Tech Tips

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

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

AUTO LEVEL OUTRIGGERS

03/22/2016
When troubleshooting any problem, it is essential that you know how the function works in order to be able to fix it.
The Skyjack Tech Tip

When troubleshooting any problem, it is essential that you know how the function works in order to be able to fix it. Outrigger inspection procedures can be found in the applicable operating manual for the serial number of the unit you are working on, as well as the Service Advisory dated September 1, 2010.

We receive many questions relating to the outrigger auto level system on the Rough Terrain Scissor lifts. Simply put, the outrigger auto level system operates in two steps:

  • Step 1: The outriggers extend until they first contact the ground and start to lift the frame slightly. The extend limit switches on the outriggers close, telling the auto level module that the outriggers have touched the ground and power to that valve should be shut off.
  • Step 2: Once all four outrigger extend limit switches verify that all outriggers are extended and on the ground, the module extends only the necessary outrigger(s) to level the frame.

If you experience one or more outriggers extending too far, the extend limit switch for that outrigger may be sticking or failing. If the outrigger extends too far, the system cannot level the unit. The module will not retract an outrigger to achieve level. The extend limit switches are located at the point where each outrigger leg is slid into the frame.

Finding the problem by testing the extend limit switch inputs to the auto level module is easy. Test at the P2 connector on the module. The extend limit switch wire numbers are 68A, 67A, 66A, and 65A. Wire 68A corresponds to the left rear limit switch. 67A right rear, 66A right front, and 65A left front. Operate the auto level function and as each outrigger closes it’s extend limit switch, you will see input voltage (12V) at that pin position. If you see voltage at the pin and the outrigger does not stop, the module is most likely bad. More specific schematic and outrigger circuit diagrams are available in the correct service manual for the serial number of the unit you are working on. Service manuals are available at www.skyjack.com or using the USB flash drive available from parts department.

If you have any questions regarding the auto level system or any other specifics on your Skyjack product, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

SKYJACK

TECHNICAL SERVICE

02/26/2016
The motor controller is simple in operation. It has 2 inputs...
The Skyjack Tech Tip

The Skyjack SJIII Compact and Conventional model electric scissor lifts with the MC option and all of the SJ12/SJ16 Vertical Mast models utilize a motor controller to control the function speeds. The motor controller controls the rotation speed of the pump motor which, through the pump rotation speed, results in precise control of the function speed.

The motor controller is simple in operation. It has 2 inputs: a control enable input that tells the controller it is OK to operate, and a speed signal input telling the controller how fast to rotate the pump motor. Once the control enable input sees a voltage higher than 12VDC, it allows the controller to monitor the speed input and operate the motor. If the enable input detects a problem (interruption or dropping below 12VDC of the input signal) it will shut down the controller. The speed signal input operates on a voltage between 0 and 5VDC. At 0.2VDC the controller will start applying voltage to the pump motor and increase this voltage until input signal is 3.86VDC which is considered 100 percent. If the speed input exceeds 4.6VDC the controller will shut down.

When troubleshooting, check the connections at the motor controller for loose or corroded terminals. Then check for the enable input, it should be system voltage. Operate the joystick and observe the speed input. It should start at 0VDC and increase as the joystick is moved from neutral staying below 4.6VDC at full joystick travel. If these inputs are correct the problem may be the motor or the controller itself.

More specific information is available in the service manual for the serial number of the unit you are working on. The full manual selection for your Skyjack model is available at www.skyjack.com or using the updateable USB flash drive available from our parts department. Use part number 167847. For technical assistance, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

TECH TIDBIT
When troubleshooting Skyjack electric and rough terrain scissor lifts remember that the platform control box can be connected at the base of the unit. This allows the technician to operate the machine from the ground position, which makes it easier to make observations and perform tests while the unit is operating. It also eliminates the scissor stack cable from the circuit shortening troubleshooting time.
SKYJACK

SERVICE BULLETINS

01/14/2016
Service Bulletins are used to communicate required modifications to machinery that is in the field.
The Skyjack Tech Tip
SERVICE BULLETINS

Skyjack products are designed and tested to ensure correct operation and reliability. In spite of our best efforts, there are occasions when a modification must be made to a piece of equipment after it has been delivered to a customer and placed in service. Service Bulletins are used to communicate required modifications to machinery that is in the field. The scope of Service Bulletins may range from the simple addition of a label to an inspection or a more involved electrical, hydraulic, or structural modification.

Service Bulletins are divided into 2 categories: safety related and non-safety related. A safety related Bulletin addresses issues that impact the safe operation of the equipment. The Bulletin cover page will have the words "SAFETY RELATED" below the Bulletin’s number and title. To ensure the safety of users and operators of the equipment, the instructions in a safety related Service Bulletin are mandatory and must be followed as directed in the Bulletin.

A non-safety related Bulletin may address items impacting owner satisfaction, such as longer-term reliability. It will not have any "Safety Related" designation on the cover. The instructions, however, are also mandatory and must be followed as directed in the Bulletin.

Once a Service Bulletin is released by Skyjack, a copy of the Bulletin will be mailed to the registered and known owners of the equipment in question. To ensure that you receive these Bulletins, Skyjack must be informed of the serial numbers of any equipment that you own. If you have sold or transferred any machine, Skyjack requires that you promptly notify us of the new owner’s contact information. Should you subsequently receive a Service Bulletin for any machine that you have sold or no longer possess, the Bulletin must be forwarded to the new owner of that machine.

It is very important that any Service Bulletin is read thoroughly and understood before attempting to perform the required inspection, repair or modification. Most questions about the work required by a Service Bulletin are alleviated by knowledge of what is to be done, before starting completion of the Bulletin.

Skyjack’s Service Bulletins are available to look at on our website, skyjack.com/bulletins. The Bulletins are identified by number and are in PDF files for easy viewing and downloading. When performing an annual inspection, check the serial number of the unit for any open Service Bulletins by contacting Skyjack Product Support.

If you have any questions regarding how to perform or process a Service Bulletin, or any other question about your Skyjack equipment, please contact Skyjack Product Support at 1-800-275-9522 or email service@skyjack.com.

TECH TIDBIT
When testing the tilt switch on any Skyjack electric powered scissor lift, remember you will not see any power to the tilt switch unless a function is used. Both the old "bubble level" type and the new electronic style tilt switches have LED lights that light up when a function is operated. Use the lift function to see if the LED’s turn on to verify the tilt switch is getting power and has a good ground connection.
SKYJACK

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.

skyjack.com/tech-tip Skyjack

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.

skyjack.com/tech-tip Skyjack

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