Tech Tips

Deutz 2.9L Trouble Codes

12/22/2016
The new Deutz 2.9L Tier 4 diesel engines are capable of providing the technician with a flash code for engine diagnostics
The Skyjack Tech Tip

The new Deutz 2.9L Tier 4 diesel engines are capable of providing the technician with a flash code for engine diagnostics to assist the technician when a computer is not available. The platform and base control panels are equipped with a warning light display to alert the operator of problems. Consult the correct operating or service manual for the model and serial number of the machine you are working on for the location and identification of the lights.

When looking at the warning lamp, it will display either a continuous light or a flashing light.

A continuous light refers to a system error; likely an engine sensor, for example the coolant temperature sensor or oil pressure sensor signal to the ECU is out of range. This is considered a non-critical fault and the ECU allows continued operation but may reduce engine power.

A flashing warning indicates a serious error. The operator should shut the engine off. The ECU will reduce engine power and shut down the engine after a certain time and in some cases may let the engine run at reduced power for a short time to cool the engine - then shut it down.

To retrieve a flash code, find the diagnostic switch located on the base control console. Turn on the power for the unit, (do not start) and hold the switch until the warning light begins to flash. Immediately start counting the flashes. The codes are a 3-digit code and are shown as a series of flashes. The first digit will be short/quick flashes followed by a 2 second pause. The second digit will be longer/slower flashes followed by a 2 second pause. The third digit will be shown as the short/quick flashes followed by a 5 second pause. Any more codes stored will be shown in order of occurrence and it will repeat the first code once all have been displayed.

Once you have the codes recorded, contact your local Deutz dealer or call Skyjack Product Support at 1-800-275-9522 or e-mail service@skyjack.com for assistance.

After the problem is corrected, the code should clear from the list and the light should go off. If it does not contact your local Deutz dealer.

TECH TIDBIT
All of us here at Skyjack Product Support would like to wish you all a very Happy Holiday, and we look forward to a peaceful and prosperous New Year.
SKYJACK

ELECTRICAL - TERMINAL BLOCKS

11/29/2016
Each terminal block can hold four conductors of the same circuit.
The Skyjack Tech Tip

The electrical circuit terminal blocks used in the Skyjack Aerial Work Platforms are a method to neatly and securely terminate wires of the same circuit at a common point. Each terminal block can hold four conductors of the same circuit. Each block is attached to a metal rail mounted to the panel or control box and are ‘stacked’ side by side to form one terminal strip assembly.

Figure 1 shows a single block from the top as you would see it in a machine. Figure 2 shows the block from the side and you can see the spring clips that secure the wires inside the block and how all four wire holes connect to each other.

Figure 1 & 2
To insert or remove a wire from the block, insert a thin blade screwdriver into the slot adjacent to the desired wire location and push in firmly. This pushes the spring metal clip away from the wire end and the wire can be inserted or removed from the round hole. See figure 3.
Figure 3

To test a circuit at the terminal block with a voltmeter probe, insert the probe into either the insertion tool slot to contact the spring clip, or use the jumper slots next to the wire number tag area.

Some of the terminal blocks are equipped with an internal diode. These blocks have a diode symbol in the middle of the block. The diode separates two round wire holes from the opposite two holes. Figure 4 shows the diode-equipped terminal block.

Figure 4

Knowing how the terminal blocks work will make troubleshooting electrical circuits easier and more accurate.

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

SKYJACK

3 Tips for Easier Troubleshooting

10/18/2016
Here are 3 tips to make your troubleshooting easier with Skyjack machines.
The Skyjack Tech Tip

1. When troubleshooting any of the new Motor Controlled Vertical Mast or Electric Powered Scissor Lifts, make sure you have good, clean & tight ground connections. A bad ground connection anywhere in the circuit can be the root cause of the malfunction. When taking volt readings please use the B- terminal at the motor controller. This is direct from the negative battery terminal.

2. When operating or testing a Skyjack vertical mast, scissorlift, or boomlift, please make sure both the base control panel and platform control panel emergency stop switches are turned on. The units will not operate with one emergency stop in the on position.

3. When checking the auto level system on the Skyjack rough terrain scissor models, use the red LED on the auto level module to tell you the system status. When the LED is off, the outriggers are fully retracted. A solid LED indicates outriggers are extended and the unit is level. The LED will flash when the outriggers are in operation — extending or retracting. If you have a flashing LED and the outriggers are not being operated, the LED is sending an error code. Please consult the chart in correct service manual for the serial number of the unit you are working on.

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

TECH TIDBIT
When replacing the batteries on your electric scissorlift or vertical mast model, please remember to use the correct specification replacement battery for that machine. Using a smaller battery for example, would not provide the needed power and amp hours which could damage the electrical components. Most importantly, the battery weight is part of the ballast for the machine and is critical to proper stability when elevated.
SKYJACK

Proportional Joystick Tests

09/16/2016
The joystick on our Vertical Mast and Electric Scissor lifts have two outputs.
The Skyjack Tech Tip

When testing the joystick output for the drive or lift function on a Skyjack Vertical Mast or Electric Scissor lift model, you need to know the joystick has two outputs. One output is a system voltage output to operate the pump motor, valve coils, and relays. The other output is the speed, or proportional signal. This is a variable output signal relating to the speed desired for the function.

To test the system voltage output, locate the ‘A’ and ‘B’ wires at the LIFT-OFF-DRIVE function selector switch. The ‘A’ output is a purple/white color wire and it should have system voltage on it when the joystick handle is moved backward for reverse drive or platform lowering. The ‘B’ output is a solid red color wire and has power when the joystick handle is moved forward for forward drive or platform lift. If no power is seen at the selector switch, look for a diode inline on the ‘A’ and ‘B’ wires. A shorted open diode would prevent power reaching the selector switch. If no power is found, try operating the steer function to verify that the enable circuit is working. If no steer, test the enable switch circuit.

To test the proportional output, check power at the orange/black color wire 59 at the joystick 9-pin connector. You should read a proportional output that increases as the handle is moved farther away from neutral. For the SJIII hydraulic proportional units, the wire 59 output will vary from zero to 13.5/14volts at full handle throw on a properly adjusted joystick. For the Vertical Mast and SJIII Motor Controller (MC) units, the output will vary from zero to 4.6 at the joystick connector.

Please note that all the joysticks are not the same. Different models and configurations have different part number joysticks. Please consult the correct service or parts manual for the serial number of the model you are working on for the correct replacement joystick. Manuals are accessible at our website www.skyjack.com, or an updatable flash drive available from our parts department. Part number 167847.

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

TECH TIDBIT
Warning and indicator lights are a very important part of safe operation of any piece of equipment. Any and all warning and indicator lights should be checked at each inspection. Any inoperable LEDs or burned out bulbs should be replaced. These lights are as critical to safe operation as the safety limit switches and warning and instruction decals. Please do not overlook them.
SKYJACK

Throttle and choke pull solenoids

08/18/2016
Many of the engines we use in our scissorlift and boomlift models utilize a simple pull solenoid
The Skyjack Tech Tip

Many of the engines we use in our scissorlift and boomlift models utilize a simple pull solenoid to operate the engine throttle and choke. The solenoid consists of a steel plunger that is placed inside a wound coil of copper wire. When this coil is energized, a magnetic field is produced which draws the plunger into the magnetic field. The other end of the plunger is connected to the throttle or choke lever to be operated.

The majority of the solenoids we use are generically known as dual-coil, internally switched devices. Dual-coil solenoids have two coil windings: a ‘pull’ coil and a ‘hold’ coil. The pull coil is a large winding, and energizing this winding produces the solenoids maximum pull force and is used to initially retract the plunger. The hold coil is a smaller winding which produces a weaker pull force and is used to hold the plunger in its retracted position.

When the solenoid is activated, both coils are powered to produce the strongest pull force possible. Once the plunger is fully retracted, power to the pull coil is shut off and only the hold coil is powered to hold the plunger in place. To accomplish this, when the plunger is fully retracted into the solenoid body, it makes contact with an internal switch in the bottom of the bore which opens the circuit to the pull coil; depowering it.

The most common cause of solenoid failure is incorrect adjustment of the plunger and linkage resulting in burnout. If the plunger does not bottom out in the solenoid bore, the internal switch will not open the circuit to the pull coil. Because of the high amp draw of the pull coil, if it remains powered for a long period of time it will heat up and literally ‘cook’ the solenoid internally. A burned out solenoid can cause the main circuit breaker to trip, shutting down the machine or not having any high throttle function.

When installing or replacing the solenoid, make sure the solenoid is mounted securely and the plunger movement is in a straight line with the lever to be actuated. Check under the solenoid boot and make sure there is no spring under it. If a spring is present, remove it. Manually pull the plunger into the solenoid, making sure it is completely ‘bottomed out’ in the bore, this will insure the internal switch is opened - breaking power to the pull coil. While holding the plunger in that position, adjust the clevis on the threaded end of the plunger to set the throttle or choke lever to the proper position. Lock the clevis into place and test the solenoid operation. Make sure the lever being actuated is moving freely so the solenoid can pull it easily. Then check that the solenoid plunger is not allowed to move out of the solenoid body too far; or the magnetic field will not be able to pull it in. The solenoid mounting may have to be adjusted to accomplish this. Proper solenoid installation and set-up is critical to proper operation and long life.

At Skyjack Product Support, we want your Skyjack equipment to operate safely and dependably. If you have any questions regarding your Skyjack product, please contact product support at 1-800-275-9522, or e-mail service@skyjack.com.

TECH TIDBIT
Skyjack aerial work platforms must have any associated service bulletins completed prior to passing their annual inspections. When performing a frequent or annual inspection, it is a good idea to contact Skyjack Product Support to check for any open service bulletins related to the machine’s serial number. Call Skyjack product support at 1-800-275-9522 and have your serial number ready and we will check to see if any bulletins apply to that machine.
SKYJACK

Hydraulic Generators

07/19/2016
RTs and booms can be equipped with a hydraulic generator option to supply AC power to the platform.
The Skyjack Tech Tip

The Skyjack engine powered rough terrain scissorlift and boomlift models can be equipped with a hydraulic generator option to supply AC power to the platform. Some boomlift models can be equipped with a welder package option to power a small welder in the platform.

The generator is controlled by a coil operated valve that routes oil flow to the pump located on the generator pack. The generator rotates and produces an AC voltage that is sent to the AC receptacle on the platform.

If you have a problem, the first thing to check is that the generator is spinning. Check the generator shaft for rotation with the circuit turned on. No rotation may mean the valve is not working or not getting powered. Check for oil flow to the generator pump.

If the generator pump shaft is rotating, check the pump/generator coupling, it can get loose and slip on either shaft. If the coupling is good and the shaft is spinning properly, check the RPM’s of the generator shaft. The generator manufacturers specify a rotation speed of no less than 3600 RPM. This is critical; some generators will have low output at 3550 rpm. Use a photo tachometer to test the shaft rotation speed. If an adjustment is needed, some generator hydraulic circuits will have a flow control valve which can adjust the flow to the generator pump to attain the proper speed. Remember to always check AC output at the generator in case the problem is the wiring to the platform. If you have good voltage, and still no tool operation, check the hertz of the AC signal. Most volt meters have a hertz test selection and in North America the hertz should be 60Hz when read on the meter.

Generator packages from several manufacturers are used on our models and can be slightly different from each other. Always reference the correct manual for the serial number of the unit you are working on to obtain the correct test and adjustment information.

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

TECH TIDBIT
To prevent premature transmission failures when operating the drive function on the telehandler models, it is best to remember to operate the machine in the proper gear or speed. The operating manual states: “Select appropriate gear for the task being performed. Select a lower gear when transporting a load, traveling through deep mud, rough terrain, or slopes. Select higher gears only when traveling long distances on smooth terrain without a load.” This information is stated in the correct operating manual for the model and serial number of the machine you are operating or servicing.
SKYJACK

HOSE AND CABLE SUPPORT

07/19/2016
The use of support clamps, cable ties, along with using the correct fittings and correct hose and cable lengths minimizes or eliminates this tension to help ensure a long life.

It is important to ensure that when performing maintenance or a repair procedure, any hoses or electrical cables that may have been replaced or moved be returned to their original positions. As the equipment is operated, the hoses and cables flex and bend, and without proper support, this action causes a straining and pulling tension on them. The use of support clamps, cable ties, along with using the correct fittings and correct hose and cable lengths minimizes or eliminates this tension to help ensure a long life. When replacing a hose or cable, make sure to use the correct parts for the model and serial number of the machine you are repairing, and use all of the support clamps and cable ties as the original configuration.

An example of an incorrect hose replacement is found in figure 1 below. The two hydraulic hoses that are loose on the right side are under tension and are being pulled up against the edge of the equipment structure. Both hoses had been replaced but were not routed through the support clamps which are just out of sight under the frame. Not using the support clamp has allowed the hoses to be pulled against the frame, resulting in damage. The bundle of hoses on the left are routed in a gentle arc and properly supported by the clamps under the frame and are not under any tension as the equipment is operated.

Figure 1

Figure 2 shows the same two hoses after being installed into the support clamp just under the frame. You will notice that the hoses no longer contact the frame and have no possibility of rubbing and becoming damaged. The clamp holds the hoses away from the frame and relieves the tension that caused the damage. These hoses still require replacement, but you can see how the support clamp would have prevented the damage to the new hoses.

When inspecting equipment, make sure the hoses and cables are properly routed, look for any damage, check the hose and fittings are the correct type and rating, and verify that there is good support to eliminate pulling or tension as the equipment is used.

When replacing a hose make sure the hose and fittings are the same specifications as the manufacturer’s original parts and make sure the length is correct. When replacing an electrical cable make certain the cable is the correct part number for the model and serial number of the equipment you are repairing and the cable is the same length as the original. Always use all of the support clamps and cable ties as the original installation.

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

TECH TIDBIT

Skyjack has introduced several new models of equipment in the past few years; telescoping and articulating boomlifts and small rough terrain models in both engine and electric powered designs. As with any equipment, it is important for the technicians to take some time with the operator’s manual and familiarize themselves with the newer models operating characteristics. Use the copy of the operator’s manual that must be in every manual box and read through it and operate the unit to get comfortable with how it is supposed to function. When troubleshooting a problem later on the old adage applies ‘you can’t fix it if you don’t know how it’s supposed to work’.

SJ12/16 DIAGNOSTIC SWITCH

06/21/2016
The Skyjack Vertical Mast models SJ12 and SJ16 feature a traversing platform...
The Skyjack Tech Tip

The Skyjack Vertical Mast models SJ12 and SJ16 feature a traversing platform that allows the operator to extend the platform when elevated and safely reach a larger area without repositioning the machine. The platform can also be fully extended into the service position which provides a means of access to the hydraulic/electric compartment in the base to allow a technician to service the unit. For information regarding the proper operation of the platform, see the correct operator’s manual for the serial number of the unit you are operating or servicing.

The following pertains to ANSI/CSA machines. For all other regions, please consult the correct operating and service manuals for the serial number of the unit involved.

The traversing platform is equipped with a service position limit switch that prevents machine operation when the platform is extended fully into the service position. For troubleshooting/testing, the machine is equipped with a diagnostic switch that overrides the service position limit switch and allows the technician to operate the unit with the platform fully extended in the service position.

Fig. 1The diagnostic switch is located on the panel above the pump motor along with the main and ground circuit breakers. The pictorial decal by the switch is shown in Figure 1. Moving the switch and holding it will power the motor controller enable circuit (19B) and allow machine operation.

If you experience a no function/no pump motor situation from both the platform and base controls, first examine the platform service position limit switch. Make sure the deck is completely retracted and the limit switch plunger is not depressed. Check that the area is clean, and the limit switch plunger is operating mechanically. If that does not fix the problem, extend the platform to the service position and access the diagnostic switch and test the unit for function operation.

For answers to technical or other questions regarding your Skyjack aerial work platform or telehandler, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

ANNUAL SERVICE MEETING

JULY 11–15, 2016

** REMEMBER THESE DATES! **

During this week, the Technical Support Staff will be involved in our Annual Training Seminar.

Monday July 11th – Thursday July 14th:
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.

Friday July 15th 2016:
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 our customers have come to expect.

THANKS AGAIN!

SKYJACK

CHARGER INTERLOCK

05/17/2016
An often overlooked spot on the Skyjack electric powered scissor lifts is the A.C. interlock connection.
The Skyjack Tech Tip

An often overlooked spot on the Skyjack electric powered scissor lifts is the A.C. interlock connection. It is located at the rear of the battery charger and is labeled as AC Interlock. If the label is missing, look for two 14 GA. wires (one black/one white) leading to a white connector. See figure 1:

Fig. 1The purpose of the interlock circuit is to prevent the unit from being operated while the charger is plugged in. When the charger is connected to an AC power source, the 120V relay (L1CR) inside the charger opens the contacts cutting power from the main circuit breaker on wire 3A to the 05 wire (power to the emergency stop switch) preventing the machine from operating. See figure 2:

Fig. 2

White Connector
If you experience total loss of functions, check that the charger is not plugged in, then check the interlock connector. The connector may be loose or corroded causing the power loss. The other cause may be a bad relay in the charger. This relay does not affect charger operation. If necessary, you can bypass the connector by connecting wires 3A and 05 together on the machine side of the connector.

If you encounter this situation or if you have a question regarding your Skyjack product, and need assistance, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

TECH TIDBIT
It is important to always check that all the warning and indicator lights are working at each inspection or service. These lights tell the operator the condition of the engine, safety status, power on, and other critical information. They can also help a technician troubleshoot a problem. Taking the time to check and replace any non-working bulbs or LED lights is something that is as important as tightening wheel bolts or checking safety switches.
SKYJACK

TECHNICAL SERVICE

04/28/2016
On the rare occasion that a Skyjack product has a problem, the service technician may need information to help troubleshoot and repair the machine.
The Skyjack Tech Tip

On the rare occasion that a Skyjack product has a problem, the service technician may need information to help troubleshoot and repair the machine. Just call Skyjack Product Support at
1-800-275-9522, and follow the prompts to get to technical support. Skyjack employs field experienced technicians that are able to answer questions and assist with any issue that you may have regarding your Skyjack product.

When you call, please have some information ready so our technicians can assist you accurately and quickly.
Please speak clearly and provide the following:

  • Your Name, Company, and location
  • Model and Serial number
  • Hour meter reading
  • An accurate description of the problem

In order for us to provide assistance in troubleshooting a problem, an accurate description of the problem is vital. A good practice is to operate all the functions and note which do not work. Many times, multiple functions that do not work will be related and can be a clue to where the problem exists. Then check the basics; make sure that all wires are connected, all relays are in their bases, the fuel tank has fuel, etc., - before you call. Many problems are solved by finding a loose connection.

As a technician, you are required to be familiarized with the operation of the equipment you work on. Please review the operator’s manual, which is required by ANSI to be in the manual box on every machine at all times.

Basic tools and test equipment are also important to have. A multimeter and hydraulic pressure gauges are essential testing tools. One of the best tools is the service manual for the model and serial number of the unit being repaired. Service manuals are easily accessed on our website www.skyjack.com or available on a USB flash drive – part number 167847 available from our parts department.

When performing an annual inspection, please contact technical support to find out if any service bulletins are open for the serial number of the machine you are inspecting. Completing all the service bulletins is necessary to satisfy the annual inspection.

We at Skyjack Product Support make it our goal to provide you with the best technical support in the industry. One of the keys to both your success and ours is effective communication. Using this information as a guide will help us help you. Please call 1-800-275-9522 or email service@skyjack.com for assistance with your Skyjack product.

TECH TIDBIT
Skyjack is now manufacturing electric scissor lifts with a motor controller option. The platform control box has a decal on the side that says MC. These control boxes only operate motor controller equipped units. The control box cable connector will only mate up to a motor controller unit machine.
SKYJACK

Filter by year

Popular Tags
  • Boom lift
  • Tilt switch
  • ANSI
  • installation
  • service manual
  • Flash Drive
  • hydraulics
  • solenoid
  • key switches
  • Download
  • pump motor
  • copper wire
  • Deutz
  • MC
  • maintenance
  • Connectors
  • Spring mounted
  • Series III
  • USB update
  • SJIII Series

Search Bulletins

BULLETINS
Please enter your Skyjack serial number to check for Service Bulletins for your machine:
Please enter the bulletin

Results

Service bulletins for serial number
12345678