Skyjack SJ12 User manual

SERVICE
MANUAL
VERTICAL MAST
213558ADA
January 17, 2022
ANSI/CSA, CE , AS
SJ12, SJ16

This manual is for MEWPs with serial numbers:
SJ12 & SJ16: A600 000 001 - A600 999 999
Please refer to the website (www.skyjack.com) for
contact information, other serial numbers, the most
recent technical manuals, and USB software.

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SJ12, SJ16 213558ADA
The Safety Alert Symbol identifies important safety
messages on MEWPs, safety signs in manuals or
elsewhere. When you see this symbol, be alert to
the possibility of personal injury or death. Follow the
instructions in the safety message.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, 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 hazardous
situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert
against unsafe practices.
IMPORTANT
IMPORTANT indicates a procedure essential for
safe operation and which, if not followed, may
result in a malfunction or damage to the MEWP.
THIS SAFETY ALERT SYMBOL MEANS ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED.

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213558ADA SJ12, SJ16
Notes

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SJ12, SJ16 213558ADA
Section 1 – Scheduled Maintenance ..........................................11
1.1 Read and heed ....................................................................11
1.1-1 Mobile Elevating Work Platform (MEWP) definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-2 Purpose of equipment ..........................................................11
1.1-3 Use of equipment ..............................................................11
1.1-4 Service policy and warranty ......................................................11
1.1-5 Ownership of MEWP ............................................................11
1.1-6 Optional equipment ............................................................11
1.2 Maintenance and Inspection Schedule ................................................12
1.2-1 Owner’s Annual Inspection Record ................................................12
1.2-2 Replacement Parts .............................................................12
1.2-3 Maintenance and Service Safety Tips ...............................................12
1.2-4 Hydraulic System & Component Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2-5 Maintenance Hints .............................................................14
1.2-6 About this Section ..............................................................15
1.3 Owner’s Annual Inspection Record ...................................................16
1.4 Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.5 General inspections ...............................................................18
1.5-1 Service Bulletins ...............................................................18
1.5-2 Annual Inspection ..............................................................18
1.5-3 Labels .......................................................................18
1.5-4 Limit switches .................................................................18
1.6 Base inspections ..................................................................19
1.7 Mast inspections ..................................................................23
1.8 Platform inspections ...............................................................24
1.9 Function Tests ....................................................................25
Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Standard Hose Numbering System ...................................................27
2.2 Specifications and Features - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Specifications and Features - CE, AS ..................................................30
2.4 Maximum Platform Capacities (Evenly Distributed) ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.5 Maximum Platform Capacities (Evenly Distributed) CE,AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.6 Floor Loading Pressure ANSI/CSA ....................................................32
2.7 Floor Loading Pressure - CE, AS .....................................................33
2.8 Torque Specifications ..............................................................35
2.9 Torque Specifications for Fasteners (Imperial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
2.10 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.11 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Table of Contents

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213558ADA SJ12, SJ16
Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 39
3.1 Electrical Symbol Chart .............................................................40
3.2 Hydraulic Symbol Chart ............................................................41
3.3 Wire Number and Color Code ........................................................42
3.4 Hydraulic Component Parts List ......................................................43
3.5 Electrical Component Parts LIst ......................................................44
3.6 Cylinders and Port Identifications ....................................................46
3.7 Wheel Brake and Port Identifications ..................................................47
3.8 Powerpack and Port Identifications ...................................................48
3.9 Platform Control Box Wiring .........................................................49
3.10 Platform Control Box Wiring - SGLE ..................................................50
3.11 Platform Control Box Cable .........................................................51
3.12 Platform Control Box Cable - SGLE ...................................................52
3.13 Terminal Strip .....................................................................53
3.14 Brake and Main Manifold and Hydraulic Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.15 Disc Brake Kits and Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.16 Hydraulic Schematic ..............................................................56
3.17 Base Control Wiring Diagram (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.18 Base Control Wiring Diagram (Page 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.19 Main Electrical Harness (Page 1 of 2) .................................................59
3.20 Main Electrical Harness (Page 2 of 2) .................................................60
3.21 Mast Control Cable ................................................................61
3.22 Limit Switches ....................................................................62
3.23 Electrical Schematic (ANSI/CSA) .....................................................63
3.24 Electrical Schematic (CE) ...........................................................64
3.25 Electrical Schematic (AS) ...........................................................65
3.26 Elevate Telematics Harness .........................................................66
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1 Introduction ......................................................................67
4.2 Electrical System Troubleshooting ....................................................69
4.2-1 All Controls Inoperative ..........................................................69
4.2-2 All Controls Except for Down Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2-3 All Controls Inoperative From Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2-4 No Up Function from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2-5 Up Function Slow from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2-6 No Down Function from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2-7 All Controls Inoperative From Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2-8 No Up Function from Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2-9 Up Function Slow from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2-10 No Down Function from Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2-11 Pothole Bars Will Not Retract .....................................................77
4.2-12 Steer Only Inoperative ...........................................................78

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SJ12, SJ16 213558ADA
4.2-13 Right Steer Inoperative ..........................................................78
4.2-14 Left Steer Inoperative ...........................................................79
4.2-15 No Drive Forward or Reverse .....................................................80
4.2-16 Brake will not Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2-17 No Elevated Drive ..............................................................81
4.2-18 Work Platform Drives in Slow Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2-19 Forward Drive Function Inoperative ................................................82
4.2-20 Reverse Drive Function Inoperative ................................................83
4.2-21 Two or More Functions at One Time ................................................83
4.3 Hydraulic System Troubleshooting ...................................................84
4.3-1 All Functions Inoperative .........................................................84
4.3-2 All System Sluggish .............................................................84
4.3-3 Platform Drifts Down ............................................................84
4.3-4 Platform Lifts Slowly ............................................................84
4.3-5 Platform Does Not Lift ...........................................................84
4.3-6 Platform Will Not Lower ..........................................................85
4.3-7 Pothole Bars Will Not Retract .....................................................85
4.3-8 Platform Drives Slow ............................................................85
4.3-9 Platform Will Not Drive in Forward .................................................85
4.3-10 Platform Will Not Drive in Reverse .................................................85
4.3-11 Brake(s) Will Not Release ........................................................85
4.3-12 Platform Does Not Steer .........................................................86
4.3-13 Platform Steers Very Slowly .......................................................86
Section 5 – Procedures ....................................................87
5.1 General ..........................................................................87
5.1-1 Safety and Workmanship ........................................................87
5.2 Electrical System Adjustments .......................................................87
5.2-1 Electrical System ...............................................................87
5.2-2 Resistor - Voltage Divider ........................................................87
5.2-3 Troubleshooting - Diagnostic Switch ...............................................88
5.2-4 Tilt Switch Orientation ...........................................................88
5.3 Hydraulic System Adjustments .......................................................89
5.3-1 System Relief Pressure Adjustment ................................................89
5.3-2 Lift Pressure Adjustment .........................................................89
5.3-3 Steer Relief Pressure Adjustment ..................................................90
5.4 Electronic Tilt Switch Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.4-1 Tilt Switch Replacement .........................................................91
5.4-2 Reprogramming Existing Tilt Switch ................................................93
5.4-3 Test and Verify Tilt Circuit ........................................................94
5.5 Wheel Reinstallation and Torquing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
5.7 Battery Maintenance ...............................................................98
5.7-1 Charger Maintenance ...........................................................98

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213558ADA SJ12, SJ16
5.7-2 Charger Profiles ...............................................................99
5.7-3 Charger Troubleshooting .......................................................100
5.7-4 Charger Error Codes ...........................................................101
5.8 Pothole Limit Switch(LS2) Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.9 Mast Lubrication Procedure ........................................................106
5.9-1 Outside Mast Lubrication .......................................................106
5.9-2 Inner wear pads lubrication .....................................................107
5.9-3 Chains and rollers lubrication ....................................................107
5.10 Mast Roller Inspection/Maintenance .................................................108
5.10-1 Roller Operation Inspection .....................................................108
5.11 Mast Chain Visual Inspection .......................................................109
5.11-1 Chain Thorough examination ....................................................110
5.11-2 Condition inspection table ......................................................110
5.12 Mast Disassembly Procedure .......................................................111
5.12-1 Extending Platform Removal .....................................................111
5.12-2 Mast Section 5 Removal (SJ16 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.12-3 Mast Section 4 Removal ........................................................114
5.12-4 Mast Section 3 Removal ........................................................116
5.12-5 Mast Section 2 Removal ........................................................118
5.12-6 Mast Section 1 Removal ........................................................120
5.13 Mast Roller Replacement ..........................................................122
5.14 Mast Assembly Procedure .........................................................123
5.14-1 Mast Section 1 Installation ......................................................123
5.14-2 Mast Section 2 Installation ......................................................124
5.14-3 Mast Section 3 Installation ......................................................125
5.14-4 Mast Section 4 Installation. ......................................................127
5.14-5 Mast Section 5 Installation (SJ16 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.14-6 Extending Platform Installation ...................................................130
5.15 Lift Cylinder Replacement ..........................................................132
5.15-1 Extending Platform Removal .....................................................132
5.15-2 Mast Assembly Removal ........................................................132
5.15-3 Lift Cylinder Removal ..........................................................135
5.15-4 Lift Cylinder Installation .........................................................136
5.15-5 Mast Assembly Installation ......................................................137
5.16 Railing Maintenance and Repair .....................................................140

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SJ12, SJ16 213558ADA
Notes

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213558ADA SJ12, SJ16
Notes