Skyjack 3215 SJIII Compact Series Service Manual
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Skyjack 3215 SJIII Compact Series Service Manual

Sjiii compact series
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See also: Operating Manual
SJIII Compact Series
Service Manual
Models 3215 & 3219
Skyjack Head Office
Phone: 519-837-0888
Toll Free: 1-800-265-2738
Fax: 519-837-8104
Email: skyjack@skyjack.com
www.skyjack.com
Printed in Canada April 2008
55 Campbell Rd. Guelph, Ontario N1H 1B9
Part No. 143909AA

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Summary of Contents for Skyjack 3215 SJIII Compact Series

  • Page 1 SJIII Compact Series Service Manual Models 3215 & 3219 Skyjack Head Office 55 Campbell Rd. Guelph, Ontario N1H 1B9 Phone: 519-837-0888 Toll Free: 1-800-265-2738 Fax: 519-837-8104 Email: skyjack@skyjack.com www.skyjack.com Part No. 143909AA Printed in Canada April 2008...
  • Page 2 3219 236285 & Below 236286 to 268399 22 000 001 & 22 013 837 22 013 838 & Above 113AA Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, 60174 USA Phone: 630-262-0005 Toll Free: 1-800-275-9522 Fax: 630-262-0006 Email: service@skyjack.com...

  • Page 3: List Of Procedures

    Section 1 - Scheduled Maintenance Inspections Table of Contents Section 2 - Maintenance Tables Table of Content Section 3 - Schematics List of Contents Section 4 - Troubleshooting Troubleshooting Section 5 - Procedures List of Procedures List of Tables SJIII Series SKYJACK, Page 3...

  • Page 4: Skyjack, Page

    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 aerial platform. SKYJACK, Page 4 SJIII Series...

  • Page 5: Table Of Contents

    Service and Maintenance About this Section ..............................15 Service Bulletins .................................15 Maintenance and Inspection .............................15 Maintenance Instructions ............................15 Scheduled Maintenance Scheduled Maintenance Inspections ......................18 Function Tests..............................25 Tables Owner’s Annual Inspection Record ........................16 Maintenance and Inspection Checklist ......................17 SJIII Series SKYJACK, Page 5...

  • Page 6: Aerial Platform Definition

    SKYJACK warrants each new SJIII Series work platform to be free of defective parts and workmanship for the first 24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor.

  • Page 7: Scope Of This Manual

    ANSI/SIA (United States) Operators are required by the current ANSI/SIA A92.6 standards to read and understand their responsibilities in the manual of responsibilities before they use or operate this aerial platform. SKYJACK, Page 8 SJIII Series...

  • Page 8: Operator Safety Reminders

    Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety devices to protect your eyes, ears, hands, feet and body. Any modifications from the original design are strictly forbidden without written permission from SKYJACK Inc. Electrocution Hazard This aerial platform is not electrically insulated.

  • Page 9: Safety Precautions

    When • DO NOT raise the aerial plat- fully lowered, ascending or form in windy or gusty condi- descending, only grades up tions. to rated maximum listed in Table 2-3a Table 2-3b permissible. SKYJACK, Page 10 SJIII Series...
  • Page 10 • DO NOT use the aerial platform without guardrails, obstructions or other possible locking pins and the entry gate in place. hazards around the aerial platform when driving or lifting. SJIII Series SKYJACK, Page 11...

  • Page 11: Fall Protection

    If additional fall protection is required, by an employer or • has been damaged or appears to have worn or the authority having jurisdiction, Skyjack recommends missing parts. the use of a fall restraint system to keep an occupant •...

  • Page 12: Maintenance And Inspection Schedule

    Disconnect Switch to the “OFF” position. wARNiNG Any unit that is damaged or not operating Preventive maintenance is the easiest and least expensive type of maintenance. properly must be immediately tagged and removed from service until proper repairs are completed. SJIII Series SKYJACK, Page 13...

  • Page 13: Hydraulic System & Component Maintenance And Repair

    When removing any hydraulic component, be sure Keep all connections tight. to cap and tag all hydraulic lines involved. Also, plug the ports of the removed components. SKYJACK, Page 14 SJIII Series...

  • Page 14: Service And Maintenance

    - Aerial platform parked on a flat and level surface - Disconnect the battery by turning the main power disconnect switch to the “OFF” position. • Repair any damaged or malfunction components before operating aerial platform. • Keep records on all inspections. SJIII Series SKYJACK, Page 15...

  • Page 15: Owner's Annual Inspection Record

    As described earlier in this section, this decal is located on the control compartment cowling. It must be completed after an annual inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 13 months. SKYJACK, Page 16 SJIII Series...

  • Page 16: Schedule Maintenance Inspections

    D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1.0 of this manual. * Perform scheduled inspection every three months or 150 hours. Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy. SJIII Series SKYJACK, Page 17...

  • Page 17: Scheduled Maintenance Inspections

    Visually inspect all limit switch located inside the scissor loose wires: arms and the outrigger assemblies for the following: • base to platform cables and wiring harness • broken or missing actuator arm • battery tray wiring harnesses • missing fasteners • hydraulic/electrical wiring harnesses • loose wiring SKYJACK, Page 18 SJIII Series...
  • Page 18 Ensure there are no loose or missing parts and there is no visible damage. • Brakes Ensure there are no loose or missing parts and there is no visible damage. Ensure tabs are not locked. SJIII Series SKYJACK, Page 19...
  • Page 19 5. Replace battery if damaged or incapable wARNiNG of holding a lasting charge. Explosion hazard. Keep flames and sparks away. Do not smoke wARNiNG near batteries. Use original or manufacturer-approved parts and components for the aerial platform. SKYJACK, Page 20 SJIII Series...
  • Page 20 Check each lug nut for proper torque to ensure none are loose. Check wheel motor assembly for loose or missing parts and signs of visible damage. Ensure wheels are aligned and true vertically and horizontally. SJIII Series SKYJACK, Page 21...
  • Page 21 For hydraulic oil replacement procedure, Ensure rod is properly secured and there refer to section is no visible damage. • Hydraulic Pump and Motor Ensure there are no loose or missing parts and there is no visible damage. SKYJACK, Page 22 SJIII Series...
  • Page 22 Ensure gate is in good working order. • Lanyard Attachment Anchors Ensure attachment rings are secure and no visible damage. • AC Outlet on Platform Ensure outlet has no visible damage and free from dirt or obstructions. SJIII Series SKYJACK, Page 23...
  • Page 23 Fully lower the platform. weldments. Ensure all pins are properly secured. Ensure cables and wires are properly routed and shows no signs of wear and/ or physical damage. SKYJACK, Page 24 SJIII Series...

  • Page 24: Function Tests

    - Start Operation of the operating manual. 1.2-1 Test Main Power Disconnect Switch At rear of the base, turn main power disconnect switch to “ ” off position. Result: Aerial platform functions should not operate. SJIII Series SKYJACK, Page 25...
  • Page 25 Result: Platform raising and lowering functions should not operate. 2. Select off/platform/base key switch to “ ” platform position. Attempt to raise or lower the platform. Result: Platform raising and lowering functions should not operate. SKYJACK, Page 26 SJIII Series...
  • Page 26 4. Turn free-wheeling valve knob clockwise Result: The platform should lower. to a fully closed position for normal operation. 4. To restore normal operation, depress and turn holding valve manual override knobs 5. Reengage the brake. clockwise. SJIII Series SKYJACK, Page 27...
  • Page 27 Test Platform Emergency Stop right. Result: Steer wheels should turn left and 1. Push in “ ” emergency stop button right. and attempt to activate any platform function. Result: All selected platform functions should not operate. SKYJACK, Page 28 SJIII Series...
  • Page 28 • Test Brakes do not operate aerial platform until brake adjustments have been checked. wARNiNG Brakes will engage instantly when you release the controller handle, causing aerial platform to stop immediately. SJIII Series SKYJACK, Page 29...
  • Page 29 Result: Horn should sound. 3. Push controller handle and raise the platform to an approximate height of 1 ft. (30.5 cm). Result: Platform should rise. 4. Pull controller handle and lower the platform fully. Result: Platform should lower. SKYJACK, Page 30 SJIII Series...
  • Page 30 Result: Aerial platform should not move forward or backward. 5. Repeat the steps above with block placed under battery tray. Result: Aerial platform should not move forward or backward. SJIII Series SKYJACK, Page 31...
  • Page 31 2. Use the ladder to dismount from platform. 3. On base control console, slowly raise the platform. Result: When platform reaches an appropriate height, a warning signal should sound and platform stop raising as lift and drive controls should be disabled. SKYJACK, Page 32 SJIII Series...

  • Page 32: Table Of Contents

    2.2b Floor Loading Pressure (CE) ..........................10 2.2c Floor Loading Pressure (AS) ...........................11 2.3a Maximum Platform Capacities (Evenly Distributed) (ANSI/CSA) ..............12 2.3b Maximum Platform Capacities (Evenly Distributed) (CE) ................13 2.3c Maximum Platform Capacities (Evenly Distributed) (AS) ................14 Torque Specifications ............................15 SJIII Series SKYJACK, Page 1...
  • Page 33 Tires Solid Rubber Solid Rubber 60156AK-ANSI-1-R * Weight with standard 3' (0.9 m) or 4' (1.2 m) extension platform. Refer to nameplate for aerial platforms with 5' (1.5 m) or 6' (1.8 m) extension platform. SKYJACK, Page 2 SJIII Series...
  • Page 34 Solid Rubber Foam Filled1 60156AK-ANSI-2-R Weight with standard 3' (0.9 m) or 4' (1.2 m) extension platform. Refer to nameplate for machines with 5' (1.5 m) or 6' (1.8 m) extension platform. Fill hardness: 55 Durometer SJIII Series SKYJACK, Page 3...
  • Page 35 12 x 4 x 8 16 x 5 x 12 Tires (Solid Rubber) 60156AL-CE-1-R * Weight with standard 0.9 m extension platform. (Refer to nameplate for aerial platforms with 1.5 m or 1.8 m extension platform.) SKYJACK, Page 4 SJIII Series...
  • Page 36 Gradeability 16 x 5 x 12 23 x 10.5 x 12 Tires Solid Rubber Foam Filled 60156AL-CE-2-R † Weight with standard 0.9m extension platform. Refer to serial nameplate for specific applications. Fill hardness: 55 Durometer SJIII Series SKYJACK, Page 5...
  • Page 37 12 x 4 x 8 16 x 5 x 12 Tires (Solid Rubber) 60156AJ-AS-1 * Weight with standard 0.9 m or 1.2 m extension platform. Refer to nameplate for aerial platforms with 1.5 m or 1.8 m extension platform. SKYJACK, Page 6 SJIII Series...
  • Page 38 Gradeability 16 x 5 x 12 23 x 10.5 x 12 Tires Solid Rubber Foam Filled 60156AJ-AS-2 † Weight with standard 0.9m extension platform. Refer to serial nameplate for specific applications. Fill hardness: 55 Durometer SJIII Series SKYJACK, Page 7...
  • Page 39 Intermixing tires of different types or using tires of types other than those originally supplied with this equipment 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 40 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. SJIII Series SKYJACK, Page 9...
  • Page 41 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. SKYJACK, Page 10 SJIII Series...
  • Page 42 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. SJIII Series SKYJACK, Page 11...
  • Page 43 300 lb. 850 lb. 300 lb. 6832 3 Persons 1 Person 3 Persons 1 Person 386 kg 136 kg 386 kg 136 kg 60315AG-ANSI NOTE: Overall Capacity - Occupants and materials not to exceed rated load SKYJACK, Page 12 SJIII Series...
  • Page 44 The aerial is equipped with a Load 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. SJIII Series SKYJACK, Page 13...
  • Page 45 136 kg 1 Person 6832 12.5 454 kg 3 Persons 136 kg 1 Person 60315AG-AS SJIII3226 shall have extension retracted when used outdoor. NOTE: Overall Capacity - Occupants and materials not to exceed rated load SKYJACK, Page 14 SJIII Series...
  • Page 46 Nm (max) 5.42 to 6.78 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 SJIII Series SKYJACK, Page 15...
  • Page 47 Electrical Schematic (CE - equipped with all options) .................27 3.24 Electrical Schematic (ANSI/CSA EE Rated - equipped with no options) ............28 3.25 Electrical Schematic (ANSI/CSA EE Rated - equipped with all options) .............29 SJIII Compact Series SKYJACK, Page 1 143909...

  • Page 48: 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 DIODE DOUBLE THROW RELAY SJIII Compact Series SKYJACK, Page 3 143909...

  • Page 49: Hydraulic Symbol Chart

    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 SKYJACK, Page 4 SJIII Compact Series 143909...

  • Page 50: 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 numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red. SJIII Compact Series SKYJACK, Page 5 143909...

  • Page 51: Hydraulic Manifold And Port Identifications

    4H-16 Forward Drive Valve Counterbalance Valve 4H-15 Reverse Drive Valve 2H-25 Cushion Valve 4H-24 Left Steering Valve 3H-17 Brake Valve 4h-23 Right Steering Valve To Proportional Valve System Relief Valve M10414AA M10561AC_1 M10589AA SKYJACK, Page 6 SJIII Compact Series 143909...
  • Page 52 147661 PUMP , Hydraulic 134431 TRANSDUCER, Pressure (2000 psi) (Model 3215) 134432 TRANSDUCER, Pressure (3000 psi) (Model 3219) 104534 VALVE, System relief 104534 VALVE, Lift relief 107271 VALVE, Emergency lowering 103136 VALVE, Free-wheeling SJIII Compact Series SKYJACK, Page 7 143909...
  • Page 53 103623 COIL, 24 Volt (Brake valve) 4H-15 128320 COIL, 24 Volt (Reverse drive spool valve) (Hytos) 4H-16 128320 COIL, 24 Volt (Forward drive spool valve) (Hytos) Parts list continued on the following page. SKYJACK, Page 8 SJIII Compact Series 143909...
  • Page 54 SWITCH, Main power disconnect 147054 N.O. CONTACT (Raise/Lower) 147053 N.C. CONTACT (Lift/Drive) 147054 N.O. CONTACT (Lift/Drive) (without power extension platform) N.O. CONTACT (Lift/Drive) (with power extension platform) Parts list continued on the following page. SJIII Compact Series SKYJACK, Page 9 143909...
  • Page 55 122872 SWITCH, Enable pushbutton 147054 N.O. CONTACT (Operator’s horn) 147053 N.C. CONTACT (Off/Platform) 147054 N.O. CONTACT (Base) 147053 N.C. CONTACT (Emergency stop) (Base control console) 146658 TILT SWITCH 103336 HOURMETER - Purchase locally. SKYJACK, Page 10 SJIII Compact Series 143909...

  • Page 56: Platform Control Console Diagram

    GREY PIN 6 - REV/DOWN PURPLE/WHITE JOYSTICK HARNESS BLUE PIN 7 - PWM 59 ORANGE/BLACK BLACK PIN 8 - GND 02 WHITE 8A BLUE WHITE/ BLUE PIN 9 - ENABLE VS+ CRD1 M146621AB SJIII Compact Series SKYJACK, Page 11 143909...

  • Page 57: Base Control Console Diagram

    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 SKYJACK, Page 12 SJIII Compact Series 143909...

  • Page 58: Scissor Arm Control Cable

    (23) BLACK WHITE (24) BLUE BLACK BLUE WHITE (8C) (OPT) GREEN BLACK RED (07) (59) ORANGE BLACK BLACK (14) (18) RED BLACK ORANGE (13) BLUE (15) (16) WHITE BLACK WHITE (02) (NOT USED) M146650AB_S3 SJIII Compact Series SKYJACK, Page 13 143909...

  • Page 59: Electrical Inverter Option: Schematic & Panel Diagram (Ansi/Csa - Equipped With Timer Cutout Relay)

    17CR1 TRANSFER RELAY 4H-15 BLUE REVERSE SOLENOID DO2-2 3H-17 BRAKE SOLENOID 4H-16 WHITE/BLACK FORWARD SOLENOID DO2-3 17CR STEER RELAY MM147370AB1 M149724AA 4H-23 BLACK/WHITE RIGHT SOLENOID SKYJACK, Page 14 SJIII Compact Series DO2-4 D23-1 143909 D24-1 BLUE/BLACK 4H-24 LEFT SOLENOID DO2-5...

  • Page 60: Hydraulic Schematic - Model 3215

    DISCONNECT MAIN MANIFOLD BLOCK BRAKE ORIFICE CUSHION RETURN CUSHION .051 DIA. ORIFICE 2H-25 FILTER VALVE LOWERING EMERGENCY CUSHION .040 DIA. BLOCK VALVE LOWERING VALVE BLOCK C4 BRAKE VALVE CYLINDER PUMP HYDRAULIC TANK M149792AA SJIII Compact Series SKYJACK, Page 15 143909...

  • Page 61: Hydraulic Schematic - Model 3219

    DISCONNECT MAIN MANIFOLD BLOCK BRAKE ORIFICE CUSHION RETURN CUSHION .051 DIA. ORIFICE 2H-25 FILTER VALVE LOWERING EMERGENCY CUSHION .040 DIA. BLOCK VALVE LOWERING VALVE BLOCK VALVE C4 BRAKE CYLINDER PUMP HYDRAULIC TANK M138023AA SKYJACK, Page 16 SJIII Compact Series 143909...

  • Page 62: Main Manifold Harness And Holding Valve Harness (Ansi/Csa)

    24 - BLUE/BLACK MOTOR (-) 25 - ORANGE/GREEN 00 - WHITE 59 - ORANGE/BLACK (14 AWG) SPLICE #1 BRAKE VALVE PROPORTIONAL VALVE 17 - BLUE/RED 59 - ORANGE/BLACK 02 - WHITE 02 - WHITE M147331AB_S3 SJIII Compact Series SKYJACK, Page 17 143909...

  • Page 63: Main Manifold Harness And Holding Valve Harness (Ce)

    25 - ORANGE/GREEN 02 - WHITE MOTOR (-) 59 - ORANGE/BLACK 00 - GREEN/YELLOW SPLICE #1 (14 AWG) BRAKE VALVE PROPORTIONAL VALVE 17 - BLUE/RED 59 - ORANGE/BLACK 02 - WHITE 02 - WHITE M147332AA_S3 SKYJACK, Page 18 SJIII Compact Series 143909...

  • Page 64: Electrical Panel Diagram (Ansi/Csa)

    PIN 3 - 02 (WHITE) HORN/FLASHING LIGHT TO MAIN DISCONNECT SWITCH PIN 4 - N/U TO (+) AT MOTOR TO FLASHING LIGHT 02 - WHITE 22 - GREEN TO HORN 02 - WHITE 49 - BLACK M149649AA1 SJIII Compact Series SKYJACK, Page 19 143909...

  • Page 65: Electrical Panel Diagram (Ce)

    7A - RED 10E - BLACK/WHITE 13 - ORANGE 14 - BLACK 15 - BLUE 16 - WHITE/BLACK HORN 18B - RED/BLACK 02 - WHITE N/U - BLUE/BLACK 49 - BLACK N/U - ORANGE/BLACK M149689AA1 SKYJACK, Page 20 SJIII Compact Series 143909...

  • Page 66: Electrical Panel Diagram (Ee Rated)

    GREEN/BLACK (18) RED BLACK ORANGE (13) TILT SWITCH RED/WHITE (16) WHITE BLACK BLUE (15) 22 02 TO HORN (NOT USED) WHITE (02) HORN/FLASHING LIGHT 02 - WHITE 49 - BLACK BACK VIEW M147957AA SJIII Compact Series SKYJACK, Page 21 143909...

  • Page 67: Limit Swtich Assemblies Diagram

    PIN 8 - 71 (BLACK/WHITE) BLUE BLACK/WHITE PIN 4 - N/U PIN 8 - 71 (BLACK/WHITE) BLUE BLACK/WHITE BROWN BLACK BROWN BLACK BLUE BLACK/WHITE BLUE BLACK/WHITE ANSI/CSA - Model 3219 CE - Model 3219 M141511AB_S3 SKYJACK, Page 22 SJIII Compact Series 143909...

  • Page 68: Horn/Tilt Switch/Flashing Light Diagram

    TILT SWITCH (ANSI/CSA) FLASHING LIGHT (ANSI/CSA) PIN 1 - 19 (BLACK) PIN 2 - 28 (GREEN) PIN 3 - 02 (WHITE) DEUTSCH PIN 4 - N/U 02 - WHITE 22 - GREEN HORN M146648AA_S3 SJIII Compact Series SKYJACK, Page 23 143909...

  • Page 69: Control Module And Beeper Diagram (Ce)

    PIN 1 - 22 BLACK PIN 2 - 29 GREEN TO GROUND PIN 3 - 60 GREEN PIN 4 - 28 BLACK PIN 5 - 02 WHITE TO ELECTRICAL PANEL PIN 6 - 28E WHITE M130612AE SKYJACK, Page 24 SJIII Compact Series 143909...

  • Page 70: Electrical Schematic (Ansi/Csa - Equipped With No Options)

    BRAKE SOLENOID D16-1 4H-16 WHITE/BLACK FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-3 ENABLE 17CR ENABLE STEER RELAY NCHO 4H-23 BLACK/WHITE RIGHT SOLENOID S7-2 DO2-4 D23-1 RIGHT S7-3 LEFT D24-1 4H-24 BLUE/BLACK LEFT SOLENOID DO2-5 M147371AB SJIII Compact Series SKYJACK, Page 25 143909...

  • Page 71: Electrical Schematic (Ansi/Csa - Equipped With All Options)

    BRAKE SOLENOID D16-1 4H-16 WHITE/BLACK FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-3 ENABLE 17CR ENABLE STEER RELAY NCHO 4H-23 BLACK/WHITE RIGHT SOLENOID S7-2 DO2-4 D23-1 RIGHT S7-3 LEFT D24-1 4H-24 BLUE/BLACK LEFT SOLENOID DO2-5 M147370AB SKYJACK, Page 26 SJIII Compact Series 143909...

  • Page 72: Electrical Schematic (Ce - Equipped With All Options)

    DO2-8 D16-1 4H-16 WHITE/BLACK FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-9 ENABLE 17CR ENABLE STEER RELAY NCHO 4H-23 BLACK/WHITE RIGHT SOLENOID S7-2 DO2-10 D23-1 RIGHT S7-3 LEFT D24-1 4H-24 BLUE/BLACK LEFT SOLENOID DO2-11 M147810AA SJIII Compact Series SKYJACK, Page 27 143909...

  • Page 73: Electrical Schematic (Ansi/Csa Ee Rated - Equipped With No Options)

    BRAKE SOLENOID D16-1 WHITE/BLACK 4H-16 FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-3 ENABLE 17CR ENABLE STEER RELAY NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID S7-2 DO2-4 D23-1 RIGHT S7-3 LEFT D24-1 4H-24 BLUE/BLACK LEFT SOLENOID DO2-5 M149688AA1 SKYJACK, Page 28 SJIII Compact Series 143909...

  • Page 74: Electrical Schematic (Ansi/Csa Ee Rated - Equipped With All Options)

    BRAKE SOLENOID D16-1 WHITE/BLACK 4H-16 FWD/UP FORWARD SOLENOID NCHO S7-6 DO2-3 ENABLE 17CR ENABLE STEER RELAY NCHO BLACK/WHITE 4H-23 RIGHT SOLENOID DO2-4 S7-2 D23-1 RIGHT S7-3 LEFT D24-1 BLUE/BLACK 4H-24 LEFT SOLENOID DO2-5 M147810AA SJIII Compact Series SKYJACK, Page 29 143909...
  • Page 75 4.2-11 Platform does not Steer ..........................13 Load Sensing System 4.3-1 Flash Code F01: Check HWFS ........................14 4.3-2 Flash Code F02: Not Ground Mode ......................14 4.3-3 Flash Code F03: Not Stopped ........................14 4.3-4 Flash Code F04: Tilted ..........................14 SJIII Compact Series SKYJACK, Page 1 143909...
  • Page 76 4.3-33 Flash Code F42:Low Pressure ........................17 4.3-34 Flash Code F43:High Pressure ........................18 4.3-35 Flash Code F44:Low Pressure ........................18 4.3-36 Flash Code F45:High Pressure ........................18 4.3-37 Flash Code F46:Check Elev .........................18 4.3-38 Flash Code F47:Check Elev .........................18 SKYJACK, Page 2 SJIII Compact Series 143909...

  • Page 77: Introduction

    The content of this section is separated into “probable cause” and “remedy.” The information preceded by a num- ber represents the “probable cause.” The following line, noted by a dash represents the “remedy” to the “probable cause” directly above it. See example below for clarification. 1. Probable Cause Remedy SJIII Compact Series SKYJACK, Page 3 143909...

  • Page 78: Electrical System

    2. Loose or broken wire #02 from base terminal block to proportional valve 2H-59. Check continuity. Replace if defective. 3. Defective proportional valve coil. Check coil for resistance. Reading should be 19 ohms. Replace if defective. SKYJACK, Page 4 SJIII Compact Series 143909...

  • Page 79: All Controls Inoperative From Base Control Console

    5. Loose or broken wire #19 from base terminal block to Aux. tilt relay 28ECR1. Check continuity. Replace if defective. 6. Loose or broken wire #19A from Aux. tilt relay 28ECR1 to tilt relay 28CR1. Check continuity. Replace if defective. SJIII Compact Series SKYJACK, Page 5 143909...

  • Page 80: No Down Or Reverse Only Function From Platform Controls

    10. Defective tilt relay 28CR (ANSI/CSA only). Check relay. Replace if defective. 11. Loose or broken wire #19A from tilt relay 28CR to pump motor contactor (ANSI/CSA only). Check continuity. Replace if defective. SKYJACK, Page 6 SJIII Compact Series 143909...

  • Page 81: No Down Function From Platform Or Base Control Console (Ansi/Csa Only)

    4.1-11 No Up Function from Base Control Console 1. Defective up/down switch S2. Check switch. Replace if defective. 2. Loose or broken wire #14E from up/down switch S2 to base terminal switch. Check continuity. Replace if defective. SJIII Compact Series SKYJACK, Page 7 143909...

  • Page 82: 12 No Down Function From Base Control Console

    4. Loose or broken wire #59 from 17CR steer relay to base terminal block TB1. Check continuity. Replace if defective. 4.1-17 Drive Only Inoperative 1. Open diode D17. Check diode. Replace if defective. SKYJACK, Page 8 SJIII Compact Series 143909...

  • Page 83: 18 No Drive Or Steer When Platform Fully Lowered

    5. Defective low voltage protection resistor RST3. Check resistor. Replace if defective. 6. Loose or broken wire #21A from low voltage protection resistor RST3 to proportional relay 21ACR. Check continuity. Replace if defective. SJIII Compact Series SKYJACK, Page 9 143909...

  • Page 84: 22 Forward Drive Function Inoperative

    4. Loose or broken wire #02 from brake valve coil 3H-17 to base terminal block. Check continuity. Replace if defective. 4.1-25 Two or more Functions at one time 1. Shorted diode. Check continuity of all diodes. Replace if defective. SKYJACK, Page 10 SJIII Compact Series 143909...

  • Page 85: Hydraulic System

    Reduce platform load to maximum capacity. 4. Up valve 3H-14 defective or is sticking. Check valve. Replace if defective. 5. Plugged deceleration valve 2H-13A (ANSI/CSA) or 2H-13C (CE). (3215 only) Clear obstruction from valve. Replace if defective. SJIII Compact Series SKYJACK, Page 11 143909...

  • Page 86: Platform Will Not Lower

    Close Valve. Replace if defective. 2. Forward drive valve 4H-16 or reverse drive valve 4H-15 defective or is sticking. Clean Valve. Replace if defective. 3. Counterbalance valve CB1 defective or is plugged. Clean Valve. Replace if defective. SKYJACK, Page 12 SJIII Compact Series 143909...

  • Page 87: 10 Brake(S) Will Not Release

    Clean valve. Replace if defective. 2. Steer cylinder C3 seals leaking. Rebuild cylinder(s). Replace if damaged. 3. Mechanical binding in king pins. Check for binding. Repair as needed. 4. Orifices 05 plugged. Clean Orifices, and reinstall. SJIII Compact Series SKYJACK, Page 13 143909...

  • Page 88: Flash Code F01: Check Hwfs

    A reading of 0V or 5V is probably due to a wiring problem. 4.3-10 Flash Code F11: Not Up 1. This message occurs at the start of the DYNAMIC lift if the operator selects a function other than UP . Select the UP function. SKYJACK, Page 14 SJIII Compact Series 143909...

  • Page 89: 11 Flash Code F12: Too Many

    1. This message is given if the elevation switch (P2-10) closed during lower at a too low height (below 5%). If it closes below 5%, height sensor fault detection is compromised. Check CALIBRATIONS / HEIGHT CALS; the “ElevDown” value shows the recorded height where the switch opened. SJIII Compact Series SKYJACK, Page 15 143909...

  • Page 90: 18 Flash Code F19: High Elev.close

    4.3-25 Flash Code F26:Check Elev 1. This message indicates a problem with the elevation switch (P2-10) during the STATIC phases. The switch is opening or closing at a different height than that recorded during the DYNAMIC phase. SKYJACK, Page 16 SJIII Compact Series 143909...

  • Page 91: 26 Flash Code F27:Bad Height

    Check CALIBRATIONS / HEIGHT CALS; the “Height” indicates the first height at which there was insufficient difference and the “Up” and “Down” values show the loaded pressure (first) and the difference between loaded and empty pressure (second). SJIII Compact Series SKYJACK, Page 17 143909...

  • Page 92: 33 Flash Code F42:Low Pressure

    1. This message indicates that the elevation switch opened more than once during the DYNAMIC lift. 4.3-38 Flash Code F47:Check Elev 1. This message indicates that the elevation switch closed more than once during the DYNAMIC lower. SKYJACK, Page 18 SJIII Compact Series 143909...
  • Page 93 5.3-3 LED Error Codes - Code Breakdown Chart ....................13 5.3-4 Hand Held Calibration/Diagnostic Tool Key Functions ...................15 5.3-5 Control Module Load Calibration - Code Messages & Definitions ..............16 5.3-6 Control Module Load Calibration Procedure ....................20 5.3-7 Curve/Group Codes Chart ..........................24 SJIII Series SKYJACK, Page 1...

  • Page 94: Service And Maintenance

    The following adjustments affect func- tion response, or speed. There may be some interaction between adjustments, making it necessary to repeat the adjustment in order to achieve the desired response. SJIII Series SKYJACK, Page 3...

  • Page 95: Oem Controller Troubleshooting

    A. Perform “Maxout” adjustment procedures. Trimpots should be sealed with nail polish The function speed remains constant regardless or enamel based paint. of the degree of handle deflection. A. Perform “Maxout” adjustment procedures. WArNING Do not use RTV silicone. SKYJACK, Page 4 SJIII Series...

  • Page 96: Oem Controller Switch Wiring

    (STEER RIGHT) STEER COMMON WHT/GRN SINGLE DOT (STEER LEFT) STEER RIGHT STEER LEFT WHT/RED ENABLE OUT WHT/BLU +24V INPUT WHT/BLK ENABLE 15589 PCB (+24V INPUT) WHT/BLK PWD OUT (A) (ENABLE) WHT/YEL GROUND (-) FORWARD/UP REVERSE/DOWN CONNECTOR SJIII Series SKYJACK, Page 5...

  • Page 97: Base

    Release steer switch and tighten the locknut. Note Remove the gauge from system pressure test Pressure setting may vary as aerial platform port. components wear. The lift pressure should be set for rated load only. SKYJACK, Page 6 SJIII Series...

  • Page 98: Electronic Tilt Switch Setup Procedure

    . Note Results: The switch Red LED The tilt circuit is only powered when Green LED is ready for normal activating a function. operation. SJIII Series SKYJACK, Page 7...
  • Page 99 Turn main disconnect switch to “ ” off position. Remove chock or wheel blocks. Remove jumper wire between #7 and #19 from Proceed to Test and Verify Tilt Circuit. terminal block. Reattach all wires #02 to motor contactor. SKYJACK, Page 8 SJIII Series...

  • Page 100: Reprogramming Existing Tilt Switch

    LED will turn on solid for 2 seconds. Red LED Red LED Green LED Green LED Red LED Red LED Green LED Green LED Results: The switch is verifying the new zero position. SJIII Series SKYJACK, Page 9...

  • Page 101: Test And Verify Tilt Circuit

    Red LED specified degrees out from the zero/ home position. On together, no blinking when Green & Red LED fault detected. Tilt Circuit Test Refer to section 2 for test tilt sensor procedure. SKYJACK, Page 10 SJIII Series...

  • Page 102: Load Sensing System - Ce

    Not Used Not Used Not Used 910 Black Positive Signal To Angle Transducer 900 White Negative Signal To Angle Transducer 902 White Negative Signal To Pressure Transducer 910A Black Positive Signal To Pressure Transducer M60303AG SJIII Series SKYJACK, Page 11...

  • Page 103: Led Error Codes - Quick Reference Chart

    4. A 4 second pause. Repeat steps 1-4 Since the GP102 only reports one error, only one code can be read from the LED per instance. If the error is cleared and another error is present, it will then be presented. SKYJACK, Page 12 SJIII Series...

  • Page 104: 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. SJIII Series SKYJACK, Page 13...
  • Page 105 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. SKYJACK, Page 14 SJIII Series...

  • Page 106: Hand Held Calibration/Diagnostic Tool Key Functions

    Read all instructions closely before attempting each phase or the calibration procedure. Symbol Key Function ESC/ENTER Buttons To move back and forth between menu and sub-menu LEFT/RIGHT Buttons Select menus and setting to be adjusted UP?DOWN BUTTONS Adjust setting values SJIII Series SKYJACK, Page 15...

  • Page 107: Control Module Load Calibration - Code Messages & Definitions

    A reading of 0V or 5V is probably due to a wiring problem. F11: Not Up This message occurs at the start of calibration if the operator selects a function other than UP . SKYJACK, Page 16 SJIII Series...
  • Page 108 Check DIAGNOSTICS / SENSORS to check the pressure. F43: High Pressure This message indicates that the pressure is too high (4.5V or more) when the elevation switch opens during calibration. Check DIAGNOSTICS / SENSORS to check the pressure. SJIII Series SKYJACK, Page 17...
  • Page 109 This message is displayed while the platform is being raised, during HEIGHT-only calibration. Lower Empty This message is displayed while the platform is being lowered to the next measurement height, when an EMPTY platform is being calibrated. SKYJACK, Page 18 SJIII Series...
  • Page 110 This message indicates that the GP102 is busy; the delay will be short (no more than 5s). Total Data: This message is displayed at the end of each phase, to confirm the number of measurements recorded by the GP102. SJIII Series SKYJACK, Page 19...

  • Page 111: Control Module Load Calibration Procedure

    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 Wire #19B Coil Black wire #14 Lift Valve Connect the Easy-Cal tool to the P1 connector on the CONTROL MODULE. SKYJACK, Page 20 SJIII Series...
  • Page 112 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. The display will show “Access Level Code (xxxx)”.
  • Page 113 “Calibrate Load: Caldate: mm/dd/yy”. It is recommended that the current date be entered here to provide easy taking of the data of last calibration. The current date must be entered using the LEFT/RIGHT UP/DOWN buttons. SKYJACK, Page 22 SJIII Series...
  • Page 114 REDO EMPTY: NO If the phase does not need to be repeated, just press ENTER to move on. If the phase does need to be repeated, press DOWN to change “NO” to “YES” then press ENTER. SJIII Series SKYJACK, Page 23...

  • Page 115: Curve/Group Codes Chart

    1 Manual Extension Platform 4626 1 Powered Extension Platform 4632 1 Manual Extension Platform 6826 1 Manual Extension Platform 6826 1 Powered Extension Platform 6832 1 Manual Extension Platform 6832 1 Powered Extension Platform 60404AD1 SKYJACK, Page 24 SJIII Series...
  • Page 116 www.skyjack.com...

This manual is also suitable for:

3219 sjiii compact seriesSjiii compact 3215Sjiii compact 3219

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