Skyjack SJ9233 RT User manual

SERVICE
MANUAL
ROUGH TERRAIN SCISSORS
229046ACA
January 2021
ANSI/CSA, CE, AS, KC
SJ9233 RT, SJ9243 RT,
SJ9253 RT, SJ9664 RT
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This manual is for MEWPs with serial numbers:
SJ9233 RT: A202 000 001 - A202 999 999
SJ9243 RT: A202 000 001 - A202 999 999
SJ9253 RT: A202 000 001 - A202 999 999
SJ9664 RT: A203 000 001 - A203 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
SJ9233 RT, SJ9243 RT, SJ9253 RT, SJ9664 RT 229046ACA
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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5
SJ9233 RT, SJ9243 RT, SJ9253 RT, SJ9664 RT 229046ACA
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/Engine ......................................................................19
1.7 Scissors inspection ................................................................24
1.8 Platform inspections ...............................................................27
1.9 Function Tests ....................................................................28
Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Standard Hose Numbering System ...................................................29
2.2 Torque Specifications for Fasteners (US Imperial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
2.5 Axle Torque Specifications ..........................................................34
2.6 Axle Maintenance Intervals ..........................................................35
2.7 Specifications - SJ9253 RT, SJ9243 RT, SJ9253 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
2.8 Specifications - SJ9664 RT ..........................................................37
2.10 Fluids ...........................................................................38
2.9 Environment ......................................................................38
Table of Contents
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SJ9233 RT, SJ9243 RT, SJ9253 RT, SJ9664 RT229046ACA
2.11 Floor Loading Pressure .............................................................39
2.12 Maximum Platform Capacities (Evenly Distributed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Section 3 – System Component Identification 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 ................................................................48
3.6 Drive Manifold - Hose Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.7 Drive Manifold - Hydraulic & Electrical Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .52
3.8 Auxiliary Manifold - Hose Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.9 Auxiliary Manifold - Hydraulic & Electrical Component Identification . . . . . . . . . . . . . . . . . . . . . . . . 54
3.10 Outrigger Manifold ................................................................55
3.11 Pressure Reducing & Motor Shift Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
3.12 Outrigger Manifold Harness .........................................................57
3.13 Drive Manifold Harness .............................................................58
3.14 Drive Manifold Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.15 Kubota D1305 Engine Harness .......................................................60
3.16 Kubota D1305 Engine Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3.17 Kubota WG972 Engine Harness ......................................................62
3.18 Kubota WG972 Engine Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.19 Fuel Pump Harness ................................................................64
3.20 ECU Power Harness ...............................................................65
3.21 Pressure Transducer Harness - SJ9233 RT, SJ9243 RT, SJ9253 RT . . . . . . . . . . . . . . . . . . . . . . . . .66
3.22 Outrigger Control Harness ..........................................................67
3.23 Outrigger Terminal Strip ............................................................68
3.24 Machine Controller Harness - SJ9233 RT, SJ9243 RT, SJ9253 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.25 Machine Controller Harness - Wiring Diagram - SJ9233 RT, SJ9243 RT, SJ9253 RT . . . . . . . . . . . .70
3.26 Machine Controller Harness - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.27 Machine Controller Harness - Wiring Diagram - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.28 Base Control Cable ................................................................73
3.29 Control Harness A .................................................................74
3.30 Control Harness B .................................................................75
3.31 Dual Holding Valve Harness - SJ9233 RT, SJ9243 RT, SJ9253 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.32 Holding Valve Harnesses - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.33 Angle Transducer/Beeper/Flashing Light Harness - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.34 Load Cell Module Harness - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.35 Load Cell Module Power Harness - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.36 Load Cell Module CAN Harness - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.37 Hydraulic Schematic - SJ9233 RT, SJ9243 RT, SJ9253 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.38 Hydraulic Schematic - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
3.39 Base Control Box Wiring - with Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
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SJ9233 RT, SJ9243 RT, SJ9253 RT, SJ9664 RT 229046ACA
3.40 Base Control Box Wiring - No Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
3.41 Platform Control Box Wiring .........................................................87
3.42 Electrical Schematic - No Options - SJ9233 RT, SJ9243 RT, SJ9253 RT . . . . . . . . . . . . . . . . . . . . . .88
3.43 Electrical Schematic - All Options - SJ9233 RT, SJ9243 RT, SJ9253 RT . . . . . . . . . . . . . . . . . . . . . .89
3.44 Electrical Schematic - No Options - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.45 Electrical Schematic - All Options - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.46 Engine Electrical Schematic - Kubota D1305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
3.47 Engine Electrical Schematic - Kubota WG972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.1 Introduction ......................................................................95
4.2 Electrical System ..................................................................96
4.2-1 All Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-2 All Functions Inoperative from Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-3 All Functions Inoperative from Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2-4 Engine Does Not Crank from Platform (Kubota Diesel D1305) . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2-5 Engine Does Not Crank from Platform (Kubota Dual Fuel DG972) . . . . . . . . . . . . . . . . . . . . . . . 104
4.2-6 Engine Does Not Crank from Base Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.2-7 Glow Plugs Inoperative from Base (Kubota Diesel D1305) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.2-8 Glow Plugs Inoperative from Platform (Kubota Diesel D1305) . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2-9 Engine Cranks but Does Not Start (Kubota Diesel D1305) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.2-10 Engine Cranks but Does Not Start (Kubota Dual Fuel WG972) . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.2-11 Drive and Steer Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.2-12 Brakes Do Not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.2-13 Steer Right Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.2-14 Steer Left Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.2-15 Reverse Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.2-16 Forward Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.2-17 High Speed/High Torque/Hill Climb Range Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.2-18 Differential Lock will not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2-19 Lift (Up) Circuit Inoperative from Platform (no Outriggers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.2-20 Lift (Up) Circuit Inoperative from Platform when using Outriggers . . . . . . . . . . . . . . . . . . . . . . . 124
4.2-21 Lift (Up) Circuit Inoperative from Platform with Outriggers Retracted (Lift operates correctly with
Outriggers extended) ..........................................................127
4.2-22 Lift (Up) Circuit Inoperative from Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2-23 Lower (Down) Circuit Inoperative from Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2-24 Down Circuit Inoperative from Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.2-25 Belt Driven 3.5kW Generator Inoperative (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.2-26 Hydraulic 7.5kW Generator Inoperative (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.2-27 Hydraulic 7.5kW Generator Does Not Shut Off from Generator Switch (if equipped) . . . . . . . . . 135
4.2-28 Left Rear Outrigger Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.2-29 Right Rear Outrigger Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.2-30 Right Front Outriggers Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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8
SJ9233 RT, SJ9243 RT, SJ9253 RT, SJ9664 RT229046ACA
4.2-31 Left Front Outriggers Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2-32 Pressure Transducer PT1 Inoperative - SJ9233/43/53 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.2-33 Load Cell Interface Inoperative - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.2-34 Angle Transducer AT1 Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.3 Hydraulic System .................................................................145
4.3-1 4.2-1 All Functions Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.3-2 Steering Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.3-3 Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.3-4 Reverse Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.3-5 Forward Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.3-6 Brakes Will Not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.3-7 Brakes Will Not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.3-8 Differential Lock Will Not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.3-9 2-Speed Motor Will Not Engage - SJ9233/43/53 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.3-10 2-Speed Motor Will Not Engage - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.3-11 Lift (Up) Circuit Inoperative - SJ9233/43/53 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.3-12 Lift (Up) Circuit Inoperative - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.3-13 Lower (Down) Circuit Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.3-14 Hydraulic 7.5kW Generator Inoperative (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.3-15 All Outriggers Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.3-16 Left Front Outrigger Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.3-17 Right Front Outrigger Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.3-18 Right Rear Outrigger Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.3-19 Left Rear Outrigger Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.3-20 Outrigger(s) Drift Down - SJ9233/43/53 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.3-21 Outrigger(s) Drift Down - SJ9664 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Section 5 – Procedures ...................................................153
5.1 General .........................................................................153
5.1-1 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.2 Base ...........................................................................154
5.2-1 Changing the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.2-2 Outrigger Lower Limit Switch Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.3 Axles ...........................................................................157
5.3-1 Wheel Bolt/Nut Inspection and Torquing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.3-2 Wheel Reinstallation and Torquing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.3-3 Change the Oil in the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.3-4 Check the Oil Level in the Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.3-5 Change the Oil in the Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.3-6 Axle Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.3-7 Brake Inspection ..............................................................160
5.3-8 Release the brakes manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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9
SJ9233 RT, SJ9243 RT, SJ9253 RT, SJ9664 RT 229046ACA
5.3-9 Winch and tow the MEWP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.4 Engines ........................................................................163
5.4-1 Replace the Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.4-2 Replace the Fuel Filter Element - Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.4-3 Bleed the Fuel System of Air - Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.4-4 Replace the Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.4-5 Check and Replenish the Radiator Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.4-6 Drain and Refill the Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.4-7 Fan Belt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.4-8 Belt-driven Generator Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.5 Manifolds and Hydraulic Pumps .....................................................170
5.5-1 System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.5-2 System Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.5-3 Load Sense Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.5-4 Load Sense Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.5-5 Lift Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.5-6 Lift Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.5-7 Brake Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.5-8 Brake Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.6 Scissors ........................................................................174
5.6-1 Lower Lift Cylinder Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.6-2 Upper Cylinder Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.7 Platform ........................................................................178
5.7-1 Single Axis Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.7-2 Gate Spring Hinge Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.7-3 Railing Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.8 Skycoded Module ................................................................180
5.8-1 Machine Controller Module Pin Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.8-2 Valve Driver Current Control Module (VCCM) Pin Reference Chart . . . . . . . . . . . . . . . . . . . . . . . 186
5.8-3 Terminal Board Module (TMB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
5.8-4 Current Sensing Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.8-5 Calibration and Diagnostic Tool Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.8-6 Machine Controller Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5.8-7 Diagnostics ..................................................................212
5.8-8 Help Messages and Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
5.8-9 Access Level Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5.8-10 Override Mode procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5.8-11 Initial Set-Up And Change Defaults procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.8-12 Calibration ...................................................................219
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11
SJ9233 RT, SJ9243 RT, SJ9253 RT, SJ9664 RT 229046ACA
Section 1 – Scheduled Maintenance
1.1 Read and heed
Skyjack is continuously improving and expanding
product features on its equipment; therefore,
specifications and dimensions are subject to change
without notice.
1.1-1 Mobile Elevating Work Platform
(MEWP) definition
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 Rough Terrain scissor 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 firm, level surface.
1.1-4 Service policy and warranty
Skyjack warrants each new product to be 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 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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