Skyjack SJIII 3220 Service Manual Download Page 107 | Manualshive

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5

section 5

pROCE UREs

Table of Contents

ervice and Maintenance

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

Platform

5.1-1  OEM Controller Electronics Information ...........................................................................................................3
5.1-2  OEM Controller  roubleshooting ......................................................................................................................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  ilt Switch Setup Procedure .............................................................................................................7

ilt Switch Replacement ....................................................................................................................................7

Reprogramming Existing ilt Switch .................................................................................................................9

est and Verify ilt Circuit ................................................................................................................................10

Load ensing ystem - 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  ool 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

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Summary of Contents for SJIII 3220

Page 1: ...Service Manual SJIII Conventional Series MODELS SJIII 3220 SJIII 3226 SJIII 4620 SJIII 4626 SJIII 4632 Part No 143911AE March 2018...

Page 2: ...E mail parts skyjack com Skyjack Australia Pty Ltd 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel 61 0 28786 3200 Fax 61 0 28786 3222 Skyjack Brasil Indaiatuba SP Brasil 13347 653 T...

Page 3: ...E Table of Contents 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...

Page 4: ...rt Your safety is involved DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury wARNiNG WARNING indicates a potentially hazardous situa...

Page 5: ...dule 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 Maintenanc...

Page 6: ...r 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...

Page 7: ...quipment 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 Europ...

Page 8: ...al 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...

Page 9: ...D falling Stay within the boundaries of the guardrails DO NOT raise the aerial plat form in windy or gusty condi tions DO NOT increase the lateral surface area of the platform Increasing the area expo...

Page 10: ...ohibited DO NOT climb on scissor arm assembly It is prohibited BE AwARE of overhead obstructions or other possible hazards around the aerial platform when driving or lifting DO NOTraise the aerial pla...

Page 11: ...mply with applicable governmental regulations and must be inspected and used in accordance with the manufacturer s recommendations All personal fall protection equipment must be attached only to appro...

Page 12: ...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 repa...

Page 13: ...ly 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 co...

Page 14: ...specified perform each 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...

Page 15: ...pected By 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...

Page 16: ...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 t...

Page 17: ...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 inspecti...

Page 18: ...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 a...

Page 19: ...ke near batteries wARNiNG Battery acid is extremely corrosive Wear proper eye and facial protec tion as well as appropriate protective clothing If contact occurs immedi ately flush with cold water and...

Page 20: ...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...

Page 21: ...t procedure refer to section 5 Hydraulic Pump and Motor Ensure there are no loose or missing parts and there is no visible damage Electrical Panel Ensure panel is properly secured and there is no visi...

Page 22: ...tachment rings are secure and no visible damage AC Outlet on Platform Ensure outlet has no visible damage and free from dirt or obstructions Platform Control Console Ensure all switches and controller...

Page 23: ...ble 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 Scissor Bumpers E...

Page 24: ...platform into service Prior to performing function tests be sure to read and understand Section 2 10 Start Operation of the operating manual 1 2 1 Test Main Power Disconnect Switch 1 At rear of the ba...

Page 25: ...Select off platform base key switch off position Attempt to raise or lower the platform Result Platform raising and lowering functions should not operate 2 Select off platform base key switch to platf...

Page 26: ...lower 4 To restore normal operation depress and turn holding valve manual override knobs clockwise Test Free wheeling 1 Ensure path of intended motion is clear 2 Release the brake manually 3 Turn fre...

Page 27: ...e base emergency stop button is pulled out 2 Select off platform base key switch to platform position 3 Ensure main power disconnect switch is in on position wARNiNG Ensure that you maintain three poi...

Page 28: ...2 Activate and hold enable trigger switch 3 Slowly move controller handle in forward direction until aerial platform begins to move and then return handle to center position Result Aerial platform sho...

Page 29: ...rd 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 hav...

Page 30: ...handle Test Horn 1 Push horn pushbutton Result Horn should sound Test Pothole Sensor wARNiNG Ensure that you maintain three points of contact to mount dismount plat form 1 Use the ladder to dismount f...

Page 31: ...r 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...

Page 32: ...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...

Page 33: ...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 aer...

Page 34: ...r 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 1 Fill hardness 55 Durometer Wor...

Page 35: ...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 Ele...

Page 36: ...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 L...

Page 37: ...ec 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 D...

Page 38: ...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 El...

Page 39: ...of Aerial Platform Capacity Foot Print Area OUP Weight of Aerial Platform Capacity Base Area Length Length Width Width wARNiNG Intermixing tires of different types or using tires of types other than t...

Page 40: ...80 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 aver...

Page 41: ...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 platfo...

Page 42: ...19 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 su...

Page 43: ...5 m s 165AB 2 Persons 1 Person 1 Person 3 Persons 1 Person 3 Persons 3215 2 Persons 2 Persons 3 Persons 1 Person 3 Persons 2 Persons 1 Person Maximum Wind Speed Tilt Cutout Setting 1 5 x 3 5 1 5 x 3...

Page 44: ...exceed rated load m s km h ft s mph 3 3 4 5 4 12 5 19 4 11 5 17 75 5 12 0 Papers and thin branches move flags wave 4 5 4 8 0 19 4 28 8 17 75 26 25 12 0 18 Dust is raised paper whirls up and small bran...

Page 45: ...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 Manu...

Page 46: ...80 Coils Size Torque All coils Ft lb max 4 to 5 In lb max 48 to 60 Nm max 5 42 to 6 78 SAE Plugs Size Torque 2 4 5 6 8 10 12 16 Ft lb max 3 10 15 15 25 25 30 35 In lb max 36 120 180 180 300 300 360 42...

Page 47: ...23 3 15 Main Manifold Harness and Holding Valve Harness CE 24 3 16 Electrical Panel Diagram ANSI CSA 25 3 17 Electrical Panel Diagram CE 26 3 18 Electrical Panel Diagram ANSI CSA EE Rated 27 3 19 Har...

Page 48: ...UITS 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 RELAY DOUBLE P...

Page 49: ...ED 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...

Page 50: ...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 10 BLU WHT 33 GRN WHT 56 YEL BLK 79 BRN PUR 107 BLK BLU 11 WHT ORG 34 ORG...

Page 51: ...f equipped FD1 Flow Divier Combiner Valve 3H 18A 2 Speed Valve B 3H 18A 1 Speed Valve A V2 Free wheeling Valve V3 Auto Reset Valve P2 Hand Pump Hydraulic Fitting R1 System Relief Valve 2H 13 Lowering...

Page 52: ...VALVE Control Powered platform retract Models 3220 4620 4626 C1 124291 1 CYLINDER Cushion C2 120989 1 CYLINDER Lift Models 3220 4620 120989 2 CYLINDER Lift Models 3226 4626 4632 C3 120236 1 CYLINDER S...

Page 53: ...7 104434 1 ORIFICE 0 040 diameter Brake Models 322x 137127 1 ORIFICE 0 020 diameter Brake Models 46xx P1 106577 1 PUMP Hydraulic Model 4620 except EE rated 106587 1 PUMP Hydraulic Models 4626 4632 exc...

Page 54: ...IL 24 Volt Lowering valve ANSI CSA 2H 13B 103605 1 COIL 24 Volt Lowering valve CE 2H 13 1 104493 1 COIL 24 Volt Holding valve ANSI CSA 2H 13 2 104493 1 COIL 24 Volt Holding valve ANSI CSA 2H 13B 1 104...

Page 55: ...tegrated sensor CE D02 X 129258 AR DIODE D19A ALARM OPTION DA1 119758 1 DIODE PACK DA2 119520 1 DIODE ASSEMBLY DA3 119624 1 DIODE ASSEMBLY DCM1 147664 1 MOTOR 24 VDC ANSI CSA 123477 1 MOTOR 24 VDC ANS...

Page 56: ...power extension platform 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...

Page 57: ...12 15 14 21B GREEN BLACK TIED BACK S8 HORN 02 07 7A 08 60 7A 8C 49 08 08 S4 EMERGENCY STOP LED 1 12B 18 8A S3 LIFT OFF DRIVE 15 13 02 08 00 RST1 PIN FUNCTION PIN 1 LEFT PIN 2 STEERING VS PIN 3 RIGHT P...

Page 58: ...A 16 14 B 16 15 D15 D16 7B 02 08 00 RST1 PIN FUNCTION CTRL BOX HARNESS JOYSTICK HARNESS PIN 1 LEFT 24 BLUE BLACK WHITE RED PIN 2 STEERING VS 12B BROWN RED WHITE GREEN PIN 3 RIGHT 23 BLACK WHITE WHITE...

Page 59: ...BLACK PIN 2 02 WHITE PIN 3 26 GREEN PIN 4 N U PIN 5 N U PIN 1 27 BLACK PIN 4 N U PIN 5 N U PIN 3 26 GREEN PIN 2 09 WHITE 08 21B 21B 27 26 02 09 BLUE BLACK 24 RED WHITE 60 7A BLACK WHITE 23 GREEN BLAC...

Page 60: ...HITE BLACK 16 ORANGE BLACK 59 GREEN BLACK 21B OPT BLACK WHITE 23 RED WHITE 60 7A BLUE BLACK 24 09 02 26 27 21B 21B 08 08 2 WHITE 09 3 GREEN 26 4 N U 1 BLACK 27 3 GREEN 26 2 WHITE 02 1 BLACK 27 D26 D27...

Page 61: ...3 GREEN 26 BACK VIEW MALE 3 4 1 2 2 WHITE 02 BACK VIEW 3 4 2 1 MALE W ALL FUNCTION CUTOUT 2 WHITE 08 3 GREEN 26 1 BLACK 27 4 N U WHITE 2 2 1 1 3 3 BOX BLACK GREEN TO POWER CONTROL CONSOLE TO POWER CO...

Page 62: ...POWER ON LSS LIGHT PIN X1 02 WHITE PIN X2 7A RED BLACK X2 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 WHITE BLACK X2 PIN 4 14E BLACK S...

Page 63: ...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 7...

Page 64: ...RGENCY LOWERING ORIFICE 067 MB3 HOLDING VALVE MANIFOLD BLOCK 2H 13B CE 2H 13 ANSI CSA LOWERINGVALVE R2 LIFT RELIEF VALVE O2 LOWERING ORIFICE SEE REFERENCETABLE 3H 14 LIFTVALVE 4H 23 RIGHT STEER VALVE...

Page 65: ...CASE DRAIN 2H 18A DIFFERENTIAL VALVE P A SJ3 3226 NONE 0 081 DIA NONE 0 073 DIA SJ3 4626 SJ3 4632 SJ3 4620 NONE MODEL SJ3 3220 SJ3D ORIFICE LIFT ORIFICE ORIFICE LOWERING 4H 24 LEFT STEER VALVE CRV1 C...

Page 66: ...T 02 24 CLEAR RIGHT 2 3 0 2 C L E A R 0 2 RIGHT STEERVALVE PIN 1 23 BLACK WHITE PIN 2 02 WHITE LEFT STEER VALVE PIN 1 24 BLUE BLACK PIN 2 02 WHITE 02 59 PROPORTIONALVALVE 59 ORANGE BLACK 02 WHITE LOWE...

Page 67: ...2 02 WHITE 15 REVERSE 1 6 C L E A R 0 2 FORWARD 02 02 24 CLEAR LEFT CLEAR INSERT ORIENTATION BOTTOM VIEW RIGHT 2 3 0 2 C L E A R FORWARD VALVE PIN 1 16 WHITE BLACK PIN 2 02 WHITE REVERSEVALVE PIN 1 15...

Page 68: ...E 02 03 02 19A PLATFORMCONTROLBOX MAINMANIFOLD REARHARNESS 3A BLACK 05 WHITE TOCHARGER TO ATMOTOR TO ATMOTOR 4 00 3A 02 03 00 02 05 02 18 14 13 14E 72 R D13 07 D14E 14 D19A D28A D14E 1 19A 21 19 W R 2...

Page 69: ...TO LOWER BASEBOX TO HIGH SPEED LIMIT 21B 18 14E 14 10E 13 D14E 1 72 60 18B W 19B 19 30 W 71 19 16 D17C 17 15 D14E 2 D17C 1 59 D21B 1 30 17B 21 87 87 87a W 24 23 85 86 14 D21B 2 87a TO CONTROL MODULE...

Page 70: ...TERY TRAY 72 BROWN 71 BLUE 19 BLUE HYDRAULIC TRAY 72 BROWN 02 05 19A 19 72 D21 1 D13 13 18 D17 1 D17C 17 71 D28A 29 D19A D21 59 D17C 1 D14E D23 D14 D17 D21A D16 D15 23 21A 14 16 15 D24 24 59A MAIN DIS...

Page 71: ...H PIN 1 19 BLACK PIN 2 28 GREEN PIN 3 02 WHITE DEUTSCH 1 4 3 2 TO ELECTRICPANEL 02 WHITE 28 GREEN 19 BLACK FROM ELECTRICPANEL 02 WHITE 7A RED 10E BLACK WHITE 13 ORANGE 14 BLACK 15 BLUE 16 WHITE BLACK...

Page 72: ...8A NC NO BROWN 2 DEUTSCH 7 3 4 6 5 PIN 3 18 BLACK WHITE PIN 1 71 BLACK WHITE PIN 4 18A BLACK PIN 2 21 BLACK 1 8 PIN 8 71 BLACK WHITE PIN 6 18B BROWN PIN 7 19 BLACK PIN 5 7A BLUE BLACK WHITE BLUE NO BR...

Page 73: ...CH PIN 1 19 RED PIN 2 28 WHITE PIN 3 02 BLACK PIN 4 N U TS1 TILT SWITCH ANSI CSA DUAL FLASHING LIGHT HARNESS BLACK 22 WHITE 02 02 22 02 BLACK 22 WHITE 02 22 22 02 22 02 02 49 02 02 22 HORN FLASHING LI...

Page 74: ...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 5 6 2 3 4 1 TO ANGLE TRANSDUCER PIN 1 910 BLACK PIN 2 28B GREEN PIN 3 902 WHITE CONNECT...

Page 75: ...TIONAL 27 RELAY 26 25 PROPORTIONAL SPEED B SOLENOID 22 24 DIFF SOLENOID 23 SPEED A SOLENOID 21 20 TILT RELAY TILT SWITCH 18 17 MOTOR CONTACTOR 0 47uF CAPACITOR 14 TWO CYLINDERS 16 BEEPER 15 UP SOLENOI...

Page 76: ...PROPORTIONAL 27 RELAY 26 25 PROPORTIONAL SPEED B SOLENOID 22 24 DIFF SOLENOID 23 SPEED A SOLENOID 21 20 TILT RELAY TILT SWITCH 18 17 MOTOR CONTACTOR 0 47uF CAPACITOR 14 TWO CYLINDERS 16 BEEPER 15 UP S...

Page 77: ...OID 22 24 DIFF SOLENOID 23 SPEED A SOLENOID 21 20 TILT RELAY TILT SWITCH 18 17 MOTOR CONTACTOR 0 47uF CAPACITOR 14 TWO CYLINDERS 16 BEEPER 15 UP SOLENOID 19 HOURMETER 4H 23 DO2 5 DO2 4 4H 15 DO2 3 4H...

Page 78: ...19 UP SOLENOID 15 BEEPER 16 TWO CYLINDERS 14 0 47uF CAPACITOR MOTOR CONTACTOR 17 18 TILT SWITCH TILT RELAY 20 21 SPEED A SOLENOID 23 DIFF SOLENOID 24 22 SPEED B SOLENOID PROPORTIONAL 25 26 RELAY 27 PR...

Page 79: ...P2 3 14 P4 9 910A P4 2 60A P4 7 900 CM1 CONTROL MODULE P2 2 10E P2 7 16 P2 8 15 P4 3 28B P4 8 902 P4 6 910 P2 4 13 13 10E 13 14E S2 D14E 2 14 P3 1 22 P3 5 02 P3 2 29 P2 11 02 P2 12 7A P3 4 28 P2 10 1...

Page 80: ...S HOLDING VALVE UP SOLENOID AUX DOWN RELAY 22 15 14 00 29 13 11 12 02 BP 29 BEEPER FLASHING LIGHT OPTION 2H 13B 2 HOLDING VALVE 9 10 00 CB1 7 6 02 8 10A CIRCUIT BREAKER DCM1 4 3 M 5 2 1 00 CHARGER PAC...

Page 81: ...PTION TIMER BREAKER INVERTER OPTION DCM1 4 3 M 5 2 1 00 CHARGER PACK BATTERY PUMP MOTOR 02 13B 28 02 28ECR2 28E 13A 13 P3 6 28E P2 10 18B P3 4 28 P2 12 7A P2 11 02 P3 2 29 P3 5 02 P3 1 22 14 D14E 2 S2...

Page 82: ...RTER OPTION DCM1 4 3 M 5 2 1 00 CHARGER PACK BATTERY PUMP MOTOR 02 13B 28 02 28ECR2 28E 13A 13 P3 6 28E P2 10 18B P3 4 28 P2 12 7A P2 11 02 P3 2 29 P3 5 02 P3 1 22 14 D14E 2 S2 14E 13 10E 13 P2 4 13 P...

Page 83: ...22 24 DIFF SOLENOID 23 SPEED A SOLENOID 21 20 TILT RELAY TILT SWITCH 18 17 MOTOR CONTACTOR 0 47uF CAPACITOR 14 TWO CYLINDERS 16 BEEPER 15 UP SOLENOID 19 HOURMETER 4H 23 DO2 5 DO2 4 4H 15 DO2 3 4H 16 0...

Page 84: ...ID 22 24 DIFF SOLENOID 23 SPEED A SOLENOID 21 20 TILT RELAY TILT SWITCH 18 17 MOTOR CONTACTOR 0 47uF CAPACITOR 14 TWO CYLINDERS 16 BEEPER 15 UP SOLENOID 19 HOURMETER 4H 23 DO2 5 DO2 4 4H 15 DO2 3 4H 1...

Page 85: ...BP 29 3H 14 29 DO2 2 19A 02 02 CAP1 02 19A 2H 18A 3H 18A 1 D17C D21 18A 21 59 21A D17C 1 17CR 17 02 17C 21CCR 21C RST3 3H 18A 2 18A 02 4H 16 DO2 3 4H 15 DO2 4 DO2 5 4H 23 HOURMETER 19 UP SOLENOID 15 B...

Page 86: ...H 15 DO2 4 DO2 5 4H 23 HOURMETER 19 UP SOLENOID 15 BEEPER 16 TWO CYLINDERS 14 0 47uF CAPACITOR MOTOR CONTACTOR 17 18 TILT SWITCH TILT RELAY 20 21 SPEED A SOLENOID 23 DIFF SOLENOID 24 22 SPEED B SOLENO...

Page 87: ...Drive or Steer when Platform Elevated 9 4 1 17 Elevated Drive Speed Does not Activate 9 4 1 18 Work Platform Drives in Slow Speed Only 9 4 1 19 Forward Drive Function Inoperative 10 4 1 20 Reverse Dr...

Page 88: ...sh Code F17 High Elev open 17 4 3 17 Flash Code F18 Low Elev close 17 4 3 18 Flash Code F19 High Elev close 18 4 3 19 Flash Code F20 Height 0 18 4 3 20 Flash Code F21 Height 0 18 4 3 21 Flash Code F22...

Page 89: ...an 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 oc curs isolate...

Page 90: ...e or broken wire 5 from charger relay L1CR to base terminal block TB 1 Check continuity Replace if defective 13 Loose or broken wire 5 from base terminal block TB 1 to base emergency stop switch S28 C...

Page 91: ...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...

Page 92: ...e 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 swi...

Page 93: ...ve 2H 13 2 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 or holding valve 2H 13 2 Check continuity Replace if de...

Page 94: ...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 Steer Only Inoperative 1 Defective rel...

Page 95: ...onal relay 21CCR ANSI CSA or 21ACR CE 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 0...

Page 96: ...e 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 21 Brake will not Release 1 Diode D 16 forwa...

Page 97: ...h Replace if defective 3 Loose or broken wire 23 from right steer switch S7 2 to base terminal block TB 1 Check continuity Replace if defective 4 Loose or broken wire 23 from base terminal block TB 1...

Page 98: ...efective 4 1 26 Power Extension Platform will not Extend 1 Powered extension platform extend retract switch S11 defective Check switch Replace if defective 2 Loose or broken wire 26 from power extensi...

Page 99: ...owering valve V1 Close valve Replace if defective 2 Lift relief valve R2 defective Check valve Replace if defective 3 Open manual override on holding valve 2H 13 1 or 2H 13 2 ANSI CSA Depress and turn...

Page 100: ...sticking Close Valve Replace if defective 3 Flow Divider Combiner valve FD1 defective or is plugged Close Valve Replace if defective 4 Counterbalance valve CB1 defective or is plugged Close Valve Rep...

Page 101: ...ing Repair as needed 4 Orifices 03 plugged Clean orifices and reinstall 4 2 12 All System sluggish 1 System Relief Valve defective or not adjusted properly Adjust valve Replace if defective 2 Hydrauli...

Page 102: ...ably due to a wiring problem 4 3 6 Flash Code F06 Check Elev 1 This message is given if the elevation switch P2 10 is open at the start of calibration when the operator has confirmed the PLATFORM DOWN...

Page 103: ...probably due to a wiring problem 4 3 14 Flash Code F15 Check Elev 1 This message is given if the elevation switch P2 10 is open when the platform has been fully lowered after the DYNAMIC lift This me...

Page 104: ...not 100 after the platform has been fully raised during either STATIC lift The platform must return to the same height each time it is fully raised Check DIAGNOSTICS SYSTEM to check the height 4 3 22...

Page 105: ...fway through the lift ie near 50 height the lowest pressure measured is at too low a height Check the pressure sensor and lift cylinder hydraulics 4 3 30 Flash Code F33 Reject Curve 1 The DYNAMIC pres...

Page 106: ...other wiring error Check DIAGNOSTICS SENSORS to check the pressure 4 3 35 Flash Code F44 Low Pressure 1 This message indicates that the pressure is too low 0 5V or less at a STATIC measurement point...

Page 107: ...djustment 6 5 2 3 Electronic Tilt Switch Setup Procedure 7 T ilt Switch Replacement 7 Reprogramming Existing Tilt Switch 9 T est and Verify Tilt Circuit 10 Load Sensing System CE 5 3 1 Control Module...

Page 108: ...mum output is preset at the factory However for optimum performance they must be adjusted while the equipment is operating Although the following adjustments affect the current voltage or percentage o...

Page 109: ...f 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 increase...

Page 110: ...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 DOUBLE DOT STEER RIGHT SINGLE DOT STEER LEFT ENABLE STEER COMMON STEER RIGHT STEE...

Page 111: ...eases pressure Turning the 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 Adjustme...

Page 112: ...stall 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 0...

Page 113: ...nce 14 Turn main disconnect 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 Re...

Page 114: ...ntinually blinking 9 Reprogram the Tilt Switch Press and hold the set a upbuttonfor3seconds Results Both LEDs will be OFF Both LEDs will flash b impORTANT Step c must be completed within a 5 second pe...

Page 115: ...t Red LED Green LED Light Indicators Set up button is located on this face next to harness Operations of Tilt Switch The following describes the LED s and what they indicate Green LED Illuminated when...

Page 116: ...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 Wh...

Page 117: ...4 2 P3 4 SHORT TO 0V 4 3 P3 4 SHORT TO SUPPLY 4 4 P3 6 SHORT TO 0V 4 5 P3 6 SHORT TO SUPPLY 4 6 FAULT BAD TILT SENSOR 7 1 FAULT BAD HWFS 7 2 FAULT BAD SLAVE ANALOGS 7 3 FAULT BAD STRAIN MONITORS 7 4 F...

Page 118: ...uard it will occur once then clean This is not a true fault but just an indica tion of the reason for the vehicle stop If the 21 or 22 flash code is triggered by a fault with the elevation switch it w...

Page 119: ...and 4 6V and should vary as the platform position varies Testing HWFS 78 Start Up 77 These are not true faults unless they do not clear the start up tests should only occur for a short time Overload...

Page 120: ...nd authorized personnel shall be permitted to service and aerial platform wARNiNG Read all instructions closely before attempting each phase or the calibration procedure Symbol Key Function ESC ENTER...

Page 121: ...output A reading of 0V or 5V is probably due to a wiring problem Code F06 Check Elev This message is given if the elevation switch P210 is open at the start of calibration when the operator has confir...

Page 122: ...P2 10 opened during lift at a too high height above 25 Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened Set up elevation switch to manufacturers specif...

Page 123: ...2 is out of range at the start of calibration The height sensor output must be between 0 5V and 4 5V Check DIAGNOSTICS SENSORS to see the output A reading of 0V or 5V is probably due to a wiring prob...

Page 124: ...urs if the wrong switch is closed when the GP102 is waiting for the platform to be raised Please Wait This message indicates that the GP102 is busy the delay will be short no more than 5 s Lower Empty...

Page 125: ...ways follow the instructions of the Calibration instrument impORTANT Make sure the aerial platform is on BASE mode NOTE To ensure a good and clear contact clean the wire terminals before attaching the...

Page 126: ...y using the Up Down buttons enter the Curve Code followed by pressing the ESCAPE button 15 The display will show Machine Defaults By using Left Right buttons select the Tilt Setups from the menu and p...

Page 127: ...aches full height release the lift switch 31 The display will briefly show TOTAL DATA 04 to indicate the number of measurements taken 32 The display will show Calibrate Load Please Lower impORTANT If...

Page 128: ...bration Once a calibration phase has been successfully completed it is not required to do it again unless of course a change to the vehicle such as a replacement sensor requires that calibration be re...

Page 129: ...s Curve Code Group Code 3220 1 Manual Extension Platform 3 3 3220 1 Powered Extension Platform 4 3 3226 1 Manual Extension Platform 5 3 4620 1 Manual Extension Platform 8 3 4620 1 Powered Extension Pl...

Page 130: ...Reliable lift solutions by people who care www skyjack com...

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