Skyjack SJ 6826RT User manual

SERVICE
MANUAL
ROUGH TERRAIN SCISSORS
213560AA
November 2019
ANSI/CSA, CE, AS, KC
SJ6826RT, SJ6832RT
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This manual is for MEWPs with serial numbers:
SJ6826 RT & SJ6832 RT: A200 000 001– A200 999 999
Please refer to the website (www.skyjack.com)
for contact information, other serial numbers, the
most recent technical manuals and USB software.
Original instructions in English.
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3
SJ6826RT, SJ6832RT 213560ABA
The Safety Alert Symbol identies 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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5
SJ6826RT, SJ6832RT 213560ABA
Section 1 – Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Read and heed ....................................................................11
1.1-1 Mobile Elevating Work Platform (MEWP) denition 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/Engine ......................................................................19
1.7 Scissors inspection ................................................................24
1.8 Platform inspections ...............................................................28
1.9 Function Tests ....................................................................29
Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Standard Hose Numbering System ...................................................31
2.2 Torque Specications for Fasteners (US Imperial) .......................................33
2.3 Torque Specications for Fasteners (Metric) ............................................34
2.4 Torque Specications for Hydraulic Couplings & Hoses ..................................35
2.5 Torque Specications ..............................................................36
2.6 Specications and Features .........................................................37
2.7 Floor loading pressure .............................................................38
2.8 Maximum platform capacities (evenly distributed) .......................................39
2.9 Environment ......................................................................39
2.10 Fluids ...........................................................................40
Table of Contents
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SJ6826RT, SJ6832RT
213560ABA
Section 3 – System Component Identication and Schematics ....................41
3.1 Electrical Symbol Chart .............................................................42
3.2 Hydraulic Symbol Chart ............................................................43
3.3 Wire Number and Color Code ........................................................44
3.4 Hydraulic Parts List ................................................................45
3.5 Electrical Parts List ................................................................47
3.6 Hydraulic Manifold Valve Port Identication ............................................53
3.7 Hydraulic Manifold Valve Assemblies and Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
3.8 Control Box Wiring Diagram .........................................................55
3.9 Base to Platform Control Cable - SJ6832 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.10 Base to Platform Control Cable - SJ6826 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.11 Beeper Wiring Assembly ............................................................58
3.12 Main Manifold Valve Harness Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.13 Kubota Engine Harness - Diesel ......................................................60
3.14 Kubota Engine Harness - Dual Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.15 Outrigger Control Box ..............................................................62
3.16 Outrigger/Hydraulic Generator Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.17 Hydraulic Generator Electrical Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.18 Telematic Harness Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
3.19 Electrical Panel Diagram - ANSI/CSA, CE & AS ..........................................67
3.20 Electrical Panel Diagram - KC ........................................................68
3.21 Electrical Panel Diagram - Positive Air Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
3.22 Electrical Panel Diagram - Soft Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
3.23 Hydraulic Schematic - ANSI/CSA .....................................................71
3.24 Hydraulic Schematic - CE/AS ........................................................72
3.25 Hydraulic Schematic - KC ...........................................................73
3.26 Electrical Schematic - Kubota Dual Fuel WG752 - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
3.27 Electrical Schematic - Kubota Diesel D902 - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
3.28 Electrical Schematic - Kubota Diesel D902- CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.29 Electrical Schematic - Kubota Diesel D902 - AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.30 Outrigger Electrical Assembly .......................................................78
3.31 Outrigger/Hydraulic Generator Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.1 Introduction ......................................................................81
4.2 Electrical System ..................................................................82
42-1 All Controls Inoperative                                                           82
42-2 No Power to Platform                                                            83
42-3 All Functions Inoperative from The Base                                             83
42-4 All Functions Inoperative from Platform                                              85
42-5 Engine Does not Crank from Platform nor Base Control Console                          87
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7
SJ6826RT, SJ6832RT 213560ABA
42-6 Engine Cranks but Does not Start – Kubota Diesel                                     89
42-7 Engine Cranks but Does not Start – Kubota Dual Fuel (Propane/ Gas)                      90
42-8 Glow Plugs Inoperative from neither Engine Controls nor Platform (Diesel Models)            91
42-9 High Throttle Inoperative                                                          92
42-10 Drive and Steer Inoperative (Machines without outriggers option)                         93
42-11 Brakes Do not Release                                                           96
42-12 Steer Right Inoperative                                                           97
42-13 Steer Left Inoperative                                                            97
42-14 Reverse Drive Inoperative                                                        97
42-15 Forward Drive Inoperative                                                        98
42-16 First Drive Speed and Steering Inoperative                                          99
42-17 Second Drive Speed Inoperative                                                 100
42-18 Third Drive Speed Inoperative                                                    102
42-19 High Torque/Parallel Drive Inoperative                                              102
42-20 Up Circuit Inoperative from Platform                                                104
42-21 Up Circuit Inoperative from Base Control Console                                    104
42-22 Up Circuit Inoperative from Platform or Base Control Console (without Outriggers)           105
42-23 Platform does not Lift from Platform or Base Control Console with Outriggers Retracted (Lift
Operates Correctly with Outriggers Extended)                                        105
42-24 Platform does not Lift from Platform or Base Control Console with Outriggers Extended       106
42-25 Platform does not Lift from Platform or Base Control Console with Outriggers Extended or
Retracted 108
42-26 Down Function Inoperative from Platform                                            108
42-27 Down Function Inoperative from Base                                              109
42-28 Hydraulic Generator Inoperative                                                   111
42-29 Hydraulic Generator does not Shut Off from Generator Switch                           112
42-30 All Outriggers Inoperative (Auto-Level and Manual)                                   113
42-31 All Outriggers Inoperative (Auto-Level and Manual from Platform Controls)                 114
42-32 All Outriggers Inoperative (Base Controls only)                                       114
42-33 All Outriggers Inoperative (Auto Level only)                                          114
42-34 All Outriggers Inoperative (Auto Level only)                                          115
42-35 Right Front Outrigger Inoperative Manually                                          117
42-36 Right Rear Outriggers Inoperative Manually                                          118
42-37 Left Rear Outriggers Inoperative Manually                                           119
42-38 Individual Outrigger Functions Inoperative (Auto-Level)                                120
42-39 Auto-Level Inoperative                                                          120
42-40 Auto All Up Inoperative (Retract)                                                  121
4.3 Hydraulic Systems ................................................................122
43-1 All Functions Inoperative                                                         122
43-2 Steering Inoperative                                                            122
43-3 Lift, Steer and First Drive Speed Inoperative                                         122
43-4 Second Drive Speed Inoperative                                                  122
43-5 Drive Inoperative 123
To order go to Discount-Equipment.com

8
SJ6826RT, SJ6832RT
213560ABA
43-6 Drive Sluggish 123
43-7 Reverse Drive Inoperative                                                        123
43-8 Forward Drive Inoperative                                                        123
43-9 Drive Inoperative When in Low Drive                                               123
43-10 Drive Inoperative When in High Drive                                               124
43-11 Brakes Do Not Release                                                          124
43-12 Up Circuit Inoperative                                                           124
43-13 Down Circuit Inoperative                                                        124
43-14 Hydraulic Generator Inoperative                                                   125
43-15 All Outriggers Inoperative                                                        125
43-16 Outriggers Inoperative                                                          125
43-17 Outriggers Drift In                                                              126
43-18 Load Sense System Codes                                                       127
Section 5 – Procedures ...................................................131
5.1 General .........................................................................131
51-1 Safety and Workmanship                                                        131
51-2 Hydraulic System 131
5.2 Base ...........................................................................131
52-1 Winching and Towing Procedures and Parking Brake System                            131
52-2 Release the Free-Wheeling Valve                                                  132
52-3 To Release the Parking Brakes Manually                                            132
52-4 Wheel Bolt / Nut Inspection and Torquing Procedure                                  133
52-5 Wheel Reinstallation and Torquing Procedure                                        133
52-6 Reconnecting the Platform Control Box for Use from the Ground                        133
52-7 Tightening and Torque Recommendations for Hydraulic Couplings and Hoses             134
52-8 Torquing Using the Flats-From-Wrench-Resistance Method                             135
52-9 Checking the Holding Valve                                                      136
52-10 System Pressure Setting                                                         136
52-11 Lift Pressure Setting                                                            137
52-12 Grease Points 138
52-13 Electronic Tilt Switch Setup Procedure (KC only)                                      140
5.3 Engine .........................................................................143
53-1 Kubota Dual Fuel (DF972 / WG752) Resistance Checks                                143
53-2 Fan Belt Replacement and Adjustment                                             144
53-3 Kubota Dual Fuel (DF972 / WG752) Engine Throttle Setting                             145
53-4 Kubota Diesel (D902) Engine Throttle Setting                                        147
53-5 Replacing the Air Cleaner Element                                                 148
53-6 Replacing the Fuel Filter Element (Kubota D902)                                      149
53-7 Bleeding the Fuel System of Air (Kubota D902)                                       149
53-8 Replacing the Oil Filter Cartridge                                                  150
To order go to Discount-Equipment.com

9
SJ6826RT, SJ6832RT 213560ABA
53-9 Changing the Oil 150
53-10 Checking and Replenishing the Radiator Coolant Level                                151
5.3-11 Draining and Relling the Radiator 151
5.4 Outriggers ......................................................................152
54-1 Auto-Leveling Outrigger PC Board Layout                                           152
54-2 Outrigger Control Module (OCM1) Pin Reference Table (GP-106)                        153
54-3 Auto-Leveling Outrigger Settings and Error Codes                                    154
54-4 Auto-Leveling Outrigger Error Code Breakdown                                      155
54-5 Hand Held (EZcal) Calibration / Diagnostic Tool Key Functions                          156
54-6 Outrigger Control Module (OCM1) Instructions                                       158
54-7 Outrigger Upper Limit Switch (LS61, LS62, LS63, LS64) Replacement and Adjustment        161
54-8 Outrigger Lower Limit Switch (LS65, LS66, LS67, LS68) Replacement and Adjustment        162
54-9 Outrigger Mechanical Limit Switch Wiring Diagram                                    163
5.5 Load Sensing System .............................................................164
55-1 Calibrate Load/Checking Load Procedure                                           164
55-2 Machine Level Calibration Procedure                                              165
55-3 Load Sense Module (CM1) Pin Reference Table (GP-102)                              166
55-4 Control Module Initial Set-up Procedures                                            167
55-5 LED Error Codes – Quick Reference Chart                                          170
55-6 LED Error Codes – Code Breakdown Chart                                          171
55-7 LED Error Codes – Code Breakdown Chart (Continued)                                172
5.5-8 Control Module Load Calibration - Code Messages & Denitions 173
55-9 Curved/Group codes chart                                                       177
5.6 Scissors ........................................................................178
56-1 High Speed Cutout Limit Switch (LS5) Replacement and Adjustment                     178
56-2 High Speed Cutout Limit Switch Testing                                             179
5.7 Platform ........................................................................179
57-1 Gate Spring Hinge Adjustment                                                    179
57-2 Railing Maintenance and Repair                                                   180
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11
SJ6826RT, SJ6832RT 213560ABA
Section 1 – Scheduled Maintenance
1.1 Read and heed
Skyjack is continuously improving and expanding
product features on its equipment; therefore,
specications and dimensions are subject to change
without notice.
1.1-1 Mobile Elevating Work Platform
(MEWP) denition
A mobile machine intended for moving persons, tools,
and material to working positions, consisting of a work
platform with controls, an extending structure and a
chassis.
1.1-2 Purpose of equipment
The Skyjack Vertical Mast lifts are designed to move
personnel, tools, and materials to working positions.
1.1-3 Use of equipment
The MEWP is a highly maneuverable, mobile work
station. Work platform elevation and elevated driving
must only be done on a rm, level surface.
1.1-4 Service policy and warranty
Skyjack warrants each new product to be free of
defective parts and workmanship for the rst 2 years
or 3000 hours, whichever occurs rst. Any defective
part will be replaced or repaired by your local Skyjack
dealer at no charge for parts or labor. In addition,
all products have a 5 year structural warranty.
Contact the Skyjack Service Department for warranty
statement extensions or exclusions.
1.1-5 Ownership of MEWP
Notify Skyjack of MEWP ownership. If you sell or
transfer the ownership of a MEWP, promptly notify
Skyjack of the new owner’s contact information.
Skyjack needs this information to inform the owner of
any updates or additional activities that are necessary
to keep the machine in proper working condition.
1.1-6 Optional equipment
This MEWP is designed to accept a variety of optional
accessories. Refer to operation manual for a list of the
optional accessories. Operating instructions for these
options are located in Operation manual.
For components or systems that are not standard,
speak to the Skyjack Service Department. Give the
model and serial number for each applicable MEWP.
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