Skyjack SJ 3220 Service Manual Download

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SERVICE

MANUAL

DC ELECTRIC SCISSORS

223198ABA

August

2020

ANSI/CSA, CE, AS, KC

SJ3220, SJ3226, SJ4720, SJ4726, SJ4732

Summary of Contents for SJ 3220

Page 1: ...SERVICE MANUAL DC ELECTRIC SCISSORS 223198ABA August 2020 ANSI CSA CE AS KC SJ3220 SJ3226 SJ4720 SJ4726 SJ4732...

Page 2: ...o the website www skyjack com for contact information other Serial Numbers the most recent Technical Manuals and USB software Original instructions in English SJ3220 3226 A B101 000 001 to A B101 999...

Page 3: ...will result in 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...

Page 4: ...4 SJ3220 SJ3226 SJ4720 SJ4726 SJ4732 223198ABA Notes...

Page 5: ...Owner s Annual Inspection Record 14 1 4 Frequent Periodic Annual Pre Delivery Inspection Checklist 15 1 5 General Inspections 16 1 5 1 Service Bulletins B 16 1 5 2 Annual Inspections B 16 1 5 3 Labels...

Page 6: ...ingle Lift Cylinder Manifold MB5 SJ3220 SJ4720 56 3 11 Dual Lift Cylinder Manifold MB3 MB4 SJ3226 SJ4726 32 57 3 12 Powerdeck Manifold MB1 SJ3220 SJ4720 58 3 13 Platform Control Box Wiring 59 3 14 Pla...

Page 7: ...form Control Console 102 4 2 8 No Up Function from Platform Controls ANSI CSA CE and AS 105 4 2 9 No Up Function from Platform Controls KC 106 4 2 10 No Down Function from Platform Controls 108 4 2 11...

Page 8: ...it Switches LS1 LS2 Replacement and Adjustment 125 5 3 4 Pothole Bar Replacement Removal for Servicing 127 5 3 5 Tightening and Torque Recommendations for Hydraulic Couplings and Hoses 129 5 3 6 Integ...

Page 9: ...free of defective parts and workmanship for the first 2 years or 3000 hours whichever occurs first Any defective part will be replaced or repaired by your local Skyjack dealer at no charge for parts...

Page 10: ...t is damaged or not operating 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 on...

Page 11: ...em 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 funn...

Page 12: ...et the very simplicity of them may be the reason they are so often overlooked They are simply these 1 Change filters annually The filters will need to be changed more often depending on the operating...

Page 13: ...h the MEWP in the following configuration MEWP parked on a flat and level surface Disconnect the batteries by disconnecting the main power connectors Repair any damaged or malfunction components befor...

Page 14: ...nature WARNING 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...

Page 15: ...no damage leaks or missing components B Wheel Tire Assembly Do a check of all tires for damage wear correctly aligned B Wheel Tire Assembly Wheel nuts torqued as recommended C Axles Correctly attache...

Page 16: ...ath or serious injury CAUTION Make sure that the 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 5 1 S...

Page 17: ...azard Do not touch battery acid Wear the correct PPE If the battery acid touches you immediately flush the area with cold water and get medical aid 1 Do an inspection of the battery case for damage 2...

Page 18: ...riodic pre delivery inspection Do a check on all the tire treads and sidewalls for cuts cracks and unusual wear Do a check on each wheel for damage and cracked welds Make sure the wheels are correctly...

Page 19: ...panel B Make sure the panel is correctly attached and there is no visible damage Hydraulic pump and motor B Make sure there are no loose or missing fasteners Make sure there is no visible damage Motor...

Page 20: ...here is no visible damage 3 Brakes B C B Frequent periodic pre delivery inspection Make sure there are no loose or missing fasteners Make sure there is no visible damage C Annual inspection Make sure...

Page 21: ...he cables and wires have the correct routing and show no signs of wear and or physical damage Make sure that the bumpers are correctly attached and have no visible damage 3 Sliders and rollers B Make...

Page 22: ...eard from seized pins Rust near the pin joint Cracks in welds of adjacent metals Dust or metal shaving from worn components Broken or missing pin retainer bolts Broken or missing pin retainers Rotated...

Page 23: ...Inspections Section 1 Scheduled Maintenance 1 1 Center Pin Outer Center Pin Middle Center Pin Inner Examples of damaged pin connections Broken retainer bolt Rust around the pin Rotated pin Rust aroun...

Page 24: ...er mount areas Look for signs of damage to the mounts 1 These signs can include Broken loose or missing retainers or bolts Bearing block degradation Cracks in welds or the surrounding metal or rust fo...

Page 25: ...ation 2 Fall protection anchorages B Make sure that the fall protection anchorages are correctly installed Make sure there is no visible damage 3 AC power socket B Make sure there is no visible damage...

Page 26: ...nd remove it for servicing Only a qualified service technician must repair the MEWP If you do not obey there is a risk of death or serious injury After repairs are completed the operator must do a pre...

Page 27: ...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 SWIVEL 100R17 H02 FEMALE 3...

Page 28: ...H38 SHORT 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 JI...

Page 29: ...NOTE Lubed includes lubricants such as lubrizing oil grease or uncured Loctite 1374AA 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 1...

Page 30: ...93 69 43 32 Nm 88 66 126 94 4 9 3 6 M14 x 2 00 ft lb 104 78 148 111 60 45 Nm 141 106 201 150 6 8 5 1 M16 x 2 00 ft lb 161 121 230 172 68 51 Nm 218 164 312 233 7 7 5 8 M18 x 2 50 ft lb 222 167 318 238...

Page 31: ...162 216 222 294 32 1276AA 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...

Page 32: ...in 11 48 m 37 ft 8 in Platform Elevated Height 5 95 m 19 ft 6 1 in 7 79 m 25 ft 7 in 7 71 m 25 ft 7 in 9 65 m 31 ft 8 in Stowed Height Railings Down 1 75 m 68 96 in 1 93 m 76 08 in 1 90 m 74 84 in 1...

Page 33: ...ft 5 7 8 in x 12 ft 7 7 8 in 1 06 m x 3 86 m 3 ft 5 7 8 in x 12 ft 7 7 8 in Height Working Height 7 78 m 25 ft 6 1 4 in 9 65 m 31 ft 8 in 9 65 m 31 ft 8 in Platform Elevated Height 5 95 m 19 ft 6 1 4...

Page 34: ...m 1 06 m x 3 24 m Height Working Height 7 95 m 9 79 m 7 94 m 9 82 m 11 65 m Platform Elevated Height 5 95 m 7 79 m 5 94 m 7 82 m 9 65 m Stowed Height Railings Down 1 75 m 1 93 m 1 72 m 1 90 m 1 99 m...

Page 35: ...4 m Height Working Height 7 95 m 9 79 m 9 82 m 11 65 m Platform Elevated Height 5 95 m 7 79 m 7 82 m 9 65 m Stowed Height Railings Down 1 75 m 1 93 m 1 90 m 1 99 m Stowed Height Railings Up 2 10 m 2 2...

Page 36: ...d 0 70 m x 2 95 m 1 06 m x 3 24 m Height Working Height 7 95 m 9 79 m 7 95 m 9 82 m 11 65 m Platform Elevated Height 5 95 m 7 79 m 5 95 m 7 82 m 9 65 m Stowed Height Railings Down 1 75 m 1 93 m 1 99 m...

Page 37: ...kg 300 lb 1 Person 400 N 90 lbf 1 5 3 5 12 5 m s 28 mph 1 Person 3226 Dual rating 227 kg 500 lb 2 Persons 113 kg 250 lb 1 Person 400 N 90 lbf 1 5 3 5 12 5 m s 28 mph 1 Person 200 N 45 lbf 4726 0 m s...

Page 38: ...pacity Extension Platform Capacity Manual Force Tilt Cutout Setting 3220 No wind 408 kg 2 Persons 136 kg 1 Person 400 N 1 5 3 5 12 5 m s 1 Person 200 N 3226 No wind 227 kg 2 Persons 113 kg 1 Person 40...

Page 39: ...Max Maximum MEWP weight Platform loaded to capacity with options attachments Wheel is the weight that can be experienced on one wheel Note This is more than 25 of the machine weight due to possible we...

Page 40: ...be experienced on one wheel Note This is more than 25 of the machine weight due to possible weight distribution over the machine and platform LCP Local Concentrated Pressure is a measure of how hard t...

Page 41: ...the machine weight due to possible weight distribution over the machine and platform LCP Local Concentrated Pressure is a measure of how hard the MEWP presses on the area in direct contact with the fl...

Page 42: ...25 of the machine weight due to possible weight distribution over the machine and platform LCP Local Concentrated Pressure is a measure of how hard the MEWP presses on the area in direct contact with...

Page 43: ...ction 5 for the full torque procedure Cartridge Coils Valve Size 8 38 58 10 12 16 All coil sizes Torque lb ft max 20 20 20 25 35 50 4 to 5 Torque lb in max 240 240 240 300 420 600 48 to 60 Torque Nm m...

Page 44: ...44 SJ3220 SJ3226 SJ4720 SJ4726 SJ4732 223198ABA Notes...

Page 45: ...45 SJ3220 SJ3226 SJ4720 SJ4726 SJ4732 223198ABA Section 3 System Component Identification and Schematics...

Page 46: ...CUITS CONNECTED 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 SI...

Page 47: ...N 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 AC...

Page 48: ...6 27 BLK 59 ORG 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...

Page 49: ...INDER Lower Scissor C3 220455 CYLINDER Upper Cylinder C4 204005 CYLINDER Pin Brake ANSI CSA Only C5 159239 CYLINDER Powerdeck ANSI CSA Only CB1 147889 COUNTERBALANCE Motors F1 109568 FILTER Return 108...

Page 50: ...I CSA AS KC O5 228014 ORIFICE 0 106 SJ3226 ANSI CSA AS KC 130407 ORIFICE Brake 0 106 SJ4720 26 32 ANSI CSA O6 130407 ORIFICE Brake 0 051 SJ3220 26 ANSI CSA P1 161936 PUMP DC Motor SJ3220 26 SJ4720 26...

Page 51: ...B1 4 103480 BATTERY 6V US 2200 106552 BATTERY 6V US 250 160933 BATTERY 6V AGM 168109 BATTERY 6V T 105 BC1 122093 INDICATOR Battery Charge BP29 170620 BEEPER All Motion Tilt Overload C1 146475 CONTACTO...

Page 52: ...3 SWITCH Right S7 3 159613 SWITCH Left S7 6 159067 SWITCH Enable S8 147054 SWITCH Horn S10 149536 SWITCH Key Idle Platform Base ANSI CSA AS KC 147057 SWITCH Key Idle Platform Base CE S11 102853 SWITCH...

Page 53: ...Manifold MB2 SJ3220 26 SJ4726 32 ANSI CSA 4H 16 To Main Manifold 4H 15 To Main Manifold To Right Motor B To Right Motor A FD1 Flow Divider Valve V2 Free wheeling Valve Orifice BRK To Main Manifold BR...

Page 54: ...M204416AB_Service V1 Brake Override FD1 Flow Divider Valve V2 Free wheeling Valve 3H 18A 1 Speed Valve A 3H 18A 2 Speed Valve A P2 Hand Pump To Main Manifold 3H 17 2H 18A Differential Valve To Batt Tr...

Page 55: ...ifold V1 Auto Reset Brake Override P2 Brake Release Hand Pump 4H 16 To Main Manifold 4H 15 To Main Manifold To Right Motor B To Right Motor A FD1 Flow Divider Valve V2 Free wheeling Valve Orifice BRK...

Page 56: ...ction 3 System Component Identification and Schematics Single Lift Cylinder Manifold MB5 SJ3220 SJ4720 3 10 Single Lift Cylinder Manifold MB5 SJ3220 SJ4720 M195285AB CylManifold To Main Manifold 3H 14...

Page 57: ...3 System Component Identification and Schematics 3 11 Dual Lift Cylinder Manifold MB3 MB4 SJ3226 SJ4726 32 M195800AC_CylinderManifolds To Lower Cylinder 2H 13 1 Holding Valve R4 Relief Valve 2H 13 2...

Page 58: ...3 System Component Identification and Schematics Powerdeck Manifold MB1 SJ3220 SJ4720 M160463AA 3 12 Powerdeck Manifold MB1 SJ3220 SJ4720 To Powerdeck Cylinder Extend To Powerdeck Cylinder Retract 4H...

Page 59: ...IN NO COLOUR CIRCUIT NO 1 WHITE 00 2 BLUE 12 3 ORANGE 09 4 BLACK 08A 5 RED 07 6 BLUE WHITE 08 7 GREEN WHITE 49 8 GREEN 08B 9 NOT USED 10 WHITE BLACK 00B 11 RED BLACK 18 12 ORANGE BLACK 59 13 GREEN BLA...

Page 60: ...ITE 08 7 GREEN WHITE 49 8 GREEN 08B 9 NOT USED 10 WHITE BLACK 00B 11 RED BLACK 18 12 ORANGE BLACK 59 13 GREEN BLACK TIED BACK 14 BLUE BLACK 24 15 BLACK WHITE 23 16 RED WHITE 60 16 15 14 13 12 11 10 9...

Page 61: ...ACK INTERLOCK WHITE BLUE 5 08 24V SUPPLY PURPLE WHITE WHITE BLACK 6 00B 0V SUPPLY WHITE BLACK GREY 7 59 PROP OUT ORANGE BLACK BLUE 8 08B 5V SUPPLY GREEN YELLOW PIN NO COLOUR CIRCUIT NO 1 WHITE 8A DESC...

Page 62: ...m Control Cable 3 16 Base to Platform Control Cable M211921AB CAVITY NO COLOUR CIRCUIT NO 1 WHITE 00 2 BLUE 12 3 ORANGE 09 4 BLACK 08A 5 RED 07 6 BLUE WHITE 08 7 GREEN WHITE 49 8 GREEN 08B 9 NOT USED...

Page 63: ...Wiring M212706AB 60 05 13A 14A 08C 07 10 05A 05A 05A 10 10 05A 05A FROM BASE CONTROLS P11 PIN 1 07 RED PIN 2 05 ORANGE BLACK PIN 3 13A ORANGE PIN 4 14A BLACK PIN 5 10 WHITE BLACK PIN 6 08C BLUE PIN 7...

Page 64: ...68AB TO MAIN HARNESS PIN 1 07 RED PIN 2 05 ORANGE BLACK PIN 3 13A ORANGE PIN 4 14A BLACK PIN 5 10 WHITE BLACK PIN 6 8C BLUE PIN 7 N C RED BLACK PIN 8 60 WHITE 4 5 6 3 7 2 8 1 TO POWERDECK TO BASE HARN...

Page 65: ...Y LOWERING PIN 1 13B ORANGE PIN 2 05 PURPLE BLACK PIN 3 13 ORANGE PIN 4 13 ORANGE PIN 5 98B WHITE PIN 6 00D WHITE PIN 7 N U PIN 8 N U PIN 9 N U PIN 10 00D WHITE PIN 11 00 WHITE PIN 12 N U D13 1 D13 2...

Page 66: ...A Section 3 System Component Identification and Schematics Limit Switch Wiring 3 20 Limit Switch Wiring M210226AA_M210227AA COLOUR CIRCUIT NO BLACK WHITE 72 BLACK 71 COLOUR CIRCUIT NO BLACK WHITE 72 B...

Page 67: ...3 21 Limit Switch Wiring Anti Overrising Posts KC Only M208038AA_M220080AA Anti Overrising Posts Limit Switches Anti Overrising Posts Limit Switches Add 2 Posts CAVITY COLOUR 1 BROWN 2 BLACK 3 BLUE 4...

Page 68: ...WIRE PIN Anti Overrising Posts Scissor Harness ID COLOUR LABEL 1 GREEN 08C 2 NOT USED 3 WHITE 51A 4 BLACK 51 ID COLOUR LABEL 1 GREEN 08C 2 RED 52A 3 WHITE 51A 4 BLACK 51 1 2 4 3 ID COLOUR LABEL 1 GRE...

Page 69: ...Valve Harness Dual Holding Valve Harness LABEL TERMINAL COLOUR 13 1 BLACK 12 VDC 00C 2 WHITE GND LABEL TERMINAL COLOUR 13 1 BLACK 12 VDC 00D 2 WHITE GND LABEL TERMINAL COLOUR 13 1 BLACK 12 VDC 00C 2 W...

Page 70: ...RDECK HARNESS 26 GREEN FEMALE SPADE 27 BLACK MALE SPADE 1 2 3 4 5 PIN NO COLOUR LABEL NO 1 BLACK 27 2 WHITE 08C 3 GREEN 26 4 N A N A 5 N A N A CIRCUIT COLOR TERMINAL DESCRIPTION 8C WHITE MALE SPADE TO...

Page 71: ...7B BLACK TO PIN10 ON CONTROLLER P5 CIRCUIT COLOR DESCRIPTION 26B WHITE TO POWERDECK EXTEND SOLENOID 27B BLACK TO POWERDECK RETRACT SOLENOID Powerdeck Valve CIRCUIT COLOR DESCIPTION 26A WHITE TO PIN2 O...

Page 72: ...1 2 3 4 5 TO FRONT GATE LIMIT SW TERM 1 07 BLACK TERM 2 7A WHITE TO EXTENSION PLATFORM WHISKER LIMIT SW TERM 1 8E BLACK TERM 2 8A WHITE TO REAR GATE LIMIT SW TERM 1 7A WHITE TERM 2 7B BLACK TO CONTROL...

Page 73: ...n and Schematics 3 26 Outdoor Switch Wiring and Harness SJ3226 ANSI CSA Only CAVITY COLOUR LABEL TERMINATION 1 GREEN 08 C TERM MALE 18 22 GA 2 NOT USED 3 WHITE 51A FEMALE WIRE PIN 4 BLACK 51 FEMALE WI...

Page 74: ...74 SJ3220 SJ3226 SJ4720 SJ4726 SJ4732 223198ABA Notes...

Page 75: ...lve 3H 14 Lift Valve To Motor Pump To Hydraulic Tank 3H 17A Brake Valve R2 Lift Relief Valve 4H 24A Left Steer Valve 4H 16 Forward Drive Valve 4H 15 Reverse Drive Valve 4H 23A Right Steer Valve 4H 16...

Page 76: ...LD SAE 06 C3 UPPER LIFT CYLINDER 2H 13 2 MB3 HOLDING MANIFOLD SAE 04 R4 RELIEF VALVE R3 RELIEF VALVE 3H 18A 1 SPEED VALVE B 3H 18A 2 SPEED VALVE A 2H 18A DIFFERENTIAL VALVE O3 040 FD1 FLOW DIVIDER COM...

Page 77: ...2 FREE WHEEL VALVE MB2 DRIVE MANIFOLD SAE 04 SAE 04 3H 17 O4 089 P2 BRAKE HAND PUMP SAE 04 V1 AUTO RESET BRAKE OVERRIDE MB6 BRAKE MANIFOLD SAE 04 SAE 04 M1 LEFT DRIVE MOTOR M2 RIGHT DRIVE MOTOR 2H 13C...

Page 78: ...PER LIFT CYLINDER 2H 13 2 MB3 HOLDING MANIFOLD SAE 04 R4 RELIEF VALVE R3 RELIEF VALVE 3H 18A 1 SPEED VALVE B 3H 18A 2 SPEED VALVE A 2H 18A DIFFERENTIAL VALVE O3 040 FD1 FLOW DIVIDER COMBINER V2 FREE W...

Page 79: ...SAE 06 C3 UPPER LIFT CYLINDER 2H 13 2 MB3 HOLDING MANIFOLD SAE 04 R4 RELIEF VALVE R3 RELIEF VALVE 3H 18A 1 SPEED VALVE B 3H 18A 2 SPEED VALVE A 2H 18A DIFFERENTIAL VALVE O3 040 FD1 FLOW DIVIDER COMBIN...

Page 80: ...V2 FREE WHEEL VALVE MB2 DRIVE MANIFOLD SAE 04 SAE 04 3H 17 O4 089 P2 BRAKE HAND PUMP SAE 04 V1 AUTO RESET BRAKE OVERRIDE MB6 BRAKE MANIFOLD SAE 04 SAE 04 M1 LEFT DRIVE MOTOR M2 RIGHT DRIVE MOTOR 2H 13...

Page 81: ...OMBINER V2 FREE WHEEL VALVE MB2 DRIVE MANIFOLD SAE 04 SAE 04 3H 17 O4 106 P2 BRAKE HAND PUMP SAE 04 V1 AUTO RESET BRAKE OVERRIDE MB6 BRAKE MANIFOLD SAE 04 SAE 04 M1 LEFT DRIVE MOTOR M2 RIGHT DRIVE MOT...

Page 82: ...S05 08C 08D S08C S08D PIN 1 PLUGGED PIN 2 08D PURPLE WHITE PIN 3 05B PURPLE BLACK PIN 4 00 WHITE PIN 5 PLUGGED PIN 6 PLUGGED PIN 7 CANH YELLOW PIN 8 CANL GREEN PIN 9 19D WHITE RED PIN 10 PLUGGED PIN 1...

Page 83: ...HARGE INDICATOR S2 LIFT LOWER 00 00 00 60 18 08A 08 24 23 00B 59 08B 12 09 26 27 CHARGER 10 27 26 TORQUE MODE DIFFERENTIAL SOLENOID TORQUE MODE SPEED SOLENOID A TORQUE MODE SPEED SOLENOID B BATTERY PA...

Page 84: ...SOLENOID TORQUE MODE SPEED SOLENOID A TORQUE MODE SPEED SOLENOID B BATTERY PACK 14 15 16 17 23A 24A 18A 18A 08 08 08 08 08 S8 HORN SWITCH DISPLAY MODULE GREEN BLACK CM1 SKYCODED CONTROLLER S1 MAIN DI...

Page 85: ...0 00 60 18 08A 08 24 23 00B 59 08B 12 09 10 TORQUE MODE DIFFERENTIAL SOLENOID TORQUE MODE SPEED SOLENOID A TORQUE MODE SPEED SOLENOID B BATTERY PACK 14 15 16 17 23A 24A 18A 18A 08 08 08 08 08 S8 HORN...

Page 86: ...TTERY CHARGE INDICATOR S2 LIFT LOWER 00 00 60 18 08A 08 24 23 00B 59 08B 12 09 10 TORQUE MODE DIFFERENTIAL SOLENOID TORQUE MODE SPEED SOLENOID A TORQUE MODE SPEED SOLENOID B BATTERY PACK 14 15 16 17 2...

Page 87: ...08A 08 24 23 00B 59 08B 12 09 CHARGER 10 TORQUE MODE DIFFERENTIAL SOLENOID TORQUE MODE SPEED SOLENOID A TORQUE MODE SPEED SOLENOID B BATTERY PACK 14 15 16 17 23A 24A 18A 18A 08 08 08 08 08 S8 HORN SW...

Page 88: ...7 2 RIGHT S7 3 LEFT BCI BATTERY CHARGE INDICATOR S2 LIFT LOWER 00 60 18 08A 08 24 23 00B 59 08B 12 09 CHARGER 10 TORQUE MODE DIFFERENTIAL SOLENOID TORQUE MODE SPEED SOLENOID A TORQUE MODE SPEED SOLENO...

Page 89: ...WHITE PIN 6 00 WHITE 1 2 3 6 5 4 J9 BACK VIEW 1 2 TO CHARGER CUTOUT PIN 1 37 GREEN WHITE PIN 2 08C PURPLE WHITE J12 BACK VIEW 1 2 3 TO PRESSURE TRANSDUCER PIN 1 910 BLACK PIN 2 60A BLACK RED GREEN PI...

Page 90: ...RD BK 16 12 BU 16 09 OR 16 23 BK WH 16 24 BU BK 16 08A BK 16 71 BU RD 18 17 BU RD 18 14 BK 18 00 WH 14 28A GN RD 18 22 OR BU 18 29 BU YL 18 00B WH BK 16 00C WH 18 Rx RD 18 BK 18 902 WH 18 Tx GN 18 Rx...

Page 91: ...D PIN 5 14 BLACK PIN 6 24A BLUE BLACK PIN 7 N U PIN 8 23A BLACK WHITE PIN 9 18A RED BLACK PIN 10 N U PIN 11 N U PIN 12 13 ORANGE TO P4 ON EZ LIFT MODULE PIN 1 13B ORANGE PIN 2 N U PIN 3 N U PIN 4 13A...

Page 92: ...18 24A BU BK 18 15 BU 18 16 WH BK 18 23A BK WH 18 13 OR 18 08B GN 16 59 OR BK 16 08C PU WH 18 18 RD BK 16 12 BU 16 09 OR 16 23 BK WH 16 24 BU BK 16 08A BK 16 71 BU RD 18 17 BU RD 18 14 BK 18 00 WH 14...

Page 93: ...93 SJ3220 SJ3226 SJ4720 SJ4726 SJ4732 223198ABA Notes...

Page 94: ...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...

Page 95: ...nuity of wire 37 from Battery Charger Cutoff Relay L1CR to Control Module CM1 pin P4 10 Use HMI Diagnostic menu to make sure Input P4 10 signal is present 3 Batteries disconnected or faulty Connect ba...

Page 96: ...continuity during correct switch function 15 Loose or broken wire 08C from Base Key switch S10 to Control module CM1 pin P3 1 Check continuity Test for 24V supply voltage between wire 08C and wire 02...

Page 97: ...il is energized when signal on wire 19 from Control Module CM1 pin P5 1 to Motor Contactor C1 is enabled Check continuity between wire 03A and 03B on the N O contact when Motor Contactor C1 coil is en...

Page 98: ...ase or Platform Check continuity between wire 05A and wire 07 on switch when selected on Platform only Check continuity between wire 05A and wire 10 on switch when selected on Base only Replace switch...

Page 99: ...ut voltage between wire 14 and wire 02 Use HMI Diagnostic menu to make sure output P5 5 signal is present Replace if defective 5 Loose or broken wire 00 from Battery to Up valve coil 3H 14 Check conti...

Page 100: ...ive 5 CE machines only Loose or broken wire 13C from Control Module CM1 pin P2 8 to Proportional Lowering Valve 2H 13C Check continuity Test for Proportional Output voltage between wire 13C and wire 0...

Page 101: ...oken wire 05 from Circuit Breaker CB1 to Emergency Lowering switch S51 Check continuity Replace if defective Open or defective Emergency Lowering switch S51 Check continuity between wire 98B and wire...

Page 102: ...ty Replace if defective 6 Loose or broken wire 00C from Control Module CM1 pin P2 8 to Holding valve coils 2H 13 1 and 2H 13 2 Check continuity Replace if defective 7 Defective isolation Diodes D00C D...

Page 103: ...Check continuity Test for 24V Input voltage between wire 08 and wire 02 Use HMI Diagnostic menu to make sure input P3 2 signal is present Replace if defective 11 Loose or broken wire 08 from platform...

Page 104: ...MI Diagnostic menu to make sure input P3 8 signal is present Replace if defective 19 Loose or broken wire 24 from Joystick S7 3 to Control Module CM1 pin P3 9 steer left signal Check continuity Test f...

Page 105: ...wire 14 and wire 02 Use HMI Diagnostic menu to make sure output P5 5 signal is present Replace if defective 6 Loose or broken wire 00 from Battery to Up valve coil 3H 14 Check continuity Replace if d...

Page 106: ...ng Limit switch LS7B Replace Limit switch if defective 6 Loose or broken wire 52A from Anti Overrising Limit switch LS7B to Anti Overrising Limit switch LS7C if equipped Check continuity Replace if de...

Page 107: ...Use HMI Diagnostic menu to make sure proportional input P1 2 signal is present Replace if defective 15 Loose or broken wire 14 from Control module CM1 pin P5 5 to Up valve coil 3H 14 Check continuity...

Page 108: ...voltage between wire 13 and wire 02 Use HMI Diagnostic menu to make sure output P5 12 signal is present Replace if defective 6 Loose or broken wire 00C from Holding valve coils to Control Module CM1 p...

Page 109: ...8 to Right Steer valve coil 4H 23A Check continuity Test for 24V Output voltage between wire 23A and wire 02 Use HMI Diagnostic menu to make sure output P5 8 signal is present Replace if defective 6...

Page 110: ...atus Correct trouble code as displayed Replace module if defective 4 2 13 Forward Drive Function Inoperative 1 Control Module CM1 display is broadcasting an error message Check Control Module display...

Page 111: ...f defective 13 Loose or broken wire 00 from Battery to Brake valve coil 3H 17 Check continuity Replace if defective 14 Defective Forward Drive valve coil 4H 16 Check continuity through coil Replace if...

Page 112: ...to Reverse Drive valve coil 4H 15 Check continuity Test for 24V Output voltage between wire 15 and wire 02 Use HMI Diagnostic menu to make sure output P5 3 signal is present Replace if defective 11 Lo...

Page 113: ...h LS1 Check continuity Test for 24V Output voltage between wire 910 and wire 902 at P6 4 Use HMI Diagnostic menu to make sure output P2 7 supply is present Replace if defective 4 Defective pothole pro...

Page 114: ...Replace if defective 9 External or internal fault detected by Control Module CM1 Check Control Module display screen Use Diagnostic Menu to see switch and sensor status Correct trouble code as display...

Page 115: ...f defective 5 Loose or broken wire 28A from Control Module pin P2 5 to SIG on Angle Transducer AT1 or AT2 if equipped Check continuity Use HMI Diagnostic menu to make sure proportional input P2 5 sign...

Page 116: ...e or broken wire 26B from Control Module CM1 pin P5 7 to Deck Extend valve coil 4H 26 Deck Extend signal Check continuity Test for 24V Output voltage between wire 26B and wire 02 Use HMI Diagnostic me...

Page 117: ...efective 4 3 4 Platform Lifts Slowly 1 Defective Lift valve 3H 14 Check valve Replace if defective 2 Lift Relief valve R2 is set incorrectly Check pressures Replace if defective 3 Defective Holding va...

Page 118: ...ive 4 Defective Counterbalance valve CB1 Check valve Replace if defective 5 Drive Motors M1 and or M2 defective Check motors Replace if defective 4 3 8 Platform Will Not Drive in Forward or Reverse 1...

Page 119: ...place as necessary 4 3 12 Platform does not Steer 1 Right Steer valve 4H 23A and or Left Steer valve 4H 24A is defective Check valves Replace if defective 2 Steer cylinder C1 seal leaking Rebuild cyli...

Page 120: ...ating work platform MEWP on a firm level surface 2 Fully lower the machine 3 Push in the emergency stop buttons on the platform control console and the base control console 4 Turn the off platform bas...

Page 121: ...1 NONE N A 2 WHITE STEER RIGHT 3 WHITE BLUE ENABLE TRIGGER 4 WHITE BLACK HANDLE COM 24V 5 GRAY GROUND 6 BLUE PROPORTIONAL OUTPUT 7 YELLOW POWER 5V 8 Joystick Specifications Input Votlage 5 0V Center 2...

Page 122: ...e sure compliance with the relevant design standards applicable for that particular unit at the time of manufacture As such any repairs made to the guardrail or basket structure need to make sure this...

Page 123: ...the lift coil 3H 14 5 Turn the base off platform key switch to platform position 6 Select lift with the lift drive select switch on the platform control console 7 Engage lift with the joystick and hol...

Page 124: ...length of the compression rod assembly matches the dimension shown below 2 The overall length is measure from the tip of the carriage bolt to the bottom of the compression rod Carriage bolt Lock nut C...

Page 125: ...tie wraps as necessary 6 Follow the cable into the main harness 7 Disconnect the limit switch wires from the main harness Discard the limit switches Replace the Limit Switches 1 Install the new limit...

Page 126: ...ighten the bolts and the plunger roller s retaining pins are fully visible Test the Limit Switches 1 Place a block approximately 3 75 cm 1 1 2 under the hydraulic tray and raise the platform to an app...

Page 127: ...How to install or remove a Rue Ring Optional manual lock Push up and back to remove Install into hole Automatic lock Installation Instructions 1 Raise the scissor stack until the pothole bars are dep...

Page 128: ...r to the pivot point from the pothole protection assembly and base weldment Keep the pins and hardware 6 If replacing the pothole bar remove and discard the old pothole bar 7 Install a new pothole bar...

Page 129: ...on and tighten Adjust the swivel nut on the straight hose end before tightening to create the desired flow Torquing Using a Torque Wrench 1 This method is applicable for JIC 37 and FFOR Flat Face O Ri...

Page 130: ...iate number of flats past the mark Do NOT over tighten 4 1 4 2 1 5 5 5 16 2 2 6 3 8 1 5 1 5 8 1 2 1 5 1 25 10 5 8 1 5 12 3 4 1 25 16 1 1 20 1 1 4 1 24 1 1 2 1 32 2 1 FLATS FROM WRENCH RESISTANCE CHART...

Page 131: ...Coat the inner and outer bearings with grease completely Be careful not to contaminate the grease This could cause internal damage and shorten the life span of the bearings Contaminants include dust d...

Page 132: ...EWP on stands adequately rated to support the weight of the machine 2 Remove and set aside the wheel motor nut or castle nut 3 Remove and discard the locktooth washer or cotter pin A new one will be r...

Page 133: ...stle nut as the bearing life would be reduced 5 Loosen the castle nut to remove the torque Do not rotate the wheel 6 Finger tighten the castle nut until it is snug NOTE The castle nut should be free t...

Page 134: ...le nut to 95 Nm 70 ft lb and insert the 1 8 x 1 1 2 cotter pin 4 If the holes do not align to install the cotter pin continue to torque the castle nut clockwise until the next hole is visible 5 Make s...

Page 135: ...covered by at least 13 mm 1 2 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 batterie...

Page 136: ...een 6 The current charger profile displays 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...

Page 137: ...Fault 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 numbe...

Page 138: ...AC voltages 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 connect...

Page 139: ...er is disconnecting 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 Technol...

Page 140: ...charger 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 incompati...

Page 141: ...e information 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...

Page 142: ...also provides active high inputs from operator controls and analog inputs from joysticks and sensors The control module has specific Skyjack software and flashed memory for use with load sensing and...

Page 143: ...1 Angle Transducer Analog Output signal P2 6 Not Used Not Used P2 7 910 Black Output supply 24V B for AT1 PT1 Transducers Pothole Protection Limit switches LS1 LS2 and Beeper BP 29 P2 8 00C White 0V R...

Page 144: ...5 2 16 White Black 24V Output for Forward Solenoid Valve 4H 16 P5 3 15 Blue 24V Output for Reverse Solenoid Valve 4H 15 P5 4 17 Blue Red 24V Output for Brake Solenoid Valve 3H 17 P5 5 14 Black 24V Out...

Page 145: ...Key Function ESC ENTER Buttons To move back and forth be tween menu and sub menu LEFT RIGHT Buttons Select menus and setting to be adjusted UP DOWN Buttons Adjust setting values Use the left and righ...

Page 146: ...TIME MAX BATTERY SYSTEM LOGGED HELP PLATFORM LANGUAGE GROUND INPUTS ANALOGS OUTPUTS LOG ENTER ENTER ENTER ENTER ENTER ENTER ENTER MODE SUPPLY MOTOR V TILT LAST MOVED TILTED LOAD AORcase TEMPERATURE HE...

Page 147: ...ocedures SYSTEM OVERRIDE RUN SYSTEM TEST ADJUSTMENTS DIAGNOSTICS ACCESS LEVEL SYSTEM OVERRIDE ACCESS LEVEL ENTER ACCESS CODE xxxx SYSTEM OVERRIDE RUN SYSTEM TEST TEST VALVES TEST LAMPS TEST INPUTS ENT...

Page 148: ...MAX DECEL MAX ACCEL IN MIN ACCEL DECEL IN MAX DECEL ELEV DRIVE COMP UP ACCEL REV MAX UP DECEL DECEL DOWN MAX MAX HEIGHT REV MIN UP ACCEL STOWED ACCEL DOWN MIN DOWN DECEL HOLD OFF CUSHION HEIGHT CUSHIO...

Page 149: ...IGHTS ENTER Xtrip ELEVATION TRIP Ytrip MAX DRIVE ARMGUARD SAFE DOWN TILT 2 MAX LIFT OVERLOAD POTHOLE CUSHION LAMP HEIGHT DELAYtrip ALARM SAFEDOWN DELAYclear DYNAMIC DELAYtrip TILT 2 SAFE TILT DELAYcle...

Page 150: ...MODEL CALIBRATE LEVEL CALIBRATE HEIGHT CALIBRATE LOAD RED KNOB BATTERY VEHICLE OL SWITCH IDLE TIMEOUT CURVE TILT SHUTDOWN ELEVATION MIN LIFT RESET OVERRIDE FAULTY LOAD TRIGGERonly TRIGGERwait FUNCTION...

Page 151: ...SERIAL NUMBER SETUPS HELP CALIBRATIONS CALIBRATIONS SERIAL NUMBER ENTER ENTER Level 1 Accessible Only Temp yy mm nnnnn Current Height1Min TiltYOff Height2Max Tilt Height1Max UserXOff ElevUp TiltXOff H...

Page 152: ...calibration Angle transducers are installed press ENTER when viewing the HEIGHT which is the average of the two To see the individual measurements of the two sensors named HEIGHT1 and HEIGHT2 press an...

Page 153: ...3 11 Shows P3 11 input status KC Anti Overrise N C signal P3 12 Shows P3 12 input status S7 6 Enable switch from joystick P4 1 Shows P4 1 input status S51 Emergency Lowering Toggle counter P4 2 Shows...

Page 154: ...6 output Steer Left P5 7 Displays state of P5 7 output deck extend if equipped P5 8 Displays state of P5 8 output Steer Right P5 9 Displays state of P5 9 output Torque Mode high speed select P5 10 Dis...

Page 155: ...d in the forward direction when the joystick is at 100 demand REV MIN Determines the slowest drive speed in the reverse direction when the joystick is at 0 demand REV MAX Determines the fastest drive...

Page 156: ...ch the cushion is enabled STEER SPEED Determines the pump speed when steering is used on its own without drive DRIVE COMP Determines the additional speed to apply to the current drive speed when steer...

Page 157: ...ed this is because when the platform is fully lowered overload cannot be determined since there is no load on the lift cylinder instead the first overload is determined according to HEIGHT and if the...

Page 158: ...rrect machine tilt so that Control Module CM1 height measurement is correct SLOWDOWN Determines whether to reduce lifting speed as platform height approaches MAX LIFT setting or not to make sure there...

Page 159: ...ate motor current TiltGain Factory set to calibrate Control Module CM1 tilt sensor TiltXoff TiltYoff UserXoff Set when the CALIBRATE LEVEL procedure is carried out to correct for slight tilt offset du...

Page 160: ...no function selected FORWARD REVERSE A Platform drive function is operating normally FORWARD LEFT FORWARD RIGHT REVERSE LEFT REVERSE RIGHT A Platform drive function is operating normally with steer al...

Page 161: ...and on again to clear TILTED The machine is tilted beyond limits with the Control Module CM1 configured to prevent some functions when tilted perhaps also elevated descend then move machine to a more...

Page 162: ...etween 15V and 32V Check the output from height and pressure sensors P2 2 P2 4 P2 5 Check the 5V sensor supply P2 1 If the Control Module CM1 heatsink is very hot then the controller has temporarily s...

Page 163: ...first shipped prior to initial calibration it is configured in a special factory override state In this state none of the normal shutdowns or interlocks will occur the MEWP can be freely raised lower...

Page 164: ...ghts Check for loose wiring and check transducer outputs or the transducer may need to be replaced 6 1 127 FAULT CHECK HEIGHT1 SENSOR 6 1 128 FAULT CHECK HEIGHT2 SENSOR A height sensor is giving an ou...

Page 165: ...been activated see DIAGNOSTICS OUTPUTS no functions are allowed Switch power off on to reset to normal operation 2 2 142 FUNCTIONS LOCKED TILTED The machine is tilted too much to allow some functions...

Page 166: ...able was closed at power on or a wiring error is causing the input to be active always Trigger switch was closed for too long with no function selected see SETUPS INTERLOCKS TRIGGERonly 2 2 161 RETRAC...

Page 167: ...y The machine can now be operated normally 5 4 5 Initial Set up and Change Defaults Procedure The model of the MEWP and battery type used must be set in the Control Module CM1 to configure the machine...

Page 168: ...store you to ACCESS LEVEL 3 5 4 7 Calibrate Level Procedure The integral tilt sensor of the Control Module CM1 must be calibrated to compensate for errors due to installation or replacement of the Con...

Page 169: ...6 Access Levels Procedure 3 Press or to get to LOAD SETUPS and press ENTER to select 4 Press ENTER to run the CALIBRATE LOAD option 5 Make sure the MEWP is in base mode on the S10 base key switch by...

Page 170: ...atform is fully lowered and height 0 is displayed release the DOWN switch the display shows TOTAL DATA xx to indicate the number of measurements taken 18 The load calibration LOADED phase is complete...

Page 171: ...ING These messages and associated codes can be found in the Help Messages and Fault Codes table These messages can be shown in different languages according to the user preference Change the language...

Page 172: ...ers require calibration with the platform fully raised F09 BAD HEIGHT1 The Angle Transducers are out of range when fully lowered 0 calibration is recorded output must be between 0 9V and 4 1V with pla...

Page 173: ...TA DOWN At the end of all static calibrations the loaded and empty height pressure curves are compared the loaded curve should be higher than the empty curve due to the additional platform load IMPORT...

Page 174: ...ed to lift or lower the platform if the switch is closed in the wrong direction no fault occurs but the machine does not move This display clarifies the error GO DOWN MORE IGNORING During static loade...

Page 175: ...175 SJ3220 SJ3226 SJ4720 SJ4726 SJ4732 223198ABA Notes...

Page 176: ......

Page 177: ...www skyjack com...

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Skyjack SJ 3220, Service Manual

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