Tech Tips

DECEMBER 2017

12/14/2017
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 scissor lifts and boom lifts 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

10/12/2017
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

06/30/2017
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

05/30/2017
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

04/25/2017
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

ELECTRIC SCISSOR WHEEL BOLT INSPECTION

03/28/2017
Wheel assemblies and their connection to the machine must be checked.
The Skyjack Tech Tip
ELECTRIC SCISSOR
WHEEL BOLT INSPECTION

As a required part of each inspection, wheel assemblies and their connection to the machine must be checked. This includes looking for any signs of damage and ensuring that the wheel bolts are properly tightened. If any wheel bolts are found to be loose or not at the correct torque value of 90 ft-lb (122 Nm), each component (wheel rim, wheel bolts, hub) should be inspected to ensure that there is no damage, prior to re-assembly. Do not attempt to re-tighten damaged parts – they must be replaced.

When replacing or re-installing a wheel/tire or wheel bolt, ensure that all the mounting surfaces are clean and free of any debris, rust, excess paint, etc. Mount the wheel on the hub, centering the mounting holes on the bolt holes as shown in Figure 1.

Figures 1 & 2

Install the wheel bolts and hand tighten to center the rim on the hub. Next, torque the bolts to approximately 50 ft-lb (68 Nm) in the tightening sequence shown in Figure 2. Torque the wheel bolts again to their final torque of 90 ft-lb (122 Nm) using the same sequence. Repeat the tightening sequence to confirm that none of the wheel bolts have changed from 90 ft-lb (122 Nm). If any wheel bolts have changed in value, repeat the complete torqueing sequence until there is no change in torque values. If possible, drive the machine prior to checking the torque values.

The regular and required checks of the wheel bolt torque will ensure that the wheels remain secure and that damage to the assembly will not occur.

To aid operators conducting daily inspections ensuring tightness of the wheel/tire assembly, torque seal paint, wheel nut indicators or other visual indicators may be used.

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

SKYJACK

Pothole Protection Maintenance

02/02/2017
The pothole protection system is designed to reduce ground clearance...
The Skyjack Tech Tip

The pothole protection system on the Skyjack SJIII model DC electric scissor lifts is designed to reduce ground clearance and assist in the stability of an elevated aerial platform in the event the aerial platform encounters a “drop-off” or “pothole.” As with all safety devices, periodic inspection and maintenance is required to ensure the proper operation of the pothole protection device. The nature of this safety feature relies on maintaining a consistent ground clearance, therefore, if the aerial platform ever does come in to rest on the pothole device, the platform should be immediately lowered and “locked out” to prevent further use until a complete inspection of the mechanism is performed by a qualified technician.

The system is comprised of four major components; the pothole bar (not shown), the camlock assembly, the compression rods, and the limit switches. See Figure 1.

Figure 1

The pothole bars are the angle parts located along the bottom edge of the tray on each side of the unit. They deploy by gravity and should pivot smoothly and not be bent or damaged.

The most important part of maintaining the system is keeping it clean. Familiarize yourself with how the mechanism correctly operates. Examine the mechanism for damage and debris. Replace any worn or damaged parts. Thoroughly clean the entire mechanism – a pressure washer works best to remove any material that may prevent smooth operation of the mechanism. Operate the mechanism and look for smooth operation of the levers, pothole bars, and camlocks. Test for correct operation by placing a block (approximately 1.5” high) under the swing out tray on one side (preventing the pothole mechanism from fully-deploying). After raising the platform to a height of approximately 7 feet, attempting to drive should result in no movement. This test should be repeated for the other pothole bar.

No lubrication is needed for the camlock assembly as it uses oil impregnated bushings. The same applies to the pothole bar pivots under the trays, they use the oil impregnated bushings as well and require no lubrication. Sparingly apply a light spray lube on the limit switch roller plunger, and the pivot pins - too much will attract dirt and debris since this mechanism is close to the ground.

For more information regarding the pothole mechanism limit switch adjustment, or replacing the camlock assembly, please visit www.skyjack.com, look under technical manuals and input your model OR serial number and watch the technical animations for those procedures. 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.

TECH TIDBIT
Training for your technicians is very necessary to maintain a dependable and safe fleet. Technical training is available for current production equipment at your location from your Skyjack Regional Service Representative. For more information, ask your rep when they stop by, or call 1-800-275-9522 and ask for Rich Soltas. You can also email rich.soltas@skyjack.com.
SKYJACK

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