Skyjack SJ 3215, SJ 3219 Service Manual

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Page 1

MODELS SJ 3215 SJ 3219

Service Manual

SJIII Compact Series

Part No. 143909AD November 2013

Page 2

This manual is based on Serial Numbers:

T T E-mail: parts@skyjack.

Skyjack Au

4 Coa W N Au T F

Skyjack Service Center

3451 S

Phone: 630-262-0005 T F Email: servi

Illinois, 60174 USA

Parts & Service (Europe)

CE & AS

SJIII 3215 10,000,330 TO 10,000,573 SJIII 3219 22,013,838 TO 22,019,596

ANSI/CSA

SJIII 3215 10,000,330 TO 10,000,630 SJIII 3219 22,013,838 TO 22,022,792

Please refer to the website www.skyjack.com for older Serial Numbers.

wenson Ave. St. Charles,

oll Free: 1-800-275-9522 ax: 630-262-0006

[email protected]

arts (North America)

oll Free: 1-800-965-4626 oll Free Fax: 1-888-782-4825

tes Place

etherill Park

ew South Wales 2164

stralia el: +61 (0) 28786 3200 ax: +61(0) 28786 3222

stralia Pty Ltd.

com

Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK Phone: +44-1691-676-235 Fax: +44-1691-676-238 E-mail: [email protected]

Skyjack Brasil

Alameda Júpiter, 710 Loteamento American Park Empresarial Indaiatuba, SP, Brasil 13347-653 Tel: +55 19 3936 0132

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SERVICE AND MAINTENANCE

Section 1 - Scheduled Maintenance Inspections

Table of Contents

Section 2 - Maintenance Tables

Table of Contents

Section 3 - Schematics

Table of Contents

Section 4 - Troubleshooting

Table of Contents

Section 5 - Procedures

Table of Contents

SKYJACK, Page 3SJIII Series

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The Safety Alert Symbol identifies important safety messages on aerial platforms, safety signs in manuals or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

DANGER indicates an imminently hazardous situation which, if not avoided,

will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

Section 1 - Scheduled MaintenanceOperator’s Responsibility for Maintenance

This Safety Alert Symbol means attention!

Become alert! Your safety is involved.

DANGER

WARNING

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. 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

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Section 1

SCHEDULE MAINTENANCE INSPECTIONS

Table of Contents

Operator’s Responsibility for Maintenance

Aerial Platform Definition ..............................................................................................................................................7

Purpose of Equipment .................................................................................................................................................7

Use of Equipment ........................................................................................................................................................7

Manuals ........................................................................................................................................................................7

Operator .......................................................................................................................................................................7

Service Policy and Warranty ........................................................................................................................................7

Optional Accessories ...................................................................................................................................................7

Scope of this Manual ...................................................................................................................................................8

Operator Safety Reminders .........................................................................................................................................9

Electrocution Hazard ...................................................................................................................................................9

Safety Precautions .....................................................................................................................................................10

Maintenance and Inspection Schedule .....................................................................................................................13

Owner’s Annual Inspection Record ...........................................................................................................................13

Replacement Parts .....................................................................................................................................................13

Maintenance and Service Safety Tips .......................................................................................................................13

Hydraulic System & Component Maintenance and Repair ......................................................................................14

Maintenance Hints .....................................................................................................................................................14

Service and Maintenance

About this Section ......................................................................................................................................................15

Service Bulletins .........................................................................................................................................................15

Maintenance and Inspection .....................................................................................................................................15

Maintenance Instructions ...........................................................................................................................................15

Scheduled Maintenance

1.1 Scheduled Maintenance Inspections ..............................................................................................................18

1.2 Function Tests..................................................................................................................................................25

Tables

1.1 Owner’s Annual Inspection Record ................................................................................................................16

1.2 Maintenance and Inspection Checklist ...........................................................................................................17

SKYJACK, Page 5SJIII Series

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Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance

SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications

and dimensions are subject to change without notice.

Aerial Platform Definition

A mobile device that has an adjustable position platform supported from ground level by a structure.

Purpose of Equipment

The SKYJACK SJIII Compact and Conventional series aerial platforms are designed to transport and raise personnel, tools and materials to overhead work areas.

Use of Equipment

The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level, compacted surface. It can be driven over uneven terrain only when the platform is fully lowered.

Manuals

Operating

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. The updated copy of the manuals are found on the company’s website: www.skyjack.com.

Operator

The operator must read and completely understand both this operating manual and the safety panel label located on the platform and all other warnings in this manual and on the aerial platform. Compare the labels on the aerial platform with the labels found within this manual. If any labels are damaged or missing, replace them immediately.

Service Policy and Warranty

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. Contact the SKYJACK Service Department for warranty statement extensions or exclusions.

Optional Accessories

The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under “Standard and Optional Features” in Table 2.1 of the operating manual. Operating instructions for these options (if equipped) are located in section 2 of the operating manual.

For non-standard components or systems, contact the SKYJACK Service Department at

North America & Asia: Europe:

( : 800 275-9522 ( : 44 1691-676-235

7 : 630 262-0006 7 : 44 1691-676-239

Include the model and serial number for each applicable aerial platform.

SKYJACK, Page 7SJIII Series

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Section 1 - Scheduled MaintenanceOperator’s Responsibility for Maintenance

Scope of this Manual

a. This manual applies to the ANSI/SIA, CSA and CE versions of the SJIII Series aerial platform models listed

on Table 2.1.

- Equipment identified with “ANSI” meets the ANSI SIA-A92.6-2006 standard.

- Equipment identified with “CSA” meets the CSA B354.2-01 standard.

- Equipment identified with “CE” meets the requirements for the European countries, i.e., Machinery Directive 98/37/EC and EMC Directive 89/336/EEC and the corresponding EN standards.

b. CSA (Canada) and CE (Europe)

Operators are required to conform to national, territorial/provincial and local health and safety regulations

applicable to the operation of this aerial platform.

c. 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

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Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance

CE Guidance Note

“Avoidance of danger from overhead lines”

Voltage Range Minimum Safe Approach Distance

(Phase to Phase) (Feet)

0 to 300V Avoid Contact

Over 300V to 50KV 10

Over 50KV to 200KV 15 Over 200KV to 350KV 20 Over 350KV to 500KV 25 Over 500KV to 750KV 35

Over 750KV to 1000KV 45

60023AD

DANGER

FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!

Avoid Power Lines

Minimum Safe Approach Distance

ANSI/SIA A92.6-2006

and CSA B354.2-01 Requirements

Adhere strictly to the governmental rulings

and regulations applicable in your country.

WARNING

Failure to comply with your required responsibilities in the use and operation of the aerial platform

could result in death or serious injury!

Operator Safety Reminders

A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to follow simple and fundamental safety rules and precautions.

You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this aerial platform is mandatory. The following pages of this manual should be read and understood completely before operating the aerial platform.

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. Maintain a Minimum Safe Approach Distance (MSAD) from energized power lines and parts as listed below. The operator must allow for the platform to sway, rock or sag. This aerial platform does not provide protection from contact with or proximity to an electrically charged conductor.

DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING.

DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS.

SKYJACK, Page 9SJIII Series

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Safety Precautions







Know and understand the safety precautions before going on to next section.

WARNING

Failure to heed the following safety precautions could result in tip over, falling, crushing, or other hazards leading

to death or serious injury.

• KNOW all national, state or territorial/provincial

and local rules which apply to your aerial platform and jobsite.

• TURN emergency main power disconnect switch

“

” off when leaving the aerial platform unattended. Remove the key to prevent unauthorized use of the aerial platform.

• WEAR all the protective clothing and personal

safety devices issued to you or called for by job conditions.

• DO NOT wear loose clothing,

dangling neckties, scarves, rings, wristwatches or other jewelry while operating this lift.

• AVOID entanglement with

ropes, cords or hoses.

Section 1 - Scheduled MaintenanceOperator’s Responsibility for Maintenance

• DO NOT increase the lateral

surface area of the platform. Increasing the area exposed to the wind will decrease aerial platform stability.

• DO NOT drive or elevate the

aerial platform if it is not on a firm level surface. Do not drive elevated near depressions or holes of any type, loading docks, debris, drop-offs and surfaces that may affect the stability of the aerial platform.

• If operation in areas with

holes or drop-offs is absolutely necessary, elevated

driving shall not be allowed. Position the aerial platform horizontally only with the platform fully lowered. After ensuring that all 4 wheels or outriggers (if equipped) have contact with level firm surface, the aerial platform can be elevated. After elevation, the drive function must not be activated.

• Elevated driving must only

• AVOID falling. Stay within the

boundaries of the guardrails.

be done on a firm level surface.

• DO NOT ascend or descend

a grade when elevated. When

• DO NOT raise the aerial plat-

form in windy or gusty conditions.

fully lowered, ascending or descending, only grades up to rated maximum listed in

Tables 2-3 are permissible.

SKYJACK, Page 10 SJIII Series

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Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance

Safety Precautions (Continued)

Know and understand the safety precautions before going on to next section.

• DO NOT operate on surfaces not capable of

holding the weight of the aerial platform including the rated load, e.g. covers, drains, and trenches.

• DO NOT oper ate an aerial

platfo r m that has ladde r s, scaffolding or other devices mounted on it to increase its size or work height. It is prohibited.

• DO NOT exert side forces on

aerial platform while elevated.

• DO NOT use the aerial platform

as a crane. It is prohibited.

• DO NOT raise the aerial platform

while the aerial platform is on a truck, fork lift or other device or vehicle.

• BE AWARE of crushing hazards.

Ke e p all body parts inside platform guardrail.

• DO NOT lower the platform

unless the area below is clear of pe r s o nnel and obstructions.

• ENSURE that there are no personnel or obstructions

in the path of travel, including blind spots.

• DO NOT sit, stand or climb on

the guardrails. It is prohibited.

• DO NOT climb on scissor arm

assembly. It is prohibited.

• BE AWARE o f o ve r hea d

obstructions or other possible hazar d s around th e aerial platform when driving or lifting.

• BE AWARE of blind spots when operating the

aerial platform.

• STUNT driving and horseplay are prohibited.

• ENSURE ALL tires are in good condition and lug

nuts are properly tightened.

• DO NOT alter or disable limit switches or other

safety devices.

• DO NOT use the aerial platform without guardrails,

locking pins and the entry gate in place.

SKYJACK, Page 11SJIII Series

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Section 1 - Scheduled MaintenanceOperator’s Responsibility for Maintenance

Safety Precautions (Continued)

Know and understand the safety precautions before going on to next section.

• DO NOT exceed the rated capacity of the

aerial platform. Do make sure the load is evenly distributed on the platform.

• DO NOT attempt to free a snagged platform with

lower controls until personnel are removed from the platform.

• DO NOT position the aerial platform against

another object to steady the platform.

• DO NOT place materials on the guardrails or

materials that exceed the confines of the guardrails unless approved by Skyjack.

Fall Protection

As per the ANSI A92.6-2006 standard, “The guardrail system of the aerial platform provides fall protection. If occupant(s) of the platform are required to wear personal fall protection equipment (PFPE), occupants shall comply with instructions provided by the aerial platform manufacturer (remanufacturer) regarding anchorage(s).”

If additional fall protection is required, by an employer or the authority having jurisdiction, Skyjack recommends the use of a fall restraint system to keep an occupant within the confines of the platform, and thus not expose the occupant to any fall hazard requiring a fall arrest.

All personal fall protection equipment must comply with applicable governmental regulations and must be insp ected and used in accordance with the manufacturer’s recommendations.

All personal fall protection equipment must be attached only to approved anchorage points within the platform of the aerial platform.

WARNING

Entering and exiting the aerial platform should only be done using the three points of contact.

• Useonlyequippedaccessopenings.

• Enterandexitonlywhentheaerial

platform is in the fully retracted position.

• Dousethreepointsofcontacttoenterandexit

the platform. Enter and exit the platform from the ground only. Face the aerial platform when entering or exiting the platform.

• Threepointsofcontactmeansthattwohands

and one foot or one hand and two feet are in contact with the aerial platform or the ground at all times during entering and exiting.

WARNING

An operator should not use any aerial platform that:

does not appear to be working properly.• has been damaged or appears to have worn or • missing parts. has alterations or modifications not approved by • the manufacturer. has safety devices which have been altered or • disabled. has been tagged or blocked out for non-use or • repair.

Failure to avoid these hazards could re-

sult in death or serious injury.

Jobsite Inspection

Do not use in hazardous locations.• Perform a thorough jobsite inspection prior to • operating the aerial platform, to identify potential hazards in your work area. Be aware of moving equipment in the area. Take • appropriate actions to avoid collision.

SKYJACK, Page 12 SJIII Series

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Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance

Maintenance and Inspection Schedule

The actual operating environment of the work platform governs the use of the maintenance schedule. The inspection points covered in Table 1.2. Maintenance and lnspection Checklist, indicates the areas of the aerial platform to be maintained or inspected and at what intervals the maintenance and inspections are to be performed.

Owner’s Annual Inspection Record

It is the responsibility of the owner to arrange quarterly and annual inspections of the aerial platform. Table 1.1. Owner’s Annual lnspection Record is to be used for recording the date of the inspection, owner’s name, and the person responsible for the inspection of the work platform.

Replacement Parts

Use only original replacement parts. Parts such as batteries, wheels, railings, etc. with weight and dimensions different from original parts will affect stability of the aerial platform and must not be used without manufacturer’s consent.

All replacement tires must be of the same size and load rating as originally supplied tires; to maintain safety and stability of aerial platform.

Consult SKYJACK’s Service Department for optional tires specifications and installation.

WARNING

Any unit that is damaged or not operating properly must be immediately tagged and removed from service until proper repairs

are completed.

Maintenance and Service Safety Tips

Maintenance and repair should only be performed by personnel who are trained and qualified to service this aerial platform.

All maintenance and service procedures should be performed in a well lighted and well ventilated area.

Anyone operating or servicing this aerial platform must read and completely understand all operating instructions and safety hazards in this manual and operating manual.

All tools, supports and lifting equipment to be used must be of proper rated load and in good working order before any service work begins. Work area should be kept clean and free of debris to avoid contaminating components while servicing.

All service personnel must be familiar with employer and governmental regulations that apply to servicing this type of equipment.

Keep sparks and flames away from all flammable or combustible materials.

Properly dispose of all waste material such as lubricants, rags, and old parts according to the relative law provisions obtaining in the country.

Before attempting any repair work, turn Battery Disconnect Switch to the “OFF” position.

Preventive maintenance is the easiest and least expensive type of maintenance.

SKYJACK, Page 13SJIII Series

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Section 1 - Scheduled MaintenanceOperator’s Responsibility for Maintenance

Hydraulic System & Component Maintenance and Repair

The following points should be kept in mind when working on the hydraulic system or any component:

1. Any structure has limits of strength and durability. To prevent failure of structural parts of hydraulic components, relief valves which limit pressure to safe operating values are included in the hydraulic circuits.

2. Tolerance of working parts in the hydraulic system is very close. Even small amounts of dirt or foreign materials in the system can cause wear or damage to components, as well as general faulty operation of the hydraulic system. Every precaution must be taken to assure absolute cleanliness of the hydraulic oil.

3. Whenever there is a hydraulic system failure which gives reason to believe that there are metal particles or foreign materials in the system, drain and flush the entire system and replace the filter cartridges. A complete change of oil must be made under these circumstances.

4. Whenever the hydraulic system is drained, check the magnets in the hydraulic reservoir for metal particles. If metal particles are present, flush the entire system and add a new change of oil. The presence of metal particles also may indicate the possibility of imminent component failure. A very small amount of fine particles is normal.

5. All containers and funnels used in handling hydraulic oil must be absolutely clean. Use a funnel when necessary for filling the hydraulic oil reservoir, and fill the reservoir only through the filter opening. The use of cloth to strain the oil should be avoided to prevent lint from getting into the system.

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

NOTE

Samples of hydraulic oil should be drawn from the reservoir and tested annually. These samples should be taken when the oil is warmed through normal operation of the system. The sample should be analyzed by a qualified lubrication specialist to determine if it is suitable for continued use.

Oil change intervals will depend on the care used in keeping the oil clean, and the operating conditions. Dirt and/or moisture cotamination will dictate that the oil should be changed more often. Under normal use and operating conditions, the hydraulic oil should be changed every two years. Refer

to Table 1.2 of this manual.

7. All hydraulic components must be dis-assembled in spo t l e s s ly cl e a n surr o u n d ings. Du ring disassembly, pay particular attention to the identification of parts to assure proper reassembly. Clean all metal parts in a clean mineral oil solvent. Be sure to thoroughly clean all internal passages. After the parts have been dried thoroughly, lay them on a clean, lint-free surface for inspection.

8. Replace all O-rings and seals when overhauling any component. Lubricate all parts with clean hydraulic oil before reassembly. Use small amounts of petroleum jelly to hold O-rings in place during assembly.

9. Be sure to replace any lost hydraulic oil when comple ting the installation of the repaired component, and bleed any air from the system when required.

10. All hydraulic connections must be kept tight. A loose connection in a pressure line will permit the oil to leak out or air to be drawn into the system. Air in the system can cause damage to the components and noisy or erratic system operation.

Maintenance Hints

Three simple maintenance procedures have the greatest effect on the hydraulic system performance, efficiency and life. Yet, the very simplicity of them may be the reason they are so often overlooked. What are they? Simply these:

Change filters annually. The filters will need 1. to be changed more often depending on the operating conditions. Dirty, dusty, high mo isture environments may cause the hydraulic system to be contaminated more quickly. Maintain a sufficient quantity of clean hydraulic 2. oil of the proper type and viscosity in the hydraulic reservoir. Keep all connections tight.3.

SKYJACK, Page 14 SJIII Series

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Section 1 - Scheduled Maintenance Service and Maintenance

About this Section

This section contains the maintenance and inspection schedule that is to be performed.

References are made to the procedures in Section 5 that outline detailed step-by-step instructions for checks

and replacements.

Service Bulletins

Before performing any scheduled maintenance inspection procedure, refer to service bulletins found in our web site: www.skyjackinc.com for updates related to service and maintenance of this aerial platform.

Maintenance and Inspection

Death or injury can result if the aerial platform is not kept in good working order. Inspection and maintenance should be performed by competent personnel who are trained and qualified on mantenance of this aerial platform.

WARNING

Failure to perform each procedure as presented and scheduled may cause death,

serious injury or substantial damage.

Maintenance Instructions

This manual consists of four schedules to be done for maintaining on an aerial platform. Inspection schedule frequency is shown below:

Inspection Schedule

Daily A Frequently A + B Annually A + B + C Bi-annually A + B + C + D

Make copies of the maintenance and inspection • checklist to be used for each inspection.

• Checkthescheduleonthechecklistforthetypeof

inspection to be performed.

• Placea checkin theappropriate box aftereach

inspection procedure is completed.

• Usethemaintenanceandinspectionchecklistand

step-by-step procedures in Section 5 to perform these inspections.

• Ifanyinspectionreceivesafail,tagandremovethe

aerial platform from service. If any aerial platform component(s) has been • repaired, an inspection must be performed again before removing the tag. Place a check in the repair column.

NOTE

Preventive maintenance is the easiest and

least expensive type of maintenance.

• Unless o t herwise specified, p erform e a ch

maintenance procedure with the aerial platform in the following configuration:

- 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.

Legend

P = Pass F = Fail R = Repaired

SKYJACK, Page 15SJIII Series

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Section 1 - Scheduled MaintenanceService and Maintenance

Recording

Date

Recording

Year #

Owner’s

Name

Inspected

60564AA

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.

54679123 8

Model Number: ____________________________ Serial Number: ____________________________

Table 1.1 Owner’s Annual Inspection Record

SKYJACK, Page 16 SJIII Series

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Section 1 - Scheduled Maintenance Service and Maintenance

Serial Number: Model: Hourmeter Reading: Name (Printed): Date: Time: Signature:

INSPECTION FREQUENCY

DAILY

P - PASS FREQUENTLY F - FAIL

NNUALLY

- REPAIRED BI-ANNUALLY

PFR PFR

Maintenance Support Scissor Assembly

111AD

A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.7 of the Operating Manual. B - Perform Scheduled Maintenance Inspection every three months or 150 hrs. Refer to Section 1 of this manual. C - Perform Scheduled Maintenance Inspection every year. Refer to Section 1 of this manual. D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1 of this manual. * Perform scheduled inspection every three months or 150 hours. † - Refer to Skyjack's website @ www.skyjack.com for latest service bulletins porior to performing quarterly or yearly inspection.

Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy.

Load/Tilt Sensor - CE

Free-wheeling Valve Knob (Compacts - Front Side)

A, B

Hydraulic Tank

Hydraulic/Electric Tray Side

Pothole Protection Device Battery Tray

A, B

Annually† A + B + C

Bi-annually†

A, BTest Emergency Lowering

Test Main Power Discconect Switch

Rollers Lift Cylinder(s) A, B

Daily A

Frequently*†

A + B

Table 1.2 MAINTENANCE AND INSPECTION CHECKLIST

Each item shall be inspected using the the appropriate section of the Skyjack operating manual. As each item is inspected, write the apropriate grade in the box.

Inspection Schedule

A, B, C

A + B + C + D

Schedule Schedule

Schedule Maintenance Inspections

Base Control Switches

Labels A

Platform Assembly

Lanyard Attachment Anchors A, B

A, B

Test Free-wheeling

A, B

Test Off/Platform/Base

A, B

A, B, C

A, B

Entrance Side

Manuals A, BMain Power Disconnect Switch A, B

Limit Switches A, B

A, B

A, B A, B A, B A, B A, B A, B A, B A, B A, B

Wheel/Tire Assembly Tie Rod (Conventionals)

A, B

Brakes AC Outlet Receptacle Ladder

Battery Tray Side

A, B A, B A, B

Test Tilt Sensor - ANSI/CSA

Test Enable Trigger Switch Test Steering Test Driving Test Brakes Test Platform Raising/Lowering Test Lowering Warning - CE Test Horn Test Pothole Sensor Test Elevated Drive Speed

Tilt Sensor - ANSI/CSA

Greasing Points

Electrical Panel

A, B, C

A, B A, B A, B

A, B, CHydraulic Oil

Proportional and Main Manifolds

A, B

A, B A, B

Emergency Lowering Access Rod (If Equipped)

A, B

Battery

Pothole Protection Device

Hydraulic Pump and Motor

Battery Charger

Steer Cylinder Assembly

A, B

AC Outlet on Platform A, B Platform Control Console A, B

Powered Extension Control Console (If Equipped)

A, B

Lift Mechanism

Scissor Bumpers A, B

Test Lower/Neutral/Raise Switch A, B

Test Base Emergency Stop

Platform Control Console

Test Platform Emergency Stop A, B

A, B

A, B A, B

Function Tests

Base Control Console



 

SKYJACK, Page 17SJIII Series

Page 17

High Speed Limit Switch

Section 1 - Scheduled MaintenanceService and Maintenance

High Speed Limit Switch

Pothole Protection

Limit Switch

1.1 Scheduled Maintenance Inspections

Begin the scheduled maintenance inspections by checking each item in sequence for the conditions listed in this section.

WARNING

To avoid injury, do not operate an aerial platform until all malfunctions have been

corrected.

WARNING

To avoid possible injury, ensure aerial platform power is off during your visual

and daily maintenance inspections.

Electrical

Maintaining the electrical components is essential to good performance and service life of the aerial platform.

Inspect the following areas for chafed, corroded and loose wires:

• basetoplatformcablesandwiringharness

• batterytraywiringharnesses

• hydraulic/electricalwiringharnesses

Hydraulic

Maintaining the hydraulic components is essential to good performance and service life of the aerial platform.

Perform a visual inspection around the following areas:

hoses and fittings• all hydraulic cylinders• all hydraulic manifolds• the underside of the base• ground area under the aerial platform•

1.1-1 Labels

Refer to the labels section in this manual and determine that all labels are in place and are legible.

1.1-2 Limit Switches

Detecting limit switch malfunction is essential to safe aerial platform operation. Ensure limit switches are properly secured and movement is not obstructed.

Visually inspect all limit switch located inside the scissor arms and the outrigger assemblies for the following:

• brokenormissingactuatorarm

• missingfasteners

• loosewiring

SKYJACK, Page 18 SJIII Series

Page 18

Section 1 - Scheduled Maintenance Service and Maintenance

Compact

1.1-3 Entrance Side

Main Power Disconnect Switch •

Turn emergency main power disconnect - switch to “ ” off position.

Ensure all cables are secure and switch - is in proper working condition.

Ladder

110V Outlet

Receptacle

Base

Control Console

Free-wheeling Valve

Brakes

Free-wheeling Valve

Brakes

Ladder

AC Outlet Receptacle•

Ensure receptacle is free from dirt and - obstructions.

Ladder•

Ensure there are no loose or missing - parts and there is no visible damage.

Emergency Main Power Disconnect Switch

110V Outlet Receptacle

Conventional

(Back View)

Compact

(Back View)

Base Control Switches•

Ensure there are no signs of visible - damage and all switches are in their neutral positions.

Free-wheeling Valve Knob•

(Compacts - Front Side)

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. -

SKYJACK, Page 19SJIII Series

Page 19

Section 1 - Scheduled MaintenanceService and Maintenance

Conventional Compact

Battery

Charger

Battery Tray

1.1-4 Battery Tray Side

Pothole Protection Device•

Battery Tray•

Battery Charger •

(Compacts - Entrance Side)

Battery

Ensure mechanisms have no sign of - visible damage and are free from dirt and obstructions.

Ensure tray latch is secure and in proper - working order.

Ensure charger is secure and shows no - visible damage.

Fuse Box

Hydraulic/Electric Tray

Battery Charger

Pothole Protection Device

Battery acid is extremely corrosive

- Wear proper eye and facial protection as well as appropriate protective clothing. If contact occurs, immediately flush with cold water and seek

medical attention.

1. Check battery case for damage.

2. Clean battery terminals and cable ends thoroughly with a terminal cleaning tool or wire brush.

Battery Tray

WARNING

Battery

Battery•

Proper battery condition is essential to

good performance and operational safety. Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions.

WARNING

Explosion hazard. Keep flames and sparks away. Do not smoke

near batteries.

SKYJACK, Page 20 SJIII Series

3. Ensure all battery connections are tight.

4. If applicable, check battery fluid level. If plates are not covered by at least 1/2” (13 mm) of solution, add distilled or demineralized water.

5. Replace battery if damaged or incapable of holding a lasting charge.

WARNING

Use original or manufacturer-approved parts and components for the aerial

platform.

Page 20

Section 1 - Scheduled Maintenance Service and Maintenance

Conventional

Wheel/Tire

Steer Cylinder

Wheel/Tire

Greasing Point

Tie RodWheel Motor

Steer Cylinder Assembly•

Ensu r e st e e r cy l i nder assembly is - properly secured and there are no loose or missing parts.

Wheel/Tire Assembly•

The aerial platform is either equipped with

solid rubber tires or foam-filled tires. Tire and/or wheel failure could result in an aerial platform tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion.

Check all tire treads and sidewalls for - cuts, cracks, punctures and unusual wear.

Check each wheel for damage and - cracked welds.

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.

Tie Rod (Conventionals)•

Ensure there are no loose or missing - parts, tie rod end studs are locked and there is no visible damage.

Greasing Points•

Ensure greasing points have no sign of - visible damage and are free from dirt and obstructions.

B - Frequent Inspection

Locate grease fittings and pump grease - as needed.

Ensure wheels are aligned and true - vertically and horizontally.

SKYJACK, Page 21SJIII Series

Page 21

Section 1 - Scheduled MaintenanceService and Maintenance

Compact

Emergency Lowering

Access Rod

Greasing Point

1.1-5 Hydraulic/Electric Tray Side

Ensure tray latch is secure and in proper - working order.

Tilt Sensor

Greasing Point

Electrical Panel

Hydraulic/Electric Tray

Main Manifold

Hydraulic Tank

Electrical Panel •

Ensure panel is properly secured and - there is no visible damage.

Pothole Protection Device•

Ensure mechanisms have no sign of - visible damage and are free from dirt and obstructions.

Hydraulic Tank •

Ensure hydraulic filler cap is secure. -

Ensure tank shows no visible damage - and no evidence of hydraulic leakage.

Hydraulic Oil•

Ensure platform is fully lowered, and then - visually inspect the sight gauge located on the side of the hydraulic oil tank.

The hydraulic oil level should be at or - slightly above the top mark of the sight glass.

C - Annual Inspection

For hydraulic oil replacement procedure, - refer to section 5.

Hydraulic Pump and Motor •

Ensure there are no loose or missing - parts and there is no visible damage.

Ensure there are no loose wires or - missing fasteners.

Proportional and Main Manifolds•

Ensure all fittings and hoses are properly - tightened and there is no evidence of hydraulic leakage.

Ensure there are no loose wires or - missing fasteners.

Tilt Sensor - ANSI/CSA•

Ensure tilt sensor is properly secured and - there is no visible damage.

Load/Tilt Sensor - CE•

Ensure load/tilt sensor is properly secured - and there is no visible damage.

Emer g enc y Lower i ng Acce s s Ro d • (If Equipped)

Ensure rod is properly secured and there - is no visible damage.

SKYJACK, Page 22 SJIII Series

Page 22

Section 1 - Scheduled Maintenance Service and Maintenance

Platform Control Console

Platform

Manual Storage

Box

Platform

Assembly

Railing

Lanyard Attachment Anchor

1.1-6 Platform Assembly

WARNING

Ensure that you maintain three points of

contact to mount/dismount platform.

1. Use the ladder of aerial platform to access platform.

2. Close the gate.

Ensure there are no loose or missing - parts and there is no visible damage.

Ensure all fasteners are securely in - place.

Ensure all railings are properly positioned - and secured.

Ensure gate is in good working order. -

Lanyard Attachment Anchors•

Ensure attachment rings are secure and - no visible damage.

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.

Manuals•

Ensure a copy of operating manual and other

important documents are enclosed in manual storage box.

Check to be sure manual storage box is - present and in good condition.

Ensure manuals are legible and in good - condition.

Always return manuals to the manual - storage box after use.

AC Outlet on Platform•

Ensure outlet has no visible damage and - free from dirt or obstructions.

SKYJACK, Page 23SJIII Series

Page 23

Lift Cylinder

Section 1 - Scheduled MaintenanceService and Maintenance

Maintenance Support

Scissor Assembly

Powered Extension Control Console • (If Equipped)

Ensure all switches are returned to

neutral and are properly secured.

Ensure there are no loose or missing - parts and there is no visible damage.

WARNING

Ensure that you maintain three points of

contact to mount/dismount platform.

3. Use the ladder to dismount from platform.

1.1-7 Lifting Mechanism

1. Raise the platform until there is adequate clearance to swing down the maintenance support.

Scissor Bumper

Roller

Scissor Bumpers•

Ensure bumpers are secure and shows - no sign of visible damage.

Rollers•

Ensure rollers are secure and there is no - visible damage.

Ensure rollers’ path of travel are free from - dirt and obstructions.

Lift Cylinder(s)•

Ensure each lift cylinder is properly - secured, there are no loose or missing parts and there is no ev idence of damage.

Ensure all fittings and hoses are properly - tightened and there is no evidence of hydraulic leakage.

Maintenance Support•

Ensure maintenance support is properly - secured and shows no visible damage.

Scissor Assembly•

Ensure scissor assembly shows no visible - damage and no signs of deformation in 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

2. Raise the platform until there is adequate clearance to swing up the maintenance support.

3. Swing up maintenance support into storage bracket.

4. Fully lower the platform.

Page 24

Section 1 - Scheduled Maintenance Function Tests

Conventional

(Back View)

Free-wheeling Valve

Lower/

Neutral/Raise

Switch

Emergency Stop

Button

1.2 Function Tests

Function tests are designed to discover any malfunctions before aerial platform is put into service. The operator must understand and follow step-by-step instructions to test all aerial platform functions.

WARNING

Never us e a malfuncti o n i ng ae r i al platform. If malfunctions are discovered, aerial platform must be tagged and placed out of service. Repairs to aerial platform may only be made by a qualified

service technician.

After repairs are completed, operator must perform a pre-operation inspection and a series of function tests again before putting aerial platform into service.

Prior to performing function tests, be sure to read and understand Section 2.10 - Start Operation of the operating manual.

Compact

(Back View)

Lower/

Neutral/Raise

Switch

Platform/Off/Base Key Switch

1.2-2 Base Control Console

Ensure that you maintain three points of contact when using the ladder to mount/

dismount platform.

1. Use the ladder of aerial platform to access platform.

2. Close the gate.

3. On platform control console, pull out “ emergency stop button.

4. Use the ladder to dismount from platform.

5. Turn main power disconnect switch to “ ” on position.

Emergency Stop

Button

WARNING

”

1.2-1 Test Main Power Disconnect Switch

1. At rear of the base, turn main power disconnect switch to “ ” off position.

Result: Aerial platform functions should not

operate.

SKYJACK, Page 25SJIII Series

Page 25

Section 1 - Scheduled MaintenanceFunction Tests

Conventional

(Back View)

Platform

Raise/Lower

Switch

Test Base Emergency Stop•

1. Push in “

attempt to raise or lower the platform.

Result: Platform raising and lowering

functions should not operate.

2. Pull out base “

button.

Test Off/Platform/Base Switch•

1. Se lect off/ platform /base ke y switch

“ ” off position. Attempt to raise or lower the platform.

Result: Platform raising and lowering

functions should not operate.

Emergency Stop

Button

” emergency stop button and

” emergency stop

WARNING

Be aware of overhead obstructions or other possible hazards around the

aerial platform when lifting.

Free-wheeling Valve

Platform

Raise/Lower

Switch

Platform/Off/Base Key Switch

Compact

(Back View)

Emergency Stop

Button

3. Select and hold off/platform/base key

switch to “ to raise or lower the platform.

Result: Platform raising and lowering

functions should operate.

Test Lower/Neutral/Raise Switch•

1. Select and hold off/platform/base key

switch to “

” raise the platform with lower/neutral/

“ raise switch.

Result: Platform should rise.

2. Select and hold off/platform/base key

switch to “ “

” lower the platform with lower/

neutral/raise switch.

Result: Platform should lower.

” base position. Attempt

” base position and

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

Section 1 - Scheduled Maintenance Function Tests

Conventional

(Back View)

Lower/

Neutral/Raise

Switch

Test Emergency Lowering•

1. Raise the platform.

Emergency Stop

Button

Free-wheeling Valve

Lower/

Neutral/Raise

Switch

Platform/Off/Base Key Switch

Compact

(Back View)

Emergency Stop

Button

Test Free-wheeling•

1. Ensure path of intended motion is clear.

2. Locate holding valve manual override knob at the base of each lift cylinder. Depress and turn counterclockwise. If necessary, use access rod that is located on the base of the aerial platform.

3. On hydraulic/electric tray, pull out and hold emergency lowering valve to fully lower the platform.

Result: The platform should lower.

4. To restore normal operation, depress and turn holding valve manual override knobs clockwise.

2. Release the brake manually.

3. Tu rn f r e e - w h e el in g va lv e k no b co untercl ockwise to a fully opened position and attempt to push/pull the aerial platform.

Result: Platform should move.

4. Turn free-wheeling valve knob clockwise to a fully closed position for normal operation.

5. Reengage the brake.

SKYJACK, Page 27SJIII Series

Page 27

Section 1 - Scheduled MaintenanceFunction Tests

Lift/Drive/Steer Enable Trigger Switch

Inclined Drive/Level Drive Switch

Lift/Off/Drive Switch

Platform Control Console with Toggle Switch Platform Control Console with Rotary Switch

1.2-3 Platform Control Console

1. Ensure base “ pulled out.

2. Select off/platform/base key switch to “ platform position.

3. Ensure main power disconnect switch is in “ ” on position.

Ensure that you maintain three points of contact when using the ladder to mount/

dismount platform.

” emergency stop button is

WARNING

Rocker Switch

Controller

Emergency Stop Button/ Operation Light

Horn Pushbutton

”

Lift/Drive/Steer Enable

Trigger Switch

Lift/Inclined Drive/Level Drive Switch

Test Platform Emergency Stop•

1. Push in “ and attempt to activate any platform function.

Result: All selected platform functions

should not operate.

Test Enable Trigger Switch•

1. Without activating “ switch, attempt to activate any platform function.

Result: All platform functions should not

operate.

Rocker Switch

Emergency Stop Button/ Operation Light

Horn Pushbutton

” emergency stop button

” enable trigger

4. Use the ladder of aerial platform to access platform.

5. Close the gate.

6. On platform control console, pull out “ ”emergency stop button.

SKYJACK, Page 28 SJIII Series

Page 28

Section 1 - Scheduled Maintenance Function Tests

Lift/Drive/Steer Enable Trigger Switch

Inclined Drive/Level Drive Switch

Lift/Off/Drive Switch

Platform Control Console with Toggle Switch Platform Control Console with Rotary Switch

Test Steering•

NOTE

Inclined drive (low speed/high torque) is

not available on 3215 and 3219 models.

Rocker Switch

Controller

Emergency Stop Button/ Operation Light

Horn Pushbutton

Lift/Drive/Steer Enable

Trigger Switch

Lift/Inclined Drive/Level Drive Switch

Test Driving•

1. Ensure path of intended motion is clear.

Rocker Switch

Emergency Stop Button/ Operation Light

Horn Pushbutton

1. For platform control console with toggle switch:

Select lift/off/drive switch to “

position.

For platform control console with rotary

switch:

Select lift/inclined drive/level drive switch

to either “

high torque) or “ speed/low torque) position.

2. Activate and hold “ switch.

3. Press rocker switch on top of controller

handle to “ ” left and “ ” right.

Result: Steer wheels should turn left and

right.

” inclined drive (low speed/

” level drive (high

” enable trigger

” drive

2. Activate and hold “ switch.

3. Slo w ly m ov e co ntr ol l er h an d le i n

“

” forward direction until aerial platform begins to move, and then return handle to center position.

Result: Aerial platform should move in

forward direction, and then come to a stop.

4. Slowly move controller handle in “ reverse direction until aerial platform begins to move, and then return handle to center position.

Result: Aerial platform should move in

reverse direction, and then come to a stop.

”enable trigger

”

SKYJACK, Page 29SJIII Series

Page 29

Section 1 - Scheduled MaintenanceFunction Tests

Lift/Drive/Steer Enable Trigger Switch

Inclined Drive/Level Drive Switch

Lift/Off/Drive Switch

Platform Control Console with Toggle Switch Platform Control Console with Rotary Switch

Test Brakes•

WARNING

Brakes will engage instantly when you release the controller handle, causing

aerial platform to stop immediately.

1. Ensure path of intended motion is clear.

Rocker Switch

Controller

Emergency Stop Button/ Operation Light

Horn Pushbutton

Lift/Drive/Steer Enable

Trigger Switch

Lift/Inclined Drive/Level Drive Switch

Result: Aerial platform should come to an

instant and abrupt stop. If aerial platform does not stop immediately, or if aerial platform pulls to one side while stopping, do not operate aerial platform until brake adjustments have been checked.

Test Platform Raising/Lowering•

Rocker Switch

Emergency Stop Button/ Operation Light

Horn Pushbutton

2. Activate and hold “ switch.

3. Drive aerial platform “

” backward. Test brake by releasing

“ controller handle.

Result: Aerial platform should come to

a stop. If aerial platform pulls to one side while stopping, do not operate aerial platform until brake adjustments have been checked.

4. Drive aerial platform “

then “

by releasing “ only.

” backward. Test brake again

” enable trigger

” forward and then

” forward and

” enable trigger switch

WARNING

Be aware of overhead obstructions or other possible hazards around the

aerial platform when lifting.

1. For platform control console with toggle switch:

Select lift/off/drive switch to “

position.

For platform control console with rotary

switch:

Select lift/inclined drive/level drive switch

” lift position.

to “

2. Activate and hold “ switch.

” enable trigger

” lift

SKYJACK, Page 30 SJIII Series

Page 30

Section 1 - Scheduled Maintenance Function Tests

Conventional Compact

Pothole Protection Device

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.

Test Lowering Warning - CE•

1. Raise the platform until approximately a height of 3 to 4 meters is reached then attempt to fully lower the platform.

Result: Platform should stop lowering at

a height of 2.5 meters high and an alarm should sound.

2. Release controller handle.

Test Horn•

1. Push “

Result: Horn should sound.

” horn pushbutton.

Pothole Protection Device

Test Pothole Sensor •

WARNING

Ensure that you maintain three points of contact to mount/dismount plat-

form.

1. Use the ladder to dismount from platform and pla c e a block , appro x i mat e l y

1.5” (3.75 cm), under the hydraulic/electric tray.

2. Use the ladder of aerial platform to access platform.

3. Close the gate.

4. Raise the platform until approximately a height of 7 feet (2 meters) is reached and attempt to drive forward or reverse.

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.

SKYJACK, Page 31SJIII Series

Page 31

Section 1 - Scheduled MaintenanceFunction Tests

Conventional Compact

Pothole Protection Device

Test Elevated Drive Speed•

WARNING

Be aware of overhead obstructions or other possible hazards around the

aerial platform when lifting.

1. Ensure path of intended motion is clear.

2. Raise the platform until approximately a height of 7 feet (2 meters) is reached and attempt to drive forward or reverse.

Result: Aerial platform should move slower

than when it was in stowed position.

Test Tilt Sensor - ANSI/CSA•

WARNING

Be aware of overhead obstructions or other possible hazards around the

aerial platform when lifting.

Pothole Protection Device

2. Use t he l ad der to d is m ou n t f r om platform.

3. On base control console, slowly raise the platform.

Result: When platform reach e s an

appropriate height, a warning signal should sound and platform stop raising as lift and drive controls should be disabled.

WARNING

Ensure that there are no personnel or obstructions in the path of travel,

including blind spots.

1. Move the aerial platform on to a slope not greater than 4.5°.

SKYJACK, Page 32 SJIII Series

Page 32

Section 2

MAINTENANCE TABLES AND DIAGRAMS

Table of Contents

Tables

2.1a Specifications and Features (ANSI/CSA) ..........................................................................................................2

2.1b Specifications and Features (CE) .....................................................................................................................4

2.1c Specifications and Features (AS) ......................................................................................................................6

2.2a Floor Loading Pressure (ANSI/CSA) .................................................................................................................9

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

2.4 Torque Specifications ......................................................................................................................................15

2.5 Scissors Fluids - Hydraulic Oil ........................................................................................................................16

SKYJACK, Page 1SJIII Series

Page 33

MODEL 3215 3219 3220 3226

2400 lb. 2580 lb. 3510 lb. 4135 lb.

1089 kg 1170 kg 1592 kg 1876 kg

21’ 25’ 26’ 32’

6.4 m 7.6 m 8.1 m 9.9 m

15' 19’ 20’ 26’

4.6 m 5.8 m 6.1 m 7.9 m

34.5” 39" 38" 45"

0.88 m 0.99 m 0.97 m 1.1 m

74” 78.5" 82" 89"

1.88 m 1.99 m 2.1 m 2.3 m

Drive Height

Lift Time (No Load) 18 s 20 s 27 s 47 s

Lower Time (No Load) 32 s 39 s 41 s 63 s

Lift Time (Rated Load) 23 s 25 s 33 s 51 s

Lower Time (Rated Load) 24 s 29 s 29 s 46 s

1.9 mph 2.4 mph

3.0 km/h 3.8 km/h

0.64 mph 0.64 mph

1.0 km/h 1.0 km/h

0.95 mph 1.2 mph

1.5 km/h 1.9 km/h

Gradeability (Ramp Angle)

Type

162AB

* 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.

23% 25%

High Torque Drive Speed N/A

0.65 mph

26” x 64” 28” x 83”

Elevated Drive Speed

1.05 km/h

Working Height

Stowed Height (Railings Up)

Normal Drive Speed

Chassis

0.66 m x 1.63 m

Height

1.78 m 2.3 m

0.81 m 0.81 m

32" 32"

70.0” 91"

Weight *

Overall width

Overall length

Platform Size (inside)

0.71 x 2.1 m

2 mph

3.2 km/h

Platform Elevated Height

FULL

Standard Operating Time

Stowed Platform Height

Hydraulic Oil

10.9 L 30 L

ATF Dexron III ATF Dexron III

Tank Capacity

2.9 gal. 7.93 gal.

Tires

Solid Rubber Solid Rubber

12 x 4 x 8 16 x 5 x 12

Section 2 - Maintenance Tables and DiagramsService and Maintenance

Table 2.1a Specifications and Features (ANSI/CSA)

SKYJACK, Page 2 SJIII Series

Page 34

Section 2 - Maintenance Tables and Diagrams Service and Maintenance

MODEL 4620 4626 4632

4100 lb. 4700 lb. 5075 lb.

1860 kg 2132 kg 2302 kg

26' 32' 38'

7.92 m 9.75 m 11.6 m

20' 26' 32'

6.1 m 7.9 m 9.8 m

38" 45" 48.5"

0.97 m 1.14 m 1.23 m

77.25" 84.5" 88"

1.96 m 2.15 m 2.24 m

Lift Time (No Load) 24 s 48 s 50 s

Lower Time (No Load) 48 s 45 s 62 s

Lift Time (Rated Load) 32 s 54 s 59 s

Lower Time (Rated Load) 32 s 32 s 49 s

Gradeability

Type

163AC

* Weight with standard 3' (0.9 m) or 4' (1.2 m) extension platform.

Refer to serial nameplate for specific applications

Fill hardness: 55 Durometer

Working Height

Platform Elevated Height

Stowed Platform Height

0.56 mph

Drive Height

Normal Drive Speed

Elevated Drive Speed

FULL

High Torque Drive Speed

16 x 5 x 12

Solid Rubber

Stowed Height Railings Up

0.90 km/h

1.0 mph

1.6 km/h

25%

1.17 m

2.31 m

46"

91"

Overall length

42" x 84"

Weight *

2.0 mph

3.2 km/h

Chassis

Standard Operating Time

Height

1.07 m x 2.13 m

Overall width

Platform Size (inside)

30 L

Tires

Hydraulic Oil

ATF Dexron III

Tank Capacity

7.93 gal.

Table 2.1a Specifications and Features (ANSI/CSA) (Continued)

SKYJACK, Page 3SJIII Series

Page 35

Section 2 - Maintenance Tables and DiagramsService and Maintenance

MODEL 3215 3219 3220 3226

Weight * 1090 kg 1170 kg 1542 kg 1896 kg

Width

Length

Platform Size

Working Height 6.4 m 7.6 m 8.1 m 9.9 m

Platform Elevated Height 4.6 m 5.8 m 6.1 m 7.9 m

Stowed Platform Height 0.88 m 0.99 m 0.97 m 1.1 m

Stowed Height Railings Up 1.88 m 1.99 m 2.1 m 2.3 m

Drive Height (All Standards)

Lift Time (No Load) 18 sec. 20 sec. 27 sec. 47 sec.

Lower Time (No Load) 32 sec. 39 sec. 41 sec. 63 sec.

Lift Time (Rated Load) 23 sec. 25 sec. 33 sec. 51 sec.

Lower Time (Rated Load) 24 sec. 29 sec. 29 sec. 46 sec.

Normal Drive Speed 3.0 km/h 3.8 km/h

Elevated Drive Speed 1.0 km/h 1.0 km/h

High Torque Drive Speed 1.5 km/h 1.9 km/h

Gradeability

Tires (Solid Rubber)

Type

Tank Capacity

60156AL-CE-1-R-S

Height

1.78 m

0.81 m 0.81 m

0.66 x 1.63 m

2.3 m

0.71 x 2.1 m

* Weight with standard 0.9 m extension platform. (Refer to nameplate for aerial platforms with 1.5 m or 1.8 m extension platform.)

12 x 4 x 8 16 x 5 x 12

Hydraulic Oil

ATF Dexron III ATF Dexron III

10.9 L 30 L

23% 25%

N/A

1.05 km/h

3.2 km/h

FULL

Standard Operating Time

Chassis

Table 2.1b Specifications and Features (CE)

SKYJACK, Page 4 SJIII Series

Page 36

Section 2 - Maintenance Tables and Diagrams Service and Maintenance

MODEL 4620 4626 4632

Weight

†

1860 kg 2130 kg 2300 kg

Width

Length

Platform Size

Height

Working Height 7.92 m 9.75 m 11.6 m

Platform Elevated Height 6.1 m 7.9 m 9.7 m

Stowed Platform Height 0.97 m 1.14 m 1.23 m

Stowed Height Railings Up 1.96 m 2.15 m 2.24 m

Drive Height 6.1 m 7.9 m 9.7 m

Standard Operating Time

Lift Time (No Load) 24 sec. 48 sec. 50 sec.

Lower Time (No Load) 48 sec. 45 sec. 62 sec.

Lift Time (Rated Load) 32 sec. 54 sec. 59 sec.

Lower Time (Rated Load) 32 sec. 32 sec. 49 sec.

Chassis

Normal Drive Speed

Elevated Drive Speed

High Torque Drive Speed

Gradeability

Tires (Solid Rubber)

Type

Tank Capacity

60156AL-CE-2-R-S

3.2 km/h

16 x 5 x 12

0.90 km/h

25%

1.6 km/h

Fill hardness: 55 Durometer

†

Weight with standard 0.9m extension platform.

1.17 m

2.31 m

1.07 x 2.11 m

Refer to serial nameplate for specific applications.

ATF Dexron III

30 L

Hydraulic Oil

Table 2.1b Specifications and Features (CE) (Continued)

SKYJACK, Page 5SJIII Series

Page 37

Section 2 - Maintenance Tables and DiagramsService and Maintenance

MODEL 3215 3219 3220 3226

Weight * 1090 kg 1170 kg 1583 kg 1864 kg

Width

Length

Platform Size

Stowed Platform Height 0.88 m 0.99 m 0.97 m 1.15 m

Platform Elevated Height 4.6 m 5.8 m 6.1 m 7.9 m

Working Height 6.4 m 7.6 m 7.92 m 9.75 m

Stowed Height Railings Up 1.88 m 1.99 m 2.02 m 2.2 m

Drive Height (All Standards)

Lift Time (No Load) 18 sec. 20 sec. 27 sec. 43 sec.

Lower Time (No Load) 32 sec. 39 sec. 41 sec. 52 sec.

Lift Time (Rated Load) 23 sec. 25 sec. 33 sec. 56 sec.

Lower Time (Rated Load) 24 sec. 29 sec. 29 sec. 42 sec.

High Travel Speed 3.9 km/h

Elevated Drive Speed 1 km/h 1.1 km/h

High Torque Drive Speed 1.9 km/h 2.14 km/h

Gradeability

Tires (Solid Rubber)

Type

Tank Capacity

60156AJ-AS-1-S

Height

0.81 m 0.84 m

1.78 m 2.32 m

0.66 x 1.57 m 0.71 x 2.13 m

23% 25%

1.05 km/h

3.2 km/h

* 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.

12 x 4 x 8 16 x 5 x 12

Hydraulic Oil

ATF Dexron III ATF Dexron III

10.9 L 30 L

FULL

Standard Operating Time

Chassis

N/A

Table 2.1c Specifications and Features (AS)

SKYJACK, Page 6 SJIII Series

Page 38

Section 2 - Maintenance Tables and Diagrams Service and Maintenance

MODEL 4620 4626 4632

Weight

†

1860 kg 2130 kg 2300 kg

Width

Length

Platform Size

Working 7.92 m 9.75 m 11.6 m

Platform Elevated 6.1 m 7.9 m 9.7 m

Fixed Railing 1.96 m 2.15 m 2.24 m

Platform Lowered 0.97 m 1.14 m 1.23 m

Drive Height 6.1 m 7.9 m 9.7 m

Lift Time (No Load) 24 sec. 48 sec. 50 sec.

Lower Time (No Load) 48 sec. 45 sec. 62 sec.

Lift Time (Rated Load) 32 sec. 54 sec. 59 sec.

Lower Time (Rated Load) 32 sec. 32 sec. 49 sec.

High Travel Speed

Elevated Drive Speed

High Torque Drive Speed

Gradeability

Tires (Solid Rubber)

Type

Tank Capacity

60156AJ-AS-2-S

Refer to serial nameplate for specific applications.

Hydraulic Oil

ATF Dexron III

30 L

0.90 km/h

Standard Operating Time

Chassis

3.2 km/h

Height

1.17 m

2.31 m

1.07 x 2.11 m

Fill hardness: 55 Durometer

†

Weight with standard 0.9m extension platform.

1.6 km/h

25%

16 x 5 x 12

Table 2.1c Specifications and Features (AS) (Continued)

SKYJACK, Page 7SJIII Series

Page 39

Section 2 - Maintenance Tables and DiagramsService and Maintenance

Length

Width

Floor Loading Pressure

Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP):

Foot Print Area = Length x Width

Weight of Aerial Platform + Capacity

LCP = 0.4 X

Foot Print Area

Base Area = Length x Width

Weight of Aerial Platform + Capacity

OUP =

Base Area

WARNING

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.

SKYJACK, Page 8 SJIII Series

Page 40

Section 2 - Maintenance Tables and Diagrams Service and Maintenance

lb. kg lb. kg psi

KPa

(kN/m

)

psf

KPa

(kN/m2)

min* 2400 1089 960 435 100 689.48 160 7.66

max* 3000 1361 1200 544 110 758.42 200 9.58

min* 2580 1170 1032 468 100 689.48 170 8.14

max* 3130 1420 1252 568 110 758.42 210 10.05

min* 3400 1542 1396 633 110 758.42 175 8.38

max* 4299 1950 1936 878 130 896.32 245 11.73

min* 4100 1860 1644 746 120 827.37 210 10.05

max* 4610 2091 1844 836 130 896.32 235 11.25

min* 4100 1860 1640 744 191 1316.90 146 6.99

max* 5620 2549 2250 1021 222 1530.64 199 9.53

min* 4700 2132 1880 853 206 1420.32 168 8.04

max* 5920 2685 2370 1075 224 1544.43 210 10.05

min* 5075 2302 2030 921 208 1434.11 180 8.62

max* 5775 2620 2310 1048 223 1537.53 205 9.82

60354AF-ANSI

NOTE:

MODEL

Total Aerial

Platform Weight

Total Aerial Platform Load

OUP**LCP**Wheel

OUP - Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the whole surface directly underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values above.

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.

min - Total aerial platform weight with no options

max - Aerial platform weight + all options + full capacity

LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform presses on

the areas in direct contact with the floor. The floor covering (tile, carpet, etc.) must be able to withstand more that the indicated values above.

3215

3220

4626

4632

4620

3226

3219

Table 2.2a Floor Loading Pressure (ANSI/CSA)

SKYJACK, Page 9SJIII Series

Page 41

Section 2 - Maintenance Tables and DiagramsService and Maintenance

Wheel LCP** OUP**

kg kg

KPa (kN/m

) KPa (kN/m2)

min* 1089 435 689.5 7.5

max* 1361 544 758.5 9.5

min* 1170 468 689.5 8.0

max* 1420 568 758.5 10.0

min* 1542 616 758.5 8.5

max* 1950 780 896.5 11.5

min* 1896 746 827.5 10.0

max* 2091 836 896.5 11.5

min* 1922 744 1316.9 7.0

max* 2568 1021 1530.6 9.5

min* 2173 853 1420.3 8.0

max* 2627 1075 1544.4 10.1

min* 2303 921 1434.1 8.6

max* 2620 1048 1537.5 9.8

60354AH-CE-R

max - Aerial platform weight + all options + full capacity

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.

4626

4632

min - Total aerial platform weight with no options

LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the

areas in direct contact with the floor. The floor covering (tile, carpet, etc.) must be able to withstand more that the indicated values above.

MODEL

3219

4620

3215

Total Aerial

Platform

Weight

Total Aerial Platform Load

3220

3226

Table 2.2b Floor Loading Pressure (CE)

SKYJACK, Page 10 SJIII Series

Page 42

Section 2 - Maintenance Tables and Diagrams Service and Maintenance

Wheel LCP** OUP**

kg kg

KPa (kN/m

) KPa (kN/m2)

min* 1089 435 689.5 7.5

max* 1361 544 758.5 9.5

min* 1170 468 689.5 8.0

max* 1420 568 758.5 10.0

min* 1542 633 758.5 8.5

max* 1950 878 896.5 11.5

min* 1860 746 827.5 10.0

max* 2091 836 896.5 11.5

min* 1860 744 1316.9 7.0

max* 2549 1021 1530.6 9.5

min* 2132 853 1420.3 8.0

max* 2685 1075 1544.4 10.1

min* 2302 921 1434.1 8.6

max* 2620 1048 1537.5 9.8

60354AF-AS-S

NOTE:

Total Aerial

Platform

Weight

Total Aerial Platform Load

MODEL

3219

4620

4626

4632

3220

3226

3215

OUP - Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the

whole surface directly underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values above.

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.

min - Total aerial platform weight with no options

max - Aerial platform weight + all options + full capacity

LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the

areas in direct contact with the floor. The floor covering (tile, carpet, etc.) must be able to withstand more that the indicated values above.

Table 2.2c Floor Loading Pressure (AS)

SKYJACK, Page 11SJIII Series

Page 43

600 lb. 250 lb.

28 mph

272 kg 113 kg

12.5 m/s

550 lb. 250 lb.

28 mph

249 kg 113 kg

12.5 m/s

900 lb. 300 lb. 800 lb. 300 lb.

28 mph

408 kg 136 kg 363 kg 136 kg

12.5 m/s

500 lb. 250 lb.

28 mph

227 kg 113 kg

12.5 m/s

1300 lb. 300 lb. 1300 lb. 300 lb.

28 mph

590 kg 136 kg 590 kg 136 kg

12.5 m/s

1000 lb. 300 lb. 1000 lb. 300 lb.

28 mph

454 kg 136 kg 454 kg 136 kg

12.5 m/s

700 lb. 250 lb.

28 mph

318 kg 113 kg

12.5 m/s

165AB

2 Persons 1 Person

1 Person3 Persons 1 Person3 Persons

3215

2 Persons

3 Persons 1 Person 3 Persons

2 Persons 1 Person

Maximum

Wind

Speed

Tilt

Cutout

Setting

1.5 x 3.5

1 Person

2 Persons 1 Person

1 Person2 Persons

MODEL

Manual Extension Platform Powered Extension Platform

Total Capacity Extension Capacity Total Capacity Extension Capacity

2.5 x 4.5

N/A

1.5 x 3.5

2.5 x 4.5

1 Person

4632

3219

3220

3226

4620

4626

Section 2 - Maintenance Tables and DiagramsService and Maintenance

Table 2.3a Maximum Platform Capacities (Evenly Distributed) (ANSI/CSA)

NOTE: Overall Capacity - Occupants and materials not to exceed rated load.

SKYJACK, Page 12 SJIII Series

Page 44

3215

227 kg 2 Persons 113 kg 1 Person No Wind 1.5 x 3.5

3219

227 kg 2 Persons 113 kg 1 Person No Wind 1.5 x 3.5

3220

2 Persons 2 Persons No Wind 1.5 x 3.5

3226

2 Persons No Wind 1.5 x 3.5

4620

590 kg 3 Persons 136 kg 1 Person 590 kg 3 Persons 136 kg 1 Person 12.5 m/s 1.5 x 3.5

4626

454 kg 3 Persons 136 kg 1 Person 454 kg 3 Persons 136 kg 1 Person 12.5 m/s 1.5 x 3.5

4632

317 kg 2 Persons 113 kg 1 Person 10.8 m/s 1.5 x 3.5

60315AJ-CE-R-S

Tilt

Cutout

Setting

363 kg

227 kg

408 kg

Maximum

Wind

Speed

N/A

MODEL

Manual Extension Platform Powered Extension Platform

Total Capacity Extension Capacity Total Capacity Extension Capacity

m/s km/h ft/s mph

3.4 – 5.4 12.5 – 19.4 11.5 – 17.75 5 – 12.0 Papers and thin branches move, flags wave

5.4 – 8.0 19.4 – 28.8 17.75 – 26.25 12.0 – 18

Dust is raised, paper whirls up, and small branches sway.

8.0 – 10.8 28.8 – 38.9 26.25 – 35.5 18 – 24.25

Shrubs with leaves start swaying. Wave crests are apparent in ponds or swamps.

10.8 – 13.9 38.9 – 50.0 35.5 – 45.5 24.5 – 31

Tree branches move. Power lines whistle. It is difficult to open an umbrella.

13.9 – 17.2 50.0 – 61.9 45.5 – 65.5 31 – 38.5

Whole trees sway. It is difficult to walk against the wind.

60338AC

Wind Speed

Ground Conditions

BEAUFORT

SCALE

Section 2 - Maintenance Tables and Diagrams Service and Maintenance

Table 2.3b Maximum Platform Capacities (Evenly Distributed) (CE)

NOTE: Overall Capacity - Occupants and materials not to exceed rated load.

WARNING

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.

SKYJACK, Page 13SJIII Series

Page 45

400 0 227 kg 2 Persons 113 kg

200 12.5 227 kg 1 Person 227 kg

400 0 249 kg 2 Persons 113 kg

200 12.5 120 kg 1 Person 120 kg

400 0 408 kg 2 Persons 136 kg

200 12.5 227 kg 1 Person 227 kg

400 0 227 kg 2 Persons 113 kg

200 12.5 120 kg 1 Person 120 kg

4620 400 12.5 590 kg 3 Persons 136 kg 1 Person 590 kg 3 Persons 136 kg 1 Person

4626 400 12.5 454 kg 3 Persons 136 kg 1 Person 454 kg 3 Persons 136 kg 1 Person

4632 400 12.5 317 kg 2 Persons 113 kg 1 Person

60315AG-AS-S

3215

3219

3220

3226*

N/A

Max. Side

Force

(N)

Max. Wind (m/s)

MODEL

Manual Extension Platform Powered Extension Platform

Total Capacity Extension Capacity Total Capacity Extension Capacity

1 Person N/A

SJIII3226 shall have extension retracted when used outdoor.

1 Person N/A

Section 2 - Maintenance Tables and DiagramsService and Maintenance

Table 2.3c Maximum Platform Capacities (Evenly Distributed) (AS)

NOTE: Overall Capacity - Occupants and materials not to exceed rated load.

SKYJACK, Page 14 SJIII Series

Page 46

Directional valve mounting bolts

Wheel mounting bolts

Torque

Ft-lb (max)

In-lb (max)

Nm (max)

Torque

Ft-lb (max)

In-lb (max)

Nm (max)

Torque

Ft-lb (max)

In-lb (max)

Nm (max)

SJIII Series

Section 2 - Maintenance Tables and Diagrams Service and Maintenance

Table 2.4 Torque Specifications

28-32 in-lb 2.2 – 3.6 Nm

90 ft-lb 122.02 Nm

Cartridge

Size

08 38 58 10 12 16 20 20 20 25 35 50

240 240 240 300 420 600

27.12 27.12 27.12 33.90 47.46 67.80

Coils

Size

All coils

4 to 5

48 to 60

5.42 to 6.78

SAE Plugs

Size

2 4 5 6 8 10 12 16 3 10 15 15 25 25 30 35

36 120 180 180 300 300 360 420

4.07 13.56 20.34 20.34 33.90 33.90 40.68 47.46

Newton-meter = Nm Foot-pound = ft-lb Inch-pound = in-lb

Additional Torque Specifications may be found in Section 3.

60056AF

SKYJACK, Page 15

Page 47

Section 3

SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS

Table of Contents

Charts

3.1 Electrical Symbol Chart ..................................................................................................................................3

3.2 Hydraulic Symbol Chart ..................................................................................................................................4

3.3 Wire Number and Color Code ........................................................................................................................5

Parts List

3.4 Hydraulic Manifold and Port Identifications ....................................................................................................6

3.5 Hydraulic Schematic Parts List .......................................................................................................................7

3.6 Electrical Component Parts List .....................................................................................................................8

3.7a Platform Control Console Diagram (Toggle Switch) ....................................................................................11

3.7b Platform Control Console Diagram (Rotary Switch).....................................................................................12

3.8 Base Control Console Diagram ....................................................................................................................13

3.9 Scissor Arm Control Cable ...........................................................................................................................14

3.10 Electrical Inverter Schematic & Panel Diagram (ANSI/CSA - Equipped with timer cutout relay) ................15

Diagrams and Schematics

3.11 Hydraulic Schematic (Model 3215) ..............................................................................................................17

3.12 Hydraulic Schematic (Model 3219) ..............................................................................................................18

3.13 Main Manifold Harness and Holding Valve Harness (ANSI/CSA) ................................................................19

3.14 Main Manifold Harness and Holding Valve Harness (CE) ...........................................................................20

3.15 Electrical Panel Diagram (ANSI/CSA) ..........................................................................................................21

3.16 Electrical Panel Diagram (CE) ......................................................................................................................22

3.17 Electrical Panel Diagram (ANSI/CSA EE Rated) ..........................................................................................23

3.18 Limit Swtich Assemblies Diagram ................................................................................................................24

3.19 Horn/Tilt Switch/Flashing Light Diagram ......................................................................................................25

3.20 Control Module and Beeper Diagram (CE) ..................................................................................................26

3.21a Electrical Schematic (ANSI/CSA - equipped with no options) .....................................................................27

3.21b Electrical Schematic (ANSI/CSA - equipped with no options) .....................................................................28

3.22a Electrical Schematic [ANSI/CSA & EE Rated - equipped with all options] .................................................29

3.22b Electrical Schematic (ANSI/CSA - equipped with all options) ....................................................................30

3.23 Electrical Schematic (CE - equipped with all options) .................................................................................31

3.24a Electrical Schematic (ANSI/CSA EE Rated - equipped with no options) ....................................................32

3.24b Electrical Schematic (ANSI/CSA EE Rated - equipped with no options) ....................................................33

3.25b Electrical Schematic (ANSI/CSA EE Rated - equipped with all options) .....................................................34

143909

SKYJACK, Page 1SJIII Compact Series

Page 48

Section 3 - System Component Identification and SchematicsService and Maintenance

HOURMETER

LIGHT

HYDRAULIC VALVE COIL

PROPORTIONAL HYDRAULIC VALVE COIL

ELECTRIC MOTOR

HORN

EMERGENCY STOP BUTTON

RESISTOR

LEVEL SENSOR

DOUBLE POLE SINGLE THROW RELAY

DIODE

CIRCUITS CROSSING NO CONNECTION

CIRCUITS CONNECTED

BATTERY

FUSE

GROUND

CIRCUIT BREAKER

VOLT METER

CAPACITOR

POTENTIOMETER

SINGLE POLE DOUBLE THROW RELAY

TRIPLE POLE DOUBLE THROW RELAY

RELAY

DOUBLE POLE DOUBLE THROW

SINGLE POLE SINGLE THROWN

TILT SWITCH

CAM OPERATED LIMIT SWITCH

LIMIT SWITCH

ROTARY SWITCH

PUSH BUTTON

TOGGLE SWITCH

FOOT SWITCH

KEY SWITCH

TEMPERATURE SWITCH

LIMIT SWITCH

CLOSED

LIMIT SWITCH

SILICON CONTROLLED RECTIFIER

PROXIMITY SWITCH

PNP TRANSISTOR

NPN TRANSISTOR

VACUUM SWITCH

RHEOSTAT

3.1 Electrical Symbol Chart

143909

SKYJACK, Page 3SJIII Compact Series

Page 49

LINE CROSSING

VARIABLE DISPLACEMENT PUMP

SHUTTLE VALVE VELOCITY FUSE

HAND PUMPLINE JOINED

ACCUMULATOR, GAS CHARGED

SINGLE ACTING CYLINDER

RELIEF VALVE

HYDRAULIC

TANK

CUSHION CYLINDER

DOUBLE ACTING CYLINDER

PRESSURE REDUCING VALVE

HYDRAULIC FILTER WITH BYPASS

PRESSURE SWITCH

DOUBLE ACTING DOUBLE RODDED

FIXED ORIFICE

ELECTRIC MOTOR

MOTION CONTROL VALVE

SPRING APPLIED HYDRAULIC RELEASED BRAKE

ADJUSTABLE FLOW CONTROL

ENGINE

FLOW DIVIDER COMBINER

BRAKE CYLINDER

CYLINDER

CHECK VALVE

FIXED DISPLACEMENT PUMP

COUNTER BALANCE VALVE

ROTARY ACTUATOR

OIL COOLER

THREE POSITION FOUR WAY PROPORTIONAL

VALVE COIL

BI DIRECTIONAL HYDRAULIC MOTOR

TWO POSITION TWO WAY NORMALLY CLOSED VALVE

SERIES PARALLEL HYDRAULIC MOTOR

TWO POSITION

THREE WAY VALVE

THREE POSITION FOUR WAY CLOSED CENTER OPEN PORT

TWO POSITION THREE WAY VALVE

TWO POSITION TWO WAY NORMALLY OPEN VALVE

THREE POSITION FOUR WAY CLOSED CENTER CLOSED PORT

THREE POSITION FOUR WAY PROPORTIONAL

PRESSURE TRANSDUCER

MAIN LINES Solid

PILOT LINES Dashed

SERVO

VARIABLE DISPLACEMENT HYDRAULIC MOTOR

Service and MaintenanceSection 3 - System Component Identification and Schematics

3.2 Hydraulic Symbol Chart

SKYJACK, Page 4 SJIII Compact Series

143909

Page 50

Section 3 - System Component Identification and SchematicsService and Maintenance

3.3 Wire Number and Color Code

WIRE

NO.

00 WHT 20 ORG/BLU 44 YEL/WHT 67 ORG/BRN 92 GRN SHLD

000 WHT 21 WHT/RED 45 YEL/ORG 68 GREY 93 BLK SHLD

B1 BLU/PINK 23 BLK/WHT 46 RED/BLK 69 WHT/GRN 95 YEL/GREY

01 PUR/BLK 24 BLU/BLK 47 PUR/ORG 70 ORG/PINK 96 WHT/GREY

02 WHT 25 BRN/BLK 48

03 GRN/PUR 26 BLU/YEL 49 GRN/RED 72 RED/BRN 98 RED SHLD

04 RED/YEL 27 RED/BLK/WHT 50 BRN 73 RED/PINK 98A BLK SHLD

05 PUR 28 GRN 51 BLK/GRN 74

06 29 GREY/ORG 52 GRN/BLU 75 GREY/PUR 103 BLK/PUR

07 RED 30 RED/GRN 53 BRN/RED 76 BRN/BLU 104 GRN/ORG

08 PUR/WHT 31 RED/WHT 54 PUR/RED 77 BRN/GREY 105 GRN/BRN

09 YEL 32 GRN/BLK 55 YEL/PUR 78 RED/BLU 106 GRN/PINK

WIRE

COLOR

WIRE

NO.

WIRE COLOR

WIRE

NO.

WIRE COLOR

YEL/GREY

WIRE

NO.

WIRE COLOR

71 RED/ORG 97 ORG/GREY

GRN/ GREY

WIRE

NO.

99 BLK/GREY

WIRE

COLOR

10 BLU/WHT 33 GRN/WHT 56 YEL/BLK 79 BRN/PUR 107 BLK/BLU

11 WHT/ORG 34 ORG/BLK 57 BRN/GRN 80

13 ORG 36 RED/PUR 59 YEL/BLU 82 BRN/WHT 110A BLU

14 BLK 37

15 BLU 38 ORG/RED 61 GREY/BRN 84

16 WHT/BLK 39 BLK/RED 62 GREY/RED 85 GREY/BLU 112 BLU/ORG

17 BLU/GRN 40 BLU/RED 63 GREY/YEL 86/87 PUR/BLU 113 BLU/BRN

18 GRN/BLU 41 BLU/PUR 64 WHT/BRN 88 BLK/ORG 114 YEL/RED

19 ORG/GRN 42 PINK 65 YEL/PINK 90 RED/GREY 115 WHT/PUR

22 PUR/GRN 43 WHT/YEL 66 ORG/YEL 91 RED SHLD 118 PUR/PINK

RED/YEL/

BLK

35 ORG/WHT 58 WHT/PUR 81 GREY/BLK 109 GRN/YEL

WHT/RED/

BLK

60 WHT/BLU 83 BLU/GREY 110B BRN

GREY/ WHT

WHT/BLK/ PUR

108 YEL/BRN

111 GREY/GRN

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.

143909

SKYJACK, Page 5SJIII Compact Series

Page 51

To Left Wheel Motor

Upper Port

To Left Wheel Motor

Lower Port

To Main Manifold

3.4 Hydraulic Manifold and Port Identifications

MB2 Drive Manifold Block

2H-59

Proportional Valve

(Internal Compensator Valve)

MB2

Proportional

Manifold Block

To Main Manifold

To Right Wheel Motor Upper Port

To Right Wheel Motor Lower Port

To Drive

Service and MaintenanceSection 3 - System Component Identification and Schematics

To Main Manifold

To Pump

Deceleration Manifold

2H-13A (ANSI/CSA)

2H-13C (CE)

Deceleration Valve

2H-13 (ANSI/CSA)

2H-13B (CE)

Lowering Valve

4H-16

Forward Drive Valve

4H-15

Reverse Drive Valve

4H-24

Left Steering Valve

4h-23

Right Steering Valve

To Return Filter

To Drive

To Left Steering

MB10

(Model 3215)

To Cushion Manifold

To Lift Cylinder

To Right Steering

R2 Lift Relief Valve

MB5 Emergency Lowering Manifold Block

3H-14 Lift Valve

CB1 Counterbalance Valve

2H-25 Cushion Valve

3H-17 Brake Valve

System Relief Valve

To Proportional Valve

M10414AA M10561AC_1 M10589AA

SKYJACK, Page 6 SJIII Compact Series

143909

Page 52

Section 3 - System Component Identification and SchematicsService and Maintenance

3.5 Hydraulic Schematic Parts List AC

Index

No.

Skyjack Part No.

Qty. Description

2H-13 103655 1 VALVE, Control (Lowering) (ANSI/CSA) 2H-13B 103655 1 VALVE, Control (Lowering) (CE) 2H-13A 134822 1 VALVE, Control (Deceleration) (Model 3215 ANSI/CSA) 2H-13C 134822 1 VALVE, Control (Deceleration) (Model 3215 CE) 2H-13-1 107629 1 VALVE, Control (Holding) (ANSI/CSA) 2H-13B-1 107629 1 VALVE, Control (Holding) (CE) 2H-25 128113 1 VALVE, Control (Cushion) 2H-59B 132749 1 VALVE, Control (Proportional) 3H-14 106273 1 VALVE, Control (Lift) 3H-17 103623 1 VALVE, Control (Brake) 4H-15 153334 1 VALVE, Control (Reverse drive) (Hytos) (includes 4H-16) 128317 1 VALVE, Control (Reverse drive) (Hytos) (includes 4H-16) (If equipped) 4H-16 - 1 VALVE, Control (Forward drive) (Hytos) 4H-23 153334 1 VALVE, Control (Right steer) (Hytos) (includes 4H-24) 128317 1 VALVE, Control (Right steer) (Hytos) (includes 4H-24) (If equipped) 4H-24 - 1 VALVE, Control (Left steer) (Hytos) C2 130709 1 CYLINDER (Lift) C3 121087 1 CYLINDER (Steer) C4 127667 1 CYLINDER (Brake) CB1 147888 1 VALVE, Counterbalance (2750 psi) F1 109568 1 FILTER, Return MI 139412 1 MOTOR, Hydraulic drive (White Hydraulics) M2 139412 1 MOTOR, Hydraulic drive (White Hydraulics) MB1 127629 1 BLOCK, Manifold (Main) MB2 139307 1 BLOCK, Manifold (Drive) MB3 128113 1 BLOCK, Manifold (Cushion valve) MB4 130480 1 BLOCK, Manifold (Holding valve) MB5 126761 1 BLOCK, Manifold (Lowering valve) MB9 132748 1 BLOCK, Manifold (Proportional control) MB10 136419 1 BLOCK, Manifold (Deceleration valve) (Model 3215) O2 130046 1 ORIFICE (0.063” diameter) (Lowering) (Model 3219) O3 108002 1 ORIFICE (0.040” diameter) (Cushion) O4 130407 1 ORIFICE (0.051” diameter) (Brake) O5 108002 2 ORIFICE (0.04” diameter) (Steering) O6 105281 1 ORIFICE (0.067” diameter) (Emergency Lowering) O7 147656 1 ORIFICE (0.024” diameter) (Drive) P1 147661 1 PUMP, Hydraulic PT1 134431 1 TRANSDUCER, Pressure (2000 psi) (Model 3215) 134432 1 TRANSDUCER, Pressure (3000 psi) (Model 3219) R1 104534 1 VALVE, Relief (System) R2 104534 1 VALVE, Relief (Lift) V1 107271 1 VALVE (Emergency lowering)

V2 103136 1 VALVE (Free-wheeling)

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3.6 Electrical Component Parts List

SUPPLY (B+) (Common)

Index

No.

CONTROL (B+)

Skyjack Part No.

NORMALLY

CLOSED

CONTACT

Qty. Description

NORMALLY

OPEN

CONTACT

GROUND (B-)

17CCR 108589 1 RELAY, 24 Volt (Cushion) 17CR 108589 1 RELAY, 24 Volt (Steer) 17CR1 108589 1 RELAY, 24 Volt (Transfer) 21ACR 108589 1 RELAY, 24 Volt (Proportional) 28CR 108589 1 RELAY, 24 Volt (Tilt switch) (ANSI/CSA) 28CR1 108589 1 RELAY, 24 Volt (TIlt switch) (CE) 28CR2 108589 1 RELAY, 24 Volt (Down) (CE) 28ECR1 108589 1 RELAY, 24 Volt (Auxillary tilt) (CE) 28ECR2 108589 1 RELAY, 24 Volt (Auxillary down) (CE) L1CR 127154 1 RELAY, 12 Volt (Charger cutout)

2H-13 103605 1 COIL, 24 Volt (Lowering valve) (ANSI/CSA) 2H-13B 103605 1 COIL, 24 Volt (Lowering valve) (CE) 2H-13A 137006 1 COIL, 24 Volt (Deceleration valve) (Model 3215 ANSI/CSA) 2H-13C 137006 1 COIL, 24 Volt (Deceleration valve) (Model 3215 CE) 2H-13-1 104493 1 COIL, 24 Volt (Holding valve) (ANSI/CSA) 2H-13B-1 104493 1 COIL, 24 Volt (Holding valve) (CE) 2H-25 103605 1 COIL, 24 Volt (Cushion) 2H-59 115370 1 COIL, 24 Volt (Proportional valve) 3H-14 106273 1 COIL, 24 Volt (Lift valve) 3H-17 103623 1 COIL, 24 Volt (Brake valve) 4H-15 153335 1 COIL, 24 Volt (Reverse drive spool valve) (Hytos) 128320 1 COIL, 24 Volt (Reverse drive spool valve) (Hytos) (If equipped) 4H-16 153335 1 COIL, 24 Volt (Forward drive spool valve) (Hytos) 128320 1 COIL, 24 Volt (Forward drive spool valve) (Hytos) (If equipped)

Parts list continued on the following page.

SKYJACK, Page 8 SJIII Compact Series

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Section 3 - System Component Identification and SchematicsService and Maintenance

3.6 Electrical Component Parts List AC

Index

No.

Skyjack Part No.

Qty. Description

Parts list continued from the following page.

4H-23 153335 1 COIL, 24 Volt (Right steer spool valve) (Hytos) 128320 1 COIL, 24 Volt (Right steer spool valve) (Hytos) (If equipped) 4H-24 153335 1 COIL, 24 Volt (Left steer spool valve) (Hytos) 128320 1 COIL, 24 Volt (Left steer spool valve) (Hytos) (If equipped) B1-B4 $ 4 BATTERY, 6 Volt (Trojan #T2200) AT1 130440 1 TRANSDUCER, Angle (CE) BC 128537 1 CHARGER, Battery (24 Volt) BCI 122093 1 BATTERY CHARGE INDICATOR BP-29 103057 1 BEEPER (28 Volt) (ANSI/CSA) BP-29 117967 1 BEEPER (28 Volt) (CE) C1 146475 1 CONTACTOR, Motor (24 Volt) CAP1 103319 1 CAPACITOR (1000 uF, 35 Volt) CAP2 110699 1 CAPACITOR (0.47 uF, 50 Volt) (ANSI/CSA) CB1 117325 1 CIRCUIT BREAKER, 15 Amp CB2 117325 1 CIRCUIT BREAKER, 15 Amp CM1 130439 1 CONTROL MODULE, Integrated Sensor (CE) DCM1 147664 1 MOTOR, 24 Volt F1 310517 1 FUSE (300 Amp) FL-22 121477 1 FLASHING LIGHT 24VDC (superior universal) FL-29 103743 1 FLASHER (Option) (ANSI/CSA) H1 146649 1 HORN, Operator (Low tone) LED-1 147061 1 POWER INDICATOR LIGHT (Platform control console) LED-2 147061 1 POWER INDICATOR LIGHT (Base control console) LS1A 121975 1 LIMIT SWITCH (High speed) LS1B 121975 1 LIMIT SWITCH (High speed) (ANSI/CSA) LS4 139228 1 LIMIT SWITCH (Pothole protection) (Battery tray) LS5 139227 1 LIMIT SWITCH (Pothole protection) (Hydraulic tray) LS6 121975 1 LIMIT SWITCH (Drive override) LS7 121975 1 LIMIT SWITCH (Deceleration) PT1 134431 1 TRANSDUCER, Pressure (2000 psi) (Model 3215 CE) 134432 1 TRANSDUCER, Pressure (3000 psi) (Model 3219 CE) RST1 119629 1 RESISTOR (2.7K ohm) RST2 147335 1 RESISTOR (16 ohm, 25W) RST3 116505 1 RESISTOR, Low voltage protection S1 119725 1 SWITCH, Main power disconnect S2 147054 2 N.O. CONTACT (Raise/Lower) S3 147053 3 N.C. CONTACT (Lift/Drive) 147054 3 N.O. CONTACT (Lift/Drive) (without powered extension platform) 4 N.O. CONTACT (Lift/Drive) (with powered extension platform)

Parts list continued on the following page.

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Service and MaintenanceSection 3 - System Component Identification and Schematics

3.6 Electrical Component Parts List (Continued)

Index

No.

Skyjack Part No.

Qty. Description

Parts list continued from the following page.

S4 147053 2 N.C. CONTACT (Emergency stop) (Platform control console)

S7 123994 1 CONTROLLER ASSEMBLY, Proportional

S7-1 122869 1 SWITCH, Neutral

S7-2 122877 1 SWITCH, Right steer

S7-3 122877 1 SWITCH, Left steer

S7-6 122872 1 SWITCH, Enable pushbutton

S8 147054 1 N.O. CONTACT (Horn)

S10 147053 2 N.C. CONTACT (Off/Platform)

147054 1 N.O. CONTACT (Base)

S28 147053 1 N.C. CONTACT (Emergency stop) (Base control console) TS1 146658 1 TILT SWITCH TT 103336 1 HOURMETER

$ - Purchase locally.

SKYJACK, Page 10 SJIII Compact Series

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Section 3 - System Component Identification and SchematicsService and Maintenance

9 PIN CONNECTOR SUB-ASSEMBLY

BLUE BLACK (24)

RED WHITE (60/7A) BLACK WHITE (23)

GREEN BLACK (21B) (OPT) ORANGE BLACK (59)

WHITE BLACK (16)

MALE

CRD1

RED BLACK (18)

(NOT USED)

BACK VIEW

7 6

(13) ORANGE

(14) BLACK

(07) RED

(8C) BLUE WHITE

(49) GREEN WHITE

(7A) GREEN

(02) WHITE

(15) BLUE

15 14

21B GREEN/BLACK - TIED BACK

S8 - HORN

60/7A

S4 - EMERGENCY STOP

LED-1

12B

18 8A

S3 - LIFT/OFF/DRIVE

RST1

PIN # - FUNCTION PIN 1 - LEFT PIN 2 - STEERING VS+ PIN 3 - RIGHT PIN 4 - FWD/UP PIN 5 - JOYSTICK VS+ PIN 6 - REV/DOWN PIN 7 - PWM PIN 8 - GND PIN 9 - ENABLE VS+

CTRL BOX HARNESS 24 BLUE/BLACK 12B BROWN/RED 23 BLACK/WHITE B RED 08 BLUE A PURPLE/WHITE 59 ORANGE/BLACK 02 WHITE 8A BLUE

JOYSTICK HARNESS WHITE/RED WHITE/GREEN WHITE YELLOW WHITE/BLACK GREY BLUE BLACK WHITE/ BLUE

CTRL BOX

JOYSTICK HARNESS

HARNESS

S27 - TORQUE

12B

3.7a Platform Control Console Diagram (Toggle Switch)

Serial Breakdown

Reference Chart

Model Serial Number

SJ3 3215 10000611 & above

SJ3 3219 22020985 & above

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Service and MaintenanceSection 3 - System Component Identification and Schematics

D15

D16

9 PIN CONNECTOR SUB-ASSEMBLY

BLUE BLACK (24)

RED WHITE (60/7A) BLACK WHITE (23)

GREEN BLACK (21B) (OPT) ORANGE BLACK (59)

WHITE BLACK (16)

MALE

CRD1

RED BLACK (18)

(NOT USED)

BACK VIEW

7 6

(13) ORANGE

(14) BLACK

(07) RED

(8C) BLUE WHITE

(49) GREEN WHITE

(7A) GREEN

(02) WHITE

(15) BLUE

2 10

15 14

21B GREEN/BLACK - TIED BACK

S8 - HORN

60/7A

08 08

S4 - EMERGENCY STOP

LED-1

S3 - LIFT/DRIVE SELECTOR

TOP SECTION

12B

S3 - LIFT/DRIVE SELECTOR

BOTTOM SECTION

S3 - LIFT/DRIVE SELECTOR

MIDDLE SECTION

RST1

PIN # - FUNCTION PIN 1 - LEFT PIN 2 - STEERING VS+ PIN 3 - RIGHT PIN 4 - FWD/UP PIN 5 - JOYSTICK VS+ PIN 6 - REV/DOWN PIN 7 - PWM PIN 8 - GND PIN 9 - ENABLE VS+

CTRL BOX HARNESS 24 BLUE/BLACK 12B BROWN/RED 23 BLACK/WHITE B RED 08 BLUE A PURPLE/WHITE 59 ORANGE/BLACK 02 WHITE 8A BLUE

JOYSTICK HARNESS WHITE/RED WHITE/GREEN WHITE YELLOW WHITE/BLACK GREY BLUE BLACK WHITE/ BLUE

CTRL BOX

JOYSTICK HARNESS

HARNESS

Serial Breakdown

Reference Chart

Model Serial Number

SJ3 3215 10000610 & below

SJ3 3219 22020984 & below

3.7b Platform Control Console Diagram (Rotary Switch)

M146621AB

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3.8 Base Control Console Diagram

S28 - EMERGENCY STOP N.C. CONTACT

PIN 1 - 5A PURPLE/WHITE PIN 2 - 05 ORANGE/BLACK

S2 - UP SWITCH

N.O. CONTACT

PIN 3 - 10E BLUE/BLACK (X2)

PIN 4 - 14E BLACK

S10 - BASE SW N.O. CONTACT

PIN 3 - 10E BLUE/BLACK (X2)

PIN 4 - 7A GREEN (X2)

S10 - IDLE SW N.C. CONTACT

PIN 1 - 5A PURPLE/WHITE PIN 2 - 07 RED

S2 - DOWN SWITCH N.O. CONTACT

PIN 3 - 10E BLUE/BLACK PIN 4 - 13 ORANGE

S10 - PLTF SW

N.C. CONTACT

PIN 1 - 8C BLUE/WHITE

PIN 2 - 07 RED (X2)

LED 2 - POWER ON/LSS LIGHT

PIN X1 - 7A GREEN

PIN X2 - 02 WHITE

DEUTSCH

4 5

BACK VIEW

2 3

1 8

7 6

PIN 5 - 10E (BLUE/BLACK) PIN 6 - 8C (BLUE/WHITE) PIN 7 - 7A (GREEN) PIN 8 - 02 (WHITE)

PIN 1 - 07 (RED) PIN 2 - 3A (BLUE)

PIN 4 - 14E (BLACK)

PIN 3 - 13 (ORANGE)

PIN 1 - 3A BLUE

TO CHARGER CUTOUT

PIN 2 - 05 ORANGE/BLACK

Section 3 - System Component Identification and SchematicsService and Maintenance

M149686AA_S3

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Page 59

FRONT VIEW BACK VIEW

FRONT VIEW TO ELECTRIC PANEL

CONTROL CABLE

TO PLATFORM CONTROL CONSOLE CONTROL CABLE

9 1

513

12 4

14 6

BACK VIEW

168

MALE

(7A) GREEN

(13) ORANGE

(02) WHITE

(15) BLUE

(14) BLACK

(07) RED

(8C) BLUE WHITE

(49) GREEN WHITE 7 15 BLACK WHITE (23)

BLUE BLACK (24)

RED BLACK (18)

ORANGE BLACK (59)

GREEN BLACK (OPT)

RED WHITE (OPT)

WHITE BLACK (16) (NOT USED)

FEMALE

GREEN (7A)

BLACK (14) ORANGE (13)

RED (07)

GREEN WHITE (49) BLUE WHITE (8C)

(OPT) RED WHITE (23) BLACK WHITE (24) BLUE BLACK

(59) ORANGE BLACK

(18) RED BLACK

(OPT) GREEN BLACK

WHITE (02)

BLUE (15)

2 1

(NOT USED)

(16) WHITE BLACK

EUROPE

WIRE NUMBER 21B

N.A

WIRE NUMBER 21B

CONTROL CABLE OPTIONS

WIRE COLOUR

GREEN/BLACK

RED/WHITE

3.9 Scissor Arm Control Cable

Service and MaintenanceSection 3 - System Component Identification and Schematics

SKYJACK, Page 14 SJIII Compact Series

M146650AB_S3

143909

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Section 3 - System Component Identification and SchematicsService and Maintenance

POWER ON LED

HORN

NCHO

10E

(IN IDLE POSITION)

IDLE/PLTF/BASE

KEY SWITCH

S10

POWER ON LIGHT

LED-2

STOP

SWITCH

S28

EMERGENCY

50A FUSE

PUMP MOTOR

INVERTER OPTION

24V

BASE

110 VAC

LINE VOLTAGE

F1 300A FUSE

24V CHARGER

L1CR

CHARGER

CUTOUT RELAY

S1 MAIN

DISCONNECT

B1 6V

BATTERY

B3 6V

BATTERY

B2 6V

BATTERY

NEGATIV

CHARGER

MOTOR

CONTACTOR

DCM1

BATTERY PACK

M 5

15A CIRCUIT

INVERTER OPTION

15A CIRCUIT

BREAKER

CB2

19A

TIMER

BREAKER

TIMER

0200

CB1

B4 6V

BATTERY

(UNAVAILABLE ON EE RATED MACHINES)

02 19A

PIN TRIG - 19A WHITE/RED

PIN LOAD - 85 VIOLET

PIN PWR - 7A RED

PIN COM - 02 WHITE

FROM INVERTER REMOTE SWITCH

TIMER RELAY

19A

3.10 Electrical Inverter Schematic & Panel Diagram (ANSI/CSA - Equipped with timer cutout relay)

Electrical Schematic

Electrical Panel

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MM147370AD1 M149724AA

Page 61

3.11 Hydraulic Schematic (Model 3215)

ORIFICE

F1 RETURN FILTER

PUMP

HYDRAULIC TANK

CYLINDER

C4 BRAKE

.051 DIA.

2H-25

VALVE

CUSHION

PROPORTIONAL

BLOCK

MANIFOLD

COMPENSATED PROPORTIONAL

PRESSURE-

2H-59

VALVE

MB9

HYDRAULIC

DISCONNECT

QUICK

CB1

VALVE

COUNTERBALANCE

RELIEF

SYSTEM

VALVE

O4 BRAKE

PORT PLUGGED

3H-17 BRAKE

4H-16

DRIVE VALVE

FORWARD

4H-15 REVERSE

VALVE

DRIVE

MB3

ORIFICE

CUSHION

.040 DIA.

CUSHION

BLOCK

VALVE

V1 EMERGENCY LOWERING VALVE

MB5

BLOCK

VALVE

LOWERING

BLOCK

MANIFOLD

VALVE

DECELERATION

PT1 PRESSURE OVERLOAD TRANSDUCER OPTION

MB4

MANIFOLD

VALVE

BLOCK

HOLDING

4H-24

VALVE

STEER

LEFT

4H-23 RIGHT

VALVE

STEER

MAIN MANIFOLD BLOCK

LIFT VALVE

MB1

3H-14

2H-13B (CE)

2H-13 (ANSI/CSA)

VALVE

LOWERING

MB10

O5 STEERING ORIFICE .040 DIA.

STEER CYLINDER

DECELERATION VALVE

RELIEF VALVE

LIFT

HOLDING VALVE

2H-13-1 (ANSI/CSA) 2H-13B-1 (CE)

2H-13C (CE)

2H-13A (ANSI/CSA)

ORIFICE .040 DIA.

O6 EMER. LOWERING

LIFT

ORFICE .067 DIA.

CYLINDER

OPTIONAL PRESSURE SWITCH

LEFT DRIVE MOTOR

MOTOR

RIGHT DRIVE

MANIFOLD BLOCK

VALVE

FREE-WHEELING

FRONT AXLE

MB2

O7 DRIVE ORIFICE .024 DIA.

A B C D E F G H

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Page 62

3.12 Hydraulic Schematic (Model 3219)

BLOCK

MANIFOLD

MB9 PROPORTIONAL

DRIVE

STEER

ORIFICE

CUSHION

.040 DIA.

CYLINDER

C4 BRAKE

HYDRAULIC TANK

P1 PUMP

FILTER

RETURN

QUICK DISCONNECT

HYDRAULIC

SYSTEM

VALVE

RELIEF

PORT PLUGGED

O4 BRAKE

.051 DIA.

ORIFICE

2H-25 CUSHION VALVE

VALVE

COUNTERBALANCE

CB1

VALVE

3H-17 BRAKE

4H-15

DRIVE VALVE

REVERSE

VALVE

2H-13 (ANSI/CSA) 2H-13B (CE)

LOWERING

CUSHION VALVE

MB3

BLOCK

MAIN MANIFOLD BLOCK

VALVE

STEER

4H-24 LEFT

VALVE

.063 DIA. (3219 ONLY)

ORIFICE

O2 LOWERING

MB1

VALVE

LIFT

3H-14

VALVE

LOWERING VALVE

VALVE

LOWERING

EMERGENCY

MB5

BLOCK

RELIEF VALVE

LIFT

LEFT DRIVE MOTOR

MOTOR

RIGHT DRIVE

VALVE

MANIFOLD

4H-16 FORWARD

BLOCK

FREE-WHEELING

FRONT AXLE

MB2

MANIFOLD BLOCK

VALVE

MB4 HOLDING

O5O5

ORIFICE .040 DIA.

STEERING

4H-23 RIGHT

ORIFICE .040 DIA.

STEERING

STEER

CYLINDER

O6 EMER. LOWERING ORFICE .067 DIA.

2H-13-1 (ANSI/CSA) 2H-13B-1 (CE)

VALVE

HOLDING

LIFT CYLINDER

O7 DRIVE ORIFICE .024 DIA.

PRESSURE-

PROPORTIONAL

COMPENSATED

2H-59

VALVE

PT1 PRESSURE OVERLOAD TRANSDUCER OPTION

A B C D E F G H

SKYJACK, Page 18

M138023AA

SJIII Compact Series

143909

Page 63

02 - WHITE

13 - BLACK

TO MAIN MANIFOLD HARNESS

PIN 2 - WHITE

PIN 1 - BLACK

TO HOLDING VALVE

HOLDING VALVE

SJ3E 3219

13 - ORANGE (18 AWG)

02 - WHITE (18 AWG)

LOWERING VALVE 13 - ORANGE 02 - WHITE

FORWARD VALVE BLACK HEIRSHMAN

PIN 1 - 16 WHITE/BLACK PIN 2 - 02 WHITE

REVERSE VALVE GREY HEIRSHMAN PIN 1 - 15 BLUE PIN 2 - 02 WHITE

INSERT ORIENTATION

BOTTOM VIEW

RIGHT STEER VALVE BLACK HEIRSHMAN

PIN 1 - 23 BLACK/WHITE PIN 2 - 02 WHITE

LEFT STEER VALVE GREY HEIRSHMAN

PIN 1 - 24 BLUE/BLACK PIN 2 - 02 WHITE

TO ELECTRIC PANEL - 12 WIRES

00 - WHITE (14 AWG) 02 - WHITE 13 - ORANGE 13A- ORANGE (3215 ONLY) 14 - BLACK 15 - BLUE

16 - WHITE/BLACK 17 - BLUE/RED 23 - BLACK/WHITE 24 - BLUE/BLACK 25 - ORANGE/GREEN 59 - ORANGE/BLACK

PROPORTIONAL VALVE 59 - ORANGE/BLACK

02 - WHITE

BRAKE VALVE

17 - BLUE/RED

02 - WHITE

HOLDING VALVE 13 - ORANGE (18 AWG) 02 - WHITE (18 AWG)

SPLICE #1

SPLICE #2

LIFT VALVE

14 - BLACK

02 - WHITE

SOFT STOP VALVE 13A - ORANGE 02 - WHITE

14A

CUSHION VALVE

25 - ORANGE/GREEN

02 - WHITE

GREY

BLACK

LOWERING VALVE 13 - ORANGE 02 - WHITE

13A

FORWARD

RIGHT

MOTOR (-)

00 - WHITE

(14 AWG)

LEFT

24 02

REVERSE

SJ3E 3215

3.13 Main Manifold Harness and Holding Valve Harness (ANSI/CSA)

A B C D E F G H

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Page 64

3.14 Main Manifold Harness and Holding Valve Harness (CE)

13B - BLACK

TO MAIN MANIFOLD HARNESS

02 - WHITE

PIN 2 - WHITE

PIN 1 - BLACK

TO HOLDING VALVE

13B

HOLDING VALVE

SJ3E 3219

SJ3E 3215

13B - ORANGE (18 AWG) 02 - WHITE (18 AWG)

13B

LOWERING VALVE 13B - ORANGE 02 - WHITE

MOTOR (-)

00 - GREEN/YELLOW

(14 AWG)

13B

RIGHT

FORWARD VALVE BLACK HEIRSHMAN

PIN 1 - 16 WHITE/BLACK PIN 2 - 02 WHITE

REVERSE VALVE GREY HEIRSHMAN PIN 1 - 15 BLUE PIN 2 - 02 WHITE

0215

GREY

REVERSE

BLACK

GREY

LEFT

02 23

INSERT ORIENTATION

BOTTOM VIEW

FORWARD

13C

LOWERING VALVE 13B - ORANGE 02 - WHITE

SOFT STOP VALVE 13C - ORANGE 02 - WHITE

PROPORTIONAL VALVE 59 - ORANGE/BLACK

02 - WHITE

LIFT VALVE 14 - BLACK 02 - WHITE

SPLICE #1

BRAKE VALVE

17 - BLUE/RED

02 - WHITE

CUSHION VALVE 25 - ORANGE/GREEN

02 - WHITE

13B

HOLDING VALVE 13B - ORANGE (18 AWG) 02 - WHITE (18 AWG)

SPLICE #2

RIGHT STEER VALVE BLACK HEIRSHMAN

PIN 1 - 23 BLACK/WHITE PIN 2 - 02 WHITE

LEFT STEER VALVE GREY HEIRSHMAN

PIN 1 - 24 BLUE/BLACK PIN 2 - 02 WHITE

TO ELECTRIC PANEL - 12 WIRES 00 - GREEN/YELLOW (14 AWG) 02 - WHITE 13B - ORANGE 13C - ORANGE (3215 ONLY) 14 - BLACK 15 - BLUE

16 - WHITE/BLACK 17 - BLUE/RED 23 - BLACK/WHITE 24 - BLUE/BLACK 25 - ORANGE/GREEN 59 - ORANGE/BLACK

A B C D E F G H

SKYJACK, Page 20

M147332AA_S3

SJIII Compact Series

143909

Page 65

3.15 Electrical Panel Diagram (ANSI/CSA)

BACK VIEW

FEMALE

GREEN (7A)

BLACK (14) ORANGE (13)

RED (07)

GREEN WHITE (49) BLUE WHITE (8C)

(7A) RED WHITE (N/U)

(23) BLACK WHITE

(24) BLUE BLACK

(59) ORANGE BLACK

(18) RED BLACK (N/U)

(21B) GREEN BLACK (N/U)

WHITE (02)

BLUE (15)

EUROPE WIRE NUMBER 21B 60

N.A WIRE NUMBER 21B 7A

(NOT USED)

(16) WHITE BLACK

1092

FRONT VIEW

CONTROL CABLE OPTIONS

WIRE COLOUR GREEN/BLACK

RED/WHITE

PIN 6 - 13A (GREEN/WHITE) PIN 7 - 19 (ORANGE/BLACK)

PIN 6 - 8C (WHITE/BLACK) PIN 7 - 7A (GREEN) PIN 8 - 02 (WHITE)

PIN 5 - 10E (BLUE/WHITE)

PIN 5 - 13 (ORANGE)

DEUTSCH

2 43

DEUTSCH

3 42 1

7 5

66 578 8

BACK VIEW

PIN 1 - 07 (RED)

PIN 4 - 14E (BLACK)

PIN 3 - 13 (ORANGE)

PIN 2 - 3A (BLUE)

PIN 2 - 21 (GREEN/BLACK) PIN 3 - 19 (ORANGE/BLACK)

PIN 1 - 17A (BLUE/BLACK)

PIN 4 - 19A (RED/WHITE) PIN 8 - 71 (BLACK/WHITE)

19A

21ACR PROPORTIONAL RELAY

PIN 86 - 21A

PIN 30 - 59A PIN 85 - 02

PIN 87 - N/U PIN 87a - 59

59A

21A

28 22

TO HIGH SPEED LIMITS TO POTHOLE LIMIT TO SOFT STOP LIMIT SWITCH

TO CHARGER CUTOUT TO LOWER BASE CTRL

REAR HARNESS

PLATFORM CONTROL BOX

MAIN MANIFOLD

TILT SWITCH

HORN/FLASHING LIGHT

TO TILT SWITCH

PIN 2 - 28 (GREEN)

PIN 1 - 19 (BLACK)

PIN 3 - 02 (WHITE)

TO FLASHING LIGHT

22 - GREEN

02 - WHITE

02 - WHITE 49 - BLACK

TO HORN

PIN 4 - N/U

7A 8C

17CR STEER RELAY PIN 30 - 59D PIN 85 - 02 PIN 86 - 17 PIN 87 - N/U PIN 87a - 59

28CR

PIN 87a - 28A

TILT SWITCH RELAY PIN 30 - 19 PIN 85 - 02 PIN 86 - 28 PIN 87 - 19A

17CCR

PIN 30 - 17D

CUSHION RELAY

PIN 87a - N/U

PIN 87 - 25

PIN 86 - 17C

PIN 85 - 02

17CR1

PIN 30 - 7A

PIN 86 - 17 PIN 87 - 17C

PIN 85 - 02

PIN 87a - 17D

TRANSFER RELAY

22 AND 29 - TO FLASHER IF

EQUIPPED OTHERWISE TIE BACK

17D

17C

17D

17C

59D

28A

19A

17CR117CR28CR 21ACR 17CCR

07 - TO INVERTER

TIMER IF EQUIPPED

OTHERWISE TIE BACK

TO MAIN MANIFOLD

19A

19 - BLACK

HYDRAULIC TRAY 72 - BLACK/WHITE

BATTERY TRAY 72 - BLACK/WHITE 71 - BLACK

59A 02

1000 uF

0202 07 13 59

D14E

D14E-1

13A 14E

D14-1

D14

21 14 19

TO (+) AT MOTOR

TO MAIN DISCONNECT SWITCH

D15

D28A D13

72 1529

D17

D16

D17-1

17 17A16

D23-1

D23

D24-1

D24

59D

19A

D19A

YELLOW

BLUE

TO BATTERY

TO POWER DECK

TO END OF STROKE

TO TILT SWITCH

TO LOWER KEYSWITCH BOX

TO HIGH SPEED LIMIT SWITCH

SOLENOID CABLES

TO OUTRIGGER

TO REAR MANIFOLD

TO MAIN MANIFOLD

TO TERMINAL BLOCK

TO JOYSTICK BOX

TO ENGINE

LEGEND:

TO FLASHER

TO HORN/FLASHING LIGHT

A B C D E F G H

143909

M149649AA2

SKYJACK, Page 21SJIII Compact Series

Page 66

3.16 Electrical Panel Diagram (CE)

19B

13B25

59A

21A

HORN

02 - WHITE 49 - BLACK

HORN

PROPORTIONAL RELAY

PIN 86 - 21A

PIN 30 - 59A PIN 85 - 02

PIN 87 - N/U PIN 87a - 59

21ACR

TO (+) AT MOTOR

TO MAIN DISCONNECT SWITCH

13C13C

13B

MAIN MANIFOLD 00 - GREEN/YELLOW 02 - WHITE 13B - ORANGE 13C - ORANGE 14 - BLACK 15 - BLUE 16 - WHITE/BLACK 17 - BLUE/RED 23 - BLACK/WHITE 24 - BLUE/BLACK 25 - ORANGE/GREEN 59 - ORANGE/BLACK

CONTROL MODULE 02 - WHITE 7A - RED 10E - BLACK/WHITE 13 - ORANGE 14 - BLACK 15 - BLUE 16 - WHITE/BLACK 18B - RED/BLACK N/U - BLUE/BLACK N/U - ORANGE/BLACK

13B

13A

28E

17D

17C

17D

59D

19A

19B

19A

28E

17CR28ECR1 28CR1 17CR1 17CCR 28ECR2 28CR2

DOWN RELAY

PIN 85 - 02 PIN 86 - 28

PIN 30 - 13A

PIN 87a - N/U

PIN 87 - 13B

19B

PIN 30 - 13 PIN 85 - 02 PIN 86 - 28E

PIN 87a - N/U

PIN 87 - 13A

AUX. DOWN RELAY

D23-1 D24-1

D24

D17-1

D17

D23

17A 2371 24

59D

28CR217CCR17CR1 28ECR228CR1 17CR28ECR1 21ACR

1000 uF

D15 D16

7260 1615 17

D14-2

D14-1

D14E-1

2159 14 19 49

D14E

10E

18B130202 07 7A 14E

CUSHION RELAY

PIN 85 - 02 PIN 86 - 17C

PIN 30 - 17D

PIN 87a - N/U

PIN 87 - 25

PIN 87a - 17D

PIN 87 - 17C

PIN 86 - 17

TRANSFER RELAY

PIN 85 - 02

PIN 30 - 7A

TILT RELAY

PIN 85 - 02 PIN 86 - 28

PIN 30 - 19A

PIN 87 - 19B PIN 87a - N/U

PIN 86 - 28E

PIN 85 - 02

AUX. TILT RELAY PIN 30 - 19

PIN 87a - N/U

PIN 87 - 19A

PIN 85 - 02

STEER RELAY PIN 30 - 59D

PIN 86 - 17

PIN 87a - 59

PIN 87 - N/U

59A

CONTROL MODULE 28 - BLACK 28E - WHITE 60 - GREEN

72 - BLK/WHT 71 - BLACK

BATTERY TRAY

MAIN MANIFOLD

PLATFORM CONTROL BOX

CONTROL MODULE

REAR HARNESS

19 - BLACK

72 - BLK/WHT

TO MAIN MANIFOLD

HYDRAULIC TRAY

R R

YELLOW

BLUE

TO HIGH SPEED LIMITS TO POTHOLE LIMIT TO SOFT STOP LIMIT SWITCH

TO CHARGER CUTOUT TO LOWER BASE CTRL

PIN 3 - 13 (ORANGE) PIN 4 - 14E (BLACK)

PIN 1 - 07 (RED) PIN 2 - 3A (BLUE)

PIN 1 - 17A (BLUE/BLACK) PIN 2 - 21 (GREEN/BLACK)

DEUTSCH

PIN 3 - 13B (GREEN)

DEUTSCH

354

PIN 4 - 13C (GREEN/WHITE)

8 7

1 2

BACK VIEW

8 7

1 2

PIN 7 - 7A (RED/WHITE)

PIN 8 - 71 (BLACK/WHITE)

PIN 7 - 19 (ORANGE/BLACK)

PIN 6 - 18B (RED/BLACK)

PIN 8 - 02 (WHITE)

PIN 5 - 7A (RED/WHITE)

PIN 5 - 10E (BLUE/WHITE) PIN 6 - 8C (WHITE/BLACK)

BACK VIEW

FEMALE

GREEN (7A)

BLACK (14) ORANGE (13)

RED (07)

GREEN WHITE (49) BLUE WHITE (8C)

(60) RED WHITE

(23) BLACK WHITE

(24) BLUE BLACK

(59) ORANGE BLACK

(18) RED BLACK (N/U)

(21B) GREEN BLACK (N/U)

WHITE (02)

BLUE (15)

EUROPE WIRE NUMBER 21B 60

N.A WIRE NUMBER 21B 7A

(NOT USED)

(16) WHITE BLACK

921

FRONT VIEW

CONTROL CABLE OPTIONS

WIRE COLOUR GREEN/BLACK

RED/WHITE

TO BATTERY

TO POWER DECK

TO END OF STROKE

TO TILT SWITCH

TO LOWER KEYSWITCH BOX

TO HIGH SPEED LIMIT SWITCH

SOLENOID CABLES

TO OUTRIGGER

TO REAR MANIFOLD

TO MAIN MANIFOLD

TO TERMINAL BLOCK

TO JOYSTICK BOX

TO ENGINE

LEGEND:

TO FLASHER

TO HORN/FLASHING LIGHT

A B C D E F G H

SKYJACK, Page 22

M149689AA2

SJIII Compact Series

143909

Page 67

3.17 Electrical Panel Diagram (ANSI/CSA EE Rated)

BACK VIEW

FEMALE

GREEN (7A)

BLACK (14) ORANGE (13)

RED (07)

GREEN WHITE (49) BLUE WHITE (8C)

(7A) RED WHITE

(23) BLACK WHITE

(24) BLUE BLACK

(59) ORANGE BLACK

(18) RED BLACK

(N/U) GREEN BLACK

WHITE (02)

BLUE (15)

2 1

(NOT USED)

(16) WHITE BLACK

TO BATTERY

TO POWER DECK

TO END OF STROKE

TO TILT SWITCH

TO LOWER KEYSWITCH BOX

TO HIGH SPEED LIMIT SWITCH

SOLENOID CABLES

TO OUTRIGGER

TO REAR MANIFOLD

TO MAIN MANIFOLD

TO TERMINAL BLOCK

TO JOYSTICK BOX

TO ENGINE

LEGEND:

TO FLASHER

BEEPER

TO BATTERIES

TO MOTOR

PIN 87a - 17D

PIN 87 - 17C

PIN 86 - 17

PIN 85 - 02

PIN 30 - 7A

TRANSFER RELAY

PIN 85 - 02 PIN 86 - 17C

PIN 30 - 17D

CUSHION RELAY

PIN 87 - 25 PIN 87a - N/U

PIN 86 - 17

PIN 85 - 02

PIN 30 - 59D

STEER RELAY

PIN 87a - 59

PIN 87 - N/U

PIN 86 - 28

PIN 85 - 02

PIN 30 - 19

PIN 87 - 19A PIN 87a - 28A

TILT SWITCH RELAY

1000 uF

PROPORTIONAL RELAY

PIN 86 - 21A

PIN 85 - 02

PIN 30 - 59A

PIN 87a - 59

PIN 87 - N/U

19A

D24

D23-1

23 24

D24-1

D17

17A

D17-1

D23

D28A

D15

72 15

D14-1

D14

19 19A14

D19A

D16

REAR HARNESS

14E 59

D14E-1

0702 13

D13

PLATFORM CONTROL BOX

MAIN MANIFOLD

REAR HARNESS

MAIN DISCONNECT

PLATFORM CONTROL BOX

MAIN MANIFOLD HARNESS WITH HOLDING VALVES

28CR 17CR 21ACR

17CR1 17CCR

28A

19A

28CR 17CR 21ACR 17CR1 17CCR

59D

21A

59A

17C

17D

17C

17D

19A

8C7A

TILT SWITCH

HORN/FLASHING LIGHT

TO CHARGER CUTOUT TO LOWER BASE CTRL

TO HIGH SPEED LIMITS TO POTHOLE LIMIT TO SOFT STOP LIMIT SWITCH

BLUE

YELLOW

72 - BLACK/WHITE

HYDRAULIC TRAY

19 - BLACK

71 - BLACK

72 - BLACK/WHITE

BATTERY TRAY

22 02

TO HORN/FLASHING LIGHT

TO TILT SWITCH PIN 1 - 19 (BLACK) PIN 2 - 28 (GREEN) PIN 3 - 02 (WHITE) PIN 4 - N/U

TO FLASHING LIGHT 02 - WHITE 22 - GREEN

TO HORN 02 - WHITE 49 - BLACK

D14E

13A

59A

PIN 6 - 13A (GREEN/WHITE) PIN 7 - 19 (ORANGE/BLACK)

PIN 6 - 8C (WHITE/BLACK) PIN 7 - 7A (GREEN) PIN 8 - 02 (WHITE)

PIN 5 - N/U

PIN 5 - 13 (ORANGE)

DEUTSCH

2 4

DEUTSCH

3 42 1

7566 578 8

BACK VIEW

PIN 1 - 07 (RED)

PIN 4 - 14E (BLACK)

PIN 3 - 13 (ORANGE)

PIN 2 - 3A (BLUE)

PIN 2 - 21 (GREEN/BLACK) PIN 3 - 19 (ORANGE/BLACK)

PIN 1 - 17A (BLUE/BLACK)

PIN 4 - 19A (RED/WHITE) PIN 8 - 71 (BLACK/WHITE)

EUROPE WIRE NUMBER 21B 60

N.A WIRE NUMBER 21B 7A

CONTROL CABLE OPTIONS

WIRE COLOUR GREEN/BLACK

RED/WHITE

A B C D E F G H

143909

M147957AA

SKYJACK, Page 23SJIII Compact Series

Page 68

ANSI/CSA - Model 3219

7 6

PIN 6 - N/U PIN 7 - 19 (BLACK)

PIN 5 - N/U

PIN 4 - 19A (BLACK/WHITE)

PIN 2 - 21 (BLACK/WHITE) PIN 3 - 19 (BLACK)

PIN 1 - 17A (BLACK)

2 3

DEUTSCH

17A

PIN 8 - 71 (BLACK/WHITE)

BLUE

BLACK

BLUE

BROWN

BLACK/WHITE

19A

BLACK

BLUE BLACK/WHITE

BROWN

BLACK/WHITE

BLACK

LS1B

LS1A

LS6

CE - Model 3215

PIN 2 - 21 (BLACK/WHITE)

PIN 1 - 17A (BLACK)

PIN 4 - 13C (BLACK/WHITE)

PIN 3 - 13B (BLACK)

BLACK/WHITE

BROWN BLACK

BLUE

13C

BLUE BLACK/WHITE

13B

BLACK

BROWN

18B

7A 17A

BLUE

BLACK/WHITE

BLACK

1 2

8 7

DEUTSCH

PIN 6 - 18B (BLUE)

PIN 5 - 7A (BROWN)

PIN 7 - 19 (BLACK) PIN 8 - 71 (BLACK/WHITE)

LS1B

LS6

LS7

ANSI/CSA - Model 3215

BLACK/WHITE

BROWN

BLUE

BLACK

BLACK/WHITE

BROWN

BLUE

BROWN

13A

BLACKBROWN

17A

BLUE21BLACK/WHITE

BLACK

19A

BLACK/WHITE

PIN 5 - 13 (BLACK)

PIN 7 - 19 (BLACK) PIN 8 - 71 (BLACK/WHITE)

PIN 6 - 13A (BLACK/WHITE)

PIN 1 - 17A (BLACK)

PIN 3 - 19 (BLACK) PIN 4 - 19A (BLACK/WHITE)

PIN 2 - 21 (BLACK/WHITE)

8 7

6 5

DEUTSCH

1 2

3 4

LS1B

LS1A

LS7

LS6

CE - Model 3219

PIN 2 - 21 (BLACK/WHITE)

PIN 4 - N/U

PIN 3 - N/U

PIN 1 - 17A (BLACK)

BROWN

BLUE

BROWN BLACK

18B

BLACK/WHITE

BLUE

BLACK

17A

BLACK/WHITE

PIN 7 - 19 (BLACK) PIN 8 - 71 (BLACK/WHITE)

1 2

8 7

DEUTSCH

PIN 6 - 18B (BLUE)

PIN 5 - 7A (BROWN)

LS1B

LS6

3.18 Limit Swtich Assemblies Diagram

A B C D E F G H

SKYJACK, Page 24

M141511AB_S3

SJIII Compact Series

143909

Page 69

H1 HORN

24V

02 - WHITE

22 - GREEN

FL-22 FLASHING LIGHT

4 1

DEUTSCH

PIN 1 - 19 (BLACK)

PIN 2 - 28 (GREEN)

PIN 3 - 02 (WHITE)

PIN 4 - N/U

TS1 TILT SWITCH (ANSI/CSA)

FROM ELEC. PANEL

BLACK - 22 WHITE - 02 (ANSI - FEM. TERM.)

HORN/FLASHING LIGHT HARNESS

DUAL FLASHING LIGHT HARNESS

WHITE - 02

BLACK - 22

WHITE - 02

BLACK - 22

WHITE - 02 (CE - RING TERM.)

3.19 Horn/Tilt Switch/Flashing Light Diagram

A B C D E F G H

143909

M146648AA_S3a

SKYJACK, Page 25SJIII Compact Series

Page 70

3.20 Control Module and Beeper Diagram (CE)

TO CONTROL MODULE - P4

PIN 1 - N/U PIN 2 - 60A GREEN PIN 3 - 28B GREEN

PIN 4 - N/U PIN 5 - N/U

PIN 6 - 910 BLACK PIN 7 - 900 WHITE PIN 8 - 902 WHITE PIN 9 - 910A BLACK

TO CONTROL MODULE - P3 PIN 1 - 22 BLACK PIN 2 - 29 GREEN PIN 3 - 60 GREEN PIN 4 - 28 BLACK PIN 5 - 02 WHITE PIN 6 - 28E WHITE

TO ANGLE TRANSDUCER PIN 1 - 910 BLACK PIN 2 - 28B GREEN PIN 3 - 902 WHITE

CONNECT GROUND WIRES

BEEPER

29 - RED (+) 02 - BLUE (-)

N/U - BLACK (-)

TO ELECTRICAL PANEL

29 GREEN (TO BEEPER) 22 BLACK (TO LIGHT)

02 WHITE

02 02

29 29

TO GROUND

TO PRESSURE TRANSDUCER PIN 1 - 910A BLACK PIN 2 - 60A GREEN PIN 3 - 900 WHITE

1-ST LEVEL INSIDE SCISSOR

CM1 OVERLOAD SENSING MODULE (CE)

P4 P3 P2 P1

A B C D E F G H

SKYJACK, Page 26

M130612AE

SJIII Compact Series

143909

Page 71

13A

DECELERATION LIMIT

SWITCH N.C. (3215 ONLY)

LS7

DECELERATION SOLENOID (3215 ONLY)

2H-13A

B4 6V

BATTERY

4H-24

4H-23

DO2-5

DO2-4

DO2-3

4H-15

4H-16

3H-17

SOLENOID

DO2-2

17CR

59D 59

D24-1D24

D23-1D23

17CR1

D16

D15

D17-1

D17

RELAY

2H-25

21A

17CCR

21ACR

59A

19A

HOURMETER

00 02

RELAY

19A

D19A

17D

7A 17C

17A

LS1A

LS1B

19A

19 TS1

19A19

28CR28

D14E-1

LOW VOLTAGE

PROTECTION

RST3

BP-29

BEEPER

3H-14

2H-13

DO2-1

2H-13-1

CB1

00 02

BREAKER

28A

D14

D14E

14E

CB2

15A CIRCUIT

BREAKER

D28A

D14-1

10E

UP/DOWN

SWITCH

HIGH SPEED

LIMIT SWITCHES N.C.

DRIVE OVERRIDE

LIMIT SWITCH N.C.

LS6

LEFT SOLENOID

RIGHT SOLENOID

BRAKE SOLENOID

STEER RELAY

FORWARD SOLENOID

TRANSFER RELAY

REVERSE SOLENOID

PROPORTIONAL

CUSHION RELAY

CUSHION SOLENOID

1000uF CAPACITOR

TILT SWITCH

MOTOR CONTACTOR

TILT SWITCH

0.47uF CAPACITOR

UP SOLENOID

HOLDING VALVE

DOWN SOLENOID

15A CIRCUIT

PACK

BATTERY

DCM1

MOTOR

CONTACTOR

CHARGER

NEGATIV

B2 6V

BATTERY

B3 6V

BATTERY

B1 6V

BATTERY

S1 MAIN

DISCONNECT

L1CR

CHARGER

CUTOUT RELAY

24V CHARGER

F1 300A FUSE

110 VAC

LINE VOLTAGE

BASECONTROL BOX

24V

PUMP MOTOR

ENABLE

S7-6

LED-1

LIGHT

POWER ON/LSS

GREEN/WHITE

RED

ORANGE

BLACK

CRD2CRD1 CRD3

WHITE

RED/BLACK

ORANGE/BLACK

WHITE/BLACK

BLUE

BLACK/WHITE

BLUE/BLACK

RED/WHITE

BLUE/WHITE

GREEN

OUTPUT

NUETRAL

S7-1

S7-3

LEFT

S7-2

REV/DN

12B

RIGHT

INDICATOR

BCI

RST1

2.7K OHMS 00

PWM

JOYSTICK

SWITCH

HORN

BATTERY CHARGE

STOP

EMERGENCY

JOYSTICK PCB

FWD/UP

ENABLE

EMERGENCY

S28

SWITCH

STOP

LED-2

POWER ON LIGHT

S10

KEY SWITCH

IDLE/PLTF/BASE

(IN IDLE POSITION)

10E

NCHO

HORN

POWER ON LED

RST2

2H-59

LS4

POTHOLE PROTECTION

LIMIT SWITCHES N.C.H.O.

LS5

D13

LIFT/

OFF/

DRIVE

SWITCH

12B

S27 TORQUE SWITCH

12B

3.21a Electrical Schematic (ANSI/CSA - equipped with no options)

A B C D E F G H

Serial Breakdown

Reference Chart

Model Serial Number

SJ3 3215 10000611 & above

SJ3 3219 22020985 & above

143909

SKYJACK, Page 27SJIII Compact Series

M147371AC

Page 72

3.21b Electrical Schematic (ANSI/CSA - equipped with no options)

SWITCH N.C. (3215 ONLY)

DECELERATION LIMIT

SOLENOID (3215 ONLY)

DECELERATION

D13

LS5

7271

LS4

2H-59

RST2

POWER ON LED

HORN

NCHO

10E

(IN IDLE POSITION)

IDLE/PLTF/BASE

KEY SWITCH

S10

POWER ON LIGHT

LED-2

STOP

SWITCH

S28

EMERGENCY

ENABLE

FWD/UP

12B

(IN LIFT POSITION)

LIFT/DRV LOW/DRV HI

JOYSTICK PCB

NCHO

NOHC

EMERGENCY

STOP

BATTERY CHARGE

HORN

SWITCH

JOYSTICK

PWM

2.7K OHMS

RST1

BCI

INDICATOR

RIGHT

12B

REV/DN

S7-2

LEFT

S7-3

D16-1

D15-1

S7-1

NUETRAL

OUTPUT

GREEN

BLUE/WHITE

RED/WHITE

BLUE/BLACK

BLACK/WHITE

BLUE

WHITE/BLACK

ORANGE/BLACK

RED/BLACK

WHITE

CRD3CRD1 CRD2

BLACK

ORANGE

RED

GREEN/WHITE

POWER ON/LSS

LIGHT

LED-1

S7-6

ENABLE

NCHO

PUMP MOTOR

24V

CONTROL BOX BASE

24V CHARGER

NEGATIV

CHARGER

DCM1

BATTERY PACK

M 5

15A CIRCUIT

DOWN SOLENOID

HOLDING VALVE

UP SOLENOID

0.47uF CAPACITOR

TILT SWITCH

MOTOR CONTACTOR

TILT SWITCH

1000uF CAPACITOR

CUSHION SOLENOID

CUSHION RELAY

PROPORTIONAL

REVERSE SOLENOID

TRANSFER RELAY

FORWARD SOLENOID

STEER RELAY

BRAKE SOLENOID

RIGHT SOLENOID

LEFT SOLENOID

LS6

10E

D14-1

D28A

CB2

14E

D14E

D14

28A

BREAKER

0200

CB1

2H-13-1

DO2-1

2H-13

3H-14

CAP2

BEEPER

BP-29

RST3

D14E-1

28 28CR

19 19A

TS119

19A

LS1B

LS1A

17A

17C7A

17D

D19A

19A

RELAY

0200

HOURMETER

19A

59A

21ACR

CAP1

17CCR

21A

2H-25

RELAY

D17

D17-1

D15

D16

17CR1

D23 D23-1

D24 D24-1

5959D

17CR

DO2-2

SOLENOID

3H-17

4H-16

4H-15

DO2-3

DO2-4

DO2-5

4H-23

4H-24

2H-13A

LS7

13A

B4 6V

BATTERY

LOW VOLTAGE

PROTECTION

15A CIRCUIT

BREAKER

UP/DOWN

SWITCH

HIGH SPEED

LIMIT SWITCHES N.C.

DRIVE OVERRIDE

LIMIT SWITCH N.C.

MOTOR

CONTACTOR

B2 6V

BATTERY

B3 6V

BATTERY

B1 6V

BATTERY

S1 MAIN

DISCONNECT

L1CR

CHARGER

CUTOUT RELAY

F1 300A FUSE

110 VAC

LINE VOLTAGE

POTHOLE PROTECTION

LIMIT SWITCHES N.C.H.O.

A B C D E F G H

Serial Breakdown

Reference Chart

Model Serial Number

SJ3 3215 10000610 & below

SJ3 3219 22020984 & below

SKYJACK, Page 28

M147371AB

SJIII Compact Series

143909

Page 73

LS5

POTHOLE PROTECTION

LIMIT SWITCHES N.C.H.O.

LS4

2H-59

RST2

POWER ON LED

HORN

NCHO

10E

(IN IDLE POSITION)

IDLE/PLTF/BASE

KEY SWITCH

S10

POWER ON LIGHT

LED-2

STOP

SWITCH

S28

EMERGENCY

ENABLE

JOYSTICK PCB

EMERGENCY

STOP

BATTERY CHARGE

HORN

SWITCH

JOYSTICK

PWM

2.7K OHMS

RST1

BCI

INDICATOR

RIGHT

12B

S7-2

LEFT

S7-3

S7-1

NUETRAL

OUTPUT

GREEN

BLUE/WHITE

RED/WHITE

BLUE/BLACK

BLACK/WHITE

BLUE

WHITE/BLACK

ORANGE/BLACK

RED/BLACK

WHITE

CRD3CRD1 CRD2

BLACK

ORANGE

RED

GREEN/WHITE

POWER ON/LSS

LIGHT

LED-1

S7-6

ENABLE

50A FUSE

PUMP MOTOR

INVERTER OPTION

24V

CONTROL BOX

BASE

110 VAC

LINE VOLTAGE

300A

FUSE

24V CHARGER

L1CR

CHARGER

CUTOUT RELAY

S1 MAIN

DISCONNECT

B1 6V

BATTERY

B3 6V

BATTERY

B2 6V

BATTERY

NEGATIV

CHARGER

MOTOR

CONTACTOR

DCM1

BATTERY PACK

M 5

FLASHING LIGHT

15A CIRCUIT

INVERTER OPTION

DOWN SOLENOID

HOLDING VALVE

UP SOLENOID

0.47uF CAPACITOR

TILT SWITCH

MOTOR CONTACTOR

TILT SWITCH

1000uF CAPACITOR

CUSHION SOLENOID

CUSHION RELAY

PROPORTIONAL

REVERSE SOLENOID

TRANSFER RELAY

FORWARD SOLENOID

STEER RELAY

BRAKE SOLENOID

RIGHT SOLENOID

LEFT SOLENOID

LS6

DRIVE OVERRIDE

LIMIT SWITCH N.C.

HIGH SPEED

LIMIT SWITCHES N.C.

UP/DOWN

SWITCH

10E

D14-1

D28A

D13

15A CIRCUIT

BREAKER

CB2

FLASHER

FL-29

14E

D14E

D14

28A

FL-22

19A

TIMER

BREAKER

TIMER

0200

CB1

FLASHER

OPTION

2H-13-1

DO2-1

2H-13

3H-14

BEEPER

BP-29

RST3

LOW VOLTAGE

PROTECTION

D14E-1

28 28CR

19 19A

TS119

19A

LS1B

LS1A

17A

17C7A

17D

D19A

19A

RELAY

0200

HOURMETER

19A

59A

21ACR

17CCR

21A

2H-25

RELAY

D17

D17-1

D15

D16

17CR1

D23 D23-1

D24 D24-1

5959D

17CR

DO2-2

SOLENOID

3H-17

4H-16

4H-15

DO2-3

DO2-4

DO2-5

4H-23

4H-24

B4 6V

BATTERY

2H-13A

SOLENOID (3215 ONLY)

DECELERATION

LS7

DECELERATION LIMIT

SWITCH N.C. (3215 ONLY)

13A

12B

S27 TORQUE SWITCH

12B

S3 LIFT/ OFF/

DRIVE

SWITCH

FWD/UP

REV/DN

(UNAVAILABLE ON EE RATED MACHINES)

3.22a Electrical Schematic [ANSI/CSA & EE Rated - equipped with all options]

A B C D E F G H

Serial Breakdown

Reference Chart

Model Serial Number

SJ3 3215 10000611 & above

SJ3 3219 22020985 & above

143909

M147370AD

SKYJACK, Page 29SJIII Compact Series

Page 74

SWITCH N.C. (3215 ONLY)

DECELERATION LIMIT

DECELERATION SOLENOID (3215 ONLY)

2H-13A

13A

LS7

LIMIT SWITCHES N.C.H.O.

POTHOLE PROTECTION

LINE VOLTAGE

110 VAC

FUSE

300A

CUTOUT RELAY

CHARGER

L1CR

DISCONNECT

MAINS1

BATTERY

6VB1

BATTERY

B3 6V

BATTERY

B2 6V

CONTACTOR

MOTOR

LIMIT SWITCH N.C.

DRIVE OVERRIDE

LIMIT SWITCHES N.C.

HIGH SPEED

SWITCH

UP/DOWN

BREAKER

15A CIRCUIT

FL-29

FLASHER

PROTECTION

LOW VOLTAGE

BATTERY

B4 6V

4H-24

4H-23

DO2-5

DO2-4

DO2-3

4H-15

4H-16

3H-17

SOLENOID

DO2-2

17CR

59D 59

D24-1D24

D23-1D23

17CR1

D16

D15

D17-1

D17

RELAY

2H-25

21A

17CCR

CAP1

21ACR

59A

19A

HOURMETER

00 02

RELAY

19A

D19A

17D

7A 17C

17A

LS1A

LS1B

19A

19 TS1

19A19

28CR28

D14E-1

RST3

BP-29

BEEPER

CAP2

3H-14

2H-13

DO2-1

2H-13-1

OPTION

FLASHER

CB1

00 02

BREAKER

FL-22

28A

D14

D14E

14E

CB2

D13

D28A

D14-1

10E

LS6

LEFT SOLENOID

RIGHT SOLENOID

BRAKE SOLENOID

STEER RELAY

FORWARD SOLENOID

TRANSFER RELAY

REVERSE SOLENOID

PROPORTIONAL

CUSHION RELAY

CUSHION SOLENOID

1000uF CAPACITOR

TILT SWITCH

MOTOR CONTACTOR

TILT SWITCH

0.47uF CAPACITOR

UP SOLENOID

HOLDING VALVE

DOWN SOLENOID

15A CIRCUIT

FLASHING LIGHT

PACK

BATTERY

DCM1

CHARGER

NEGATIV

24V CHARGER

BASECONTROL BOX

24V

PUMP MOTOR

NCHO

ENABLE

S7-6

LED-1

LIGHT

POWER ON/LSS

GREEN/WHITE

RED

ORANGE

BLACK

CRD2CRD1 CRD3

WHITE

RED/BLACK

ORANGE/BLACK

WHITE/BLACK

BLUE

BLACK/WHITE

BLUE/BLACK

RED/WHITE

BLUE/WHITE

GREEN

OUTPUT

NUETRAL

S7-1

D15-1

D16-1

S7-3 LEFT

S7-2

REV/DN

12B

RIGHT

INDICATOR

BCI

RST1

2.7K OHMS 00

PWM

JOYSTICK

SWITCH

HORN

BATTERY CHARGE

STOP

EMERGENCY

NOHC

NCHO

JOYSTICK PCB

LIFT/DRV LOW/DRV HI

(IN LIFT POSITION)

12B

FWD/UP

ENABLE

EMERGENCY

S28

SWITCH

STOP

LED-2

POWER ON LIGHT

S10

KEY SWITCH

IDLE/PLTF/BASE

(IN IDLE POSITION)

10E

NCHO

HORN

POWER ON LED

RST2

2H-59

LS4

71 72

LS5

3.22b Electrical Schematic (ANSI/CSA - equipped with all options)

A B C D E F G H

Serial Breakdown

Reference Chart

Model Serial Number

SJ3 3215 10000610 & below

SJ3 3219 22020984 & below

SKYJACK, Page 30

SJIII Compact Series

M147370AB

143909

Page 75

SWITCH N.C. (3215 ONLY)

DECELERATION LIMIT

DECELERATION SOLENOID (3215 ONLY)

LIMIT SWITCH N.C.

HIGH SPEED

SWITCH

UP/DOWN

LIMIT SWITCH N.C.

DRIVE OVERRIDE

LINE VOLTAGE

110 VAC

BATTERY

B3 6V

CUTOUT RELAY

CHARGER

L1CR

DISCONNECT

MAINS1

FUSE

300A

BATTERY

B4 6V

BATTERY

B2 6V

BATTERY

6VB1

CONTACTOR

MOTOR

PROTECTION

LOW VOLTAGE

BREAKER

15A CIRCUIT

LIMIT SWITCHES N.C.H.O.

POTHOLE PROTECTION

TRANSDUCER

PRESSURE

PT1

TRANSDUCER

ANGLE

AT1

P2-12 = 7A

P3-3 = 60

P4-8 = 902

P4-6 = 910

P4-3 = 28B

P4-9 = 910A

P4-2 = 60A

P4-7 = 900

P2-11 = 02

LS7

13C

13B

2H-13C

DO2-1

LS4

LS5

72 19

2H-59

RST2

59A59

FL-22

BP-29

CB2

HORN

POWER ON LED

POWER ON LIGHT

LED-2

10E

NCHO

(IN IDLE POSITION)

IDLE/PLTF/BASE

KEY SWITCH

S10

STOP

SWITCH

S28

EMERGENCY

02 60

ENABLE

FWD/UP

12B

(IN LIFT POSITION)

LIFT/DRV LOW/DRV HI

JOYSTICK PCB

NCHO

NOHC

EMERGENCY

STOP

BATTERY CHARGE

HORN

SWITCH

JOYSTICK

PWM

2.7K OHMS

RST1

BCI

INDICATOR

RIGHT

12B

REV/DN

S7-2

LEFT

S7-3

D16-1

D15-1

S7-1

NUETRAL

OUTPUT

GREEN

BLUE/WHITE

RED/WHITE

BLUE/BLACK

BLACK/WHITE

BLUE

WHITE/BLACK

ORANGE/BLACK

RED/BLACK

WHITE

CRD3CRD1 CRD2

BLACK

ORANGE

RED

GREEN/WHITE

POWER ON/LSS

LIGHT

LED-1

S7-6

ENABLE

NCHO

LEFT SOLENOID

RIGHT SOLENOID

4H-24

DO2-10

DO2-11

FORWARD SOLENOID

STEER RELAY

BRAKE SOLENOID

PROPORTIONAL SOLENOID

REVERSE SOLENOID

TRANSFER RELAY

DO2-9

4H-16

DO2-8

4H-23

DO2-7

4H-15

3H-17

D24-1

D23-1

D24

D23

59D

17CR

17CR1

D16

D15

PROPORTIONAL RELAY

CUSHION SOLENOID31

3029CUSHION RELAY

1000uF CAPACITOR

21A

21ACR

DO2-6

2H-25

AUX. TILT RELAY

HOURMETER

22 DOWN RELAY

MOTOR CONTACTOR

AUX. DOWN RELAY

19B

DO2-5

TILT RELAY

RST3

17D

CAP1

17C7A

D14-1

18B

28ECR1

19A

19B

28E

28ECR2

D14-2

14E

D14E-2

D14E-1

28CR2

17CCR

28CR1

DOWN SOLENOID

UP SOLENOID

HOLDING VALVE

FLASHING LIGHT OPTION

2H-13B

DO2-4

3H-14

2H-13B-1

DO2-2

DO2-3

BEEPER

15A CIRCUIT

BREAKER

CB1

13 13A 13B

P3-4 = 28

P3-1 = 22

P3-5 = 02

P2-4 = 13

P2-3 = 14

P2-10 = 18B

P3-6 = 28E

P3-2 = 29

PUMP MOTOR

PACK

BATTERY

CHARGER

NEGATIV

DCM1

24V CHARGER

D17

17A

LS1

N.O.

LS6

10E

P2-7 = 16

P2-8 = 15

P2-2 = 10E

D17-1

24V

BASECONTROL BOX

MODULE

CM1 CONTROL

3.23 Electrical Schematic (CE - equipped with all options)

A B C D E F G H

143909

SKYJACK, Page 31SJIII Compact Series

M147810AA

Page 76

3.24a Electrical Schematic (ANSI/CSA EE Rated - equipped with no options)

110 VAC

LINE VOLTAGE

24V CHARGER

110 VAC

TO BATTERIES

LS5

POTHOLE PROTECTION

LIMIT SWITCHES N.C.H.O.

LS4

2H-59

RST2

POWER ON LED

HORN

NCHO

10E

(IN IDLE POSITION)

IDLE/PLTF/BASE

KEY SWITCH

S10

POWER ON LIGHT

LED-2

STOP

SWITCH

S28

EMERGENCY

ENABLE

JOYSTICK PCB

EMERGENCY

STOP

BATTERY CHARGE

HORN

SWITCH

JOYSTICK

PWM

2.7K OHMS

RST1

BCI

INDICATOR

RIGHT

12B

S7-2

LEFT

S7-3

S7-1

NUETRAL

OUTPUT

GREEN

BLUE/WHITE

RED/WHITE

BLUE/BLACK

BLACK/WHITE

BLUE

WHITE/BLACK

ORANGE/BLACK

RED/BLACK

WHITE

CRD3CRD1 CRD2

BLACK

ORANGE

RED

GREEN/WHITE

POWER ON/LSS

LIGHT

LED-1

S7-6

ENABLE

PUMP MOTOR

24V

CONTROL BOX

BASE

300A

FUSE

S1 MAIN

DISCONNECT

B1 6V

BATTERY

B3 6V

BATTERY

B2 6V

BATTERY

NEGATIV

CHARGER

MOTOR

CONTACTOR

DCM1

BATTERY PACK

15A CIRCUIT

DOWN SOLENOID

HOLDING VALVE

UP SOLENOID

0.47uF CAPACITOR

TILT SWITCH

MOTOR CONTACTOR

TILT SWITCH

1000uF CAPACITOR

CUSHION SOLENOID

CUSHION RELAY

PROPORTIONAL

REVERSE SOLENOID

TRANSFER RELAY

FORWARD SOLENOID

STEER RELAY

BRAKE SOLENOID

RIGHT SOLENOID

LEFT SOLENOID

LS6

DRIVE OVERRIDE

LIMIT SWITCH N.C.

HIGH SPEED

LIMIT SWITCHES N.C.

UP/DOWN

SWITCH

10E

D14-1

D28A

15A CIRCUIT

BREAKER

CB2

14E

D14E

D14

28A

BREAKER

0200

CB1

2H-13-1

DO2-1

2H-13

3H-14

BEEPER

BP-29

RST3

LOW VOLTAGE

PROTECTION

D14E-1

28 28CR

19 19A

TS119

19A

LS1B

LS1A

17A

17C7A

17D

D19A

19A

RELAY

0200

HOURMETER

19A

59A

21ACR

17CCR

21A

2H-25

RELAY

D17

D17-1

D15

D16

17CR1

D23 D23-1

D24 D24-1

5959D

17CR

DO2-2

SOLENOID

3H-17

4H-16

4H-15

DO2-3

DO2-4

DO2-5

4H-23

4H-24

B4 6V

BATTERY

2H-13A

DECELERATION

LS7

DECELERATION LIMIT

SWITCH N.C. (3215 ONLY)

13A

D13

LIFT/

OFF/

DRIVE

SWITCH

12B

S27 TORQUE SWITCH

12B

REV/DN

FWD/UP

A B C D E F G H

Serial Breakdown

Reference Chart

Model Serial Number

SJ3 3215 10000611 & above

SJ3 3219 22020985 & above

SKYJACK, Page 32

M149688AB

SJIII Compact Series

143909

Page 77

3.24b Electrical Schematic (ANSI/CSA EE Rated - equipped with no options)

110 VAC

LINE VOLTAGE

24V CHARGER

110 VAC

TO BATTERIES

LS5

POTHOLE PROTECTION

LIMIT SWITCHES N.C.H.O.

LS4

2H-59

RST2

POWER ON LED

HORN

NCHO

10E

(IN IDLE POSITION)

IDLE/PLTF/BASE

KEY SWITCH

S10

POWER ON LIGHT

LED-2

STOP

SWITCH

S28

EMERGENCY

ENABLE

FWD/UP

12B

(IN LIFT POSITION)

LIFT/DRV LOW/DRV HI

JOYSTICK PCB

NCHO

NOHC

EMERGENCY

STOP

BATTERY CHARGE

HORN

SWITCH

JOYSTICK

PWM

2.7K OHMS

RST1

BCI

INDICATOR

RIGHT

12B

REV/DN

S7-2

LEFT

S7-3

D16-1

D15-1

S7-1

NUETRAL

OUTPUT

GREEN

BLUE/WHITE

RED/WHITE

BLUE/BLACK

BLACK/WHITE

BLUE

WHITE/BLACK

ORANGE/BLACK

RED/BLACK

WHITE

CRD3CRD1 CRD2

BLACK

ORANGE

RED

GREEN/WHITE

POWER ON/LSS

LIGHT

LED-1

S7-6

ENABLE

NCHO

PUMP MOTOR

24V

CONTROL BOX BASE

F1 300A FUSE

S1 MAIN

DISCONNECT

B1 6V

BATTERY

B3 6V

BATTERY

B2 6V

BATTERY

NEGATIV

CHARGER

MOTOR

CONTACTOR

DCM1

BATTERY PACK

M 5

15A CIRCUIT

DOWN SOLENOID

HOLDING VALVE

UP SOLENOID

0.47uF CAPACITOR

TILT SWITCH

MOTOR CONTACTOR

TILT SWITCH

1000uF CAPACITOR

CUSHION SOLENOID

CUSHION RELAY

PROPORTIONAL

REVERSE SOLENOID

TRANSFER RELAY

FORWARD SOLENOID

STEER RELAY

BRAKE SOLENOID

RIGHT SOLENOID

LEFT SOLENOID

LS6

DRIVE OVERRIDE

LIMIT SWITCH N.C.

HIGH SPEED

LIMIT SWITCHES N.C.

UP/DOWN

SWITCH

10E

D14-1

D28A

15A CIRCUIT

BREAKER

CB2

14E

D14E

D14

28A

BREAKER

0200

CB1

2H-13-1

DO2-1

2H-13

3H-14

16 BEEPER

BP-29

RST3

LOW VOLTAGE

PROTECTION

D14E-1

28 28CR

19 19A

TS119

19A

LS1B

LS1A

17A

17C7A

17D

D19A

19A

RELAY

0200

HOURMETER

19A

59A

21ACR

17CCR

21A

2H-25

RELAY

D17

D17-1

D15

D16

17CR1

D23 D23-1

D24 D24-1

5959D

17CR

DO2-2

SOLENOID

3H-17

4H-16

4H-15

DO2-3

DO2-4

DO2-5

4H-23

4H-24

B4 6V

BATTERY

2H-13A

SOLENOID (3215 ONLY)

DECELERATION

LS7

DECELERATION LIMIT

SWITCH N.C. (3215 ONLY)

13A

D13

A B C D E F G H

Serial Breakdown

Reference Chart

Model Serial Number

SJ3 3215 10000610 & below

SJ3 3219 22020984 & below

143909

M149688AA1

SKYJACK, Page 33SJIII Compact Series

Page 78

LS5

7271

LS4

2H-59

RST2

POWER ON LED

HORN

NCHO

10E

(IN IDLE POSITION)

IDLE/PLTF/BASE

KEY SWITCH

S10

POWER ON LIGHT

LED-2

STOP

SWITCH

S28

EMERGENCY

ENABLE

FWD/UP

12B

(IN LIFT POSITION)

LIFT/DRV LOW/DRV HI

JOYSTICK PCB

NCHO

NOHC

EMERGENCY

STOP

BATTERY CHARGE

HORN

SWITCH

JOYSTICK

PWM

2.7K OHMS

RST1

BCI

INDICATOR

RIGHT

12B

REV/DN

S7-2

LEFT

S7-3

D16-1

D15-1

S7-1

NUETRAL

OUTPUT

GREEN

BLUE/WHITE

RED/WHITE

BLUE/BLACK

BLACK/WHITE

BLUE

WHITE/BLACK

ORANGE/BLACK

RED/BLACK

WHITE

CRD3CRD1 CRD2

BLACK

ORANGE

RED

GREEN/WHITE

POWER ON/LSS

LIGHT

LED-1

S7-6

ENABLE

NCHO

PUMP MOTOR

24V

CONTROL BOX BASE

NEGATIV

CHARGER

DCM1

BATTERY PACK

M 5

FLASHING LIGHT

15A CIRCUIT

DOWN SOLENOID

HOLDING VALVE

UP SOLENOID

0.47uF CAPACITOR

TILT SWITCH

MOTOR CONTACTOR

TILT SWITCH

1000uF CAPACITOR

CUSHION SOLENOID

CUSHION RELAY

PROPORTIONAL

REVERSE SOLENOID

TRANSFER RELAY

FORWARD SOLENOID

STEER RELAY

BRAKE SOLENOID

RIGHT SOLENOID

LEFT SOLENOID

LS6

10E

D14-1

D28A

D13

CB2

14E

D14E

D14

28A

FL-22

BREAKER

0200

CB1

FLASHER

OPTION

2H-13-1

DO2-1

2H-13

3H-14

BEEPER

BP-29

RST3

D14E-1

28 28CR

19 19A

TS119

19A

LS1B

LS1A

17A

17C7A

17D

D19A

19A

RELAY

0200

HOURMETER

19A

59A

21ACR

17CCR

21A

2H-25

RELAY

D17

D17-1

D15

D16

17CR1

D23 D23-1

D24 D24-1

5959D

17CR

DO2-2

SOLENOID

3H-17

4H-16

4H-15

DO2-3

DO2-4

DO2-5

4H-23

4H-24

B4 6V

BATTERY

LOW VOLTAGE

PROTECTION

FLASHER

FL-29

15A CIRCUIT

BREAKER

UP/DOWN

SWITCH

HIGH SPEED

LIMIT SWITCHES N.C.

DRIVE OVERRIDE

LIMIT SWITCH N.C.

MOTOR

CONTACTOR

B2 6V

BATTERY

B3 6V

BATTERY

B1 6V

BATTERY

S1 MAIN

DISCONNECT

300A

FUSE

POTHOLE PROTECTION

LIMIT SWITCHES N.C.H.O.

LS7

13A

2H-13A

SOLENOID (3215 ONLY)

DECELERATION

DECELERATION LIMIT

SWITCH N.C. (3215 ONLY)

110 VAC

LINE VOLTAGE

24V CHARGER

110 VAC

TO BATTERIES

3.25b Electrical Schematic (ANSI/CSA EE Rated - equipped with all options)

A B C D E F G H

Serial Breakdown

Reference Chart

Model Serial Number

SJ3 3215 10000610 & below

SJ3 3219 22020984 & below

SKYJACK, Page 34

SJIII Compact Series

M149867AA

143909

Page 79

Section 4

TROUBLESHOOTING INFORMATION

Table of Contents

Introduction ..................................................................................................................................................................3

Electrical System

4.1-1 All Controls Inoperative ...................................................................................................................................4

4.1-2 All Controls Except for Down Function Inoperative ......................................................................................4

4.1-3 All Controls Inoperative From Base Control Console ....................................................................................5

4.1-4 All Controls Inoperative From Platform Control Console ...............................................................................5

4.1-5 No Drive or Up Function from Platform or Base Controls (CE only) .............................................................5

4.1-6 No Down or Reverse Only Function from Platform Controls .........................................................................6

4.1-7 No Up or Forward Only Function from Platform Control Console .................................................................6

4.1-8 No Up Function from Platform or Base Control Console ...............................................................................6

4.1-9 No Down Function from Platform or Base Control Console (ANSI/CSA only) ..............................................7

4.1-10 No Down Function from Platform or Base Control Console (CE only) ..........................................................7

4.1-11 No Up Function from Base Control Console ..................................................................................................7

4.1-12 No Down Function from Base Control Console .............................................................................................8

4.1-13 Platform Lowers Slowly from Platform and Base (Model 3215) ....................................................................8

4.1-14 Platform does not Decelerate when Lowering (Model 3215) .........................................................................8

4.1-15 Platform Lifts Slowly from Platform and Base Control console .....................................................................8

4.1-16 Steer Only Inoperative ....................................................................................................................................8

4.1-17 Drive Only Inoperative ....................................................................................................................................8

4.1-18 No Drive or Steer when Platform Fully Lowered ............................................................................................9

4.1-19 No Drive or Steer when Platform Elevated .....................................................................................................9

4.1-20 Elevated Drive Speed Does Not Activate .......................................................................................................9

4.1-21 Work Platform Drives in Slow Speed Only .....................................................................................................9

4.1-22 Forward Drive Function Inoperative .............................................................................................................10

4.1-23 Reverse Drive Function Inoperative ..............................................................................................................10

4.1-24 Brake will not Release...................................................................................................................................10

4.1-25 Two or more Functions at one time ..............................................................................................................10

Hydraulic System

4.2-1 All Functions Inoperative ..............................................................................................................................11

4.2-2 All Functions Sluggish ..................................................................................................................................11

4.2-3 Platform Drifts Down .....................................................................................................................................11

4.2-4 Platform Lifts Slowly ......................................................................................................................................11

4.2-5 Platform Does Not Lift ...................................................................................................................................11

4.2-6 Platform will not Lower ..................................................................................................................................12

4.2-7 Platform Lowers Slowly ................................................................................................................................12

4.2-8 Platform Drives Slow .....................................................................................................................................12

4.2-9 Platform will not Drive in Forward or Reverse ..............................................................................................12

4.2-10 Brake(s) will not Release ..............................................................................................................................13

4.2-11 Platform does not Steer ................................................................................................................................13

SKYJACK, Page 1SJIII Compact Series

143909

Page 80

Section 4 - Troubleshooting Information Service and Maintenance

Introduction

The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and deficiencies that may occur. If a specific trouble is not listed, isolate the major component in which the trouble occurs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem.

The content of this section is separated into “probable cause” and “remedy.” The information preceded by a number 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 -

143909

SKYJACK, Page 3SJIII Compact Series

Page 81

Section 4 - Troubleshooting Information Service and Maintenance

Electrical System

4.1-1 All Controls Inoperative

1. Battery charger plugged into external power source.

Disconnect charger cord. -

2. Batteries disconnected.

Connect batteries. -

3. Dirty or loose battery terminals.

Clean and tighten connections. -

4. Battery charge low.

Check each cell with a hydrometer. Reading should be 1.275 (fully charged). Recharge if low reading. Replace if reading difference between cells is 0.050.

5. Main battery cables open or defective.

Check continuity. Replace if defective. -

6. Fuse F1 defective.

Replace fuse. -

7. Main battery disconnect switch S1 open or defective.

Close switch. Check continuity. Replace if defective. -

8. Loose or broken wire #3 from motor contactor C1 to circuit breaker CB2.

Check continuity. Replace if defective. -

9. Loose or broken wire #3A from circuit breaker CB2 to charger relay L1CR.

Check continuity. Replace if defective. -

10. Defective or tripped circuit breaker CB2.

Reset circuit breaker. Replace if defective. -

11. Defective battery charger relay L1CR.

Check relay. Replace if defective. -

12. Loose or broken wire #5 from charger relay L1CR to base emergency stop switch S28.

Check continuity. Replace if defective. -

13. Open or defective base emergency stop switch S28.

Close switch. Check switch. Replace if defective. -

14. Loose or broken wire #5A from base emergency stop switch S28 to base key switch S10.

Check continuity. Replace if defective. -

15. Open or defective base key switch S10.

Select function with switch. Check switch. Replace if defective. -

16. Loose or broken wire #00 from pump motor DCM1 to circuit breaker CB1.

Check continuity. Replace if defective. -

17. Defective or tripped circuit breaker CB1.

Reset circuit breaker. Replace if defective. -

18. Loose or broken wire #02 from circuit breaker CB1 to base terminal block.

Check continuity. Replace if defective. -

19. Loose or broken wire #7A from base terminal block to CM1 control module pin P2-12. (CE)

Check continuity. Replace if defective. -

20. Loose or broken wire #02 from base terminal block to CM1 control module pin P2-11. (CE)

Check continuity. Replace if defective. -

4.1-2 All Controls Except for Down Function Inoperative

1. Loose or broken wire #59 from base terminal block to proportional valve 2H-59.

Check continuity. Replace if defective. -

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. -

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Electrical System (Continued)

4.1-3 All Controls Inoperative From Base Control Console

1. Loose or broken wire #07 from base terminal block to platform emergency stop switch S4.

Check continuity. Replace if defective. -

2. Open or defective platform emergency stop switch S4.

Close switch. Replace if defective. -

3. Loose or broken wire #7A from platform emergency stop switch S4 to base terminal block.

Check continuity. Replace if defective. -

4. Loose or broken wire #7A from base terminal block to base key switch S10.

Check continuity. Replace if defective. -

5. Open or defective base key switch S10.

Close switch. Replace if defective. -

6. Loose or broken wire #10E from base key switch S10 to base up/down switch S2.

Check continuity. Replace if defective. -

4.1-4 All Controls Inoperative From Platform Control Console

1. Loose or broken wire #8C from base key switch S10 to base terminal block.

Check continuity. Replace if defective. -

2. Loose or broken wire #8C or wire #02 from base terminal block to platform emergency stop switch

S4.

Check continuity. Replace if defective. -

3. Open or defective platform emergency stop switch S4.

Close switch. Replace if defective. -

4. Loose or broken wire #8 or wire #02 from emergency stop switch S4 to battery charge indicator

BCI.

Check continuity. Replace if defective. -

5. Loose or broken wire #8 or wire #02 from battery charge indicator BC1 to joystick S7.

Check continuity. Replace if defective. -

6. Defective joystick enable switch S7-6.

Check switch. Replace if defective. -

7. Defective joystick neutral switch S7-1.

Check switch. Replace if defective. -

8. Defective joystick S7.

Check joystick. Replace if defective. -

4.1-5 No Drive or Up Function from Platform or Base Controls (CE only)

1. Defective tilt relay 28CR1 or Aux. tilt relay 28ECR1.

Check relay. Replace if defective. -

2. Loose or broken wire #02 from base terminal block to tilt relay 28CR1 or Aux. tilt relay 28ECR1.

Check continuity. Replace if defective. -

3. Loose or broken wire #28 from CM1 control module pin P3-4 to tilt relay 28CR1.

Check continuity. Replace if defective. -

4. Loose or broken wire #28E from CM1 control module pin P3-6 to Aux. tilt relay 28ECR1.

Check continuity. Replace if defective. -

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. -

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Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

7. Loose or broken wire #19B from tilt relay 28CR1 to base terminal block.

Check continuity. Replace if defective. -

8. Loose or broken wire #19B from base terminal block to motor contactor C1.

Check continuity. Replace if defective. -

4.1-6 No Down or Reverse Only Function from Platform Controls

1. Loose or broken wire “A” from proportional controller S7 to lift/drive switch S3.

Check continuity. Replace if defective. -

2. Lift/Drive switch S3 defective.

Check switch. Replace if defective. -

3. Defective PWM card on joystick S7.

Check joystick card. Replace if defective. -

4. Loose or broken wire #13 down or #15 reverse from lift/drive switch S3 to base terminal block.

Check continuity. Replace if defective. -

4.1-7 No Up or Forward Only Function from Platform Control Console

1. Loose or broken wire “B” from proportional controller S7 to lift/drive switch S3.

Check continuity. Replace if defective. -

2. Lift/Drive switch S3 defective.

Check switch. Replace if defective. -

3. Defective PWM card on joystick S7.

Check joystick card. Replace if defective. -

4. Loose or broken wire #14 up or #16 forward from lift/drive switch S3 to base terminal block.

Check continuity. Replace if defective. -

4.1-8 No Up Function from Platform or Base Control Console

1. Loose or broken wire #14 from base terminal block to up valve coil 3H-14.

Check continuity. Replace if defective. -

2. Defective up valve coil 3H-14.

Check continuity through coil. Replace if defective. -

3. Open diode D14-1.

Check diode. Replace if defective. -

4. Open diode D14 (ANSI/CSA) or D14-2 (CE).

Check diode. Replace if defective. -

5. Machine not level. (Above high speed limit switch)

Use on level surface. -

6. Loose or broken wire #19 from base terminal block to tilt switch TS1 (ANSI/CSA).

Check continuity. Replace if defective. -

7. Defective tilt switch TS1 (ANSI/CSA).

Test tilt switch. Replace if defective. -

8. Loose or broken wire #28 from tilt switch TS1 to tilt relay 28CR (ANSI/CSA).

Check continuity. Replace if defective. -

9. Loose or broken wire #02 from tilt switch TS1 to base terminal strip (ANSI/CSA).

Check continuity. Replace if defective. -

10. Defective tilt relay 28CR (ANSI/CSA).

Check relay. Replace if defective. -

11. Loose or broken wire #19A from tilt relay 28CR to pump motor contactor (ANSI/CSA).

Check continuity. Replace if defective. -

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Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

12. Open or defective diode D14E-1

Check diode. Replace if defective. -

13. See 4.1-5 of this section for more troubleshooting information.

4.1-9 No Down Function from Platform or Base Control Console (ANSI/CSA only)

NOTE

Down function is not proportionally controlled.

1. Loose or broken wire #13 from base terminal block to down valve 2H-13 or holding valve 2H-13-1.

Check continuity. Replace if defective. -

2. Loose or broken wire #02 from base terminal block to down valve 2H-13 or holding valve 2H-13-1.

Check continuity. Replace if defective. -

3. Defective down valve 2H-13.

Check continuity through coil. Replace if defective. -

4. Defective lift cylinder holding valve 2H-13-1.

Check continuity through coil. Replace if defective. -

4.1-10 No Down Function from Platform or Base Control Console (CE only)

NOTE

Down function is not proportionally controlled.

1. Loose or broken wire #13 from base terminal block to CM1 control module pin P2-4.

Check continuity. Replace if defective. -

2. Defective down relay 28CR2 or Aux. down relay 28ECR2.

Check relay. Replace if defective. -

3. Loose or broken wire #02 from base terminal block to down relay 28CR2 or Aux. down relay

28ECR2.

Check continuity. Replace if defective. -

4. Loose or broken wire #13 from base terminal block to Aux. down relay 28ECR2.

Check continuity. Replace if defective. -

5. Loose or broken wire #13A from Aux. down relay 28ECR2 to down relay 28CR2.

Check continuity. Replace if defective. -

6. Loose or broken wire # 13B from down relay 28CR2 to down valve 2H-13B or holding valve

2H-13B-1.

Check continuity. Replace if defective. -

7. Defective down valve 2H-13B.

Check continuity through coil. Replace if defective. -

8. Defective lift cylinder holding valve 2H-13B-1.

Check continuity through coil. Replace if defective. -

9. Loose or broken wire #02 from holding valve 2H-13B-1 or down valve 2H-13B to base terminal

block.

Check continuity. Replace if defective. -

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. -

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Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

3. Open diode D14E-1.

Check diode. Replace if defective. -

4. Open diode D14E.

Check diode. Replace if defective. -

4.1-12 No Down Function from Base Control Console

1. Defective up/down switch S2.

Check switch. Replace if defective. -

2. Loose or broken wire #13 from up/down switch S2 to base terminal block.

Check continuity. Replace if defective. -

4.1-13 Platform Lowers Slowly from Platform and Base (Model 3215)

1. Deceleration limit switch LS7 stuck, out of adjustment or is defective.

Readjust limit switch so it returns to the normally closed position at 14” before completely stowed. Check the limit switch is functioning. Replace if defective.

4.1-14 Platform does not Decelerate when Lowering (Model 3215)

1. Deceleration limit switch LS7 out of adjustment.

Readjust limit switch so it returns to the normally closed position at 14” before completely stowed. Check the limit switch is functioning. Replace if defective. -

2. Loose or broken wire #13A (ANSI/CSA) or #13C (CE) from terminal strip to deceleration valve coil

2H-13A (ANSI/CSA) or 2H-13C (CE).

Check continuity. Replace if defective. -

3. Loose or broken wire #02 from terminal strip to deceleration valve coil 2H-13A (ANSI/CSA) or 2H-13C

(CE).

Check continuity. Replace if defective. -

4. Defective deleration valve coil 2H-13A (ANSI/CSA) or 2H-13C (CE).

Check coil. Replace if defective. -

4.1-15 Platform Lifts Slowly from Platform and Base Control console

1. Open diode D14-1.

Check diode. Replace if defective. -

4.1-16 Steer Only Inoperative

1. Defective relay 17CR.

Check relay. Replace if defective. -

2. Loose or broken wire #59D from diodes D23-1 and D24-1 to base terminal block TB1.

Check continuity. Replace if defective. -

3. Loose or broken wire #59D from 17CR steer relay to base terminal block TB1.

Check continuity. Replace if defective. -

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. -

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Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

4.1-18 No Drive or Steer when Platform Fully Lowered

1. Loose or broken wire #71 from base terminal block to drive override limit switch LS6.

Check continuity. Replace if defective. -

2. Defective drive override switch LS6.

Check switch. Replace if defective. -

3. Loose or broken wire #19 from drive override limit switch LS6 to base terminal block.

Check continuity. Replace if defective. -

4.1-19 No Drive or Steer when Platform Elevated

1. Pothole protection bars not fully lowered.

Clear obstructions. Repair as needed. -

2. Loose or broken wire #71 from base terminal block to pothole protection limit switch LS4.

Check continuity. Replace if defective. -

3. Defective pothole protection limit switch LS4.

Check switch. Replace if defective. -

4. Loose or broken wire #72 from pothole protection limit switch LS4 to base terminal block.

Check continuity. Replace if defective. -

5. Loose or broken wire #72 from base terminal block to pothole protection limit switch LS5.

Check continuity. Replace if defective. -

6. Defective pothole protection limit switch LS5.

Check switch. Replace if defective. -

7. Loose or broken wire #19 from pothole protection limit switch LS5 to base terminal block.

Check continuity. Replace if defective. -

4.1-20 Elevated Drive Speed Does Not Activate

1. Loose or broken wire #59 from base terminal strip proportional relay 21ACR.

Check continuity. Replace if defective. -

1. Loose or broken wire #59A from proportional relay 21ACR to resistor RST2.

Check continuity. Replace if defective. -

2. Resistor RST2 open.

Check resistor ohms, it should be 30 ohms. Replace if defective. -

3. Loose or broken wire #02 from resistor RST2 to base terminal block.

Check continuity. Replace if defective. -

4. Proportional relay 21ACR defective.

Check relay, replace if defective. -

4.1-21 Work Platform Drives in Slow Speed Only

1. Open diode D17-1.

Check diode. Replace if defective. -

2. Loose or broken wire #17A from base terminal block to high speed limit switch LS1B.

Check continuity. Replace if defective. -

3. Open or defective high speed limit switch LS1B.

Check switch. Replace if defective. -

4. Loose or broken wire #21 from high speed limit switch LS1B to low voltage protection resistor RST3.

Check continuity. Replace if defective. -

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. -

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Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

7. Proportional relay 21ACR defective.

Check relay, replace if defective. -

8. Loose or broken wire #2 from proportional relay 21ACR to base terminal block.

Check continuity. Replace if defective. -

9. Proportional controller S7 out of adjustment.

Adjust controller. Refer to Section 5, Joystick Adjusting Procedure. -

4.1-22 Forward Drive Function Inoperative

1. Loose or broken wire #16 from lift/drive switch S3 to base terminal block.

Check continuity. Replace if defective. -

2. Loose or broken wire #16 from base terminal block to forward drive valve coil 4H-16.

Check continuity. Replace if defective. -

3. Forward drive valve coil 4H-16 defective.

Check continuity through coil. Replace if defective. -

4. Loose or broken wire #02 from forward drive valve coil 4H-16 to base terminal block.

Check continuity. Replace if defective. -

5. Open diode D16.

Check diode. Replace if defective. -

4.1-23 Reverse Drive Function Inoperative

1. Loose or broken wire #15 from lift/drive switch S3 to base terminal block.

Check continuity. Replace if defective. -

2. Loose or broken wire #15 from base terminal block to reverse drive valve coil 4H-15.

Check continuity. Replace if defective. -

3. Reverse drive valve coil 4H-15 defective.

Check continuity through coil. Replace if defective. -

4. Loose or broken wire #02 from reverse drive valve coil 4H-15 to base terminal block.

Check continuity. Replace if defective. -

5. Open diode D15.

Check diode. Replace if defective. -

4.1-24 Brake will not Release

1. Diode D-16 forward or D-15 reverse is shorted or open.

Check diode. Replace if defective. -

2. Loose or broken wire #17 from base terminal strip to brake coil 3H-17.

Check continuity. Replace if defective. -

3. Brake valve coil 3H-17 defective.

Check continuity through coil. Replace if defective. -

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. -

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Section 4 - Troubleshooting Information Service and Maintenance

Hydraulic System

4.2-1 All Functions Inoperative

1. Proportional valve 2H-59 defective or is sticking.

Check valve. Replace if defective. -

2. Compensator portion of proportional valve defective or is sticking.

Check valve. Replace if defective. -

3. Pump P1 defective.

Check pump. Replace if defective. -

4.2-2 All Functions Sluggish

1. System relief valve R1 defective or not adjusted properly.

Adjust valve. Replace if defective. -

2. Hydraulic pump P1 worn.

Check pump. Replace if defective. -

4.2-3 Platform Drifts Down

1. Defective lift cylinder gland seal.

Check for hydraulic oil leaking from the gland seal. Rebuild cylinder. Replace if damaged. -

2. Combination of: Defective holding valve 2H-13-1 and either defective lowering valve 2H-13 or relief

valve R2 or manual lowering valve V1. (ANSI/CSA)

Check valves. Replace if defective. -

Combination of: Defective holding valve 2H-13B-1 and either defective lowering valve 2H-13B or relief

valve R2 or manual lowering valve V1. (CE)

Check valves. Replace if defective. -

3. Defective o-ring between lift cylinder and holding valve manifold block or loose bolts holding the

manifold.

Check for hydraulic oil leaking from between cylinder and manifold. Tighten bolts on manifold or replace o-ring. Replace manifold if damaged.

4.2-4 Platform Lifts Slowly

1. Open or leaking manual lowering valve V1.

Close valve. Replace if defective. -

2. Lift relief valve R2 defective or not adjusted correctly.

Adjust valve. Replace if defective. -

3. Open manual override on holding valve 2H-13-1 (ANSI/CSA) or 2H-13B-1 (CE).

Depress and turn manual override clockwise to close. Replace if defective. -

4. Stuck or defective deceleration valve 2H-13A (Model 3215 ANSI/CSA) or 2H-13C (Model 3215 CE).

Check valve. Replace if defective. -

4.2-5 Platform Does Not Lift

1. Open manual lowering valve V1.

Close valve. Replace if defective. -

2. Hydraulic oil level too low.

Fully lower the platform. Fill hydraulic tank with recommended fluid to appropriate level. -

3. Platform weight excessive.

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 (Model 3215 ANSI/CSA) or 2H-13C (Model 3215 CE).

Clear obstruction from valve. Replace if defective. -

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Section 4 - Troubleshooting Information Service and Maintenance

Hydraulic System (Continued)

4.2-6 Platform will not Lower

NOTE

Down function is not proportionally controlled.

1. Lowering valve 2H-13 (ANSI/CSA) or 2H-13B (CE) defective or is sticking.

Clean valve. Replace if defective. -

2. Defective holding valve 2H-13-1(ANSI/CSA) or 2H-13B-1 (CE).

Clean valve. Replace if defective. -

3. Lowering orifice O2 (Model 3219) plugged or contaminated.

Clear debris. Replace Orifice. Replace if defective. -

4. Emergency lowering orifice O6 plugged or contaminated.

Clear debris. Replace Orifice. Replace if defective. -

5. Plugged deceleration valve 2H-13A (ANSI/CSA) or 2H-13C (CE).

Clear obstruction from valve. Replace if defective. -

4.2-7 Platform Lowers Slowly

1. Stuck or defective deceleration valve 2H-13A (ANSI/CSA) or 2H-13C (CE).

Check valve. Replace if defective. -

4.2-8 Platform Drives Slow

1. Free-wheeling valve V2 open or defective.

Close valve. Replace if defective. -

2. Drive motor M1 or M2 defective.

Check motors. Replace if defective. -

3. Cushion valve 2H-25 is stuck or defective.

Check valve. Replace if defective. -

4.2-9 Platform will not Drive in Forward or Reverse

1. Open free-wheeling valve V2.

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. -

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Section 4 - Troubleshooting Information Service and Maintenance

Hydraulic System (Continued)

4.2-10 Brake(s) will not Release

1. Brake valve 3H-17 defective or is sticking.

Clean valve. Replace if defective. -

2. Brake orifice 04 plugged.

Remove orifice. Clean and reinstall. -

3. Brake cylinder C4 defective.

Rebuild cylinder. Replace if damaged. -

4.2-11 Platform does not Steer

1. Right steer valve 4H-23 or left steer valve 4H-24 defective or sticking.

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. -

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Section 5

PROCEDURES

Table of Contents

Service and Maintenance

General .........................................................................................................................................................................3

Safety and Workmanship .............................................................................................................................................3

Platform

5.1-1 OEM Controller Electronics Information ...........................................................................................................3

5.1-2 OEM Controller Troubleshooting ......................................................................................................................4

5.1-3 OEM Controller switch wiring ............................................................................................................................5

Base

5.2-1 System Relief Pressure Adjustment ..................................................................................................................6

5.2-2 Lift Pressure Adjustment ...................................................................................................................................6

5.2-3 Electronic Tilt Switch Setup Procedure .............................................................................................................7

Tilt Switch Replacement ....................................................................................................................................7

Reprogramming Existing Tilt Switch .................................................................................................................9

Test and Verify Tilt Circuit ................................................................................................................................10

Load Sensing System - CE

5.3-1 Control Module Pin Reference Chart ..............................................................................................................11

5.3-2 LED Error Codes - Quick Reference Chart .....................................................................................................12

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

SKYJACK, Page 1SJIII Series

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Section 5 - Procedures Service and Maintenance

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.

Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

Platform

5.1-1 OEM Controller Electronics Information

Flow Control

Single coil or solenoid for single direction. The coil has two connections; one is wired to the P.C. Board (A) terminal and the other is wired to (-), or the negative side of the supply voltage. Switches to control directional valves may be provided on the controller.

“Threshold” Adjustments

Adjust the initial current flow or duty cycle, affecting the function response or speed when the handle is first moved from the off position. Deflect the handle slowly to the position where the controller first turns on. Adjust the threshold trimpot screw to the point where the controlled function just starts to move, then turn the trimpot screw one, full turn in the counterclockwise direction. This adjustment should be done first.

“Maxout” Adjustments

Adjust the full stroke current or duty cycle affecting the maximum function response, or speed when the handle is deflected to its full travel. Fully deflect the handle, and adjust the maxout trimpot for maximum desired function response or speed. To obtain proportional resolution, it is important that the function starts to slow down as soon as the handle is moved back from the fully deflected position.

The ideal adjustment occurs when the function just begins to move when the handle is deflected, and the output increases until it reaches its maximum desired response or speed at the end of handle travel.

Adjustment Procedures

Adjustments are made by turning a trimpot adjustment screw. The trimpots are multi-turn, end-to-end devices. It may be necessary to turn the adjustment screw several turns to observe a change in output.

Clockwise (CW) adjustment of the trimpot increases the output.

Counter-clockwise (CCW) adjustment of the trimpot decreases the output.

Adjustments affect output current, voltage or percentage of duty cycle to the coil. The minimum and maximum output is preset at the factory. However, for optimum performa nce, they mus t be adjusted while the equipment is operating.

Although the following adjustments affect the current/ voltage or percentage of duty cycle, the best way to adjust the function is to observe the response or speed of the function. The following adjustments affect function response, or speed. There may be some interaction between adjustments, making it necessary to repeat the adjustment in order to achieve the desired response.

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Section 5 - ProceduresService and Maintenance

5.1-2 OEM Controller Troubleshooting

Problem

1. The function will not operate when the handle is moved. The LEDs do not light

A. Check that voltage is present at the positive

(+)input terminal.

B. Check that ground is connected to the

negative (-) terminal.

C. If there is an in-line fuse, check to see if it is

good.

D. Check the controller on/off switch and the

connectors. Voltage should be present at the (X) terminal when the controller is turned on.

E. Check that valve wiring is not shorted to

ground. The LEDs will not light.

F. Check that valve wiring is not open. The

LEDs will light, but the intensity will not vary.

G. Check trimpot settings. Fully “CCW” turns

output off, “CW” turns output fully on.

2. The function jumps or lurches when turned on.

A. P e r f o r m “ T h r e s h o ld ” a d ju st me nt

procedures.

3. The function reaches maximum speed before the handle is fully deflected,

A. Perform “Maxout” adjustment procedures.

4. The function speed remains constant regardless of the degree of handle deflection.

A. Perform “Maxout” adjustment procedures.

IRS Option

1. Function speed reacts too slowly or too quickly in relation to handle deflection.

A. Check “IRS” (Ramp) trimpot adjustment.

“CW ” inc r ea s e s ra m p ti m e, “ C CW ” decreases ramp time.

Integrated Ramp System (IRS)

Provides smooth function response ,when reacting to an abrupt change in handle deflection. “CW” rotation of the trimpot increases ramp time and slows the response time. “CCW” decreases ramp time and increases the response time. To increase the ramp time, turn the adjusting screw “CW” a few turns, then move the controller handle abruptly. Continue to adjust until a smooth response is observed. Most controllers have on/off contacts which remove power from the P.C. Board when the handle is returned to the off position. When the handle is abruptly returned to neutral, the output will not ramp down, and the function will stop.

Ramp Thru Off

The P.C. Board should be adjusted as outlined in the IRS adjustment procedure. If the handle is abruptly returned to neutral (OFF) the output will ramp down to off. Ramp time is factory set to 2 seconds, unless otherwise specified.

NOTE

Trimpots should be sealed with nail polish

or enamel based paint.

WARNING

Do not use RTV silicone.

SKYJACK, Page 4 SJIII Series

Page 94

Section 5 - Procedures Service and Maintenance

DOUBLE DOT (STEER RIGHT)

SINGLE DOT

(STEER LEFT)

ENABLE

STEER COMMON

STEER RIGHT

STEER LEFT

ENABLE OUT

+24V INPUT

WHT/GRN

WHT

BLU PWD OUT (A)

BLK GROUND (-)

YEL FORWARD/UP

GRY

RED NO

H10

15589 PCB

BLK

REVERSE/DOWN

CONNECTOR

WHT/RED

WHT/BLU

WHT/BLK

WHT/BLK(+24V INPUT) WHT/YEL(ENABLE)

5.1-3 OEM Controller switch wiring

WIRE CHART

COLOR FROM TO

WHT/RED STEER LEFT PIN #1

WHT/GRN STEER COMMON PIN #2

WHT STEER RIGHT PIN #3

YEL FORWARD/UP PIN #4

WHT/BLK +24V INPUT PIN #5

GRY REVERSE/DOWN PIN #6

BLU PWM OUT (A) PIN #7

BLK GROUND (-) PIN #8

WHT/BLU ENABLE OUT PIN #9

SKYJACK, Page 5SJIII Series

Page 95

Section 5 - ProceduresService and Maintenance

Base

5.2-1 System Relief Pressure Adjustment

1. Locate the system pressure quick disconnect port on the main manifold.

2. Install a calibrated 5000 psi gauge to the system pressure quick disconnect port.

3. Remove the platform control console the guardrail and disconnect from the main control cable.

4. Locate the main control cable plug at the rear of the aerial platform.

5. Disconnect the main cable and connect the platform control console into the plug.

6. At the main manifold, loosen the locknut on the system relief valve R1.

7. Select drive with the lift/drive select switch on the platform control console.

8. Engaged steer right and hold.

9. Observe reading on gauge. Adjust the R1 system relief value listed on the serial number plate. Turning the stem on the relief valve clockwise wi ll increa ses press ure. Tu rning th e stem counterclockwise will decreases pressure.

10. Release steer switch and tighten the locknut.

11. Remove the gauge from system pressure test port.

5.2-2 Lift Pressure Adjustment

NOTE

Adequate area to raise the platform to full

height is required for the following steps.

1. Locate the lift pressure test port on the main manifold.

2. Install a calibrated 3000 psi gauge to the lift pressure quick disconnect port.

3. At the main manifold, loosen the locknut on the lift relief valve R2.

4. Close the manual lowering valve. Use the lift switch at the base control console to raise the platform to full height and hold the lift up switch on.

5. Observe the reading on the gauge. Adjust the R2 relief valve to the value listed on the serial number plate. Turning the stem of the relief valve clockwise will increases pressure. Turning the stem counterclockwise will decreases pressure.

6. Remove the gauge from lift pressure test port.

NOTE

Pressure setting may vary as aerial platform components wear. The lift pressure should

be set for rated load only.

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Section 5 - Procedures Service and Maintenance

Y AXIS

X AXIS

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

5.2-3 Electronic Tilt Switch Setup Procedure

The following information is supplied for replacement or reprogramming of the electronic tilt switch. Also included are test and verification instructions. Follow the appropriate procedures below.

Tilt Switch Replacement

1. Ensure aerial platform is parked on a firm level surface.

2. Chock or block wheels to keep the aerial platform from rolling forward or backward.

3. Lower/Raise the platform and secure the scissors using the maintenance bar. (Refer to Operating manual for Maintenance Support Procedure)

4. Push in “

” emergency stop buttons and turn

main disconnect switch to “ ” off position.

5. Remove any covers to locate and view the tilt switch.

6. Disconnect tilt switch from 4 pin connector.

7. Remove old tilt switch from mount.

NOTE

Ensure part number of old and new tilt

switch are the same.

8. Install new switch to mount (in the same orientation as the old switch) and connect switch plug to 4 pin connector.

NOTE

The tilt circuit is only powered when

activating a function.

9. Disconnect all wires #02 from motor contactor.

10. Install jumper wire between #7 and #19 to terminal strip.

11. Turn main disconnect switch to “

” ON position.

12. Verify switch is powered. (Red or green LED will be continually blinking)

13. Program the Tilt Switch

Press and release the set up button 3 a. times.

Observe program delay b. / stabilization time. (Only the red LED will blink for 4 seconds)

B o t h L E D s w i l l c. flash for 1 second. Results: The switch is learning the new zero position.

Bo th LEDs will turn d. on solid for 1 second. Results: The new zero po s it io n ha s be e n learned.

The green LED will flash and then the e. red LED will turn on solid for 2 seconds.

Results: The switch is verifying the new zero position.

T h e g r e e n L E D f. will turn on solid. Results: The switch is ready fo r normal operation.

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14. Turn main di s c o n nect switch to “ ” off position.

15. Remove jumper wire between #7 and #19 from terminal block.

16. Reattach all wires #02 to motor contactor.

17. Reinstall any covers that was removed.

18. Remove chock or wheel blocks.

19. Proceed to Test and Verify Tilt Circuit.

Section 5 - ProceduresService and Maintenance

SKYJACK, Page 8 SJIII Series

Page 98

Section 5 - Procedures Service and Maintenance

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Red LED

Green LED

Reprogramming Existing Tilt Switch

Set up button is located on this

Light Indicators

face next to harness

1. Ensure aerial platform is parked on a firm level surface.

2. Chock or block wheels to keep the aerial platform from rolling forward or backward.

3. Lower/Raise the platform and secure the scissors using the maintenance bar. (Refer to Operating manual for Maintenance Support Procedure)

NOTE

The tilt circuit is only powered when

activating a function.

4. Remove any covers to locate and view the tilt switch.

5. Disconnect all wires #02 from motor contactor.

9. Reprogram the Tilt Switch

Press and hold the set a. up button for 3 seconds. Results: Both LEDs will be OFF.

Both LEDs will flash. b.

IMPORTANT

Step “c” must be completed within a 5 second period, or the switch will automatically exit program mode and return to normal operation using previously

stored data.

Press and release set up button 3 times.c.

If 5 seco n d pe r iod has expired prior d. completion, repeat Step “a”, “b” and “c”.

Observe program delay e. / stab i l i zation time. (Only the red LED will blink for 4 seconds)

B o t h L E D s w i l l f. flash for 1 second. Results: The switch is learning the new zero position.

6. Install jumper wire between #7 and #19 to terminal strip.

Both LEDs will turn g. on solid for 1 second. Results: T he n e w

7. Turn main disconnect switch to “

” ON position.

zero position has been learned.

8. Verify switch is powered. (Red or green LED will be continually blinking)

The green LED will flash and then the h. red LED will turn on solid for 2 seconds.

Results: The switch is verifying the new zero position.

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Section 5 - ProceduresService and Maintenance

Red LED

Green LED

Red LED

Green LED

T h e g r e e n L E D i. will turn on solid. Results: The switch is rea d y for no r mal operation.

10. Turn main di s c o n nect switch to “

” off

position.

11. Remove jumper wire between #7 and #19 from terminal block.

12. Reattach all wires #02 to motor contactor.

13. Reinstall any covers that was removed.

14. Remove chock or wheel blocks.

15. Proceed to Test and Verify Tilt Circuit.

Test and Verify Tilt Circuit

Set up button is located on this

Light Indicators

face next to harness

Operations of Tilt Switch

The following describes the LED’s and what they indicate.

Illuminated whenever both tilt axes are within the specified deg r e e s of the zero/ home

Green LED

Red LED

Green & Red LED

learned position. Flashes when transitioning in or out of tilt angle limits, but built in time delay has not fully occurred.

Illuminated whenever tilt on one or more axes is more than the specified degrees out from the zero/ home position.

On together, no blinking when fault detected.

Tilt Circuit Test

1. Refer to section 2 for test tilt sensor procedure.

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Section 5 - Procedures Service and Maintenance

PLUG

WIRE #

AND COLOUR

WIRE FUNCTION

P1 The Calibration Connection

P2 1 Not Used Not Used

P2 2 10E Black/White Input Power From Base Terminal Strip To Confirm Lower Control Is Selected P2 3 14 Black Raise Platform Input P2 4 13 Orange Lower Platform Input

P2 5 Not Used Not Used P2 6 Not Used Not Used

P2 7 16 White/Black Forward Direction Input P2 8 15 Blue Reverse Direction Input

P2 9 Not Used Not Used

P2 10 18B Red/Black Input From LS1 High Speed Limit Switch To Verify ON/OFF Limits P2 11 02 White Negative Input From Base Terminal Strip P2 12 7A Red Main Power Input From Base Terminal Strip P3 1 22 Red Output To FL-22 Flashing Light P3 2 29 Black Output To BP-29 Beeper P3 3 60 Black/White Output To Overload Warning Light On Control Box P3 4 28 Green/Black Output To 28CR1 Tilt Relay And 28CR2 Down Relay P3 5 02 White Negative for Flashing Light and Beeper P3 6 28E Green/White Output To 28ECR1 Aux. Tilt Relay And 28ECR2 Aux. Down Relay

P4 1 Not Used Not Used

P4 2 60A Green Varied Input From Transducer P4 3 28B Green Varied Input From Angle Transducer P4 4 Not Used Not Used P4 5 Not Used Not Used P4 6 910 Black Positive Signal To Angle Transducer P4 7 900 White Negative Signal To Angle Transducer P4 8 902 White Negative Signal To Pressure Transducer P4 9 910A Black Positive Signal To Pressure Transducer

M60303AG

Load Sensing System - CE

5.3-1 Control Module Pin Reference Chart

SKYJACK, Page 11SJIII Series