Skyjack SJ12 SJ16 Vertical Mast Service Manual 213558AAA – PDF DOWNLOAD
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Skyjack SJ12 SJ16 Vertical Mast Service Manual 213558AAA – PDF DOWNLOAD
Language : English
Pages : 140
Downloadable : Yes
File Type : PDF
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Skyjack SJ12 SJ16 Vertical Mast Service Manual 213558AAA – PDF DOWNLOAD
SJ12/16: A600 000 001 – A600 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 Mobile Elevating Work Platform (MEWP) definition:
A mobile machine intended for moving persons, tools, and material to working positions, consisting
of a work platform with controls, an extending structure and a chassis.
A mobile machine intended for moving persons, tools, and material to working positions, consisting
of a work platform with controls, an extending structure and a chassis.
1.1-2 Purpose of equipment:
The Skyjack Vertical Mast lifts are designed to move personnel, tools, and materials to working
positions.
The Skyjack Vertical Mast lifts are designed to move personnel, tools, and materials to working
positions.
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 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.
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.
1.1-5 Ownership of MEWP:
Notify Skyjack of MEWP ownership. If you sell or transfer the ownership of a MEWP, promptly notify
Skyjack of the new owner’s contact information.
Skyjack needs this information to inform the owner of any updates or additional activities that are
necessary to keep the machine in proper working condition.
1.1-6 Optional equipment:
Notify Skyjack of MEWP ownership. If you sell or transfer the ownership of a MEWP, promptly notify
Skyjack of the new owner’s contact information.
Skyjack needs this information to inform the owner of any updates or additional activities that are
necessary to keep the machine in proper working condition.
1.1-6 Optional equipment:
- This MEWP is designed to accept a variety of optional accessories. Refer to the operation manual
for a list of the optional accessories. Operating instructions for these options are located in
Operation manual. - For components or systems that are not standard, speak to the Skyjack Service Department. Give the
model and serial number for each applicable MEWP.
TABLE OF CONTENTS:
Skyjack SJ12 SJ16 Vertical Mast Service Manual 213558AAA – PDF DOWNLOAD
Section 1 – Scheduled Maintenance....................................... 11 1.1 Read and heed.................................................. 11 1.1-1 Mobile Elevating Work Platform (MEWP) definition.......... 11 1.1-2 Purpose of equipment...................................... 11 1.1-3 Use of equipment.......................................... 11 1.1-4 Service policy and warranty............................... 11 1.1-5 Ownership of MEWP......................................... 11 1.1-6 Optional equipment........................................ 11 1.2 Maintenance and Inspection Schedule............................ 12 1.2-1 Owner’s Annual Inspection Record.......................... 12 1.2-2 Replacement Parts......................................... 12 1.2-3 Maintenance and Service Safety Tips....................... 12 1.2-4 Hydraulic System & Component Maintenance and Repair....... 13 1.2-5 Maintenance Hints......................................... 14 1.2-6 About this Section........................................ 15 1.3 Owner’s Annual Inspection Record............................... 16 1.4 Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist..... 17 1.5 General inspections............................................ 18 1.5-1 Service Bulletins (B)..................................... 18 1.5-2 Annual Inspection (B)..................................... 18 1.5-3 Labels (B)................................................ 18 1.5-4 Limit switches (B)........................................ 18 1.6 Base inspections............................................... 19 1.7 Mast inspections............................................... 22 1.8 Platform inspections........................................... 23 1.9 Function Tests................................................. 24 Section 2 – Maintenance Tables and Diagrams............................. 25 2.1 Standard Hose Numbering System................................. 25 2.2 Specifications and Features - ANSI/CSA......................... 27 2.3 Specifications and Features - CE, AS........................... 28 2.4 Maximum Platform Capacities (Evenly Distributed) ANSI/CSA..... 29 2.5 Maximum Platform Capacities (Evenly Distributed) CE,AS......... 29 2.6 Floor Loading Pressure ANSI/CSA................................ 30 2.7 Floor Loading Pressure - CE, AS................................ 31 2.8 Torque Specifications.......................................... 33 2.9 Torque Specifications for Fasteners (Imperial)................. 34 2.10 Torque Specifications for Fasteners (Metric).................. 35 2.11 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 Box Wiring.................................... 47 3.10 Platform Control Box Wiring - SGLE............................ 48 3.11 Platform Control Box Cable.................................... 49 3.12 Platform Control Box Cable - SGLE............................. 50 3.13 Terminal Strip................................................ 51 3.14 Brake and Main Manifold and Hydraulic Identifications......... 52 3.15 Disc Brake Kits and Torque Specifications..................... 53 3.16 Hydraulic Schematic .......................................... 54 3.17 Base Control Wiring Diagram (Page 1 of 2)..................... 55 3.18 Base Control Wiring Diagram (Page 2 of 2)..................... 56 3.19 Main Electrical Harness (Page 1 of 2)......................... 57 3.20 Main Electrical Harness (Page 2 of 2)......................... 58 3.21 Mast Control Cable............................................ 59 3.22 Limit Switches................................................ 60 3.23 Electrical Schematic (ANSI/CSA)............................... 61 3.24 Electrical Schematic (CE)..................................... 62 3.25 Electrical Schematic (AS)..................................... 63 3.26 Elevate Telematics Harness.................................... 64 Section 4 – Troubleshooting Information................................. 65 4.1 Introduction................................................... 65 4.2 Electrical System Troubleshooting.............................. 67 4.2-1 All Controls Inoperative.................................. 67 4.2-2 All Controls Except for Down Function Inoperative......... 69 4.2-3 All Controls Inoperative From Base Control Console........ 70 4.2-4 No Up Function from Base Control Console.................. 70 4.2-5 Up Function Slow from Base Control Console................ 71 4.2-6 No Down Function from Base Control Console................ 72 4.2-7 All Controls Inoperative From Platform Control Console.... 72 4.2-8 No Up Function from Platform Controls..................... 73 4.2-9 Up Function Slow from Platform Control Console............ 74 4.2-10 No Down Function from Platform Controls.................. 75 4.2-11 Pothole Bars Will Not Retract............................ 75 4.2-12 Steer Only Inoperative................................... 76 4.2-13 Right Steer Inoperative................................. 76 4.2-14 Left Steer Inoperative................................... 77 4.2-15 No Drive Forward or Reverse.............................. 78 4.2-16 Brake will not Release................................... 79 4.2-17 No Elevated Drive........................................ 79 4.2-18 Work Platform Drives in Slow Speed Only.................. 79 4.2-19 Forward Drive Function Inoperative....................... 80 4.2-20 Reverse Drive Function Inoperative....................... 81 4.2-21 Two or More Functions at One Time........................ 81 4.3 Hydraulic System Troubleshooting............................... 82 4.3-1 All Functions Inoperative................................. 82 4.3-2 All System Sluggish....................................... 82 4.3-3 Platform Drifts Down...................................... 82 4.3-4 Platform Lifts Slowly..................................... 82 4.3-5 Platform Does Not Lift.................................... 82 4.3-6 Platform Will Not Lower................................... 83 4.3-7 Pothole Bars Will Not Retract............................. 83 4.3-8 Platform Drives Slow...................................... 83 4.3-9 Platform Will Not Drive in Forward........................ 83 4.3-10 Platform Will Not Drive in Reverse....................... 83 4.3-11 Brake(s) Will Not Release................................ 83 4.3-12 Platform Does Not Steer.................................. 84 4.3-13 Platform Steers Very Slowly.............................. 84 Section 5 – Procedures.................................................. 85 5.1 General........................................................ 85 5.1-1 Safety and Workmanship.................................... 85 5.2 Electrical System Adjustments.................................. 85 5.2-1 Electrical System......................................... 85 5.2-2 Resistor - Voltage Divider................................ 85 5.2-3 Troubleshooting - Diagnostic Switch....................... 86 5.2-4 Tilt Switch Orientation................................... 86 5.3 Hydraulic System Adjustments................................... 87 5.3-1 System Relief Pressure Adjustment......................... 87 5.3-2 Lift Pressure Adjustment.................................. 87 5.3-3 Steer Relief Pressure Adjustment.......................... 88 5.4 Electronic Tilt Switch Setup Procedure......................... 89 5.4-1 Tilt Switch Replacement................................... 89 5.4-2 Reprogramming Existing Tilt Switch........................ 91 5.4-3 Test and Verify Tilt Circuit.............................. 92 5.5 Wheel Reinstallation and Torquing Procedure.................... 93 5.6 Battery Maintenance ........................................... 96 5.6-1 Charger Maintenance....................................... 96 5.6-2 Charger Profiles.......................................... 97 5.6-3 Charger Troubleshooting................................... 98 5.6-4 Charger Error Codes....................................... 99 5.7 Pothole Limit Switch(LS2) Replacement and Adjustment ..........103 5.8 Mast Lubrication Procedure.....................................104 5.8-1 Outside Mast Lubrication..................................104 5.8-2 Inner Mast Lubrication....................................105 5.9 Mast Chain Inspection..........................................106 5.10 Mast Roller Inspection/Maintenance............................107 5.10-1 Roller Operation Inspection..............................107 5.11 Mast Disassembly Procedure....................................108 5.11-1 Extending Platform Removal...............................108 5.11-2 Mast Section 5 Removal (SJ16 Only).......................110 5.11-3 Mast Section 4 Removal...................................111 5.11-4 Mast Section 3 Removal...................................113 5.11-5 Mast Section 2 Removal...................................115 5.11-6 Mast Section 1 Removal...................................117 5.12 Mast Roller Replacement.......................................119 5.13 Mast Assembly Procedure.......................................120 5.13-1 Mast Section 1 Installation..............................120 5.13-2 Mast Section 2 Installation..............................121 5.13-3 Mast Section 3 Installation..............................122 5.13-4 Mast Section 4 Installation..............................124 5.13-5 Mast Section 5 Installation (SJ16 Only)..................126 5.13-6 Extending Platform Installation..........................127 5.14 Lift Cylinder Replacement.....................................129 5.14-1 Extending Platform Removal...............................129 5.14-2 Mast Assembly Removal....................................129 5.14-3 Lift Cylinder Removal....................................132 5.14-4 Lift Cylinder Installation...............................133 5.14-5 Mast Assembly Installation...............................134 5.15 Railing Maintenance and Repair................................137
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