Skyjack SJ20 Service Manual Download Page 65

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SJ20

238886ABA

Section 5 – Procedures

Display Module

Display Message

Description

Display Message

Description

S170-CTRL_ERR

INCORRECT KEY voltage

S175-M3_ERR

SPEED SENSOR ERROR

S177-BRK2_ERR

SHORT CIRCUIT COIL BRAKE

S178-M3_TEMP

STOP MOTOR TEMP

S180-M3_ERR

OVERLOAD

S181-M3_ERR

INCORRECT ENCODER

S186-M3_ERR

WAIT FOR MOTOR POSITION

S187-CTRL_ERR

L LOWERING

S188-CTRL_ERR

INTERNAL CAN BUS ERROR

S189-SEQUENCE

INCORRECT PUMP STARTING

S190-M1_ERR

PUMP FEEDBACK VOLTAGE NOT GOOD

S191-JSTK_ERR

CONTROL LEVER VOLTAGE NOT GOOD

S192-JSTK_ERR

THE CONTROL LEVER ACQUISITION NOT
GOOD

S193-CTRL_ERR

FAULTY SMARTDRIVE

S194-CTRL_ERR

AUXILIARY BATTERY SHORT CIRCUIT

S195-BRK2_ERR

SHORT CIRCUIT POSITIVE COIL BRAKE

S196-M3_ERR

SHORT CIRCUIT MOTOR PHASE

S97-CTRL_ERR

SECONDARY INCORRECT VERSION

S198-CTRL_ERR

MAIN / SECONDARY INCORRECT CHECK
PARAMETER

S199-CTRL_ERR

PARAMETER TRANSFER

S200-CTRL_ERR

VDC OFF SHORT CIRCUIT

S201-M3_ERR

TORQUE PROFILE

S202-CTRL_ERR

HIGH VOLTAGE VDC LINK

S204-BRK2_ERR

FAULTY SERVICE BRAKE

S206-CTRL_ERR

INTERNAL VOLTAGE TOO HIGH

S207-CTRL_ERR

INTERNAL VOLTAGE TOO LOW

S208-CTRL_ERR

FAULTY EEPROM

S209-CTRL_ERR

RESTORE PARAMETER

S10-CTRL_ERR

INCORRECT RAM MEMORY

S211-M3_ERR

STALL ROTOR

S212-M3_ERR

POWER NOT PAIRED

S213-C1_ERR

LC POSITIVE COIL OPEN

S214-2H-13_ERR

OPEN COIL EVP

S215-2H-13_ERR

SHORT-CIRCUIT CONTROL DRIVER EVP

S216-BRK2_ERR

OPEN COIL BRAKE

S217-CB2_PWR

INCORRECT PEB

S218-M3_TEMP

ENGINE SENSOR TEMP DEFECTIVE

S219-2H-13_ERR

EVP1 POISITVE COIL INCORRECT

S220-08C_LOW

VKEY OFF SHORT CIRCUITY

S223-C1_ERR

MC SHORT CIRCUIT COIL

S224-CHK_
SECONDARY

WAITING FOR NODE

S226-JSTK_ERR

DEFECTIVE VACC

S227-CTRL_ERR

FAULT MATERIAL

S29-CTRL_ERR

FAULT MATERIAL BRAKE

S230-C1_ERR

LC OPEN COIL

S231-CTRL_ERR

CURRENT PUMP NOT ZERO

S232-CTRL_ERR

ELECTRIC VALVE DRIVER

S233-CTRL_ERR

SHORT CIRCUIT POWER MOSFET

S234-CTRL_ERR

EV SHORT-CIRCUIT

S235-CTRL_ERR

CTRAP THRESHOLD

S236-CTRL_ERR

CURRENT GAIN

S38-CTRL_ERR

EV FAULT MATERIAL

S239-CTRL_ERR

FAULTY CONTROLLERS

S240-CTRL_ERR

OPEN CONTROL PILOT EVP

S241-COIL_ERRXX

SHORT CIRCUIT COIL EVAUX

S242-COIL_ERRXX

EV OPEN COIL

S244-CHK_
SECONDARY

SECONDARY FAULT

S245-CTRL_ERR

IQ NOT MATCHED

S246-CTRL_ERR

OPEN CONTROL PILOT COIL BRAKE

S248-CAN_ERRXX

NO CAN MESSAGE

S249-CTRL_ERR

VERIFICATION NECESSARY

S50-M3_TEMP

TEMP SENSOR FAULT

S251-CTRL_ERR

INCORRECT BATTERY

S253-CTRL_ERR

FAULT FIELD ORIENTED CONTROL

S254-CTRL_ERR

SHORT CIRCUIT CONTROL PILOT COIL
BRAKE

Summary of Contents for SJ20

Page 1: ...SERVICE MANUAL VERTICAL MAST LIFTS 238886ABA November 16 2021 ANSI CSA SJ20...

Page 2: ...his manual is based on serial numbers SJ20 A601 000 001 above Please refer to the website www skyjack com for contact information other serial numbers the most recent technical manuals and USB softwar...

Page 3: ...death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situ...

Page 4: ...4 SJ20 238886ABA Notes...

Page 5: ...1 3 Hydraulic System Component Maintenance and Repair 11 1 3 1 Maintenance Hints 11 1 4 About this Section 12 1 4 1 Service Bulletins 12 1 4 2 Maintenance and Inspection 12 1 4 3 Maintenance Instructi...

Page 6: ...ulic Connections 39 3 7 Platform Control Box Wiring 40 3 8 Platform Control Cable Wiring 41 3 9 Platform Control Box Wiring SGLE 42 3 10 Platform Control Cable Wiring SGLE 43 3 11 Beeper 44 3 12 Base...

Page 7: ...Maintenance 69 5 5 2 Charger Profiles 70 5 5 3 Charger Troubleshooting 71 5 5 4 Charger Error Codes 72 5 6 Mast Lubrication 76 5 6 1 Outer Mast Lubrication 76 5 6 2 Inner Mast Lubrication 77 5 7 Platf...

Page 8: ...8 SJ20 238886ABA Notes...

Page 9: ...esistant 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 prom...

Page 10: ...properly must be immediately tagged and removed from service until proper repairs are completed 1 2 3 Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel...

Page 11: ...ulic 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 hydrauli...

Page 12: ...g configuration MEWP parked on a flat and level surface Disconnect the batteries by disconnecting the main power connectors Repair any damaged or malfunction components before operating MEWP Keep reco...

Page 13: ...Do not use the MEWP if there is no inspection recorded in the last 13 months If you do not obey there is a risk of death or serious injury IMPORTANT The Owner s annual inspection record is located on...

Page 14: ...ires for damage wear correctly aligned B Wheel Tire Assembly Wheel nuts torqued as recommended C Axles Correctly attached no missing components Tight fittings and hoses no leaks B Axles Do a check and...

Page 15: ...MEWP is on a firm level surface before you do the visual and daily maintenance inspections If you do not obey there is a risk of machine damage 1 7 1 Labels B Refer to your MEWP s operation manual fo...

Page 16: ...arger is correctly installed and in good condition Make sure there is no visible damage 5 Pothole protection B Make sure there are no visible cracks or signs of damage or deformation 1 7 6 Wheel tire...

Page 17: ...unks in the edges and tread face of the tire Refer to Figure 02 The cut or missing chunk must not extend more than 10 mm 3 8 towards the centre of the tire Each cut or chunk should not be larger than...

Page 18: ...foot pedal is in good working order and that it has no loose or missing parts and there is no visible damage 2 Fall protection anchorages B Make sure that the fall protection anchorages are correctly...

Page 19: ...battery case for damage 2 Make sure all the battery connections are tight 3 If applicable do a check on the battery fluid levels If the plates do not have a minimum 13 mm 1 2 inch of solution above th...

Page 20: ...embly is correctly installed Make sure there are no loose or missing fasteners Make sure there is no visible damage 6 Steer linkages B Make sure there are no loose or missing fasteners and lock pins M...

Page 21: ...ear pads B Make sure the bolts are tight Make sure there are no loose or missing parts Make sure there is no visible damage 1 7 10 Optional equipment and attachments 10 Flashing lights B Make sure the...

Page 22: ...22 SJ20 238886ABA Notes...

Page 23: ...ID 3 16 1 4 3 8 1 2 5 8 3 4 1 1 1 4 1 1 2 2 2 1 2 3 3 1 2 4 Fitting Arrangement Schedule Hose Prefix Hose End Fitting Hose End Fitting S A E Hose Specification H01 FEMALE 37 JIC SWIVEL FEMALE 37 JIC...

Page 24: ...ORT 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R4 H39 LONG 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R4 H40 SHORT 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R16 H43 FEMALE 37 JIC SWIVE...

Page 25: ...in Stowed Platform Height Railings Up 2 01 m 79 19 in Drive Height Full Stowed Platform Height 0 75 m 29 7 in Standard Operating Times Lift Time Rated Load 26 s Lower Time Rated Load 26 s Chassis Sto...

Page 26: ...ty Traversing Platform Capacity Manual Side Force Tilt Cutout Setting side to side x front to back SJ20 Indoor 0 m s 0 mph 159 kg 350 lb 1 person 159 kg 350 lb 1 person 200 N 45 lbf 1 5 x 2 5 2066AA N...

Page 27: ...h the floor tire OFL Overall Floor Load Pressure is a measure of the average load the MEWP imparts on the whole surface directly underneath the chassis This has been calculated by dividing the MEWP we...

Page 28: ...ex head 3 8 16 x 1 1 2 Grade 5 23 31 Location Description Torque ft lb Torque Nm Mast Emergency Lowering Coil Washer N A 4 5 6 Emergency Lowering Valve N A 21 28 Mast to Base Mounting Bolts BOLT Hex h...

Page 29: ...0 90 Nm 75 54 122 88 163 122 Size Torque Type SAE2 SAE 5 SAE 8 Dry Lubed Dry Lubed Dry Lubed 9 16 12 ft lb 70 55 110 80 150 110 Nm 95 75 149 108 203 149 9 16 18 ft lb 80 60 120 90 170 130 Nm 108 81 16...

Page 30: ...94 M14 x 2 00 ft lb 104 78 148 111 Nm 141 106 201 150 M16 x 2 00 ft lb 161 121 230 172 Nm 218 164 312 233 M18 x 2 50 ft lb 222 167 318 238 Nm 301 226 431 323 M20 x 2 50 ft lb 314 235 449 337 Nm 426 31...

Page 31: ...614 Hose End Torque Chart for JIC Size Steel Brass Dash Frac ft lb Nm ft lb Nm Min Max Min Max Min Max Min Max 4 1 4 10 11 13 15 5 6 6 75 9 6 3 8 17 19 23 26 12 15 17 20 8 1 2 34 38 47 52 20 24 27 66...

Page 32: ...32 SJ20 238886ABA Notes...

Page 33: ...33 SJ20 238886ABA Section 3 System Component Identification and Schematics...

Page 34: ...BATTERY FUSE GROUND CIRCUIT BREAKER VOLT METER CAPACITOR POTENTIOMETER SINGLE POLE DOUBLE THROW RELAY TRIPLE POLE DOUBLE THROW RELAY RELAY RELAY DOUBLE POLE DOUBLE THROW SINGLE POLE SINGLE THROWN TIL...

Page 35: ...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 COOL...

Page 36: ...BLK 102 PNK 2005 GRN WHT 07 RED 28 GRN RED 60 BLK RED GRN 103 RED 3008 GRY 08 PUR WHT 29 BLU YEL 71 BLU RED 103B BLK 4002 RED 09 ORG RED 30 BRN 72 WHT BLK RED 103C WHT 7002 RED 10 BLU WHT 31 RED WHT...

Page 37: ...COIL 24 V C1 4 234130 CYLINDER Multistage with cushion C1 5 234078 STEER CYLINDER CV1 234711 VALVE Check F1 234269 FILTER 7 Micron return F2 234270 FILTER 7 Micro return MB1 234720 MANIFOLD SJ20 Main...

Page 38: ...1 234591 DUAL FLASHING LIGHTS H1 146649 HORN 24V Low tone J11 213098 TELEMATICS Optional LS1 199405 LIMIT SWITCH Base LS3 234218 LIMIT SWITCH Platform service position LS4 234219 LIMIT SWITCH Platfor...

Page 39: ...9 SJ20 238886ABA Section 3 System Component Identification and Schematics Hydraulic Connections S2 Left Steer Right Steer S1 3 6 Hydraulic Connections M234628AA Steer Cylinder Power Unit Lift Cylinder...

Page 40: ...N HI 10 GREEN CAN LO 11 BLACK 120 12 BLACK 120A 13 N A N A 14 WHITE 00 15 WHITE 00 16 WHITE 00 POSITION CIRCUIT FUNCTION COLOUR 1 6 N A N A N A 7 12 DRIVE BROWN RED 8 49 HORN GREEN 9 14 N A N A N A 15...

Page 41: ...07 RED 16 12A GY OR 20 51 BK GN 20 08 PU WH 20 S4 EMERGENCY STOP S8 HORN S3 LIFT OFF DRIVE TO BATTERY CHARGE INDICATOR 08C PU WH 20 08C PU WH 18 00 WH 18 00 WH 16 CANHI YL 20 CANLO GN 20 07 RED 16 08...

Page 42: ...GREEN 51 8 BROWN WHITE 82 9 YELLOW CAN HI 10 GREEN CAN LO 11 BLACK 120 12 BLACK 120A 13 N A N A 14 WHITE 00 15 WHITE 00 16 WHITE 00 16 PIN JOYSTICK CONNECTOR POSITION CIRCUIT FUNCTION COLOUR 1 6 N A N...

Page 43: ...09 OR RD 20 07 RED 16 12A GY OR 20 51 BK GN 20 08 PU WH 20 S4 EMERGENCY STOP S8 HORN S3 LIFT OFF DRIVE TO BATTERY CHARGE INDICATOR 08C PU WH 20 08C PU WH 18 00 WH 18 00 WH 16 CANHI YL 20 CANLO GN 20...

Page 44: ...Beeper 3 12 Base Limit Switch 3 13 Platform Limit Switches M215817AC_M234204AC_M234218AD_M234219AE WIRE COLOUR WIRE LABEL RED 29 BLACK 02 WIRE CAVITY BROWN 1 BLUE 2 BLACK 3 BLACK WHITE 4 YELLOW GREEN...

Page 45: ...J20 238886ABA Section 3 System Component Identification and Schematics Motor and Controller Connections 3 14 Motor and Controller Connections M234099AC Power Unit Left Motor Right Motor SW SW SV SV SU...

Page 46: ...4 08C PU WH 18 OUTDR JUMPER 8 07 RD 16 82 9 08 PU WH 18 CAN HI 10 08C PU WH 18 CAN LO 11 08C PU WH 18 OUTDR JUMPER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 1 2 3 4 5 6 5 6 07 RD 16 08 PU WH 18...

Page 47: ...Component Identification Platform Control Console Platform Maintenance Lock ZAPI Controller Base Controls Load Cells Charger Main Disconnect Switch Load Cell Junction Box Deck Extended Limit Switch Ba...

Page 48: ...8886ABA 3 17 Hydraulic Schematic M234001AB 0 079 in C5 RV2 RV1 CV1 OR1 2H 13 3H 14 4H 23 4H 24 P1 F1 F2 3 59 CC REV LIFT S1 S2 MB1 SV3 SV1 SV2 2900 6400 RPM C1 C2 C3 C4 2000 psi LIFT CYLINDER STEERING...

Page 49: ...MODULE 08L 08L RD 29 BK 03B 03A D 3 0 08C 00 07 S10 KEY SWITCH 49 30 08C 08L 03C 13A 14A 60 19B 05A H1 HORN S6 BRAKE RELASE SWITCH S5 DIAGNOSTIC SWITCH S28 EMERGENCY STOP S2 LIFT LOWER J4 TO ZAPI B CO...

Page 50: ...ITE 19 GREEN BLACK 03A GREEN PURPLE 08C 08C SCANHI P3 P9 TO LEFT BRAKE S05C 19A TO TELEMATIC SYSTEM PIN 1 19A ORANGE BLACK SCANLO P3 BACK VIEW TO LOWER CONTROL BOX PIN 1 08 PURPLE WHITE PIN 2 08C PURP...

Page 51: ...O MAST RAISE SOLENOID EN1 TO RIGHT MOTOR SENSOR TO BATTERY CHARGER CAN TO BATTARY NEGTIVE 08R PU WH 18 05C PU BU 18 00R WH 18 CHBR BU 18 30R BU RD 18 TMPR BK WH 18 00R WH 18 S00B CANL GN 20 CANH YL 20...

Page 52: ...8 7 6 5 9 10 11 12 15 14 13 16 17 18 19 23 22 21 20 TO P4 LOWER CONTROL BOX PIN 1 60 BLACK GREEN PIN 2 03C GREEN PURPLE PIN 3 14A BLACK PIN 4 13A ORANGE PIN 5 10 BLUE WHITE PIN 6 07 RED PIN 7 19B GREE...

Page 53: ...U BN BN BK WH BK B3 P22 1 P22 2 DIAG CONN 00 08C J2 1 J2 2 J2 3 J2 4 J1 1 J1 6 J1 3 J1 4 DIAGNOSTIC CONNECTOR P 25 07 B12 10 08 08 A7 08C X1 4 CAN L 5 08C B11 30 S6 BRAKE RELEASE SWITCH 08C HORN H1 CB...

Page 54: ...54 SJ20 238886ABA Notes...

Page 55: ...oubles 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 isola...

Page 56: ...ose or broken wire 03A from motor contactor C1 to circuit breaker CB1 Check continuity Replace if defective 8 Circuit breaker CB1 tripped or defective Reset breaker check for defective wiring Replace...

Page 57: ...hine controller pin B19 Check continuity Replace if defective 9 Loose or broken wire 03C from circuit breaker CB2 to lift 3H 14 right steer 4H 23 and left steer 4H 24 coils Check continuity Replace if...

Page 58: ...Controls 1 Loose or broken wire 14A from lift lower switch S2 to machine controller pin B2 Check continuity Replace if defective 2 Open or defective lift lower switch S2 Close switch Replace if defect...

Page 59: ...on upper contol joystick Check wiring and switch Repair or replace if defective 4 2 12 No Drive 1 Loose or broken 12 wire from lift off drive switch S3 to joystick pin P 07 Check continuity Replace if...

Page 60: ...place if defective 3 Defective pump P1 Check pump output Replace if defective 4 System relief valve RV1 set too low or stuck open Check and adjust valve setting Replace if defective 4 3 2 No Lift Func...

Page 61: ...op buttons on the platform control console and the base control console 4 Turn the off platform base key switch to the off position Remove the key 5 Turn the main power disconnect switch to the off po...

Page 62: ...CLOSED M38 C1 OPEN CONTACTOR OPEN M52 M2_AMP_LOW PUMP I 0 ALL THE TIME M53 M2_AMP_HI HIGH STANDBY CURRENT M60 CTRL_ERR CAPACITOR CHARGER M62 CTRL_TEMP THERMAL PROTECTION M65 M2_TEMP MOTOR TEMPERATURE...

Page 63: ...IVE M194 CTRL_ERR AUXILIARY BATTERY SHORT CIRCUIT M195 BRK1_ERR SHORT CIRCUIT POSITIVE COIL BRAKE M196 M1_ERR SHORT CIRCUIT MOTOR PHASE M197 CTRL_ERR SECONDARY INCORRECT VERSION M198 CTRL_ERR MAIN SEC...

Page 64: ...LOW_BATT LOW BATTERY S74 CTRL_ERR DRIVER SHORT CIRCUIT S75 CTRL_ERR CONTACTOR DRIVER FAULTY S78 JSTK_VERR ACCELERATOR VOLTAGE NOT OK S79 ENABLE_ERR INCORRECT START UP S80 JSTK_ERR FORWARD BACKWARD S1...

Page 65: ...PROM S209 CTRL_ERR RESTORE PARAMETER S10 CTRL_ERR INCORRECT RAM MEMORY S211 M3_ERR STALL ROTOR S212 M3_ERR POWER NOT PAIRED S213 C1_ERR LC POSITIVE COIL OPEN S214 2H 13_ERR OPEN COIL EVP S215 2H 13_ER...

Page 66: ...an the bearings using solvent and allow them to dry 3 Coat the inner and outer bearings with grease completely Be careful not to contaminate the grease This could cause internal damage and shorten the...

Page 67: ...e wheel 5 Use a hub puller to remove the wheel from the motor Front Wheel Install 1 Install the new wheel onto the spindle 2 Install the castle nut Finger tighten the nut 3 Torque the castle nut to 20...

Page 68: ...ing life would be reduced 4 Loosen the castle nut to remove the torque Do not rotate the wheel 5 Finger tighten the castle nut until it is snug NOTE The castle nut should be free to rotate with the on...

Page 69: ...n of solution add distilled or demineralized water 4 Make sure all the battery connections are tight NOTE Do not use any batteries other than the flooded lead acid batteries of the proper Ah rating WA...

Page 70: ...splays up to three times NOTE The process times out and the profile remains unchanged if there are 15 seconds of inactivity or if the charging profile is allowed to display three times 7 Press and rel...

Page 71: ...t Error Indicator Read fault code e g F 0 0 1 number on the Charge Algorithm Error Display and refer to the fault code table Flashing Amber Fault Error Indicator Read error code e g E 0 0 1 number on...

Page 72: ...ltages Check for shorted or damaged cells Poor battery health Replace the battery Batteries too large for the charger Replace batteries Very deeply discharged battery Retry charge Battery connections...

Page 73: ...sconnecting DC or AC E 0 1 9 Hardware build does not support software version The charger hardware does not support the new software version Existing SW is left running Contact Delta Q Technologies E...

Page 74: ...to an AC source with a stable AC voltage between 85 and 270 VAC 45 65 Hz This error will automatically clear once the condition has been corrected E 0 2 8 Attempt to select algorithm incompatible with...

Page 75: ...ation This error automatically clears once the condition has been corrected E 0 3 8 Fan will not turn Fan equipped models only Check fan connections Check to make sure the fan turns freely and is not...

Page 76: ...ast Lubrication 1 Use the base controls to fully extend the mast 2 Turn the main disconnect switch to the off position 3 Clean any existing lubricant off of the sides of the vertical mast 4 Apply DuPo...

Page 77: ...nter the platform 4 Remove and set aside the top mast cover and wing screws 5 Apply DuPont Multi Use Lubricant 158692 or any PTFE wax based dry lubricant behind and around all top wear pads in each se...

Page 78: ...tch connections from the mast electrical housing 4 Loosen the strain relief from the bottom of the housing and pull out the limit switch wires 5 Attach the platform control and limit switch cables to...

Page 79: ...ifting device to pull out the platform fully and set it aside on a protective surface 10 Remove the bolts and nuts that secure the lower platform to the mast 11 Make sure the load cells stay attached...

Page 80: ...latform Removal 13 Remove and set aside the hardware from the junction box 14 Put the junction box on the chassis 15 Tilt the lower platform backwards 16 Use an appropriate lifting device or a second...

Page 81: ...ond person to help install the lower platform 2 Tilt the platform towards the chassis 3 Use the bolts and nuts removed earlier to secure the lower platform to the mast load cells 4 Use the screws remo...

Page 82: ...lts and washers removed earlier to secure the front rollers 9 Push the platform in fully 10 Use a screwdriver to open the mast electrical housing so you can see the wire connections 11 Loose the strai...

Page 83: ...ottom of the lift cylinder 2 Disconnect the hydraulic hose from the bottom of the holding valve manifold Put a cap and plug on all open hydraulic ports and fittings 3 Remove and set aside the hardware...

Page 84: ...l 5 Remove and set aside the hex standoff and red knob from the holding valve manifold 6 Remove and set aside the mast cover and wing screws 7 Use lifting straps to raise the lift cylinder out of the...

Page 85: ...t cylinder and install it inside the mast Make sure the holding valve coil faces the rear of the machine 2 Use the bolts and washers removed earlier to secure the lift cylinder from the bottom of the...

Page 86: ...nstallation 5 Connect the electrical connector to the holding valve coil 6 Use the bolts and washers removed earlier to secure the lift cylinder to the mast 7 Put the mast cover on top of the mast 8 F...

Page 87: ...emoved later 3 Open the service compartment cover 4 Disconnect the mast connector from the main harness 5 Cut zip ties along the cable bundles to free the mast cable 6 At the rear of the machine drill...

Page 88: ...sconnect the hydraulic hose from the bottom of the holding valve manifold Put a cap and plug on all open hydraulic ports and fittings 14 Remove and set aside the hex standoff and red knob from the hol...

Page 89: ...cylinder and install it onto the chassis Make sure the holding valve coil faces the rear of the machine 2 Use the bolts and washers removed earlier to secure the mast assembly to the chassis 3 Connect...

Page 90: ...st electrical connector to the main harness 9 Use tie wraps to secure the mast cable to the existing cable bundles 10 Route the AC power cable towards the rear of the machine and out the AC inlet hole...

Page 91: ...nder Installation 13 Use the nut removed earlier to secure the green ground wire from the AC inlet to the chassis 14 Use tie wraps to secure the AC power cable to the existing cable bundles 15 Install...

Page 92: ...d one section at a time Refer to the image below for the mast identification number when following this procedure Mast 5 Mast 4 Mast 3 Mast 2 Mast 1 5 13 2 Remove mast 5 and wear pads 1 Open the servi...

Page 93: ...e 8 Cut the tie wraps that secure the AC power cable to the cable carrier and existing cable bundles 9 Remove and set aside the screws that secure the mast electrical housing to the mast 10 Remove the...

Page 94: ...t the bottom of each cable coil Set the steel weights and mast cable aside 14 Use hoist rings and lifting straps to raise mast 5 until the bottom wear pads are visible 15 Remove and discard the rear w...

Page 95: ...there is a risk of minor or moderate injury 17 Remove mast 5 completely and set it aside on a protective surface 5 13 3 Remove mast 4 through 2 and wear pads 1 Wipe away the lubricant around the four...

Page 96: ...ottom of the mast CAUTION Crush hazard Personnel on the ground must stay away from the mast while it is being moved Make sure the wear pads are dry and do not have lubricant before you raise the mast...

Page 97: ...1 Remove and discard the wear pads at the top of mast 1 2 Use new pop rivets to attach two new thick and short wear pads 234170 to the front of the mast 3 Use new pop rivets to attach two new thin an...

Page 98: ...out through the base of the mast 2 The mast cable has tape markers at specific intervals so you know where to clamp it on the cable carriers at the top of each mast 3 Use the three cable clamps remov...

Page 99: ...ay down mast 1 2 Use lifting straps to put mast 2 onto mast 1 Make sure the holding valve cutout faces the rear of the machine 3 Keep mast 2 raised so that the bottom part is visible 4 Use new thread...

Page 100: ...lower it between mast 1 and mast 2 until the next tape marker is at the top of the cable carrier 7 Use the three cable clamps removed earlier to secure the cable to the mast 2 cable carrier 8 Raise ma...

Page 101: ...ers all the way down mast 2 12 Repeat steps 2 through 11 for masts 3 to 4 5 13 7 Install the mast 5 and bottom wear pads 1 Use hoist rings and lifting straps to put mast 5 onto the chassis 2 Keep the...

Page 102: ...g wear pads 234171 to the front of the mast 5 Pull the mast cable out of mast 1 and lower it between mast 4 and mast 5 6 Use the screws removed earlier to mount the mast electrical housing to the side...

Page 103: ...eplacement 8 Use the cable clamp nut and bolt removed earlier to attach the mast cable to the inner face of mast 5 9 Raise mast 5 until the cable loop is visible 10 Insert the weighted roller into the...

Page 104: ...the AC power cable to the inlet Green wire to the green terminal Black wire to the bronze terminal White wire to the silver terminal 18 Use new pop rivets to mount the AC inlet to the chassis 19 Use...

Page 105: ...d to the items listed below bent deformed guardrail sections cracks or broken welds in railing sections damaged pin connections missing pins or broken pin lanyards missing railing hardware loose or mi...

Page 106: ...106 SJ20 238886ABA Notes...

Page 107: ......

Page 108: ...www skyjack com...

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