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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 &...
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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...
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 .........................
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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.
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.
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”...
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.
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.
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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...
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Skyjack. Failure to avoid these hazards could arning result in death or serious injury.
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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...
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”...
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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"...
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...
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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...
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"...
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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.
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.
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.
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...
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.
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...
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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)
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...
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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)
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...
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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)
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...
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...
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...
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...
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...
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...
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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...
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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°...
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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...
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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.
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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 &...
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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 &...
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Figure 3.4-1. Control Box Diagram - ANSI/CSA Models Equipped With No Options 10562AA JIII eries - The Compacts 118941 ECTION 3, Page 19...
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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...
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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...
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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...
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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...
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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 &...
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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...
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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 &...
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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 &...
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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 &...
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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...
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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.
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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...
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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 &...
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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 &...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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.
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.
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.
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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.
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.
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.
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.
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.
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.
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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 ..........................
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...
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...
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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...
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...
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.
(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...
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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...
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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...
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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).
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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...
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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 •...
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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...
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Figure 6.1-10. Platform AC Outlet 11088AA 11121AA 11121AC ECTION 6, Page 18 JIII eries - he Compacts 118941...
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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,...
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Figure 6.1-11. Operator’s Control Box Assembly - ANSI/CSA EE Rated Models 11161AA ECTION 6, Page 20 JIII eries - he Compacts 118941...
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• 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 •...
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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:...
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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 •...
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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 &...
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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)
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• 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...
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Figure 6.1-14. Scissor Arm Control Cable Assemblies 10547AA ECTION 6, Page 32 JIII eries - he Compacts 118941...
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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...
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Figure 6.2-1. Scissor Arm Assembly, Accessories And Hardware 10552AC ECTION 6, Page 34 JIII eries - he Compacts 118941...
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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...
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Figure 6.2-2. Scissor Arm Weldments Model 3219 Model 3215 10553AA ECTION 6, Page 36 JIII eries - he Compacts 118941...
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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).
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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...
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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...
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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...
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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)
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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...
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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)
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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...
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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...
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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 •...
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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...
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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”...
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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 •...
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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...
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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 •...
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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...
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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...
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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...
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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 •...
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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 •...
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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...
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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...
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Figure 6.8 3. Labels And Nameplates Misc 11001AB ECTION 6, Page 118 JIII eries The Compacts 118941...
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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...
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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...
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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...
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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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