Skyjack SJIII Series Maintenance & Parts Manual
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Skyjack SJIII Series Maintenance & Parts Manual

Skyjack SJIII Series Maintenance & Parts Manual

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TM
MAINTENANCE &
PARTS MANUAL
800 275-9522
For Service please call .....................................................................
Skyjack Inc. Service Center, 3451 Swenson Ave., St. Charles, IL. 60174 .... FAX 630 262-0006
800 965-4626
For Parts in North America and Asia please call .....................................
Skyjack Inc. Parts Center, 3451 Swenson Ave., St. Charles, IL. 60174 .............. FAX 888 782-4825
44-1691-676 236
For Parts & Service in Europe please call ................................................
Skyjack Europe Glovers Meadow, Maesbury Road,Oswestry, Shropshire , UK ......... FAX 44-169- 676 238
129945AB
Printed in Canada
November 2 2022

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  • Page 1 PARTS MANUAL 800 275-9522 For Service please call ..............Skyjack Inc. Service Center, 3451 Swenson Ave., St. Charles, IL. 60174 ..FAX 630 262-0006 800 965-4626 For Parts in North America and Asia please call ........Skyjack Inc. Parts Center, 3451 Swenson Ave., St. Charles, IL. 60174 ....FAX 888 782-4825 44-1691-676 236 For Parts &...
  • Page 2 USE THE SERIAL NUMBER OF YOUR MACHINE TO DETERMINE THE CORRECT Maintenance & Parts Manual TO USE MANUAL 117128AE 118940AN 122909AG 129919AG 129926AC 129945AA PART # October 2005 Release Date May 1999 April 2004 April 2004 January 2006 May 2005 3220 609330 &...
  • Page 3 Aerial Platform. A mobile device that has an adjustable position platform supported from ground level by a structure. Purpose Of Equipment. The SKYJACK SJIII series aerial platforms are designed to transport and raise personnel, tools and materials to overhead work areas.
  • Page 4 - Equipment identified with “CE” meets the the warranty card has been completed and returned requirements for the European countries, to Skyjack within 15 days of invoiced. When aerial i.e. Machinery Directive 98/37/EEC and EMC platforms are put into Dealer’s stock, the warranty...
  • Page 5 For could result in the denial of a warranty claim. Skyjack’s instance, if you have a faulty switch on a controller, dealer’s accounts must be kept current in order to ap- please replace the switch.
  • Page 6 The following pages of this manual should be read and understood completely before operating the aerial platform. Any modifications from the original design are strictly forbidden without written permission from SKYJACK Inc. - . Electrocution Hazard Maintain a minimum safe approach distance (MSAD) from This aerial platform is not electrically insulated.
  • Page 7 • DO NOT (4832) or 25% (4620, 4626, 6826 in windy or gusty conditions. & 6832). Ascend or descend grades only when fully lowered and then only to the maximums noted above. SJIII Series SKYJACK, Page 5...
  • Page 8 • DO NOT exceed the rated capacity of the aerial platform. Do make sure the load is evenly distrib- uted on the platform. SKYJACK, Page 6 SJIII Series...
  • Page 9 • Has been damaged or appears to have worn or missing parts. • Has alterations or modifications not approved by the manufacturer. • Has safety devices which have been altered or disabled. Failure to avoid these hazards could result in death or serious injury. SJIII Series SKYJACK, Page...
  • Page 10 Notes SKYJACK, Page SJIII Series...

  • Page 11: Table Of Contents

    Table 2-1. Specifications and Features ........................2, 3 Table 2-2. Floor Loading Pressure ..........................4, 5 Table 2-3. Owner’s Annual Inspection Record ......................6 Table 2-4. Maximum Platform Capacities (Evenly Distributed) ...................6 Table 2-5. Maintenance And Inspection Schedule ......................7 SJIII Series SKYJACK, Page...

  • Page 12: Table 2-1. Specifications And Features

    16 x 5 x 12 Tires Solid Rubber 60156AF Ω Weight with standard 3’ (0.9m) extension platform. (Refer to nameplate for machines with 5’ (1.5m) or 6’ (1.8m) extension platform, CE models and other options.) SKYJACK, Page 2 SJIII Series...
  • Page 13 Weight with standard 3’ (0.9m) extension platform. Refer to Serial Nameplate for specific applications. (Refer to nameplate for machines with 5’ (1.5m) or 6’ (1.8m) extension platform, CE models and other options.) Fill Hardness: 55 Durometer SJIII Series SKYJACK, Page 3...

  • Page 14: Table 2-2. Floor Loading Pressure

    NOTE The LCP or OUP that an individual surface can withstand varies from structure to structure and is gener- ally determined by the engineer or architect for that particular structure. SKYJACK, Page 4 SJIII Series...
  • Page 15 Intermixing tires of different types or using tires of types other than those originally supplied with this equip- ment can adversely affect stability. Therefore, replace tires only with the exact original Skyjack-approved type. Failure to operate with matched approved tires in good condition may result in death or serious injury.

  • Page 16: Table 2-3. Owner's Annual Inspection Record

    This aerial platform is equipped with a Overload Sensing System. Do not exceed the rated capacity of the aerial platform. Failure to avoid this will prevent operation of all normal controls/functions of the aerial platform. To resume normal operation remove the additional loads. SKYJACK, Page 6 SJIII Series...

  • Page 17: General Maintenance

    60028AB Warning Use original or equivalent to the original parts and components for the aerial platform. SJIII Series SKYJACK, Page...
  • Page 18 Notes SKYJACK, Page 8 SJIII Series...
  • Page 19 Control Box Wiring Diagram ....................16 Figure 3.3-5. Control Box Wiring Diagram (Model 3226M) ................. 17 Electrical Panel Diagram Figure 3.4-1. Electrical Panel Diagram ......................19 Electrical Schematic Figure 3.5-1. Electrical Schematic ....................... 20 SJIII Series - The Conventionals 129945 SECTION 3, Page...

  • Page 20: Normally Closed Contact

    RELAY NO. RELAY FUNCTION 17CR TRANSFER RELAY 21ACR PROPORTIONAL RELAY (CE) 28CR1 TILT RELAY (CE) 28CR2 DOWN RELAY (CE) 28ECR1 AUXILIARY TILT RELAY (CE) 28ECR2 AUXILIARY DOWN RELAY (CE) 603 8AC-M SECTION 3, Page SJIII Series - The Conventionals 129945...
  • Page 21 Production 60041AD-M Y-AXIS NOTE: Ensure the platform is parked on a flat level surface before performing any adjust- X-AXIS ments or repairs to the tilt switch assembly. M 0 96AA SJIII Series - The Conventionals 129945 SECTION 3, Page 3...
  • Page 22 LEVEL SENSOR TRANSISTOR RELAY DOUBLE POLE SINGLE POLE DOUBLE POLE DOUBLE THROW DOUBLE THROW SINGLE THROW TRANSISTOR RELAY RELAY RELAY PRESSURE/ TRIPLE POLE TRANSISTOR VACUUM DIODE DOUBLE THROW SWITCH RELAY TEMPERATURE SWITCH SECTION 3, Page SJIII Series - The Conventionals 129945...
  • Page 23 TWO POSITION TWO POSITION FOUR WAY FOUR WAY TWO WAY THREE WAY CLOSED CENTER PROPORTIONAL NORMALLY OPEN CLOSED PORT VARIABLE PRESSURE DISPLACEMENT PILOT LINES Dashed MAIN LINES Solid TRANSDUCER HYDRAULIC MOTOR SERVO SJIII Series - The Conventionals 129945 SECTION 3, Page...
  • Page 24 Notes SECTION 3, Page 6 SJIII Series - The Conventionals 129945...
  • Page 25 BLOCK, Powered extension platform manifold (part of cylinder weldment) 132748 BLOCK, Proportional manifold (Equipped with Internal Compensator Valve) 115349 BLOCK, Proportional manifold (Equipped with External Compensator Valve) Parts list continued on following page. SJIII Series - The Conventionals 129945 SECTION 3, Page...
  • Page 26 VALVE, System relief 104534 VALVE, Lift relief 106557 VALVE, Holding valve relief (Model 3 115336 VALVE, Cross-over relief (Option) 115336 VALVE, Cross-over relief (Option) 107271 VALVE, Emergency lowering 103136 VALVE, Free-wheeling SECTION 3, Page 8 SJIII Series - The Conventionals 129945...
  • Page 27 VALVE FORWARD LEFT 2H-59B LIFT DRIVE STEER PROPORTIONAL RELIEF LOWERING COUNTER- VALVE VALVE VALVE VALVE ORIFICE BALANCE VALVE RETURN FILTER EMERGENCY PUMP LOWERING LOWERING VALVE CUSHION VALVE BLOCK CYLINDER HYDRAULIC TANK M10967AB SJIII Series - The Conventionals SECTION 3, Page...
  • Page 28 LEFT LIFT 2H-59B DRIVE STEER RELIEF PROPORTIONAL LOWERING COUNTER- VALVE VALVE VALVE VALVE ORIFICE BALANCE VALVE RETURN FILTER LOWERING EMERGENCY PUMP VALVE LOWERING CUSHION BLOCK VALVE CYLINDER HYDRAULIC TANK M10968AC SECTION 3, Page 10 SJIII Series - The Conventionals 129945...

  • Page 29: Main Manifold

    DISCONNECT VALVE (IF EQUIPPED) LIFT RELIEF VALVE 4H-24 4H-15 4H-23 2H-13 LEFT STEER REVERSE RIGHT STEER LOWERING QUICK VALVE DRIVE VALVE VALVE SYSTEM DISCONNECT VALVE RELIEF (IF EQUIPPED) VALVE 10192AC SJIII Series - The Conventionals 129945 SECTION 3, Page 11...
  • Page 30 119758 DIODE PACK 119520 DIODE ASSEMBLY 119624 DIODE ASSEMBLY 117619 FUSE, 300 Amp FL-22 121477 FLASHING LIGHT (option) FL-22A 103743 FLASHER, Flashing light Parts list continued on the following page. SECTION 3, Page 12 SJIII Series - The Conventionals 129945...

  • Page 31: Hour Meter

    SWITCH, Powered extension platform extend/retract toggle (Option) 102853 SWITCH, Powered extension platform enable toggle (Option) 115574 SWITCH, Torque toggle 103225 N.C. CONTACT, Emergency stop switch (Base Control Box) TMR-19B 132494 RELAY, Inverter Timer cut-out 103336 HOURMETER SJIII Series - The Conventionals 129945 SECTION 3, Page 13...
  • Page 32 PIN 2 - 29 GREEN 28 BLACK PIN 3 - 60 GREEN 28E WHITE PIN 4 - 28 BLACK 60 GREEN PIN 5 - 02 WHITE PIN 6 - 28E WHITE 10921AD SECTION 3, Page 14 SJIII Series - The Conventionals 129945...
  • Page 33 (OPT) BLUE WHITE BLUE BLACK (24) GREEN BLACK (OPT) (07) RED (14) BLACK ORANGE BLACK (59) (13) ORANGE RED BLACK (18) WHITE BLACK (16) (15) BLUE (02) WHITE (NOT USED) 10897AA SJIII Series - The Conventionals 129945 SECTION 3, Page 15...
  • Page 34 (13) ORANGE RED BLACK (18) (15) BLUE WHITE BLACK (16) (02) WHITE (NOT USED) CONTROL CABLE OPTIONS EUROPE N.A. WIRE COLOUR WIRE NUMBER WIRE NUMBER GREEN/BLACK RED/WHITE BLUE/WHITE GREEN/WHITE GREEN 10866AA SECTION 3, Page 16 SJIII Series - The Conventionals 129945...
  • Page 35 CONTROL BOX 1. BLACK (27) 2. WHITE (09) 3. GREEN (26) 4. (N/U) CONTROL CABLE OPTIONS EUROPE N.A. WIRE COLOUR WIRE NUMBER WIRE NUMBER GREEN/BLACK RED/WHITE BLUE/WHITE GREEN/WHITE GREEN 10868AB SJIII Series - The Conventionals 129945 SECTION 3, Page 17...
  • Page 36 Notes SECTION 3, Page 18 SJIII Series - The Conventionals 129945...
  • Page 37 LEFT STEER VALVE TO 4H-15 TO 4H-16 PIN 1 - 15 BLUE PIN 1 - 24 BLUE/BLACK TO FLASHER REVERSE FORWARD PIN 2 - 02 WHITE PIN 2 - 02 WHITE M10891AE SJIII Series - The Conventionals 129945 SECTION 3, Page 19...
  • Page 38 BOARD BLUE NEUTRAL REVERSE SOLENOID S7-4 CONTROL REV/DN TRANSFER RELAY WHITE/BLACK FORWARD SOLENOID S7-5 FWD/UP BLACK/WHITE RIGHT SOLENOID S7-2 RIGHT BRAKE SOLENOID S7 - 3 LEFT BLUE/BLACK LEFT SOLENOID M50190AF SECTION 3, Page 20 SJIII Series - The Conventionals 129945...
  • Page 39 4.2-10. Machines Will Not Hold on a Grade (Machines with Integral Brakes) ..........11 4.2-11. Platform Does Not Steer ........................11 4.2-12. All Systems Sluggish ......................... 11 4.2-13. Power Extension Platform Will Not Extend Or Retract ..............11 4.2-14. High/Low Torque Inoperative ......................11 SJIII Series - The Conventionals 129945 SECTION 4, Page...

  • Page 40: Introduction

    If a specific trouble is not listed, isolate the major component in which the trouble occurs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem. SECTION 4, Page 2 SJIII Series - The Conventionals 129945...

  • Page 41: All Controls Inoperative

    Loose or broken wire #7A from Platform Emergency Stop Check continuity. Replace if defective. Switch (S4) to Key Switch (S3). Open or defective Key Switch (S3). Close switch. Replace if defective. SJIII Series - The Conventionals 129945 SECTION 4, Page...

  • Page 42: Lift And Drive Inoperative From Platform Controls

    10. Defective Tilt Relay (28CR). 10. Check relay. Replace if defective. 11. Loose or broken wire #19A from Tilt Relay (28CR) to 11. Check continuity. Replace if defective. Pump Motor Contactor. SECTION 4, Page 4 SJIII Series - The Conventionals 129945...

  • Page 43: 7. No Down Function From Platform Controls (Ce Machines Only)

    Defective Drive Override Switch (LS6). Check switch. Replace if defective. Loose or broken wire #19 from Drive Override Limit Switch Check continuity. Replace if defective. (LS6) to Base Terminal Block (TB-1). SJIII Series - The Conventionals 129945 SECTION 4, Page 5...

  • Page 44: 13. No Drive Or Steer When Platform Elevated (All Machines)

    Loose or broken wire #02 from Steer Left Valve Coil (4H- Check continuity. Replace if defective. 24) to Base Terminal Block (TB-1). Open Diode (D24). Check diode. Replace if defective. SECTION 4, Page 6 SJIII Series - The Conventionals 129945...

  • Page 45: 17. No Elevated Drive Function

    Loose or broken wire #02 from Brake Valve Coil (3H-17A) Check continuity through coil. Replace if defective. to Base Terminal Block (TB-1). Open Diode (D17). Check diode. Replace if defective. Transfer Relay (17CR) defective. Check relay. Replace if defective. SJIII Series - The Conventionals 129945 SECTION 4, Page 7...

  • Page 46: 22. Lift Up Inoperative From Base Controls

    Check continuity through coil, replace if defective. Check diode. Replace if defective. Open Diode (D26). Check continuity through coil. Replace if defective. Loose or broken wire #02 from Extend Valve Coil (4H- 26). SECTION 4, Page 8 SJIII Series - The Conventionals 129945...

  • Page 47: 27. Powered Extension Platform Will Not Retract

    Defective Speed Valve Coils (3H-18A-1) or (3H-18A-2). Check continuity through coil. Replace if defective. 10. Loose or broken wire #02 from Rear Drive Manifold to 10. Check continuity. Replace if defective. Base Terminal Block (TB-1). SJIII Series - The Conventionals 129945 SECTION 4, Page 9...

  • Page 48: All Functions Inoperative

    (Machines with Integral Brakes) Plugged or defective brake orifice (07). Clear obstruction. Replace if defective. Damaged integral brake in wheel motor. Inspect wheel motor assembly. Repair and replace as necessary. SECTION 4, Page 0 SJIII Series - The Conventionals 129945...

  • Page 49: 9. Brake(S) Will Not Release (Machines With Integral Brakes)

    Mechanical binding in powered platform mechanism. Check for binding. Repair as needed. 4.2- 4. High/Low Torque Inoperative Stuck Speed Valve (3H-18A-1). Clean valve. Replace if defective. Stuck Speed Valve (3H-18A-2). Clean valve. Replace if defective. SJIII Series - The Conventionals 129945 SECTION 4, Page...
  • Page 50 Notes SECTION 4, Page 2 SJIII Series - The Conventionals 129945...

  • Page 51: Section 5 Maintenance And Service

    Table 5-2. Torque Specifications .................Section 5, Page 5 List Of Figures Figure 5-1. OEM Joystick Switch Wiring (Without Enable Relay) ......Section 5, Page 9 Figure 5-2. OEM Joystick Switch Wiring (Equipped with Enable Relay) ....Section 5, Page 10 SECTION 5, Page SJIII Series - The Conventionals 129945...

  • Page 52: Operators Responsibility For Maintenance

    (-) lead. safety bar properly positioned. Failure to avoid this hazard will result in death or serious injury! • Preventive maintenance is the easiest and least expensive type of maintenance. SECTION 5, Page SJIII Series - The Conventionals 129945...

  • Page 53: Hydraulic System And Component Maintenance And Repair

    Use ATF Dexron III (ESSO) or equivalent hydraulic oil. For Keep all connections tight. conditions causing oil temperatures below -31°F (-35°C) and above 122°F (50°C) consult Skyjack, Inc. SECTION 5, Page SJIII Series - The Conventionals 129945...
  • Page 54 16 x 5 x 12 16 x 5 x 12 16 x 5 x 12 Tires Solid Rubber Solid Rubber Solid Rubber Solid Rubber Solid Rubber 60337AC Refer to serial number nameplate for specific pressures. SECTION 5, Page SJIII Series - The Conventionals 129945...
  • Page 55 SAE Plugs Size Torque Lbf.ft (max) Lbf.in (max) Nm (max) 4.07 13.56 20.34 20.34 33.90 33.90 40.68 47.46 Newton-meter = Nm Pound-force foot = lbf.ft Pound-force inch = lbf.in 60056AC SECTION 5, Page 5 SJIII Series - The Conventionals 129945...

  • Page 56: 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. SECTION 5, Page 6 SJIII Series - The Conventionals 129945...
  • Page 57 The ideal adjustment occurs when the function just begins to move when the handle is deflected, and the out- put increases until it reaches its maximum desired response or speed at the end of handle travel. SECTION 5, Page SJIII Series - The Conventionals 129945...

  • Page 58: Oem Joystick - Troubleshooting Procedures

    (OFF) the output will ramp down to off. Ramp time is factory set to 2 seconds, unless other- wise specified. Note: Trimpots should be sealed with nail polish or enamel based paint. DO NOT USE RTV SILICONE SECTION 5, Page SJIII Series - The Conventionals 129945...

  • Page 59: Wire Chart

    8446 PCB WHT/BLU WHT/BLU ENABLE WHT/GRN +24 INPUT STEER COMMON PWM OUT ( A ) STEER RIGHT GROUND ( - ) WHT/RED STEER LEFT WHT/BLK WHT/BLK +24V INPUT AMP CONNECTOR 11095AA SECTION 5, Page SJIII Series - The Conventionals 129945...
  • Page 60 +24V INPUT STEER COMMON PWM OUT ( A ) STEER RIGHT GROUND ( - ) WHT/RED STEER LEFT WHT/BLK +24V INPUT WHT/BLU 129ACR / 8BCR ENABLE RELAY AMP CONNECTOR 50276AA SECTION 5, Page 0 SJIII Series - The Conventionals 129945...

  • Page 61: Platform Mounting Hardware Inspection

    . Remove any debris, oils or grease from the threads. 2. Replace all of the platform mounting hardware (bolts, flat washers, and spring washers) with new Skyjack-approved parts. Refer to the parts Platform manual for the part numbers for your specific Mounting MEWP .
  • Page 62 Notes SECTION 5, Page 2 SJIII Series - The Conventionals 129945...

  • Page 63: Section 6 Parts Lists

    How To Order Repair Parts Parts are listed in order according to the reference 1. Address all orders to your local SKYJACK dealer. number shown in the illustration, followed by a full 2. Specify model and serial number of the work description based upon the “NOUN FIRST”...

  • Page 64: Table Of Contents

    Brake Cylinder Assembly ....................... 66 Figure 6.3-8 Rear Drive Manifold Assembly ....................67 Figure 6.3-9 Hydraulic Hose Connections ....................68 Figure 6.3-10 Base Control Box Option ....................... 70 Figure 6.3-11 Tilt Usage Chart ........................73 SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 65 Label Kit ..........................92 Figure 6.7-2 Labels - Operators Control Box ..................... 93 Figure 6.7-3 Labels And Nameplates - Misc....................94 Figure 6.7-4 Labels And Nameplates - Chassis ..................96 SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 66 Figure 6.1-1. Entrance Gates M10155AB SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 67 (For components, refer to Figure 6.1-7) 600531 SCREW, Rambo (ST 3.5 x 13 DIN7504) 103540 TUBE, Top rail 125691 PADDING, Entry rail 103864 BOLT, Hex head (5/16-18 x 1” GR5) 103404 WASHER, Lock (5/16” ) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 68 Notes SECTION 6, Page 6 SJIII Series - The Conventionals 129945...
  • Page 69 Description Part No. 600449 ASSEMBLY, Latch pin spring 600451 • PIN, Latch 600450 • GUIDE, Nylon spring 600452 • PLATE, Gate latch release 600454 • PIN, Roll 600495 • SPRING, Compression SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 70 Figure 6.1-3. Side Railings M10166AA SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 71 (For components, refer to Figure 6.1-8) 125336 SPACER, Railing (Ref.) AC outlet on the platform (For components, refer to Figure 6.1-4) (Ref.) Entrance rails and gates (For components, refer to Figure 6.1-1) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 72 Figure 6.1-4. Platform AC Outlet M10197AB SECTION 6, Page 10 SJIII Series - The Conventionals 129945...
  • Page 73 114678 SCREW, Machine (#6-32 x 1/2”) A, B 124562 BOLT, Hex head washer (12-24 x 1/2”) A, B 104694 WASHER, Flat (#10) A, B (Ref.) LABELS (Refer to Figure 6.7-3) SJIII Series - The Conventionals 129945 SECTION 6, Page 11...
  • Page 74 Figure 6.1-5A. Extension Platform Railings M11534AA SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 75 (For components, refer to Figure 6.1-7) 125336 SPACER, Railing 600599 MANUAL ENCLOSURE ASSEMBLY 117293 • ENCLOSURE, Manual 600597 • Nut, Hex head lock (M4-0.7 DIN985) 600428 • SCREW, Machine cheese head (M4-0.7 x 25) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 76 Figure 6.1-5B. Extension Platform Railings (Powered) M11535AA SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 77 (For components, refer to Figure 6.1-7) 125336 SPACER, Railing 600599 MANUAL ENCLOSURE ASSEMBLY 117293 • ENCLOSURE, Manual 600597 • NUT, HEx head lock (M4-0.7 DIN985) 600428 • SCREW, Machine cheese head (M4-0.7 x 25) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 78 • NUT, Lock (Hex) (M8-1.25 GR8.8 DIN985) (Ref.) • PIN ASSEMBLY, Quick release large or small loop (For components, refer to Figure 6.1-7) 600261 BOLT, Hex head (M8-1.25 x 50 GR8.8 DIN931), B, D SECTION 6, Page 6 SJIII Series - The Conventionals 129945...
  • Page 79 NUT, Lock (Hex) (M10-1.5 GR8.8 DIN985) 124547 PIN ASSEMBLY, Quick release small loop 100509 • PIN, Quick release (3/8” dia. x 2”) 105807 • LANYARD, 6” Plastic coated 600531 SCREW, Rambo (ST 3.5 x 13 DIN7504) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 80 Figure 6.1-8. Main Platforms Assemblies M10121AA SECTION 6, Page SJIII Series - The Conventionals 129945...

  • Page 81: Hydraulic Cylinder Assembly

    600179 PIN, Cotter (ST 6.3 x 45 DIN94) 600206 BUSHING, Slider 600531 BOLT, Self tapping (ST 3.5 x 13 DIN7504) 108772 ANGLE, Extension slider (1-1/8” x 1-3/8” x 1/8” x 22”) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 82 Figure 6.1-9. Extension Platform Assemblies M10189AA SECTION 6, Page 0 SJIII Series - The Conventionals 129945...
  • Page 83 • STOP , Extension deck 600262 • NUT, Lock (Hex) (M8-1.25 GR8.8 DIN985) 600296 • BOLT, Button head (M8-1.25 x 25 GR10.9) (Ref.) • KIT, Safety D-ring (For components, refer to Figure 6.1-15) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 84 HOSE ASSEMBLY, From main manifold return 300” lg. Use part #107234 for machines prior to S/N 613588 (3220M) 126021 HOSE ASSEMBLY, From main manifold return 312” lg. Use part #125395 for machines prior to S/N 61355 (3220M) SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 85 • SEAL, O-ring 125736 • ROD, 6’ Powered deck cylinder 108798 • SEAL, Rod 120436 • SEAL, O-ring 125698 • GLAND, Powered deck cylinder 106449 • SEAL, Rod wiper 107396 KIT, Seal repair SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 86 • CONNECTOR ASSEMBLY, 5 Pole male 114377 • PLUG, Plastic (1/2”) 102853 • SWITCH, Toggle 111181 • GUARD, Toggle switch 117188 PLATE, Powered extension control box mounting (Ref.) LABELS (Refer to Figure 6.7-2 and 6.7-3) SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 87 • SWITCH, Roller level limit 107712 • CONNECTOR ASSEMBLY, 5 Pin male 117184 BRACKET, Limit switch mounting 103958 BOLT, Machine (#8-32 x 0.75”) 112249 WASHER (#8) 103632 BOLT, Self tapping (1/4-14 x 0.75”) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 88 ASSEMBLY, Hydraulic extension platform solenoid cable 103257 • CABLE, Cabtire (18/3) 107712 • CONNECTOR, 5 Pin male 102734 • WIRE, White (16 AWG) 300772 • TERMINAL, Female disconnect (14-16 AWG, 90°) SECTION 6, Page 6 SJIII Series - The Conventionals 129945...
  • Page 89 600316 • BOLT, Hex head (M10-1.5 x 25 GR8.8) 600225 • BRACKET, Safety ring 600226 • D-Ring, Safety 600315 • WASHER, Flat (M10) 600287 • NUT, Hex nylon lock (M10-1.5 GR8.8) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 90 Notes SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 91 (Model 109050 • FITTING, Hose barb 107886 • CLAMP , Hose 102891 • STRAP , Tie (7” lg.) 102893 • STRAP , Tie (10-1/2” lg.) 107887 • LABEL, Connect air here SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 92 Figure 6.1-17. Operator’s Control Box Assembly M10220AC SECTION 6, Page 0 SJIII Series - The Conventionals 129945...
  • Page 93 (Ref.) SWITCH ASSEMBLY, Emergency stop 102769 • HEAD, STOP switch 103100 • BASE, Contact 103225 • BLOCK, N.C. Contact 121058 HORN, 24 Volt operator Parts list continued on the following page. SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 94 Figure 6.1-17. Operator’s Control Box Assembly (Continued) M10220AC SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 95 CABLE ASSEMBLIES, Powered extension option (For components, refer to FIgure 6.1-12, 6.1-13, & 6.1-14) (Ref.) CABLE ASSEMBLY, Scissor arm (For components, refer to Figure 6.1-19) (Ref.) LABEL (Refer to Figure 6.7-2) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 96 Figure 6.1-18. Proportional Controller Assembly 13 12 M122849AA 31 30 29 M123994AB SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 97 • • PIN, Male wire 122867 • SCREW, Circuit board 122868 • CIRCUIT BOARD ASSEMBLY 122869 • SWITCH, Micro 122870 • WASHER, Switch micro 122857 • SCREW, Switch micro 124820 • SHAFT, Modified joystick SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 98 Figure 6.1-19. Scissor Arm Control Cable Assemblies M11541AA SECTION 6, Page 6 SJIII Series - The Conventionals 129945...
  • Page 99 103564 • • HOUSING, Top 103574 • • INSERT, Male 118711 • LABEL, Hydraulic proportional Cable Lengths Models Wire Part Wire Type Number 16/10 102888 384” 468” 16/15 102887 384” 468” SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 100 Figure 6.2-1. Scissor Arm Assembly - Model 3220M M11106AD-M SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 101 600087 WELDMENT, Cable carrier 600170 BUMBER, Scissor bottom (Ref.) ASSEMBLY, Flashing light option (For components, refer to Figure 6.2-5) (Ref.) HARDWARE, Lift cylinder and mounting (For components, refer to Figure 6.2-7) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 102 Figure 6.2-2. Scissor Arm Assembly - Model 3226M M11104AD-M SECTION 6, Page 0 SJIII Series - The Conventionals 129945...
  • Page 103 SCISSOR LEVEL, Inside cylinder bottom 600170 BUMBER, Scissor bottom (Ref.) ASSEMBLY, Flashing light option (For components, refer to Figure 6.2-5) (Ref.) HARDWARE, Lift cylinder and mounting (For components, refer to Figure 6.2-7) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 104 Figure 6.2-3. Scissor Stack Assembly Mounting A - Top Slider Assembly B - Main Platform Bracket Mounting Assembly C - Bottom Slider Assembly D - End Pin Assembly at Base M11302AA SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 105 PIN, Inside Scissors (20mm x 112mm) (With cable carrier weldment) 600142 BRACKET, Platform mounting 600173 SPACER, Bottom roller pin 600131 PIN, Bottom roller 600140 ROLLER, Scissor 600126 TUBE, Outside scissor arms cross member SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 106 Figure 6.2-4. Scissor Arm Assembly Connecting Hardware Outside End Pin Assembly Inside End Pin Assembly (With Cross Member Tube) (Without Cross Member Tube) Limit Switch Pin Assembly Center Pin Assembly M11303AA SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 107 WASHER, Nylon (65mm O.D. x 33mm I.D.) 600174 BUSHING (32mm dia. x 50mm) 600176 SPACER, Thrust fiberglide (1-1/4” I.D.) 600707 WASHER, Flat (1-1/4” I.D. x 2-1/4” O.D.) 600179 PIN, Cotter (6mm dia. x 45mm) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 108 Notes SECTION 6, Page 6 SJIII Series - The Conventionals 129945...
  • Page 109 • NUT (#10-32) 104694 • WASHER, Flat (#10) 104185 • WASHER, Lock (#10) 126104 HARNESS, Flashing light (Model 103256 48” • CABTIRE (18/2) 126100 HARNESS, Flashing light (Model 103256 228” • CABTIRE (18/2) SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 110 Figure 6.2-6. Scissor Arm Limit Switch Assemblies YELLOW HEATSHRINK HIGH SPEED HIGH SPEED POTHOLE YELLOW HEATSHRINK END OF STROKE BLUE HEATSHRINK DRIVE CUTOUT M10193AA SECTION 6, Page SJIII Series - The Conventionals 129945...
  • Page 111 • HEATSHRINK, Blue 121869 CLAMP , 2.5” Worm gear 118713 JUMPER ASSEMBLY, Optional drive cutout 121991 SWITCH ASSEMBLY, Optional drive cutout limit 122010 • SWITCH, Drilled sealed limit 119130 • KIT, 4-Pole receptacle SJIII Series - The Conventionals 129945 SECTION 6, Page...
  • Page 112 Figure 6.2-7. Lift Cylinder Assembly And Mounting Hardware M10140AA SECTION 6, Page 0 SJIII Series - The Conventionals 129945...
  • Page 113 WASHER, Flat (5/16 SAE) (4 per cylinder) 103404 WASHER, Lock (5/16 NOM x 0.07) (4 per cylinder) 100397 NUT, Hex head (5/16-18 Grade B) (4 per cylinder) 121097 KIT, Seal repair SJIII Series - The Conventionals 129945 SECTION 6, Page 51...
  • Page 114 (For components, refer to Figure 6.2-7) 103865 BOLT, Hex head (5/16 - 18 x 2.00 lg.) 103996 WASHER, Flat (5/16 SAE) 103404 WASHER, Lock (5/16 NOM) 114578 FITTING, Elbow 104135 HOSE ASSEMBLY, Lift cylinder SECTION 6, Page 52 SJIII Series - The Conventionals 129945...
  • Page 115 CONNECTOR, Straight (Upper lift cylinder) 114579 FITTING, Tee (Lower lift cylinder) 102635 HOSE ASSEMBLY, Upper lift cylinder to lower lift cylinder 104657 HOSE ASSEMBLY, Lower lift cylinder to main manifold SJIII Series - The Conventionals 129945 SECTION 6, Page 53...
  • Page 116 Figure 6.3-1. Base, Axle & Wheels M10172AA SECTION 6, Page 54 SJIII Series - The Conventionals 129945...
  • Page 117 • WASHER, Lock (M10 NOM) 600291 • NUT, Hex head (M10-1.5) 102027 FITTING, Grease (Ref.) CONTROL BOX ASSEMBLY, Base (For components, refer to Figure 6.3-10) Parts list continued on the following page SJIII Series - The Conventionals 129945 SECTION 6, Page 55...
  • Page 118 Figure 6.3-1. Base, Axle & Wheels (Continued) M10172AA SECTION 6, Page 56 SJIII Series - The Conventionals 129945...
  • Page 119 WELDMENT, Brake pin RH (Model 3220M) 124229 WELDMENT, Brake pin RH (Model 3226M) 103940 • BOLT, Soc-hd (1/4-20 x 1-1/4” lg.) 104000 • WASHER, Lock (1/4”) 103983 • NUT, Jam (1/4-20) SJIII Series - The Conventionals 129945 SECTION 6, Page 57...
  • Page 120 Figure 6.3-2. Pothole Protection Device M10195AA SECTION 6, Page 58 SJIII Series - The Conventionals 129945...
  • Page 121 PLATE, Kicker 600479 PIN, Clevis 600500 BUSHING, Fiberglide (8 I.D. X 10mm lg.) 600489 PIN, Lock 600476 PIN, Spring (2.5mm dia. x 22mm) Parts list continued on the following page. SJIII Series - The Conventionals 129945 SECTION 6, Page 59...
  • Page 122 Figure 6.3-2. Pothole Protection Device (Continued) M10195AA SECTION 6, Page 60 SJIII Series - The Conventionals 129945...
  • Page 123 600417 FLAP WELDMENT, Hydraulic tray (Ref.) HARDWARE, Flap weldment retaining 103473 • BOLT, Hex head (3/8-16 x 1” lg.) 600383 PIN, Lever 100446 PIN, Eccentric 600516 PIN, Tray spring guide SJIII Series - The Conventionals 129945 SECTION 6, Page 61...
  • Page 124 • KIT, Seal 106451 • NUT, Hex jam (1”- 20) 103789 • WASHER, Lock (1”) 600554 BOLT, Hex head (M12-1.75x65) 600555 NUT, Hex head jam (M12-1.75) 600549 WASHER, Lock (M12) SECTION 6, Page 62 SJIII Series - The Conventionals 129945...
  • Page 125 • • BEARING, Outer cup 103003 • • BEARING, Outer cone 102829 • • WASHER, Flat 102749 • • NUT, Castle (1” - 14) 102865 • • CAP , Dust SJIII Series - The Conventionals 129945 SECTION 6, Page 63...
  • Page 126 • BOLT, Hex head (5/8” - 11 x 2 3/4”) 100856 • SPACER 103998 • WASHER, Lock (5/8”) 103982 • NUT, Hex head (5/8” - 11) 107797 • BOLT, Hex head (5/8” - 11 x 3 1/2”) SECTION 6, Page 64 SJIII Series - The Conventionals 129945...
  • Page 127 100252 NUT, Hex head jam (3/4”-10) 104002 WASHER, Lock (3/4”) 119310 BOLT, Hex head (3/4”-10 x 2-3/4”) (Ref.) FITTINGS, Hydraulic (For components, refer to Figure 6.3-9) 105816 KIT, Seal repair SJIII Series - The Conventionals 129945 SECTION 6, Page 65...
  • Page 128 • SEAL, Rod 120148 • GLAND 103827 • WIPER, Rod 103897 BOLT, Hex head (5/8” - 11 x 2”) 103982 NUT, Hex head (5/8” - 11) 105816 KIT, Seal repair SECTION 6, Page 66 SJIII Series - The Conventionals 129945...
  • Page 129 • FITTING, Tee (#6 orb - #6 - #6) 103874 BOLT, Hex head (3/8-16 x 2-3/4” lg.) 126068 SPACER, Tube (Model 3220M) 103999 WASHER, Lock (3/8”) 103472 WASHER, Flat (3/8” SAE) SJIII Series - The Conventionals 129945 SECTION 6, Page 67...
  • Page 130 Figure 6.3-9. Hydraulic Hose Connections Steer Cylinder Main Manifold Rear Drive Left Right Manifold wheel Wheel Motor Motor Left Brake Right Brake Cylinder Cylinder M10009AA SECTION 6, Page 68 SJIII Series - The Conventionals 129945...
  • Page 131 CYLINDER ASSEMBLY, Brake (For components, refer to Figure 6.3-7) 102540 HOSE ASSEMBLY, Brake (RH) 126015 HOSE ASSEMBLY, Brake (LH) (Ref.) MANIFOLD ASSEMBLY, Rear drive (For components, refer to Figure 6.3-8) SJIII Series - The Conventionals 129945 SECTION 6, Page 69...
  • Page 132 PIN 3 - 02 (WHITE) PIN 5 - 10E (WHITE) PIN 4 - N/U PIN 6 - 28 (GREEN) PIN 7 - 19 (BLACK) PIN 8 - 02 (WHITE) M10325AA SECTION 6, Page 70 SJIII Series - The Conventionals 129945...
  • Page 133 • STRAIN RELIEF, Cord (1/2”) 103260 34” • CORD (18/5) 103257 12” • CORD (18/3) 119132 • KIT-8 POLE, Deutsch plug 126689 • PLATE, Adapter (If Equipped) (Ref.) • LABELS (Refer to Figure 6.7-3) SJIII Series - The Conventionals 129945 SECTION 6, Page 71...
  • Page 134 Notes SECTION 6, Page 72 SJIII Series - The Conventionals 129945...
  • Page 135 Production Current Production 60041AD-M Y-AXIS NOTE: Ensure the platform is parked on a flat level surface X-AXIS before performing any adjust- ments or repairs to the tilt switch assembly. M10196AA SJIII Series - The Conventionals 129945 SECTION 6, Page 73...
  • Page 136 Figure 6.4-1. Hydraulic/Electric Tray Assembly 39 38 37 M10190AB SECTION 6, Page 74 SJIII Series - The Conventionals 129945...
  • Page 137 • BOLT, Hex head (M8-1.25 x 25) 600188 • NUT, Lock (M8-1.25) 600185 • WASHER, Lock (M8) 600647 INSERT, Threaded (Not needed if ordering gauge assembly) Parts list continued on the following page. SJIII Series - The Conventionals 129945 SECTION 6, Page 75...
  • Page 138 Figure 6.4-1. Hydraulic/Electric Tray Assembly (Continued) 39 38 37 M10190AB SECTION 6, Page 76 SJIII Series - The Conventionals 129945...
  • Page 139 600426 WASHER, Flat (M12) 600549 WASHER, Lock (M12) 103873 BOLT, Hex head (3/8”-16 x 2 1/2” lg.) (Ref.) MANIFOLD ASSEMBLY, Main (For components, refer to Figure 6.4-4) 600463 WEIGHT ASSEMBLY SJIII Series - The Conventionals 129945 SECTION 6, Page 77...
  • Page 140 • BOLT, Hex head (5/16-18 x 1/2” lg.) 103996 • WASHER, Flat (5/16”) 103404 • WASHER, Lock (5/16”) 124323 CABLE, Motor/Main Contactor (#4 5/16 x 35 x 3/8) 124325 CABLE, Motor/Battery (#4 5/16 x 116 x 3/8) SECTION 6, Page 78 SJIII Series - The Conventionals 129945...
  • Page 141 102665 • FITTING, Elbow (90° #8 orb - #6) (Earlier models) 103070 • FITTING, Connector straight (#8 orb - #8) (Later models) 103070 • FITTING, Connector (#8 orb - #8) SJIII Series - The Conventionals 129945 SECTION 6, Page 79...
  • Page 142 Figure 6.4-4. Main Manifold Assembly M10192AA SECTION 6, Page 80 SJIII Series - The Conventionals 129945...
  • Page 143 • BOLT, Soc-head (#10 - 24 x 3” lg.) 701956 FITTING, Connector (#6 orb - #4) (Machines with powered extension platform) Use part #103069 for machines prior to S/N 613588 (3220). SJIII Series - The Conventionals 129945 SECTION 6, Page 81...
  • Page 144 Figure 6.4-5. Hydraulic Hose Connections - Hydraulic/Electric Tray M10178AB SECTION 6, Page 82 SJIII Series - The Conventionals 129945...
  • Page 145 (For components, refer to Figure 6.4-1) 119851 HOSE, Suction (3/4”) (Ref.) FILTER ASSEMBLY, Return (For components, refer to Figure 6.4-1) 109052 FITTING, Connector (#12 orb - #6) 125486 HOSE ASSEMBLY, Filter to main manifold SJIII Series - The Conventionals 129945 SECTION 6, Page 83...
  • Page 146 Figure 6.5-1. Battery Tray Assembly 23 22 M11540AA SECTION 6, Page 84 SJIII Series - The Conventionals 129945...
  • Page 147 BOOT, Red Battery 117407 BOOT, Black Battery 100440 PLYWOOD (3/8” x 10-1/2” x 28-1/2” lg.) (Ref.) CHARGER ASSEMBLY, Battery (For components, refer to Figure 6.5-2) Parts list continued on the following page. SJIII Series - The Conventionals 129945 SECTION 6, Page 85...
  • Page 148 Figure 6.5-1. Battery Tray Assembly (Continued) 23 22 M11540AA SECTION 6, Page 86 SJIII Series - The Conventionals 129945...
  • Page 149 600185 • WASHER, Lock (M8) 600188 • NUT, Lock (M8-1.25) 600191 • WASHER, (Lock M6) (Ref.) POT HOLE PROTECTION DEVICE (For components, refer to Figure 6.3-2) $ - Purchase locally. SJIII Series - The Conventionals 129945 SECTION 6, Page 87...
  • Page 150 Figure 6.5-2. Battery Charger Assembly DO NOT CHANGE THE INPUT V BEFORE ‘THREE LEDS TURN OFF’ VIEW “A” M10493AH SECTION 6, Page 88 SJIII Series - The Conventionals 129945...
  • Page 151 103856 BOLT (1/4 - 20 x 3/4 GR5) 103995 WASHER, Flat (1/4) 104000 WASHER, Lock (1/4) 103980 NUT (1/4 - 20 Grade B) 129702 SCREW, Slot hex washer head tapping SJIII Series - The Conventionals 129945 SECTION 6, Page 89...
  • Page 152 Figure 6.6-1. Electrical Panel Assembly MSP-1028AA MS1F-1028AB SECTION 6, Page 90 SJIII Series - The Conventionals 129945...
  • Page 153 (For components, refer to Figure 6.2-6) 118713 JUMPER, 4 Pin 119730 CABLE ASSEMBLY, Electrical panel control 102887 73” • CABLE (16/15) 107821 • CONNECTOR, 16 Pin (Ref.) LABELS (Refer to Figures 6.7-2 and 6.7-3) SJIII Series - The Conventionals 129945 SECTION 6, Page 91...
  • Page 154 Items with * are part of the label kit. Label Kit ANSI/CSA MODELS Part # 129980 Part # 129981 3220 615767 & ABOVE 3226 272100 & ABOVE 4620 4626 710000 & ABOVE 4632 60393AA SECTION 6, Page 92 SJIII Series - The Conventionals 129945...
  • Page 155 LABEL, Torque Normal/High 124199 LABEL, Joystick Controller 105352 LABEL, Horn 130639 LABEL, Overload *Included in the label kit NOTE: Supply Model Number, Serial Number, Country and Language when ordering complete machine labels. SJIII Series - The Conventionals 129945 SECTION 6, Page 93...
  • Page 156 Figure 6.7-3. Labels And Nameplates - Misc CROSS MEMBER 1ST LEVEL LIFT CYLINDER RAILING PINS PLATFORM REAR POCKET INSIDE SCISSORS CONTROL BOX - POWER ELECTRICAL PANEL EXTENSION DECK BATTERY TRAY M11027M-AD SECTION 6, Page 94 SJIII Series - The Conventionals 129945...
  • Page 157 109442 LABEL, Emergency lowering 106703 LABEL, Orifice detail 111814 LABEL, Emergency Stop *Included in the label kit NOTE: Supply Model Number, Serial Number,Country and Language when ordering complete machine labels. SJIII Series - The Conventionals 129945 SECTION 6, Page 95...
  • Page 158 Figure 6.7-4. Labels And Nameplates - Chassis Note: Supply Model Number, Serial Number, Country and Language when ordering complete machine labels. M11000AH SECTION 6, Page 96 SJIII Series - The Conventionals 129945...
  • Page 159 LABEL, Model Designation SJIII 3226 129758 LABEL, Skyjack logo, small blue *Included in the label kit NOTE: Supply Model Number, Serial Number, Country and Language when ordering complete machine labels. SJIII Series - The Conventionals 129945 SECTION 6, Page 97...
  • Page 161 ELEVATING THE WORLD www.skyjackinc.com...
  • Page 162 Notes SECTION 6, Page 98 SJIII Series - The Conventionals 129945...

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