Tech Tips

USB Flash Drive

The USB Flash Drive that is available from our parts department contains the current Service and Parts manuals.
Skyjack
TECH TIP
USB Flash Drive

The USB Flash Drive (part #167847) that is available from our parts department contains the current Service and Parts manuals. This flash drive is an easy way for service personnel to access the manuals without internet access. It is perfect for technicians in the field with a laptop but no internet connection. It also allows the technician to access the correct manual for the serial number of the unit they are working on.

The flash drive is designed to be updated manually every 30 days. A new update is available after the 15th of each month. You will need a computer with internet access to load the update. To update the drive, open the Skyjack drive and look at the menu. Double-click on UpdateUSB and a menu containing AutoUpdateUSB will appear. Double-click on that and a dialog box will open asking Would you like to update? Y/N. Type in "Y" and hit Enter and it will start the update. The update contains any additions and changes made to the manual since the last update. Be patient, as some updates are long and take time to complete. Once completed, it will ask you to press enter to exit. USB

Recently there was a technical glitch with the update program, but there is a fix. Use this link www.skyjack.com/usb-fix or go to our website www.skyjack.com and look for the banners (see below) throughout the website, click on the banner and follow the instructions.

Any new USB Flash Drive purchased after October 25th, 2018 will have the fix installed.

As usual, if you have any questions regarding your Skyjack product, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com for assistance. Visit our website www.skyjack.com for access to product information and technical manuals.

On-Board Diagnostic Display

The SJ30 AJE/ARJE and SJ6832 RTE models use a motor controller system for function operation

Skyjack Tech Tip
SJ30 ARJE

The electric powered SJ30 AJE/ARJE articulating booms and the SJ6832 RTE rough terrain scissor models use a motor controller system for function operation. The system features an on-board Hour Meter/Diagnostic Display. When the unit is powered up, there will be some general information shown on the display.

First, it flashes the software revision number of the display followed by the software revision of the motor controller. For example, you may see “EP019” then “EP026” when the key is turned on. These are not error codes and aren’t listed in any code tables. The display then shows the hours of use.

Note: If the batteries are low, a turtle icon will appear; this means the unit is in creep mode and in need of recharge.

If the system detects an error, a flashing red LED and a wrench symbol will appear on the display along with any error codes. Consult the code tables in the correct Service Manual for the Serial Number of the machine you are working on for information regarding the specific codes that are displayed.

On-board Diagonstic Display
For more information please consult the correct Service Manual for the Serial Number of the unit you are working on. These are available at www.skyjack.com in section 5.

If you have any questions regarding your Skyjack product, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

MODULAR KEY SWITCHES

It's important to use the correct switch blocks and key operator parts

Skyjack Tech Tip
MODULAR KEY SWITCHES

It is important, when replacing any pieces of the modular key switches, to use the correct switch blocks and key operator parts and to install them in the correct position.

For example, the current production Skyjack boomlift models 40/45T, 61/66T, 46/63AJ, and 82/86T with the Deutz 2.9L engine use a modular style key switch at the base controls.

Figure A shows a sample arrangement of the switch blocks – highlighting some items to look for when replacing some parts. Note: not all models use this exact switch block arrangement, always reference the correct drawing in the manual for the serial number of the unit you are working on.

Figures A and B

1. Looking at the switch from the back, the NOEM switch block mounts to the left side of the switch frame.
2. The NCLB switch block mounts to the center position of the switch frame.
3. The NC switch block mounts on top of the NCLB switch block as in Figure B.
4. There is no switch block mounted to the right space on the switch frame.

Figure B shows the NC and NCLB switch blocks - correctly assembled.

***After replacing any switch or other electrical component, fully function test the machine, making sure each function operates properly from all the controls in the platform and base. Consult the correct Operator’s Manual for that machine’s serial number.

Always use the correct Service, Parts, and Operator’s Manuals for the serial number of the unit you are servicing.

As always, if you have a question regarding this tech tip or any Skyjack product, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

MOTOR CONTROLLER UNITS: CONTACTOR DIODE

Skyjack electric scissor lifts and vertical mast units both use a Motor Controller to regulate the speed of functions.

Skyjack Tech Tip
Motor Controller

Skyjack electric scissor lifts (MC labeled units) and vertical mast units (SJ12 & SJ16) both use a Motor Controller to regulate the speed of functions. These Motor Controller equipped models use the same pump motor contactor as the models without a Motor Controller, but with one important difference: the Motor Controller units require a suppression, or flyback diode between the coil terminals on the contactor.

The diode is placed between the power wire (19A) and ground wire (02). This diode prevents the voltage created when the contactor coil collapses from feeding back and damaging the Motor Controller.

The diode is shown between the power (19A) and ground (02) wires at the contactor coil terminals. See Figure 1.

Figure 1

Original equipment diodes have a + and – sign molded into the diode body as shown. If you are using a replacement diode, Part #102921, make sure the silver stripe on the diode is facing wire 19A. The contactor replacement part number is #165865. It will arrive with a new diode installed, but always make sure the diode is installed on all Motor Controller units.

If you have any questions regarding this part or anything regarding your Skyjack product, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

Manual Storage Box

All Skyjack mobile elevating work platforms are equipped with a manual storage box.

MANUAL STORAGE BOX ON AN SJ66 T

All Skyjack mobile elevating work platforms are equipped with a manual storage box. The weather resistant plastic box is located either on the platform or in the base control area. The manual storage box should always be in good condition – attached securely to the machine, no missing parts, and weather tight to keep the documents inside clean and dry. The box contains important documents for personnel who use the mobile elevating work platform - the ANSI Manual of Responsibilities and the Skyjack Operating Manual for that model and serial number. Current ANSI standards require both the ANSI Manual of Responsibilities and the Skyjack Operating Manual to be with the machine at all times. Some jurisdictions also require that a copy of the Certificate of Compliance to relevant ANSI and CSA standards be kept with the machine. All new Skyjack mobile elevating work platforms are shipped with these documents in the storage box.

As stated on its front cover, the ANSI Manual of Responsibilities is a compliance guide for dealers, owners, users, operators, lessors, lessees, and brokers. The manual in the storage box should be clean, complete, and legible. It must be the most current edition from ANSI, and copies are available from Skyjack's parts department and ANSI.

The Skyjack Operating Manual must be the correct manual for the model and serial number of the work platform on which it is placed. Reprints of the Skyjack Operating Manual are permitted but they must be complete, legible, and correct for the platform on which it is placed. Skyjack has the operating manuals in .pdf format and available for print on our website www.skyjack.com.

There is another manual that you may find in the storage box: the AEM Aerial Platform Safety Manual for Operating and Maintenance Personnel. This manual from the Association of Equipment Manufacturers is a generic safety manual for mobile elevating work platforms. The AEM manual can be in the storage box but it is not required by the relevant ANSI standards and it is not a substitute for either the ANSI Manual of Responsibilities or the Skyjack Operating Manual.

If you have any questions regarding your Skyjack equipment, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

DECEMBER 2017

3 things to remember!
The Skyjack Tech Tip
3 THINGS TO REMEMBER


1. The new Deutz engines with the common rail-electronic injection system will not allow the starter to crank if the fuel pump does not operate. If you get a no crank situation with one of these engines, check that the fuel pump is operating.

2. All Skyjack scissorlifts and boomlifts use dedicated ground wires for all ground connections. There is no frame ground available. When testing electrical issues please remember to use the battery ground, any 00 or 02 white wires for a good ground connection.

3. When installing and calibrating a tilt switch or auto level module, the most important part of the procedure is to ensure the machine frame is level (i.e. the machine is positioned on a level surface). If the frame is not level and the switch is calibrated to that incorrect level, the tilt switch will allow the unit to elevate when outside the allowable amount of tilt on one side – unsafe

If you have any questions regarding your Skyjack Product, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com for assistance.

SKYJACK

OCTOBER 2017

Skyjack electric scissor models that use a Motor Controller – the units labeled as MC
The Skyjack Tech Tip
MOTOR CONTROLLERS

For the Skyjack electric scissor models that use a Motor Controller – the units labeled as MC - testing to find why the pump motor will not run is more than just checking for power and ground at the pump motor terminals. The motor controller controls the ground signal and the current to the motor. Varying this current will vary the speed of the motor. In the event that the pump motor will not run, you will need to make several tests to determine if the input signals to the motor controller, the motor controller or the pump motor is at fault.

First, make sure the basic tests are completed. The batteries must be charged, power switches on, and correct operational procedures must be followed. Make sure all the terminals at the batteries, motor and motor controller are clean and tight.
Test for system voltage at the enable input terminal (19A wire) at the motor controller when operating a function. This should read between 19 and 24VDC. This circuit also powers the pump motor contactor (solenoid) so it is a good idea at this point to make sure the contactor is working. Trace and repair that circuit as needed.

Then test for a variable voltage to the speed signal input terminal (59I wire) at the motor controller. This should read between 0 to 4.8VDC when using the joystick. Trace and repair that circuit as needed.

Once these basic tests are complete, conduct the following test:

  • Turn off the main power disconnect switch and remember to observe all safety precautions when working with batteries and associated power cables.
  • To bypass the motor controller, disconnect M- & B- cables from the motor controller and connect them together using one of the bolts from the motor controller.
  • Turn on the main power disconnect switch, activate the steer function, and observe if the pump motor runs.

    → If the pump motor runs, replace the motor controller.
    → If the pump motor does not run, replace the motor.

Anytime you have a question regarding your Skyjack product, please contact Skyjack Product Support at 1-800-275-9522 or service@skyjack.com.

TECH TIDBIT

In order to assist our customers better, we have started a new website to provide improved access to operating, service and parts manuals. The new site is techpub.skyjack.com and is accessible from our main website www.skyjack.com.

This improved site will allow our customers to open, download, and then print complete equipment manuals or specific pages very quickly. You can download the manual to your computer and print from that file using an "XPS to PDF" converter*. The manuals are updated frequently to keep the information current.

*You might be required to download this free application if your operating system does not already have it installed.

SKYJACK

JUNE 2017

The Deutz 2.9L Tier 4 engines utilize a common rail fuel injection system.
The Skyjack Tech Tip
ELECTRICAL FUEL PUMPS

The Deutz 2.9L Tier 4 engines utilize a common rail fuel injection system. Gone is the familiar lift pump and injector pump arrangement. These engines use an electric fuel pump to deliver fuel through the filter to the high pressure fuel pump. The pump is mounted near the fuel tank near the replaceable cartridge fuel filter.

When the machine is powered up, the fuel pump runs to build pressure in the circuit. Once pressure is detected by the ECU sensor, it allows the engine to crank.

If you encounter a no crank/no fuel situation, check the following:

  1. Check that the circuit breaker CB3 is not tripped. This breaker is for the fuel pump only. Check the connections at the spades on the breaker; look for loose terminals and burnt or loose connections. Replace any wire terminals or the breaker itself if required. Do not assume the fuel pump itself is at fault. Check the fuel lines from the pump to the engine for any kinks, pinches or restrictions that can cause the fuel pump to work harder than normal.
  2. With the base and platform e-stops ON, key switch ON, check for power and ground at the fuel pump terminals located on the fuel pump or at the connector plug - if equipped. Make sure the terminals are clean and free of rust and debris that may cause a short. Clean or replace as needed.
  3. If power and ground are present at the fuel pump, check that the fuel pump is running. If not running, replace the fuel pump.
  4. If there is no power at the fuel pump, check the relay 56ACR located in the base control panel. The engine ECU supplies ground for the relay on wire 56A. If no ground is present, check the ECU harness and connectors. No ground at 56A may indicate an ECU problem.
  5. At the relay 56ACR, check wire 54 for power to the coil. With ground on 56A and power on 54 at the relay, you should read power at 56B wire direct to the fuel pump through a harness connector. Check power from the relay through the connector to the fuel pump.

Using this test procedure should help determine the cause of the problem – it is not always the fuel pump that is at fault. If you have questions or further problems please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

ANNUAL SERVICE MEETING

************ REMEMBER THESE DATES! ************

JULY 17, 18, 19, 20, & 21st 2017:
DURING THIS WEEK THE TECHNICAL SUPPORT STAFF WILL BE INVOLVED IN OUR ANNUAL TRAINING SEMINAR.

On Monday July 17th, Tuesday July 18th, Wednesday July 19th, & Thursday July 20th:
ALL ACCESS TO OUR TECHNICAL STAFF WILL BE VERY LIMITED DUE TO TRAINING CLASSES.
WE WILL BE TAKING MESSAGES, AND OUR TECHNICIANS WILL BE RETURNING IMPORTANT PHONE CALLS DURING THESE DAYS.

On Friday July 21st:
NORMAL ACCESS TO THE SERVICE TECHNICIANS WILL RESUME.
TECHNICAL INFORMATION IS ALWAYS AVAILABLE AT www.skyjack.com

***THE PARTS DEPARTMENT WILL NOT BE AFFECTED***

WE APPRECIATE YOUR PATIENCE DURING THESE FEW DAYS.
THIS TIME ALLOWS US TO WORK TOGETHER TO PROVIDE THE HIGH LEVEL OF TECHNICAL SUPPORT THAT OUT CUSTOMERS HAVE COME TO EXPECT.

THANKS AGAIN!

SKYJACK

MAY 2017

Electrical connectors are an effective and durable way to make terminal connections
The Skyjack Tech Tip
ELECTRICAL CONNECTORS

Electrical connectors are an effective and durable way to make terminal connections at valve coils, wiring harness connections, and various other locations on equipment. Enclosed wiring terminals help to protect against corrosion-causing moisture, however, they can be susceptible to water intrusion. Time, pressure washing, improper or loose re-assembly, and damage are all factors that contribute to failure of a connector.

Once a connector is corroded, it can be difficult to clean and service the part completely back to original condition. Any part that has been damaged by corrosion will likely fail again. Keeping the connectors tight, clean, and sealed will help to prevent this damage.

When checking any connector, inspect it for damage or improper assembly. Make sure the wire entrance, (strain relief) is tight and no places exist where water can intrude. Examine any latches or locks for damage or incorrect assembly. Open the connector and check for corrosion at the terminal contacts and wire connections. Look for loose wire connections and damaged wires. Correct any problems and if necessary, replace the connector. When inspecting or replacing the part, apply some dielectric grease to the wire terminals and the terminal contacts to prevent corrosion. If water does get in, the dielectric grease will help to prevent corrosion problems.

A little preventive maintenance on any electrical connectors will ensure that the connector will remain clean and intact for a long time. Ensuring that connections are properly maintained helps you to provide a safe and dependable piece of equipment that will satisfy your customer each time they use it.

If you have any questions regarding your Skyjack product, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

TECH TIDBIT
Technicians be aware! There are new North American (ANSI and CSA) standards on the horizon. These new standards will affect machine operation and capabilities. It is a good idea to familiarize yourself with the new standards to be prepared for upcoming changes in order to do your job correctly and effectively. You can look at the information at www.skyjack.com/ansi-whitepaper.
SKYJACK

New Models

It is every technician’s responsibility to keep up-to-date on the new equipment’s proper and safe operation.
The Skyjack Tech Tip
NEW MODELS

Skyjack is constantly improving and developing new products for our customers. We recently added a motor controller option to our electric scissor models and have redesigned our telehandler line with the new TH series. The T and AJ model boomlifts are still relatively new with an 86-foot straight stick boom being the latest addition. An 85-foot articulating boom will debut soon.

When new models and designs are implemented, there are often different functions and capabilities that the equipment can perform. It is every technician’s responsibility to keep up-to-date on the new equipment’s proper and safe operation. This means taking the time to educate yourself about any new equipment. The old adage, “you can’t fix it if you do not know how it works” comes into play here. If you do not know if the equipment is performing a function properly or if a circuit is working correctly, you would not know if it needs to be repaired or adjusted. This lack of equipment knowledge can lead to problems with unsafe equipment operation or incorrect adjustment of parts that can cause premature wear of components or damage.

The operator’s manual and the service manual are tools a technician can use to accomplish this. The service and operation manuals provide test procedures and operation instructions and descriptions that are to be used when maintaining the equipment. Always use the correct manual for the serial number of the unit you are servicing to assure you have the correct information at hand. The manuals are available at our website, www.skyjack.com or on an updatable flash drive available from parts department as part number 167847.

If you ever have any questions regarding an older or newer Skyjack product, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

TECH TIDBIT
One of the most important maintenance items for any of the telehandler models is proper lubrication. When servicing the unit always use the decals on the unit and/or the service manual for the location of all the lube points, proper intervals, and the correct lubricant to use.
SKYJACK

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