Skyjack SJ6832 RTE User manual

Type
User manual
SERVICE
MANUAL
ROUGH TERRAIN SCISSORS
167574AGA
October 13, 2023
ANSI/CSA
SJ6832 RTE
This manual is for MEWPs with serial numbers:
SJ6832 RTE: 37 300 001 - 37 399 999
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.
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SJ6832 RTE 167574AGA
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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SJ6832 RTE167574AGA
Notes
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SJ6832 RTE 167574AGA
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 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 Owners 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 .............................................................14
1.3-2 Railing Maintenance and Repair ...................................................14
1.4 About this Section .................................................................16
1.4-1 Service Bulletins ...............................................................16
1.4-2 Maintenance and Inspection .....................................................16
1.4-3 Pre-delivery/Maintenance Inspection ...............................................16
1.5 Owners Annual Inspection Record ...................................................17
1.5-1 Pre-delivery/maintenance inspection checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6 Scheduled Maintenance Inspections ..................................................19
1.6-1 Manuals (B) ...................................................................19
1.6-2 Labels (B) ....................................................................19
1.6-3 Limit Switches (B) ..............................................................20
1.6-4 Battery/Electrical Compartment ...................................................20
1.6-5 Motor/Hydraulic Compartment ....................................................22
1.6-6 Platform Assembly .............................................................23
1.6-7 Lifting Mechanism ..............................................................24
1.6-8 Base ........................................................................28
1.7 Function Tests ....................................................................30
Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Specifications and Features .........................................................32
2.2 Floor Loading Pressure .............................................................34
2.3 Maximum Platform Capacities (Evenly Distributed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Fluids Table ......................................................................35
2.5 Torque Specifications ..............................................................36
Table of Contents
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SJ6832 RTE167574AGA
2.6 Torque Specifications for Fasteners (Imperial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.7 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.8 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 41
3.1 Electrical Symbol Chart .............................................................42
3.2 Hydraulic Symbol Chart ............................................................43
3.3 AC Cord Color Code ...............................................................44
3.4 Hydraulic Schematic Parts List .......................................................45
3.5 Electrical Parts List ................................................................47
3.6 Hydraulic Schematic ...............................................................50
3.7 Main Manifold Component and Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.8 Splitter and Outrigger Manifolds Component and Port Identification . . . . . . . . . . . . . . . . . . . . . . . .52
3.9 Control Box Wiring Diagram .........................................................53
3.10 Outrigger Control Box Wiring Diagram ................................................54
3.11 Scissor Arm Control Cable Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
3.12 Main Manifold Harness Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
3.13 Outrigger Harness Wiring Diagram ...................................................57
3.14 Motor Controller Electrical Schematic .................................................58
3.15 Hybrid Power Pack Wiring ..........................................................59
3.16 Flashing Light Relay Harness ........................................................60
3.17 Electrical Panel Wiring Diagram – S/N 37300235 & above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3.18 Electrical Panel Wiring Diagram – S/N 37300234 & below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.19 Electrical Schematic – No Options – S/N 37300235 & above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.20 Electrical Schematic – No Options – S/N 37300234 & below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.21 Electrical Schematic – All Options – S/N 37300235 & above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.22 Electrical Schematic – All Options – S/N 37300234 & below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1 Introduction ......................................................................67
4.2 Electrical System ..................................................................68
4.2-1 All Controls Inoperative ..........................................................68
4.2-2 No Power To Platform ...........................................................69
4.2-3 All Functions Inoperative from The Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2-4 Drive and Steer Inoperative (Machines without outriggers option) . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2-5 Drive and Steer Inoperative (Machines with outriggers option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2-6 Brakes Does not Release ........................................................71
4.2-7 Steer Right Inoperative ..........................................................72
4.2-8 Steer Left Inoperative ...........................................................72
4.2-9 Reverse Drive Inoperative ........................................................73
4.2-10 Forward Drive Inoperative ........................................................73
4.2-11 High Drive Speed Inoperative .....................................................74
4.2-12 Up Circuit Inoperative from Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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SJ6832 RTE 167574AGA
4.2-13 Up Circuit Inoperative from Base Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2-14 Up Circuit Inoperative from Platform or Base Control Console (without Outriggers) . . . . . . . . . . . 77
4.2-15 Platform does not Lift from Platform or Base Control Console with Outriggers Retracted (Lift
Operates Correctly with Outriggers Extended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2-16 Platform does not Lift from Platform or Base Control Console with Outriggers Extended . . . . . . . 79
4.2-17 Platform does not Lift from Platform or Base Control Console with Outriggers Extended or
Retracted .....................................................................80
4.2-18 Down Circuit Inoperative from Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.2-19 Down Circuit Inoperative from Base ................................................81
4.2-20 All Outriggers Inoperative (Auto-Level and Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2-21 All Outriggers Inoperative (Auto-Level and Manual from Platform Controls) . . . . . . . . . . . . . . . . . 82
4.2-22 All Outriggers Inoperative (Base Controls only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2-23 All Outriggers Inoperative (Auto Level only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2-24 All Outriggers Inoperative (Auto Level only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2-25 Left Front Outrigger Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2-26 Right Front Outrigger Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2-27 Right Rear Outriggers Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2-28 Left Rear Outriggers Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2-29 Individual Outrigger Functions Inoperative (Auto Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2-30 Auto Level Inoperative ..........................................................87
4.2-31 Auto All Up Inoperative (Retract) ...................................................87
4.2-32 Hybrid Power Pack (Gasoline) does not Start – Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2-33 Hybrid Power Pack does not Start (Auto mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-34 Hybrid Power Pack does not Shut Off (Auto mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-35 Hybrid Power Pack does not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3 Hydraulic System ..................................................................90
4.3-1 All Functions Inoperative .........................................................90
4.3-2 All Functions Sluggish ...........................................................90
4.3-3 Steering Inoperative ............................................................90
4.3-4 Drive Inoperative ...............................................................90
4.3-5 Drive Sluggish .................................................................91
4.3-6 Reverse Drive Inoperative ........................................................91
4.3-7 Forward Drive Inoperative ........................................................91
4.3-8 Drive Inoperative When in Low Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.3-9 Drive Inoperative When in High Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.3-10 Brakes Does not Release ........................................................91
4.3-11 Up Circuit Inoperative ...........................................................92
4.3-12 Down Circuit Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.3-13 All Outriggers Inoperative ........................................................92
4.3-14 Left Front Outriggers Inoperative ..................................................92
4.3-15 Right Front Outriggers Inoperative .................................................92
4.3-16 Right Rear Outrigger Inoperative ..................................................93
4.3-17 Left Rear Outrigger Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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SJ6832 RTE167574AGA
4.3-18 Outriggers Drift In ..............................................................93
Section 5 Procedures ....................................................95
5.1 General ..........................................................................95
5.1-1 Safety and workmanship .........................................................95
5.2 Platform .........................................................................96
5.2-1 Adjust the gate spring hinge ......................................................96
5.2-2 Platform mounting hardware ......................................................96
5.3 Scissors .........................................................................97
5.3-1 Repalce and adjust the high speed cutout limit switch (LS5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.4 Base ............................................................................99
5.4-1 Inspect and torque the wheel bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.4-2 Install and torque the wheels .....................................................99
5.4-3 Grease points ................................................................100
5.4-4 Tilt switch setup ..............................................................101
5.5 Hydraulics ......................................................................104
5.5-1 Tightening and torque recommendations for hydraulic couplings and hoses . . . . . . . . . . . . . . 104
5.5-2 Set the system pressure ........................................................106
5.5-3 Set the lift pressure ............................................................107
5.5-4 Drive Circuit Flush Procedure ....................................................108
5.5-5 Drive motor test ...............................................................109
5.5-6 System pressure test ...........................................................109
5.5-7 Drive pressure test ............................................................109
5.6 Outriggers ......................................................................110
5.6-1 Outrigger mechanical limit switch wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.6-2 Replace and adjust the outrigger upper limit switch (LS61, LS62, LS63, LS64) . . . . . . . . . . . . . 111
5.6-3 Replace and adjust the outrigger lower limit switch (LS65, LS66, LS67, LS68) . . . . . . . . . . . . . 112
5.7 ZAPI Motor Controller .............................................................113
5.7-1 Motor controller panel pin interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.7-2 Motor controller panel pin interface – hybrid power pack (gasoline) . . . . . . . . . . . . . . . . . . . . . 114
5.7-3 ZAPI MDI CAN Display – motor controller master flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.7-4 MDI-CAN Controller master codes ................................................116
5.7-5 MDI-CAN Controller slave codes .................................................123
5.7-6 ZIVAN SG3 Battery charger and fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.7-7 SG3 Charger setup ............................................................126
5.7-8 SG3 Charger fault codes .......................................................126
5.8 EZcal Diagnostic Tool .............................................................128
5.8-1 Hand held EZcal calibration and diagnostic tool key functions . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.8-2 Flash the controller ............................................................129
5.8-3 Outrigger codes ..............................................................130
5.9 Auto-leveling outrigger PC board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
5.10 GP-106 (OCM1) Control Module .....................................................132
5.10-1 Outrigger control module (GP-106/OCM1) instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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SJ6832 RTE 167574AGA
5.10-2 Auto-leveling outrigger settings and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.10-3 Auto-leveling outrigger error code breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.10-4 Set up the GP-106 outrigger controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.10-5 GP-106 Outrigger controller pin reference table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.11 GP-108 Control Module ............................................................139
5.11-1 Set up the GP-108 outrigger controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.11-2 GP-108 Outrigger controller pin reference table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.11-3 LED error codes ..............................................................143
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SJ6832 RTE167574AGA
Notes
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SJ6832 RTE 167574AGA
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 MEWP is a mobile machine intended for moving
persons, tools, and material to working positions. It
consists of a work platform with controls, an extending
structure, and a chassis.
1.1-2 Purpose of Equipment
The SKYJACK Rough Terrain Compact Electric Series
MEWP are designed to transport and raise personnel,
tools and materials to overhead work areas.
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. It can be
driven over uneven terrain only when the platform is
fully lowered.
1.1-4 Manual
Operating Manual: The operating manual is
considered a fundamental part of the MEWP. It is a
very important way to communicate necessary safety
information to users and operators. A complete
and legible copy of this manual must be kept in the
provided weather-resistant storage compartment on
the MEWP at all times.
Service & Maintenance: The purpose of this is
to provide the customer with the servicing and
maintenance procedures essential for the promotion
of proper machine operation for its intended purpose.
All information in this manual should be read and
understood before any attempt is made to service the
machine. The updated copy of the manuals are found
on the company’s website: www.skyjack.com.
1.1-5 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.
1.1-6 Operator Safety Reminders,
Warnings and Precautions
Operator safety is Skyjack’s priority. The operator
should comply with all applicable safety-related
reminders, warnings and precautions found in
the Operating Manual. They should be read and
understood completely before operating the MEWP.
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SJ6832 RTE167574AGA
Section 1 – Scheduled Maintenance Maintenance and Inspection Schedule
1.2 Maintenance and
Inspection Schedule
The actual operating environment of the work
platform governs the use of the maintenance
schedule. The inspection points covered in Table
1.2 Maintenance and lnspection Checklist, indicates
the areas of the MEWP to be maintained or
inspected and at what intervals the maintenance and
inspections are to be performed.
1.2-1 Owner’s Annual Inspection Record
It is the responsibility of the owner to arrange
quarterly and annual inspections of the MEWP. Table
1.1 Owner’s Annual lnspection Record is to be used
for recording the date of the inspection, owner’s
name, and the person responsible for the inspection
of the work platform.
1.2-2 Replacement Parts
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and
dimensions different from original parts will affect
stability of the work platform and must not be used
without manufacturer’s consent.
Use only original filled tires for models which must be
so equipped. Consult factory.
All replacement tires must be of the same size and
load rating as original equipment to maintain safety
and stability of the work platform. Consult
WARNING
Any unit that is damaged or not operating properly
must be immediately tagged and removed from
service until proper repairs are completed.
1.2-3 Maintenance and Service Safety
Tips
Maintenance and repairs should only be performed by
personnel who are trained and qualified to service this
MEWP.
All maintenance and service procedures should be
performed in a well lighted and well ventilated area.
Anyone operating or servicing this MEWP must read
and completely understand all operating instructions
and safety hazards in this manual and the operator’s
manual.
All tools, supports and lifting equipment to be used
must be of proper rated load and in good working
order before any service work begins. Work area
should be kept clean and free of debris to avoid
contaminating components while servicing.
Keep personnel clear of components, systems or
unsupported loads that may move unexpectedly
during maintenance procedures.
All service personnel must be familiar with employer
and governmental regulations that apply to servicing
this type of equipment.
Keep sparks and flames away from all flammable or
combustible materials.
Properly dispose of all waste material such as
lubricants, rags, and old parts according to the local
law provisions in the country of operation.
Before attempting any repair work, turn Battery
Disconnect Switch to the OFF position.
Preventive maintenance is the easiest and least
expensive type of maintenance.
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SJ6832 RTE 167574AGA
Hydraulic System & Component Maintenance and Repair Section 1 – Scheduled Maintenance
1.3 Hydraulic System &
Component Maintenance
and Repair
The following points should be kept in mind when
working on the hydraulic system or any component:
WARNING
Escaping fluid from a hydraulic pressure leak can
damage your eyes, penetrate the skin and cause
serious injury. Use proper personal preotection at
all times.
1. Any structure has limits of strength and
durability. To prevent failure of structural parts of
hydraulic components, relief valves which limit
pressure to safe operating values are included in
the hydraulic circuits.
2. Tolerance of working parts in the hydraulic
system is very close. Even small amounts of dirt
or foreign materials in the system can cause
wear or damage to components, as well as
general faulty operation of the hydraulic system.
Every precaution must be taken to assure
absolute cleanliness of the hydraulic oil.
3. Whenever there is a hydraulic system failure
which gives reason to believe that there are
metal particles or foreign materials in the system,
drain and flush the entire system and replace the
filter cartridges. A complete change of oil must
be performed under these circumstances.
4. Whenever the hydraulic system is drained,
check the magnets in the hydraulic reservoir for
metal particles. If metal particles are present,
flush the entire system and add a new change
of oil. The presence of metal particles also may
indicate the possibility of imminent component
failure. A very small amount of fine particles is
normal.
5. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic
oil reservoir, and fill the reservoir only through
the filter opening. The use of cloth to strain the
oil should be avoided to prevent lint from getting
into the system.
6. When removing any hydraulic component,
be sure to cap and tag all hydraulic lines
involved. Also, plug the ports of the removed
components.
7. All hydraulic components must be disassembled
in spotlessly clean surroundings. During
disassembly, pay particular attention to
the identification of parts to assure proper
reassembly. Clean all metal parts in a clean
mineral oil solvent. Be sure to thoroughly clean
all internal passages. After the parts have been
dried thoroughly, lay them on a clean, lint-free
surface for inspection.
8. Replace all O-rings and seals when overhauling
any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
amounts of petroleum jelly to hold O-rings in
place during assembly.
9. Be sure to replace any lost hydraulic oil when
completing the installation of the repaired
component, and bleed any air from the system
when required.
10. All hydraulic connections must be kept tight. A
loose connection in a pressure line will permit
the oil to leak out or air to be drawn into the
system. Air in the system can cause damage
to the components and noisy or erratic system
operation.
NOTE
Samples of hydraulic oil should be drawn from
the reservoir and tested annually. These samples
should be taken when the oil is warmed through
normal operation of the system. The sample
should be analyzed by a qualified lubrication
specialist to determine if it is suitable for
continued use. Oil change intervals will depend
on the care used in keeping the oil clean, and
the operating conditions. Dirt and/or moisture
contamination will dictate that the oil should be
changed more often. Under normal use and
operating conditions, the hydraulic oil should be
changed every two years. Refer to Table 1.2 of
this manual
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SJ6832 RTE167574AGA
Section 1 – Scheduled Maintenance Hydraulic System & Component Maintenance and Repair
1.3-1 Maintenance Hints
Three simple maintenance procedures have the
greatest effect on the hydraulic system performance,
efficiency, and life:
11. Change filters annually. The filters will need
to be changed more often depending on the
operating conditions. Dirty, dusty, high moisture
environments may cause the hydraulic system
to be contaminated more quickly.
12. Maintain a sufficient quantity of clean hydraulic
oil of the proper type and viscosity in the
hydraulic reservoir.
13. Keep all connections tight.
1.3-2 Railing Maintenance and Repair
Skyjack MEWPs have been designed to ensure
compliance with the relevant design standards
applicable for that particular unit at the time of
manufacture. As such, any repairs made to the
guardrail or basket structure need to ensure this
compliance is not compromised and must return the
structure to its original condition.
Any damage must be repaired by returning the railing
assembly to its undamaged state. Damage includes,
but is not limited to, the items listed below:
bent/deformed guardrail sections
cracks or broken welds in railing sections
damaged pin connections
missing pins or broken pin lanyards
missing railing hardware
loose or missing parts
additional holes in guardrail sections other than
those approved by Skyjack
Additionally, the guardrails must be properly
positioned and secured, and the entry gate must be
in good working order.
The strength of the guardrail system, and therefore
its ability to provide fall protection for platform
occupants, depends upon the design being secure
and undamaged.
Skyjack railings are designed for modular
replacement, and Skyjack recommends replacement
of any damaged railing section. Skyjack-approved
replacement parts will meet this requirement.
15
SJ6832 RTE 167574AGA
Notes
16
SJ6832 RTE167574AGA
Section 1 – Scheduled Maintenance About this Section
1.4 About this Section
This section contains the maintenance and inspection
schedule that is to be performed.
References are made to the procedures in Section
5 that outline detailed step-by-step instructions for
checks and replacements.
1.4-1 Service Bulletins
Before performing any scheduled maintenance
inspection procedure, refer to service bulletins found
on our website: www.skyjack.com for updates related
to service and maintenance of this MEWP.
1.4-2 Maintenance and Inspection
Death or injury can result if the MEWP is not kept in
good working order. Inspection and maintenance
should be performed by competent personnel who
are trained and qualified on maintenance of this
MEWP.
WARNING
Risk of death, serious injury or substantial
machine damage. Always perform each procedure
as described at the scheduled interval.
NOTE
Preventive maintenance is the easiest and least
expensive type of maintenance.
Unless otherwise specified, perform each
maintenance procedure with the MEWP in the
following configuration:
Parked on a flat and level surface.
Battery disconnected by turning the main power
disconnect switch off.
Repair any damaged or malfunction
components before operating MEWP.
Keep records on all inspections.
1.4-3 Pre-delivery/Maintenance
Inspection
The Pre-delivery/Maintenance Inspection checklist
on the next page consists of four inspection types
that must be performed to keep an MEWP in a
safe, working order. Inspection schedule interval is
described below:
Inspection Type Interval
PDI B Perform PDI prior to each
delivery.
Frequent B Perform Frequent Inspection
every 3 months or 150 hours.
Annual C Perform Scheduled
Maintenance Inspections every
year.
Additional * Perform at time-sensitive
maintenance intervals.
Make copies of the Maintenance and Inspection
Checklist to be use for each inspection.
Follow These Steps:
Check the schedule on the checklist for the type
of inspection to be performed.
Place a mark in the appropriate box after each
inspection procedure is completed.
Use the Maintenance and Inspection Checklist
and step-by-step procedures starting on page
19 to perform these inspections.
If any inspection receives a fail, tag-out and
remove the MEWP from service. If any MEWP
component has been repaired, an inspection
must be performed again before removing the
tag. Place a mark in the repair column.
Inspection Schedule Legend
P = Pass
F = Fail
R = Repaired
N/A = Not applicable
17
SJ6832 RTE 167574AGA
Owner’s Annual Inspection Record Section 1 – Scheduled Maintenance
1.5 Owner’s Annual Inspection RecordTable
Description Label Pictorial
1 Inspection Date
Description Label Pictorial
2 Inspector
Signature
*
**
1
2
Figure 01 This decal is located on the scissor assembly. It must be completed after an
annual inspection has been completed. Do not use the MEWP if an inspection has not been
recorded in the last 13 months.
18
SJ6832 RTE167574AGA
Section 1 – Scheduled Maintenance Owner’s Annual Inspection Record
Frequent/Periodic/Annual PDI Checklist
Vertical Mast, Electric Scissor, Micro Scissor & Rough Terrain
Serial Number: Starting with serial number A/B/C000 000 000 or 09 000 000 and above
Use this table for pre-delivery inspections (PDI) before each rental, lease or sale and as an instruction for all frequent inspections and annual inspections.
Refer to the operation and service manuals for inspection instructions (for example, visual inspection and function tests, torque specs, engine oil, chain
inspection intervals, and more).
B - Do the pre-delivery inspection before the machine is sent out or during the frequent inspections at 200 days or 200 hour
intervals. For more instructions, refer to the operation and service manuals.
C - Do the scheduled maintenance Inspections each year. For more instructions, refer to the operation and service manuals.
P - Pass
N/A - Not Applicable
Put a check mark on the “Pass” column as you meet the requirements of the inspection of each item. Add a comment if the item does not pass inspection.
Model:
Hourmeter Reading:
Date/Time:
Inspection Type (Choose one): Pre-delivery Frequent Periodic Annual
Product User:
Product Owner:
Inspection Type Schedule
PDI/Frequent/Periodic B
Annual B+C
Items for Inspection P N/A
Service Bulletins. Make sure there are no open service bulletins. B
Annual Inspection. Make sure you complete it within 13 months. B
Labels. In place, correctly attached & you can read them. B
Limit Switches. Correctly installed & no obstructions or damage. B
BASE/ENGINE
Engine and Components. Do a check on engine and components for any
loose, missing, damaged, or failed items. Make sure you do not exceed the
recommended fluid, oil and coolant change intervals.
B
Engine and Components. Replace the engine oil and filter. C
Engine Intake Air Filter. No damage or missing component. Remove dirt & dust. B
Engine Intake Air Filter. Replace the air filter if necessary. C
Engine Oil. Oil level between “L” and “H”. Make sure you do not exceed the oil
change interval. B
Radiator. Correctly attached & no damage or missing components. Do a check
of coolant level. B
Radiator. Do a check of coolant level & condition & replace if necessary. C
Fuel Tank & Lines. Filler cap, tank, fittings and hoses are tightly closed & no
damage or leaks. B
Propane Tank & Lines. Straps are correctly installed to brackets &
couplers are tight. Make sure there are no damage or leaks. B
Outriggers. No damage or missing components. B
Pothole Protection. Both sides have no obstructions, dirt or damage. B
Battery/Hydraulic Tray. Trays are latched tightly & no missing components. B
Batteries. No damage, tight connections & sufficient fluid levels. Clean terminals
and cable ends. B
Battery Charger. Correctly attached & no damage. B
Steer Assembly. Correctly attached & no damage leaks or missing components. B
Wheel/Tire Assembly. Do a check of all tires for damage, missing parts, wear &
correctly aligned. B
Wheel/Tire Assembly. Wheel nuts torqued as recommended. C
Axles. Correctly attached & no missing components. Tight fittings and hoses &
no leaks. B
Axles. Do a check and replace oil if necessary. C
Hydraulic Tank, Pump, Motor & Lines. Filler cap, hoses, and other hydraulic
components are closed tightly & no damage or leaks. B
Hydraulic Oil. Level at, or slightly above top mark. B
Hydraulic Oil. Do a check and replace oil and filters if necessary. C
Electrical Components. Do a check on all electrical components such as the
motor controller if necessary. Correctly attached & no damage. Tight wire con-
nections and fasteners.
B
Items for Inspection P N/A
Manifolds. Tight fittings and hoses & no damage or leaks. Tight wire
connections, no missing components & correctly working valves. B
Main Power Disconnect Switch. Cables tight & in working order. B
Base Controls. Operate switches and make sure they all operate correctly. No
damage or missing components. B
Brakes. Correctly attached & no damage or leaks. B
Brakes. Do a check on disc wear and replace if necessary. C
Base Weldment. No deformation or cracks. B
Grease Points. No obstructions, dirt, or damage. Add grease if necessary. B
Ladder. Correctly attached & no damage. B
Tilt Sensor. Correctly attached & no damage. B
LIFTING MECHANISM - MAST/SCISSORS
Maintenance Support(s). Correctly attached & no damage. B
Scissor Assembly & Bumpers. Correctly attached, no deformation/damage.
Cables & wires installed with no damage. B
Sliders & Rollers. Correctly attached & no obstructions, dirt, or damage/wear. B
Lift Cylinder(s). No damage or missing components. Tight fittings and hoses &
no leaks. Correctly installed. B
Angle Transducer. Correctly attached & no damage. B
Scissor Pins. Correctly attached & no damage. B
Mast Assembly. No damage, cracks or deformation. B
Mast Assembly. Lubricate the mast as recommended. C
Chains, Rollers & Control Cables. No damage or missing components. B
Wear Pads. No damage/wear or missing components. Fasteners tight. B
PLATFORM
Railings and Gate. Correctly attached & no damage or missing
components. B
Fall-Protection Anchorage. Attachment rings correctly attached & no damage. B
AC Power Socket. No obstructions, dirt, or damage. B
Platform Control Console. Operate the switches and make sure they all
operate correctly. No damage or missing components. B
Manual Storage Box. Manuals and documents are in storage box, in good
condition, and you can read them. B
Powered Extension Control Console. Operate switches and make sure they
all operate correctly. No damage or missing components. B
Extension Platform. Correctly attached & no damage or missing components. B
Function Tests. Refer to the operation manual for your serial number for
information on how to run these tests.
PASS
FAIL
Comments:
Print Name
Print Name
Owner:
199341AEA
Signature
Signature
Date (DD/MM/YY)
Date (DD/MM/YY)
The undersigned has made sure that all areas in the list have received an inspection.
The undersigned has told the machine owner of all inconsistencies in the inspection and corrected them before machine operation.
1.5-1 Pre-delivery/maintenance inspection checklist
19
SJ6832 RTE 167574AGA
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance
1.6 Scheduled Maintenance
Inspections
Begin the scheduled maintenance inspections by
checking each item in sequence for the conditions
listed in this section.
WARNING
To avoid injury, do not operate a MEWP until
all malfunctions have been corrected.
WARNING
To avoid possible injury, ensure MEWP power
is off during your visual and daily maintenance
inspections.
Electrical
Maintaining the electrical components is essential to
good performance and service life of the MEWP.
Inspect the following areas for chafed, corroded
and loose wires:
base to platform cables and wiring harness
battery/electrical compartment
hydraulic/electrical wiring harnesses
Hydraulic
Maintaining the hydraulic components is essential to
good performance and service life of the MEWP
Perform a visual inspection around the following
areas:
hydraulic tank filter, fittings, hoses,
emergency power unit (if equipped) and
base surfaces
hydraulic compartment fittings, hoses, main
pump, and filter
all hydraulic cylinders
all hydraulic manifolds
the underside of the base
ground area under the MEWP
outriggers (if equipped)
1.6-1 Manuals (B)
Ensure a copy of the operating manual and any other
important documents are enclosed in the manual
storage box.
Check to be sure manual storage box is
present and in good condition.
Ensure manuals are legible and in good
condition.
Always return manuals to the manual storage
box after use.
1.6-2 Labels (B)
Refer to the labels section in the operating manual
and determine that all labels are in place and are
legible.
Base
Outriggers
Platform
Assembly
Scissor
Assembly
Limit Switch
Platform Control
Console
Outriggers
Limit Switch
20
SJ6832 RTE167574AGA
Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections
1.6-3 Limit Switches (B)
Detecting limit switch malfunction is essential to
safe MEWP operation. Ensure limit switches are
properly secured with no signs of visible damage and
movement is not obstructed.
Visually inspect all limit switch located inside the
scissor arms and the outrigger assemblies for the
following:
broken or missing actuator arm
missing fasteners
loose wiring
1.6-4 Battery/Electrical Compartment
Ensure compartment latch is secure and in
proper working order.
1 Main Power Disconnect Switch (B)
Turn main power disconnect switch to off
position.
Ensure all cables are secure and switch is in
proper working condition.
2 Base Control Switches (B)
Ensure there are no signs of visible damage
and all switches are in their neutral positions.
3 Battery (B)
Proper battery condition is essential to
good performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in component damage
and hazardous conditions.
.
1. Check battery case for damage.
B - Frequent Inspection
2. Clean battery terminals and cable ends
thoroughly with a terminal cleaning tool or wire
brush.
3. Ensure all battery connections are tight.
1
2
3
4
5
6
WARNING
Explosion hazard. Keep flames and sparks away.
Do not smoke near batteries.
WARNING
Battery acid is extremely corrosive – Wear proper
eye and facial protection as well as appropriate
protective clothing. If contact occurs, immediately
flush with cold water and seek medical attention.
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Skyjack SJ6832 RTE User manual

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