Skyjack SJIII 3215 Service Manual
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Skyjack SJIII 3215 Service Manual

Skyjack SJIII 3215 Service Manual

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SERVICE
MANUAL
SJIII 3215, SJIII 3219
DC ELECTRIC SCISSORS
165977AK
May 2 2023
CE

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Summary of Contents for Skyjack SJIII 3215

  • Page 1 SERVICE MANUAL SJIII 3215, SJIII 3219 DC ELECTRIC SCISSORS 165977AK May 2 2023...
  • Page 2 This manual is for MEWPs with serial numbers: SJIII 3215: 10 000 996 to 10 999 999 SJIII 3219: 22 057 772 to 22 999 999 Please refer to the website (www.skyjack.com) for contact information, other serial numbers, the most recent technical manuals, animations, and USB software.
  • Page 3 It may also be used to alert against unsafe practices. IMPORTANT IMPORTANT indicates a procedure essential for safe operation and which, if not followed, may result in a malfunction or damage to the MEWP . SJIII 3215, SJIII 3219 165977AK...
  • Page 4 Notes 165977AK SJIII 3215, SJIII 3219...

  • Page 5: Table Of Contents

    Torque Specifications for Fasteners (US) ..........31 SJIII 3215, SJIII 3219...
  • Page 6 Up Function Slow from Base Control Console ........73 165977AK SJIII 3215, SJIII 3219...
  • Page 7 Platform ............... . 105 SJIII 3215, SJIII 3219...
  • Page 8 Flash the GP-108 Controller ........... . . 130 165977AK SJIII 3215, SJIII 3219...

  • Page 9: Section 1 - Scheduled Maintenance

    SKYJACK dealer at no charge for parts or labor. In addition, all products have a 5 year structural 1.1-1 Aerial Platform and Mobile warranty.

  • Page 10: Maintenance And Inspection Schedule

    MEWP . relative law provisions obtaining in the country. Consult SKYJACK’s Service Department for optional Before attempting any repair work, disconnect the tires specifications and installation. main power conenctors.

  • Page 11: Hydraulic System & Component Maintenance And Repair

    6. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also, plug the ports of the removed components. SJIII 3215, SJIII 3219 165977AK...

  • Page 12: Maintenance Hints

    1.3-1 Maintenance Hints 1.3-2 Railing Maintenance and Repair Three simple maintenance procedures have the Skyjack MEWPs have been designed to ensure greatest effect on the hydraulic system performance, compliance with the relevant design standards efficiency and life. Yet, the very simplicity of them may applicable for that particular unit at the time of be the reason they are so often overlooked.

  • Page 13: About This Section

    Disconnect the battery by turning the main Pass power disconnect switch to the “OFF” position. Fail ▪ Repair any damaged or malfunction Repaired components before operating MEWP . ▪ Not applicable Keep records on all inspections. SJIII 3215, SJIII 3219 165977AK...

  • Page 14: Owner's Annual Inspection Record

    Do not use the aerial platform if an inspection has not been recorded in the last 13 months. annual inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 13 months. Description Label Pictorial Description Label Pictorial Inspector Inspection Date Signature 165977AK SJIII 3215, SJIII 3219...

  • Page 15: Pre-Delivery/Maintenance Inspection Checklist

    Owner: ________________________________________________ / _____________________________________________ / ______________________________________________________ Print Name Signature Date (DD/MM/YY) User: _________________________________________________ / _____________________________________________ / _______________________________________________________ Print Name Signature Date (DD/MM/YY) 167830AC Note: Visit skyjack.com for a printable copy of this form. SJIII 3215, SJIII 3219 165977AK...

  • Page 16: Visual & Daily Maintenance Inspections

    ▪ Broken or missing actuator arm. ▪ Missing fasteners. ▪ Loose wire connections. 165977AK SJIII 3215, SJIII 3219...

  • Page 17: Electrical

    Free-wheeling Valve Knob ▪ Ensure there are no loose or missing parts and there is no visible damage. Wheel Motor Assembly ▪ Ensure there is no loose or missing parts and signs of visible damage. SJIII 3215, SJIII 3219 165977AK...

  • Page 18: Battery Tray Side

    Improper fluid levels or damaged cables and connections can result in component damage WARNING and hazardous conditions. Use original or manufacturer-approved parts and WARNING components for the MEWP . Explosion hazard. Keep flames and sparks away. Do not smoke near batteries. 165977AK SJIII 3215, SJIII 3219...

  • Page 19: Extension Side

    WARNING Tie Rod Do not use tires other than the tires that Skyjack ▪ Ensure there are no loose or missing parts, specifies for this MEWP . Do not mix different types tie rod end studs are locked and there is no of tires or use tires that are not in good condition.
  • Page 20 There should be no more than 2 cuts or chunks in each 1/4 section of the tire. There must be no more than 6 cuts or chunks in total in the tire. ▪ There should be no embedded debris. 165977AK SJIII 3215, SJIII 3219...

  • Page 21: Hydraulic/Electric Tray Side

    Ensure there are no loose or missing parts and there is no visible damage. Electrical Panel ▪ Ensure panel is properly secured and there is no visible damage. ▪ Ensure there are no loose wires or missing fasteners. SJIII 3215, SJIII 3219 165977AK...

  • Page 22: 10 Platform Assembly

    3. Use the MEWP ladder to exit the platform. Platform Control Console ▪ Ensure all switches and controller are returned to neutral and are properly secured. ▪ Ensure there are no loose or missing parts and there is no visible damage. 165977AK SJIII 3215, SJIII 3219...
  • Page 23 ▪ If any of the above conditions are not met, immediately tag and lock the MEWP and remove it from service for repair. ▪ Refer to 5.3-2 Platform Mounting Hardware the maintenance/installation procedure. SJIII 3215, SJIII 3219 165977AK...

  • Page 24: 11 Lifting Mechanism

    2. Raise the platform until there is adequate visible damage. clearance to swing up the maintenance support. ▪ Ensure rollers’ path of travel are free from dirt 3. Swing up maintenance support into storage and obstructions. bracket. 4. Fully lower the platform. 165977AK SJIII 3215, SJIII 3219...
  • Page 25 Pin retainer/retainer bolts are in place Pin retainer in place Center pin pivot - Outer No rust. Pin has not rotated. Area is clean of dust/metal Center pin pivot - Middle shavings Center pin pivot - Inner SJIII 3215, SJIII 3219 165977AK...

  • Page 26: Thrust Washer

    Contact Skyjack Service for direction on how to repair the unit. Retainer bolt hole out of line indicates pin has rotated Rust around pin...
  • Page 27 Cracks in welds or the surrounding metal, or rust forming in the area. Bearing block degradation Broken, missing, or Cracks in weld or loose retainers or bolts surrounding metal, rust in the area Note: weld intentionally not located at bolt area SJIII 3215, SJIII 3219 165977AK...

  • Page 28: Function Tests

    For function test that are to be performed, please refer to the operating manual that corresponds to the correct serial number. Found there will be detailed instructions for which tests to perform, as well as how to properly and successfully perform them. 165977AK SJIII 3215, SJIII 3219...

  • Page 29: Section 2 - Maintenance Tables And Diagrams

    Section 2 – Maintenance Tables and Diagrams SJIII 3215, SJIII 3219 165977AK...

  • Page 30: Specifications And Features

    Hydraulic Oil ATF Dexron III Type Shell Naturelle HF-E-32 Tank Capacity (Litres) *Weight with standard 0.9m extension platform. Refer to serial nameplate for specific applications. 1664AA NOTE Emmission sound pressure level does not exceed 70 dB(A). 165977AK SJIII 3215, SJIII 3219...

  • Page 31: Torque Specifications For Fasteners (Us)

    2660 1 1/2-12 1329 2983 2224 4827 3606 NOTE: Lubed includes lubricants such as lubrizing, oil, grease, and some uncured thread lockers. Refer to the specific 1374AB thread locker manufacturer’s instructions for specific torque adjustments. SJIII 3215, SJIII 3219 165977AK...

  • Page 32: Torque Specifications For Fasteners (Metric)

    2024 M36 x 4.00 2557 1918 3659 2744 NOTE: Lubed includes lubricants such as lubrizing, oil, grease, and some uncured thread lockers. 1375AC Refer to the specific thread locker manufacturer’s instructions for specific torque adjustments. 165977AK SJIII 3215, SJIII 3219...

  • Page 33: Torque Specifications For Hydraulic Couplings & Hoses

    Min. Max. Min. Max. Min. Max. 1/4" 6.75 1/4" 3/8" 3/8" 1/2" 27.66 1/2" 5/8" 46.33 5/8" 3/4" 72.33 3/4" 1" 100.5 1" 1 1/4" 101.5 1 1/4" 1 1/2 1 1/2 2" 2" 1276AA SJIII 3215, SJIII 3219 165977AK...

  • Page 34: Floor Loading Pressure

    The structure of the operating surface (beam, etc.) must be able to withstand more than the indicated values above. NOTE The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or architect for that particular structure. 165977AK SJIII 3215, SJIII 3219...

  • Page 35: Locally Concentrated Pressure (Lcp)

    Do not mix different types of tires. Tires other than those specified can adversely affect stability. Failure to operate with matched, approved tires in good condition can result in death or serious injury. Replace tires with the exact, Skyjack-approved types only. SJIII 3215, SJIII 3219 165977AK...

  • Page 36: Maximun Platform Capacities (Evenly Distributed)

    This MEWP is equipped with a load sensing system. Do not exceed the rated capacity of the MEWP . Failure to avoid this will prevent operation of all normal controls/functions of the MEWP . To resume normal operation remove the additional loads. 165977AK SJIII 3215, SJIII 3219...

  • Page 37: Torque Specifications

    Torque (lb-ft) max Torque (lb-in) max Torque (Nm) max 4.07 13.56 20.34 20.34 33.9 33.9 40.68 47.46 Newton-meter = Nm Pound-foot = lb-ft Pound-inch = lb-in 1658AC Additional torque specifications may be found in Section 3. SJIII 3215, SJIII 3219 165977AK...
  • Page 38 Notes 165977AK SJIII 3215, SJIII 3219...

  • Page 39: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJIII 3215, SJIII 3219 165977AK...

  • Page 40: Electrical Symbol Chart

    SINGLE POLE VACUUM POTENTIOMETER SINGLE THROWN LEVEL SENSOR SWITCH RELAY DOUBLE POLE TEMPERATURE SINGLE POLE DOUBLE POLE DOUBLE THROW SWITCH DOUBLE THROW SINGLE THROW RELAY RELAY RELAY TRIPLE POLE RHEOSTAT TILT SWITCH DIODE DOUBLE THROW RELAY 165977AK SJIII 3215, SJIII 3219...

  • Page 41: Hydraulic Symbol Chart

    CLOSED VALVE THREE POSITION THREE POSITION TWO POSITION TWO POSITION FOUR WAY FOUR WAY TWO WAY THREE WAY VALVE CLOSED CENTER PROPORTIONAL NORMALLY CLOSED PORT OPEN VALVE PRESSURE PILOT LINES Dashed MAIN LINES Solid TRANSDUCER SERVO SJIII 3215, SJIII 3219 165977AK...

  • Page 42: Wire Number And Color Code

    This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire num- bers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red. 165977AK SJIII 3215, SJIII 3219...

  • Page 43: Ac Cord Color Code

    3.4 AC Cord Color Code Standard Definition NEC Colours IEC Colours Protective Ground/Protective Earth Green Green-Yellow Neutral White Blue Line, Single Phase Black Black/Brown/Grey 1659AA Note: Standard colours referenced from IEC 60445:2010, Annex A:Table A. 1 SJIII 3215, SJIII 3219 165977AK...

  • Page 44: Hydraulic Schematic Parts List

    130046 ORIFICE (0.063” diameter) (Lowering) 108002 ORIFICE (0.040” diameter) (Cushion) 108002 ORIFICE (0.040” diameter) (Steering) 105281 ORIFICE (0.067” diameter) (Emergency Lowering) 147656 ORIFICE (0.024” diameter) (Drive) (For model 3219 with serial number 22092255 & Below) 165977AK SJIII 3215, SJIII 3219...
  • Page 45 Part No. 147661 PUMP , Hydraulic 134431 (Model 3215) TRANSDUCER, Pressure (2000 psi) 134432 (Model 3219) TRANSDUCER, Pressure (3000 psi) 104534 VALVE, Relief (System) 104534 VALVE, Relief (Lift) 107271 VALVE (Emergency lowering) 103136 VALVE (Free-Wheeling) SJIII 3215, SJIII 3219 165977AK...

  • Page 46: Electrical Component Parts List

    COIL, 24 Volt (Forward drive spool valve) (Hytos) 4H-23 153335 COIL, 24 Volt (Right steer spool valve) (Hytos) 4H-24 153335 COIL, 24 Volt (Left steer spool valve) (Hytos) B1-B4 BATTERY, 6 Volt (Trojan #T2200) 130440 TRANSDUCER, Angle 165977AK SJIII 3215, SJIII 3219...
  • Page 47 HARNESS, Motor Controller (3.00” / 2.2k Ohms) 151644 • RESISTOR, (2.2K Ohms) RST6 166238 HARNESS, Motor Controller (3.00” / 1.2 Ohms) 163253 • RESISTOR, (1.2K Ohms) RST7 163238 RESISTOR, (270 Ohms) RST8 156564 RESISTOR, (1.5 Ohms) SJIII 3215, SJIII 3219 165977AK...
  • Page 48 SWITCH, Enable pushbutton 147054 N.O. CONTACT (Horn) 147053 N.C. CONTACT (Off/Platform) 147054 N.O. CONTACT (Base) 115574 SWITCH, Toggle (Inclined Drive/Level Drive) 147053 N.C. CONTACT (Emergency stop) (Base control console) 195940 HOURMETER, Digital $ - Purchase locally. 165977AK SJIII 3215, SJIII 3219...

  • Page 49: Hydraulic Manifold And Port Identifications

    4H-15 Reverse Drive Valve 2H-25 Cushion Valve 4H-24 3H-17 Left Steering Valve Brake Valve 4h-23 To Filter Right Steering Valve Test Port To Proportional Valve To Emergency Lowering To Cushion Valve System Relief Valve M155708AA1 SJIII 3215, SJIII 3219 165977AK...

  • Page 50: Platform Control Console Wiring Diagram

    PIN 5 - JOYSTICK VS+ WHITE/BLACK PIN 6 - REV/DOWN PURPLE/WHITE GREY BLUE PIN 7 - PWM 59 ORANGE/BLACK 02 WHITE BLACK CRD1 PIN 8 - GND PIN 9 - ENABLE VS+ 8A BLUE WHITE/ BLUE M163169AA 165977AK SJIII 3215, SJIII 3219...

  • Page 51: Base Control Console Diagram

    PIN 2 - 3A (BLUE) PIN 3 - 13 (ORANGE) PIN 4 - 14E (BLACK) PIN 5 - 10E (BLUE/BLACK) PIN 6 - 8C (BLUE/WHITE) PIN 7 - 7A (GREEN) PIN 8 - 02 (WHITE) BACK VIEW M149686AA_S3 SJIII 3215, SJIII 3219 165977AK...

  • Page 52: Base Control Console

    PIN 2 - 05 ORANGE/BLACK PIN 3 - 13 (ORANGE) PIN 4 - 14E (BLACK) PIN 5 - 10E (BLUE/BLACK) PIN 6 - 8C (BLUE/WHITE) PIN 7 - 7A (GREEN) PIN 8 - 02 (WHITE) BACK VIEW M195827AC 165977AK SJIII 3215, SJIII 3219...

  • Page 53: Scissor Arm Control Cable

    GREEN WHITE (49) (23) BLACK WHITE (24) BLUE BLACK BLUE WHITE (8C) (OPT) GREEN BLACK RED (07) BLACK (14) (59) ORANGE BLACK (18) RED BLACK ORANGE (13) (16) WHITE BLACK BLUE (15) WHITE (02) (NOT USED) M163170AA SJIII 3215, SJIII 3219 165977AK...

  • Page 54: Limit Switch Assemblies

    PIN 2 - 21 (BLACK/WHITE) PIN 6 - 18B (BLUE) PIN 3 - N/U PIN 7 - 19 (BLACK) BLUE BLACK/WHITE PIN 4 - N/U PIN 8 - 71 (BLACK/WHITE) BROWN BLACK BLUE BLACK/WHITE CE - Model 3219 M141511AB_S6 165977AK SJIII 3215, SJIII 3219...

  • Page 55: Disc Brake Kits And Torque Specifications

    1 - TORQUE CASTLE NUT TO 237 Nm 2 - TORQUE BRAKE BOLTS TO 115 Nm 3 - TORQUE MOUNTING BOLTS TO 122 Nm OIL TYPE SECTION B-B SPRING ARRANGEMENT CATERPILLAR T0-4 SAE 30 HYDRAULIC OIL (200 mL) M154839AA_S4 SJIII 3215, SJIII 3219 165977AK...

  • Page 56: Hydraulic Schematic

    VALVE VALVE VALVE .063 DIA. (3219 ONLY) HYDRAULIC QUICK DISCONNECT MAIN MANIFOLD BLOCK CUSHION CUSHION LOWERING EMERGENCY RETURN ORIFICE VALVE VALVE LOWERING FILTER .040 DIA. 2H-25 BLOCK BLOCK VALVE CUSHION VALVE PUMP M163457AB HYDRAULIC TANK 165977AK SJIII 3215, SJIII 3219...

  • Page 57: Hydraulic Schematic

    VALVE VALVE VALVE .063 DIA. (3219 ONLY) HYDRAULIC QUICK DISCONNECT MAIN MANIFOLD BLOCK CUSHION CUSHION LOWERING EMERGENCY RETURN ORIFICE VALVE VALVE FILTER LOWERING .040 DIA. 2H-25 BLOCK BLOCK VALVE CUSHION VALVE PUMP M163457AC HYDRAULIC TANK SJIII 3215, SJIII 3219 165977AK...

  • Page 58: Main Manifold Harness And Holding Valve Harness

    23 - BLACK/WHITE 24 - BLUE/BLACK 25 - ORANGE/GREEN CUSHION VALVE 59L - ORANGE/BLACK 25 - ORANGE/GREEN 02 - WHITE BATTERY (-) SPLICE #1 00 - GREEN/YELLOW BRAKE VALVE 17 - BLUE/RED 02 - WHITE M163239AB 165977AK SJIII 3215, SJIII 3219...

  • Page 59: Main Manifold Harness And Holding Valve Harness

    25 - ORANGE/GREEN 19B - WHITE/RED 02 - WHITE 23 - BLACK/WHITE 24 - BLUE/BLACK BATTERY (-) 25 - ORANGE/GREEN 00 - WHITE 59I - ORANGE/BLACK (14 AWG) BRAKE VALVE 17B - BLUE/RED 02 - WHITE M163239AF SJIII 3215, SJIII 3219 165977AK...

  • Page 60: Elevate19 Telematics Harness

    PIN 11 - 18X-RED/BLACK PIN 12 - 17-BLUE/RED TO TERMINAL STRIP TO TELEMATICS UNIT NORMALLY CONNECTED TO TERMINAL STRIP TO TERMINAL STRIP MOTOR CONTACTOR CONNECTIONS FOR LIMIT SWITCH CONNECTIONS FOR BMS CONNECTIONS FOR CHARGER M226428AB_Service 165977AK SJIII 3215, SJIII 3219...

  • Page 61: Electrical Panel

    PIN 8 - 15 BLUE PIN 9 - N/U PIN 10 - 18B RED/BLACK HORN PIN 11 - 02 WHITE 02 - WHITE PIN 12 - 7A RED 49 - BLACK BLUE/BLACK - N/U ORANGE/BLACK - N/U M163034AC SJIII 3215, SJIII 3219 165977AK...

  • Page 62: Electrical Panel

    PIN 8 - 15 BLUE PIN 9 - N/U PIN 10 - 18B RED/BLACK HORN PIN 11 - 02 WHITE 02 - WHITE 49 - BLACK PIN 12 - 7A RED BLUE/BLACK - N/U ORANGE/BLACK - N/U M163034AF 165977AK SJIII 3215, SJIII 3219...

  • Page 63: Electrical Panel

    PIN 15 - 23 BLACK/WHITE BLUE/BLACK - N/U TO OUTRIGGER PIN 8 - 7A GREEN PIN 16 - 60 RED/WHITE TO END OF STROKE SOLENOID CABLES ORANGE/BLACK - N/U TO FLASHER TO HORN/FLASHING LIGHT M199447AB SJIII 3215, SJIII 3219 165977AK...

  • Page 64: Control Module And Beeper Diagram

    PIN 1 - 22 BLACK PIN 2 - 29 GREEN TO GROUND PIN 3 - 60 GREEN PIN 4 - 28 BLACK TO ELECTRICAL PANEL PIN 5 - 02 WHITE PIN 6 - 28E WHITE M130612AE 165977AK SJIII 3215, SJIII 3219...

  • Page 65: Electrial Schematic (Equipped With All Option)

    NUETRAL 3H-17 BRAKE SOLENOID DO2-8 FWD/UP WHITE/BLACK 4H-16 FORWARD SOLENOID S7-6 DO2-9 17CR ENABLE ENABLE STEER RELAY BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-10 RIGHT S7-3 D17F-1 LEFT BLUE/BLACK 4H-24 LEFT SOLENOID DO2-11 D17F-2 WHITE M163178AC SJIII 3215, SJIII 3219 165977AK...

  • Page 66: Electrial Schematic (Equipped With All Option)

    DO2-8 FWD/UP WHITE/BLACK 4H-16 FORWARD SOLENOID S7-6 DO2-9 17CR ENABLE STEER RELAY ENABLE BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-10 RIGHT BRAKE RELEASE RELAY S7-3 D17F-1 19BCR LEFT 4H-24 BLUE/BLACK LEFT SOLENOID DO2-11 D17F-2 WHITE M163178AD 165977AK SJIII 3215, SJIII 3219...

  • Page 67: Electrical Schematic (Equipped With All Options)

    DO2-8 FWD/UP WHITE/BLACK 4H-16 FORWARD SOLENOID S7-6 DO2-9 17CR ENABLE ENABLE STEER RELAY BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-10 RIGHT BRAKE RELEASE RELAY S7-3 D17F-1 LEFT 19BCR BLUE/BLACK 4H-24 LEFT SOLENOID DO2-11 M163178AK D17F-2 WHITE SJIII 3215, SJIII 3219 165977AK...
  • Page 68 165977AK SJIII 3215, SJIII 3219...

  • Page 69: Section 4 - Troubleshooting Information

    “probable cause.” The information in the right-hand column, in bold text, represents the “remedy” to the “probable cause” directly beside it. See the example below for clarification. 1. Probable cause Remedy SJIII 3215, SJIII 3219 165977AK...

  • Page 70: Electrical System

    21. Open or defective base key switch S10. 22. Loose or broken wire #00 from motor controller to Check continuity. Replace if defective. circuit breaker CB1. Reset circuit breaker. Replace if defective. 23. Defective or tripped circuit breaker CB1. 165977AK SJIII 3215, SJIII 3219...

  • Page 71: All Controls Except For Down Function Inoperative

    11. Loose or broken B- cable from motor DCM1 to M- lug Check continuity. Replace if defective. on motor controller. Check continuity. Replace if defective. 12. Defective motor controller. Check motor for operation with 24 volt supply. Replace if 13. Defective motor DCM1. defective. SJIII 3215, SJIII 3219 165977AK...

  • Page 72: All Controls Inoperative From Base Control Console

    17. Loose or broken wire #59D from lift speed relay Check continuity. Replace if defective. 14CR1 to base terminal block. Check resistor and make sure it is secure. Replace 18. Defective base lift resistor RST6. if defective. 165977AK SJIII 3215, SJIII 3219...

  • Page 73: Up Function Slow From Base Control Console

    Check continuity through coil. Replace if defective. 10. Defective lift cylinder holding valve coil 2H-13C-1. 11. Loose or broken wire #02 from holding valve coil Check continuity. Replace if defective. 2H-13C-1 or down valve coil 2H-13C to base terminal block. SJIII 3215, SJIII 3219 165977AK...

  • Page 74: All Controls Inoperative From Platform Control Console

    10. Loose or broken wire #28E from CM1 control Check continuity. Replace if defective. module pin P3-6 to Aux. tilt relay 28ECR1. 11. Loose or broken wire #19 from base terminal Check continuity. Replace if defective. block to Aux. tilt relay 28ECR1. 165977AK SJIII 3215, SJIII 3219...

  • Page 75: Up Function Slow From Platform Control Console

    1. Loose or broken wire “A” from proportional Check continuity. Replace if defective. controller S7 to lift/drive switch S3. 2. Lift/Drive switch S3 defective. Check switch. Replace if defective. 3. Defective PWM card on joystick S7. Check joystick card. Replace if defective. SJIII 3215, SJIII 3219 165977AK...

  • Page 76: 11 Steer Only Inoperative

    10. Loose or broken wire #59C from 14CR1 lift speed Check continuity. Replace if defective. relay to base terminal block. Check resistor and make sure it is secure. Replace 11. Defective steer only resistor RST5. if defective. 165977AK SJIII 3215, SJIII 3219...

  • Page 77: 12 Right Steer Inoperative

    LS6. 2. Defective drive override switch LS6. Check switch. Replace if defective. 3. Loose or broken wire #19 from drive override Check continuity. Replace if defective. limit switch LS6 to base terminal block. SJIII 3215, SJIII 3219 165977AK...

  • Page 78: 16 No Drive Or Steer When Platform Elevated

    3H-17. 3. Brake valve coil 3H-17 defective. Check continuity through coil. Replace if defective. 4. Loose or broken wire #02 from brake valve coil Check continuity. Replace if defective. 3H-17 to base terminal block. 165977AK SJIII 3215, SJIII 3219...

  • Page 79: 19 Forward Drive Function Inoperative

    4. Reverse drive valve coil 4H-15 defective. Check continuity through coil. Replace if defective. 5. Loose or broken wire #02 from reverse drive valve coil Check continuity. Replace if defective. 4H-15 to base terminal block. SJIII 3215, SJIII 3219 165977AK...

  • Page 80: Hydraulic System

    4.3-6 Platform will not Lower NOTE Down function is not proportionally controlled. 1. Lowering valve 2H-13C defective or is sticking. Clean valve. Replace if defective. 2. Defective holding valve 2H-13C-1. Clean valve. Replace if defective. 165977AK SJIII 3215, SJIII 3219...

  • Page 81: Platform Lowers Slowly (3215 Only)

    Clean valve. Replace if defective. defective or sticking. 2. Steer cylinder C3 seals leaking. Rebuild cylinder(s). Replace if damaged. Check for binding. Repair as needed. 3. Mechanical binding in kingpins. Clean orifices, and reinstall. 4. Orifices O5 plugged. SJIII 3215, SJIII 3219 165977AK...
  • Page 82 Notes 165977AK SJIII 3215, SJIII 3219...

  • Page 83: Section 5 - Procedures

    5. Turn the main power disconnect switch to the “ ” off position. After completing any procedure which involves modifying, adjusting, or replacing any hydraulic or electrical components, perform all of the function tests given in your unit’s Operating Manual. SJIII 3215, SJIII 3219 165977AK...

  • Page 84: Base

    9. Remove the gauge from system pressure test 6. Remove the gauge from lift pressure test port. port. NOTE Pressure setting may vary as aerial platform components wear. The lift pressure should be set for rated load only. 165977AK SJIII 3215, SJIII 3219...

  • Page 85: Resistor - Voltage Divider

    * 4.8 volts refers to full stroke on the joystick. 24 volts represents a full charge on the battery pack. ** Values given are with all connections tight and free from corrosion + or - 10%. SJIII 3215, SJIII 3219 165977AK...

  • Page 86: Electronic Tilt Switch Setup Procedure

    17. Reinstall any covers that was removed. 11. Pull out emergency stop button and turn 18. Remove chock or wheel blocks. main disconnect switch to ON position. 19. Proceed to Test and Verify Tilt Circuit. 165977AK SJIII 3215, SJIII 3219...
  • Page 87 12. Reattach all wires #02 to motor contactor. b. Both LEDs will flash. 13. Reinstall any covers that was removed. 14. Remove chock or wheel blocks. Red LED Green LED 15. Proceed to Test and Verify Tilt Circuit. SJIII 3215, SJIII 3219 165977AK...
  • Page 88 Red LED the specified degrees out from the zero/ home position. On together, no blinking when Green & Red LED fault detected. Tilt Circuit Test 1. Refer to section 2 for test tilt sensor procedure. 165977AK SJIII 3215, SJIII 3219...

  • Page 89: Pothole Limit Switch (Ls4 & Ls5) Replacement And Adjustment

    7 feet (2 meters) or until the pothole protection is activated. Attempt to drive forward or reverse. Aerial platform should not move forward or backward. SJIII 3215, SJIII 3219 165977AK...

  • Page 90: Integrated Hub Wheel Replacement

    Grease Application - New Rear Wheels with Pin Brakes Only (if required) Model Recommended Grease Type STARPLEX EP2 SJIII 3215, SJIII 3219 UNIREX EP2 SHELL GADUS S2 1. If the bearings are provided separately, they will need to be coated in grease before installing on Grease seal the rear wheels.
  • Page 91 4. Use a hub puller to remove and discard the hub/ integrated hub wheel from the spindle. 5. For integrated hub wheels, use two 3/8”-24 bolts with a hub puller to remove the wheel. Remove Integrated Hub Wheel SJIII 3215, SJIII 3219 165977AK...
  • Page 92 10. Torque the wheel motor nut to 380 Nm (280 ft-lb). 11. Apply torque seal to the wheel motor nut. Hub Install Hub Install Integrated Hub Wheel Install Integrated Hub Wheel Install 165977AK SJIII 3215, SJIII 3219...
  • Page 93 7. Use a wrench to re-engage the pin brakes on both sides. Do not lower the machine while the pin brakes are disengaged. 8. Turn the castle nut back slightly until the next cotter pin hole is visible on the spindle. SJIII 3215, SJIII 3219 165977AK...
  • Page 94 5. Ensure the cotter pin is pushed in completely. 6. Bend the ends of the cotter pin to secure the castle nut. Hub Install Integrated Hub Install 165977AK SJIII 3215, SJIII 3219...
  • Page 95 If possible, drive the machine prior to checking torques. 7. Apply dots of torque seal at the base of the wheel bolts. 8. Check torque values after 8 hours of operation. SJIII 3215, SJIII 3219 165977AK...

  • Page 96: Tightening And Torque Recommendations For Hydraulic Couplings And Hoses

    O-ring when installed. 6. Install any 45° and 90° hydraulic hose ends first, then align direction and tighten. Adjust the swivel nut on the straight hose end before tightening to create the desired flow. 165977AK SJIII 3215, SJIII 3219...
  • Page 97 Chart for JIC Hose Ends Size FFWR 7. Apply a drop of torque seal to the connection. Dash Frac. (in.) 37° Tube Nut Swivel Nut 1/4'' 5/16'' 3/8'' 1/2'' 1.25 5/8'' 3/4'' 1.25 1 1/4'' 1 1/2'' 1649AA SJIII 3215, SJIII 3219 165977AK...

  • Page 98: Battery Maintenance

    MEWP . amber manual. Charging Solid Charger output is output yellow active. Charge Current profile/ algorithm N/A. error or fault/ display error code Select Current charge charging N/A. profile algorithm 165977AK SJIII 3215, SJIII 3219...
  • Page 99 U.S. Battery - US 250 XC/XC2 Flooded-lead, 6V, 255 Ah Trojan - T105 ELPT Flooded, 6V, 225 Ah 150 - 250 Ah 6V, 8V, 12V flooded #3 (P-0-0-3) *The batteries used for these charger profiles are connected in a series-parallel circuit. SJIII 3215, SJIII 3219 165977AK...

  • Page 100: Charger Troubleshooting

    The charger has been unable to calibrate the F-0-0-4 current offset. The voltage drop across the DC relay is too high F-0-0-5 while the relay is closed. Large difference between internal DC-DC and F-0-0-6 battery sense currents. 165977AK SJIII 3215, SJIII 3219...

  • Page 101: Charger Error Codes

    ▪ Extra loads. Turn off other devices running on the battery ▪ This error automatically clears once the charger is reset by cycling ▪ DC or by loss of AC for over 10 minutes. SJIII 3215, SJIII 3219 165977AK...
  • Page 102 New batteries, if charged when already full, may also cause this error. Disconnect and reconnect the batteries a few times. ▪ Check the battery voltage and cable connections. ▪ This error automatically clears once the condition has been corrected. 165977AK SJIII 3215, SJIII 3219...
  • Page 103 Internal charger error. Disconnect AC and the battery for a minimum of 30 seconds and retry. has triggered an alarm ▪ If the problem persists, contact Delta-Q Technologies. ▪ This error automatically clears once the condition has been corrected. SJIII 3215, SJIII 3219 165977AK...
  • Page 104 Invalid PDO Length This error automatically clears once the condition has been corrected ▪ A battery or some other source has been connected to E-0-4-7 Platform overvoltage alarm the charger that exceeds the hardware’s design limits. 165977AK SJIII 3215, SJIII 3219...

  • Page 105: Platform

    4. Adjust the tension on both hinges until the gate releases and latches from a half open position. 5. Reinstall the safety locking screws into the hinges when tension adjustment is complete. SJIII 3215, SJIII 3219 165977AK...

  • Page 106: Platform Mounting Hardware

    2. Replace all of the platform mounting hardware (bolts, flat washers, and spring washers) with new Skyjack-approved parts. Refer to the parts manual for the part numbers for your specific MEWP . 3. Apply a high-strength threadlocker (Loctite 270 or equivalent) to each bolt.

  • Page 107: Scissors - (Ce)

    Model 3215 5. Remove the limit switches and free the limit switch cable(s) by cutting the tie wraps. SJIII 3215, SJIII 3219 165977AK...
  • Page 108 7 feet (2 meters) or until the pothole protection is activated. Attempt to drive forward or reverse. Aerial platform should not move forward or backward. 165977AK SJIII 3215, SJIII 3219...

  • Page 109: Ezcal Diagnostic Tool

    ENTER ESC ENTER ESC/ENTER Use these to move back and forth between menus and submenus and to make a selection. Up/Down Adjust the settings values. Left/Right Select the menus and settings to be adjusted. SJIII 3215, SJIII 3219 165977AK...

  • Page 110: Load Sensing Controller

    10. If at any time it is not possible to perform the required operation, go to step 15. 11. Select the Diagnostics>System>Height menu. 165977AK SJIII 3215, SJIII 3219...

  • Page 111: Gp-102 Control Module Pin Reference Chart

    Output To Overload Warning Light On Control Box 28 Green/Black Output To 28CR1 Tilt Relay And 28CR2 Down Relay 02 White Negative for Flashing Light and Beeper 28E Green/White Output To 28ECR1 Aux. Tilt Relay And 28ECR2 Aux. Down Relay SJIII 3215, SJIII 3219 165977AK...
  • Page 112 Not Used Not Used Not Used Not Used 910 Black Positive Signal To Angle Transducer 900 White Negative Signal To Pressure Transducer 902 White Negative Signal To Angle Transducer 910A Black Positive Signal To Pressure Transducer 165977AK SJIII 3215, SJIII 3219...

  • Page 113: Gp-102 Led Error Codes - Quick Reference Chart

    FAULT: BAD SLAVE ANALOGS FAULT: BAD STRAIN MONITORS FAULT: BAD SLAVE MICRO FAULT: HWFS STALLED! STARTUP! TESTING HWFS P3-4 RELAY SHORT! P3-4 RELAY SHORT? P3-4 RELAY OPEN? P3-6 RELAY OPEN? P3-6 RELAY SHORT? IDLE TIMEOUT ACTIVE! 1650AB SJIII 3215, SJIII 3219 165977AK...

  • Page 114: Led Error Codes - Code Breakdown Chart

    Check that the battery voltage is not too low. Verify battery voltage on P2-12. Disconnect plug P4 – if the fault clears there is a wiring fault from P4-1 to the rest of the vehicle. 165977AK SJIII 3215, SJIII 3219...
  • Page 115 Action a function to clear the idle timeout if it occurred. Ensure the GP102 is correctly mounted – incorrect mounting can cause the “bad tilt sensor” diagnostic to occur. Otherwise there may be an internal problem with the GP102. SJIII 3215, SJIII 3219 165977AK...

  • Page 116: Control Module Load Calibration - Code Messages & Definitions

    0.9V and 4.1V. Code F11: Not Up Select the UP function only. This message occurs at the start of calibration if the operator selects a function other than UP . 165977AK SJIII 3215, SJIII 3219...
  • Page 117 Check DIAGNOSTICS / SENSORS to see the sensor output (P4-3) during calibration. output. A reading of 0V or 5V is probably due to a wiring problem. The height sensor output must be between 1.0V and 4.0V at all times. SJIII 3215, SJIII 3219 165977AK...
  • Page 118 Press ENTER to confirm when the platform is fully lowered. Platform Empty? This message is prompting for confirmation that the platform is completely empty. Press ENTER to confirm if the platform is empty. 165977AK SJIII 3215, SJIII 3219...
  • Page 119 The last calibrate date can be viewed in DIAGNOSTICS / LOG. Press LEFT & RIGHT to select the flashing digits. Press UP & DOWN to change the flashing digits. Press ENTER when the entry is complete. IMPORTANT: The date 00/00/00 is not allowed! Finished This message confirms that calibration is complete and successful. SJIII 3215, SJIII 3219 165977AK...

  • Page 120: Control Module Load Calibration Procedure

    6. The jumper connection must be connected between the contractor (wire #19B) and the lift coil (instead of the black wire #14) Contactor Main Manifold JUMPER, Insulated Alligator Clip Coil Black wire #14 Wire #19B Lift Valve 7. Connect the Easy-Cal tool to the P1 connector on the CONTROL MODULE. 165977AK SJIII 3215, SJIII 3219...
  • Page 121 8. The display will show “Help: Press Enter”. By using Left/Right buttons, select the “Access Level ( ? )” from the menu and press the ENTER button. Contact Skyjack Service Department at: (44) 1691-676 236 for your Access Level Code Number.
  • Page 122 If the phase does not need to be repeated, just press ENTER to move on. If the phase does need to be repeated, press UP or DOWN to change “NO” to “YES” then press ENTER. 165977AK SJIII 3215, SJIII 3219...

  • Page 123: Curve/Group Codes Chart

    GP-102 Load Sensing Controller Section 5 – Procedures 5.6-6 Curve/Group Codes Chart Model Number of Extension Platforms Group Code Curve Code 3215 1 Manual Extension Platform 3219 1 Manual Extension Platform 1660AA SJIII 3215, SJIII 3219 165977AK...

  • Page 124: Load Sensing Controller

    12V Input From LS1 High Speed Limit Switch To Verify ON/OFF Limits 02 White 0V GND (-) Negative Reference From Base Terminal Strip 10A Blue/Black 12V Main Power Input thru Main Power Relay 10BCR From Base Terminal Strip 165977AK SJIII 3215, SJIII 3219...
  • Page 125 12V Output for Outrigger Right Front Up signal to 4H-72 Solenoid 71 Orange 12V Output for Outrigger Left Front Up signal to 4H-71 Solenoid 35C White/Black 12V Output for Outrigger Enable signal from Enable switch S9A or Relay 9CR3 SJIII 3215, SJIII 3219 165977AK...

  • Page 126: Set Up The Gp-108 Controller

    If you let go of the keyswitch in the middle of the process, the controller resets and you have to start again from the beginning. 5.7-6 Curve/group code chart Curve Group Model Extension Decks Code Code SJIII 3215 1 manual deck SJIII 3219 1 manual deck 165977AK SJIII 3215, SJIII 3219...

  • Page 127: Gp-108 Controller Setup Flowchart

    0=CUSTOM Select the curve code. CURVE: ENTER Refer to 3.5-6 5.7-6. SETUPS: SETUPS: ENTER CHANGE DEFAULTS TILT SETUPS TILT SETUPS: CALIBRATE LEVEL: YES:ENTER, NO:ESC ENTER ENTER CALIBRATE LEVEL YES:ENTER, NO:ESC TILT 0.0’ , 0.0’ ENTER SJIII 3215, SJIII 3219 165977AK...
  • Page 128 MEASURING #XX CALDATE: 00/00/00 the lower switch. (mm/dd/yy) Enter the date. Push and pull the CALIBRATE LOAD: ENTER To the home screen. emergency stop button to FINISHED! cycle the power and save the settings. 165977AK SJIII 3215, SJIII 3219...

  • Page 129: Gp-108 Led Error Codes - Quick Reference Chart

    FAULT: BATTERY VOLTAGE TOO HIGH! IDLE TIMEOUT ACTIVE! GP106 P2-8 SHORT TO SUPPLY! CHECK GP106 CONNECTIONS! GP106 P2-x SHORT TO SUPPLY? CHECK GP102 CONNECTIONS! GP106 P4-x SHORT TO SUPPLY? FACTORY OVERRIDE GP102 P3-4 SHORT TO SUPPLY? 2236AA SJIII 3215, SJIII 3219 165977AK...

  • Page 130: Flash The Gp-108 Controller

    EZcal Pro, press the enter key until it displays the required le. EZcal Pro MENU: XXXXXXX :YES ENTER PGFLASH WORKING Wait for the ash to nish. This could take several minutes. PGFLASH OK/VX.X FINSHED 165977AK SJIII 3215, SJIII 3219...
  • Page 132 www.skyjack.com...

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