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SJ20

238886ABA

Section 5 – Procedures

Display Module

Display Message

Description

Display Message

Description

M145-TILT_ERR

NO TILT SENSOR MESSAGE

M147-SERV_MODE

FACTORY OVERRIDE

M151-KSW_ERR

THE PLATFORM AND BASE ARE ACTIVE

M152-ENABLE_ERR

REQUESTED FACILITATOR CYCLE

M153-M2_ERR_XX

XX ENCODER ERROR

M154-M2_ERR_XX

POWER NOT PAIRED XX

M155-M2_ERR_XX

SPEED NOT MATCHED XX

M156-S10_ERR

BASIC MODE + FUNCTION COMMAND

M157-M2_ERR_XX

VOLTAGE NOT MATCHED

M158-CTRL_ERR

NOT READY CONTROL DRIVER POWER

M159-CTRL_ERR

HVIL FAIL

M160-TILTED

MACHINE TILTED

M-163-M2_ERR

ED SLIP NOT MATCHED

M169-M2_ERR_XX

ENCODER ERROR XX

M170-CTRL_ERR

INCORRECT KEY voltage

M175-M2_ERR

SPEED SENSOR ERROR

M177-BRK1_ERR

SHORT CIRCUIT COIL BRAKE

M178-M2_TEMP

STOP MOTOR TEMP

M180-M2_ERR

OVERLOAD

M181-M2_ERR

INCORRECT ENCODER

M186-M2_ERR

WAIT FOR MOTOR POSITION

M187-CTRL_ERR

L LOWERING

M188-CTRL_ERR

INTERNAL CAN BUS ERROR

M189-SEQUENCE

INCORRECT PUMP STARTING

M190-CTRL_ERR

PUMP RETURN VOLTAGE NOT GOOD

M191-A1_ERR

THE TENSION CONTROL LEVER NOT
GOOD

M192-A1_ERR

THE CONTROL LEVER ACQUISITION NOT
GOOD

M193-CTRL_ERR

FAULTY SMARTDRIVE

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 / SECONDARY INCORRECT CHECK
PARAMETER

M199-CTRL_ERR

PARAMETER TRANSFER

M200-CTRL_ERR

VDC OFF SHORT CIRCUIT

M201-M1_ERR

TORQUE PROFILE

M202-CTRL_ERR

HIGH VOLTAGE VDC LINK

M204-BRK1_ERR

FAULTY SERVICE BRAKE

M206-CTRL_ERR

INTERNAL VOLTAGE TOO HIGH

M207-CTRL_ERR

INTERNAL VOLTAGE TOO LOW

M208-CTRL_ERR

FAULTY EEPROM

M209-CTRL_ERR

RESTORE PARAMETER

M210-CTRL_ERR

INCORRECT RAM MEMORY

M211-M2_ERR

STALL ROTOR

M212-M2_ERR

POWER NOT PAIRED

M213-C1_ERR

LC POSITIVE COIL OPEN

M214-2H-13_ERR

OPEN COIL EVP

M215-2H-13_ERR

SHORT-CIRCUIT CONTROL PILOT EVP

M216-BRK1_ERR

OPEN COIL BRAKE

M217-CB2_PWR

INCORRECT PEB

M218-M1_TEMP

ENGINE SENSOR TEMP DEFECTIVE

M219-2H-13_ERR

EVP1 POISITVE COIL INCORRECT

M220-08C_LOW

VKEY OFF SHORT CIRCUITY

M223-C1_ERR

MC SHORT CIRCUIT COIL

M224-CHK_
SECONDARY

WAITING FOR NODE

M226-JSTK_ERR

DEFECTIVE VACC

M227-CTRL_ERR

FAULT MATERIAL

M229-CTRL_ERR

FAULT MATERIAL BRAKE

M230-C1_ERR

LC OPEN COIL

M231-CTRL_ERR

CURRENT PUMP NOT ZERO

M232-CTRL_ERRXX

EV XX COMMON PILOT

M233-CTRL_ERR

SHORT CIRCUIT POWER MOSFET

M234-CTRL_ERR

EV SHORT-CIRCUIT

M235-CTRL_ERR

CTRAP THRESHOLD

M236-CTRL_ERR

CURRENT GAIN

Содержание SJ20

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

Страница 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...

Страница 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...

Страница 4: ...4 SJ20 238886ABA Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ...8 SJ20 238886ABA Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 22: ...22 SJ20 238886ABA Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 32: ...32 SJ20 238886ABA Notes...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 54: ...54 SJ20 238886ABA Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 106: ...106 SJ20 238886ABA Notes...

Страница 107: ......

Страница 108: ...www skyjack com...

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