Tech Tips

THE SERVICE MANUAL

12/09/2015
The correct service manual is as much a tool as any impact wrench or pry bar.
The Skyjack Tech Tip

Technicians are asked to perform a variety of tasks on a wide range of equipment. Whether it is a simple repair at a wire connection or a major component overhaul, two of the essentials needed to successfully accomplish the job at hand are proper tools and correct information. The technician’s goal is to correctly diagnose and repair the problem in the least amount of time. Technicians invest to ensure that they have a tool box with all the necessary tools to complete any job safely and correctly. Wrenches, socket sets, screwdrivers, and volt meters - the list goes on. All of these tools can be rendered useless without the correct knowledge and information of how to use them.

The correct service manual is as much a tool as any impact wrench or pry bar. It contains information such as electrical and hydraulic schematics, safeguards for performing certain repairs, and other valuable information necessary to repair the equipment quickly and safely. Although swapping or replacing parts to see what makes a change or solves the problem can work, that method of troubleshooting and repair can prove costly in parts, as well as time.

Service departments work most efficiently when they have at a minimum, the correct hydraulic and electrical schematics and panel diagrams on the field service trucks, and maintain full manuals for all the equipment in the fleet, making them available in the shop for service and parts personnel to reference. Utilizing the service and maintenance manuals as a valuable tool will raise safety and productivity levels, positively affect employee attitude, and increase customer satisfaction and profits.

In an effort to make accurate information in the service and parts manuals quickly and easily available to you, all current production and most prior production manuals can be accessed at www.skyjack.com and are also available on an updatable USB stick format (part number 167847) available through our parts department. Hard copy manuals are also available for purchase from our parts department.

As always, if you have any questions regarding your Skyjack product, please call Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com for assistance.

HOLIDAY HOURS 2015

SKYJACK PRODUCT SUPPORT AND PARTS DEPARTMENT

TECHNICAL SUPPORT WILL BE CLOSED:

DECEMBER 24TH FOR CHRISTMAS EVE
DECEMBER 25TH FOR CHRISTMAS DAY
JANUARY 1ST 2016 NEW YEAR’S DAY

ST CHARLES PARTS WILL BE CLOSED:

DECEMBER 24TH FOR CHRISTMAS EVE
DECEMBER 25TH FOR CHRISTMAS DAY
**** DECEMBER 30TH AND 31ST FOR INVENTORY ****
JANUARY 1ST 2016 NEW YEAR’S DAY

CANADA PARTS WILL BE CLOSED:

DECEMBER 25TH FOR CHRISTMAS DAY
DECEMBER 28TH FOR BOXING DAY
**** DECEMBER 30TH AND 31ST FOR INVENTORY ****
JANUARY 1ST 2016 NEW YEAR’S DAY

**** ALL WILL REOPEN ON JANUARY 4th 2016 ****

OUR BEST WISHES FOR A JOYOUS HOLIDAY SEASON
AND A HEALTHY AND HAPPY NEW YEAR

skyjack.com/tech-tip Skyjack

DIESEL ENGINE POSITIVE AIR SHUTOFF VALVE

11/06/2015
You may have seen the optional ‘positive air shutoff valve’ for diesel engine equipped machines on one of your Skyjack models.
The Skyjack Tech Tip
DIESEL ENGINE POSITIVE AIR
SHUTOFF VALVE

You may have seen the optional ‘positive air shutoff valve’ for diesel engine equipped machines on one of your Skyjack models. This valve is a device that cuts the air supply to the engine to ensure the engine RPM’s do not over speed when it is being operated in a fuel charged atmosphere (some models also cut the power to the fuel pump). There are work site situations, such as mining, where the atmosphere can possibly contain natural gas, leaking propane, or other gases that a diesel engine can use as fuel. Since diesel engines do not require a spark to run, any gaseous fuel drawn into the combustion chamber along with the intake air can be ignited and allow the engine RPM’s to climb – potentially destroying the engine. The positive air shutoff blocks the intake air from reaching the combustion chamber, preventing this problem from occurring.

Figure 1The valve is located in the air intake tube just past the air filter. (See Figure 1). It has an external solenoid on an aluminum body that houses a throttle plate. Under the solenoid is a manual reset knob that is used to reset the system once it has been tripped. The solenoid is controlled by a rev controller that shuts the valve once the RPM’s exceed a preset point.

Regular maintenance is important to make sure the valve operates every time. Keep the valve clean and moving freely, and keep debris etc. from the mechanical portion that operates the valve. Check wiring for damage or corroded terminals. Inspect the solenoid boot for cracks or tears and replace if necessary. Push the solenoid in and check the valve for smooth operation. Inspect the wiring at the rev controller for loose or corroded terminals.

For component and switch location information, testing instructions and frequency, please consult the correct operating manual for the serial number of the unit you are working on.

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

TECH TIDBIT

With colder weather moving in, it is essential to check the usual items to prepare for the lower temperatures. Make sure anti-freeze levels and coolant/water mix is correct for your area. Make sure batteries are fully charged and check that they have tight, clean terminals. Check the operation of any cold weather options the machine may be equipped with. Gasoline and diesel fuels are usually blended for warm and cold weather. Make sure you have the correct blend for the season and use any fuel additives for cold weather as needed. These precautions will minimize the problems that the cold temperatures brings our way.

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3 Things to Remember

10/14/2015
This month we have 3 small items that are important to remember when troubleshooting your Skyjack Aerial Work Platform.
The Skyjack Tech Tip
3 THINGS TO REMEMBER

This month we have 3 small items that are important to remember when troubleshooting your Skyjack Aerial Work Platform.

1. When testing electrical circuits on Skyjack aerial equipment, please remember that we do not use the machine frame as a ground. The ground circuits on Skyjack models are a dedicated ground circuit with their own wiring and are circuit protected. Any solid white #02 wire or solid white #00 wire is intended as a ground wire. Every valve coil, light, alarm, etc, has a ground wire attached to it that will provide the ground portion of the circuit. When troubleshooting, please check the ground circuit breaker and use the white ground wires when attaching your volt meter leads.
2. When working on any Skyjack scissor lift, the serial number plate is a source of valuable information. In addition to the machine model and serial number, the serial number plate states the main relief and lift relief valve settings, the maximum drive height, and the model year. When testing the machine’s hydraulic pressures, consult the serial number plate for the correct relief valve pressure settings. When testing the machine functions and limit switches, it is valuable to know if the machine is drivable at full height, consult the serial number plate for that information. If the plate is damaged and unreadable or missing, a replacement part is available from Skyjack parts department.
3. When you are troubleshooting a problem on any equipment, it is always best to test ALL functions before trying to determine the exact problem. Look for function/problem commonality. Multiple functions can be affected by the same limit switch or valve and if all the functions related to that specific limit switch or valve are failing; this may pinpoint the source of the problem. By operating ALL functions and checking common points, you can save a lot of troubleshooting time and effort.

When servicing or troubleshooting your Skyjack scissor lift, boomlift, or telehandler, please use the correct manual for the model and serial number of the unit you are working on. If you have any questions or need further assistance, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com

TECH TIDBIT

In order to make all the latest information available to technician in the field and the shop, we have put all the operating, service, and parts manuals on a portable USB Flash Drive. This allows the technician to access pertinent information without having an internet connection. The flash drive is updated once a month at the Skyjack website skyjack.com/usb-update and any manual additions and corrections are installed. The flash drive is available from Skyjack Parts department and has part number 167847. This can be a valuable tool for technicians particularly in the field where internet access can be difficult.

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Deutz 2.9L T4 Fuel Pumps

09/15/2015
The new Deutz 2.9L tier 4 engines utilize a common rail fuel injection system.
The Skyjack Tech Tip
Deutz 2.9L T4 Fuel Pumps

The new Deutz 2.9L tier 4 engines utilize a common rail fuel injection system. Gone are 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 enough pressure is seen by the ECU sensor, it allows the engine to crank. If you encounter a no crank situation, check that the fuel pump is running and that the fuel lines are not pinched or constricted. If the pump is not running, check the CB3 circuit breaker on the base control panel. If the breaker is not tripped, you can check for power at the fuel pump terminals located at the fuel outlet end of the pump. See figure 1.

Notice the terminals are marked with positive and negative symbols. Note: the replacement part will not have darkened symbols. Verify that the power and ground wires are on the correct terminals or the pump will run backward. Test for good voltage (12V) and a good ground. Make sure there is no rusty or loose connections at the terminals or wire ends.

Once these tests have been made, you can determine if the fuel pump needs replacement. If your Deutz engine is still under warranty, please contact your local Deutz service center for replacement. If the engine is out of warranty you can purchase a replacement part from Skyjack parts department.

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

TECH TIDBIT
Technical training is an integral part of keeping your fleet operating safely and efficiently. Less down time means more production and profit from your Skyjack equipment. Skyjack offers technical training for the equipment we manufacture at your location. For more information, contact your regional service representative or call Skyjack Product Support at 1-800-275-9522 and ask for Rich Soltas. A well trained service staff is part of a safe and profitable service department.
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OCM/SCM TEST BASICS

08/26/2015
The OCM/SCM has a two line LCD display and a membrane keypad that allows the technician to access the programming without the need for a separate plug-in calibrator.
The Skyjack Tech Tip
OCM/SCM TEST BASICS

All the latest Skyjack boomlift models utilize a function control module called the OCM – On-board Control Module, or the newer version; the SCM – Skyjack Control Module which are located in the platform control console. The OCM/SCM has a two line LCD display and a membrane keypad that allows the technician to access the programming without the need for a separate plug-in calibrator. Once the programming is accessed, the technician can monitor function status and make adjustments to function speeds similar to adjusting the trim potentiometers on a joystick circuit card.

When troubleshooting a ‘no functions at platform controls’ problem, there are a few tests that need to be done initially to help determine the problem. With the machine powered up, the key switch in platform position, and both the base and platform emergency stop buttons pulled out, please check the following items.

  • Using a voltmeter, check wire 04 for 12 volts at the start or horn switch. Wire 4 (or 4A if generator equipped) supplies power to the foot switch.
  • With foot switch depressed, test wire 08A out of foot switch to the OCM/SCM.
  • Then test wire 08B from the OCM to relay 08BCR.
  • Test wire 08 at 08BCR for power when the relay is activated.
  • Once these steps are completed and you have power at the correct terminals, you can test the OCM/SCM output for the function or functions you are having a problem with. Activate a function and observe the display – it should show which function is being operated and the percentage value it is currently supplying to the function valve.

By checking the above first, the technician can determine if the OCM/SCM is getting power into it and then putting power out to the switches. This enables the technician to quickly and accurately diagnose a ‘no platform function’ problem.

For more information regarding the OCM/SCM operation and input and output voltages, please consult the service manual for the serial number of the machine you are working on. If you have any questions regarding a Skyjack product, please call Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com

TECH TIDBIT
With the increased use of electronic circuits, the voltages that each circuit requires are more precise than a simpler wire/relay circuit. As a result, a good ground circuit is essential for correct operation. When testing for correct voltages make certain that the ground circuit is good.
skyjack.com/tech-tip Skyjack

FIBERGLIDE BUSHINGS

07/14/2015
Skyjack uses Fiberglide bushings, which are self-lubricating and maintenance-free.

Skyjack aerial work platforms utilize bushings at major pivot points such as the scissor stack end and center pins, steer kingpins and most boom pivot points. We use Fiberglide bushings, which are self-lubricating and maintenance-free. The bushing consists of a thin-wall steel backing with a woven PTFE bearing material bonded to it as seen in Figure 1. The bushings are designed to run dry with no additional lubrication required for the entire life of the bushing.

The best method to maintain the bushings and pins is to thoroughly pressure wash the pivot area and then blow the bushings and pins dry with compressed air. Do not add lubricants since this can flush the self-lubricating particles from the bearing and/or attract and retain dirt – both leading to reduced bearing life.  Bushings and/or pins should be inspected and may need to be replaced if there are signs of damage, rust, wear or noise at the pin connection.

When replacing these bushings, they are usually easy to remove from the mounting boss since they are a thin-wall design that is open along one side and will collapse with little effort. When installing a new bushing, it is recommended to use a step mandrel tool that is the same O.D. as the I.D. of the bushing, to prevent the bushing sustaining damage when installed. The step of the tool applies the force to the bushing as it is installed in the boss as in Figure 2.

Figure 2

When ordering replacement bushings and pins, please use the parts manual for the serial number of the machine you are servicing to get the correct parts and quantities. If you have any questions regarding your Skyjack product, please call Skyjack Product Support at 1-800-275-9522 or email to service@skyjack.com

TECH TIDBIT

The new Deutz Tier 4 2.9 Liter diesel engines are now being shipped in Skyjack boomlifts. The engines feature improved exhaust emissions that meet EPA standards and use engine computer controls. Please refer to the information in the Deutz engine manuals supplied with each machine and the recommended service intervals and procedures in the Skyjack and Deutz service manuals.

A.C. Power Cord Wire Colors

07/06/2015
The U.S./CA follow the NEC standardized colors. The U.K./Australia wiring uses the IEC standardized colors.
The Skyjack Tech Tip
A.C. Power Cord Wire Colors
When working with the A.C. power cords for the power to platform and the battery charger replacement cords, the wire colors for U.S./CA (North America) power cords may differ from U.K./Australia wire colors. The U.S./CA follow the NEC standardized colors. The U.K./Australia wiring uses the IEC standardized colors. The table below shows the corresponding colors for the NEC and IEC wire identification.
NEC Wire Color Description IEC Wire Color
Black Single Phase Line (hot/live) Brown
White Neutral Blue
Green Protective Earth (Ground) Green-Yellow
To help technicians identify the wiring colors, we have added the wiring color code identification and cross-reference to the service manuals. A label is also being installed on the power to platform cable showing the wire colors and how they correspond (see Figure 1). As you can see, the decal depicts the NEC wire colors and their corresponding IEC wire colors.
Figure 1
When troubleshooting or repairing your Skyjack product, please consult the correct operating, service or parts manual for the serial number of the unit you are working on. If you have any questions regarding wiring, or any questions at all regarding your Skyjack Product, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.
TECH TIDBIT
When contacting our Service Technicians, please have your pertinent information ready. Your name, company name, branch location or branch number, and the machine model and serial number. Please test ALL the functions from both the platform and base controls. This information will help our techs help you troubleshoot problems quickly and accurately.
SERVICE REMINDER
JULY 11 — 15, 2015

During this week, the Technical Support Staff will be involved in our Annual Training Seminar. For more information, please visit our website.
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SKYTOOL1 - Pin Extractor Tool

05/31/2015
The Skyjack SJ12 and SJ16 model vertical mast lifts share many characteristics of the SJIII scissor lifts.

The Skyjack SJ12 and SJ16 model vertical mast lifts share many characteristics of the SJIII Compact and Conventional scissor lifts. One feature is the ability to remove the platform control box from the machine. This allows the operator to prevent unauthorized use of the machine or allows a technician to swap in a different control box if the control box becomes damaged or for troubleshooting. The connector contacts use a male and female pin and socket arrangement.

As with any connector, contamination or damage can result in electrical issues. Always check for dirt, rust, or bent and loose contacts. With this particular connector, the wires are directly crimped to the contacts and then inserted into the block in the connector housing. Ensure that the contacts are secure in the block when inspecting the connector. If the male connector is mated to the female side without indexing properly, or forced into connecting, the contacts can be damaged.

If the contacts need replacing, a special tool is needed to remove the pin/socket. Skyjack parts department has the tool available as part number ‘SKYTOOL1’. It is a pen shaped tool that allows contact removal without damaging the block. The tool is slid over the contact from the mating side until it stops. Push a little harder and the contact will unlock and push in to the wire side.

For more specific information regarding the SJ12/16 Mast Lifts, please refer to the correct service or parts manual for the serial number of the unit you are servicing. If you have any questions regarding your Skyjack Aerial Work Platform or Telehandler, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

TECH TIDBIT

When servicing the wear pads on a boomlift, remember that an important part of what he wear pads do is to center the inner boom section in the outer section. Adjust the wear pads so that there is the manufacturer’s specified clearance between the pad and the boom and that the inner boom is centered in the opening of the outer boom section. The wear pad adjustment helps the platform to remain stable as the operator moves from side-to-side in the platform.

P.D.I. PRE-DELIVERY INSPECTIONS

05/21/2015
It is recommended that all aerial work platforms be inspected prior to being sold, leased, or rented.

It is recommended that all aerial work platforms be inspected prior to being sold, leased, or rented. Completing the Pre-delivery Inspection, or PDI ensures that the machine has been tested and inspected for proper and safe operation prior to being put into service, and that the unit has no worn or missing parts and is not damaged. Skyjack furnishes forms to assist in the completion the PDI inspection. These forms are available in the Forms Library. There is a form for the vertical mast/electric powered scissors and engine powered scissor lifts, as well as for the telescoping and articulating boomlifts. These PDI inspection sheets help you comply with the inspection requirements.

When a new unit is being put into service for the initial rental or sale, use of the Pre-delivery Inspection is very important. It documents completion of the final inspection before the unit is put into service for the first time. The Pre-delivery Inspection also serves as the owner’s verification of the condition of the machine at the start of the warranty period. Skyjack uses the date of the PDI as the warranty start date. Any problems identified are reported on the inspection sheet and can be corrected, under warranty, before the unit is put into service.

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

TECH TIDBIT

With the use of new engine designs and hydraulic system components in our equipment, please check the correct service manual for the serial number of the machine you are servicing for the correct oil and fluid specifications. There may be different motor oils, hydraulic fluids, and coolants that the engine and hydraulic manufacturers recommend for these new components.

BOOM JOYSTICK CONTROLLERS

03/27/2015
The joystick controllers used on the Skyjack telescoping (40/45 T & 61/66 T) and the articulating (46/51 AJ & 63 AJ) boom lift models all operate similarly. Whether it is a single or dual function joystick, testing and troubleshooting steps are the same.

The joystick controllers used on the Skyjack telescoping (40/45 T & 61/66 T) and the articulating (46/51 AJ & 63 AJ) boom lift models all operate similarly. Whether it is a single or dual function joystick, testing and troubleshooting steps are the same.

When the joystick is powered, it shows a neutral signal to the On-board Control Module or OCM. This neutral signal is between 4.2 and 4.8 volts. As the joystick is moved in any direction, this signal changes by either rising toward 8.5 volts maximum, or dropping to .5 volts minimum. This change in signal tells the OCM which direction you are asking the function to move – the volts drop or rise, and how fast you want the function to move – how much rise or drop in voltage occurs.

Reading this on a voltmeter would show the neutral signal sitting at 4.2/4.8 volts. As the joystick is moved forward, and the voltage rises to 4.9, the valve will start to move the function and as the voltage continues to rise toward the 8.5 volt maximum, the function speed will increase. When the boom is to be lowered, the volt reading would start again at the neutral signal of 4.2/4.8 volts. As the joystick is moved backward, and the voltage drops to 4.1, the valve will start to move the function and as the voltage continues to drop toward the .5 volt minimum, the function speed will increase.

Troubleshooting the joystick is simple. Connect your voltmeter to the power and ground wires at the joystick. Power up the control box and you should read your system voltage. If no voltage is seen, repair the ground or power circuit to the joystick. With good power and ground to the joystick established, move the meter positive lead to the signal wire to the OCM. Power up the controls and check that the OCM is powered and shows FUNCTIONS OFF. The signal wire should read 4.2 to 4.8 VDC. If not, check the OCM and if OK, replace the joystick. If OK, operate the joystick and watch the signal raise or lower as the handle is moved. If no signal change is seen replace the joystick. If the signal changes as it should, the joystick is working.

The correct service manual for the model and serial number of the machine you are servicing has complete joystick controller and OCM information and voltage references for troubleshooting. These manuals are available here. You can also contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com if you have any questions regarding this or any Skyjack product.

TECH TIDBIT

Make sure to keep all your indicator lights and LEDs in working order. They inform the operator to safe and unsafe conditions, engine distress, and can also help when troubleshooting a problem. They can indicate function operation or tell a technician if power is present without opening a panel or control box saving time and work. Checking all the indicator lights and LEDs should be a regular part of your maintenance and safety checklist.

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