Skyjack SJ12 SJ16 Vertical Mast Service Manual 161917AE – PDF DOWNLOAD
FILE DETAILS:
Skyjack SJ12 SJ16 Vertical Mast Service Manual 161917AE – PDF DOWNLOAD
Language : English
Pages : 132
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Skyjack SJ12 SJ16 Vertical Mast Service Manual 161917AE – PDF DOWNLOAD
SJ 12 & SJ 16 : 14 002 154 – 14 999 999
Scheduled Maintenance:
1.1 Read and Heed:
SKYJACK is continuously improving and expanding product features on its equipment, therefore,
specifications and dimensions are subject to change without notice.
1.1 Read and Heed:
SKYJACK is continuously improving and expanding product features on its equipment, therefore,
specifications and dimensions are subject to change without notice.
1.1-1 Aerial Platform and Mobile Elevating Work Platform Definition:
A mobile device that has a positionable platform supported from ground level by a structure.
A mobile device that has a positionable platform supported from ground level by a structure.
1.1-2 Purpose of Equipment:
The SKYJACK SJ Vertical Mast Series MEWPs are designed to transport and raise personnel, tools and
materials to overhead work areas.
The SKYJACK SJ Vertical Mast Series MEWPs are designed to transport and raise personnel, tools and
materials to overhead work areas.
1.1-3 Use of Equipment:
The MEWP is a highly maneuverable, mobile work station. Work platform elevation and elevated
driving must only be done on a firm, level surface.
The MEWP is a highly maneuverable, mobile work station. Work platform elevation and elevated
driving must only be done on a firm, level surface.
1.1-4 Manual:
Operating Manual: The operating manual is considered a fundamental part of the aerial platform. It
is a very important way to communicate necessary safety information to users and operators. A
complete and legible copy of this manual must be kept in the provided weather-resistant storage
compartment on the aerial platform at all times.
Service & Maintenance: The purpose of this is to provide the customer with the servicing and
maintenance procedures essential for the promotion of proper machine operation for its intended
purpose.
All information in this manual should be read and understood before any attempt is made to service
the machine.
Operating Manual: The operating manual is considered a fundamental part of the aerial platform. It
is a very important way to communicate necessary safety information to users and operators. A
complete and legible copy of this manual must be kept in the provided weather-resistant storage
compartment on the aerial platform at all times.
Service & Maintenance: The purpose of this is to provide the customer with the servicing and
maintenance procedures essential for the promotion of proper machine operation for its intended
purpose.
All information in this manual should be read and understood before any attempt is made to service
the machine.
1.1-5 Service Policy and Warranty:
SKYJACK warrants each new product to be free of defective parts and workmanship for the first 2
years or 3000 hours, whichever occurs first. Any defective part will be replaced or repaired by
your local SKYJACK dealer at no charge for parts or labor. In addition, all products have a 5 year
structural warranty. Contact the SKYJACK Service Department for warranty statement extensions or
exclusions.
years or 3000 hours, whichever occurs first. Any defective part will be replaced or repaired by
your local SKYJACK dealer at no charge for parts or labor. In addition, all products have a 5 year
structural warranty. Contact the SKYJACK Service Department for warranty statement extensions or
exclusions.
1.1-6 Operator Safety Reminders, Warnings and Precautions:
Operator safety is SKYJACK’s priority. The operator should comply with all applicable
safety-related reminders, warnings and precautions found in
the Operating Manual. They should be read and understood completely before operating the aerial
platform.
Operator safety is SKYJACK’s priority. The operator should comply with all applicable
safety-related reminders, warnings and precautions found in
the Operating Manual. They should be read and understood completely before operating the aerial
platform.
TABLE OF CONTENTS:
Skyjack SJ12 SJ16 Vertical Mast Service Manual 161917AE – PDF DOWNLOAD
Section 1 – Scheduled Maintenance.............................................. 9 1.1 Read and Heed......................................................... 9 1.1-1 Aerial Platform and Mobile Elevating Work Platform Definition.... 9 1.1-2 Purpose of Equipment............................................. 9 1.1-3 Use of Equipment................................................. 9 1.1-4 Manual........................................................... 9 1.1-5 Service Policy and Warranty...................................... 9 1.1-6 Operator Safety Reminders, Warnings and Precautions.............. 9 1.2 Maintenance and Inspection Schedule................................... 10 1.2-1 Owner’s Annual Inspection Record................................. 10 1.2-2 Replacement Parts................................................ 10 1.2-3 Maintenance and Service Safety Tips.............................. 10 1.3 Hydraulic System & Component Maintenance and Repair................... 11 1.3-1 Maintenance Hints................................................ 12 1.4 Railing Maintenance and Repair........................................ 12 1.5 About this Section.................................................... 13 1.5-1 Service Bulletins................................................ 13 1.5-2 Maintenance and Inspection....................................... 13 1.5-3 Maintenance Instructions......................................... 13 1.6 Owner’s Annual Inspection Record...................................... 14 1.7 Pre-Delivery/Maintenance Inspection................................... 15 1.8 Scheduled Maintenance Inspections..................................... 16 1.8-1 Electrical....................................................... 16 1.8-2 Hydraulic........................................................ 16 1.8-3 Manuals & Required Documents (B)................................. 16 1.8-4 Labels (B)....................................................... 16 1.8-5 Limit Switches (B)............................................... 17 1.8-6 Base............................................................. 17 1.8-7  Platform Assembly.............................................. 18 1.8-8 Hydraulic/Electrical Compartment................................. 19 1.8-9 Lifting Mechanism................................................ 21 1.9 Function Tests........................................................ 22 Section 2 – Maintenance Tables and Diagrams.................................... 23 2.1 Standard Hose Numbering System........................................ 23 2.2 Specifications and Features - ANSI/CSA................................ 25 2.3 Specifications and Features - KC...................................... 26 2.4 Specifications and Features - CE...................................... 27 2.5 Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA........... 28 2.6 Maximum Platform Capacities (Evenly Distributed) - KC................. 28 2.7 Maximum Platform Capacities (Evenly Distributed) - CE................. 28 2.8 Floor Loading Pressure ANSI/CSA & KC.................................. 29 2.9 Floor Loading Pressure - KC........................................... 30 2.10 Floor Loading Pressure - CE.......................................... 31 2.11 Torque Specifications................................................ 33 2.12 Torque Specifications for Fasteners (Imperial)....................... 34 2.13 Torque Specifications for Fasteners (Metric)......................... 35 2.14 Torque Specifications for Hydraulic Couplings & Hoses................ 36 Section 3 – System Component Identification and Schematics..................... 37 3.1 Electrical Symbol Chart............................................... 38 3.2 Hydraulic Symbol Chart................................................ 39 3.3 Wire Number and Color Code............................................ 40 3.4 Hydraulic Component Parts List........................................ 41 3.5 Electrical Component Parts LIst....................................... 42 3.6 Cylinders and Port Identifications.................................... 44 3.7 Wheel Brake and Port Identifications.................................. 45 3.8 Powerpack and Port Identifications.................................... 46 3.9 Platform Control Console Wire Diagram................................. 47 3.10 Brake and Main Manifold and Hydraulic Identifications................ 49 3.11 Disc Brake Kits and Torque Specifications............................ 50 3.12 Hydraulic Schematic - SJ12/SJ16...................................... 51 3.13 Main Electrical Harness - SJ12/SJ16.................................. 52 3.14 Mast Control Cable................................................... 53 3.15 Limit Switches....................................................... 54 3.16 Base Control Wiring Diagram (SJ12/SJ16 - ANSI)....................... 55 3.17 Base Control Wiring Diagram (SJ12/SJ16 - CE/KC)...................... 56 3.18 Electrical Schematic (SJ12/SJ16 - ANSI/CSA).......................... 57 3.19 Electrical Schematic (SJ12/SJ16 - CE/KC)............................. 58 3.20 Harness Assembly Trackunit........................................... 59 3.21 Harness Assembly Elevate............................................. 60 Section 4 – Troubleshooting Information........................................ 62 4.1 Introduction.......................................................... 62 4.2 Electrical System Troubleshooting..................................... 63 4.2-1 All Controls Inoperative......................................... 63 4.2-2 All Controls Except for Down Function Inoperative................ 63 4.2-3 All Controls Inoperative From Base Control Console............... 64 4.2-4 No Up Function from Base Control Console......................... 65 4.2-5 Up Function Slow from Base Control Console....................... 66 4.2-6 No Down Function from Base Control Console....................... 66 4.2-7 All Controls Inoperative From Platform Control Console........... 67 4.2-8 No Up Function from Platform Control Console..................... 67 4.2-9 Up Function Slow from Platform Control Console................... 68 4.2-10 No Down Function from Platform Control Console.................. 69 4.2-11 Pothole Bars Will Not Retract................................... 70 4.2-12 Steer Only Inoperative.......................................... 70 4.2-13 Right Steer Inoperative........................................ 70 4.2-14 Left Steer Inoperative.......................................... 71 4.2-15 No Drive Forward or Reverse..................................... 71 4.2-16 Brake will not Release.......................................... 72 4.2-17 No Elevated Drive............................................... 72 4.2-18 Work Platform Drives in Slow Speed Only......................... 73 4.2-19 Forward Drive Function Inoperative.............................. 73 4.2-20 Reverse Drive Function Inoperative.............................. 74 4.2-21 Two or More Functions at One Time............................... 74 4.3 Hydraulic System Troubleshooting...................................... 76 4.3-1 All Functions Inoperative........................................ 76 4.3-2 All Functions Sluggish........................................... 76 4.3-3 Platform Drifts Down............................................. 76 4.3-4 Platform Lifts Slowly............................................ 76 4.3-5 Platform Does Not Lift........................................... 76 4.3-6 Platform Will Not Lower.......................................... 77 4.3-7 Pothole Bars Will Not Retract.................................... 77 4.3-8 Platform Drives Slow............................................. 77 4.3-9 Platform Will Not Drive in Forward............................... 77 4.3-10 Platform Will Not Drive in Reverse.............................. 77 4.3-11 Brake(s) Will Not Release....................................... 77 4.3-12 Platform Does Not Steer......................................... 78 4.3-13 Platform Steers Very Slowly..................................... 78 Section 5 – Procedures......................................................... 79 5.1 General............................................................... 79 5.1-1 Safety and Workmanship........................................... 79 5.2 Electrical System Adjustments......................................... 79 5.2-1 Electrical System................................................ 79 5.2-2 Resistor - Voltage Divider....................................... 79 5.2-3 Troubleshooting - Diagnostic Switch.............................. 80 5.2-4 Tilt Switch Orientation.......................................... 80 5.3 Hydraulic System Adjustments.......................................... 81 5.3-1 System Relief Pressure Adjustment................................ 81 5.3-2 Steer Relief Pressure Adjustment................................. 82 5.4 Electronic Tilt Switch Setup Procedure................................ 83 5.4-1 Tilt Switch Replacement.......................................... 83 5.4-2 Reprogramming Existing Tilt Switch............................... 85 5.4-3 Test and Verify Tilt Circuit..................................... 86 5.5 Wheel Reinstallation and Torquing Procedure........................... 87 5.6 Wheel Reinstallation and Torquing Procedure........................... 89 5.7 Battery Maintenance................................................... 90 5.8 Charger Maintenance - Delta-Q......................................... 90 5.9 Mast Lubrication Procedure............................................ 98 5.9-1 Outside Mast Lubrication......................................... 98 5.9-2 Inner Mast Lubrication........................................... 99 5.10 Mast Chain Inspection................................................100 5.11 Mast Roller Inspection/Maintenance...................................101 5.11-1 Roller Operation Inspection.....................................101 5.12 Mast Disassembly Procedure...........................................102 5.12-1 Extending Platform Removal......................................102 5.12-2 Mast Section 5 Removal (SJ16 Only)..............................104 5.12-3 Mast Section 4 Removal..........................................105 5.12-4 Mast Section 3 Removal..........................................107 5.12-5 Mast Section 2 Removal..........................................109 5.12-6 Mast Section 1 Removal..........................................111 5.13 Mast Roller Replacement..............................................113 5.14 Mast Assembly Procedure..............................................114 5.14-1 Mast Section 1 Installation.....................................114 5.14-2 Mast Section 2 Installation.....................................115 5.14-3 Mast Section 3 Installation.....................................116 5.14-4 Mast Section 4 Installation.....................................118 5.14-5 Mast Section 5 Installation (SJ16 Only).........................120 5.14-6 Extending Platform Installation.................................121 5.15 Lift Cylinder Replacement............................................123 5.15-1 Extending Platform Removal......................................123 5.15-2 Mast Assembly Removal...........................................123 5.15-3 Lift Cylinder Removal...........................................126 5.15-4 Lift Cylinder Installation......................................127 5.15-5 Mast Assembly Installation......................................128
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