 - 18 x 2”...
Page 155 Figure 6.3 1. Base, Axle & Wheels M139463AG ECTION 6, Page 52 JIII eries The Compacts 118941...
Page 156 Figure 6.3 1. Base, Axle & Wheels Index kyjack Qty. Description Part No. 39465 WELDMENT, Base (Ref.) ASSEMBLY, Access Plate 28048 • PLATE, Access Cover 03995 • WASHER, Flat /4 04000 • WASHER, Lock /4 03980 • NUT, Hex Head /4 - 20 Grade 5 39470 ASSEMBLY, Ladder 03472...
Page 157 Figure 6.3 1. Base, Axle & Wheels (Continued) Index kyjack Qty. Description Part No. Parts list continued from the previous page. 25798 BOLT, Carriage /2 - 3 x - /2 Grade 5 0347 NUT, Hex Head /2 - 3 Grade 5 (Ref.) ASSEMBLY, Wheel Motor (For components, refer to Figure 6.3-4)
Page 158 Figure 6.3 2. Pothole Protection Device M20003AB 20001AA ECTION 6, Page 56 JIII eries The Compacts 118941...
Page 159 Figure 6.3 2. Pothole Protection Device Index kyjack Qty. Description Part No. 364 7 ROD, Compression Assembly 3 0229 CAM LOCK, Hydraulic Tray Assembly 3 0230 CAM LOCK, Battery Tray Assembly 93 4 • SPRING, Cam Lock 9728 • WASHER, Driver 8720 •...
Page 160 Figure 6.3 2. Pothole Protection Device (Continued) Index kyjack Qty. Description Part No. Parts list continued from the previous page. (Ref.) SWITCH, Pothole Device Limit Assembly 29430 • RETAINER, Limit Switch 39227 • LIMIT SWITCH, Pothole Hydraulic Tray 39228 • LIMIT SWITCH, Pothole Battery Tray 04 85 •...
Page 161 Figure 6.3 3. Hydraulic Hose Connections 10558AA ECTION 6, Page 60 JIII eries The Compacts 118941...
Page 162 Figure 6.3 3. Hydraulic Hose Connections Index kyjack Qty. Description Part No. 0773 HOSE, Hydraulic 3/8 x 25 07732 HOSE, Hydraulic 3/8 x 25.5 0697 HOSE, Right/Left Steer 29492 HOSE, Drive 3055 HOSE, Lift Cylinder (Order P/N 128180 for Machines with Serial No. 152099 (3215), 237786 (3219), &...
Page 163 Figure 6.3 4. Steer Mechanism 10597AC ECTION 6, Page 62 JIII eries The Compacts 118941...
Page 164 6.3-4. Steer Mechanism ndex Skyjack Qty. Description Part No. 28222 HOUSING, Wheel Motor RH 28223 HOUSING, Wheel Motor LH 3 0545 MOTOR, Hydraulic Drive 9574 SPACER, Bearing 95742 BEARING, Roller 95743 BEARING, Thrust 96 45 WASHER, Thrust 03307 FITTING, STR Connector - 0 SAE-6 JIC...
Page 165 Figure 6.3 5. Steering Assembly Battery Side ydraulic Side 10558AA Index kyjack Qty. Description Part No. TEERING, Arm - RH ( attery Side ) (Ref.) CYLINDER, teering (For Components, Refer to Figure 6.3-8) CREW, Hex ocket houlder 5/8 x 1-1/4 0795 TEERING, Arm - LH ( ydraulic Side ) 00050...
Page 166 Figure 6.3 6. Rear Axle Assembly 10568AB Index kyjack Qty. Description Part No. (Ref.) 282 5 REAR AXLE, Assembly 03978 • NUT, Hex Head 3/8 - 6 Grade 5 03999 • WASHER, Lock 3/8 282 8 • WELDMENT, Rear Axle 03870 •...
Page 167 Figure 6.3 7. Brake Cylinder Assembly 10566AA Index kyjack Qty. Description Part No. (Ref.) 27900 CYLINDER, Brake Assembly 03940 • SHCS, /4 - 20 x - /4 04000 • WASHER, Lock /4 03983 • NUT, Hex Head Jam /4 - 20 Grade 5 28 87 •...
Page 168 Figure 6.3 8. Steer Cylinder Assembly 10565AA Index kyjack Qty. Description Part No. (Ref.) 2 087 CYLINDER, Steer Assembly 2 089 • BARREL, Steer Cylinder 07 46 • SEAL 07 44 • SEAL 20438 • O-RING 2 088 • GLAND 06450 •...
Page 169 Figure 6.3 9. Base Control A,B,C ANSI/CSA & CE Models EE Rated Models 10579AG ECTION 6, Page 68 JIII eries The Compacts 118941...
Page 170 Figure 6.3 9. Base Control Index kyjack Qty. Description Part No. 297 6 BOX, Base Control Assembly (AN I/C A) 2786 BOX, Base Control Assembly (CE without Load ensing ystem) 30650 BOX, Base Control Assembly (CE with Load ensing ystem) 297 5 HARNESS, Base Control Switch, 28386...
Page 171 Figure 6.3 9. Base Control (Continued) Index kyjack Qty. Description Part No. Parts list continued from the previous page. 0328 SWITCH, -Contact Sing. N.C. 03 00 • BASE, Contact Block 03225 • -CONTACT BLOCK, N.C. 03278 SWITCH, 2-Contact N.O. 03 00 •...
Page 172 Figure 6.4 1. Hydraulic/Electric Tray Assembly 10540AB ECTION 6, Page 72 JIII eries The Compacts 118941...
Page 173 Figure 6.4 1. Hydraulic/Electric Tray Assembly Index kyjack Qty. Description Part No. (Ref.) HYDRAULIC/ELECTRIC TRAY (EE Rated) (Ref.) HYDRAULIC/ELECTRIC TRAY (Standard) 26760 WELDMENT, Hydraulic tray, 27588 WELDMENT, Hydraulic Tray, 20 90 PLUG, Seal Drain THREAD, Straight and Gasket Magnetic 00335 BUSHING, Bronze 07949 NUT, Hex Head Jam /2 - 3 Grade 5...
Page 174 Figure 6.4 2. Hydraulic Hose Connections 10551AA Index kyjack Qty. Description Part No. 28 69 HOSE-Hydraulic Line /4” DIA x 5” HOSE-Hydraulic Line /4” DIA x 26” Order P/N 128170 for machines with Serial No. 152201 (3215), 239960 (3219), & below) 32773 TUBE-Hydraulic 3/8 OD x 0.049”...
Page 175 Figure 6.4-3. Tank Lid ssembly 10549 ndex Skyjack Qty. Description Part No. 127567 ASSEMBLY, Hydraulic Tank Lid 10269 • FILLER/CAP , Assembly 10 962 • SCREW, Round Head Machine 10 - 2 x 1/2 105446 • CONNECTOR, Fitting Steering -12 SAE-8 10 864 •...
Page 176 Figure 6.4 4 . Motor/Pump Assembly 10550AA ECTION 6, Page 76 JIII eries The Compacts 118941...
Page 177 Figure 6.4 4 . Motor/Pump Assembly Index kyjack Qty. Description Part No. (Ref.) MOTOR/PUMP , Assembly (EE Rated) (Ref.) MOTOR/PUMP , Assembly (Standard) 03886 BOLT, Hex Head 5/ 6 - 8 x - /2 Grade 5 03404 WASHER, Lock 5/ 6 03996 WASHER, Flat 5/ 6 32756...
Page 178 Figure 6.4 5. Main Manifold Assembly 10561AC ECTION 6, Page 78 JIII eries The Compacts 118941...
Page 179 Figure 6.4 5. Main Manifold Assembly Index kyjack Qty. Description Part No. Ref.) 127629 MANIFOLD, Assembly 127592 • MANIFOLD, Assembly Without Directional Valves) 114581 • • FITTING, Run Tee 6-6 102856 • • PLUG, O-Ring #3 114578 • • ELBOW, 6-6 O-Ring 114580 •...
Page 180 Figure 6.4 6. Steering Manifold Assembly 10564AA Index kyjack Qty. Description Part No. 376 6 BOLT, Hex Head /4 - 20 x 3.75 Grade 5 03 36 VALVE, Manual Needle 07369 MANIFOLD, Steering 4578 ELBOW, 6-6 O-Ring 03354 VALVE, Flow Divider 03980 NUT, Hex Head /4 - 20 Grade 5 04000...
Page 181 Figure 6.4 7A. Proportional Control Manifold Assembly Internal Compensator Valve (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 3215 152202 & Above 50353AB erial Breakdown Reference Chart Model Serial Number 3219 239961 & Above 50354AB Mounting Plate 11212AA Index...
Page 182 Figure 6.4 7B. Proportional Control Manifold Assembly External Compensator Valve (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 3215 152201 & Below 50353AA erial Breakdown Reference Chart Model Serial Number 3219 239960 & Below 50354AA Mounting Plate 11211AA Index...
Page 183 Figure 6.5 1A. Electrical Panel Assembly (ANSI/SIA And CSA) SJIII 3215 & 3219 (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 3 15 151951 & Below 50157AB 10543AA ECTION 6, Page 84 JIII eries The Compacts 118941...
Page 184 Figure 6.5 1A. Electrical Panel Assembly (ANSI/SIA And CSA) SJIII 3215 & 3219 (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. 1 7615 WELDMENT, Electrical Panel 11531 RESISTOR, 40 Ohm 5 WATT 1 5893 BUMPERS, Rubber Female 103057 BEEPER, 4 Volt 1173 5...
Page 185 Figure 6.5 1B. Electrical Panel Assembly (ANSI/SIA And CSA) (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 3 15 15 538 & Above 50343AC 10543AB ECTION 6, Page 86 JIII eries The Compacts 118941...
Page 186 Figure 6.5 1B. Electrical Panel Assembly (ANSI/SIA And CSA) (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. 1 7615 WELDMENT, Electrical Panel 11531 RESISTOR, 40 Ohm 5 WATT 1 5893 BUMPERS, Rubber Female 103057 BEEPER, 4 Volt 1173 5 CIRCUIT BREAKER, 15 Amp 103743...
Page 187 Figure 6.5 2A. Electrical Panel Assembly (CE Without Load Sensing System) SJIII 3215 & 3219 (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 32 5 5 95 & Below 50157AB 10544AB ECTION 6, Page 88 JIII eries The Compacts 118941...
Page 188 Figure 6.5 2A. Electrical Panel Assembly (CE Without Load Sensing System) SJIII 3215 & 3219 (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. 276 5 WELDMENT, Electrical Panel 53 2 RESISTOR, 40 Ohm 25 WATT 25893 BUMPERS, Rubber Female 03057 BEEPER, 24 Volt...
Page 189 Figure 6.5 2B. Electrical Panel Assembly (CE with Load Sensing System) (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model erial Number 32 5 52538 & Above 50 57AC 10544AC ECTION 6, Page 90 JIII eries The Compacts 118941...
Page 190 Figure 6.5 2B. Electrical Panel Assembly (CE with Load Sensing System) (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. 30647 WELDMENT, Electrical Panel CE LS 53 2 RESISTOR, 40 Ohm 25 WATT 25893 BUMPERS, Rubber Female 08589 RELAY, 24V Selaed 03336...
Page 191 Figure 6.5 3A. Electrical Panel Assembly (EE Rated) (ANSI/SIA And CSA) SJIII 3215 & 3219 (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model erial Number 32 5 52537 & Below 10556AA ECTION 6, Page 92 JIII eries The Compacts 118941...
Page 192 Figure 6.5 3A. Electrical Panel Assembly (EE Rated) (ANSI/SIA And CSA) SJIII 3215 & 3219 (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. 26326 PANEL, Weldment EE 03 0 CONTACTOR, Solenoid BLOCK, Terminal 2p Large BLOCK, Terminal 7p Large 256 3 COVER, EE Gasket 256 2...
Page 193 Figure 6.5 3B. Electrical Panel Assembly (EE Rated) (ANSI/SIA And CSA) (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model erial Number 32 5 52538 & Above 50 57AC 10556AC ECTION 6, Page 94 JIII eries The Compacts 118941...
Page 194 Figure 6.5 3B. Electrical Panel Assembly (EE Rated) (ANSI/SIA And CSA) (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. 26326 PANEL, Weldment EE 03 0 CONTACTOR, Solenoid BLOCK, Terminal 2p Large BLOCK, Terminal 7p Large 256 3 COVER, EE Gasket 256 2 GASKET, EE 7 Hole...
Page 195 Figure 6.5 4. Electrical Panel Assembly (CE) 11233AB ECTION 6, Page 96 JIII eries The Compacts 118941...
Page 196 Figure 6.5 4. Electrical Panel Assembly (CE) Index kyjack Qty. Description Part No. 30648 ASSEMBLY, Electrical Panel (CE) 30647 • WELDMENT, Control panel 2495 • • BOLT, Hex Hd /4”-20 x 3/8” Gr. 5 03 0 • CONTACTOR, Solenoid (SPNO) •...
Page 197 Figure 6.5 5A. Electrical Panel Harness (CE) - SJIII 3215 & 3219 (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model erial Number 32 5 52537 & Below 11231AB ECTION 6, Page 98 JIII eries The Compacts 118941...
Page 198 Figure 6.5 5A. Electrical Panel Harness (CE) - SJIII 3215 & 3219 (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. 3065 HARNESS, Rear Manifold/Limit Switch 02887 62” • CABTIRE, Cable 6/ 5 7583 • PLUG, Connector 8-Pin 7585 •...
Page 199 Figure 6.5 5B. Electrical Panel Harness (CE) (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model erial Number 32 5 52538 & Above 50 57AC 11231AC ECTION 6, Page 100 JIII eries The Compacts 118941...
Page 200 Figure 6.5 5B. Electrical Panel Harness (CE) (Refer to Serial Breakdown Reference Chart) Index kyjack Qty. Description Part No. 3065 HARNESS, Rear Manifold/Limit Switch 02887 62” • CABTIRE, Cable 6/ 5 7583 • PLUG, Connector 8-Pin 7585 • WEDGE, Connector Plug 8-Pin 7593 •...
Page 201 Figure 6.6 1. Battery Tray Assembly For Machines with Inline Fuse 10541AA ECTION 6, Page 102 JIII eries The Compacts 118941...
Page 202 Figure 6.6 1. Battery Tray Assembly Index kyjack Qty. Description Part No. (AN I/C A) Ref.) BATTERY TRAY ASSEMBLY Ref.) BATTERY TRAY ASSEMBLY (EE Rated Option) Ref.) BATTERY TRAY ASSEMBLY (CE) Ref.) BATTERY OPTION U2500 103480 BATTERY, 6V 106552 BATTERY, 6V, 129631 SPACER, Wood battery Tray, 111423...
Page 203 Figure 6.6 1. Battery Tray Assembly Index kyjack Qty. Description Part No. Parts list continued from the previous page. 05600 BOOT, Red battery, B & C 0560 BOOT, Black battery, B & C 7407 BOOT, Black battery, 20394 BOOT, Black battery (Large), 20425 CABLE, Battery jumper 9548...
Page 204 Figure 6.6 2. Battery charger 10493AF The Compacts 118941...
Page 205 Figure 6.6 2. Battery Charger Index kyjack Qty. Description Part No. 29720 CHARGER ASSEMBLY, (Standard) CHARGER ASSEMBLY, (EE Rated) 28537 CHARGER, 24V DC Battery 27 7 • RELAY, Power ON 27 54 • • RELAY, Interlock 29 63 • LABEL, Front Plate 27 59 •...
Page 206 Figure 6.7 1 24VDC Inverter 17 18 & B Early Model 11188AB M137417AA 10702AA & D Later Model 11513AA ECTION 6, Page 108 JIII eries The Compacts 118941...
Page 207 Figure 6.7 1 24VDC Inverter Index kyjack Qty. Description Part No. (AN I/C A) (Early Model) 128769 INVERTER, 24VDC - 120VAC @ 60 Hz 128770 INVERTER, 24VDC - 110/220VAC @ 0 Hz (CE) (Early Model) 13 990 INVERTER, 24VDC - 120VAC @ 60 Hz (AN I/C A) (Later Model) 13 991 INVERTER, 24VDC - 110/220VAC @ 0 Hz...
Page 208 Figure 6.7 2 Inverter Assembly 10636AB ECTION 6, Page 110 JIII eries The Compacts 118941...
Page 209 Figure 6.7 2 Inverter Assembly Index kyjack Qty. Description Part No. 29854 Cover Assy Case ZX White 29860 XFR 24/800 NX 29855 Chassis Assembly Case Z White 2986 Fan 80CFM 29862 Capacitator 0uF 230 VAC 29866 Black DC Input Wire W/Ring Terminal 29865 Red DC Input Wire W/Ring Terminal 29864...
Page 210 Figure 6.7 3 Inverter Label Placement 4620/4832 New Platforms 3226 Platform 4626 New Platforms 3220 Platform 6826 New Platforms 32 5/32 9 Platforms 6832 New Platforms 10703AA Index kyjack Qty. Description Part No. 30 5 LABEL, Inverter Switch ECTION 6, Page 112 JIII eries The Compacts 118941...
Page 211 Figure 6.7 4 Work Light Option M137979AB Index kyjack Qty. Description Part No. 37979 ASSEMBLY, Work light 4 732 • BULB, 50 Watt halogen, 78 mm 4 70 • WORK LIGHT, Dual 250 Watt halogen 38050 • BRACKET, Work light 0386 •...
Page 212 Figure 6.8 1 Label Kit Label Kits he following label kits are for models SJIII 3215 & 3219. Each contains labels that are common to both machines. It excludes: • serial numbers • nameplates • registrations • stripes • tapes •...
Page 213 Figure 6.8 2A. Labels Main Control Box (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 32 5 52099 & Below 32 9 237628 & Below 50355AA 10989AA Index kyjack Qty. Description Part No. (Ref) (To order a complete label kit, refer to Figure 6.8- 24080 LABEL, Enable Joystick...
Page 214 Figure 6.8 2B. Labels Main Control Box (Refer to Serial Breakdown Reference Chart) erial Breakdown Reference Chart Model Serial Number 32 5 52 00 & Above 32 9 237629 & Above 50355AB 10989AB Index kyjack Qty. Description Part No. (Ref) (To order a complete label kit, refer to Figure 6.8- 30634...
Page 215 Figure 6.8 3. Labels And Nameplates Misc 11001AB ECTION 6, Page 118 JIII eries The Compacts 118941...
Page 216 Figure 6.8 3. Labels And Nameplates Misc Index kyjack Qty. Description Part No. (Ref) (To order a complete label kit, refer to Figure 6.8- 29868 LABEL, Up/Off/Down 30790 LABEL, Enable LABEL, Emergency Stop 7387 LABEL, Push to Reset Power 7389 LABEL, Push to Reset Ground 57 9 LABEL, Connect Charger Here...
Page 217 Figure 6.8 4. Labels And Nameplates Chassis See Detail 35&36 Detail 35 & 36 10626AE ECTION 6, Page 120 JIII eries The Compacts 118941...
Page 218 Qty. Description Part No. (Ref) (To order a complete label kit, refer to Figure 6.8-1) 1 9758 LABEL, Skyjack Small, Blue 1 9838 LABEL, Keep 1 9839 LABEL, Clear 1 9783 LABEL, Model Designation SJIII 3 19 1 9787 LABEL, Model Designation SJIII 3 15...
Page 219 Figure 6.8 4. Labels And Nameplates Chassis (Continued) Index kyjack Qty. Description Part No. Parts list continued from the previous page. 134109 LABEL, Made in America with Pride (AN I/C A) 117023 LABEL, CE (CE) 132209 LABEL, Registration (For Australian/New Zealand machines) 128160 LABEL, Batt.
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Skyjack SJIII Series Maintenance & Parts Manual

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