Skyjack SJ6826 RT User manual

SERVICE
MANUAL
ROUGH TERRAIN SCISSORS
167955AGA
September 12, 2023
ANSI/CSA
SJ6826RT, SJ6832RT

This manual is for MEWPs with serial numbers:
SJ6826 RT: 37 004 671 - 37 299 999
SJ6832 RT: 37 004 671 - 37 299 999
Please refer to the website (www.skyjack.com) for contact
information, other serial numbers, the most recent technical
manuals, animations, and USB software.
The original instructions are in English.

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! BE ALERT! YOUR SAFETY IS INVOLVED.
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Notes

Section 1 – Scheduled Maintenance ..........................................11
1.1 Read and Heed ...................................................................11
1.1-1 Aerial Platform and Mobile Elevating Work Platform Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-2 Purpose of Equipment ..........................................................11
1.1-3 Use of Equipment ..............................................................11
1.1-4 Manual ......................................................................11
1.1-5 Service Policy and Warranty ......................................................11
1.1-6 Operator Safety Reminders, Warnings and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
1.3 Hydraulic System & Component Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.3-1 Maintenance Hints .............................................................13
1.4 About this Section .................................................................14
1.4-1 Service Bulletins ...............................................................14
1.4-2 Maintenance and Inspection .....................................................14
1.4-3 Maintenance Instructions ........................................................14
1.5 Owner’s Annual Inspection Record ...................................................15
1.6 Scheduled Maintenance Inspections ..................................................17
1.6-1 Electrical .....................................................................17
1.6-2 Hydraulic .....................................................................17
1.6-3 Manuals (B) ...................................................................18
1.6-4 Labels (B) ....................................................................18
1.6-5 Limit Switches (B) ..............................................................18
1.6-6 Engine Compartment ...........................................................18
1.6-7 Hydraulic / Fuel Compartment ....................................................21
1.6-8 Platform Assembly .............................................................22
1.6-9 Lifting Mechanism ..............................................................23
1.6-10 Base ........................................................................27
1.7 Function Tests ....................................................................29
Section 2 – Specifications ..................................................31
2.1 Specifications and Features .........................................................31
2.2 Floor Load Calculation .............................................................32
2.4 Floor Loading Pressure .............................................................33
2.3 Maximum Platform Capacities .......................................................33
2.5 Fluid Specifications ................................................................34
Table of Contents
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2.6 Torque Specifications ..............................................................35
2.7 Torque Specifications for Fasteners (Imperial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
2.8 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.9 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 39
3.1 Hydraulic Symbol Chart ............................................................40
3.2 Electrical Symbol Chart .............................................................41
3.3 AC Cord Color Code ...............................................................42
3.4 Hydraulic Schematic Parts List .......................................................43
3.5 Electrical Parts List ................................................................45
3.6 Hydraulic Schematic S/N 37006450 and above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.7 Hydraulic Schematic S/N 37006449 and below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
3.8 Hydraulic Manifold Valve Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
3.9 Hydraulic Manifold Valve Assemblies and Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
3.10 Control Box Wiring Diagram .........................................................54
3.11 Outrigger / Hydraulic Generator Control Console Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .55
3.12 Scissor Arm Control Cable Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
3.13 Main Manifold Valve Harness Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.14 Kubota Engine Wiring Diagram – Dual Fuel System – S/N 37009728 and Below . . . . . . . . . . . . . . . 58
3.15 Kubota Engine Wiring Diagram – Dual Fuel System – S/N 37009729 and Above . . . . . . . . . . . . . . . 59
3.16 Kubota Engine Wiring Diagram (Diesel Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.17 Outrigger Harness Wiring Diagram ...................................................61
3.18 Hydraulic Generator Electrical Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3.19 All Motion Alarm Electrical Panel Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.20 Telematics Harness Wiring Diagram ..................................................64
3.21 Flashing Light Relay Harness ........................................................65
3.22 Electrical Panel Wiring Diagram S/N 37000235 and above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.23 Electrical Panel Wiring Diagram S/N 37000234 and below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
3.24 Electrical Panel Diagram with Positive Air Shut Off Option S/N 37000235 and above . . . . . . . . . . .68
3.25 Electrical Panel Diagram with Positive Air Shut Off Option S/N 37000234 and below . . . . . . . . . . .69
3.26 Positive Air Shut Off Harness Wiring Diagram – Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.27 Electrical Schematic (No Option with Kubota Dual Fuel Engine) S/N 37009565 and above . . . . . . .71
3.28 Electrical Schematic (No Option with Kubota Dual Fuel Engine) S/N 37000235 to 37009564 . . . . .72
3.29 Electrical Schematic (No Option with Kubota Dual Fuel Engine) S/N 37000234 and below . . . . . . .73
3.30 Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37009565 and above . . . . . . .74
3.31 Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37000235 to 37009564 . . . . .75
3.32 Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37000234 and below . . . . . . . 76
3.33 Electrical Schematic (All Option with Kubota Diesel Engine) S/N 37000235 and above . . . . . . . . .77
3.34 Electrical Schematic (All Option with Kubota Diesel Engine) S/N 37000234 and below . . . . . . . . . .78
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Section 4 – Troubleshooting Guide ...........................................79
4.1 Introduction ......................................................................79
4.2 Electrical System ..................................................................80
4.2-1 All Controls Inoperative ..........................................................80
4.2-2 No Power To Platform ...........................................................80
4.2-3 All Functions Inoperative from The Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2-4 Engine Will Not Crank from Platform or Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2-5 Engine Cranks But Does not Start – Kubota Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2-6 Engine Cranks But Does not Start – Kubota Dual Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2-7 Glow Plugs Inoperative from Engine Controls or Platform (Diesel Models) . . . . . . . . . . . . . . . . . . 83
4.2-8 Choke Inoperative from Engine Controls or Platform (Kubota Dual Fuel) . . . . . . . . . . . . . . . . . . . 84
4.2-9 High Throttle Inoperative .........................................................84
4.2-10 High Throttle On Demand Inoperative (Kubota Dual Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2-11 Drive and Steer Inoperative (Machines without outriggers option) . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2-12 Drive and Steer Inoperative (Machines with outriggers option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2-13 Brakes Does not Release ........................................................88
4.2-14 Steer Right Inoperative ..........................................................88
4.2-15 Steer Left Inoperative ...........................................................88
4.2-16 Reverse Drive Inoperative ........................................................88
4.2-17 Forward Drive Inoperative ........................................................89
4.2-18 First Drive Speed and Steering Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-19 Second Drive Speed Inoperative ..................................................91
4.2-20 Third Drive Speed Inoperative ....................................................92
4.2-21 High Drive Speed Inoperative .....................................................92
4.2-22 Up Circuit Inoperative from Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-23 Up Circuit Inoperative from Base Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-24 Up Circuit Inoperative from Platform or Base Control Console (without Outriggers) . . . . . . . . . . . 93
4.2-25 Platform does not Lift from Platform or Base Control Console with Outriggers Retracted (Lift
Operates Correctly with Outriggers Extended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-26 Platform does not Lift from Platform or Base Control Console with Outriggers Extended . . . . . . . 95
4.2-27 Platform does not Lift from Platform or Base Control Console with Outriggers Extended or
Retracted .....................................................................96
4.2-28 Down Circuit Inoperative from Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-29 Down Circuit Inoperative from Base ................................................97
4.2-30 Hydraulic Generator Inoperative ...................................................97
4.2-31 Hydraulic Generator does not Shut Off from Generator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-32 All Outriggers Inoperative (Auto-Level and Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-33 All Outriggers Inoperative (Auto-Level and Manual from Platform Controls) . . . . . . . . . . . . . . . . . 99
4.2-34 All Outriggers Inoperative (Base Controls only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-35 All Outriggers Inoperative (Auto Level only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-36 All Outriggers Inoperative (Auto Level only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2-37 Left Front Outrigger Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2-38 Right Front Outrigger Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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4.2-39 Right Rear Outriggers Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2-40 Left Rear Outriggers Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2-41 Individual Outrigger Functions Inoperative (Auto-Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2-42 Auto-Level Inoperative .........................................................103
4.2-43 Auto All Up Inoperative (Retract) ..................................................103
4.3 Hydarulic System .................................................................104
4.3-1 All Functions Inoperative ........................................................104
4.3-2 Steering Inoperative ...........................................................104
4.3-3 Lift, Steer and First Drive Speed Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.3-4 Second Drive Speed Inoperative .................................................104
4.3-5 Drive Inoperative ..............................................................104
4.3-6 Drive Sluggish ................................................................104
4.3-7 Reverse Drive Inoperative .......................................................105
4.3-8 Forward Drive Inoperative .......................................................105
4.3-9 Drive Inoperative When in Low Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3-10 Drive Inoperative When in High Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3-11 Brakes Does not Release .......................................................105
4.3-12 Up Circuit Inoperative ..........................................................105
4.3-13 Down Circuit Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3-14 Hydraulic Generator Inoperative ..................................................106
4.3-15 All Outriggers Inoperative .......................................................106
4.3-16 Left Front Outriggers Inoperative .................................................106
4.3-17 Right Front Outriggers Inoperative ................................................106
4.3-18 Right Rear Outriggers Inoperative ................................................106
4.3-19 Left Rear Outriggers Inoperative ..................................................106
4.3-20 Outriggers Drift In .............................................................106
Section 5 – Service Procedures ............................................109
5.1 General .........................................................................109
5.1-1 Safety and workmanship ........................................................109
5.2 Platform ........................................................................110
5.2-1 Adjust the gate spring hinge .....................................................110
5.2-2 Platform mounting hardware .....................................................110
5.3 Scissors ........................................................................111
5.3-1 Replace and adjust the high speed cutout limit switch (LS5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.3-2 Test the high speed cutout limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.4 Engine .........................................................................113
5.4-1 Kubota dual fuel (DF972 / WG752) resistance checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.4-2 Kubota dual fuel (DF972/WG752) engine throttle setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.4-3 Kubota diesel D902 engine throttle setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.4-4 Replace the fuel filter element - Kubota D902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.4-5 Bleed the fuel system of air - Kubota D902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.4-6 Replace and adjust the fan belt ..................................................118
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5.4-7 Replace the air cleaner element ..................................................119
5.4-8 Replace the oil filter cartridge ....................................................119
5.4-9 Change the oil ................................................................120
5.4-10 Check and replenish the radiator coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.4-11 Drain and refill the radiator ......................................................121
5.5 Base ...........................................................................122
5.5-1 Inspect and torque the wheel bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.5-2 Install and torque the wheels ....................................................122
5.5-3 Grease points ................................................................123
5.5-4 Reconnect the platform control box for use from the ground . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.5-5 Electronic tilt switch set up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.6 Hydraulics ......................................................................128
5.6-1 Tightening and torque recommendations for hydraulic couplings and hoses . . . . . . . . . . . . . . 128
5.6-2 Do a check of the holding valve ..................................................129
5.6-3 Set the system pressure ........................................................130
5.6-4 Set the lift pressure ............................................................131
5.7 Drive Circuit Flush Procedure ......................................................132
5.8 Drive Pressure and Wheel Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.8-1 Drive motor test ...............................................................133
5.8-2 System pressure test ...........................................................133
5.8-3 Drive pressure test ............................................................133
5.9 Outriggers ......................................................................134
5.9-1 Outrigger mechanical limit switch wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.9-2 Replace and adjust the outrigger upper limit switches (LS61, LS62, LS63, LS64) . . . . . . . . . . . 135
5.9-3 Replace and adjust the Outrigger lower limit switches (LS65, LS66, LS67, LS68) . . . . . . . . . . . 136
5.10 EZcal Diagnostic Tool .............................................................137
5.10-1 Hand held EZcal calibration and diagnostic tool key functions . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.10-2 Flash the controller ............................................................138
5.10-3 Outrigger codes ..............................................................139
5.11 OCM1 Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.11-1 Auto-leveling outrigger PC board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.11-2 Outrigger control module (OCM1) instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.11-3 Auto-leveling outrigger settings and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.11-4 Auto-leveling outrigger error code breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.12 GP-106 Control Module ............................................................146
5.12-1 Set up the GP-106 outrigger controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.12-2 GP-106 outrigger controller pin reference table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.13 GP-108 Control Module ............................................................148
5.13-1 Set up the GP-108 outrigger controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.13-2 GP-108 outrigger controller pin reference table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.13-3 LED error codes ..............................................................152
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Notes