SJ 16 Service Manual

SERVICE
MANUAL
SJ12, SJ16
VERTICAL MAST
161917AG
August 30, 2021
ANSI, CE & KC
This manual is based on Serial Number(s):
SJ 12 & SJ 16 : 14 002 154 - 14 999 999
Please refer to the website (www.skyjack.com) for

other Serial Numbers, most recent Technical Manuals
and USB software.
Skyjack Service Center Parts & Service (Europe)

3451 Swenson Ave. St. Charles, Unit 1 Maes Y Clawdd
Illinois, 60174 USA Maesbury Road Industrial Estate
Phone: 630-262-0005 Oswestry, Shropshire SY10 8NN UK
Toll Free: 1-800-275-9522 Phone: +44-1691-676-235
Fax: 630-262-0006 Fax: +44-1691-676-238
Email: [email protected] E-mail: [email protected]
Parts (North America) Skyjack Brasil

Toll Free: 1-800-965-4626 Alameda Júpiter, 710
Toll Free Fax: 1-888-782-4825 Loteamento American Park Empresarial
E-mail: [email protected] Indaiatuba, SP, Brasil 13347-653
Tel: +55 19 3936 0132
Skyjack Australia Pty Ltd.
Unit 1, 35 Honeycomb Drive
Eastern Creek
New South Wales 2766
Australia
Tel: +61 (0) 2 9854 0700
Fax: +61 (0) 2 9854 0777
THIS SAFETY ALERT SYMBOL MEANS ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED.
The Safety Alert Symbol identifies important safety

messages on MEWPs, safety signs in manuals or
elsewhere. When you see this symbol, be alert to
the possibility of personal injury or death. Follow the
instructions in the safety message.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert
against unsafe practices.
IMPORTANT
IMPORTANT indicates a procedure essential for
safe operation and which, if not followed, may
result in a malfunction or damage to the MEWP.
SJ12, SJ16 161917AG

3
Notes
161917AG SJ12, SJ16
4
Table of Contents
Section 1 – Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Read and Heed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1-1 Aerial Platform and Mobile Elevating Work Platform Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1-2 Purpose of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1-3 Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1-4 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1-5 Service Policy and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1-6 Operator Safety Reminders, Warnings and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2-1 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2-2 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2-3 Maintenance and Service Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Hydraulic System & Component Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3-1 Maintenance Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Railing Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 About this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5-1 Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5-2 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5-3 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7 Pre-Delivery/Maintenance Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.8 Scheduled Maintenance Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.8-1 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.8-2 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.8-3 Manuals & Required Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.8-4 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.8-5 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.8-6 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.8-7 Platform Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8-8 Hydraulic/Electrical Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.8-9 Lifting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.9 Function Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.1 Standard Hose Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Specifications and Features - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Specifications and Features - KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Specifications and Features - CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SJ12, SJ16 161917AG

5
2.5 Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.6 Maximum Platform Capacities (Evenly Distributed) - KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.7 Maximum Platform Capacities (Evenly Distributed) - CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.8 Floor Loading Pressure ANSI/CSA & KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.9 Floor Loading Pressure - KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.10 Floor Loading Pressure - CE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.11 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.12 Torque Specifications for Fasteners (Imperial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.13 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.14 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 39

3.1 Electrical Symbol Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2 Hydraulic Symbol Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3 Wire Number and Color Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.4 Hydraulic Component Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.5 Electrical Component Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.6 Cylinders and Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.7 Wheel Brake and Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.8 Powerpack and Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.9 Platform Control Console Wire Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.10 Brake and Main Manifold and Hydraulic Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.11 Disc Brake Kits and Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.12 Hydraulic Schematic - SJ12/SJ16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.13 Main Electrical Harness - SJ12/SJ16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.14 Mast Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.15 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.16 Base Control Wiring Diagram (SJ12/SJ16 - ANSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.17 Base Control Wiring Diagram (SJ12/SJ16 - CE/KC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.18 Electrical Schematic (SJ12/SJ16 - ANSI/CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.19 Electrical Schematic (SJ12/SJ16 - CE/KC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.20 Harness Assembly Trackunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.21 Harness Assembly Elevate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2-1 All Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2-2 All Controls Except for Down Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2-3 All Controls Inoperative From Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2-4 No Up Function from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2-5 Up Function Slow from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2-6 No Down Function from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
161917AG SJ12, SJ16
6
4.2-7 All Controls Inoperative From Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2-8 No Up Function from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2-9 Up Function Slow from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2-10 No Down Function from Platform Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2-11 Pothole Bars Will Not Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2-12 Steer Only Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2-13 Right Steer Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2-14 Left Steer Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2-15 No Drive Forward or Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2-16 Brake will not Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2-17 No Elevated Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2-18 Work Platform Drives in Slow Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2-19 Forward Drive Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2-20 Reverse Drive Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2-21 Two or More Functions at One Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3 Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3-1 All Functions Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3-2 All Functions Sluggish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3-3 Platform Drifts Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3-4 Platform Lifts Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3-5 Platform Does Not Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3-6 Platform Will Not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3-7 Pothole Bars Will Not Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3-8 Platform Drives Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3-9 Platform Will Not Drive in Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3-10 Platform Will Not Drive in Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3-11 Brake(s) Will Not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3-12 Platform Does Not Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.3-13 Platform Steers Very Slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.1-1 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2 Electrical System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2-1 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2-2 Resistor - Voltage Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2-3 Troubleshooting - Diagnostic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2-4 Tilt Switch Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.3 Hydraulic System Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3-1 System Relief Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3-2 Steer Relief Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.4 Electronic Tilt Switch Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.4-1 Tilt Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SJ12, SJ16 161917AG

7
5.4-2 Reprogramming Existing Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.4-3 Test and Verify Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.5 Wheel Reinstallation and Torquing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.6 Wheel Reinstallation and Torquing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.7 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.8 Charger Maintenance - Delta-Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.9 Pothole Limit Switch(LS2) Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.10 Mast Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.10-1 Outside Mast Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.10-2 Inner wear pads lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.10-3 Chains and rollers lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.11 Mast Roller Inspection/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.11-1 Roller Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.12 Mast Chain Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.12-1 Chain Thorough examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.12-2 Condition inspection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.13 Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.13-1 Extending Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.13-2 Mast Section 5 Removal (SJ16 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.13-3 Mast Section 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.14 Mast Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.15 Mast Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.15-1 Mast Section 1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.15-4 Mast Section 4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.15-5 Mast Section 5 Installation (SJ16 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.15-6 Extending Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.16 Lift Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.16-1 Extending Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.16-2 Mast Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.16-3 Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.16-4 Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.16-5 Mast Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
161917AG SJ12, SJ16
8
Section 1 – Scheduled Maintenance
1.1 Read and Heed 1.1-5 Service Policy and Warranty
SKYJACK warrants each new product to be free
SKYJACK is continuously improving and expanding
of defective parts and workmanship for the first 2
product features on its equipment, therefore,
years or 3000 hours, whichever occurs first. Any
specifications and dimensions are subject to change
defective part will be replaced or repaired by your
without notice.
local SKYJACK dealer at no charge for parts or labor.
In addition, all products have a 5 year structural
1.1-1 Aerial Platform and Mobile warranty. Contact the SKYJACK Service Department
Elevating Work Platform Definition for warranty statement extensions or exclusions.
A mobile device that has a positionable platform
supported from ground level by a structure. 1.1-6 Operator Safety Reminders,
Warnings and Precautions
1.1-2 Purpose of Equipment Operator safety is SKYJACK’s priority. The operator
The SKYJACK SJ Vertical Mast Series MEWPs are should comply with all applicable safety-related
designed to transport and raise personnel, tools and reminders, warnings and precautions found in
materials to overhead work areas. the Operating Manual. They should be read and
understood completely before operating the aerial
1.1-3 Use of Equipment platform.
The MEWP is a highly maneuverable, mobile work
station. Work platform elevation and elevated driving
must only be done on a firm, level surface.
1.1-4 Manual
Operating Manual: The operating manual is
considered a fundamental part of the aerial platform.
It is a very important way to communicate necessary
safety information to users and operators. A complete
and legible copy of this manual must be kept in the
provided weather-resistant storage compartment on
the aerial platform at all times.
Service & Maintenance: The purpose of this is
to provide the customer with the servicing and
maintenance procedures essential for the promotion
of proper machine operation for its intended purpose.
All information in this manual should be read and
understood before any attempt is made to service the
machine. The updated copy of the manuals are found
on the company’s website: www.skyjack.com.
SJ12, SJ16 161917AG

9
Section 1 – Scheduled Maintenance Maintenance and Inspection Schedule
1.2 Maintenance and 1.2-3 Maintenance and Service Safety

Tips
Inspection Schedule Maintenance and repair should only be performed by
The actual operating environment of the work platform personnel who are trained and qualified to service this
governs the use of the maintenance schedule. The MEWP.
inspection points covered in Table 1.2. Maintenance
All maintenance and service procedures should be
and lnspection Checklist, indicates the areas of the
performed in a well lighted and well ventilated area.
MEWP to be maintained or inspected and at what
intervals the maintenance and inspections are to be Anyone operating or servicing this MEWP must read
performed. and completely understand all operating instructions
and safety hazards in this manual and operating
1.2-1 Owner’s Annual Inspection Record manual.
It is the responsibility of the owner to arrange quarterly All tools, supports and lifting equipment to be used
and annual inspections of the MEWP. Table 1.1. must be of proper rated load and in good working
Owner’s Annual lnspection Record is to be used for order before any service work begins. Work area
recording the date of the inspection, owner’s name, should be kept clean and free of debris to avoid
and the person responsible for the inspection of the contaminating components while servicing.
work platform. Ensure personnel are clear from under unsupported
components/systems that are at risk of movement
1.2-2 Replacement Parts during maintenance.
Use only original replacement parts. Parts such All service personnel must be familiar with employer
as batteries, wheels, railings, etc. with weight and and governmental regulations that apply to servicing
dimensions different from original parts will affect this type of equipment.
stability of the MEWP and must not be used without
manufacturer’s consent. Keep sparks and flames away from all flammable or
combustible materials.
All replacement tires must be of the same size and
load rating as originally supplied tires; to maintain Properly dispose of all waste material such as
safety and stability of MEWP. lubricants, rags, and old parts according to the
relative law provisions obtaining in the country.
Consult SKYJACK’s Service Department for optional
tires specifications and installation. Before attempting any repair work, disconnect the
main power connectors.
WARNING Keep personnel clear of components, systems or
unsupported loads that may move unexpectedly
Any unit that is damaged or not operating properly during maintenance procedures.
must be immediately tagged and removed from
service until proper repairs are completed. Preventive maintenance is the easiest and least
expensive type of maintenance.
161917AG SJ12, SJ16
10
Hydraulic System & Component Maintenance and Repair Section 1 – Scheduled Maintenance
1.3 Hydraulic System & 7. All hydraulic components must be disassembled

in spotlessly clean surroundings. During
Component Maintenance disassembly, pay particular attention to
the identification of parts to assure proper
and Repair reassembly. Clean all metal parts in a clean
The following points should be kept in mind when mineral oil solvent. Be sure to thoroughly clean
working on the hydraulic system or any component: all internal passages. After the parts have been
dried thoroughly, lay them on a clean, lint-free
WARNING surface for inspection.
8. Replace all O-rings and seals when overhauling
Escaping fluid from a hydraulic pressure leak can
any component. Lubricate all parts with clean
damage your eyes, penetrate the skin and cause
hydraulic oil before reassembly. Use small
serious injury. Use proper personal protection at
amounts of petroleum jelly to hold O-rings in
all times.
place during assembly.
1. Any structure has limits of strength and 9. Be sure to replace any lost hydraulic oil when
durability. To prevent failure of structural parts of completing the installation of the repaired
hydraulic components, relief valves which limit component, and bleed any air from the system
pressure to safe operating values are included in when required.
the hydraulic circuits. 10. All hydraulic connections must be kept tight. A
2. Tolerance of working parts in the hydraulic loose connection in a pressure line will permit
system is very close. Even small amounts of dirt the oil to leak out or air to be drawn into the
or foreign materials in the system can cause system. Air in the system can cause damage
wear or damage to components, as well as to the components and noisy or erratic system
general faulty operation of the hydraulic system. operation.
Every precaution must be taken to assure
absolute cleanliness of the hydraulic oil.
3. Whenever there is a hydraulic system failure
which gives reason to believe that there are
metal particles or foreign materials in the system,
drain and flush the entire system and replace the
filter cartridges. A complete change of oil must
be performed under these circumstances.
4. Whenever the hydraulic system is drained,
check the magnets in the hydraulic reservoir for
metal particles. If metal particles are present,
flush the entire system and add a new change
of oil. The presence of metal particles also may
indicate the possibility of imminent component
failure. A very small amount of fine particles is
normal.
5. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic
oil reservoir, and fill the reservoir only through
the filter opening. The use of cloth to strain the
oil should be avoided to prevent lint from getting
into the system.
6. When removing any hydraulic component,
be sure to cap and tag all hydraulic lines
involved. Also, plug the ports of the removed
components.
SJ12, SJ16 161917AG

11
Section 1 – Scheduled Maintenance Railing Maintenance and Repair
1.3-1 Maintenance Hints 1.4 Railing Maintenance and

Three simple maintenance procedures have the
greatest effect on the hydraulic system performance, Repair
efficiency and life. Yet, the very simplicity of them may Skyjack MEWPs have been designed to ensure
be the reason they are so often overlooked. They are compliance with the relevant design standards
simply these: applicable for that particular unit at the time of
1. Change filters annually. The filters will need manufacture. As such, any repairs made to the
to be changed more often depending on the guardrail or basket structure need to ensure this
operating conditions. Dirty, dusty, high moisture compliance is not compromised and must return the
environments may cause the hydraulic system structure to its original condition.
to be contaminated more quickly. Any damage must be repaired by returning the railing
2. Maintain a sufficient quantity of clean hydraulic assembly to its undamaged state. Damage includes,
oil of the proper type and viscosity in the but is not limited to, the items listed below:
hydraulic reservoir. ▪ bent/deformed guardrail sections
3. Keep all connections tight. ▪ cracks or broken welds in railing sections
▪ damaged pin connections
▪ missing pins or broken pin lanyards
▪ missing railing hardware
▪ loose or missing parts
▪ additional holes in guardrail sections other than
those approved by Skyjack
Additionally, the guardrails must be properly
positioned and secured, and the entry gate must be
in good working order.
The strength of the guardrail system, and therefore
its ability to provide fall protection for platform
occupants, depends upon the design being secure
and undamaged.
Skyjack railings are designed for modular
replacement, and Skyjack recommends replacement
of any damaged railing section. Skyjack-approved
replacement parts will meet this requirement.
161917AG SJ12, SJ16
12
About this Section Section 1 – Scheduled Maintenance
1.5 About this Section 1.5-3 Maintenance Instructions

This manual consists of four schedules to be done
This section contains the maintenance and inspection
for maintaining on an MEWP. Inspection schedule
schedule that is to be performed.
frequency is shown below:
References are made to the procedures in Section
5 that outline detailed step-by-step instructions for
checks and replacements. Issue or Symptom
Perform PDI prior to each

1.5-1 Service Bulletins delivery, or Frequent
Before performing any scheduled maintenance PDI/Frequent B
Inspection every 3 months
inspection procedure, refer to service bulletins found or 150 hours.
in our web site: www.skyjackinc.com for updates
related to service and maintenance of this MEWP. Perform Scheduled
Annual B+C Maintenance Inspections
every year.
1.5-2 Maintenance and Inspection
Death or injury can result if the MEWP is not kept in Perform at time sensitive
Additional *
good working order. Inspection and maintenance maintenance intervals.
should be performed by competent personnel who
are trained and qualified on maintenance of this
▪ Make copies of the maintenance and inspection
MEWP.
checklist to be used for each inspection.
▪ Check the schedule on the checklist for the type
WARNING of inspection to be performed.
Failure to perform each procedure as presented ▪ Place a check in the appropriate box after each
and scheduled may cause death, serious injury or inspection procedure is completed.
substantial damage.
▪ Use the maintenance and inspection checklist
and step-by-step procedures in Section 1 to
NOTE perform these inspections.
Preventive maintenance is the easiest and least ▪ If any inspection receives a fail, tag and remove
expensive type of maintenance. the MEWP from service.
▪ If any MEWP component(s) has been repaired,
▪ Unless otherwise specified, perform each an inspection must be performed again before
maintenance procedure with the MEWP in the removing the tag. Place a check in the repair
following configuration: column.
▪ MEWP parked on a flat and level surface
▪ Disconnect the batteries by disconnecting the Legend
main power connectors. Pass P
▪ Repair any damaged or malfunction
components before operating MEWP. Fail F
▪ Keep records on all inspections. Repaired R
Not applicable N/A
SJ12, SJ16 161917AG

13
Section 1 – Scheduled Maintenance Owner’s Annual Inspection Record
Table 1.6 Owner’s Annual Inspection Record
**
2
Figure 01 This decal is located on the scissor assembly. It must be completed after an
annual inspection has been completed. Do not use the aerial platform if an inspection has
not been recorded in the last 13 months.
Description Label Pictorial Description Label Pictorial
2 Inspector
1 Inspection Date
Signature
161917AG SJ12, SJ16
14
Pre-Delivery/Maintenance Inspection Section 1 – Scheduled Maintenance
1.7 Pre-Delivery/Maintenance Inspection

Pre-Delivery/Maintenance Inspection Checklist
Vertical Mast, SJIII, & Rough Terrain
Serial Number: Product Owner:
Model:
Hourmeter Reading: Product User:
Date/Time:
Use this form for Pre-Delivery Inspections (PDI) prior to each rental, lease or sale, or as a guide for all Frequent Inspections and Annual Inspections. Refer to the
applicable Operating and Service Manuals for inspection details (eg. Visual Inspection and Function Tests, Torque Specs., Engine Oil, Chain Inspection Intervals, etc.).
Inspection Type Schedule P - Pass

 PDI B B - Perform PDI prior to each delivery or Frequent Inspections every 3 months or 150 hrs. For further details refer to Service & Operating F - Fail
 Frequent B Manuals. R - Repaired
 Annual B+C C - Perform Scheduled Maintenance Inspections every year. For further details refer to Service & Operating Manuals. N/A - Not Applicable
Check the appropriate box as each item is inspected. If an item is found to be not acceptable, please describe the issue in the comments box provided.
Items for Inspection P F R N/A Items for Inspection P F R N/A

Refer to skyjack.com for the latest service bulletins. B Engine Control Console. Secure & no damage. B
Ensure Annual Inspection has been completed within the Engine Air Filter. No damage or missing parts. B, C
B
last 13 months. Engine Oil. Level between "L" and "H". Ensure oil change
B
Manuals & Required Documents. In storage box, in interval has not been exceeded.
B
good condition & legible. Radiator. Secure & no damage or missing parts. Check
B, C
Labels. In place, secure & legible. B coolant level.
Limit Switches. Secured & no obstructions or damage. B Muffler and Exhaust. Secure & no damage. B
Main Power Disconnect Switch. Cables secure & in Fuel Shut-off Valve. No damage or missing parts. B
B
working order. Fuel Tank. Filler cap is secure & no damage. B
Battery/ Hydraulic Tray. Latch is secure, & no missing Fuel Leaks. Tight fittings and hoses & no damage or
B B
parts. leaks.
Battery Charger. Secure, & no damage. B Propane Tank. Straps fastened to brackets & coupler
B
Battery. No damage, tight connections, fluid levels correct. tight.
B
Clean terminals and cable ends. Propane Tank Leaks. No leaks (refer to service manual
B
Manifolds. Tight fittings and hoses & no damage or leaks. for procedure).
B, C
Tight wire connections & no missing parts. Scissor Assembly. No deformation/damage. Pins secure.
B
Motor Controller. Secure & no damage. No loose Cables & wires routed with no damage.
B
connections. Mast Assembly. No damage or deformation. Lubricated B, C
Electrical Panel / Control Module. Secure & no Mast Chains. No damage or missing parts. B, C
B
damage. Tight wire connections and fasteners. Control Cables. No damage or missing parts. B, C
Hydraulic Tank. Filler cap secure & no damage or leaks. B Rollers. Secure & no obstructions, dirt, or damage/wear. B, C
Hydraulic Oil. Level at, or slightly above top mark. B, C Wear Pads. No damage/wear or missing parts. Fasteners
B, C
Hydraulic Components & Hoses. Secure & no damage tightened.
B
or leaks. Scissor Bumpers. Secure & no damage. B
Base Weldment. No deformation or cracks. B Sliders. Secure & no obstructions, dirt, or damage/wear. B
Base Control Switches. Switches to neutral position & no Maintenance Support. Secure & no damage. B
B
damage. Lift Cylinder(s). No damage or missing parts. Tight
B
Free-wheeling Valve Knob. Secure & no damage or fittings and hoses & no leaks.
B
missing parts. Scissor Pins. No damage/wear or missing parts. B
Ladder. Secure & no damage. B Platform Control Console. Switches to neutral position &
B
AC Power to Platform (Plug Cord Receptacle). No secure. No missing parts.
B
obstructions, dirt or damage. Raillings and Gate/Chain. Secure & no damage or
B
Pothole Protection Device. Check both sides for missing parts.
B
obstructions, dirt, or damage. Lanyard Attachment Anchorage. Attachment rings
B
Brakes. Secure & no damage or leaks. B, C secure & no damage.
Steer Cylinder Assembly. Secure & no damage, leaks or AC Outlet. No obstructions, dirt, or damage. B
B
missing parts. Powered Extension Control Console. Switches to
B
Wheel/Tire Assembly. Check all tires for damage, wear neutral position & secure. No missing parts.
B
& proper alignment. Lug nuts torqued as recommended. Extension Deck. Secure & no damage or missing parts.
B
Axles. Secure & no missing parts. Tight fittings and hoses Check fluid level (if applicable).
B
& no leaks. Outriggers. No damage or missing parts. B
Tie Rod. End studs locked & no damage. B Scissor Guards. Secure & no damage. B
Tilt (Load) Sensor. Secure & no damage. B Greasing Points. No obstructions, dirt, or damage. B, C
Emergency Lowering Access Rod. Secure & no Function Tests (Refer to your corresponding Serial #'s Operating  PASS
B
damage. Manual for information on running these tests.)  FAIL
Engine Tray. No damage or missing parts. B
Comments:
The undersigned confirms that all areas listed have been inspected, and any and all discrepancies have been brought to the attention of the owner. Furthermore, the
undersigned confirms that all discrepancies have been corrected prior to using this machine.
Owner: ________________________________________________ / _____________________________________________ / ______________________________________________________

Print Name Signature Date (DD/MM/YY)
User: _________________________________________________ / _____________________________________________ / _______________________________________________________

Print Name Signature Date (DD/MM/YY)
Note: Visit skyjack.com for a printable copy of this form. 167830AC
SJ12, SJ16 161917AG

15
Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections
1.8 Scheduled Maintenance 1.8-2 Hydraulic

Maintaining hydraulic components is essential to
Inspections good performance and service life of the aerial
Begin the scheduled maintenance inspections by platform.
checking each item in sequence for the conditions Perform a visual inspection around the following
listed in this section. areas:
▪ hoses and fittings
WARNING
▪ hydraulic cylinder
To avoid injury, do not operate an aerial platform/
▪ all hydraulic manifolds
MEWP until all malfunctions have been corrected.
▪ the underside of the base 1
▪ ground area under the aerial platform 2

WARNING
To avoid possible injury, ensure aerial platform/ 1.8-3 Manuals & Required Documents (B)
MEWP power is off during your visual and daily Ensure a copy of the operating manual and other
maintenance inspections. important documents are enclosed in the manual
storage box. 3
CAUTION ▪ Check to be sure the manual storage box is
present and in good condition.
Ensure aerial platform is on firm and level ground.
▪ Ensure manuals are legible and in good
condition.
1.8-1 Electrical ▪ Always return manuals to the manual storage
Maintaining electrical components is essential to good box after use.
performance and service life of aerial platform.
Perform a visual inspection around the following 1.8-4 Labels (B)
areas: Refer to the labels section in the Operating Manual
and ensure that all labels are in place and are legible.
▪ all wiring harnesses/engine compartment
▪ hydraulic/electrical wiring harnesses
161917AG SJ12, SJ16
16
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance
2 3
6 5
1.8-5 Limit Switches (B) 5 Pothole Protection Device (B)

Detecting limit switch malfunction is essential to safe ▪ Ensure mechanisms have no sign of
aerial platform operation. Ensure limit switches are visible damage and are free from dirt and
properly secured with no signs of visible damage and obstructions.
movement is not obstructed. 6 Wheel/Tire Assembly (B)
Visually inspect all limit switch located inside the A small amount of wear is permitted. But if any of the
scissor arms and the outrigger assemblies for the wear or damage meets the criteria mentioned below,
following: the tire should be replaced.
▪ broken or missing actuator arm
▪ missing fasteners
▪ loose wiring WARNING
Do not use tires other than the tires that Skyjack
1.8-6 Base
specifies for this MEWP. Do not mix different types
1 Main Power Disconnect Switch (B) of tires or use tires that are not in good condition.
▪ Turn main power disconnect switch to the off Only replace the tires with the same types that are
position. approved by Skyjack. The use of other tires can
make the MEWP less stable. If you do not obey,
▪ Ensure all cables are secure and switch is in
there is a risk of death or serious injury.
proper working condition.
2 Base Control Switches (B)
▪ Ensure there are no signs of visible damage
and all switches are in their neutral positions.
3 110/220V Outlet Receptacle (ANSI/CSA) (B)
▪ Ensure receptacle is free from dirt and
obstructions.
4 Steer Cylinder Assembly (B)
▪ Ensure steer cylinder assembly is properly
secured and there are no loose or missing
parts.
SJ12, SJ16 161917AG

17
The tire treads have been

removed from the illustra-
tion for clarity.
Figure 03
▪ B - Frequent/periodic/pre-delivery inspection Do a check for cuts or missing chunks in the edges

Do a check for damage or wear on each tire and rim. and tread face of the tire. Refer to Figure 03.
▪ Look for damage or cracked welds on each rim. ▪ The cut or missing chunk should not extend
The rims should be round. more than 10 mm (3/8”) towards the centre of
the tire.
▪ Look for uneven or unusual wear on the tire.
▪ Each cut or chunk should not be larger than
▪ Look for flat spots on the tread face of the tire.
25 mm x 10 mm (1” x 3/8”), or deeper than
▪ The tire tread should be visible and not worn 20 mm (3/4”).
down completely. Refer to Figure 02.
▪ There should be no more than 2 cuts or
chunks in each 1/4 section of the tire. There
should be no more than 6 cuts or chunks in
total in the tire.
▪ There should be no embedded debris.
Do a check of the wheel components and mounts.

▪ Make sure the wheels are correctly aligned
vertically and horizontally.
▪ Make sure the wheel motors have no loose or
missing parts and there is no visible damage.
▪ C - Annual inspection
▪ Make sure the castle nut is in position and is
tight.
Figure 02
▪ Make sure the cotter pin is correctly installed.
▪ If the cotter pin is not installed, refer to 2.11
Torque Specifications.
161917AG SJ12, SJ16
18
1
2
1.8-7 Platform Assembly 2 Fall Protection Anchorage (B)

▪ Ensure attachment anchors area secure and
WARNING there is no visible damage.
Ensure that you maintain three points of contact to
mount/dismount platform. 3 AC Outlet (B)
1. Open the gate/chain and access the platform 1

▪ Ensure outlet has no visible damage and free
from dirt or obstructions.
2. Close the gate/ Secure chain. 4 Platform Control Console (B)
▪ Ensure all railings are properly positioned and ▪ Ensure all switches and controller are returned
secured.
to neutral and are properly secured.
▪ Ensure all fasteners are securely in place. ▪ Ensure there are no loose or missing parts and
▪ Ensure gate/chain is in good working order. there is no visible damage.
▪ Ensure there are no loose or missing parts and
there is no visible damage. WARNING
▪ Ensure platform foot pedal is in good working Ensure that you maintain three points of contact to
order and no loose or missing parts and there mount/dismount platform.
is no visible damage
3. Dismount from platform.
4. Close the gate/Secure chain
SJ12, SJ16 161917AG

19
5 2
4
3
1.8-8 Hydraulic/Electrical Compartment 5. Replace battery if damaged or incapable of

1. Access the hydraulic/electrical compartment. holding a lasting charge.
1 Battery (B) WARNING

▪ Proper battery condition is essential to Use original or manufacturer-approved parts and
good performance and operational safety.
components for the aerial platform.
Improper fluid levels or damaged cables and
connections can result in component damage 2 Battery Charger (B)
and hazardous conditions.
▪ Ensure charger is secure and shows no visible
WARNING damage.
Explosion hazard. Keep flames and sparks away.

3 Main Manifolds (B,C)
Do not smoke near batteries. ▪ Ensure all fittings and hoses are properly
tightened and there is no evidence of hydraulic
leakage.
WARNING
▪ Ensure there are no loose wire connections or
Battery acid is extremely corrosive - Wear proper missing fasteners.
eye and facial protection as well as appropriate
protective clothing. If contact occurs, immediately
flush with cold water and seek medical attention.
1. Check battery case for damage.

2. Clean battery terminals and cable ends
thoroughly with a terminal cleaning tool or wire
brush.
3. Ensure all battery connections are tight.
4. If applicable, check battery fluid level.
If plates are not covered by at least 1/2”
(13 mm) of solution, add distilled or
demineralized water.
161917AG SJ12, SJ16
20
5 2
4
3
4 Hydraulic Tank (B) Tilt Sensor (If Equipped) (B)

▪ Ensure hydraulic filler cap is secure. ▪ Ensure tilt sensor is properly secured and
there is no visible damage.
▪ Ensure tank shows no visible damage and no
evidence of hydraulic leakage. Load Sensor (If Equipped) (B)
Hydraulic Oil (B,C) ▪ Ensure load sensor is properly secured and
▪ Ensure platform is fully lowered, and
outriggers retracted, and then visually inspect
the sight gauge located on the side of the 2. Close the compartment access door and latch
hydraulic oil tank. Check oil level against label in place.
that indicates minimum and maximum oil
3. Push the platform back to its operating position
levels.
and latch in place.
▪ Refer to 1.3 Hydraulic System & Component
Maintenance and Repair on page 11
5 Hydraulic Pump and Motor (B)
▪ Ensure all bolts are properly tightened.
▪ Ensure all fittings and hoses are properly
tightened and there is no evidence of hydraulic
leakage.
Motor Controller (B)
▪ Ensure the controller is properly secured and
▪ Ensure there are no loose wire connections or
missing fasteners.
SJ12, SJ16 161917AG

21
1.8-9 Lifting Mechanism Lift Cylinder(s) (B)

▪ Ensure each lift cylinder is properly secured,
there are no loose or missing parts and there
1 Mast Assembly (B) is no evidence of damage.
▪ Ensure mast assembly shows no visible ▪ Ensure all fittings and hoses are properly
damage and no signs of deformation in tightened and there is no evidence of hydraulic
weldments. leakage.
▪ Lubricate every 200 days, refer to section 5.10 Rollers (B)
Mast Lubrication Procedure.
▪ Increase lubrication frequency if used in a ▪ Ensure rollers are properly secured,
severe application (e.g. frequently lifting movement is not obstructed.
the rated load, used in an extremely dusty ▪ Ensure there are no loose or missing parts or
environment) or if not moving freely. signs of visible damage.
Wear Pads (B) ▪ Refer to section 5.11 Mast Roller Inspection/
Maintenance for Roller and Roller Mount
▪ Ensure all bolts are tight, there is no visible Inspection details and instructions.
damage to the wear pads and that no parts
are missing. Chains (C)
Control Cables (B) ▪ Visually inspect all accessible sections of chain
for broken, cracked, corroded or worn links.
▪ Ensure cables are secure and there are no ▪ Make sure the chains are securely anchored.
visible signs of damage.
▪ Refer to section 5.12 Mast Chain Visual
Inspection for details and instructions
Flashing Light(s) (If Equipped) (B)
161917AG SJ12, SJ16
22
Function Tests Section 1 – Scheduled Maintenance
1.9 Function Tests

Function tests are designed to discover any
malfunctions before aerial platform is put into service.
The operator must understand and follow step-by-
step instructions to test all aerial platform functions.
WARNING
Never use a malfunctioning aerial platform. If
malfunctions are discovered, aerial platform must be
tagged and placed out of service. Repairs to aerial
platform may only be made by a qualified service
technician.
After repairs are completed, operator must perform a

pre-operation inspection and a series of function tests
again before putting aerial platform into service.
Prior to performing function tests, be sure to read

and understand Section 2.9 - Start Operation of the
Operating manual.
For function tests that are to be performed, please

refer to the operating manual that corresponds
to the correct serial number. Here there will be
detailed instructions for which tests to perform, as
well as how to properly and successfully perform
them.
SJ12, SJ16 161917AG

23
Notes
161917AG SJ12, SJ16
24
Section 2 – Maintenance Tables and
Diagrams
Table 2.1 Standard Hose Numbering System
H1104 0081 2
LENGTH IN FRACTIONS
FITTING (1/4” INCREMENTS) I.E.
LENGTH OF
ARRANGEMENT HOSE SIZE
HOSE IN WHOLE 1=1/4”
(See Schedule (See Chart 2=1/2”
INCHES
Below) Below) 3=3/4”
Using the number above as an example (H1104 0081 2). This hose requires a 37°
JIC, female swivel fitting on one end. A medium length 90° JIC, female swivel fitting
for the other end. The Hose must meet or exceed S.A.E. 100R13 hose specifica-
tion, and be a total of 81-1/2” long. NOTE: Hose ends and hose must be from same
manufacturer per S.A.E. J1273 Nov. ‘91, Sections 3.10 and 4.2. Hose ends and hose
must be of the same size i.e. #4 size fittings must be used with #4 size hose.
Hose Size Chart
Hose Size Chart
Size 03 04 06 08 10 12 16 20 24 32 40 48 56 64
ID 3/16" 1/4" 3/8" 1/2" 5/8" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 3-1/2" 4"
Fitting Arrangement Schedule (Continued on the following page)
SAE Hose
Hose Prefix Hose End Fitting Hose End Fitting
Specification
Subhead Division
H01 Female 37 ˚ JIC Swivel Female 37 ˚ JIC Swivel 100R17
H03 Female 37 ˚ JIC Swivel 45˚, Female 37˚ JIC Swivel 100R17
Long 90˚, Female 37˚ JIC

H05 Female 37 ˚ JIC Swivel 100R17
Swivel
Short 90˚, Female 37˚ JIC
Swivel
Long 90˚, Female 37˚ JIC Long 90˚, Female 37˚ JIC
H07 100R17
Swivel Swivel
SJ12, SJ16 161917AG

25
Section 2 – Maintenance Tables and Diagrams Standard Hose Numbering System
SAE Hose
Hose Prefix Hose End Fitting Hose End Fitting
Specification
Subhead Division
H10 Female 37 ˚ JIC Swivel Male Pipe Thread Fitting 100R17
Medium 90˚, Female 37˚ JIC

Swivel
Short 90 ˚, Female 37 ˚ JIC Short 90˚, Female 37˚ JIC
H12 100R17
Swivel Swivel
Reusable Male Pipe Thread
H013 Female 37˚ JIC Swivel 300PSI
Fitting
Reusable Male Pipe Thread
H014 No Fiting 300PSI
Fitting
Reusable Female 37 ˚ JIC Reusable Female 37 ˚ JIC
H015 300PSI
Swivel Swivel
H016 No Fiting No Fiting 100R4
H017 No Fiting No Fiting 300PSI
Reusable Female 37 ˚ JIC

H018 No Fiting 300PSI
Swivel
Long 90˚, Female 37˚ JIC
Swivel
Short 90 ˚, Female 37 ˚ JIC
Swivel
H021 Female 37 ˚ JIC Swivel 100R2AT
Swivel
H022 Female 37 ˚ JIC Swivel Female 37 ˚ JIC Swivel 100R2AT
Long 90 ˚, Female 37 ˚ JIC

H023 Female 37 ˚ JIC Swivel 100R2AT
Swivel
Swivel

Swivel
Long 90 ˚, Female 37 ˚ JIC
Swivel
H029 45 ˚, Female 37 ˚ JIC Swivel Female 37 ˚ JIC Swivel 100R17
Medium 90 ˚, Female 37 ˚
JIC Swivel
1601
161917AG SJ12, SJ16
26
Specifications and Features - ANSI/CSA Section 2 – Maintenance Tables and Diagrams
Table 2.2 Specifications and Features - ANSI/CSA
Model SJ12 SJ16
Weight * 1720 Ib. 2130 lb.

Overall Width 30 in. 30 in.
Overall Length 53.5 in. 53.5 in.
Platform Size (Inside) 27.0 in. x 36.8 in. 27.0 in. x 36.8 in.
Platform Traversing 20 in. 20 in.
Height
Working Height 18 ft. 21.7 ft.
Platform Elevated Height 12 ft. 15.7 ft.
Stowed Height 70.3 in. 70.3 in.
Drive Height Full Full
Lowered Platform Height 18 in. 18 in.
Standard Operating Times
Lift Time (Rated Load) 16 s 20 s
Lower Time (Rated Load) 14 s 18 s
Chassis
Normal Drive Speed 2.5 mph 2.5 mph
Elevated Drive Speed 0.5 mph 0.5 mph
Gradeability (Ramp Angle)** 30% / 25% 30% / 25%
Tires (Solid Rubber) 12 x 4 in. 12 x 4 in.
Hydraulic Oil
Type ATF Dexron III ATF Dexron III
Tank Capacity 1.3 gal. 1.3 gal.
*Weight * 1720
Weights are Ib. 2130
approximate; referlb.
to serial nameplate for specific weight. 1602
** Refer toWidth
Overall Section30
3.9 in. 30 in.
Loading/Unloading in the Operator’s Manual for more details.
Stowed Height 70.3 in. 70.3 in.
Lowered Platform Height 18 in. 18 in.
Normal Drive Speed 2.5 mph 2.5 mph
SJ12, SJ16 161917AG

27
Section 2 – Maintenance Tables and Diagrams Specifications and Features - KC
Table 2.3 Specifications and Features - KC
Model SJ12 SJ16
Weight * 780 kg 966 kg

Overall Width 76.2 cm 76.2 cm
Overall Length 137 cm 137 cm
Platform Size (Inside) 68.5 x 93.5 cm 68.5 x 93.5 cm
Platform Traversing 40.6 cm 40.6 cm
Height
Working Height 5.65 m 6.75 m
Platform Elevated Height 3.65 m 4.75 m
Stowed Height 179 cm 179 cm
Lowered Platform Height 45 cm 45 cm
Chassis
Normal Drive Speed 4 km/h 4 km/h
Elevated Drive Speed 0.8 km/h 0.8 km/h
Tires (Solid Rubber) 309 x 100 mm 309 x 100 mm
Hydraulic Oil
Tank Capacity 4.92 L 4.92 L
*Weight * 1720
** Refer toWidth
Overall Section30
3.9 in. 30 in.
161917AG SJ12, SJ16
28
Specifications and Features - CE Section 2 – Maintenance Tables and Diagrams
Table 2.4 Specifications and Features - CE
Model SJ12 SJ16
Weight * 780 kg 966 kg

Overall Width 76.2 cm 76.2 cm
Overall Length 137 cm 137 cm
Platform Size (Inside) 68.5 x 93.5 cm 68.5 x 93.5 cm
Platform Traversing 40.6 cm 40.6 cm
Height
Working Height 5.65 m 6.75 m
Platform Elevated Height 3.65 m 4.75 m
Stowed Height 179 cm 179 cm
Lowered Platform Height 45 cm 45 cm
Chassis
Normal Drive Speed 4 km/h 4 km/h
Elevated Drive Speed 0.8 km/h 0.8 km/h
Tires (Solid Rubber) 309 x 100 mm 309 x 100 mm
Hydraulic Oil
Tank Capacity 4.92 L 4.92 L
*Weight * 1720
** Refer toWidth
Overall Section30
3.9 in. 30 in.
SJ12, SJ16 161917AG

29
Section 2 – Maintenance Tables and Diagrams Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA
Table 2.5 Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA
Model SJ12 Maximum Wind Speed Tilt Cutout Setting
SJ12 500 lb. 2 Person(s) 28 mph 1.5 x 3

SJ16 500 lb 2 Person(s) 28 mph 1.5 x 3
Weight * 1720 Ib. 2130 lb. 1605
Overall Width 30 in. 30 in.
Table 2.6 Maximum Platform Capacities (Evenly Distributed) - KC

2 Person(s) No Wind
SJ12 227 kg 1.5 x 3
1 Person(s) 12.5 m/s
SJ16 227 kg 2 Person(s) No Wind 1x2
Weight * 1720 Ib. 2130 lb. 1606
Table 2.7 Maximum Platform Capacities (Evenly Distributed) - CE

2 Person(s) No Wind
SJ12 227 kg 1.5 degrees x 3 degrees
1 Person(s) 12.5 m/s
SJ16 227 kg 2 Person(s) No Wind 1 degrees x 2 degrees
Weight * 1720 Ib. 2130 lb. 1607
161917AG SJ12, SJ16
30
Floor Loading Pressure ANSI/CSA & KC Section 2 – Maintenance Tables and Diagrams
Table 2.8 Floor Loading Pressure ANSI/CSA & KC

Total Aerial Maximum Wind Speed
Platform Tilt Cutout Setting
Model Weight Wheel OUP**
lb. lb psf
min* 1720 430 151

SJ12
max* 2220 880 196
min* 2130 531 188
SJ16
max* 2630 1052 234
1608
* min - Aerial platform weight with no options
max - Aerial platform weight + all options + full capacity
** LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the areas in direct contact with the floor.
The floor covering (tile, carpet, etc.) must be able to withstand more that the indicated values above.
OUP - Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the whole surface directly underneath it.
The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values above.
Note:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or
architect for that particular structure.
Floor Loading Pressure

130
SJ16
120
Locally Concentrated Pressure [psi]
SJ12
110
100
90
80
0 50 100 150 200 250 300 350 400 450 500
Load on the Platform [lb]
SJ12 SJ16
SJ12, SJ16 161917AG

31
Section 2 – Maintenance Tables and Diagrams Floor Loading Pressure - KC
Table 2.9 Floor Loading Pressure - KC

kg kg kPa (kN/m2)
min* 780 195 7.0
SJ12
max* 1007 402 9.4
min* 966 241 9.0
SJ16
max* 1193 477 11.2
* min - Aerial platform weight with no options 1609
Note:
SJ16
SJ12
161917AG SJ12, SJ16
32
Floor Loading Pressure - CE Section 2 – Maintenance Tables and Diagrams
Table 2.10 Floor Loading Pressure - CE

kg kg kPa (kN/m2)
min* 780 195 7.0
SJ12
max* 1007 402 9.4
min* 966 241 9.0
SJ16
max* 1193 477 11.2
* min - Aerial platform weight with no options 1610
Note:
SJ16
SJ12
SJ12, SJ16 161917AG

33
Section 2 – Maintenance Tables and Diagrams Floor Loading Pressure - KC
Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP):
Foot Print Area = Length x Width Base Area = Length x Width
Weight of Aerial Platform + Capacity Weight of Aerial Platform + Capacity

LCP = 0.4 X OUP =
Foot Print Area Base Area
Width Width
Length
Length
WARNING
Intermixing tires of different types or using tires of types other than those originally supplied with this
equipment can adversely affect stability. Therefore, replace tires only with the exact original Skyjack-
approved type. Failure to operate with matched approved tires in good condition may result in death or
serious injury.
161917AG SJ12, SJ16
34
Torque Specifications Section 2 – Maintenance Tables and Diagrams
Table 2.11 Torque Specifications
Location Description Torque (ft-lb) Torque (Nm)

Base
Wheel Mounting Bolts on Hub BOLT, Wheel (1/2”-20 x 1-1/2”) 90 122
Wheel Mounting Castle Nut on
NUT, Slotted Hex (1-1/8"-18) 70 95
Integarted Hub
Power Pack Mounting Bolts BOLT, Hex head (5/16”-18 x 3/4”, Grade 5) 18 24
Hydraulic Motor Mounting Bolts BOLT, Hex head (1/2”-13 x 2-3/4” grade 8) 80 108
Wheel Brake Mounting Bolts BOLT, Hex head (1/2”-13 x 4” Grade 8) 85 115
Location Description Torque (ft-lb) Torque (Nm)
Mast
Chain Tensioner Assembly
BOLT, Hex head (5/16”-18 x 1”, Grade 8) 18 24
(Mast 1)
Roller Support (Mast 2) BOLT, Hex head (5/16”-18 x 1”, Grade 8) 18 24
Roller Support Left/Right (Mast 2) SCREW, Socket Head Cap (10-32 x 3/4”) 4.25 5.8
Chain Tensioner Assembly
BOLT, Hex head (5/16”-18 x 3/4”, Grade 8) 18 24
(Mast 3)
Roller Mount Left/Right (Mast 3) BOLT, Hex head (5/16”-18 x 1”, Grade 8) 18 24
Roller Mount Right (Mast 3) SCREW, Socket Head Cap (10-32 x 1-3/4”) 4.25 5.8
Chain Tensioner Assy
(Mast 4, SJ16)
Roller Mount Left/Right
(Mast 4, SJ16)
1611
SJ12, SJ16 161917AG

35
Section 2 – Maintenance Tables and Diagrams Torque Specifications for Fasteners (Imperial)
Table 2.12 Torque Specifications for Fasteners (Imperial)

Torque SAE2 SAE 5 SAE 8 Torque SAE2 SAE 5 SAE 8
Size Size
Type Dry Lubed Dry Lubed Dry Lubed Type Dry Lubed Dry Lubed Dry Lubed
(in-lb) (5) (4) (8) (6) (12) (9) ft-lb 70 55 110 80 150 110
4-40 9/16-12
Nm 0.6 0.5 0.9 0.7 1.4 1.0 Nm 95 75 149 108 203 149
(in-lb) (6) (5) (9) (7) (13) (10) ft-lb 80 60 120 90 170 130
4-48 9/16-18
Nm 0.7 0.6 1.0 0.8 1.5 1.1 Nm 108 81 163 122 230 176
(in-lb) (10) (8) (16) (12) (23) (17) ft-lb 100 75 150 110 220 170
6-32 5/8-11
Nm 1.1 0.9 1.8 1.4 2.6 1.9 Nm 136 102 203 149 298 230
(in-lb) (12) (9) (18) (13) (25) (19) ft-lb 110 85 180 130 240 180
6-40 5/8-18
Nm 1.4 1.0 2.0 1.5 2.8 2.1 Nm 149 115 244 176 325 244
(in-lb) (19) (14) (30) (22) (41) (31) ft-lb 175 130 260 200 380 280
8-32 3/4-10
Nm 2.1 1.6 3.4 2.5 4.6 3.5 Nm 237 176 353 271 515 380
(in-lb) (20) (15) (31) (23) (43) (32) ft-lb 200 150 300 220 420 320
8-36 3/4-16
Nm 2.3 1.7 3.5 2.6 4.9 3.6 Nm 271 203 407 298 569 434
ft-lb 170 125 430 320 600 460
(in-lb) (27) (21) (43) (32) (60) (45) 7/8-9
10-24 Nm 230 169 583 434 813 624
Nm 3.1 2.4 4.9 3.6 6.8 5.1
ft-lb 180 140 470 360 660 500
(in-lb) (31) (23) (49) (36) (68) (51) 7/8-14
10-32 Nm 244 190 637 488 895 678
Nm 3.5 2.6 5.5 4.1 7.7 5.8
ft-lb 250 190 640 480 900 680
(in-lb) ft-lb (66) (50) 8 (75) 12 9 1-8
1/4-20 Nm 339 258 868 651 1220 922
Nm 7.5 5.6 11 8.5 16 12
ft-lb 270 210 710 530 1000 740
(in-lb) ft-lb (76) (56) 10 (86) 14 10 1-12
1/4-28 Nm 366 285 963 719 1356 1003
Nm 8.6 6.3 14 9.7 19 14
ft-lb 280 210 730 540 1020 760
ft-lb 11 8 17 13 25 18 1-14
5/16-18 Nm 380 285 990 732 1383 1030
Nm 15 11 23 18 34 24
ft-lb 350 270 800 600 1280 960
ft-lb 12 9 19 14 25 20 1 1/8-7
5/16-24 Nm 475 366 1085 813 1735 1302
Nm 16 12 26 19 34 27
ft-lb 400 300 880 660 1440 1080
ft-lb 20 15 30 23 45 35 1 1/8-12
3/8-16 Nm 542 407 1193 895 1952 1464
Nm 27 20 41 31 61 47
ft-lb 500 380 1120 840 1820 1360
ft-lb 23 17 35 25 50 35 1 1/4-7
3/8-24 Nm 678 515 1519 1139 2468 1844
Nm 31 23 47 34 68 47
ft-lb 550 420 1240 920 2000 1500
ft-lb 32 24 50 35 70 55 1 1/4-12
7/16-14 Nm 746 569 1681 1247 2712 2034
Nm 43 33 68 47 95 75
ft-lb 670 490 1460 1100 2380 1780
ft-lb 36 27 55 40 80 60 1 3/8-6
7/16-20 Nm 908 664 1979 1491 3227 2413
Nm 49 37 75 54 108 81 ft-lb 750 560 1680 1260 2720 2040
ft-lb 50 35 75 55 110 80 1 3/8-12
1/2-13 Nm 1017 759 2278 1708 3688 2766
Nm 68 47 102 75 149 108 ft-lb 870 650 1940 1460 3160 2360
1 1/2-6
ft-lb 55 40 90 65 120 90 Nm 1180 881 2630 1979 4284 3200
1/2-20
Nm 75 54 122 88 163 122 ft-lb 980 730 2200 1640 3560 2660
* Inch-Pound Force = in-lb Foot-Pound Force = ft-lb 1 1/2-12
Newton-Meter = Nm Nm 1329 990 2983 2224 4827 3606
1612
NOTE
Lubed includes lubricants such as lubrizing oil, grease or uncured loctite.
161917AG SJ12, SJ16
36
Torque Specifications for Fasteners (Metric) Section 2 – Maintenance Tables and Diagrams
Table 2.13 Torque Specifications for Fasteners (Metric)

SAE2 SAE 5
Size Torque Type
Dry Lubed Dry Lubed
(in-lb) (54) (41) (78) (59)
M5 x 0.80
Nm 6.1 4.6 8.8 6.7
(in-lb) (92) (69) (133) (99)
M6 x 1.00
Nm 10.4 7.8 15 11.2
(in-lb) (156) (116) (222) (167)
M7 x 1.00
Nm 17.6 13.1 25.1 18.9
(in-lb) (225) (169) (333) (242)
M8 x 1.25
Nm 25.4 19.1 37.6 27.3
ft-lb 37 28 53 40
M10 x 1.50
Nm 50 38 72 54
ft-lb 65 49 93 69
M12 x 1.75
Nm 88 66 126 94
ft-lb 104 78 148 111
M14 x 2.00
Nm 141 106 201 150
ft-lb 161 121 230 172
M16 x 2.00
Nm 218 164 312 233
ft-lb 222 167 318 238
M18 x 2.50
Nm 301 226 431 323
ft-lb 314 235 449 337
M20 x 2.50
Nm 426 319 609 457
ft-lb 428 321 613 460
M22 x 2.50
Nm 580 435 831 624
ft-lb 543 407 776 582
M24 x 3.00
Nm 736 552 1052 789
ft-lb 796 597 1139 854
M27 x 3.00
Nm 1079 809 1544 1158
ft-lb 1079 809 1543 1158
M30 x 3.50
Nm 1463 1097 2092 1570
ft-lb 1468 1101 2101 1576
M33 x 3.50
Nm 1990 1493 2849 2137
ft-lb 1886 1415 2699 2024
M36 x 4.00
Nm 2557 1918 3659 2744
Inch-Pound Force = in-lb Foot-Pound Force = ft-lb Newton-Meter = Nm 1613
NOTE: Lubed includes lubricants such as lubrizing, oil, grease, or uncured Loctite.
SJ12, SJ16 161917AG

37
Section 2 – Maintenance Tables and Diagrams Torque Specifications for Hydraulic Couplings & Hoses
Table 2.14 Torque Specifications for Hydraulic Couplings & Hoses
Hydraulic Coupling Torque Chart

O-Ring Port Connectors
Steel Ports Non-ferrous Ports
SAE Size
ft-lb Nm ft-lb Nm
4 14-16 20-22 9-10 12-13
6 24-26 33-35 15-16 20-21
8 50-60 68-78 30-36 41-47
10 72-80 98-110 43-48 60-66
12 125-135 170-183 75-81 102-110
16 200-220 270-300 120-132 162-180
20 210-280 285-380 126-168 171-228
24 270-360 370-490 162-216 222-294
32 - - - -
Hose End Torque Chart Hose End Torque Chart

for JIC for Flat-Face O-Ring Seal (Steel)
Size Steel Brass Size Torque Specification
ft-lb Nm ft-lb Nm ft-lb Nm
Dash Frac. Dash Frac.
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
-4 1/4" 10 11 13 15 5 6 6.75 9 -4 1/4" 10 12 14 16
-6 3/8" 17 19 23 26 12 15 17 20 -6 3/8" 18 20 24 27
-8 1/2" 34 38 47 52 20 24 27.66 33 -8 1/2" 32 40 43 54
-10 5/8" 50 56 69 76 34 40 46.33 55 -10 5/8" 46 56 60 75
-12 3/4" 70 78 96 106 53 60 72.33 82 -12 3/4" 65 80 90 110
-16 1" 94 104 127 141 74 82 100.5 111 -14 1" 65 80 90 110
-20 1 1/4" 124 138 169 188 75 83 101.5 113 -16 1 1/4" 92 105 125 240
-24 1 1/2 156 173 212 235 79 87 107 118 -20 1 1/2 125 140 170 190
-32 2" 219 243 296 329 158 175 214 237 -24 2" 150 180 200 245
1614
161917AG SJ12, SJ16
38
Section 3 – System Component
Identification and Schematics
SJ12, SJ16 161917AG

39
Section 3 – System Component Identification and Schematics Electrical Symbol Chart
Table 3.1 Electrical Symbol Chart
CIRCUITS CROSSING LIMIT SWITCH

NO CONNECTION HOURMETER KEY SWITCH
LIMIT SWITCH
CIRCUITS LIGHT FOOT SWITCH
CONNECTED CLOSED
LIMIT SWITCH
HYDRAULIC
BATTERY TOGGLE SWITCH
VALVE COIL
PROPORTIONAL LIMIT SWITCH

GROUND HYDRAULIC PUSH BUTTON
VALVE COIL
SILICON
ELECTRIC CONTROLLED
FUSE ROTARY SWITCH
MOTOR RECTIFIER
CIRCUIT PROXIMITY
HORN LIMIT SWITCH
BREAKER SWITCH
EMERGENCY CAM OPERATED PNP

VOLT METER STOP BUTTON LIMIT SWITCH TRANSISTOR
CAPACITOR RESISTOR NPN

TILT SWITCH
TRANSISTOR
SINGLE POLE
POTENTIOMETER LEVEL SENSOR SINGLE THROWN VACUUM
RELAY SWITCH
SINGLE POLE DOUBLE POLE DOUBLE POLE TEMPERATURE

DOUBLE THROW SINGLE THROW DOUBLE THROW SWITCH
RELAY RELAY RELAY
TRIPLE POLE
DOUBLE THROW DIODE RHEOSTAT
RELAY
161917AG SJ12, SJ16
40
Hydraulic Symbol Chart Section 3 – System Component Identification and Schematics
Table 3.2 Hydraulic Symbol Chart

VARIABLE
LINE CROSSING DISPLACEMENT SHUTTLE VALVE VELOCITY FUSE
PUMP
ACCUMULATOR, SINGLE ACTING

LINE JOINED HAND PUMP GAS CHARGED CYLINDER
HYDRAULIC CUSHION DOUBLE ACTING

TANK RELIEF VALVE CYLINDER CYLINDER
DOUBLE ACTING
HYDRAULIC PRESSURE
PRESSURE DOUBLE
FILTER WITH REDUCING
SWITCH RODDED
BYPASS VALVE
CYLINDER
ELECTRIC MOTION SPRING APPLIED

MOTOR FIXED ORIFICE CONTROL VALVE HYDRAULIC
RELEASED
BRAKE
ADJUSTABLE FLOW DIVIDER BRAKE

ENGINE FLOW CONTROL COMBINER CYLINDER
FIXED
DISPLACEMENT COUNTER ROTARY
CHECK VALVE BALANCE VALVE ACTUATOR
PUMP
VARIABLE BI DIRECTIONAL
DISPLACEMENT HYDRAULIC
OIL COOLER VALVE COIL
HYDRAULIC MOTOR MOTOR
SERIES TWO POSITION THREE POSITION

PARALLEL TWO WAY FOUR WAY
HYDRAULIC TWO POSITION CLOSED CENTER
NORMALLY
MOTOR THREE WAY VALVE OPEN PORT
CLOSED VALVE
TWO POSITION THREE POSITION

TWO WAY TWO POSITION FOUR WAY
NORMALLY THREE WAY VALVE CLOSED CENTER
OPEN VALVE CLOSED PORT
PRESSURE PILOT LINES Dashed

MAIN LINES Solid
TRANSDUCER
SERVO
SJ12, SJ16 161917AG

41
Section 3 – System Component Identification and Schematics Wire Number and Color Code
3.3 Wire Number and Color Code

WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE
WIRE COLOR
NO. COLOR NO. NO. COLOR NO. COLOR NO. COLOR
00 WHT 20 ORG/BLU 44 YEL/WHT 67 ORG/BRN 92 GRN SHLD
000 WHT 21 WHT/RED 45 YEL/ORG 68 GREY 93 BLK SHLD
B1 BLU/PINK 23 BLK/WHT 46 RED/BLK 69 WHT/GRN 95 YEL/GREY
01 PUR/BLK 24 BLU/BLK 47 PUR/ORG 70 ORG/PINK 96 WHT/GREY
02 WHT 25 BRN/BLK 48 YEL/GREY 71 RED/ORG 97 ORG/GREY
03 GRN/PUR 26 BLU/YEL 49 GRN/RED 72 RED/BRN 98 RED SHLD
04 RED/YEL 27 RED/BLK/WHT 50 BRN 73 RED/PINK 98A BLK SHLD
GRN/
05 PUR 28 GRN 51 BLK/GRN 74 99 BLK/GREY
GREY
06 29 GREY/ORG 52 GRN/BLU 75 GREY/PUR 103 BLK/PUR
07 RED 30 RED/GRN 53 BRN/RED 76 BRN/BLU 104 GRN/ORG
08 PUR/WHT 31 RED/WHT 54 PUR/RED 77 BRN/GREY 105 GRN/BRN
09 YEL 32 GRN/BLK 55 YEL/PUR 78 RED/BLU 106 GRN/PINK
10 BLU/WHT 33 GRN/WHT 56 YEL/BLK 79 BRN/PUR 107 BLK/BLU

GREY/
11 WHT/ORG 34 ORG/BLK 57 BRN/GRN 80 WHT 108 YEL/BRN
RED/YEL/
12 35 ORG/WHT 58 WHT/PUR 81 GREY/BLK 109 GRN/YEL
BLK
13 ORG 36 RED/PUR 59 YEL/BLU 82 BRN/WHT 110A BLU
WHT/RED/
14 BLK 37 60 WHT/BLU 83 BLU/GREY 110B BRN
BLK
WHT/BLK/
15 BLU 38 ORG/RED 61 GREY/BRN 84 111 GREY/GRN
PUR
16 WHT/BLK 39 BLK/RED 62 GREY/RED 85 GREY/BLU 112 BLU/ORG
17 BLU/GRN 40 BLU/RED 63 GREY/YEL 86/87 PUR/BLU 113 BLU/BRN
18 GRN/BLU 41 BLU/PUR 64 WHT/BRN 88 BLK/ORG 114 YEL/RED
19 ORG/GRN 42 PINK 65 YEL/PINK 90 RED/GREY 115 WHT/PUR
22 PUR/GRN 43 WHT/YEL 66 ORG/YEL 91 RED SHLD 118 PUR/PINK
This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire
numbers will retain their original color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red.
161917AG SJ12, SJ16
42
Hydraulic Component Parts List Section 3 – System Component Identification and Schematics
3.4 Hydraulic Component Parts List

Index Skyjack
Description
No. Part No.
2H-13 151696 VALVE, Control (Emergency lowering)
2H-21 158183 VALVE, Pothole release
2H-14A 158185 VALVE, Lift
2H-17 103656 VALVE, Control (Brake)
4H-15 156850 VALVE, Control (Reverse drive) (Includes 4H-16)
4H-16 - VALVE, Control (Forward drive) (Includes 4H-15)
4H-23 158186 VALVE, Control (Right steer) (Includes 4H-24)
4H-24 - VALVE, Control (Left steer) (Includes 4H-23)
BP1 154839 MOTOR, Brake (Right)
BP2 154839 MOTOR, Brake (Left)
C1 151733 CYLINDER (Steer)
C2 159471 CYLINDER (Lift)
C3 158123 CYLINDER (Pothole)
CB1 147889 VALVE, Counterbalance
EM1 N/A MOTOR, Electric
FC1 158852 CONTROLLER (Priority flow)
HP1 151678 HANDPUMP (Brake release)
M1 139412 MOTOR, Drive (Right)
M2 139412 MOTOR, Drive (Left)
MB1 151270 BLOCK, Manifold (Powerpack)
MB2 158099 BLOCK, Manifold (Main)
MB3 151458 BLOCK, Manifold (Brake)
MB4 159802 BLOCK, Manifold (Lift cylinder)
O1 108721 ORIFICE (0.055”) (Lowering speed) (SJ12)
159416 ORIFICE (0.043”) (Lowering speed) (SJ16)
O2 N/A ORIFICE (Wheel motor)
R1 N/A VALVE, Relief (System)
R2 158583 VALVE, Relief (Steering)
R3 151684 VALVE, Relief (Lift)
TP1 N/A TEST PORT
V1 113752 VALVE, Reset (Brake)
SJ12, SJ16 161917AG

43
Section 3 – System Component Identification and Schematics Electrical Component Parts List
3.5 Electrical Component Parts List

SUPPLY (B+) (Common)
CONTROL (B+) GROUND (B-)
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Description
No. Part No.
14CR 108589 RELAY, 24 Volt 40 Amp (Base control centre - Lift speed)
14CR1 108589 RELAY, 24 Volt 40 Amp (Base control centre - Lift speed 2)
15BCR 108589 RELAY, 24 Volt 40 Amp (Base control centre - Reverse cutout)
16BCR 108589 RELAY, 24 Volt 40 Amp (Base control centre - Forward cutout)
17CR 108589 RELAY, 24 Volt 40 Amp (Base control centre - Steer)
21CR 108589 RELAY, 24 Volt 40 Amp (Base control centre - High speed)
28CR 108589 RELAY, 24 Volt 40 Amp (Base control centre - Tilt)
59ACR 108589 RELAY, 24 Volt 40 Amp (Base control centre - Base control)
2H-13 151683 COIL, 24 Volt (Emergency lowering valve)
3H-14A 151683 COIL, 24 Volt (Lift valve)
3H-17 151683 COIL, 24 Volt (Brake valve)
4H-15A 151682 COIL, 24 Volt (Reverse drive valve)
4H-16A 151682 COIL, 24 Volt (Forward drive valve)
4H-23 151683 COIL, 24 Volt (Right steer valve)
4H-24 151683 COIL, 24 Volt (Left steer valve)
B1 103480 BATTERY, 6V
BC1 122093 BATTERY CHARGER INDICATOR (Platform control console)
BP-29 103057 BEEPER, 4-28 VDC Slow pulsing (Base control centre)
BP-49 146649 HORN, 24V (Low tone)
CB1 117325 CIRCUIT BREAKER (15 Amp)
CB2 117325 CIRCUIT BREAKER (15 Amp)
Parts list continued on following page.
161917AG SJ12, SJ16
44
Electrical Component Parts List Section 3 – System Component Identification and Schematics
3.5 Electrical Component Parts List

Index Skyjack
Description
No. Part No.
- - Parts list continued from previous page.
C1 165865 CONTACTOR
164671 • KIT, Diode
D12B 129258 DIODE (8 Amp)
DA 102921 DIODE (6 Amp)
DB 102921 DIODE (6 Amp)
DCM1 156877 MOTOR
F1 310517 FUSE (300 Amp)
LED-1 147061 POWER INDICATOR LIGHT (Platform control console)
LED-2 147061 POWER INDICATOR LIGHT (Base control centre)
LS1 196453 LIMIT SWITCH (High speed)
LS2 158318 LIMIT SWITCH (Pothole protection)
LS3 156523 LIMIT SWITCH (Service position) (Fixed position)
156523 LIMIT SWITCH (Service position) (Variable position)
LS4 156522 LIMIT SWITCH (Drive cutout) (CE)
RST1 119629 RESISTOR (2.7k ohm) (Platform control console)
RST2 151646 RESISTOR (1k ohm, 1 watt) (Base control centre)
RST3 156515 RESISTOR (220 ohm, 3/4 watt) (Base control centre)
RST4 151645 RESISTOR (4.7k ohm, 1 watt) (Base control centre)
RST5 156527 RESISTOR (2k ohm, 2 watt) (Base control centre)
RST6 151643 RESISTOR (250 ohm, 1 watt) (Base control centre)
RST7 156564 RESISTOR (1.5 ohm, 1 watt) (Base control centre)
RST8 151647 RESISTOR (68 ohm, 1 watt) (Base control centre)
S1 119725 SWITCH, Main power disconnect
S2 147054 N.O. CONTACT, Lift/Drive (Base control centre)
S3 147053 N.C. CONTACT, Lift/Drive (Platform control console)
147054 N.O. CONTACT, Lift/Drive (Platform control console)
S4 147053 N.C. CONTACT, Emergency stop (Platform control console)
S5 115573 SWITCH, Diagnostic
S7 151201 CONTROLLER ASSEMBLY
S8 147054 N.O. CONTACT, Horn (Platform control console)
S10 147053 N.C. CONTACT, Off/Platform/Base (Base control centre)
147054 N.O. CONTACT, Off/Platform/Base (Base control centre)
S28 147053 N.C. CONTACT, Emergency stop (Base control centre)
TT1 103336 HOUR METER
TS1 157375 SWITCH, Tilt
SJ12, SJ16 161917AG

45
Section 3 – System Component Identification and Schematics Cylinders and Port Identifications
3.6 Cylinders and Port Identifications
C1
Steer Cylinder
C2
Lift Cylinder
O1
Lowering Orifice
2H-13
Emergency Lowering Valve
To Main Manifold
M157322AB_3
161917AG SJ12, SJ16
46
Wheel Brake and Port Identifications Section 3 – System Component Identification and Schematics
3.7 Wheel Brake and Port Identifications
BH1
Wheel Brake (Right)
To Brake Manifold
BH2
Wheel Brake (Left)
A To Brake Manifold
To Drive Motor (Left)
B
To Main Manifold
M1
Drive Motor (Right)
A
To Drive Motor (Right)
M2
Drive Motor (Left)
B
To Main Manifold
M149106AA_S3
SJ12, SJ16 161917AG

47
Section 3 – System Component Identification and Schematics Powerpack and Port Identifications
3.8 Powerpack and Port Identifications
T
To Main Manifold
P
To Main Manifold
TP
Test Port
R1
Relief Valve
P1
Pump
MB1
Powerpack Manifold
EM1
Motor
M151460AD_s3b
161917AG SJ12, SJ16
48
Platform Control Console Wire Diagram Section 3 – System Component Identification and Schematics
3.9 Platform Control Console Wire Diagram

S3 - LIFT/DRIVE TOGGLE S8 - HORN
15 16 12B
8A
8A
49
D12B
00
13 14 S4 - EMERGENCY STOP
RST1
8B 8A
08
A 02
7A LED-1 02
X2
X1
B
7A
8A 07 7A
TIE BACK UNUSED WIRES
9 PIN CONNECTOR SUB-ASSEMBLY
CTRL BOX
HARNESS
PIN # - FUNCTION CTRL BOX HARNESS JOYSTICK HARNESS

PIN 1 - LEFT 24 BLUE/BLACK WHITE/RED
PIN 2 - STEERING VS+ 12B BROWN/RED WHITE/GREEN
PIN 3 - RIGHT 23 BLACK/WHITE WHITE
PIN 4 - FWD/UP B RED YELLOW
JOYSTICK HARNESS PIN 5 - JOYSTICK VS+ 8A BLUE WHITE/BLACK
PIN 6 - REV/DOWN A PURPLE/WHITE GREY
PIN 7 - 0-5VDC PROP. 59 ORANGE/BLACK BLUE
CRD1
PIN 8 - GND 02 WHITE BLACK

PIN 9 - ENABLE VS+ 8B BLUE WHITE/ BLUE
CTRL BOX CABLE 10 5 10 5 10 5

A1 - N/U B1 - 12A RED/WHITE C1 - 7A GREEN
A2 - 02 WHITE B2 - N/U C2 - 7A JUMPER WIRE 9 4 9 4 9 4
A3 - 07 RED B3 - 23 BLACK/WHITE C3 - 7A JUMPER WIRE
8 3 8 3 8 3
A4 - N/U B4 - 24 BLUE/BLACK C4 - JUMPER TO C5
A5 - N/U B5 - 49 GREEN/WHITE C5 - JUMPER TO C4 7 2 7 2 7 2
A6 - 08 BLUE/WHITE B6 - 59 ORANGE/BLACK C6 - JUMPER TO C7 & C8
A7 - 13 ORANGE B7 - N/U GREEN/BLACK C7 - JUMPER TO C6 & C8 6 1 6 1 6 1
A8 - 14 BLACK B8 - N/U RED/BLACK C8 - JUMPER TO C6 & C7
A9 - 15 BLUE B9 - N/U C9 - JUMPER TO C10
A10 - 16 WHITE/BLACK B10 - N/U C10 - JUMPER TO C9
A B C
INSERTION SIDE VIEW
M151467AH
SJ12, SJ16 161917AG

49
Notes
161917AG SJ12, SJ16
50
3.10 Brake and Main Manifold and Hydraulic Identifications
A B C D E F G H
4H-15A V
V1 2H-17
Reverse Drive Valve
Auto Reset Valve Brake Valve
4H-16A
Forward Drive Valve FC1
Priority Steer Valve
R3
MB3 Lift Relief valve 4H-23
Brake Manifold Right Steer Valve
4H-14A
W
Lift Valve 4H-24
HP1 Left Steer Valve
Hand Pump B2
To Left Brake
2H-21 R2
Pothole Valve Steering Relief Valve
To Main Manifold
B
To Brake Manifold X
B1
To Right Brake L
To Lift Cylinder
PH
To Pothole Cylinder CB1
Counterbalance Valve
SR
To Steer Cylinder Y
SL
To Steer Cylinder
P1
To Powerpack Manifold MB2 R
Main Manifold To Right Drive Motor
M2
T
To Right Drive Motor
To Powerpack Manifold
M1 F Z
To Left Drive Motor To Left Drive Motor
M158154AB_4
SJ12, SJ16 161917AG

51
3.11 Disc Brake Kits and Torque Specifications
A B C D E F G H
K2 K2 K2 K2 K3 K3 OIL FILL
PORT
K3
A V
K1 HYDRAULIC OIL
PORT
W
K3
K3 B
K1 K3
K1
B X
A
SECTION A-A
BRAKE KITS K2
K1 - KIT, BEARING AND SEAL
K2 - KIT, BRAKE STACK Y
K3 - KIT, O-RING
TORQUE SPECIFICATIONS
1 - TORQUE CASTLE NUT TO 237 Nm
2 - TORQUE BRAKE BOLTS TO 115 Nm
3 - TORQUE MOUNTING BOLTS TO 115 Nm
OIL TYPE Z
CATERPILLAR T0-4 SAE 30 HYDRAULIC OIL (200 mL) SECTION B-B SPRING ARRANGEMENT
M154839AA_S3
161917AG SJ12, SJ16
52
3.12 Hydraulic Schematic - SJ12/SJ16
A B C D E F G H
BH2 BH1
LEFT RIGHT
C1 BRAKE BRAKE
STEER
C2 CYLINDER V
LIFT
SAE04
SAE04
CYLINDER L R
O1 B1 B2
MB3
LOWERING BRAKE
ORIFICE MANIFOLD
SEE CHART ASSEMBLY
MB4 HP1
2H-13 LIFT CYLINDER HAND
HOLD/EMERG
LOWERING VALVE
MANIFOLD ASSEMBLY PUMP V1
AUTO
RESET
VALVE
B
2H-21 W
POTHOLE
VALVE
M2 M1
LEFT RIGHT
DRIVE DRIVE
MOTOR MOTOR
C3 B A A B
POTHOLE
CYLINDER
TP1
SAE06
SAE04
SAE04
SAE04
SAE04
SAE06
SAE06
SAE06
SAE06
MB1
X
POWERPACK
MANIFOLD
MB2 L PH SL SR B F O2 M2 M1 R
MAIN WHEEL MOTOR
ASSEMBLY MANIFOLD ORIFICE
ASSEMBLY 0.031DIA.
TEST
P
4H-24 4H-23
LEFT RIGHT
STEER STEER
VALVE VALVE 4H-16A 4H-15A
FORWARD REVERSE
DRIVE DRIVE
VALVE VALVE
R2
R3 STEERING
EM1 LIFT RELIEF RELIEF
1500PSI
Y
R1 2000PSI (SJ12)
2700PSI (SJ16)
SYSTEM
P1 RELIEF FC1
PRIORITY
M PUMP 3000PSI
STEERING
3.7CC/REV VALVE
4H-14A CB1
COUNTERBALANCE
STRAINER LIFT VALVE
VALVE 2H-17
P1 BRAKE
SAE06 VALVE
T SAE06
T
HYDRAULIC RESERVOIR
Z
M158134AG
SJ12, SJ16 161917AG

53
3.13 Main Electrical Harness - SJ12/SJ16
A B C D E F G H
X14 - DRIVE REV X15 - MAST RAISE

SOLENOID SOLENOID
14A
02
15A
02
X13 - DRIVE FWD
SOLENOID X16 - STEER L
24
02
SOLENOID
16
02
V
A
X12 - BRAKE
SOLENOID 02
23
X17 - STEER R
X11 - POTHOLE 17 SOLENOID
LIMIT SWITCH 02
PIN 1 - 71A - RD/YL 21

PIN 2 - 72 - PK X10 - POTHOLE
PIN 3 - NOT USED 02
PIN 4 - NOT USED SOLENOID
X18 - BATTERY
CHARGER
PIN 1 - 3A - YL
PIN 2 - 05 - RD
02
W
17
X9 - MOTOR
19A
19A
02
CONTACTOR
07
X8 - TILT SWITCH
00
19E
PIN 1 - 19 - RD/BK
PIN 2 - 7B - GN/YL
19B 19
E PIN 3 - 28 - BR/GN
03
19B E PIN 4 - 16B WH/BK
X7 - MOTOR 59B 08 19
PIN 5 - 15B - BL
CONTROLLER PIN 6 - 02 - WH
X6 - ELEVATED DRIVE
LIMIT SWITCH
PIN 1 - B+ - GN/PR
X3 - MAST CABLE PIN 2 - 18X - GN/PR X5 - MAST LOWER
POWER PIN 3 - 71 - GY/OR SOLENOID X
PIN 4 - 21 - GN/WH PIN 1 - 13 - OR
PIN 1 - 07 - RD PIN 2 - 02 - WH
PIN 2 - 07A - GN/YL
PIN 3 - 08 - BL/WH
X1 - LOWER PIN 4 - 02 - WH
CONTROLS
59B-OR/BK 12"
15-BL 12"
16-WH/BK 12"
05-RD 18"
07-RD 14" X2 - MAST CABLE
07A-GN/YL 14" FUNCTIONS
08-BL/WH 15" PIN 1 - 13 - OR
13-OR 9" PIN 2 - 14 - BK
PIN 3 - 15 - BL
72-PK 10" PIN 4 - 16 - WH/BK
15A-BL 12" PIN 5 - 19A - RD/WH
15B-BL 12" PIN 6 - 19B - RD/WH
PIN 7 - 23 - BK/WH
16A-WH/BK 12"
16B-WH/BK 11"
PIN 8 - 24 - BL/BK
PIN 9 - 49 - GN/WH
Y
PIN 10 - 59 - OR/BK
X21 - STROBE
71-GY/OR 14" PIN 11 - 7B - GN/YL OPTION
19-RD/BK 10" PIN 12 - NOT USED PIN 1 - 29 - PR/WH
14A-BK 13" PIN 2 - 02 - WH
21-GN/WH 12"
23-BK/WH 8"
24-BL/BK 8"
28-BR/GN 8"
02-WH 13"
59-OR/BK 14"
17-GN/BK 10"
17-GN/BK 5" 02
19A-RD/WH 8"
49
19A-RD/WH 8" 19A X22 - HORN
14-BK 13" 19B
03
14-BK 4" X19 - DIAG.
14-BK 15"
SWITCH 00 02
3A
X24 - POS. CCT
Z
29-PR/WH 10" BREAKER
29-PR/WH 8" X23 - NEG. CCT
71A-RD/YL 4"
BREAKER
10"
18X
B+
M196172AD
161917AG SJ12, SJ16
54
3.14 Mast Control Cable
A B C D E F G H
CONNECTION CHART V
TOP OF MAST BOTTOM OF MAST

WIRE NUMBER
CONNECTOR/CAVITY CONNECTOR/CAVITY
CONNECTOR 'X1'
BLACK 14 X1/A8 X2/2
WHITE 02 X1/A2 X3/4

GREEN 7A X1/C1 X3/2 W
RED 07 X1/A3 X3/1
ORANGE 13 X1/A7 X2/1
BLUE 15 X1/A9 X2/3
LIMIT SWITCHES WHITE/BLACK 16 X1/A10 X2/4
RED/BLACK 19B X1/C9 X2/6
GREEN/BLACK 7B X1/C6 X2/11 X
ORANGE/BLACK 59 X1/B6 X2/10

BLUE/BLACK 24 X1/B4 X2/8
BLACK/WHITE 23 X1/B3 X2/7
RED/WHITE 19A X1/C4 X2/5
GREEN/WHITE 49 X1/B5 X2/9
Y
BLUE/WHITE 08 X1/A6 X3/3
WHITE JUMPER* 12A/7B X1/B1 & C7 N/U
CONNECTOR 'X2 ' * ANSI/CSA ONLY
CONNECTOR 'X3'
M156524AA_S3
SJ12, SJ16 161917AG

55
3.15 Limit Switches
A B C D E F G H
W
LS3 - SERVICE
20” TRANSLATING PLATFORM - ANSI/CSA
WIRE CAVITY
BLACK C5
BLACK/WHITE C10
BROWN C3
BLUE C8
YELLOW/GREEN NOT USED X
16” TRANSLATING PLATFORM - CE Y

LS4 - DRIVE CUTOUT LS3 - SERVICE
LS1 - MAST LIMIT SWITCH WIRE CAVITY WIRE CAVITY
BLACK B1 BLACK C5
WIRE CAVITY
BLACK/WHITE C7 BLACK/WHITE C10
BROWN 1 BROWN B9 BROWN C3
BLUE 2 B10
BLUE BLUE C8
BLACK 3
YELLOW/GREEN NOT USED YELLOW/GREEN NOT USED
BLACK/WHITE 4 Z
YELLOW/GREEN NOT USED
M151629AF_2
161917AG SJ12, SJ16
56
3.16 Base Control Wiring Diagram (SJ12/SJ16 - ANSI)
A B C D E F G H
14CR 14CR1 15BCR 16BCR 17CR 21CR 28CR 59ACR 21CR1

87 87 87 87 87 87 87 87 87
86 85 86 85 86 85 86 85 86 85 86 85 86 85 86 85 86 85
87A 87A 87A 87A 87A 87A 87A 87A 87A
30 30 30 30 30 30 30 30 30
59G
59H
59C
59D
59D
16B
17B
59B
15A
16A
17A
59K
19A
28A
59E
59A
71A
15B
59F
59J
02
59
14
02
14
02
15
02
16
02
17
02
21
02
19
28
02
02
71
21
28
19A
17
14
16B
16
15B
15
15A
16A
W
S2 59
08
05
07
07A
02
59B
10E
10E
19
72
29
13
23
24
21
14A
71
71A
S10
RST7
X
D17B D21
A B C D E F
08
RST3 D17 D13

05A
D14B
07
07A
10E
08
08
05A
02
RST2 RST5 D15A D17B-1 D14 D19A D23

Y
S28
RST6 RST8 RST4 D16A D14B-1 D72 D28A D24
05
07A
H29 Z
+
M196178AC_M196179AA
-
SJ12, SJ16 161917AG

57
3.17 Base Control Wiring Diagram (SJ12/SJ16 - CE/KC)
A B C D E F G H
14CR 14CR1 15BCR 16BCR 17CR 21CR 28CR 59ACR 21CR1

87 87 87 87 87 87 87 87 87
86 85 86 85 86 85 86 85 86 85 86 85 86 85 86 85 86 85
87A 87A 87A 87A 87A 87A 87A 87A 87A
30 30 30 30 30 30 30 30 30
59G
59H
59C
59D
59D
16B
17B
59B
15A
16A
17A
59K
19A
28A
59E
59A
71A
15B
59F
59J
02
59
14
02
14
02
15
02
16
02
17
02
21
02
19
28
02
02
71
21
28
19A
17
14
16B
16
15B
15
15A
16A
W
59
08
05
07
07A
02
59B
19
10E
72
29
13
23
24
21
14A
71
71A
D17B RST7 D21

X
RST3 D17 D13

08
D14B
05A
07
07A
10E
08
08
02
05A
RST2 RST5 D15A D17B-1 D14 D19A D23 Y
RST6 RST8 RST4 D16A D14B-1 D72 D28A D24

05
07A
H29
Z
+
SPECIAL ASSEMBLY NOTE: THIS DIODE
TO BE REMOVED FROM ASSEMBLY TO
ALLOW CORRECT ALARM OPERATION OF
CE PANELS -
M196178AC_M196472AA
161917AG SJ12, SJ16
58
3.18 Electrical Schematic (SJ12/SJ16 - ANSI/CSA)
A B C D E F G H
24V DELTA-Q CHARGER
110 VAC
LINE VOLTAGE
DELTA-Q
24V CHARGER/INVERTER OPT

110 VAC
24V SIGNET CHARGER B+ B- V
110 VAC C1
LINE VOLTAGE LINE VOLTAGE
L1CR1
F2 CHARGER
80A BC TEMP COMP CABLE SIGNET CUTOUT RELAY
FUSE INVERTER OPTION ONLY

24V
CONTROL BOX MAST 2 1

BASE B-
1 CHARGER
CRD4 L1CR
INV CHARGER
CUTOUT RELAY
B4 6V F1 B3 6V B2 6V B1 6V
2
BATTERY 300A BATTERY BATTERY BATTERY
TIMER 05 24V FUSE
L P B- BATTERY
3
T C PACK
CRD1 CRD2 CRD3 J5 C1
2 1 4
19A 02 MOTOR
CONTACTOR DCM1
S10
S4 IDLE/PLTF/BASE M M- 5 PUMP MOTOR
EMERGENCY KEY SWITCH
D219D
STOP (IN IDLE POSITION)
S1 MAIN
B+ B- 6 MOTOR CONTROLLER
W
8A 8A BLUE/WHITE F2
08 08 08 5A S28 DISCONNECT 07 219DCR 19B
1A ENABLE 7 MOTOR CUT-OUT RELAY
EMERGENCY FUSE
STOP S5 DIAGNOSTIC
07 SWITCH
SWITCH 59B
D08 SPEED 8 POSITIVE CIRCUIT BREAKER 15A
LED-1 219D 00
CB1
POWER ON LIGHT 7A 07 07 RED 07 5A 05 3A 03 19A 19B CB2
00 02 9 NEGATIVE CIRCUIT BREAKER 15A
02 7A GREEN 7A 07A TT1

19A 10 HOURMETER
RED/BLACK TT
19B
7A 02
02 LS3
SERVICE POSITION 11 POWER ON LED
LIMIT SWITCH N.C.H.O 19A
LED-2
S8 IN SERVICE POS. D21 D19A BP-29
RED/WHITE 10E 07A POWER ON LIGHT 29
HORN SWITCH 12 BEEPER
NO
07
8A 49 13 ORANGE 13 2H-13
13 DOWN SOLENOID
DO2-1
19 28A D28A D13
29 FLASHING LIGHT
14
13 OPTION
BCI 10E D14B D14 19E FL-29
19 19A 02
BATTERY CHARGE 15 MOTOR CONTACTOR
14B
INDICATOR NOHC S2 UP/DOWN DO2-2
8A
V
02 7A 7B
SWITCH
LS2
D14B-1
POTHOLE TS1
28 02
16 TILT RELAY
X
LIMIT SWITCH N.C.H.O.
WHEN PLATFORM STOWED D72 19 28CR
02 GREEN/WHITE 49 71A 72
17 TILT SWITCH
02
02 7B
16B 15B BP-49 18 HORN
14 BLACK 14 B+ RST7 LOW VOLTAGE RESISTOR 14A 4H-14A

RST1 19 UP SOLENOID
LS1 14
2.7K OHMS 21CR 1.5 OHM STD
02 00 71 N.C. 21 21 02 DO2-3
20 HIGH SPEED RELAY
B+ 18X 14CR
14 02
N.O. 21 LIFT SPEED RELAY
220 OHM
S7 MAST POSITION 59 59C RST3
22 PLATFORM LIFT RESISTOR
JOYSTICK LIMIT SWITCH
68 OHM
D17B RST8
59D 59K
23 HI SPEED DRIVE RESISTOR
JOYSTICK PCB 845 OHM 250 OHM
8A 59 59 ORANGE/BLACK 59 59 59D 59D 59F RST2 59E 59B 59B RST6
0-5VDC
OUTPUT 24 ELEVATED DRIVE RESISTOR
4.7K OHM
02 21 07A 59G 59J 59B
25 STEER ONLY RESISTOR
21CR1
07A 59H
RST4 2K OHM
RST5
Y
21 00 219D 26 BASE LIFT RESISTOR
B+
D12B J4 14 02 LIFT SPEED RELAY 2

12A 7B 71 71A 27
12B 12A 02
71 14CR1
59A 02
28 BASE CONTROL RELAY
S3 59ACR 07 3 4 9
LIFT/OFF/DRIVE 2
(IN OFF POSITION) 19A 17 29 TRACK UNIT TELEMATICS
1 TU 12
15BCR 11
7B GREEN/BLACK 7B 15B 02
7B 30 REV CUT-OUT RELAY
16BCR 18X
16B 02
31 FWD CUT-OUT RELAY
S7-1 13
NUETRAL DA 4H-15A
A A 15 15 BLUE 15 15 15A
REV/DN 32 REVERSE SOLENOID
NO DO2-4
D15A
2H-17
33 BRAKE SOLENOID
14 DO2-5
DB D16A
B B 16 16 WHITE/BLACK 16 16 16A 4H-16A
FWD/UP 34 FORWARD SOLENOID
S7-6 NO 17CR DO2-6
ENABLE D17
ENABLE
8B 8B
NO
12B 71 17 17 02
35 STEER RELAY Z
23 23 BLACK/WHITE 23 4H-23
36 RIGHT SOLENOID
S7-2 DO2-7
D23 D17B-1
RIGHT 12B 17B 21 2H-21
12B 17A
37 POTHOLE RELEASE SOLENOID
S7-3 DO2-7
LEFT D24
24 24 BLUE/BLACK 24 4H-24
38 LEFT SOLENOID
DO2-8
02 WHITE 02 02
M158132AK
SJ12, SJ16 161917AG

59
3.19 Electrical Schematic (SJ12/SJ16 - CE/KC)
A B C D E F G H
24V DELTA-Q CHARGER
110 VAC
LINE VOLTAGE
24V SIGNET CHARGER
110 VAC
LINE VOLTAGE
DELTA-Q
SIGNET
B+ B-
V
C1
1 CHARGER
L1CR
CHARGER
CUTOUT RELAY
L1CR1 B4 6V F1 B3 6V B2 6V B1 6V
CHARGER 2
CUTOUT RELAY
BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
CONTROL BOX MAST BASE B- BATTERY
3
PACK
CRD1 CRD2 CRD3 2 1 2 1
MOTOR 4
CONTACTOR DCM1
S10
S4 IDLE/PLTF/BASE M M- 5 PUMP MOTOR
EMERGENCY KEY SWITCH
D219D
STOP (IN IDLE POSITION)
B+ B- 6 MOTOR CONTROLLER
NCHO
S1 MAIN
8A 8A BLUE/WHITE F2
08 08 08 5A S28 DISCONNECT 07 219DCR 19B
1A ENABLE 7 MOTOR CUT-OUT RELAY
EMERGENCY FUSE
STOP S5 DIAGNOSTIC
07 SWITCH
SWITCH 59B
D08 SPEED 8 POSITIVE CIRCUIT BREAKER 15A
LED-1
POWER ON LIGHT 7A 07 07 RED 07 5A 05 3A
CB1
03
219D
19A 19B CB2
00
W
00 02 9 NEGATIVE CIRCUIT BREAKER 15A
02 7A GREEN 7A
19A 10 HOURMETER
RED/BLACK TT
19B
7A 02 TT1
02 LS3
SERVICE POSITION 11 POWER ON LED
LIMIT SWITCH N.C.H.O 19A
LED-2
S8 IN SERVICE POS. D21 D19A BP-29
RED/WHITE 10E 07A POWER ON LIGHT 29
HORN SWITCH 12 BEEPER
NO
07
8A 49 13 ORANGE 13 2H-13
13 DOWN SOLENOID
DO2-1
19 28A D28A D13
29 FLASHING LIGHT
14
13 OPTION
10E D14B D14 19E FL-29
BCI 19 19A 02
BATTERY CHARGE 15 MOTOR CONTACTOR
14B
INDICATOR NOHC S2 UP/DOWN DO2-2
SWITCH D14B-1
8A 02 7A 7B 28 02
V LS2 POTHOLE TS1 16 TILT RELAY
LIMIT SWITCH N.C.H.O.
WHEN PLATFORM STOWED D72 19 28CR
02 GREEN/WHITE 49 71A 72
17 TILT SWITCH
02 7B
02
BP-49 X
16B 15B 18 HORN
14 BLACK 14 B+ RST7 LOW VOLTAGE RESISTOR 14A 4H-14A

RST1 19 UP SOLENOID
2.7K OHMS LS1 14 1.5 OHM STD DO2-3
21CR
02 00 71 N.C. 21 21 02
20 HIGH SPEED RELAY
B+ 18X 14CR
14 02
N.O. 21 LIFT SPEED RELAY
220 OHM
S7 MAST POSITION 59 59C RST3
22 PLATFORM LIFT RESISTOR
JOYSTICK LIMIT SWITCH
68 OHM
D17B RST8
59D 59K
23 HI SPEED DRIVE RESISTOR
JOYSTICK PCB 845 OHM 250 OHM
8A 59 59 ORANGE/BLACK 59 59 59D 59D 59F RST2 59E 59B 59B RST6
0-5VDC
OUTPUT 24 ELEVATED DRIVE RESISTOR
4.7K OHM
02 21 07A 59G 59J 59B
25 STEER ONLY RESISTOR
RST4 2K OHM
21CR1 RST5
02 07A 59H
21 00 219D 26 BASE LIFT RESISTOR
LS4
B+ Y
D12B 14 02 LIFT SPEED RELAY 2
12A 7B 71 71A 27
12B 12A 02
71 14CR1
DRIVE CUTOUT 59A 02
LIMIT SWITCH N.C.H.O. 28 BASE CONTROL RELAY
S3 WHEN DECK EXTENDED 59ACR 07 3 4 9
LIFT/OFF/DRIVE 2
(IN OFF POSITION) 19A 17 29 TRACK UNIT TELEMATICS
1 TU 12
15BCR 11
7B GREEN/BLACK 7B 15B 02
7B 30 REV CUT-OUT RELAY
16BCR 18X
16B 02
31 FWD CUT-OUT RELAY
S7-1 13
NUETRAL DA 4H-15A
A A 15 15 BLUE 15 15 15A
REV/DN 32 REVERSE SOLENOID
NO DO2-4
D15A
2H-17
33 BRAKE SOLENOID
14 DO2-5
DB D16A
B B 16 16 WHITE/BLACK 16 16 16A 4H-16A
FWD/UP 34 FORWARD SOLENOID
S7-6 NO 17CR DO2-6
ENABLE D17
8B 8B 12B 71 17 17 02
ENABLE 35 STEER RELAY
NO
BLACK/WHITE
Z
23 23 23 4H-23
36 RIGHT SOLENOID
S7-2 DO2-7
D23 D17B-1
RIGHT 12B 17B 21 2H-21
12B 17A
37 POTHOLE RELEASE SOLENOID
S7-3 DO2-7
LEFT D24
24 24 BLUE/BLACK 24 4H-24
38 LEFT SOLENOID
DO2-8
02 WHITE 02 02
M158133AK
161917AG SJ12, SJ16
60
3.20 Harness Assembly Trackunit
A B C D E F G H
TO BATTERY POSITIVE (+)
ATTACH RELAY TO HORN/CB ASSEMBLY
19E
B+
219D 07
19A
W
TO BATTERY NEGATVIE (-)
00
1 AMP FUSE AND FUSE HOLDER

1A
SUPPLIED WITH TRACK UNIT TELEMATICS

07
B+
07
19A X
19B BASE CONTROL PANEL
219D
B+
J1 19E
TO TELEMATICS UNIT
17
DISCARD JUMPER
NORMALLY CONNECTED
VCT
Y
00
Note - On Telematics harness 221088, tie back VCT, B+
and 00 wires will not be used. MOTOR CONTACTOR
M221088AB
SJ12, SJ16 161917AG

61
3.21 Harness Assembly Elevate
A B C D E F G H
TO BATTERY POSITIVE (+)

V
ATTACH RELAY TO HORN/CB ASSEMBLY
19E
B+
219D 07
19A
TO BATTERY NEGATVIE (-)

00
1 AMP FUSE AND FUSE HOLDER

1A
SUPPLIED WITH TRACK UNIT TELEMATICS W

B+
07
D219D 19A
D
219
19B BASE CONTROL PANEL
18X X
17
J1 07 19E
TO TELEMATICS UNIT SCH SB+ S07 YELLOW SB+1
B+ CONNECT 19B, 18X, 17, 07, AND B+
SCL S00 TO BASE CONTROL TERMINALS DISCARD JUMPER
B+ NORMALLY CONNECTED
00
CAN
CA H
NL
CONNECTIONS FOR BMS

Y
MOTOR CONTACTOR
CANL
CANH
CONNECTIONS FOR CHARGER
M228562AC
161917AG SJ12, SJ16
62
Notes
161917AG SJ12, SJ16
63
Section 4 – Troubleshooting Information
4.1 Introduction
The following pages contain a table of
Troubleshooting Information for locating and
correcting most service trouble which can develop.
Careful and accurate analysis of the systems listed in
the table of Troubleshooting Information will localize
the trouble more quickly than any other method.
This manual cannot cover all possible troubles and
deficiencies that may occur. If a specific trouble
is not listed, isolate the major component in which
the trouble occurs, isolate whether the problem is
electrical or hydraulic, and then isolate and correct the
specific problem.
The content of this section is separated into “probable
cause” and “remedy.” The information preceded
by a number represents the “probable cause.”
The following line, noted by a dash represents the
“remedy” to the “probable cause” directly above it.
See example below for clarification.
1. Probable cause Remedy
SJ12, SJ16 161917AG

64
Electrical System Troubleshooting Section 4 – Troubleshooting Information
4.2 Electrical System Troubleshooting

4.2-1 All Controls Inoperative
1. Battery charger plugged into external power
Disconnect charger cord.
source.
2. Batteries disconnected. Connect batteries.
3. Dirty or loose battery terminals. Clean and tighten connections.
Check each cell with a hydrometer. Reading should
be 1.275 (fully charged). Recharge if low reading.
4. Battery charge low.
Replace if reading difference between cells is
0.050.
5. Main battery cables open or defective. Check continuity. Replace if defective.
6. Fuse F1 defective. Replace fuse.
7. Main battery disconnect switch S1 open or Close switch. Check continuity. Replace if
defective. defective.
8. Loose or broken wire #3 from motor contactor
Check continuity. Replace if defective.
C1 to circuit breaker CB1.
9. Loose or broken wire #3A from circuit breaker
CB1 to charger relay L1CR.
10. Defective or tripped circuit breaker CB1. Reset circuit breaker. Replace if defective.
11. Defective battery charger relay L1CR. Check relay. Replace if defective.
12. Loose or broken wire #5 from charger relay
L1CR to base emergency stop switch S28.
13. Open or defective base emergency stop switch
Close switch. Check switch. Replace if defective.
S28.
14. Loose or broken wire #5A from base emergency
stop switch S28 to base key switch S10.
Select function with switch. Check switch. Replace
15. Open or defective base key switch S10.
if defective.
16. Loose or broken wire #00 from motor controller
to circuit breaker CB2.
17. Defective or tripped circuit breaker CB2. Reset circuit breaker. Replace if defective.
18. Loose or broken wire #02 from circuit breaker Check continuity. Replace if defective.
CB1 to base terminal block.
4.2-2 All Controls Except for Down Function Inoperative

1. Loose or broken wire #59B from base terminal
block to motor controller.
SJ12, SJ16 161917AG

65
Section 4 – Troubleshooting Information Electrical System Troubleshooting
2. Loose or broken wire #19A from base terminal

block to diagnostic switch S5
3. Loose or broken wire #19A from diagnostic
switch S5 to mast control cable.
4. Loose or broken wire #19A in mast control cable Check for continuity between base connector X2
or its connectors. pin #5 and platform connector X1 pin #C4 on
cable. Check for loose or corroded connections on
cable connectors. Replace if wire is defective.
5. Loose or broken wire #19A from control box
connector pin #C4 to limit switch LS4.
6. Loose or broken wire #19B from limit switch LS4
to control box connector pin #C9.
7. Defective limit switch LS4. Check limit switch. Replace if defective.
8. Loose or broken wire #19B in mast control cable Check for continuity between base connector X2
or its connectors. pin #6 and platform connector X1 pin #C9 on
9. Loose or broken wire #19B from diagnostic
switch S5 to mast control cable.
10. Loose or broken wire #19B from diagnostic
switch S5 to motor controller.
11. Defective resistor RST6. (With joystick fully Check resistor and make sure it is secure. Replace
stroked) if defective.
12. Loose or broken B- cable from batteries to B- lug
on motor controller.
13. Loose or broken B+ cable from main battery
disconnect switch S1 to motor contactor C1.
14. Loose or broken B+ cable from motor contactor
C1 to motor DCM1.
15. Loose or broken B+ cable from motor DCM1 to
B+ lug on motor controller.
16. Loose or broken B- cable from motor DCM1 to
M- lug on motor controller.
17. Defective motor controller. Check motor controller input and output voltage.
Replace if defective.
18. Defective motor DCM1. Check motor for operation with 24 volt supply.
Replace if defective.
4.2-3 All Controls Inoperative From Base Control Console

1. Loose or broken wire #7 from base key switch
1. Check continuity. Replace if defective.
S10 to base terminal block.
161917AG SJ12, SJ16
66
2. Loose or broken wire #7 from base terminal

block to mast control cable.
Check for continuity between base connector X3
3. Loose or broken wire #7 in mast control cable or pin #1 and platform connector X1 pin #A3 on
its connectors. cable. Check for loose or corroded connections on
4. Loose or broken wire #7 from control box
connector pin #A3 to emergency stop switch S4.
5. Open or defective platform emergency stop
Close switch. Replace if defective.
switch S4.
6. Loose or broken wire #7A from emergency stop
switch S4 to control box connector pin #C1.
7. Loose or broken wire #7A in mast control cable pin #2 and platform connector X1 pin #C1 on
or its connectors. cable. Check for loose or corroded connections on
8. Loose or broken wire #7A from mast control
cable to base terminal block.
block to base key switch S10.
10. Open or defective base key switch S10. Close switch. Replace if defective.
11. Loose or broken wire #10E from base key switch Check continuity. Replace if defective.
S10 to base up/down switch S2.
4.2-4 No Up Function from Base Control Console

1. Defective up/down switch S2. Check switch. Replace if defective.
2. Loose or broken wire #14B from up/down switch
3. Open diode D14B-1. Check diode. Replace if defective.
4. Open diode D14B. Check diode. Replace if defective.
block to relay 14CR.
6. Loose or broken wire #14 from relay 14CR to
relay 14CR1.
7. Open diode D14. Check diode. Replace if defective.
Check resistor and make sure it is secure. Replace
8. Defective low voltage protection resistor RST7.
if defective.
block to up valve coil 4H-14A.
SJ12, SJ16 161917AG

67
11. Defective up valve coil 4H-14A. Check continuity through coil. Replace if defective.
12. Machine not level. (Above high speed limit
Use on level surface.
switch)
block to tilt switch TS1.
14. Defective tilt switch TS1. Test tilt switch. Replace if defective.
15. Loose or broken wire #28 from tilt switch TS1 to
tilt relay 28CR.
base terminal strip.
17. Defective tilt relay 28CR. Check relay. Replace if defective.
18. Loose or broken wire #19A from tilt relay 28CR to
pump motor contactor.
block to base control relay 59ACR.
21. Defective base control relay 59ACR. Check relay. Replace if defective.
block to lift speed relay 14CR1.
23. Loose or broken wire #59H from lift speed relay
14CR1 to base terminal block.
24. Defective base lift resistor RST5.
if defective.
25. Loose or broken wire #59J from base terminal Check continuity. Replace if defective.
4.2-5 Up Function Slow from Base Control Console

1. Loose or broken wire #14 from base terminal Check continuity. Replace if defective.
3. Defective lift speed relay 14CR1. Check relay. Replace if defective.
4.2-6 No Down Function from Base Control Console

1. Defective up/down switch S2. Check switch. Replace if defective.
2. Loose or broken wire #13 from up/down switch
161917AG SJ12, SJ16
68

block to down valve coil 2H-13.
5. Defective down valve coil 2H-13. Check continuity through coil. Replace if defective.
4.2-7 All Controls Inoperative From Platform Control Console

1. Loose or broken wire #7 from base key switch
3. Loose or broken wire #8 in mast control cable or pin #3 and platform connector X1 pin #A6 on
its connectors. cable. Check for loose or corroded connections on
4. Loose or broken wire #8 from control box
connector pin #A6 to emergency stop switch S4.
5. Open or defective platform emergency stop
Close switch. Replace if defective.
switch S4.
6. Loose or broken wire #8A or wire #02 from
emergency stop switch S4 to joystick S7.
7. Defective joystick enable switch S7-6. Check switch. Replace if defective.
8. Defective joystick neutral switch S7-1. Check switch. Replace if defective.
9. Defective joystick S7. Check joystick. Replace if defective.
4.2-8 No Up Function from Platform Control Console

1. Loose or broken wire “B” from proportional Check continuity. Replace if defective.
controller S7 to diode DB.
2. Open diode DB. Check diode. Replace if defective.
3. Loose or broken wire “B” from diode DB to lift/off/
drive switch S3.
4. Lift/Off/Drive switch S3 defective. Check switch. Replace if defective.
6. Loose or broken wire #14 from lift/off/drive switch
S3 to control box connector pin #A8.
7. Loose or broken wire #14 in mast control cable pin #2 and platform connector X1 pin #A8 on
SJ12, SJ16 161917AG

69
8. Loose or broken wire #14 from mast control

cable to relay 14CR1.
9. Loose or broken wire #14 from relay 14CR to
relay 14CR1.
block to relay 14CR
12. Defective low voltage protection resistor RST7.
if defective.
15. Defective up valve coil 4H-14A. Check continuity through coil. Replace if defective.
16. Machine not level. (Above high speed limit
Use on level surface.
switch)
18. Defective tilt switch TS1. Test tilt switch. Replace if defective.
tilt relay 28CR.
base terminal strip.
21. Defective tilt relay 28CR. Check relay. Replace if defective.
22. Loose or broken wire #19A from tilt relay 28CR to
pump motor contactor.
23. Defective platform lift resistor RST3.
if defective.
24. Loose or broken wire #59C from base terminal Check continuity. Replace if defective.
block to lift speed relay 14CR.
4.2-9 Up Function Slow from Platform Control Console

3. Defective lift speed relay 14CR. Check relay. Replace if defective.
161917AG SJ12, SJ16
70
4.2-10 No Down Function from Platform Control Console
NOTE
Down function is not proportionally controlled.
1. Loose or broken wire “A” from proportional Check continuity. Replace if defective.
controller S7 to diode DA.
2. Open diode DA. Check diode. Replace if defective.
3. Loose or broken wire “A” from diode DA to lift/off/ Check continuity. Replace if defective.
drive switch S3.
6. Loose or broken wire #13 from lift/off/drive switch Check continuity. Replace if defective.
S3 to control box connector pin #A7.
7. Loose or broken wire #13 in mast control cable Check for continuity between base connector X2
or its connectors. pin #1 and platform connector X1 pin #A7 on
8. Loose or broken wire #13 from mast control Check continuity. Replace if defective.
cable to down valve coil 2H-13.
9. Loose or broken wire #02 from base terminal Check continuity. Replace if defective.
10. Defective down valve coil 2H-13. Check continuity through coil. Replace if defective.
SJ12, SJ16 161917AG

71
4.2-11 Pothole Bars Will Not Retract
NOTE
Machine must be below high speed limit switch to allow the pothole bars to retract

block to pothole release valve coil 2H-21.
block to pothole release valve coil 2H-21.
3. Defective pothole release valve coil 2H-21. Check continuity through coil. Replace if defective.
4.2-12 Steer Only Inoperative

1. Loose or broken wire #8B from proportional
controller S7 to lift/off/drive switch S3.
3. Loose or broken wire #12B from steer switches
S7-2 and S7-3 to lift/off/drive switch S3.
block to relay 17CR.
5. Defective relay 17CR. Check relay. Replace if defective.
6. Loose or broken wire #17B from relay 17CR to
base terminal block.
7. Open diode D17B-1. Check diode. Replace if defective.
8. Open diode D17B. Check diode. Replace if defective.
9. Defective lift speed relay 14CR1. Check relay. Replace if defective.
10. Loose or broken wire #59G from 14CR1 lift
speed relay to base terminal block.
11. Defective steer only resistor RST4. Check resistor and make sure it is secure. Replace
if defective.
4.2-13 Right Steer Inoperative

1. Defective right steer switch S7-2. Check switch. Replace if defective.
2. Loose or broken wire #23 from right steer switch
S7-2 to control box connector pin #B3.
3. Loose or broken wire #23 in mast control cable pin #7 and platform connector X1 pin #B3 on
161917AG SJ12, SJ16
72

cable to right steer valve coil 4H-23.
block to right steer valve coil 4H-23.
8. Defective right steer valve coil 4H-23. Check continuity through coil. Replace if defective.
4.2-14 Left Steer Inoperative

1. Defective left steer switch S7-3. Check switch. Replace if defective.
2. Loose or broken wire #24 from left steer switch
S7-3 to control box connector pin #B4.
3. Loose or broken wire #24 in mast control cable pin #8 and platform connector X1 pin #B4 on
cable to left steer valve coil 4H-24.
block to left steer valve coil 4H-24.
8. Defective left steer valve coil 4H-24. Check continuity through coil. Replace if defective.
4.2-15 No Drive Forward or Reverse

2. Loose or broken wire #7A from emergency stop
switch S4 to control box connector pin #C1.
3. Open or loose diode D12B. Check diode. Replace if defective.
4. Loose or broken wire #12A from diode D12B to
control box connector pin #B1.
5. Loose or broken jumper wire from #12A pin #B1
to #7B pin #C7 at mast connector X1. Check continuity. Replace if defective.
(ANSI/CSA only)
6. Loose or broken wire #12A from mast connector
X1 pin #B1 to drive cutout limit switch LS4. Check continuity. Replace if defective.
(CE & KC only)
SJ12, SJ16 161917AG

73
7. Drive cutout limit switch LS4 defective or out of

adjustment. Check switch for adjustment. Replace if defective.
(CE & KC only)
8. Loose or broken wire #7B from drive cutout limit
switch LS4 to mast connector X1 pin #C7. Check continuity. Replace if defective.
(CE & KC only)
9. Loose or broken wire #7B in mast control cable pin #11 and platform connector X1 pin #C6 on
10. Loose or broken wire #7B from mast control
cable to tilt switch TS1.
Adjust the set up of the tilt switch using section 5 of
12. Tilt switch TS1 defective or out of adjustment.
this manual. Replace if defective.
4.2-16 Brake will not Release

1. Diode D16A forward or D15A reverse is shorted
Check diode. Replace if defective.
or open.
block to brake valve coil 2H-17.
3. Brake valve coil 2H-17 defective. Check continuity through coil. Replace if defective.
4. Loose or broken wire #02 from brake valve coil Check continuity. Replace if defective.
2H-17 to base terminal block.
4.2-17 No Elevated Drive

1. Pothole protection bars not fully lowered. Clear obstructions. Repair as needed.
2. Loose or broken wire #71 from base wire
harness to high speed limit switch LS1.
3. Defective high speed limit switch LS1. Check switch. Replace if defective.
4. Loose or broken wire #71A from high speed limit
switch LS1 to pothole protection limit switch LS2.
5. Defective pothole protection limit switch LS2. Check switch. Replace if defective.
6. Loose or broken wire #72 from pothole
protection limit switch LS2 to base terminal block.
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74
8. Loose or broken wire #59F from base terminal

block to relay21CR.
9. Defective relay 21CR. Check relay. Replace if defective.
10. Defective elevated drive resistor RST2. Check resistor and make sure it is secure. Replace
if defective.
4.2-18 Work Platform Drives in Slow Speed Only

1. Loose or broken wire #71 from base wire
harness to high speed limit switch LS1.
2. Open or defective high speed limit switch LS1. Check switch. Replace if defective.
3. Loose or broken wire #21 from high speed limit
switch LS1 to base terminal block.
block to high speed relay 21CR.
5. High speed relay 21CR defective. Check relay, replace if defective.
6. Loose or broken wire #02 from high speed relay
21CR to base terminal block.
7. Loose or broken wire #59K from base terminal
block to high speed relay 21CR.
8. Defective high speed drive resistor RST8. Check resistor and make sure it is secure. Replace
if defective.
4.2-19 Forward Drive Function Inoperative

1. Loose or broken wire #16 from Lift/Off/Drive
switch S3 to control box connector pin #A10.
cable to relay 16BCR.
4. Loose or broken wire #16B from tilt switch TS1 to
relay 16BCR.
block to relay 16BCR.
6. Forward drive relay 16BCR defective. Check relay, replace if defective.
7. Loose or broken wire #16A from relay 16BCR to
SJ12, SJ16 161917AG

75

block to forward drive valve coil 4H-16A.
9. Loose or broken wire #02 from forward drive
valve coil 4H-16A to base terminal block.
10. Forward drive valve coil 4H-16A defective. Check continuity through coil. Replace if defective.
11. Open diode D16A. Check diode. Replace if defective.
12. Tilt switch TS1 defective or out of adjustment. Adjust the set up of the tilt switch using section 5 of
4.2-20 Reverse Drive Function Inoperative

1. Loose or broken wire #15 from Lift/Off/Drive
switch S3 to control box connector pin #A9.
cable to relay 15BCR.
4. Loose or broken wire #15B from tilt switch TS1 to
relay 15BCR.
block to relay 15BCR.
6. Reverse drive relay 15BCR defective. Check relay, replace if defective.
7. Loose or broken wire #15A from relay 15BCR to
block to reverse drive valve coil 4H-15A.
9. Loose or broken wire #02 from reverse drive
valve coil 4H-15A to base terminal block.
10. Reverse drive valve coil 4H-15A defective. Check continuity through coil. Replace if defective.
11. Open diode D16A. Check diode. Replace if defective.
12. Tilt switch TS1 defective or out of adjustment. Adjust the set up of the tilt switch using section 5 of
4.2-21 Two or More Functions at One Time

1. Shorted diode. Check continuity of all diodes. Replace if defective.
161917AG SJ12, SJ16
76
Notes
SJ12, SJ16 161917AG

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Section 4 – Troubleshooting Information Hydraulic System Troubleshooting
4.3 Hydraulic System Troubleshooting
4.3-1 All Functions Inoperative

1. Pump P1 defective. Check pump. Replace if defective.
2. Pump coupler broken or defective. Check coupler. Replace if defective.
3. System relief valve R1 stuck open. Clean valve. Replace if defective.
4.3-2 All Functions Sluggish

1. System relief valve R1 defective or not adjusted Adjust valve. Replace if defective.
properly.
2. Hydraulic pump P1 worn. Check pump. Replace if defective.
3. Suction strainer contaminated. Clean strainer. Replace if defective.
4.3-3 Platform Drifts Down

1. Defective holding/emergency/lowering valve 2H- Check valve. Replace if defective.
13.
2. Defective lift cylinder gland seal. Check for hydraulic oil leaking from the gland seal.
Rebuild cylinder. Replace if damaged.
4.3-4 Platform Lifts Slowly

1. Holding/emergency/lowering valve 2H-13 stuck Check valve. Replace if defective.
in the shifted position or is defective.
2. Lift relief valve R3 defective or not adjusted Adjust valve. Replace if defective.
correctly.
4.3-5 Platform Does Not Lift

1. Up valve 4H-14A defective or is sticking. Check valve. Replace if defective.
2. Lift relief valve R3 defective or not adjusted Adjust valve. Replace if defective.
correctly.
3. Hydraulic oil level too low. Fully lower the platform. Fill hydraulic tank with
recommended fluid to appropriate level.
4. Platform weight excessive. Reduce platform load to maximum capacity.
161917AG SJ12, SJ16
78
Hydraulic System Troubleshooting Section 4 – Troubleshooting Information
4.3-6 Platform Will Not Lower
NOTE
Down function is not proportionally controlled
1. Defective holding/emergency/lowering valve 2H- Check valve. Replace if defective.

13.
2. Lowering orifice O1 plugged or contaminated. Clear debris. Replace Orifice. Replace if defective.
4.3-7 Pothole Bars Will Not Retract
NOTE
Down function is not proportionally controlled
1. Pothole valve 2H-21 defective or is sticking. Check valve. Replace if defective.

2. Defective or binding pothole cylinder. Check for mechanical binding. Rebuild cylinder.
Replace if damaged.
4.3-8 Platform Drives Slow

1. Drive motor M1 or M2 defective. Check motors. Replace if defective.
4.3-9 Platform Will Not Drive in Forward

1. Forward drive valve 4H-16A defective or is Clean Valve. Replace if defective.
sticking.
2. Counterbalance valve CB1 defective or is Clean Valve. Replace if defective.
plugged.
4.3-10 Platform Will Not Drive in Reverse

1. Reverse drive valve 4H-15A defective or is Clean Valve. Replace if defective.
sticking.
2. Counterbalance valve CB1 defective or is Clean Valve. Replace if defective
plugged.
4.3-11 Brake(s) Will Not Release

1. Brake valve 2H-17 defective or is sticking. Clean valve. Replace if defective.
2. Brake hubs BH1 or BH2 sticking or defective. Check for hydraulic pressure at brake hubs. If
pressure is available rebuild brake hubs. Replace if
defective.
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79
Section 4 – Troubleshooting Information Hydraulic System Troubleshooting
4.3-12 Platform Does Not Steer

1. Priority steer valve FC1 defective or not adjusted Adjust valve. Replace if defective.
correctly.
2. Steer relief valve R2 defective or not adjusted Adjust valve. Replace if defective.
correctly.
3. Right steer valve 4H-23 or left steer valve 4H-24 Clean valve. Replace if defective.
defective or sticking.
4. Steer cylinder C1 seals bypassing. Rebuild cylinder. Replace if damaged.
5. Mechanical binding in king pins. Check for binding. Repair as needed.
4.3-13 Platform Steers Very Slowly

1. Priority steer valve FC1 defective or not adjusted Adjust valve. Replace if defective.
correctly.
161917AG SJ12, SJ16
80
Section 5 – Procedures
5.1 General
The following information is provided to assist you in the use and application of servicing and maintenance
procedures contained in this chapter.
5.1-1 Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate
support is provided.
5.2 Electrical System Adjustments

5.2-1 Electrical System
RST2,3,4,5 and 8
+ Resistor +
Voltage RST6 Voltage

In Resistor Out
- -
5.2-2 Resistor - Voltage Divider
Common Resistor Resistor Ohm Function Input voltage* Output Voltage**
RST3 220 Platform lift resistor 4.8 2.5
RST6 RST8 68 Hi speed drive resistor 4.8 3.8
250 Ohm RST2 845 Elevated drive resistor 4.8 1.1
RST4 4.7K Steer only resistor 24 1.2
RST5 2K Base lift resistor 24 2.7
* 4.8 volts refers to full stroke on the joystick. 24 volts represents a full charge on the battery pack.
** Values given are with all connections tight and free from corrosion + or - 10%.
SJ12, SJ16 161917AG

81
Section 5 – Procedures Electrical System Adjustments
5.2-3 Troubleshooting - Diagnostic 5.2-4 Tilt Switch Orientation

Switch
The design of this equipment and the tilt switch
require it to be installed in a specific direction. Below
The SJ12 and SJ16 machines are equipped with a
you will find a picture indicating the direction of TS1
diagnostic switch for the purpose of troubleshooting.
Tilt Switch. As indicated in the picture the tilt switch is
Once the deck is in the service position (deck
oriented so that the wiring harness as well as the reset
fully extended out), the electric signal to the motor
buttons face the center of the machine.
controller enable function is disengaged. All electrical
wiring and components can be checked in the service
position other than the signal to the enable of the Steer Cylinder
motor controller. To accomplish this you would be
TS1 - Tilt Switch
required to engage the diagnostic switch.
Diagnostic Switch Figure 05 Tilt Switch Orientation
Figure 04 Diagnostic and Horn Assembly
161917AG SJ12, SJ16
82
Hydraulic System Adjustments Section 5 – Procedures
5.3 Hydraulic System 5.2-2 Lift Pressure Adjustment
Adjustments 1. Extend transverse deck to service position, then

raise the service access door and secure in
position with the prop rod provided.
All adjustments must be made with a calibrated
2. Locate the hose going to the lift cylinder on
gauge. Refer to the serial number plate located on
the main manifold. Remove and plug the hose.
the rear of the machine for system and lift pressure
Refer to Section 3 Main Manifold Assembly for
values. location.
3. Install a calibrated 5000 PSI gauge to the port on
5.3-1 System Relief Pressure Adjustment the manifold where the hose was disconnected.
4. At the main manifold, loosen the locknut on the
lift relief valve R3.
1. Extend transverse deck to service position, then
raise the service access door and secure in 5. Select lift with the Lift/Drive select switch on the
position with the prop rod provided. platform control box.
2. Locate system pressure test port on power pack 6. Engage platform lift function and hold. Engage
manifold. Refer to Section 3 Power Pack and diagnostic switch and hold.
Port Identification for location. 7. Observe reading on gauge. Adjust lift relief
3. Install a calibrated 5000 PSI gauge to the system valve R3 to the value listed on the serial
pressure test port. number plate. Turn the stem of the relief valve
clockwise to increase pressure. Turn the stem
4. Remove platform control box from guardrail and
counterclockwise to decrease pressure.
locate it in the proximity of the work area of the
power pack. 8. Release platform lift function, diagnostic switch
and then tighten the locknut.
5. At the power pack manifold, loosen locknut on
system relief valve R1. Refer to Section 3 Power 9. Remove the gauge from the lift port on the
pack and Port Identification for location. manifold. Reattach lift cylinder hose and tighten.
6. Remove wires #15A and #16A from the valve 10. Store prop rod back to its holder, then lower
coils. Refer to Section 3 Power Pack and Port Service access door and secure it. Push the
Identification for location. transverse deck back to the working position.
7. Select drive with the Lift/Drive switch on the
platform control box. NOTE
Pressure setting may vary as machine
8. Engage either forward or reverse drive and hold.
components wear. The lift pressure should be set
Engage diagnostic switch and hold.
for rated load only.
9. Observe reading on gauge when drive is
selected. Adjust system relief valve R1 value
listed on the serial number plate. Turn the
stem on the relief valve clockwise to increase
pressure. Turn the stem counterclockwise to
decrease pressure.
10. Release joystick, diagnostic switch and then
tighten the locknut.
11. Reinstall wires #15A and #16A to the valve
coils.
12. Remove the gauge from the system pressure
test port.
13. Store prop rod back to its holder, then lower
service access door and secure it. Push the
transverse deck back to the working position.
SJ12, SJ16 161917AG

83
Section 5 – Procedures Hydraulic System Adjustments
5.3-2 Steer Relief Pressure Adjustment
1. Extend transverse deck to service position, then

raise the service access door and secure in
position with the prop rod provided.
2. Locate system pressure test port on power pack
manifold. Refer to Section 3 Power pack and
Port Identification for location.
3. Install a calibrated 5000 PSI gauge to the system
pressure test port.
4. Remove platform control box from guardrail and
locate it in the proximity of the work area of the
power pack.
5. At the power pack manifold, loosen locknut on
steer relief valve R2. Refer to Section 3 Power
pack and Port Identification for location.
6. Select drive with the Lift/Drive switch on the
platform control box.
7. Engage steer right and hold. Engage diagnostic
switch and hold.
8. Observe reading on gauge when steering is
at full stroke. Adjust steer relief valve R2 value
at 1500 psi. Turn the stem on the relief valve
clockwise to increase pressure. Turn the stem
counterclockwise to decrease pressure.
9. Release steer switch, diagnostic switch and then
tighten the locknut.
10. Remove the gauge from the system pressure
test port.
11. Store prop rod back to its holder, then lower
service access door and secure it. Push the
transverse deck back to the working position.
161917AG SJ12, SJ16
84
Electronic Tilt Switch Setup Procedure Section 5 – Procedures
5.4 Electronic Tilt Switch 9. Disconnect all wires #02 from motor contactor.
10. Remove base control console from the base.
Setup Procedure Remove the cover plate on the base control
console to access the terminal strip.
The following information is supplied for replacement 11. Install jumper wire between #7 and #19 to
or reprogramming of the electronic tilt switch. Also terminal strip.
included are test and verification instructions. Follow 12. Turn main disconnect switch to “ ” ON position.
the appropriate procedures below. Pull out “ ” emergency stop buttons.
13. Verify switch is powered. (Red or green LED will
5.4-1 Tilt Switch Replacement be continually blinking)
Y AXIS
X AXIS
Red LED Red LED

Green LED Green LED
14. Program the Tilt Switch

A. Press and release the set up button 3 times.
B. Observe program delay / stabilization time.
(Only the red LED will blink for 4 seconds)
1. Ensure aerial platform is parked on a firm level Red LED

surface. Green LED
2. Chock or block wheels to keep the aerial

platform from rolling forward or backward. C. Both LEDs will flash for 1 second.
3. Lower platform completely. Extend the Results: The switch is learning the new zero
transverse deck to the service position. Open position.
the base cover and prop it in position using the
rod provided.
4. Push in emergency stop buttons and turn Red LED
Green LED
main disconnect switch to off position.
5. Remove any covers to locate and view the tilt
switch. D. Both LEDs will turn on solid for 1 second.
Results: The new zero position has been
6. Disconnect tilt switch from 6 pin connector.
learned.
7. Remove old tilt switch from mount.
NOTE
Red LED
Ensure part number of old and new tilt switch are
Green LED
the same.
8. Install new switch to mount (in the same

orientation as the old switch) and connect switch
plug to 6 pin connector.
NOTE
The tilt circuit is only powered when activating a
function.
SJ12, SJ16 161917AG

85
Section 5 – Procedures Electronic Tilt Switch Setup Procedure
E. The green LED will flash and then the

red LED will turn on solid for 2 seconds.
Results: The switch is verifying the new zero
position.
Red LED Red LED

Green LED Green LED
F. The green LED will turn on solid.

Results: The switch is ready for normal
operation.
Red LED
Green LED
15. Turn main disconnect switch to “ ” off position.

16. Remove jumper wire between #7 and #19 from
terminal block.
17. Reattach all wires #02 to motor contactor.
18. Reinstall cover plate on the base control
console. Reinstall the base control console into
the base of the machine and secure with old
hardware.
19. Reinstall any covers that were removed.
20. Close the base cover making sure it is secure.
Retract the transverse deck to the stored
position.
21. Remove chock or wheel blocks.
22. Proceed to Test and Verify Tilt Circuit.
161917AG SJ12, SJ16
86
Electronic Tilt Switch Setup Procedure Section 5 – Procedures
5.4-2 Reprogramming Existing Tilt Switch 11. Reprogram the Tilt Switch
A. Press and hold the set up button for 3
seconds.
Set up button is located on Results: Both LEDs will be OFF.
Light Indicators this face next to harness
Red LED
Green LED
R
Gre ed LE
en D
LE
D
B. Both LEDs will flash.
Red LED
Green LED
IMPORTANT
Step “c” must be completed within a 5 second
1. Ensure aerial platform is parked on a firm level
period, or the switch will automatically exit
surface.
program mode and return to normal operation
2. Chock or block wheels to keep the aerial using previously stored data.
platform from rolling forward or backward.
3. Lower platform completely. Extend the C. Press and release set up button 3 times.
transverse deck to the service position. Open D. If 5 second period has expired prior
the base cover and prop it in position using the completion, repeat Step “a”, “b” and “c”.
rod provided. E. Observe program delay / stabilization time.
4. Push in “ ” emergency stop buttons and turn (Only the red LED will blink for 4 seconds)
main disconnect switch to “ ” off position.
NOTE
Red LED
The tilt circuit is only powered when activating a Green LED
function.
5. Remove any covers to locate and view the tilt F. Both LEDs will flash for 1 second.
switch. Results: The switch is learning the new zero
6. Disconnect all wires #02 from motor contactor. position.
7. Remove base control console from the base.
Remove the cover plate on the base control
console to access the terminal strip. Red LED
Green LED
8. Install jumper wire between #7 and #19 to
terminal strip.
9. Turn main disconnect switch to “ ” ON position.
Pull out “ ” emergency stop buttons.
10. Verify switch is powered. (Red or green LED will
be continually blinking)
Red LED Red LED

Green LED Green LED
SJ12, SJ16 161917AG

87
Section 5 – Procedures Electronic Tilt Switch Setup Procedure
G. Both LEDs will turn on solid for 1 second. 5.4-3 Test and Verify Tilt Circuit
Results: The new zero position has been
learned.
Set up button is located on
Light Indicators this face next to harness
Red LED
Green LED
H. The green LED will flash and then the red R

Gre ed LE
en D
LE
LED will turn on solid for 2 seconds. D
Results: The switch is verifying the new zero

position.
Red LED Red LED

Green LED Green LED
I. The green LED will turn on solid. Operations of Tilt Switch

Results: The switch is ready for normal The following describes the LED’s and what they
operation. indicate.
12. Turn main disconnect switch to “ ” off
position. Illuminated whenever both tilt
13. Remove jumper wire between #7 and #19 from axes are within the specified
terminal block. degrees of the zero/ home
learned position.
14. Reattach all wires #02 to motor contactor. Green LED
Flashes when transitioning in
15. Reinstall cover plate on the base control or out of tilt angle limits, but
console. Reinstall the base control console into built in time delay has not fully
the base of the machine and secure with old occurred.
hardware. Illuminated whenever tilt on one
or more axes is more than the
16. Reinstall any covers that were removed. Red LED
specified degrees out from the
17. Close the base cover making sure it is secure. zero/ home position.
Retract the transverse deck to the stored On together, no blinking when
position. Green & Red LED
fault detected.
18. Remove chock or wheel blocks.
19. Proceed to Test and Verify Tilt Circuit.
Tilt Circuit Test
1. Refer to section 2 for test tilt sensor procedure.
161917AG SJ12, SJ16
88
Wheel Reinstallation and Torquing Procedure Section 5 – Procedures
5.5 Wheel Reinstallation and 3. For wheels with the bolted-on hubs, use a
socket wrench to remove the five wheel bolts
Torquing Procedure and Set aside the five wheel bolts.
Tools Needed 4. Use a hub puller to remove the hub from the
▪ Adjustable Torque Wrench brake. Then remove the wheel.
Capacity 380 Nm (280 ft-lb)
▪ Hub Puller
Hub/Integrated Hub Wheel Removal
1. Use an appropriately rated lifting device to raise
up the MEWP until all the wheels are off the
ground. Set the MEWP on stands adequately
rated to support the weight of the machine.
2. Remove the cotter pin and castle nut from the
brake. Set aside the castle nut and discard the
rest.
Bolted-On Hub
5. For integrated hub wheels, use two 3/8”-24 bolts
with a hub puller to remove the wheel.
Bolted-On Hub
Integrated Hub
Integrated Hub
SJ12, SJ16 161917AG

89
Section 5 – Procedures Wheel Reinstallation and Torquing Procedure
6. For wheels with the bolted-on hubs, Install the

hub and secure it with the castle nut.
7. For wheels with the integrated hub, install the
wheel onto the brake.
For integrated hub wheels only

13. To limit rust bleed, it is recommended that a
few drops of grease be applied to the two small
tapped holes on the front wheels.
Integrated Hub
8. Use a torque wrench to tighten the castle nut to
95 Nm ( 70 ft-lb ) and insert the cotter pin.
9. If the holes do not align to install the cotter pin,
continue to torque the castle nut clockwise until
the next hole is visible.
10. Ensure the cotter pin is pushed in completely.
11. Bend the ends of the cotter pin to secure the
castle nut.
Bolted-On Hub
Bolted-On Hub
12. Install the wheel onto the hub and secure it with
the five wheel bolts removed earlier. Torque the
bolts to 122 Nm (90 ft-lb) in a criss-cross pattern
using a torque wrench. Integrated Hub
161917AG SJ12, SJ16
90
Wheel Reinstallation and Torquing Procedure Section 5 – Procedures
5.6 Wheel Reinstallation and 7. Repeat the tightening sequence to confirm that
none have changed from 90 ft-lb. If any are found
Torquing Procedure below 90 ft-lb, repeat complete sequence until
there is no change in torque values. If possible,
When a wheel/tire assembly has removed or replaced,
drive the machine prior to checking torques.
it will be necessary to follow the procedure below to
ensure proper installation: 8. Check torque values after 8 hours of operating
and then at weekly intervals.
1. Inspect wheel fastener threads for damage or

defects. Replace if defective.
2. Clean the mounting surfaces of the hub and
wheel rim of debris, rust, excess paint, etc.
3. Mount the wheel on the hub, centering mounting
holes on the wheel studs or bolt holes. Ensure
the face of the rim with the raised mounting hole
edges is facing outward (see below). Use an
appropriate lifting device as required.
Raised holes
face outward
Figure 06 Wheel Alignment
4. Install wheel nuts or wheel bolts and hand tighten

to center the rim.
5. Torque nuts or bolts to approximately 50 ft-lb
using the tightening sequence shown below.
1
4
3
2 5
Figure 07 Tightening Sequence
6. Torque again to 90 ft-lb using the same sequence.
SJ12, SJ16 161917AG

91
Section 5 – Procedures Battery Maintenance
5.7 Battery Maintenance 5.8 Charger Maintenance -

This section provides the operator with procedures Delta-Q
on how to service and charge the battery. This also
provides the charger operation instructions. 3
2b
Servicing the battery
WARNING 2a
Explosion hazard. Keep flames and

sparks away. Do not smoke near 1
batteries. Battery acid releases 4
explosive gas while charging. Charge 5
batteries in a well-ventilated area. 6
Battery Charger
WARNING
Battery acid is extremely corrosive – wear proper Indicator Description/action
No. State
eye and facial protection as well as appropriate type required
protective clothing. If contact occurs, immediately
Battery charger is
flush with cold water and seek medical attention. AC
1 Blue connected to the AC
power
power.
1. Turn the main power disconnect switch to the off
position. Flashing Low charge— continue
2. Check the battery case for damage. Battery charging.
green
3. Check the battery fluid level in each battery. If the 2a charging
plates are not covered by at least 13 mm (1/2 in) <80% Solid High charge—
of solution, add distilled or demineralized water. green continue charging.
4. Make sure all the battery connections are tight.
Flashing High charge— can
Battery green discontinue charging.
NOTE 2b charging
Do not use any batteries other than the flooded >80% Solid Charge complete—
lead-acid batteries of the proper Ah rating. green discontinue charging.
Charger fault—refer to
WARNING Solid red
the service manual.
Fault/
Use the original or equivalent to the original parts 3
Error encountered—
error Flashing
and components for the MEWP. refer to the service
amber
manual.
Charging Solid Charger output is
4
output yellow active.
Charge Current
profile/ algorithm
5 N/A.
error or fault/
display error code
Select Current
6 charge charging N/A.
profile algorithm
161917AG SJ12, SJ16
92
Battery Maintenance Section 5 – Procedures
Charger Profiles 5. Continue to hold the button for approximately 10

seconds or until the Error Indicator turns orange
and the Battery Charging Indicator starts flashing
IMPORTANT green.
Charge profiles differ depending on the battery 6. The current charger profile displays up to three
type and manufacturer. Only use charge profiles times.
with the batteries they were designed for. Using
other incompatible batteries may cause poor NOTE
charging performance and a decreased battery The process times out and the profile remains
health. unchanged if there are 15 seconds of inactivity, or
if the charging profile is allowed to display three
1. Place the charger near a power outlet, but leave it
times.
unplugged.
2. Find your battery type in the following chart, and 7. Press and release the button to scroll through the
make a note of the profile number (starting with charging profiles.
P). 8. Select a profile, and press and hold the button for
3. Press and hold the Select Charger Profile button 10 seconds or until the Error Indicator and Battery
(wrench icon) on the Delta-Q charger. You will Charging Indicator lights turn off.
hear a small click when you press the button. 9. Press the button again to confirm the selected
4. Continue to hold the Select Charger Profile profile.
button, and connect the charger to a power outlet. 10. Disconnect the charger from the power outlet.
Battery Brand Compatible with Profiles
U.S. Battery - US 2200 XC/XC2 Flooded, 6V, 232 Ah 200 - 255 Ah flooded #11 (P-0-1-1)
East Penn - 8GGC2 Gel, 6V, 180 Ah 150 - 230 Ah gel #26 (P-0-2-6)
Discover Energy - EVGC6A-A AGM, 6V, 220 Ah

220 - 400 Ah AGM #43 (P-0-4-3)
Discover Energy - EV12A-A AGM, 12V, 140 Ah*
U.S. Battery - US 12V XC2 Flooded, 12V, 155 Ah*

330 - 425 Ah flooded #73 (P-0-7-3)
U.S. Battery - US 250 XC/XC2 Flooded-lead, 6V, 255 Ah
Trojan - T105 ELPT Flooded, 6V, 225 Ah 150 - 250 Ah 6V, 8V, 12V flooded #3 (P-0-0-3)
*The batteries used for these charger profiles are connected in a series-parallel circuit.
SJ12, SJ16 161917AG

93
Charger Troubleshooting
The IC Series charger is continuously monitoring itself and its environment for unusual conditions. There are a few
indications that may require the user’s attention.
Symptom Recommended Action
No Indicator Lights Check AC voltage and connection to wall power.
Charger is connected to AC and is waiting for a battery to be connected, or for CAN remote
Only Blue AC Light On control commands. Battery voltage must rise over 0.1V/cell before charging will begin.
Some charging algorithms require a higher battery voltage to begin.
Read fault code (e.g., F-0-0-1) number on the Charge Algorithm/Error Display and refer to
Solid Red Fault/Error Indicator
the fault code table.
Flashing Amber Fault/Error Read error code (e.g., E-0-0-1) number on the Charge Algorithm/Error Display and refer to
Indicator the error code table.
Charger Fault Codes
Fault
Description Troubleshooting/Customer Actions
Code
F-0-0-1 DC-DC Failure: LLC excessive leakage fault. Internal charger fault. Disconnect AC and battery from
Power Factor Correction (PFC) Failure: PFC charger for a minimum of 30 seconds. If it fails again, contact
F-0-0-2 Skyjack service.
excessive leakage fault.
F-0-0-3 PFC has taken too long to boost.
The charger has been unable to calibrate the
F-0-0-4
current offset.
The voltage drop across the DC relay is too high
F-0-0-5
while the relay is closed.
Large difference between internal DC-DC and
F-0-0-6
battery sense currents.
161917AG SJ12, SJ16
94
Charger Error Codes

Fault
Description Troubleshooting/Customer Actions
Code
E-0-0-1 Battery voltage over limit in software. Typically ▪ Check the battery voltage and cable connections.
2.5V/cell. At the start of a charger cycle only and
only for lead acid batteries. It is acceptable for ▪ Check charger voltage model is appropriate for
the voltage to go above this during charging batteries.
and when charging Lithium batteries. ▪ This error automatically clears once the condition has
been corrected.
E-0-0-2 Battery voltage too low to start a charge cycle. ▪ Check the battery voltage and cable connections.
Algorithm dependent. Typically 0.1V/cell.
▪ Check the charger is the correct voltage for the batteries
it is connected to.
▪ Check battery size and condition. Batteries may be
overdischarged. Use another charger to bring the
batteries above the minimum voltage.
▪ This error automatically clears once the condition has
been corrected.
E-0-0-3 Charge time limit reached. Algorithm ▪ Charger output reduced due to high temperatures.
dependent. Operate at lower ambient temperature.
▪ Charger output reduced due to low AC voltages. Check
AC voltages.
▪ Check for shorted or damaged cells.
▪ Poor battery health. Replace the battery.
▪ Batteries too large for the charger. Replace batteries.
▪ Very deeply discharged battery. Retry charge.
▪ Battery connections are loose or corroded. Check
connections.
▪ Extra loads. Turn off other devices running on the battery
▪ This error automatically clears once the charger is reset
by cycling DC or by loss of AC for over 10 minutes.
E-0-0-4 Battery could not be trickle charged up to ▪ Check for shorted or damaged cells.
the minimumvoltage. May also be used for
other battery-related errors depending on the ▪ Poor battery health. Replace the battery.
algorithm. ▪ Check DC connections.
▪ May be caused because of output reduced due to high
temperature.
▪ Some new batteries may trigger these alarms as there
voltage dips
▪ when charging starts before it goes onto rise.
E-0-0-7 Charge amp-hour Limit reached. Algorithm ▪ Charger output reduced due to high temperatures.
dependent. Operate at lower ambient temperature
▪ Charger output reduced due to low AC voltages. Check
AC voltage.
▪ Check for shorted or damaged cells.
▪ Poor battery health. Replace the battery.
▪ Very deeply discharged battery. Retry charge.
▪ Battery connections are loose or corroded. Check
connections.
▪ Extra loads. Turn off other devices running on the battery
▪ This error automatically clears once the charger is reset
by cycling
▪ DC or by loss of AC for over 10 minutes.
SJ12, SJ16 161917AG

95
E-0-0-8 Battery temperature out of range. Algorithm ▪ Cool or warm batteries as needed.
dependent.
▪ Check temperature sensor and connections.
been corrected.
E-0-1-1 Charge disabled by external command ▪ Charger has been disabled by an external controller
over the CANbus network.
▪ This error automatically clears once the command has
been removed.
E-0-1-2 Reverse polarity ▪ Battery is connected the wrong way around. Check the
battery connections.
been corrected.
E-0-1-3 Battery does not take current ▪ Check for an electrical component or loose connection
between the charger and the battery.
▪ When charging lithium batteries, make sure the charger
is properly connected to the battery and battery
management system.
▪ This error automatically clears once the charger is
disconnecting DC or AC.
E-0-1-9 Hardware build does not support software ▪ The charger hardware does not support the new
version software version.
▪ Existing SW is left running. Contact Delta-Q
Technologies.
E-0-2-0 No active algorithm selected ▪ Reprogram the charger with its original software,
algorithms, and settings.
▪ Use the wrench button to select the correct algorithm if
still available on the charger.
▪ The problem clears automatically when an available
algorithm is set on the charger, as default.
E-0-2-1 High battery voltage while charging. Algorithm ▪ When already charged, some new batteries may exhibit
dependent. Typically 2.8V/cell. this error.
▪ Disconnect the battery connection and wait for the
battery voltage to fall. Reconnect the batteries to see if
the condition reoccurs.
▪ Check battery size and condition. Batteries in poor
condition, with a high internal resistance, may cause
this error. New batteries, if charged when already full,
may also cause this error. Disconnect and reconnect the
batteries a few times.
▪ Check the battery voltage and cable connections.
been corrected.
161917AG SJ12, SJ16
96
E-0-2-2 Low battery voltage while charging. Algorithm ▪ Another device may be drawing current from the battery.
dependent. Typically 0.1V/cell.
▪ Check the battery voltage and cable connections.
▪ Check battery size and condition. Batteries may be
overdischarged.
▪ Use another charger to bring the batteries above the
minimum voltage.
been corrected.
E-0-2-3 High AC voltage error (>270 VAC) ▪ AC voltage is too high. Connect charger to an AC
source that has a stable AC voltage between 85 and 270
VAC/45-65 Hz.
▪ In newer software versions this does not prevent
charging.
▪ This error will automatically clear once the condition has
been corrected.
E-0-2-4 Charger failed to turn on properly ▪ Disconnect AC input and battery for 30 seconds. If the
error persists, contact Delta-Q Technologies.
E-0-2-5 AC voltage has dipped below 80 VAC 3 times in ▪ AC source is unstable. This could be caused by an
30 seconds undersized generator and/or input cables that are too
long or too small.
▪ Connect the charger to an AC source with a stable AC
voltage between 85 and 270 VAC/45-65 Hz.
▪ This error will automatically clear once the condition has
been corrected.
E-0-2-8 Attempt to select algorithm incompatible with ▪ Update charger software, continue to use existing
this software algorithm* or select a different charging algorithm that is
compatible.
* Notes
▪ If selecting a different algorithm, the existing algorithm
will remain in the charger.
▪ If upgrading an existing algorithm, the existing algorithm
will be deleted. Contact Delta-Q Technologies for a
software upgrade to run the new algorithm.
E-0-2-9 Cannot transmit on CAN bus ▪ Check the physical CAN connector, electrical bus
conditions, and other CAN modules for correct
functioning. For example, check that termination
resistance is approximately 60 ohms.
E-0-3-0 CAN heartbeat timeout on Battery module ▪ May be caused by a missing heartbeat message. Check
the CAN bus battery module for correct function.
been corrected.
E-0-3-1 The Vref for the ADC measurements ▪ Internal charger error. Disconnect AC and the battery for
has triggered an alarm a minimum of 30 seconds and retry.
▪ If the problem persists, contact Delta-Q Technologies.
been corrected.
SJ12, SJ16 161917AG

97
E-0-3-2 CAN Heartbeat Lost ▪ An error was detected with the CAN heartbeat
communications with a registered node being guarded.
▪ Check the networked CANbus device(s) for correct
functioning.
▪ This alarm does not display or get logged on the
charger but does appear on the CAN bus via an
emergency message.
E-0-3-6 Battery temperature sensor is missing or ▪ Check sensor connections.
shorted
▪ The charger behavior when this fault occurs can be
configured. OEMs may contact Delta-Q Technologies for
more information.
been corrected.
E-0-3-8 Fan will not turn (Fan-equipped models only)
▪ Check fan connections.
▪ Check to make sure the fan turns freely and is not
obstructed.
been corrected.
E-0-4-0 Fan voltage pulled low (Fan-equipped models only)
▪ Check to make sure the fan turns freely.
▪ Battery disconnected
E-0-4-5 Battery disconnected
▪ Reconnect the battery or check the wiring
▪ Check to make sure all PDOs are valid length.

E-0-4-6 Invalid PDO Length ▪ This error automatically clears once the condition has
been corrected
▪ A battery or some other source has been connected to

E-0-4-7 Platform overvoltage alarm
the charger that exceeds the hardware’s design limits.
161917AG SJ12, SJ16
98
Pothole Limit Switch(LS2) Replacement and Adjustment Section 5 – Procedures
5.9 Pothole Limit Switch(LS2) Limit Switch Electrical Connections

2. Route the new limit switch cable along the same
Replacement and path as the old one to the main harness. Use
tie wraps as needed to secure them at regular
Adjustment intervals.
Machine Preparation
1. Make sure the MEWP is parked on a firm level 3. Plug the spade connectors into the same wire
surface and fully lower the platform. numbers. The #71A and #72 wires from the limit
switches connect to the respective wires on the
2. Chock or block the wheels to keep the MEWP main harness.
from rolling forward or backward.
Limit Switch Setup
Limit Switches Removal 4. Loosen the hardware securing the limit switch
1. Extend the platform to the service position. to the limit switch bracket. Adjust and move
the limit switch towards the lever bar until it
depresses the plunger roller.
2. Open the service cover door, and properly install
the prop bar.
3. Remove the bolts and nuts (x2) securing the

limit switch to the limit switch bracket. Set the
hardware aside for later reinstallation.
5. Fully tighten the bolts securing the limit switch.

Make sure the limit switch does not move while
tightening the bolts.
Limit Switch Testing

4. Remove the limit switch and free the limit switch 1. Place a block, approximately 1.5” (3.75 cm),
cable by cutting the tie wraps. under the pothole bar and then raise the
platform to an approximate height of 7 feet
5. Follow the cable into the main harness, and (2 meters) or until the pothole protection is
disconnect the limit switch wire from the main activated.
harness. Discard the limit switch.
2. Attempt to drive forward or reverse. The MEWP
Limit Switch Replacement should not move forward or backward when
1. Mount loosely the new limit switch assembly: , pothole protection is on a block.
using the hardware removed previously.
SJ12, SJ16 161917AG

99
Section 5 – Procedures Mast Lubrication Procedure
5.10 Mast Lubrication

Procedure
CAUTION
Risk of personal injury or equipment damage.
Always use suitable lifting equipment and safe
lifting practices when performing the following
procedure.
WARNING
Risk of personal injury. Do not stand or pass under
a suspended load.
WARNING
Crushing/entrapment hazard due to moving
chains/rollers and mast components. Keep all Lubricate
hands, other body parts and clothing away from
moving parts.
5.10-1 Outside Mast Lubrication

1. Using the base controls,fully extend the mast.
2. Turn main disconnect switch to off position.
IMPORTANT
The operator must understand and follow the step-
Lubricate
by-step instructions to test all MEWP functions.
3. Clean any existing lubricant on the sides of the

vertical mast.
4. Apply DuPont Multi-Use Lubricant (158692) or
any PTFE wax based dry lubricant covering
1-1/2” wide along the outside corners of each
section of the mast except to top/outer mast.
Lubricate
5. Allow 10 minutes for the lubricant to dry, then
retract the mast using the base controls.
Lubricate
Figure 08 Mast Lubrication Zone.
161917AG SJ12, SJ16
100
Mast Lubrication Procedure Section 5 – Procedures
5.10-2 Inner wear pads lubrication 5.10-3 Chains and rollers lubrication
1. Using the base controls, fully retract the mast.
2. Turn main disconnect switch to off position. NOTE
Make sure the proper type of lubrication is used
3. Remove top mast cover.
in the correct locations.
1. Locate the roller assemblies inside the mast.

Lubricate the entire assemblies using standard
bearing grease (NLGI level 2 grease, or
equivalent) and apply a generous film on all
visible areas of the roller assembly.
Apply Lubricant
Figure 09 Top Cover Removal.
NOTE
Make sure the proper type of lubrication is used
in the correct locations.
Apply Lubricant
4. Apply DuPont Multi-Use Lubricant (158692) or
any PTFE wax based dry lubricant behind and Figure 11 Rollers lubrication
around all top wear pads only, in each section
of the mast. 2. For replacement rollers, pack the thrust washers
and the sides of the replacement rollers with
grease prior to installation.
Figure 10 Inner wear pads lubrication.
SJ12, SJ16 161917AG

101
Section 5 – Procedures Mast Roller Inspection/Maintenance
3. Locate the chain assemblies inside the mast. 5.11 Mast Roller Inspection/
Lubricate the entire length of chain and anchor
points using spray on industrial “Moly based” Maintenance
chain lubricant (for example Crown Wire Rope,
Chain and Cable Lube 7043). 5.11-1 Roller Operation Inspection
Apply Lubricant 1. Using the base controls, fully retract the mast.
WARNING
Crushing/entrapment hazard due to moving
chains/rollers and mast components. Keep all
moving parts.
2. Enter the platform and remove top mast cover.
Figure 12 Chain lubrication
4. Exit the work platform.

5. From the base controls, fully raise and lower the
platform three times to distribute the lubricant.
6. Install the mast cover at the top.
Figure 14 Top Cover Removal.
3. Inspect for metal shavings and dusty residue

around the roller mounts and on the chain.
This could indicate roller and/or chain erosion.
Monitor for visible (magnetic) dusting and feel
rollers for any grooving.
Figure 13 Mast Top Cover Installation.
161917AG SJ12, SJ16
102
Mast Chain Visual Inspection Section 5 – Procedures
4. Inspect rollers for uneven movement, rollers out 5.12 Mast Chain Visual
of alignment, uneven gaps on either side of the
rollers and excessive wear or gouging on the Inspection
mast, brackets or rollers. Replace brackets and
rollers if damaged. NOTE
When inspecting chains, wipe off any grease
or dirt as required to allow for proper visual
inspection of the chain. When inspection is
complete and the chain has been determined to
be in good condition lubricate the chain as per
5.10-3 Chains and rollers lubrication
1. Using the base controls, fully retract the mast.
3. Remove top mast cover.
4. Using non-specialized equipment (flashlight,
mirror) inspect all surfaces of visible sections
of chain, including anchor points, for broken,
cracked, corroded or worn links (Refer to
5.12-2 Condition inspection table for examples)
5. Mark each roller with an indelible marker. While Replace the chain if required.
slowly raising the mast observe and ensure the
rollers rotate freely. WARNING
6. Fully retract the mast. Crushing/entrapment hazard due to moving
7. Install the mast cover at the top. chains/rollers and mast components. Keep all
moving parts.
5. Turn on the Main Power Disconnect and pull out

both e-stops.
6. Re-enter the platform
7. While observing the roller movement, slowly lift
the platform using the platform controls.
8. If there is any uneven roller movement, or stiff
roller movement, refer to roller inspection and
maintenance section.
9. Stop lifting when 6 to 8 inches have traveled
over the top roller.
10. Push the E-stop on the platform.
11. Keeping hands clear of the rollers and chains,
use a flashlight to inspect the newly exposed
Figure 15 Mast Top Cover Installation. chain links for broken, cracked, corroded or
worn links, with particular attention to wear on
8. Exit the work platform. the links that have traveled over the rollers.
If during any of the inspections outlined above, a
NOTE chain shows any signs of degradation, perform a
When rollers are replaced for any reason, perform thorough chain examination as per 5.12-1 Chain
a full inspection on the chain for damage as Thorough examination as well as mast roller
described in section 5.12-1 Chain Thorough inspection as per 5.11-1 Roller Operation Inspection.
examination If there is any reason to suspect a chain of damage,
or if the mast is apart for other repairs then a thorough
chain examination or replacement is recommended.
SJ12, SJ16 161917AG
103
Section 5 – Procedures Mast Chain Visual Inspection
5.12-1 Chain Thorough examination

1. Remove all chains from the masts following section 5.13 Mast Disassembly Procedure of the manual.
2. Clean off all debris, grease and lubricant from the chain and anchor sections.
3. Lay the chain onto a clean bench.
4. Inspect the full length of the chain using an elongation gauge to ensure no section fails the limits set out in
table 1.
5. Inspect each chain link for damage as set out in the condition inspections table.
▪ For link wear, use a Digital Calliper
▪ For elongation use a Chain Gauge
▪ Visually inspect for the start of crack propagation and other types of damage
6. Inspect anchor points for missing parts, cracks, damage, rubbing or wear.
7. Turn the chain over and re-inspect each chain link for damage as set out in 5.12-2 Condition inspection
table.
8. Replace chain if necessary.
5.12-2 Condition inspection table
Inspection Description Limit

Stretched &
elongated chain
Stretched links &
A 3% across the chain or links
elongated chain
any broken link or start of

Broken or cracked
B crack propagation on any
links
leaf
Any lack of free movement

C Stiff links
under load
5% material loss on any link,

D Worn link & pins
leaving height of 11.5 mm
E Corroded links Any evidence
Abnormal Turned pin

Turned or protruding pin
F abnormally Any evidence
protruding pins
161917AG SJ12, SJ16
104
Mast Disassembly Procedure Section 5 – Procedures
5.13 Mast Disassembly Procedure 5. Disconnect the platform control cable quick
connector from the mast.
6. Remove the control cable enclosure that houses
CAUTION the hour meter from the side of the mast.
Risk of personal injury or equipment damage. 7. Disconnect the wires for the platform limit switch
Always use suitable lifting equipment and safe harness with the contact pin extraction tool
lifting practices when performing the following (208767).
procedure.
Control
CAUTION Cable Quick
Hourmeter Connector
Risk of personal injury or equipment damage. The
Enclosure
use of an assistant is required to safely complete
this procedure
WARNING
Risk of personal injury. Do not stand or pass under
a suspended load. Sample warning text. Limit
Switch
NOTE Harness
It is recommended that 2 lifting straps (or similar)
be used for a straight, even lift. Figure 18 Harnesses Disconnection
8. Pull the limit switch harness through the strain

NOTE
connector and out of the box. Tie the harness
SJ16 machines have one more mast section than
and the platform control cable to the platform.
the SJ12 machines. Some of the following steps
(as indicated) apply only to the SJ16 machines.
Control
5.13-1 Extending Platform Removal Cable Quick
Connector Limit Switch
1. With the platform fully-lowered, enter the Harness
platform. Traverse the platform by stepping
on the foot pedal, grasping the platform
repositioning handle, then pushing the platform
until fully-traversed. Exit the platform.
2. From base controls, lift the platform
approximately 10 in (25 cm).
3. Put a wood block (4’’ x 4’’) between the platform
and the base.
Figure 19 Harnesses Secured
SJ12, SJ16 161917AG

105
9. From a position outside of the work platform, 11. Raise the platform slightly then carefully and
remove the mast cover. slowly slide the platform towards the back of the
machine to clear the mast.
Figure 22 Platform Positioning
12. Raise the platform over the mast and set aside.
Figure 20 Top Cover Removal
10. Support the platform using suitable lifting straps.

Remove the hardware securing the platform to
the mast. Set aside.
Remove
Figure 21 Platform Hardware Removal

Figure 23 Platform Removal
161917AG SJ12, SJ16
106
13. On the side of the mast disconnect the AC 5.13-2 Mast Section 5 Removal (SJ16
power supply cable from the weatherproof outlet Only)
box, then loosen strain relief and remove the
harness (ANSI/CSA Only).
NOTE
14. Remove the 3 harness clamps at the top of the It is recommended that 2 lifting straps (or similar)
mast assembly. Secure the harnesses to the be attached evenly to mast section 5 for a
cylinder mounting bracket with cable ties. straight, even lift
NOTE
Clamp
Attach lifting straps away from mast grab handle
and receptacle box.
1. Disconnect the chains by removing the

hardware securing the chain mounts inside mast
section 5 as shown.
Cable Wrap
Figure 24 Harness Clamps
Figure 25 Chain Tensioner Disconnection (Section 5)
SJ12, SJ16 161917AG

107
2. Once the chains are disconnected, raise the 5.13-3 Mast Section 4 Removal
mast section and remove the lower wear pads.
Mark the location of each wear pad.
1. (SJ16 Only) Pull the chains laying on the
3. Lift mast section 5 up and away from the mast
outside of section 4 up and over the single
column, ensure the harnesses and the control
rollers so they drop into the mast column.
cable enclosure box are clear at the top of the
Ensure they do not tangle.
mast. Set the mast section aside.
Section 4
Figure 27 Section 3 to Section 5 Chains (SJ16 Only)
Figure 26 Wear Pads Removal (Section 5)

NOTE
be attached evenly to mast section 4 for a
straight, even lift.
NOTE
For SJ12 - Attach lifting straps away from mast
grab handle and receptacle box.
161917AG SJ12, SJ16
108
2. Carefully lift mast section 4, just enough so 4. Pry/push the bottom of the mast section forward
that the chains are not in tension. Remove the to allow the chain tensioner to drop past the
hardware securing the chain tensioner block bottom edge of the mast section.
inside mast 4.
Chain
Tensioner
Block
Figure 30 Chain Tensioner Release (Section 4)
5. Lift mast section 4 up and away from the mast

column. Ensure the harnesses and the control
cable enclosure box are clear at the top of the
mast. Set the mast section aside.
3. Lift the mast section up to a suitable working

height and remove the lower wear pads. Mark
the location of each wear pad.
Section 3
Figure 31 Mast Section 4 Removal
SJ12, SJ16 161917AG

109
5.13-4 Mast Section 3 Removal 2. vPull the chains attached to mast section 2 up
and over the double rollers so they can drop into
the mast column. Ensure they do not tangle.
1. (SJ16 Only) Pull the chains attached to mast
section 3 out of the mast column and lay them
against the front of mast section 3.
Figure 32 Section 3 Chains (SJ16 Only)
Figure 33 Section 2 to Section 4 Chains
NOTE
161917AG SJ12, SJ16
110
3. Carefully lift mast section 3 evenly, just enough 5. Lift mast section 3 up and away from the mast
so that chains are not in tension. Remove the column. Ensure the harnesses and the control
hardware securing the chain tensioner block cable enclosure box are clear. Set the mast
inside mast 4. section aside.
Chain
Tensioner
Block
4. Lift the mast section up to a suitable working

location of each wear pad.

Section 2
SJ12, SJ16 161917AG

111
5.13-5 Mast Section 2 Removal 3. Pull the chains attached to mast section 2 out of
the mast column and lay them against the front
of mast section 2.
1. Remove the hydraulic cylinder rod pin securing
the cylinder to the mount bracket in section 2 as
shown in figure below.
2. Cut all the cable ties securing the harnesses to
the cylinder mount bracket.
Rod Pin
Cylinder
Cotter Pin Rod
Section 2
Cable
Ties
Figure 37 Rod Pin Removal
Figure 38 Section 2 Chains
161917AG SJ12, SJ16
112
4. Pull the chains attached to mast section 1 up

and over the double rollers so they drop into the NOTE
mast column. Ensure they do not tangle. It is recommended that 2 lifting straps (or similar)
5. Lift the mast section up to a comfortable working
the location of each wear pad.
Section 2
Section 1
SJ12, SJ16 161917AG

113
6. Lift mast section 2 up and away from the mast 5.13-6 Mast Section 1 Removal
column. Ensure the harnesses and the control
cable enclosure box are clear. Set the mast
1. Pull the chains attached to mast section 1 out of
section aside.
of the mast.
Figure 41 Section 2 Removal

161917AG SJ12, SJ16
114
Top View
NOTE Clamp Clamp
Main
Harness
Platform
Control Limit Switch
Harness Harness
Figure 44 Harnesses Disconnection
3. Remove the rivets securing the power inlet at the

base of the mast. Disconnect the wires from it
and pull the harness through from the inside of
the base so that it is clear. (ANSI/CSA Only)
Rivet
Figure 43 Mast Section 1 Secured
2. Remove the 4 clamps that secure the harnesses

to the mast base, then disconnect the two
harness plug connectors and the mast limit
switch harness. Figure 45 Power Inlet Removal
NOTE
Disconnect the harness ground wire connected
to a mast mounting bolt at the base of the mast.
SJ12, SJ16 161917AG

115
Section 5 – Procedures Mast Roller Replacement
4. Remove all hardware securing the mast to the 5.14 Mast Roller Replacement
base.
1. Remove the hardware securing the roller

assembly to the mast.
2. Tap the roll pins out of the mast and pull the
roller assembly off.
3. Pull the roller assembly apart. Replace worn
parts as required.
Mounting
Bracket Roller
Bearing
Figure 46 Mast Hardware Removal
5. Lift mast section 1 up and away from the lift

Dowel
cylinder. Ensure all harnesses are clear. Set the
mast section aside. Pin
Pin
Roll Pin
Figure 48 Roller Pin Components
4. Reassemble the roller assembly.

5. Align the holes in the roller assembly with the
holes in the mast. Tap the roll pins into the holes.
6. Apply Loctite 242 (blue) to the threads and
install the bolts. Torque to 18 ft-lb
IMPORTANT
Once installed, the rollers must turn freely. Check
rotation before assembling the mast.
161917AG SJ12, SJ16
116
Mast Assembly Procedure Section 5 – Procedures
5.15 Mast Assembly Procedure

5.15-1 Mast Section 1 Installation Clamp
Clamp
CAUTION
A second person to assist will be required to
complete this procedure.
Figure 50 Harness Routing

WARNING
Do not stand or pass under a suspended load. 4. Connect the mast control cable and limit switch
harness plugs.
1. Ensure the main power disconnect switch is in
the off position.
2. Lift mast section 1 over the lift cylinder then
slowly and carefully lower the section in place,
ensuring the electrical harnesses are secured
at the top and bottom of the mast. Apply Loctite
242 (blue) to the threads of the 8 mounting
bolts and install them with flat washers and lock
washers. Torque to 23 ft-lb (31 N·m)
Plugs
Figure 51 Harness Plugs Connection
5. Connect the AC power supply harness to the

inlet at the base. Match the green wire to the
green terminal, the black wire to the bronze
terminal, and the white wire to the silver terminal.
Install the inlet with a 1/16” rivet in each hole.
(ANSI/CSA only)
Figure 49 Mast Hardware Installation
3. Organize and route the harnesses at the back

end of the base. Leave enough length to
properly secure them with the clamps.
Rivet
Figure 52 Power Inlet Installation
SJ12, SJ16 161917AG

117
Section 5 – Procedures Mast Assembly Procedure
6. Locate the limit switch at the top of the mast,

then press and hold the plunger away from NOTE
the opening with a piece of tape to avoid any It is recommended that 2 lifting straps (or similar)
potential damage when the next section passes be attached evenly to mast section 2 for a
over it. straight, even lift.
2. Lift mast section 2 over the mast column, then

slowly and carefully lower the section in place.
Ensure the harnesses and the control cable
enclosure box are clear at the top of mast
section 1.
3. Lower the section until the bottom end of the
mast is at a suitable working height to install the
lower wear pads.
4. Install the rear (short) wear pads with the 10-32
x 3/8’’ screws. Install the front (long) wear pads
Figure 53 Mast Limit Switch using 3/16’’ x 1/4’’-3/8’’ rivets.
5.15-2 Mast Section 2 Installation

1. Pull the chains attached to the mast section 1 up
and over so the they drop into the mast column.
Ensure they do not tangle.
Rear Wear
Pads
Section 1
Front Wear
Pads
Figure 55 Wear Pads Installation (Mast Section 2)
5. Fully lower the section in place.

6. Remove tape to release the limit switch.
Figure 54 Mast Section 1 Chains
161917AG SJ12, SJ16
118
5.15-3 Mast Section 3 Installation 2. Pull the chains attached to mast section 2 up
and over the double rollers so they drop into the
mast column. Ensure they do not tangle.
of mast section 2.
Section 2
Section 2
Figure 56 Section 1 to Section 3 Chains NOTE

SJ12, SJ16 161917AG

119
3. Lift mast section 3 over the mast column, then 6. Continue lowering until the chain block tensioner
slowly and carefully lower the section in place. inside the mast section can be attached. Apply
Ensure the harnesses and the control cable Loctite 242 (blue) to the threads of the six bolts
enclosure box are clear at the top. and install them with the flat washers.
4. Once in place, lower the section until the bottom
end of the mast is in a suitable working height to
install the lower wear pads.
x 3/8” screws. Install the front (long) wear pads Chain Block
using 3/16” rivets. Tensioner
Rear Wear
Pads
Section 2
Figure 59 Chain Tensioner Installation (Section 3)

Front Wear
Pads 7. Fully lower mast section 3. Guide the electrical
harnesses and the control cable enclosure out
of the mast column.
Figure 58 Wear Pads Installation (Section 3)
161917AG SJ12, SJ16
120
5.15-4 Mast Section 4 Installation. 2. (SJ16 Only) Pull the chains attached to mast
section 3 up and over the double rollers so they
can drop into the mast column. Ensure they do
not tangle.
of mast section 3.
Figure 61 Section 3 Chains (SJ16 Only)
NOTE
SJ12, SJ16 161917AG

121
3. Lift mast section 4 over the mast column, then 5. Lower the section until the bottom end of the
slowly and carefully lower the section in place, mast is in a suitable working height to install the
ensure the harnesses and the control cable lower wear pads.
enclosure box are clear at the top. 6. Install the rear (short) wear pads with the 10-32
4. Lower mast section 4 enough to connect the x 3/8” screws. Install the front (long) wear pads
chain block tensioner. Push the mast section using 3/16’’ x 1/4’’-3/8’’ rivets.
slightly forward to allow the chain tensioner to
pass through the mast section. Apply Loctite 242
(blue) to the threads of the four bolts and install
them with flat washers.
Rear Wear
Pads
Section 3
Front Wear
Pads
Chain Block Figure 63 Wear Pads Installation (Section 4)

Tensioner
7. Fully lower mast section 4. Guide the electrical
harnesses and the control cable enclosure out
of the mast column.
161917AG SJ12, SJ16
122
5.15-5 Mast Section 5 Installation (SJ16

Only) NOTE
of mast section 4. 2. Lift mast section 5 over the mast column, then
slowly and carefully lower the section in place.
Ensure the harnesses and the control cable
enclosure box are clear at the top.
3. Lower the section until the bottom end of the
mast is in a comfortable working height to install
the lower wear pads.
x 3/8” screws. Install the front (long) wear pads
using 3/16” rivets.
Rear Wear
Pads
Section 4
Front Wear
Pads
Figure 65 Wear Pads Installation (Section 5)
SJ12, SJ16 161917AG

123
5. Lower mast section 5 enough to connect the 5.15-6 Extending Platform Installation
chain tensioner. Apply Loctite 242 (blue) to the 1. Secure the harnesses with the clamps at the top
threads of the four bolts and install them with the of the mast as shown in figure below.
flat washers.
Figure 67 Harness and Clamps Installation

2. Route the AC power supply harness through the
6. Fully lower mast section 5. Guide the electrical strain relief to the inside of to the receptacle box
harnesses and the control cable enclosure out on the side of the mast and connect the harness
of the mast column. to the outlet (ANSI/CSA Only).
Strain
Relief AC Power
Supply
Harness
Receptacle
Box
Outlet
Figure 68 AC Power Supply Harness Connection
161917AG SJ12, SJ16
124
3. Lift platform in position over the mast then slowly 4. Apply Loctite 242 (blue) to the threads of the
and carefully lower it in place. upper 4 bolts then install them with the washers.
Torque to 23 ft-lb (31 N·m).
Figure 70 Platform Upper Bolts Installation
5. Route the limit switch harness through the

plastic clips and behind the manual box.
6. Route the limit switch harness through the
strain connector at the bottom of the enclosure
box then connect the wires to the appropriate
terminal block. Refer to section 3.15 Limit
Switches.
7. Connect the platform control cable quick
connector.
Limit Switch Platform Control

Harness Cable
Figure 69 Platform Installation
Manual Box
Figure 71 Platform Harnesses Installation
SJ12, SJ16 161917AG

125
Section 5 – Procedures Lift Cylinder Replacement
8. Raise the platform into position using the base 5.16 Lift Cylinder Replacement
controls so the lower platform bolts can be
installed. Apply Loctite 242 (blue) to the threads
and install the lower 4 bolts. Torque to 30 ft-lb CAUTION
(41 N·m). A second person to assist will be required to
complete this procedure.
WARNING
Do not stand or pass under a suspended load.
To remove the lift cylinder from the machine, the
platform and mast assembly must be removed
first. Fully lower the platform and shut down the
MEWP before starting this procedure.
5.16-1 Extending Platform Removal

1. See 5.8-1 Extending Platform Removal for
platform removal.
Figure 72 Platform Lower Bolts Installation 5.16-2 Mast Assembly Removal

1. Remove the cover on the top of the mast.
9. Fully lower the platform.
10. Install the mast cover
Figure 73 Mast Cover Installation

Figure 74 Mast Top Cover Removal
11. Perform a full function test before putting
machine into service as outlined in 2.4
Specifications and Features - CE of the
operating manual.
161917AG SJ12, SJ16
126
Lift Cylinder Replacement Section 5 – Procedures
2. Remove the hydraulic cylinder rod pin securing 3. Lift the mast enough to reach the harness plug
the cylinder to the mount bracket. connectors at the base.
Rod Pin
Cotter Pin
Figure 75 Rod Pin Removal
NOTE
be attached evenly to the cylinder mounting
bracket on mast section 2 for a straight, even lift.
Figure 76 Mast Positioning
4. Turn the main power disconnect switch to the off

position.
SJ12, SJ16 161917AG

127
5. Disconnect the two harness plug connectors 9. Remove all hardware securing the mast to the
and the mast limit switch harness. base as shown.
6. Remove all clamps securing the harnesses to
the mast base.
Top View
Disconnect
Harness Figure 79 Mast Hardware Removal
Plugs
10. Lift the mast assembly straight up and off the
cylinder, ensuring the harnesses are clear. Set
the mast aside.
Figure 77 Harness Disconnection
7. Remove the rivets securing the power inlet at the

base of the mast, then disconnect the wires and
pull the harness through from the inside of the
base so that it is clear.(ANSI/CSA Only)
Rivet
Figure 78 Power Inlet Removal
8. Lower the mast so that is slightly supported by

the lifting straps. Figure 80 Mast Removal
161917AG SJ12, SJ16
128
5.16-3 Lift Cylinder Removal 3. Carefully raise the cylinder approximately 4 in

(10 cm). Ensure the valve at the base of the
cylinder is clear.
1. Attach appropriate slings at the top of the
cylinder to secure it.
Figure 83 Cylinder Manifold
4. Place a suitable container underneath to catch

any escaping oil. Disconnect the hydraulic hose
at the base of the cylinder and the harness
connected to the valve. Install caps on all fittings
Figure 81 Cylinder Secured (hose and valve).
2. Remove the 2 socket head screws and flat

washers at the base of the cylinder.
Disconnect
Hose
Disconnect
Figure 82 Cylinder Hardware Harness
Figure 84 Manifold Hose and Harness Disconnection
5. Lift the cylinder carefully out of the base while

ensuring the valve on the base of the cylinder is
clear.
SJ12, SJ16 161917AG

129
5.16-4 Lift Cylinder Installation 2. Lower the cylinder so there is a distance of

approximately 4 in (10 cm) between the cylinder
manifold and the base plate. Ensure the valve on
1. Attach appropriate slings at the top of the cylinder
the base of the cylinder is clear
then carefully lift the cylinder over the base plate.
Cylinder
Manifold
Base
Plate
Figure 86 Cylinder Manifold
3. Connect the hydraulic hose to the cylinder

manifold, then torque the hose fitting to 19 ft-lb
(26 N·m) .
4. Connect the harness plug to the valve coil.
Figure 85 Cylinder Positioning
Figure 87 Manifold Hose and Harness Connection
161917AG SJ12, SJ16
130
5. Fully lower the cylinder in place. Apply loctite 5.16-5 Mast Assembly Installation
242 (blue) to the threads of 2 socket head
screws then install with flat washers at the base NOTE
of the cylinder as shown. Torque to 18ft-lb (24.4 It is recommended that 2 lifting straps (or similar)
N·m). be attached evenly to the cylinder mounting
bracket on mast section 2 for a straight, even lift.
1. Carefully lift the mast assembly over the lift

cylinder and slowly lower the mast in place.
Ensure the harnesses are clear while lowering
the mast.
Figure 88 Cylinder Hardware Installation
Figure 89 Mast Installation
SJ12, SJ16 161917AG

131
2. Apply Loctite 242 (blue) to the threads and

install the eight mounting bolts with the flat and
the lock washers. Torque to 23 ft-lb (31 N·m).
Connect
Plugs
Figure 90 Mast Hardware Installation Figure 92 Mast Harness Connection
3. Lift the mast enough to connect the harness 4. Connect the AC power supply harness to the
plug connectors at the base. power inlet at the base. Match the green wire to
the green terminal, the black wire to the bronze
terminal, and the white wire to the silver terminal.
Install the socket with the ground pin down
using a 1/16” rivet in each hole.
Rivet
Green Green
Bronze Bronze
Silver Silver
Figure 93 Power Inlet and Harness Installation
Figure 91 Mast Positioning
161917AG SJ12, SJ16
132
5. Secure the mast control and AC power supply 8. Install the mast cover at the top.
harnesses with the clamps and hardware at the
base of the mast.
Clip Clip
Figure 94 Mast Base Clamps Installation
6. Fully lower the mast and remove the lifting

straps.
7. Secure the lift cylinder to the cylinder mount
Figure 96 Mast Top Cover Installation
bracket on section 2 with the rod pin and cotter
pin.
9. Refer to 5.10-6 Extending Platform Installation
for platform installation.
10. Perform a full function test as outlined in
Rod Pin
2.4 Specifications and Features - CE of the
operating manual.
Cotter Pin
Figure 95 Rod Pin Installation
161917AG SJ12, SJ16
133
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SERVICE

SJ 12 & SJ 16 : 14 002 154 - 14 999 999

Please refer to the website (www.skyjack.com) for

Skyjack Service Center Parts & Service (Europe)

Parts (North America) Skyjack Brasil

BECOME ALERT! YOUR SAFETY IS INVOLVED.

The Safety Alert Symbol identifies important safety

SJ12, SJ16 161917AG

161917AG SJ12, SJ16

Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SJ12, SJ16 161917AG

Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 39

Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

161917AG SJ12, SJ16

SJ12, SJ16 161917AG

161917AG SJ12, SJ16

SJ12, SJ16 161917AG

1.2 Maintenance and 1.2-3 Maintenance and Service Safety

161917AG SJ12, SJ16

1.3 Hydraulic System & 7. All hydraulic components must be disassembled

SJ12, SJ16 161917AG

1.3-1 Maintenance Hints 1.4 Railing Maintenance and

161917AG SJ12, SJ16

1.5 About this Section 1.5-3 Maintenance Instructions

Perform PDI prior to each

SJ12, SJ16 161917AG

Table 1.6 Owner’s Annual Inspection Record

Description Label Pictorial Description Label Pictorial

161917AG SJ12, SJ16

1.7 Pre-Delivery/Maintenance Inspection

Serial Number: Product Owner:

Hourmeter Reading: Product User:

Inspection Type Schedule P - Pass

Items for Inspection P F R N/A Items for Inspection P F R N/A

Owner: ________________________________________________ / _____________________________________________ / ______________________________________________________

User: _________________________________________________ / _____________________________________________ / _______________________________________________________

Note: Visit skyjack.com for a printable copy of this form. 167830AC

SJ12, SJ16 161917AG

1.8 Scheduled Maintenance 1.8-2 Hydraulic

▪ ground area under the aerial platform 2

161917AG SJ12, SJ16

1.8-5 Limit Switches (B) 5 Pothole Protection Device (B)

SJ12, SJ16 161917AG

The tire treads have been

▪ B - Frequent/periodic/pre-delivery inspection Do a check for cuts or missing chunks in the edges

Do a check of the wheel components and mounts.

161917AG SJ12, SJ16

1.8-7 Platform Assembly 2 Fall Protection Anchorage (B)

1. Open the gate/chain and access the platform 1

SJ12, SJ16 161917AG

1.8-8 Hydraulic/Electrical Compartment 5. Replace battery if damaged or incapable of

1 Battery (B) WARNING

Explosion hazard. Keep flames and sparks away.

1. Check battery case for damage.

161917AG SJ12, SJ16

4 Hydraulic Tank (B) Tilt Sensor (If Equipped) (B)

SJ12, SJ16 161917AG

1.8-9 Lifting Mechanism Lift Cylinder(s) (B)

161917AG SJ12, SJ16

1.9 Function Tests

Owner: __________________________ / _ / ________________________________

User: ___________________________ / _ / _________________________________