SJ16 Service

SERVICE MANUAL (ALL STANDARDS)
VERTICAL MAST
MODELS SJ12 SJ16
157981AG January 2022

This manual is based on Serial Numbers:
SJ 12 14,001,106 to 14,002,153
SJ 16 14,001,077 to 14,002,153
Please refer to the website - www.skyjack.com for older Serial Numbers.
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: service@skyjack.com E-mail: info@skyjackeurope.co.uk
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: parts@skyjack.com 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
SERVICE AND MAINTENANCE
Table of Contents
Section 1 - Scheduled Maintenance

Table of Contents
Section 2 - Maintenance Tables

List of Tables
Section 3 - System Component Identification and Schematics

Table of Contents
Section 4 - Troubleshooting Information

Table of Contents
Section 5 - Procedures
List of Procedures
Vertical Mast Series Page 3

Models SJ12 & SJ16
157981
The Safety Alert Symbol identifies important
safety messages on aerial platforms, safety This Safety Alert Symbol means attention!
signs in manuals or elsewhere. When you
see this symbol, be alert to the possibility of Become alert! Your safety is involved.
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 aerial platform.
Page 4 Vertical Mast Series

Models SJ12 & SJ16
157981
Section 1
SCHEDULED MAINTENANCE
Operator’s Responsibility for Maintenance

Table of Contents
Aerial Platform and Mobile Elevating Work Platform (MEWP) Definition .....................................................7
1
Purpose of Equipment ...................................................................................................................................7
Use of Equipment...........................................................................................................................................7
Manuals ..........................................................................................................................................................7
Operator .........................................................................................................................................................7
Service Policy and Warranty ...........................................................................................................................7
Optional Accessories ......................................................................................................................................7
Scope of this Manual .....................................................................................................................................8
Operator Safety Reminders ............................................................................................................................8
Electrocution Hazard ......................................................................................................................................9
Maintenance and Inspection Schedule ........................................................................................................14
Owner’s Annual Inspection Record ..............................................................................................................14
Replacement Parts ........................................................................................................................................14
Hydraulic System & Component Maintenance and Repair ..........................................................................15
Maintenance Hints .......................................................................................................................................16
Railing Maintenance and Repair ..................................................................................................................16
Service and Maintenance
About this Section ........................................................................................................................................17
Service Bulletins ...........................................................................................................................................17
Maintenance and Inspection........................................................................................................................17
Maintenance Instructions ............................................................................................................................17
Tables
1.1 Owner’s Annual Inspection Record ........................................................................................................18
1.2 Maintenance and Inspection Checklist ..................................................................................................19
Scheduled Maintenance Inspections
1.1 Scheduled Maintenance Inspections......................................................................................................20
1.2 Function Tests .........................................................................................................................................27

Models SJ12 & SJ16
157981
Notes

Models SJ12 & SJ16
157981
Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Aerial Platform and Mobile Elevating Work Platform (MEWP) Definition

A mobile device that has a positionable platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK Veritcal Mast series aerial platform are designed to transport and raise personnel, tools and materials
to overhead work areas.
Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level,
compacted surface.
Manuals
Operating
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.
Operator
The operator must read and completely understand both this operating manual and the safety panel label located
on the platform and all other warnings in this manual and on the aerial platform. Compare the labels on the aerial
platform with the labels found within this manual. If any labels are damaged or missing, replace them immediately.
Service Policy and Warranty

SKYJACK warrants each new SJT series work platform to be free of defective parts and workmanship for the first
24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or
labor. Contact SKYJACK Service Department for warranty statement extensions or exclusions.
Optional Accessories
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under “Standard
and Optional Features” in Table 2.1 of the operating manual. Operating instructions for these options (if equipped)
are located in Section 2 of the operating manual.
For non-standard components or systems, contact the SKYJACK Service Department at
North America & Asia: Europe:

( : 800 275-9522 ( : 44-1691-676-235
7 : 630 262-0006 7 : 44-1691-676-239
Include the model and serial number for each applicable aerial platform.

Models SJ12 & SJ16
157981
Operator’s Responsibility for Maintenance Section 1 - Scheduled Maintenance
Scope of this Manual

a. This manual applies to the ANSI/SIA, CSA, AS and CE versions of the Vertical Mast Series aerial platform
models listed on Table 2.1 of the operating manual.
- Equipment identified with “ANSI” meets the ANSI SIA-A92.6-2006 standard.

- Equipment identified with “CSA” meets the CSA B354.2-01 standard.
- Equipment identified with “CE” meets the requirements for the European countries, i.e., Machinery Directive
2006/42/EC and Directive 2004/108/EC and the corresponding EN standards.
- Equipment identified with “AS” meets requirements of the Guideline published by the National Regulators’
Committee on High Risk Plant dated 27 May 2010.
- Equipment identified with “KC” meets the requirements for South Korea, i.e., Act 2008-75 and the
corresponding KS B ISO 16368:2004 Korean standard.
b. CSA (Canada) and CE (Europe)

Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this aerial platform.
c. ANSI/SIA (United States)

Operators are required by the current ANSI/SIA A92.5 standards to read and understand their responsibilities
in the manual of responsibilities before they use or operate this aerial platform.
WARNING
Failure to comply with your required responsibilities in the use and operation of the aerial platform
could result in death or serious injury!
Operator Safety Reminders

A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to
follow simple and fundamental safety rules and precautions.
You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this aerial platform
is mandatory. The following pages of this manual should be read and understood completely before operating the
aerial platform.
Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety
devices to protect your eyes, ears, hands, feet and body.
Any modifications from the original design are strictly forbidden without written permission from SKYJACK.

Models SJ12 & SJ16
157981
Electrocution Hazard
This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from energized
power lines and parts as listed below. The operator must allow for the platform to sway, rock or sag. This aerial
platform does not provide protection from contact with or proximity to an electrically charged conductor.
Per ANSI A92.5-2006 8.10(7)

“The operator shall perform only the work for which he or she is qualified, in compliance with all applicable safety
related work practices intended to prevent electric shock covered by the Code of Federal Regulations (CFR) 1910.333.
The operator’s level of competence shall be established only by persons qualified to do so. Operators shall
maintain the appropriate minimum approach distance (MAD) from energized power lines and parts covered by
CFR 1910.333 (c).”
Unqualified persons must maintain a minimum approach distance of 10 feet from any energized power line up to
50 kV. Energized power lines over 50 kV require a greater minimum approach distance to be maintained. Refer to
CFR 1910.333.
As per CSA B354.4-02

“The operator shall maintain the minimum safe approach distance (MSAD) from energized conductors at all times
in accordance with the authority having jurisdiction.”
Refer to CFR 1910.333 or the authority having jurisdiction.
DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING.

DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS.
D A NG E R
Avoid Power Lines
Minimum Safe Approach Distance

ANSI/SIA A92.6-2006
CE & AS Guidance Note
and CSA B354.2-01 Requirements
Voltage Range Minimum Safe Approach Distance
(Phase to Phase) (Feet)
Adhere strictly to the governmental rulings
and regulations applicable in your country.
0 to 300V Avoid Contact
Over 300V to 50KV 10

AS 2550.10-2006 Requirements
Over 50KV to 200KV 15
Over 200KV to 350KV 20 Voltage Range Minimum Safe Approach Distance (Meters)
Over 350KV to 500KV 25 (Phase to Phase) Without Spotter With Spotter
Over 500KV to 750KV 35 Up to and including 133KV 6.4 3
Over 750KV to 1000KV 45 Greater than 133KV 10 8
FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!

1019AA

Models SJ12 & SJ16
157981
Safety Precautions
Know and understand the safety precautions before going on to next section.
• DO NOT increase the lateral surface area of the

WARNING
platform. Increasing the area
Failure to heed the following safety exposed to the wind will de-
precautions could result in tip over, crease aerial platform stability.
falling, crushing, or other hazards leading
to death or serious injury.
• KNOW all national, state or territorial/provincial • DO NOT drive or elevate the

and local rules which apply to your aerial platform aerial platform if it is not on a
and job site. firm level surface. Do not drive
elevated near depressions
• TURN main power disconnect switch “ ” off or holes of any type, loading
when leaving the aerial platform unattended. Re- docks, debris, drop-offs and
move the key to prevent unauthorized use of the surfaces that may affect the
aerial platform. stability of the aerial platform.
• WEAR all the protective clothing and personal

safety devices issued to you or called for by job • If operation in areas with holes or drop-
conditions. offs is absolutely neces-
sary, elevated driving shall
• DO NOT wear loose clothing, not be allowed. Position the
dangling neckties, scarves, aerial platform horizontally
rings, wristwatches or other jew- only with the platform fully
elry while operating this lift. lowered. After ensuring that
all 4 wheels or outriggers (if
�
��
�
�
equipped) have contact with

level firm surface, the aerial
platform can be elevated. Af-
• AVOID entanglement with ropes, ter elevation, the drive func-
cords or hoses. tion must not be activated.
• Elevated driving must only

be done on a firm level sur-
face.
• AVOID falling. Stay within the
boundaries of the guardrails.
• DO NOT ascend or descend

a grade when elevated. When
fully lowered, ascending or
descending grades up to max-
• DO NOT raise the aerial platform imum rated inclines listed in
in windy or gusty conditions. Table 2.3.
• DO NOT operate on surfaces

not capable of holding the
weight of the aerial platform including the rated
load, e.g., covers, drains, and trenches.

Models SJ12 & SJ16
157981
Safety Precautions (Continued)

is on a truck, fork lift or other

device or vehicle.
• DO NOT operate an aerial platform that has

ladders, scaffolding or other
devices mounted on it to in-
crease its size or work height. • BE AWARE of crushing haz-
It is prohibited. ards. Keep all body parts in-
side platform guardrail.
• DO NOT exert side forces on

aerial platform while elevated.
• DO NOT lower the platform
unless the area below is clear
of personnel and obstruc-
tions.
• DO NOT use the aerial plat-

form as a crane. It is prohib- • ENSURE that there are no
ited. personnel or obstructions in
the path of travel, including
blind spots.
• DO NOT sit, stand or climb on

the guardrails. It is prohibited.
• DO NOT climb on base and • DO NOT use with improp-

mast. It is prohibited. erly inflated/damaged tires
or wheels. Tires should be
checked daily for pressure,
torn side walls and soft spots.
• BE AWARE of overhead ob-

structions or other possible
hazards around the aerial
platform when driving or lifting. • DO NOT alter or disable limit
switches or other safety de-
vices.
• DO NOT raise the aerial plat-

form while the aerial platform

Models SJ12 & SJ16
157981

• BE AWARE of blind spots when operating the

• DO NOT use the aerial plat- aerial platform.
form without guardrails, lock-
ing pins and the entry gate in • STUNT driving and horseplay are prohibited.
place.
• DO NOT attempt to free a snagged platform with
lower controls until personnel are removed from
the platform.
• DO NOT exceed the rated capacity of the aerial
platform. Do make sure the load is evenly distrib- • DO NOT position the aerial platform against an-
uted on the platform. other object to steady the platform.
• DO NOT place materials on the guardrails or ma-

terials that exceed the confines of the guardrails
unless approved by Skyjack.
• DO NOT operate if aerial

platform is not working prop-
erly or if any parts are dam-
aged or worn.
• DO NOT leave aerial plat-

form unattended with key in
key switch.
• DO NOT use under influence

of alcohol or drugs.
• DO NOT access the

hydraulic/electrical
compartment while the
platform is raised.

Models SJ12 & SJ16
157981

Fall Protection
As per the ANSI A92.6-2006 standard, “The WARNING
guardrail system of the aerial platform provides
fall protection. If occupant(s) of the platform are An operator should not use any aerial
required to wear personal fall protection equipment platform that:
(PFPE), occupants shall comply with instructions • does not appear to be working properly.
provided by the aerial platform manufacturer • has been damaged or appears to have worn or
(remanufacturer) regarding anchorage(s).” missing parts.
• has alterations or modifications not approved by
If additional fall protection is required, by an the manufacturer.
employer or the authority having jurisdiction, • has safety devices which have been altered or
Skyjack recommends the use of a fall restraint disabled.
system to keep an occupant within the confines • has been tagged or locked out for non-use or
of the platform, and thus not expose the occupant repair.
to any fall hazard requiring a fall arrest.
Failure to avoid these hazards could
All personal fall protection equipment must result in death or serious injury.
comply with applicable governmental regulations
and must be inspected and used in accordance Job site Inspection
with the manufacturer’s recommendations. • Do not use in hazardous locations.
• Perform a thorough job site inspection prior to
All personal fall protection equipment must be operating the aerial platform, to identify potential
attached only to approved anchorage points hazards in your work area.
within the platform of the aerial platform. • Be aware of moving equipment in the area. Take
appropriate actions to avoid collision.
WARNING
Entering and exiting the aerial platform
should only be done using the three
points of contact.
• Use only equipped access openings.
• Enter and exit only when the aerial
platform is in the fully retracted position.
• Do use three points of contact to enter and exit

the platform. Enter and exit the platform from the
ground only. Face the aerial platform when enter-
ing or exiting the platform.
• Three points of contact means that two hands

and one foot or one hand and two feet are in con-
tact with the aerial platform or the ground at all
times during entering and exiting.

Models SJ12 & SJ16
157981
Maintenance and Inspection Schedule Maintenance and Service Safety Tips

The actual operating environment of the work platform Maintenance and repair should only be performed by
governs the use of the maintenance schedule. The personnel who are trained and qualified to service this
inspection points covered in Table 1.2. Maintenance aerial platform.
and lnspection Checklist, indicates the areas of the
aerial platform to be maintained or inspected and at All maintenance and service procedures should be
what intervals the maintenance and inspections are to performed in a well lighted and well ventilated area.
be performed.
Anyone operating or servicing this aerial platform
Owner’s Annual Inspection Record must read and completely understand all operating
It is the responsibility of the owner to arrange quarterly instructions and safety hazards in this manual and
and annual inspections of the aerial platform. Table 1.1. operating manual.
Owner’s Annual lnspection Record is to be used for
recording the date of the inspection, owner’s name, All tools, supports and lifting equipment to be used
and the person responsible for the inspection of the must be of proper rated load and in good working order
work platform. before any service work begins. Work area should be
kept clean and free of debris to avoid contaminating
Replacement Parts components while servicing.
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and All service personnel must be familiar with employer
dimensions different from original parts will affect and governmental regulations that apply to servicing
stability of the aerial platform and must not be used this type of equipment.
without manufacturer’s consent.
Keep sparks and flames away from all flammable or
All replacement tires must be of the same size and load combustible materials.
rating as originally supplied tires; to maintain safety and
stability of aerial platform. Properly dispose of all waste material such as lubricants,
rags, and old parts according to the relative law
Consult SKYJACK’s Service Department for optional provisions obtaining in the country.
tires specifications and installation.
Before attempting any repair work, turn Battery
Disconnect Switch to “ ” off position.
WARNING
Any unit that is damaged or not operating Preventive maintenance is the easiest and least
properly must be immediately tagged and expensive type of maintenance.
removed from service until proper repairs
are completed.

Models SJ12 & SJ16
157981
Section 1 - Scheduled Maintenance Scheduled Maintenance Inspections
Hydraulic System & Component Maintenance 7. All hydraulic components must be disassembled
and Repair in spotlessly clean surroundings. During
The following points should be kept in mind when disassembly, pay particular attention to the
working on the hydraulic system or any component: identification of parts to assure proper reassembly.
Clean all metal parts in a clean mineral oil solvent.
1. Any structure has limits of strength and durability. Be sure to thoroughly clean all internal passages.
To prevent failure of structural parts of hydraulic After the parts have been dried thoroughly, lay
components, relief valves which limit pressure to them on a clean, lint-free surface for inspection.
safe operating values are included in the hydraulic
circuits. 8. Replace all O-rings and seals when overhauling
any component. Lubricate all parts with clean
2. Tolerance of working parts in the hydraulic system hydraulic oil before reassembly. Use small
is very close. Even small amounts of dirt or foreign amounts of petroleum jelly to hold O-rings in place
materials in the system can cause wear or damage during assembly.
to components, as well as general faulty operation
of the hydraulic system. Every precaution must 9. Be sure to replace any lost hydraulic oil when
be taken to assure absolute cleanliness of the completing the installation of the repaired
hydraulic oil. component, and bleed any air from the system
when required.
3. Whenever there is a hydraulic system failure
which gives reason to believe that there are metal 10. All hydraulic connections must be kept tight. A
particles or foreign materials in the system, drain loose connection in a pressure line will permit
and flush the entire system and replace the filter the oil to leak out or air to be drawn into the
cartridges. A complete change of oil must be system. Air in the system can cause damage
performed under these circumstances. to the components and noisy or erratic system
operation.
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.

Models SJ12 & SJ16
157981
Scheduled Maintenance Inspections Section 1 - Scheduled Maintenance
Maintenance Hints Railing Maintenance and Repair

Three simple maintenance procedures have the greatest Skyjack MEWPs have been designed to ensure
effect on the hydraulic system performance, efficiency and compliance with the relevant design standards
life. Yet, the very simplicity of them may be the reason they applicable for that particular unit at the time of
are so often overlooked. What are they? Simply these: manufacture. As such, any repairs made to the
guardrail or basket structure need to ensure this
1. Change filters annually. The filters may need compliance is not compromised and must return the
to be changed more often depending on the structure to its original condition.
operating conditions. Dirty, dusty, high moisture
environments may cause the hydraulic system Any damage must be repaired by returning the railing
to be contaminated more quickly. assembly to its undamaged state. Damage includes,
2. Maintain a sufficient quantity of clean hydraulic but is not limited to, the items listed below:
oil of the proper type and viscosity in the ▪ bent/deformed guardrail sections
hydraulic reservoir.
▪ cracks or broken welds in railing sections
3. Keep all connections tight.
▪ 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.

Models SJ12 & SJ16
157981
About this Section Maintenance Instructions

This section contains the maintenance and inspection This manual consists of four schedules to be done for
schedule that is to be performed. maintaining on an aerial platform. Inspection schedule
frequency is shown below:
References are made to the procedures in Section 5
that outline detailed step-by-step instructions for checks Inspection Schedule
and replacements. Daily A
Frequently A+B
Service Bulletins Annually A+B+C
Before performing any scheduled maintenance Bi-annually A+B+C+D
inspection procedure, refer to service bulletins found in
our web site: www.skyjackinc.com for updates related • Make copies of the maintenance and inspection
to service and maintenance of this aerial platform. checklist to be used for each inspection.
• Check the schedule on the checklist for the type of
Maintenance and Inspection inspection to be performed.
Death or injury can result if the aerial platform is not kept • Place a check in the appropriate box after each
in good working order. Inspection and maintenance inspection procedure is completed.
should be performed by competent personnel who • Use the maintenance and inspection checklist and
are trained and qualified on mantenance of this aerial step-by-step procedures in Section 5 to perform
platform. these inspections.
• If any inspection receives a fail, tag and remove the
aerial platform from service.
WARNING • If any aerial platform component(s) has been
Failure to perform each procedure as pre- repaired, an inspection must be performed again
sented and scheduled may cause death, before removing the tag. Place a check in the repair
serious injury or substantial damage. column.
NOTE Legend
Preventive maintenance is the easiest and P = Pass
least expensive type of maintenance. F = Fail
R = Repaired
• Unless otherwise specified, perform each
maintenance procedure with the aerial platform in
the following configuration:
- Aerial platform parked on a flat and level

surface
- Disconnect the battery by turning the main
power disconnect switch to “ ”off position.
• Repair any damaged or malfunction components

before operating aerial platform.
• Keep records on all inspections.

Models SJ12 & SJ16
157981
Table 1.1 Owner’s Annual Inspection Record
WARNING
Do not use the aerial platform if an inspection has not been recorded in the last
6 months (CE) or 13 months (ANSI/CSA, AS & KC).
This decal must be completed, dated and signed, after each inspection time intervals as stated above.
Pictorial Description
Inspection Date
Inspector Signature
**

Models SJ12 & SJ16
157981
Table 1.2 MAINTENANCE AND INSPECTION CHECKLIST
Serial Number:
Model:
Hourmeter Reading: Name (Printed):
Date:
Time: Signature:
Each item shall be inspected using the the appropriate section of the Skyjack service manual.
As each item is inspected, write the apropriate grade in the box.
INSPECTION FREQUENCY Inspection Schedule
 DAILY Daily A
P - PASS  FREQUENTLY Frequently*† A +B
F - FAIL  ANNUALLY Annually† A+B+C
R - REPAIRED  BI-ANNUALLY Bi-annually† A+B+C+D
Schedule P F R Schedule P F R
Schedule Maintenance Inspections Function Tests
Labels A Test Main Power Disconnect Switch A, B
Limit Switches A, B Base Control Console
Base Test Base Emergency Stop A, B
Main Power Disconnect Switch A, B Test Off/Platform/Base Switch A, B
Base Control Switches A, B Test Lower/Neutral/Raise Switch A, B
100V Outlet Receptacle Test Platform Self-leveling A, B
A, B
- ANSI/CSA Test Emergency Power A, B
Pothole Protection Device A, B Test Platform Maintenance Limit Switch A, B
Wheel/Tire Assembly A, B Platform Control Console
Platform Assembly Test Platform Emergency Stop A, B
Lanyard Attachment Anchors A, B Test Enable Trigger Switch A, B
AC Outlet - ANSI/CSA A, B Test Lift/Off/Drive Switch Off Position A, B
Platform Control Console A, B Test Steering A, B
Manuals A, B Test Drive Cutout Limit Switch - CE A, B
Hydraulic/Electrical Compartment Test Driving A, B
Battery A, B Test Brakes A, B
Battery Charger A, B Test Horn A, B
Main Manifolds A, B, C Test Platform Raising/Lowering A, B
Hydraulic Tank A, B Test Pothole Sensor A, B
Hydraulic Pump and Motor A, B 159AC
Hydraulic Oil A, B, C
Motor Controller A, B
Tilt Sensor A, B
Pothole Protection Device A, B
Limit Switches A, B
Lift Mechanism
Mast Assembly A, B
Wear Pads A, B
Chains A, B
Rollers and Roller Mounts A, B
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.7 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every three months or 150 hrs. Refer to Section 1.0 of this manual.
C - Perform Scheduled Maintenance Inspection every year. Refer to Section 1.0 of this manual.
D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1.0 of this manual.
* Perform scheduled inspection every three months or 150 hours.
† - Refer to Skyjack's website @ www.skyjack.com for latest service bulletins prior to performing quarterly or yearly inspection.
Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy.

Models SJ12 & SJ16
157981
Mast
Platform
Base
1.1 Scheduled Maintenance Inspections Perform a visual inspection around the following areas:
Begin the visual and daily maintenance inspections • all wiring harnesses
by checking each item in sequence for the conditions • hydraulic/electrical wiring harnesses
listed in this section.
Hydraulic
WARNING Maintaining hydraulic components is essential to good
performance and service life of the aerial platform.
To avoid injury, do not operate an aerial
platform until all malfunctions have been Perform a visual inspection around the following areas:
corrected. • hoses and fittings
• hydraulic cylinder
WARNING • all hydraulic manifolds
• the underside of the base
To avoid possible injury, ensure aerial
• ground area under the aerial platform
platform power is off during your visual
and daily maintenance inspections.
1.1-1 Labels
Refer to the labels section in the operating manual and
NOTE
ensure that all labels are in place and are legible.
While performing visual and daily
inspections in different areas, be aware to
also inspect limit switches, electrical and 1.1-2 Limit Switches
hydraulic components. Ensure limit switches are properly secured and no signs
of visible damage and movement is not obstructed.
Detecting limit switch malfunction is essential to safe
CAUTION aerial platform operation.
Ensure aerial platform is on firm and level
ground. Visually inspect all limit switch for the following:
• broken or missing actuator arm
Electrical • missing fasteners
Maintaining electrical components is essential to good • loose wiring
performance and service life of aerial platform.

Models SJ12 & SJ16
157981
Main Power Disconnect Switch
Base Control
Switches 110/220V Outlet
Receptacle
Pothole Protection Battery Charger
Wheel/Tire Assembly
Device
1.1-3 Base • Wheel/Tire Assembly

The aerial platform is equipped with solid
• Main Power Disconnect Switch rubber tires. Tire and/or wheel failure could
- Turn main power disconnect switch to result in an aerial platform tip-over. Component
“ ” off position. damage may also result if problems are not
discovered and repaired in a timely fashion.
- Ensure all cables are secure and switch
is in proper working condition. - Check all tire treads and sidewalls for
• Base Control Switches cuts, cracks, punctures and unusual
- Ensure there are no signs of visible wear.
damage and all switches are in their - Check each wheel for damage and
neutral positions. cracked welds.
• 110/220V Outlet Receptacle - Check each lug nut for proper torque to
- ANSI/CSA ensure none are loose.
- Ensure receptacle is free from dirt and
obstructions. - Check wheel motor assembly for loose
or missing parts and signs of visible
• Battery Charger damage.
- Ensure charger is secure and shows no
visible damage. - Ensure wheels are aligned and true
vertically and horizontally.
• Steer Cylinder Assembly
- Ensure steer cylinder assembly is
properly secured and there are no loose
or missing parts.
• Pothole Protection Device
- Ensure mechanisms have no sign of
visible damage and are free from dirt and
obstructions.

Models SJ12 & SJ16
157981
AC Outlet
Manuals Box
Platform Assembly
Lanyard Attachment Anchors
Platform Control Console
1.1-4 Platform Assembly • Platform Control Console

- Ensure all switches and controller are
WARNING returned to neutral and are properly
secured.
Ensure that you maintain three points
of contact to mount/dismount platform. - Ensure there are no loose or missing
parts and there is no visible damage.
1. Open the gate and access the platform.
• Manuals
Ensure a copy of operating manual and
2. Close the gate.
certificate are enclosed in manual storage
box.
- Ensure all railings are properly positioned
- Check to be sure manual storage box is
and secured.
present and in good condition.
- Ensure all fasteners are securely in place.
- Ensure manuals are legible and in good
- Ensure gate is in good working order. condition.
- Ensure there are no loose or missing - Always return manuals to the manual
parts and there is no visible damage. storage box after use.
- Ensure platform foot pedal is in good

working order and no loose or missing WARNING
parts and there is no visible damage
• Lanyard Attachment Anchors of contact to mount/dismount platform.
- Ensure attachment anchors are secure
and no visible damage. 3. Dismount from platform.
4. Close the gate.
• AC Outlet - ANSI/CSA
- Ensure outlet has no visible damage and
free from dirt or obstructions.

Models SJ12 & SJ16
157981
Hydraulic Pump and Motor
Batteries
Hydraulic
Main Manifolds Tank
1.1-5 Hydraulic/Electrical Compartment d. If applicable, check battery fluid level. If plates

are not covered by at least 1/2” (13 mm) of
1. Access the hydraulic/electrical solution, add distilled or demineralized water.
compartment. e. Replace battery if damaged or incapable of
holding a lasting charge.
• Battery
Proper battery condition is essential to WARNING
good performance and operational safety.
Improper fluid levels or damaged cables and Use original or manufacturer-approved
connections can result in component damage parts and components for the aerial
and hazardous conditions. platform.
• Battery Charger
WARNING - Ensure charger is secure and shows no
Explosion hazard. Keep flames and visible damage.
sparks away. Do not smoke near
batteries. • Main Manifolds
- Ensure all fittings and hoses are properly
tightened and there is no evidence of
WARNING hydraulic leakage.
Battery acid is extremely corrosive -
- Ensure there are no loose wires or
Wear proper eye and facial protection as
missing fasteners.
well as appropriate protective clothing.
If contact occurs, immediately flush with • Hydraulic Tank
cold water and seek medical attention. - Ensure hydraulic filler cap is secure.
a. Check battery case for damage. - Ensure tank shows no visible damage
b. Clean battery terminals and cable ends and no evidence of hydraulic leakage.
thoroughly with a terminal cleaning tool or • Hydraulic Pump and Motor
wire brush. - Ensure there are no loose or missing
c. Ensure all battery connections are tight. parts and there is no visible damage.

Models SJ12 & SJ16
157981
Motor Controller
Tilt Sensors
Mast Assembly Chains (Front)
Pothole Protection Device
• Hydraulic Oil 1.1-6 Lifting Mechanism

- Ensure platform is fully lowered, and then
visually inspect the hydraulic oil level • Mast Assembly
- Ensure mast assembly shows no visible
• Motor Controller damage and no signs of deformation in
- Ensure the controller is properly secured weldments.
and there is no visible damage.
- Lubricate every 200 days, refer to section
- Ensure there are no loose wires or 5.5 Mast Lubrication Procedure.
missing fasteners.
- Increase lubrication frequency if used in a
• Tilt Sensors severe application (e.g. frequently lifting
- Ensure tilt sensors are properly secured the rated load, used in an extremely dusty
and there is no visible damage. environment) or if not moving freely.
• Pothole Protection Device 1. Complete section 1.2 Function Tests.
- Ensure mechanisms have no sign of
visible damage and are free from dirt and 2. Raise the platform.
obstructions.
• Limit Switches • Wear Pads
- Ensure limit switches are properly - Ensure all bolts are tight, there is no
secured with no signs of visible damage visible damage to the wear pads and that
and movement is not obstructed. no parts are missing.
2. Close the compartment access door and latch • Chains

in place. - Visually inspect all accessible sections
3. Push the platform back to its operating of chain for broken, cracked, corroded
position and latch in place. or worn links.
- Ensure chains are securely anchored.
- Refer to section 5.7 Mast Chain Visual
Inspection for details and instructions

Models SJ12 & SJ16
157981
Section 1 - Scheduled Maintenance Function Tests
Motor Controller
Tilt Sensors
Mast Assembly Chains (Front)
Pothole Protection Device
• Flashing Light(s) (If Equipped)

- Ensure there are no loose or missing parts and
there is no visible damage.
• Rollers
- Ensure rollers are properly secured, movement
is not obstructed.
- Ensure there are no loose or missing parts or
signs of visible damage.
- Refer to section 5.6 Mast Roller Inspection/
Maintenance for Roller and Roller Mount
Inspection details and instructions.

Models SJ12 & SJ16
157981
Notes

Models SJ12 & SJ16
157981
Main Power
Disconnect
Switch
Base
Emergency
Stop
1.2 Function Tests 1.2-2 Base Control Console

ANSI/CSA, CE & KC
Function tests are designed to discover any malfunctions 1. Turn main power disconnect switch to “ ” on
before aerial platform is put into service. The operator position.
must understand and follow step-by-step instructions 2. On platform control console, pull out “ ”
to test all aerial platform functions. emergency stop button.
AS
WARNING 1. Open the gate (if equipped) of aerial platform
to access platform.
Never use a malfunctioning aerial
2. Close the gate (if equipped).
platform. If malfunctions are discovered,
aerial platform must be tagged and 3. On platform control console, push in “ ”
placed out of service. Repairs to aerial emergency stop button.
platform may only be made by a qualified 4. Open the gate (if equipped) to dismount from
service technician. platform.
5. Close the gate (if equipped).
After repairs are completed, operator must perform a 6. Turn main power disconnect switch to “ ” on
pre-operation inspection and a series of function tests position.
again before putting aerial platform into service.
• Test Base Emergency Stop Light
Prior to performing function tests, be sure to read
and understand Section 2.9 - Start Operation of the 1. Pull out base “ ” emergency stop
Operating manual. button.
Result: Emergency stop light should
1.2-1 Test Main Power Disconnect Switch continuously illuminate.
1. At rear of the base, turn main power disconnect

switch to “ ” off position and attempt to
activate all aerial platform functions.
Result: Aerial platform functions should not
operate.
• Test Base Emergency Stop

Models SJ12 & SJ16
157981
Function Tests Section 1 - Scheduled Maintenance
Base Control Console Emergency Lowering
Result: Platform raising and lowering

1. Push in “ ” emergency stop button and functions should operate.
attempt to raise or lower the platform.
Result: Platform raising and lowering • Test Lower/Neutral/Raise Switch
functions should not operate.
• Test Off/Platform/Base Switch 1. Select and hold off/platform/base
key switch to “ ” base position and

WARNING
“ ” raise the platform with lower/neutral/
Be aware of overhead obstructions
raise switch.
or other possible hazards around the
Result: Platform should rise.
aerial platform when lifting.
2. Select and hold off/platform/base
1. Select off/platform/base key switch to
“ ” off position. Attempt to raise or lower key switch to “ ” base position and
the platform.
Result: Platform raising and lowering “ ” lower the platform with lower/neutral/
functions should not operate. raise switch.
Result: Platform should lower.
2. Select off/platform/base key switch to
“ ” platform position. Attempt to raise

or lower the platform.
Result: Platform raising and lowering
functions should not operate.
3. Select and hold off/platform/base key • Test Emergency Lowering
switch to “ ” base position. Attempt to

WARNING
raise or lower the platform.

Models SJ12 & SJ16
157981
Base Control Console Emergency Lowering
Be aware of overhead obstructions 1. Ensure main power disconnect switch is in “ ”

or other possible hazards around the on position.
aerial platform when lifting.
2. Ensure base “ ” emergency stop button is
1. Raise the platform.
pulled out.
2. On rear of the base, pull out and hold 3. Select off/platform/base key switch to “ ”
emergency lowering valve to fully lower platform position.
the platform.
Result: The platform should lower.
WARNING
1.2-3 Test Platform Maintenance Limit Switch Ensure that you maintain three points
of contact to mount/dismount platform.
1. Traverse the platform to maintenance position.
4. Open the gate and access the platform.
2. At the platform control console, attempt to
activate any function. 5. Close the gate.
Result: All functions should not operate.
6. On platform control console, pull out “ ”
3. Push the platform back to its operating emergency stop button.
position and latch in place.
1.2-4 Platform Control Console

• Test Platform Emergency Stop

Models SJ12 & SJ16
157981
Rocker Switch
Lift/Drive/Steer Enable Controller

Trigger Switch
Emergency Stop Button/

Operation Light
Lift/Off/Drive Switch
Horn Pushbutton
1. Push in “ ” emergency stop button and

attempt to activate any platform function. 1. Select lift/off/drive switch to “ ” drive
Result: All selected platform functions position.
should not operate.
2. Without activating “ ” enable trigger
switch.
2. Pull out “ ” emergency stop button.
3. Press rocker switch on top of controller
3. While activating any platform functions,
push in emergency stop button. handle to “ ” left and “ ” right.
Result: Current activated aerial platform Result: Steer wheels should not operate
function should immediately stop
operating. 4. Activate and hold “ ” enable trigger
switch.
• Test Enable Trigger Switch
5. Press rocker switch on top of controller
1. Without activating “ ” enable trigger handle to “ ” left and “ ” right.
switch, attempt to activate any platform Result: Steer wheels should turn left and
function. right.
Result: All platform functions should not
operate. • Test Drive Cutout Limit Switch
• Test Lift/Off/Drive Switch Off Position 1. Traverse platform to any position, then
1. Select lift/off/drive switch to“ ” off attempt to drive “ ” forward and

position, attempt to activate any platform
function. “ ” reverse.
Result: All platform functions should not Result: Forward and reverse drive
operate. functions should not operate.
• Test Steering

Models SJ12 & SJ16
157981
Rocker Switch

Trigger Switch

Operation Light
Horn Pushbutton
• Test Driving • Test Brakes

WARNING
1. Ensure path of intended motion is clear.
Brakes will engage instantly when you
release the controller handle, causing
2. Without activating “ ” enable trigger aerial platform to stop immediately.
switch attempt to drive “ ” forward and 1. Ensure path of intended motion is clear.
reverse “ ”.
Result: Aerial platform drive functions 2. Activate and hold “ ” enable trigger
should not operate. switch.
3. Drive aerial platform “ ” forward and then

3. Activate and hold “ ”enable trigger
switch. “ ” backward. Test brake by releasing
4. Slowly move controller handle in controller handle.
Result: Aerial platform should come to
“ ” forward direction until aerial platform a stop. If aerial platform pulls to one side
begins to move, and then return handle to while stopping, do not operate aerial
center position. platform until brake adjustments have been
Result: Aerial platform should move in checked.
forward direction, and then come to a
stop. 4. Drive aerial platform “ ” forward and
5. Slowly move controller handle in
then “ ” backward. Test brake again by
“ ” reverse direction until aerial platform releasing “ ” enable trigger switch only.
begins to move, and then return handle to Result: Aerial platform should come to an
center position. instant and abrupt stop. If aerial platform
Result: Aerial platform should move in does not stop immediately, or if aerial
reverse direction, and then come to a stop. platform pulls to one side while stopping,
do not operate aerial platform until brake
adjustments have been checked.

Models SJ12 & SJ16
157981
Rocker Switch

Trigger Switch

Operation Light
Horn Pushbutton
• Test Horn Test Pothole Sensor
1. Push “ ” horn pushbutton. WARNING

Result: Horn should sound.
of contact to mount/dismount platform.
• Test Platform Raising/Lowering
1. Dismount from platform and place a block,
WARNING approximately 1.5” (3.75 cm), under one
Be aware of overhead obstructions side of the pothole protection device.
or other possible hazards around the 2. Open the gate and access the platform.
aerial platform when lifting. 3. Close the gate.
4. Raise the platform until approximately a
height of 2 feet is reached and attempt to
1. Select lift/off/drive switch to “ ” lift drive forward or reverse.
position. Result: Aerial platform should not move
2. Without activating “ ” enable trigger forward or backward.
switch attempt to lift/lower the platform. 5. Repeat the steps above with block placed
Result: Aerial platform lift/lower functions under the other-side of the pothole
should not operate. protection device.
Result: Aerial platform should not move
3. Activate and hold “ ” enable trigger forward or backward.
switch.
4. Push controller handle and raise the • Test Flashing Light (If Equipped)
platform to an approximate height of 1 ft.
(30.5 cm). 1. Ensure path of intended motion is clear.
Result: Platform should rise.
5. Pull controller handle and lower the 2. Activate any drive or lift functions.
platform fully. Result: Light should flash.
Result: Platform should lower.
3. Stop all platform motion.
Result: Light should stop flashing.

Models SJ12 & SJ16
157981
Section 2
MAINTENANCE TABLES
Table of Contents
Tables
Table 2.1 Standard Hose Numbering System ..............................................................................................34
Table 2.2a Specifications and Features - ANSI/CSA .....................................................................................36
Table 2.2b Specifications and Features - KC ................................................................................................37
Table 2.2c Specifications and Features - CE ................................................................................................38
Table 2.2d Specifications and Features - AS ................................................................................................39
Table 2.3a Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA ................................................40
Table 2.3b Maximum Platform Capacities (Evenly Distributed) - KC ..........................................................40
Table 2.3c Maximum Platform Capacities (Evenly Distributed) - CE ...........................................................40
Table 2.3d Maximum Platform Capacities (Evenly Distributed) - AS ..........................................................40
Table 2.4b Floor Loading Pressure - KC ........................................................................................................42
2
Table 2.4c Floor Loading Pressure - CE .........................................................................................................43
Table 2.4d Floor Loading Pressure - AS ........................................................................................................44
Table 2.5 Torque Specifications ...................................................................................................................46

Models SJ12 & SJ16
157981
Service and Maintenance Section 2 - Maintenance Tables and Diagrams
Table 2.1 Standard Hose Numbering System
H1104 0081 2
FITTING LENGTH IN FRACTIONS (1/4”

ARRANGEMENT LENGTH OF HOSE IN INCREMENTS) I.E.
(See Schedule WHOLE INCHES 1=1/4”
HOSE SIZE
Below) 2=1/2”
(See Chart
3=3/4”
Below)
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 specification, 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

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)
S.A.E. Hose
Hose Prefix Hose End Fitting Hose End Fitting
Specification
H01 FEMALE, 37º JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H02 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R13
H03 FEMALE, 37º JIC, SWIVEL 45º, FEMALE, 37º JIC, SWIVEL 100R17
H05 FEMALE, 37º JIC, SWIVEL LONG 90º, FEMALE, 37º JIC, SWIVEL 100R17
H06 FEMALE, 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 100R17
H07 LONG 90º, FEMALE, 37º JIC, SWIVEL LONG 90º, FEMALE, 37º JIC, SWIVEL 100R17
H10 FEMALE, 37º JIC, SWIVEL MALE PIPE THREAD FITTING 100R17
H11 FEMALE, 37º JIC, SWIVEL MEDIUM 90º, FEMALE, 37º JIC, SWIVEL 100R13
H12 SHORT 90º, FEMALE, 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 100R17
H13 FEMALE, 37º JIC, SWIVEL REUSABLE MALE PIPE THREAD FITTING 300 PSI
H14 REUSABLE MALE PIPE THREAD FITTING NO FITTING 300 PSI
H15 REUSABLE, FEMALE, 37º JIC, SWIVEL REUSABLE, FEMALE, 37º JIC, SWIVEL 300 PSI

Models SJ12 & SJ16
157981
Section 2 - Maintenance Tables and Diagrams Service and Maintenance
Table 2.1 Standard Hose Numbering System (Continued)

Fitting Arrangement Schedule (Continued from the previous page)
S.A.E. Hose
Hose Prefix Hose End Fitting Hose End Fitting
Specification
H16 NO FITTING NO FITTING 100R4
H17 NO FITTING NO FITTING 300 PSI
H18 REUSABLE, FEMALE, 37º JIC, SWIVEL NO FITTING 300 PSI
H19 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R13
H21 FEMALE, 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 100R2AT
H22 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R2AT
H23 FEMALE, 37º JIC, SWIVEL LONG 90º, FEMALE, 37º JIC, SWIVEL 100R2AT
H26 SHORT 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17
H27 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17
H29 45º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17
H30 MEDIUM 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17
60589AA

Models SJ12 & SJ16
157981
Table 2.2a 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. 22 ft.
Platform Elevated Height 12 ft. 16 ft.
Stowed Height 18 in. 18 in.
Drive Height Full Full
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.

266AB_ANSI
* Weights are approximate; refer to serial nameplate for specific weight.

** Refer to Section 3.9 Loading/Unloading for more details.

Models SJ12 & SJ16
157981
Table 2.2b Specifications and Features - KC
MODEL SJ12 SJ16

*
Weight 780 kg 966 kg
Overall Width 76.2 cm 76.2 cm
Overall Length 136 cm 136 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 5.5 m 6.7 m
Platform Elevated Height 3.7 m 4.9 m
Stowed Height 45.7 cm 45.7 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
262AD_KC


Models SJ12 & SJ16
157981
Table 2.2c Specifications and Features - CE
MODEL SJ12 SJ16

*
Platform Size (Inside) 68.5 x 93.5 cm 68.5 x 93.5 cm
Height
Chassis
Normal Drive Speed 4 km/h 4 km/h
Hydraulic Oil
262AD_CE


Models SJ12 & SJ16
157981
Table 2.2d Specifications and Features - AS
MODEL SJ12 SJ16

*
Platform Size (inside) 68.5 x 93.5 cm 68.5 x 93.5 cm
Height
Chassis
Normal Drive Speed 4.0 km/h 4.0 km/h
Hydraulic Oil
262AB_AS


Models SJ12 & SJ16
157981
Table 2.3a Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA
Tilt
Maximum Wind
MODEL Capacity Cutout
Speed
Setting
2 Person(s) No Wind
SJ12 500 lb. 1.5 x 3
1 Person(s) 28 mph
2 Person(s) No Wind
SJ16 500 lb. 1.5 x 3
1 Person(s) 28 mph
267AB_ANSI
Table 2.3b Maximum Platform Capacities (Evenly Distributed) - KC
Maximum Tilt Cutout

MODEL Capacity
Wind Speed Setting
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

263KCAA
Table 2.3c Maximum Platform Capacities (Evenly Distributed) - CE
Maximum Tilt Cutout

MODEL Capacity
Wind Speed Setting
2 Person(s) No wind
SJ12 227 kg 1.5 x 3
SJ16 227 kg 2 Person(s) No wind 1x2

263AD_CE
Table 2.3d Maximum Platform Capacities (Evenly Distributed) - AS
Maximum Tilt Cutout

MODEL Capacity
Wind Speed Setting
2 Person(s) No wind
SJ12 227 kg 1.5 x 3
2 Person(s) No wind
SJ16 227 kg 1.5 x 3
263AA_AS

Models SJ12 & SJ16
157981
Table 2.4a Floor Loading Pressure - ANSI/CSA & KC
Total Aerial Total Aerial Platform Load

Platform
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
268AB_ANSI
* 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

Models SJ12 & SJ16
157981
Table 2.4b Floor Loading Pressure - KC

MODEL Platform Weight Wheel OUP**
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
264AC_KC

** 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.
SJ16
SJ12

Models SJ12 & SJ16
157981
Table 2.4c 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
264AC_CE

above.
NOTE:
structure.
SJ16
SJ12

Models SJ12 & SJ16
157981
Table 2.4d Floor Loading Pressure - AS

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
264AA_AS

above.
NOTE:
structure.
SJ16
SJ12

Models SJ12 & SJ16
157981
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.

Models SJ12 & SJ16
157981
Table 2.5 Torque Specifications
Location Description Torque (ft-lb) Torque (Nm)

Base
Wheel Mounting Bolts BOLT, Wheel (.5"-20 x 1 9/16") 90 122
Power Pack Mounting Bolts BOLT, Hex head (3/8”-16 x 5/8”, Grade 5) 85 115
Hydraulic Motor (Front) Wheel Nut 280 380
Hydraulic Motor Mounting Bolts BOLT, Hex head (1/2”-13 x 2.75”, Grade 5) 85 115
Wheel Brake (Rear) Wheel Nut 180 237
Wheel Brake Mounting Bolts BOLT, Hex head (1/2”-13 x 4”, Grade 5) 85 115
Location Description Torque (in-lb) Torque (Nm)

Mast
Double-Roller Assy Mount (Mast 2) SCREW, Socket head cap (1/4"-20 x 3/4", zinc) 100 11
Chain Mount Assy-Single (Mast 2) SCREW, Socket head cap (zinc, 1/4”-20 x 7/8”) 100 11
Single-Roller Assy (Mast 3) SCREW, Socket head cap (#10-24 x 3/4”) 79 9
Single-Roller Assy Mount (Mast 3) SCREW, Button head cap (ZN, 1/4”-20 x 3/4”) 100 11
Chain Mount Assy-Double (Mast 3) SCREW, Socket head cap (zinc, 1/4”-20 x 7/8”) 100 11
Spacer Plate (Mast 4) BOLT, Hex head (3/8"-16 x 1.25", Grade 8) 35 4

276AC

Models SJ12 & SJ16
157981
Section 3
SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Table of Contents
Charts
3.1 Hydraulic Symbol Chart ........................................................................................................................49
3.2 Electrical Symbol Chart .........................................................................................................................50
3.3 Wire Number and Color Code ...............................................................................................................51
Parts List
3.4 Hydraulic Component Parts List ...........................................................................................................53
3.5 Electrical Component Parts List ............................................................................................................54
Diagrams and Schematics
3.6 Cylinders and Port Identifications .........................................................................................................56
3.7 Wheel Brake and Port Identifications ...................................................................................................57
3.8 Powerpack and Port Identifications ......................................................................................................58
3.9 Platform Control Console Wire Diagram ..............................................................................................59
3.10 Brake and Main Manifold and Hydraulic Identifications ....................................................................60
3.11 Disc Brake Kits and Torque Specifications...........................................................................................61
3.12 Hydraulic Schematic - SJ12/SJ16 .........................................................................................................62
3.13 Main Electrical Harness - SJ12/SJ16 .....................................................................................................63
3.14 Mast Control Cable .............................................................................................................................64
3.15 Limit Switches .....................................................................................................................................65
3.16a Base Control Wiring Diagram (SJ12/SJ16 - ANSI) ..............................................................................66
3.16b Base Control Wiring Diagram (SJ12/SJ16 - CE/KC) ............................................................................67
3.16c Base Control Wiring Diagram (SJ12/SJ16 - AS) ..................................................................................68
3.17a Electrical Schematic (SJ12/SJ16 - ANSI/CSA) ......................................................................................69
3
3.17b Electrical Schematic (SJ12/SJ16 - CE/KC) ...........................................................................................70
3.17c Electrical Schematic (SJ12/SJ16 - AS) .................................................................................................71

Models SJ12 & SJ16
157981
Notes

Models SJ12 & SJ16
157981
Section 3 - System Component Identification and Schematics Service and Maintenance
3.1 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

Models SJ12 & SJ16
157981
Service and Maintenance Section 3 - System Component Identification and Schematics
3.2 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

Models SJ12 & SJ16
157981
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 origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red.

Models SJ12 & SJ16
157981
Notes

Models SJ12 & SJ16
157981
3.4 Hydraulic Component Parts List
Index Skyjack
Qty. Description
No. Part No.
2H-13 151696 1 VALVE, Control (Emergency lowering)

2H-21 158183 1 VALVE, Pothole release
2H-14A 158185 1 VALVE, Lift
3H-17 158184 1 VALVE, Control (Brake)
4H-15 156850 1 VALVE, Control (Reverse drive) (Includes 4H-16)
4H-16 - - VALVE, Control (Forward drive) (Includes 4H-15)
4H-23 158186 1 VALVE, Control (Right steer) (Includes 4H-24)
4H-24 - - VALVE, Control (Left steer) (Includes 4H-23)
BP1 154839 1 MOTOR, Brake (Right)
BP2 154839 1 MOTOR, Brake (Left)
C1 151733 1 CYLINDER (Steer)
C2 159471 1 CYLINDER (Lift)
C3 158123 1 CYLINDER (Pothole)
CB1 147889 1 VALVE, Counterbalance
EM1 N/A - MOTOR, Electric
FC1 158852 1 CONTROLLER (Priority flow)
HP1 151678 1 HANDPUMP (Brake release)
M1 139412 1 MOTOR, Drive (Right)
M2 139412 1 MOTOR, Drive (Left)
MB1 151270 1 BLOCK, Manifold (Powerpack)
MB2 158099 1 BLOCK, Manifold (Main)
MB3 151458 1 BLOCK, Manifold (Brake)
MB4 156866 1 BLOCK, Manifold (Lift cylinder)
O1 108721 1 ORIFICE (0.055”) (Lowering speed) (SJ12)
159416 1 ORIFICE (0.043”) (Lowering speed) (SJ16)
O2 N/A 1 ORIFICE (Wheel motor)
R1 N/A 1 VALVE, Relief (System)
R2 158583 1 VALVE, Relief (Steering)
R3 151684 1 VALVE, Relief (Lift)
TP1 N/A 1 TEST PORT
V1 113752 1 VALVE, Reset (Brake)

Models SJ12 & SJ16
157981
3.5 Electrical Component Parts List
SUPPLY (B+) (Common)
CONTROL (B+) GROUND (B-)
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Qty. Description
No. Part No.
14CR 108589 1 RELAY, 24 Volt 40 Amp (Base control centre - Lift speed)
14CR1 108589 1 RELAY, 24 Volt 40 Amp (Base control centre - Lift speed 2)
15BCR 108589 1 RELAY, 24 Volt 40 Amp (Base control centre - Reverse cutout)
16BCR 108589 1 RELAY, 24 Volt 40 Amp (Base control centre - Forward cutout)
17CR 108589 1 RELAY, 24 Volt 40 Amp (Base control centre - Steer)
21CR 108589 1 RELAY, 24 Volt 40 Amp (Base control centre - High speed)
28CR 108589 1 RELAY, 24 Volt 40 Amp (Base control centre - Tilt)
59ACR 108589 1 RELAY, 24 Volt 40 Amp (Base control centre - Base control)
2H-13 151683 1 COIL, 24 Volt (Emergency lowering valve)
3H-14A 151683 1 COIL, 24 Volt (Lift valve)
3H-17 151683 1 COIL, 24 Volt (Brake valve)
4H-15A 151682 1 COIL, 24 Volt (Reverse drive valve)
4H-16A 151682 1 COIL, 24 Volt (Forward drive valve)
4H-23 151683 1 COIL, 24 Volt (Right steer valve)
4H-24 151683 1 COIL, 24 Volt (Left steer valve)
B1 103480 1 BATTERY, 6V
B2 103480 1 BATTERY, 6V
B3 103480 1 BATTERY, 6V
B4 103480 1 BATTERY, 6V
BC1 122093 1 BATTERY CHARGER INDICATOR (Platform control console)
BP-29 103057 1 BEEPER, 4-28 VDC Slow pulsing (Base control centre)
BP-49 146649 1 HORN, 24V (Low tone)
CB1 117325 1 CIRCUIT BREAKER (15 Amp)
CB2 117325 1 CIRCUIT BREAKER (15 Amp)
Parts list continued on following page.

Models SJ12 & SJ16
157981
3.5 Electrical Component Parts List
Index Skyjack
Qty. Description
No. Part No.
Parts list continued from previous page.
C1 165865 1 CONTACTOR
164671 1 KIT, Diode
DCM1 156877 1 MOTOR
F1 310517 1 FUSE (300 Amp)
LED-1 147061 1 POWER INDICATOR LIGHT (Platform control console)
LED-2 147061 1 POWER INDICATOR LIGHT (Base control centre)
LS1 156521 1 LIMIT SWITCH (High speed)
LS2 156520 1 LIMIT SWITCH (Pothole protection)
LS3 156520 1 LIMIT SWITCH (Pothole protection)
LS4 156522 1 LIMIT SWITCH (Service position) (Fixed position)
156523 1 LIMIT SWITCH (Service position) (Variable position)
LS5 156522 1 LIMIT SWITCH (Drive cutout) (CE)
RST1 119629 1 RESISTOR (2.7k ohm) (Platform control console)
RST2 151646 1 RESISTOR (1k ohm, 1 watt) (Base control centre)
RST3 156515 1 RESISTOR (220 ohm, 3/4 watt) (Base control centre)
RST4 151645 1 RESISTOR (4.7k ohm, 1 watt) (Base control centre)
RST5 156527 1 RESISTOR (2k ohm, 2 watt) (Base control centre)
RST6 151643 1 RESISTOR (250 ohm, 1 watt) (Base control centre)
RST7 156564 1 RESISTOR (1.5 ohm, 1 watt) (Base control centre)
RST8 151647 1 RESISTOR (68 ohm, 1 watt) (Base control centre)
S1 119725 1 SWITCH, Main power disconnect
S2 147054 2 N.O. CONTACT, Lift/Drive (Base control centre)
S3 147053 3 N.C. CONTACT, Lift/Drive (Platform control console)
147054 2 N.O. CONTACT, Lift/Drive (Platform control console)
S4 147053 2 N.C. CONTACT, Emergency stop (Platform control console)
S5 115573 1 SWITCH, Diagnostic
S7 151201 1 CONTROLLER ASSEMBLY
S8 147054 1 N.O. CONTACT, Horn (Platform control console)
S10 147053 2 N.C. CONTACT, Off/Platform/Base (Base control centre)
147054 1 N.O. CONTACT, Off/Platform/Base (Base control centre)
S28 147053 2 N.C. CONTACT, Emergency stop (Base control centre)
TT1 103336 1 HOUR METER
TS1 157375 1 SWITCH, Tilt

Models SJ12 & SJ16
157981
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

Models SJ12 & SJ16
157981
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

Models SJ12 & SJ16
157981
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

Models SJ12 & SJ16
157981
3.9 Platform Control Console Wire Diagram
S8 - HORN
S3 - LIFT/DRIVE TOGGLE
15 16 12B
8A
8A
49
A
D12B
00
13 14 S4 - EMERGENCY STOP
RST1
B 8B 8A
08
02
7A LED-1 02
X2
X1
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
PIN 5 - JOYSTICK VS+ 8A BLUE WHITE/BLACK
JOYSTICK HARNESS
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 - N/U 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
M151467AE1

Models SJ12 & SJ16
157981
AB 3.10 Brake and Main Manifold and Hydraulic Identifications
A B C D E F G H
V
4H-15A
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 X
To Brake Manifold
B1
To Right Brake L
To Lift Cylinder
PH
To Pothole Cylinder CB1
Counterbalance Valve
SR Y
To Steer Cylinder
SL
To Steer Cylinder
P1
To Powerpack Manifold MB2 R
Main Manifold To Right Drive Motor
M2
T
To Right Drive Motor Z
To Powerpack Manifold
M1 F
To Left Drive Motor To Left Drive Motor
M158154AB_4

Model SJ12 & SJ16
157981
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 V
K3
A
K1 HYDRAULIC OIL
PORT
3
W
K3
K3 B
K1 K3
X
K1
A
SECTION A-A
BRAKE KITS K2
Y
K1 - KIT, BEARING AND SEAL
K2 - KIT, BRAKE STACK
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 Z
OIL TYPE
CATERPILLAR T0-4 SAE 30 HYDRAULIC OIL (200 mL) SECTION B-B SPRING ARRANGEMENT
M154839AA_S3

Models SJ12 & SJ16
157981
3.12 Hydraulic Schematic - SJ12/SJ16
A B C D E F G H
C2 BH2 BH1
LIFT LEFT RIGHT V
CYLINDER
C1 BRAKE BRAKE
STEER
CYLINDER
SAE04
SAE04
L R
O1
LOWERING
ORIFICE
B1 B2 MB3
BRAKE
MANIFOLD
2H-13 MB4 ASSEMBLY
LIFT CYLINDER
HOLD/EMERG MANIFOLD ASSEMBLY
LOWERING VALVE
HP1
HAND
PUMP V1
AUTO
RESET
VALVE
B W
M2 M1
LEFT RIGHT
DRIVE DRIVE
MOTOR MOTOR
C3 B A A B
POTHOLE
CYLINDER
SAE06
TP1 X
SAE04
SAE04
SAE04
SAE04
SAE06
SAE06
SAE06
SAE06
MB1
POWERPACK
MANIFOLD
MB2 L PH SL SR B F O2 M1 M2 R
MAIN WHEEL MOTOR
ASSEMBLY MANIFOLD ORIFICE
ASSEMBLY 0.031DIA.
TEST
P
4H-24 4H-23
LEFT RIGHT
STEER STEER
2H-21 VALVE VALVE 4H-16A 4H-15A
FORWARD REVERSE
POTHOLE DRIVE DRIVE
VALVE VALVE VALVE
Y
R2
R3 STEERING
RELIEF
LIFT RELIEF
EM1 R1 2000PSI (SJ12) 1500PSI
SYSTEM 2700PSI (SJ16)
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
Z
T SAE06
T
HYDRAULIC RESERVOIR
M158134AD

Model SJ12 & SJ16
157981
AB 3.13 Main Electrical Harness - SJ12/SJ16
A B C D E F G H
X14 - DRIVE REV X15 - MAST RAISE

SOLENOID SOLENOID
02
15A
14A
X13 - DRIVE FWD
02
SOLENOID X16 - STEER L
24 SOLENOID
02
V
16
02
A
X12 - BRAKE
SOLENOID 02
23
X17 - STEER R
17 SOLENOID
X11 - POTHOLE 02
LIMIT SWITCH SPLICE 02 DETAIL
21
PIN 1 - 71A - RD/YL A B
X10 - POTHOLE
PIN 2 - 72 - PK 02
PIN 3 - NOT USED A: 02.1 - 02.7 SOLENOID
PIN 4 - NOT USED B: 02.9, 02.16
X18 - BATTERY
02 CHARGER
PIN 1 - 3A - YL W
PIN 2 - 05 - RD
X8 - TILT SWITCH
PIN 1 - 19 - RD/BK
02 X9 - MOTOR PIN 2 - 7B - GN/YL
CONTACTOR PIN 3 - 28 - BR/GN
PIN 4 - 16B WH/BK
00
PIN 5 - 15B - BL
PIN 6 - 02 - WH
19A
X7 - MOTOR
CONTROLLER 19B
03
59B
X6 - ELEVATED DRIVE
LIMIT SWITCH X5 - MAST LOWER
PIN 1 - 71 - GY/OR SOLENOID
X
PIN 2 - 71A - RD/YL PIN 1 - 13 - OR
PIN 3 - 71 - GY/OR PIN 2 - 02 - WH
PIN 4 - 21 - GN/WH
X3 - MAST CABLE
POWER
X1 - LOWER PIN 1 - 07 - RD
CONTROLS PIN 2 - 07A - GN/YL
59B-OR/BK 12" PIN 3 - 08 - BL/WH
PIN 4 - 02 - WH
15-BL 12"
16-WH/BK 12"
05-RD 18" B
13 .2
07-RD 14" X2 - MAST CABLE 13
FUNCTIONS A .1-
07A-GN/YL 14" : 13 3.3
A :1 SPLICE 21 DETAIL
08-BL/WH 15" PIN 1 - 13 - OR B
13-OR 9" PIN 2 - 14 - BK A B
PIN 3 - 15 - BL
72-PK 10"
PIN 4 - 16 - WH/BK A: 21.1-21.2
Y
15A-BL 12" PIN 5 - 19A - RD/WH B: 21.3
15B-BL 12" PIN 6 - 19B - RD/WH
PIN 7 - 23 - BK/WH
16A-WH/BK 12" PIN 8 - 24 - BL/BK
16B-WH/BK 11" PIN 9 - 49 - GN/WH X21 - STROBE
PIN 10 - 59 - OR/BK
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" 71 21 23 24
24-BL/BK 8"
28-BR/GN 8"
02-WH 13"
59-OR/BK 14"
17-GN/BK 10"
17-GN/BK 5" 02
SPLICE 71 DETAIL SPLICE 23 DETAIL SPLICE 24 DETAIL
19A-RD/WH 8"
49
X22 - HORN
19A-RD/WH 8"
14-BK 13"
A B 19A
19B
A B A B
Z
03
14-BK 4"
14-BK 15"
A: 71.1
B: 71.2 - 71.3 X19 - DIAG. 3A
A: 23.1-23.2
B: 23.3
A: 24.1-24.2
B: 24.3
SWITCH 00 02 X24 - POS. CCT
29-PR/WH 10" BREAKER
29-PR/WH 8"
X23 - NEG. CCT
BREAKER
M158723AC

Models SJ12 & SJ16
157981
3.14 Mast Control Cable
A B C D E F G H
V
CONNECTION CHART
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
X
GREEN/BLACK 7B X1/C6 X2/11
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
Y
GREEN/WHITE 49 X1/B5 X2/9
BLUE/WHITE 08 X1/A6 X3/3
WHITE JUMPER* 12A/7B X1/B1 & C7 N/U
CONNECTOR 'X2 ' * ANSI/CSA ONLY
CONNECTOR 'X3'
Z
M156524AA_S3

Model SJ12 & SJ16
157981
AB 3.15 Limit Switches
A B C D E F G H
LS4 - SERVICE
20” TRANSLATING PLATFORM - ANSI/CSA
WIRE CAVITY
BLACK C5
BLACK/WHITE C10
BROWN C3
BLUE C8 X
YELLOW/GREEN NOT USED
16” TRANSLATING PLATFORM - CE

LS5 - DRIVE CUTOUT LS4 - 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 Z
BLACK 3
YELLOW/GREEN NOT USED YELLOW/GREEN NOT USED
BLACK/WHITE 4
YELLOW/GREEN NOT USED
M151629AF_1

Models SJ12 & SJ16
157981
3.16a Base Control Wiring Diagram (SJ12/SJ16 - ANSI)
A B C D E F G H
14CR 14CR1 15BCR 16BCR 17CR 21CR 28CR 59ACR
87 87 87 87
86 85 86 86 85 85 86 85 86 85
87A 87A 87A 87A 87A 87A
30 30
V
07A
59D
59H
59G
59C
15A
59D
16A
19A
28A
59A
15B
17B
59K
59B
59F
59E
59J
02
02
02
W
16A
S2 59
08
05
07
07A
02
59B
10E
19
72
29
23
24
14A
71
05A
10E
X
S10 RST7
D17
07
08
07A
05A
02
RST2 -1 Y
S28
-1
05
H29
+ Z
-
M158826AB_1

Model SJ12 & SJ16
157981
3.16b Base Control Wiring Diagram (SJ12/SJ16 - CE/KC)
A B C D E F G H

87 87 87 87
85 86 85 86 85 85 86 85 86
87A 87A 87A 87A
30 30 30
07A
59D
59H
59G
59C
15A
59D
16A
19A
28A
59A
15B
59K
59B
59F
59E
59J
02
02
02
02
02
02
14B
15 AIN HARNESS
S2 59 W
05
07
07A
02
59B
10E
10E
29
23
24
14A
05A
07
S10 X
08
07A
05A
02
RST5
S28 Y
RST6 RST4 D16A -1 D28A
07A
05
Z
Y NO
O BE REMOVED FROM ASSEMBL TO
OW CORRECT ALARM OPERATION OF
CE PANELS
M158826AB_2

Models SJ12 & SJ16
157981
3.16c Base Control Wiring Diagram (SJ12/SJ16 - AS)
A B C D E F G H
87 87 87 87 87 87 87
86 86 85 86 85 86 85 86 85
87A 87A 87A 87A 87A 87A 87A
30 30 30
59D
59H
59C
15A
59D
19A
28A
59A
15B
17B
59K
59B
59F
59E
02
02
02
02
21
02
19
28
02
28
19A
16B
15A
16A
W
08
05
S2
02
59B
24
14A
05A
10E
D17B RST7 X
S10
RST3
08
07
05A
RST2 RST5
Y
S28 RST6 RST8 RST4 D28A D24

05
07
M158826AB_3

Model SJ12 & SJ16
157981
3.17a Electrical Schematic (SJ12/SJ16 - ANSI/CSA)
A B C D E F G H
M158132AD

Models SJ12 & SJ16
157981
3.17b Electrical Schematic (SJ12/SJ16 - CE/KC)
A B C D E F G H
110 VAC
LINE VOLTAGE
BC 24V CHARGER
L1CR
CHARGER
CUTOUT RELAY
V
1 CHARGER
B4 6V F1 B3 6V B2 6V B1 6V
2
BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
CONTROL BOX MAST BASE B- BATTERY
3
PACK
CRD1 CRD2 CRD3
4
DCM1
S10 C1
S4 IDLE/PLTF/BASE MOTOR M M- 5 PUMP MOTOR
EMERGENCY KEY SWITCH CONTACTOR
STOP (IN IDLE POSITION)
B+ B- 6 MOTOR CONTROLLER
S1 MAIN
8A 8A 08 BLUE/WHITE 08 08 07 S28 DISCONNECT 19B
ENABLE 7
NCHO EMERGENCY
STOP
SWITCH 59B
S5 DIAGNOSTIC
SPEED 8 POSITIVE CIRCUIT BREAKER 15A
LED-1 00
CB1 SWITCH
POWER ON LIGHT 7A 07 07 RED 07 NCHO 5A 5A 05 3A 03 CB2
00 02 9 NEGATIVE CIRCUIT BREAKER 15A
19A 19B W
02 7A GREEN 7A
19A 10 HOURMETER
RED/BLACK TT
19B
02 7A 02 TT1
SERVICE POSITION LS3
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
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 FL-29
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 BP-49
02
16B 15B 18 HORN
X
14 BLACK 14 14 RST7 14A 4H-14A
RST1 19 UP SOLENOID
2.7K OHMS LS1 21CR 1.5 OHM DO2-3
N.C.
02 00 71 21 21 02 LOW VOLTAGE RESISTOR
20 HIGH SPEED RELAY
71A 14CR
71 14 02
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 ORANGE/BLACK 59 59D 59D 59F RST2 59E 59B 59B RST6
0-5VDC 59 59 59
OUTPUT 24 ELEVATED DRIVE RESISTOR
4.7K OHM
02 07A 59G 59J 59B STEER ONLY RESISTOR
25
RST4 2K OHM
07A 59H RST5
26 BASE LIFT RESISTOR
LS4
12B
D12B
12A 12A 7B
14 02 27 LIFT SPEED RELAY 2 Y
14CR1
DRIVE CUTOUT 59A 02
LIMIT SWITCH N.C.H.O. 28 BASE CONTROL RELAY
S3 WHEN DECK EXTENDED
59ACR
LIFT/OFF/DRIVE
(IN OFF POSITION) 29
15BCR
GREEN/BLACK 7B 15B
7B 7B 02
30 REV CUT-OUT RELAY
16BCR
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
23 23 BLACK/WHITE 23 4H-23
36 RIGHT SOLENOID Z
S7-2 D23 DO2-7
RIGHT D17B-1 2H-21
12B 12B 17A 17B 21
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
M158133AC

Model SJ12 & SJ16
157981
3.17c Electrical Schematic (SJ12/SJ16 - AS)
A B C D E F G H
110 VAC
LINE VOLTAGE
BC 24V CHARGER
L1CR
CHARGER
CUTOUT RELAY
1 CHARGER
V
B4 6V F1 B3 6V B2 6V B1 6V
2
BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
CONTROL BOX MAST BASE B- BATTERY
3
PACK
CRD1 CRD2 CRD3
4
DCM1
S10 C1
S4 IDLE/PLTF/BASE MOTOR M M- 5 PUMP MOTOR
EMERGENCY KEY SWITCH CONTACTOR
STOP (IN IDLE POSITION)
B+ B- 6 MOTOR CONTROLLER
S1 MAIN
8A 8A 08 BLUE/WHITE 08 08 07 S28 DISCONNECT 19B
ENABLE 7
NCHO EMERGENCY
STOP
SWITCH 59B
S5 DIAGNOSTIC
SPEED 8 POSITIVE CIRCUIT BREAKER 15A
LED-1 00
CB1 SWITCH
POWER ON LIGHT 7A 07 07 RED 07 NCHO 5A 5A 05 3A 03 CB2 02
00 9 NEGATIVE CIRCUIT BREAKER 15A
02 7A GREEN 7A
19A 19B W
19A 10 HOURMETER
RED/BLACK TT
19B
02 LS3 07 02 TT1
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 07 POWER ON LIGHT
HORN SWITCH 12 BEEPER
NO
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 FL-29
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 BP-49
02
18 HORN
16B 15B
RST7
X
14 BLACK 14 14 14A 4H-14A
RST1 19 UP SOLENOID
2.7K OHMS LS1 21CR 1.5 OHM DO2-3
N.C.
02 00 71 21 21 02 LOW VOLTAGE RESISTOR
20 HIGH SPEED RELAY
71A 14CR
71 14 02
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
ORANGE/BLACK 59 59D 59D 59F RST2 59E 59B 59B RST6
8A 0-5VDC 59 59 59
OUTPUT 24 ELEVATED DRIVE RESISTOR
4.7K OHM
02 07 59G 59J 59B STEER ONLY RESISTOR
25
RST4 2K OHM
07 59H RST5
26 BASE LIFT RESISTOR
LS4
14 02
12B
D12B
12A 12A 7B
14CR1
27 LIFT SPEED RELAY 2
Y
DRIVE CUTOUT 59A 02
LIMIT SWITCH N.C.H.O. 28 BASE CONTROL RELAY
S3 WHEN DECK EXTENDED
59ACR
LIFT/OFF/DRIVE
(IN OFF POSITION) 29
15BCR
GREEN/BLACK 7B 15B
7B 7B 02
30 REV CUT-OUT RELAY
16BCR
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
S7-2
23 23 23
DO2-7
4H-23
36 RIGHT SOLENOID Z
D23 D17B-1
RIGHT 12B 12B 17B 21 2H-21
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
M158131AC

Models SJ12 & SJ16
157981
Notes

Models SJ12 & SJ16
157981
Section 4
TROUBLESHOOTING INFORMATION
Table of Contents
Introduction .................................................................................................................................................74
Electrical System
4.1-2 All Controls Except for Down Function Inoperative .........................................................................75
4.1-3 All Controls Inoperative From Base Control Console (ANSI/CSA, CE, KC) ..........................................76
4.1-4 All Controls Inoperative From Base Control Console (AS) .................................................................77
4.1-5 No Up Function from Base Control Console ......................................................................................77
4.1-6 Up Function Slow from Base Control Console ...................................................................................78
4.1-7 No Down Function from Base Control Console .................................................................................78
4.1-8 All Controls Inoperative From Platform Control Console ..................................................................78
4.1-9 No Up Function from Platform Control Console ...............................................................................79
4.1-10 Up Function Slow from Platform Control Console ..........................................................................80
4.1-11 No Down Function from Platform Control Console .......................................................................80
4.1-12 Pothole Bars Will Not Retract ...........................................................................................................81
4.1-13 Steer Only Inoperative .....................................................................................................................81
4.1-14 Right Steer Inoperative ....................................................................................................................81
4.1-15 Left Steer Inoperative ......................................................................................................................82
4.1-16 No Drive Forward or Reverse ...........................................................................................................82
4.1-17 Brake will not Release ......................................................................................................................83
4.1-18 No Elevated Drive .............................................................................................................................83
4.1-19 Work Platform Drives in Slow Speed Only .......................................................................................83
4.1-20 Forward Drive Function Inoperative ................................................................................................84
4.1-21 Reverse Drive Function Inoperative .................................................................................................84
4.1-22 Two or More Functions at One Time ................................................................................................85
Hydraulic System
4.2-1 All Functions Inoperative ...................................................................................................................86
4.2-2 All Functions Sluggish ........................................................................................................................86
4.2-3 Platform Drifts Down .........................................................................................................................86
4.2-4 Platform Lifts Slowly ..........................................................................................................................86
4
4.2-5 Platform Does Not Lift .......................................................................................................................86
4.2-6 Platform Will Not Lower ....................................................................................................................86
4.2-7 Pothole Bars Will Not Retract .............................................................................................................87
4.2-8 Platform Drives Slow..........................................................................................................................87
4.2-9 Platform Will Not Drive in Forward ...................................................................................................87
4.2-10 Platform Will Not Drive in Reverse...................................................................................................87
4.2-11 Brake(s) Will Not Release .................................................................................................................87
4.2-12 Platform Does Not Steer ..................................................................................................................88
4.2-13 Platform Steers Very Slowly .............................................................................................................88

Models SJ12 & SJ16
157981
Service and Maintenance Section 4 - Troubleshooting Information
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 de-
ficiencies 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 num-
ber 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

Models SJ12 & SJ16
157981
Section 4 - Troubleshooting Information Service and Maintenance
Electrical System
4.1-1 All Controls Inoperative

1. Battery charger plugged into external power source.
- Disconnect charger cord.
2. Batteries disconnected.
- Connect batteries.
3. Dirty or loose battery terminals.
- Clean and tighten connections.
4. Battery charge low.
- Check each cell with a hydrometer. Reading should be 1.275 (fully charged). Recharge if low
reading. 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 defective.
- Close switch. Check continuity. Replace if defective.
8. Loose or broken wire #3 from motor contactor 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 S28.
- Close switch. Check switch. Replace if defective.
14. Loose or broken wire #5A from base emergency stop switch S28 to base key switch S10.
15. Open or defective base key switch S10.
- Select function with switch. Check switch. Replace 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 CB1 to base terminal block.
4.1-2 All Controls Except for Down Function Inoperative

1. Loose or broken wire #59B from base terminal block to motor controller.
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 or its connectors.
- Check for continuity between base connector X2 pin #5 and platform connector X1 pin #C4 on
cable. Check for loose or corroded connections on cable connectors. Replace if wire is defective.

Models SJ12 & SJ16
157981
Electrical System (Continued)
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 or its connectors.
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 stroked)
- Check resistor and make sure it is secure. Replace 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.
4.1-3 All Controls Inoperative From Base Control Console (ANSI/CSA, CE, KC)
1. Loose or broken wire #7 from base key switch S10 to base terminal block.
2. Loose or broken wire #7 from base terminal block to mast control cable.
3. Loose or broken wire #7 in mast control cable or its connectors.
- Check for continuity between base connector X3 pin #1 and platform connector X1 pin #A3 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 switch S4.
- Close switch. Replace if defective.
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 or its connectors.
8. Loose or broken wire #7A from mast control cable to base terminal block.

Models SJ12 & SJ16
157981
9. Loose or broken wire #7A from base terminal block to base key switch S10.
11. Loose or broken wire #10E from base key switch S10 to base up/down switch S2.
4.1-4 All Controls Inoperative From Base Control Console (AS)

1. Loose or broken wire #07 from base terminal block to base key switch S10.
3. Loose or broken wire #10E from base key switch S10 to base up/down switch S2.
4.1-5 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 S2 to base terminal block.
3. Open diode D14B-1.
- Check diode. Replace if defective.
4. Open diode D14B.
5. Loose or broken wire #14 from base terminal block to relay 14CR.
6. Loose or broken wire #14 from relay 14CR to relay 14CR1.
7. Open diode D14.
8. Defective low voltage protection resistor RST7.
9. Loose or broken wire #14A from base terminal block to up valve coil 4H-14A.
10. Loose or broken wire #02 from base terminal block to up valve coil 4H-14A.
11. Defective up valve coil 4H-14A.
- Check continuity through coil. Replace if defective.
12. Machine not level. (Above high speed limit switch)
- Use on level surface.
13. Loose or broken wire #19 from base terminal 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.
16. Loose or broken wire #02 from tilt switch TS1 to base terminal strip.
17. Defective tilt relay 28CR.

Models SJ12 & SJ16
157981
18. Loose or broken wire #19A from tilt relay 28CR to pump motor contactor.
19. Loose or broken wire #59A from base terminal block to base control relay 59ACR.
20. Loose or broken wire #02 from base terminal block to base control relay 59ACR.
21. Defective base control relay 59ACR.
22. Loose or broken wire #7A from base terminal block to lift speed relay 14CR1. (ANSI/CSA, CE & KC)
23. Loose or broken wire #7 from base terminal block to lift speed relay 14CR1. (AS)
24. Loose or broken wire #59H from lift speed relay 14CR1 to base terminal block.
25. Defective base lift resistor RST5.
26. Loose or broken wire #59J from base terminal block to base control relay 59ACR.
4.1-6 Up Function Slow from Base Control Console

1. Loose or broken wire #14 from base terminal block to lift speed relay 14CR1.
2. Loose or broken wire #02 from base terminal block to lift speed relay 14CR1.
3. Defective lift speed relay 14CR1.
4.1-7 No Down Function from Base Control Console

1. Defective up/down switch S2.
2. Loose or broken wire #13 from up/down switch S2 to base terminal block.
3. Loose or broken wire #13 from base terminal block to down valve coil 2H-13.
5. Defective down valve coil 2H-13.
4.1-8 All Controls Inoperative From Platform Control Console

1. Loose or broken wire #7 from base key switch S10 to base terminal block.
4. Loose or broken wire #8 from control box connector pin #A6 to emergency stop switch S4.

Models SJ12 & SJ16
157981
5. Open or defective platform emergency stop 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.
8. Defective joystick neutral switch S7-1.
9. Defective joystick S7.
- Check joystick. Replace if defective.
4.1-9 No Up Function from Platform Control Console

1. Loose or broken wire “B” from proportional controller S7 to diode DB.
2. Open diode DB.
3. Loose or broken wire “B” from diode DB to lift/off/drive switch S3.
4. Lift/Off/Drive switch S3 defective.
6. Loose or broken wire #14 from lift/off/drive switch S3 to control box connector pin #A8.
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.
10. Loose or broken wire #14 from base terminal block to relay 14CR.
11. Open diode D14.
12. Defective low voltage protection resistor RST7.
13. Loose or broken wire #14A from base terminal block to up valve coil 4H-14A.
14. Loose or broken wire #02 from base terminal block to up valve coil 4H-14A.
15. Defective up valve coil 4H-14A.
16. Machine not level. (Above high speed limit switch)
- Use on level surface.
16. Defective tilt switch TS1.
- Test tilt switch. Replace if defective.

Models SJ12 & SJ16
157981
17. Loose or broken wire #28 from tilt switch TS1 to tilt relay 28CR.
18. Loose or broken wire #02 from tilt switch TS1 to base terminal strip.
19. Defective tilt relay 28CR.
20. Loose or broken wire #19A from tilt relay 28CR to pump motor contactor.
21. Defective platform lift resistor RST3.
22. Loose or broken wire #59C from base terminal block to lift speed relay 14CR.
4.1-10 Up Function Slow from Platform Control Console

1. Loose or broken wire #14 from base terminal block to lift speed relay 14CR.
2. Loose or broken wire #02 from base terminal block to lift speed relay 14CR.
3. Defective lift speed relay 14CR.
4.1-11 No Down Function from Platform Control Console
NOTE
Down function is not proportionally controlled.
1. Loose or broken wire “A” from proportional controller S7 to diode DA.

2. Open diode DA.
3. Loose or broken wire “A” from diode DA to lift/off/drive switch S3.
6. Loose or broken wire #13 from lift/off/drive switch S3 to control box connector pin #A7.
8. Loose or broken wire #13 from mast control cable to down valve coil 2H-13.
10. Defective down valve coil 2H-13.

Models SJ12 & SJ16
157981
4.1-12 Pothole Bars Will Not Retract
NOTE
Machine must be below high speed limit switch to allow the pothole
bars to retract.
1. Loose or broken wire #21 from base terminal block to pothole release valve coil 2H-21.
2. Loose or broken wire #02 from base terminal block to pothole release valve coil 2H-21.
3. Defective pothole release valve coil 2H-21.
4.1-13 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.
4. Loose or broken wire #17A from base terminal block to relay 17CR.
5. Defective relay 17CR.
6. Loose or broken wire #17B from relay 17CR to base terminal block.
7. Open diode D17B-1.
8. Open diode D17B.
9. Defective lift speed relay 14CR1.
10. Loose or broken wire #59G from 14CR1 lift speed relay to base terminal block.
11. Defective steer only resistor RST4.
4.1-14 Right Steer Inoperative

1. Defective right steer switch S7-2.
2. Loose or broken wire #23 from right steer switch S7-2 to control box connector pin #B3.
- Check for continuity between base connector X2 pin #7 and platform connector X1 pin #B3 on
5. Open diode D23.

Models SJ12 & SJ16
157981
6. Loose or broken wire #23 from mast control cable to right steer valve coil 4H-23.
7. Loose or broken wire #02 from base terminal block to right steer valve coil 4H-23.
8. Defective right steer valve coil 4H-23.
4.1-15 Left Steer Inoperative

1. Defective left steer switch S7-3.
2. Loose or broken wire #24 from left steer switch S7-3 to control box connector pin #B4.
- Check for continuity between base connector X2 pin #8 and platform connector X1 pin #B4 on
5. Open diode D24.
6. Loose or broken wire #24 from mast control cable to left steer valve coil 4H-24.
7. Loose or broken wire #02 from base terminal block to left steer valve coil 4H-24.
8. Defective left steer valve coil 4H-24.
4.1-16 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.
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.
(ANSI/CSA only)
6. Loose or broken wire #12A from mast connector X1 pin #B1 to drive cutout limit switch LS5.
(CE, KC & AS only)
7. Drive cutout limit switch LS4 defective or out of adjustment. (CE KC AS only)
- Check switch for adjustment. Replace if defective.
8. Loose or broken wire #7B from drive cutout limit switch LS5 to mast connector X1 pin #C7.
(CE, KC & AS only)
9. Loose or broken wire #7B in mast control cable or its connectors.
- Check for continuity between base connector X2 pin #11 and platform connector X1 pin #C6
on cable. Check for loose or corroded connections on cable connectors. Replace if wire is
defective.

Models SJ12 & SJ16
157981
10. Loose or broken wire #7B from mast control cable to tilt switch TS1.
12. Tilt switch TS1 defective or out of adjustment.
- Adjust the set up of the tilt switch using section 5 of this manual. Replace if defective.
13. Open diode D17.
4.1-17 Brake will not Release

1. Diode D16A forward or D15A reverse is shorted or open.
2. Loose or broken wire #17 from base terminal block to brake valve coil 2H-17.
3. Brake valve coil 2H-17 defective.
4. Loose or broken wire #02 from brake valve coil 2H-17 to base terminal block.
4.1-18 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.
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.
6. Loose or broken wire #72 from pothole protection limit switch LS2 to base terminal block.
7. Open diode D72.
8. Loose or broken wire #59F from base terminal block to relay21CR.
9. Defective relay 21CR.
10. Defective elevated drive resistor RST2.
4.1-19 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.
3. Loose or broken wire #21 from high speed limit switch LS1 to base terminal block.
4. Loose or broken wire #21 from base terminal block to high speed relay 21CR.

Models SJ12 & SJ16
157981
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.
4.1-20 Forward Drive Function Inoperative

1. Loose or broken wire #16 from Lift/Off/Drive switch S3 to control box connector pin #A10.
3. Loose or broken wire #16 from mast control cable to relay 16BCR.
4. Loose or broken wire #16B from tilt switch TS1 to relay 16BCR.
5. Loose or broken wire #02 from base terminal block to relay 16BCR.
6. Forward drive relay 16BCR defective.
7. Loose or broken wire #16A from relay 16BCR to base terminal block.
8. Loose or broken wire #16A from base terminal 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.
11. Open diode D16A.
4.1-21 Reverse Drive Function Inoperative

1. Loose or broken wire #15 from Lift/Off/Drive switch S3 to control box connector pin #A9.
3. Loose or broken wire #15 from mast control cable to relay 15BCR.
4. Loose or broken wire #15B from tilt switch TS1 to relay 15BCR.
5. Loose or broken wire #02 from base terminal block to relay 15BCR.
6. Reverse drive relay 15BCR defective.

Models SJ12 & SJ16
157981
7. Loose or broken wire #15A from relay 15BCR to base terminal block.
8. Loose or broken wire #15A from base terminal 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.
11. Open diode D16A.
4.1-22 Two or More Functions at One Time

1. Shorted diode.
- Check continuity of all diodes. Replace if defective.

Models SJ12 & SJ16
157981
Hydraulic System
4.2-1 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.
4.2-2 All Functions Sluggish

1. System relief valve R1 defective or not adjusted properly.
- Adjust valve. Replace if defective.
2. Hydraulic pump P1 worn.
- Check pump. Replace if defective.
3. Suction strainer contaminated.
- Clean strainer. Replace if defective.
4.2-3 Platform Drifts Down

1. Defective holding/emergency/lowering valve 2H-13.
- Check valve. Replace if defective.
2. Defective lift cylinder gland seal.
- Check for hydraulic oil leaking from the gland seal. Rebuild cylinder. Replace if damaged.
4.2-4 Platform Lifts Slowly

1. Holding/emergency/lowering valve 2H-13 stuck in the shifted position or is defective.
2. Lift relief valve R3 defective or not adjusted correctly.
4.2-5 Platform Does Not Lift

1. Up valve 4H-14A defective or is sticking.
2. Lift relief valve R3 defective or not adjusted 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.
4.2-6 Platform Will Not Lower
NOTE
Down function is not proportionally controlled.
1. Defective holding/emergency/lowering valve 2H-13.

2. Lowering orifice O1 plugged or contaminated.
- Clear debris. Replace Orifice. Replace if defective.

Models SJ12 & SJ16
157981
Hydraulic System (Continued)
4.2-7 Pothole Bars Will Not Retract
NOTE
Machine must be below high speed limit switch to allow the pothole
bars to retract.
1. Pothole valve 2H-21 defective or is sticking.

2. Defective or binding pothole cylinder.
- Check for mechanical binding. Rebuild cylinder. Replace if damaged.
4.2-8 Platform Drives Slow

1. Drive motor M1 or M2 defective.
- Check motors. Replace if defective.
4.2-9 Platform Will Not Drive in Forward

1. Forward drive valve 4H-16A defective or is sticking.
- Clean Valve. Replace if defective.
2. Counterbalance valve CB1 defective or is plugged.
4.2-10 Platform Will Not Drive in Reverse

1. Reverse drive valve 4H-15A defective or is sticking.
2. Counterbalance valve CB1 defective or is plugged.
4.2-11 Brake(s) Will Not Release

1. Brake valve 2H-17 defective or is sticking.
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.

Models SJ12 & SJ16
157981
Hydraulic System (Continued)
4.2-12 Platform Does Not Steer

1. Priority steer valve FC1 defective or not adjusted correctly.
2. Steer relief valve R2 defective or not adjusted correctly.
3. Right steer valve 4H-23 or left steer valve 4H-24 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.
4.2-13 Platform Steers Very Slowly

1. Priority steer valve FC1 defective or not adjusted correctly.

Models SJ12 & SJ16
157981
Notes

Models SJ12 & SJ16
157981
Notes

Models SJ12 & SJ16
157981
Section 5
PROCEDURES
List of Procedures
General .........................................................................................................................................................92
Safety and Workmanship .............................................................................................................................92
Electrical System
5.1 Electrical System Adjustment.................................................................................................................92
5.1-1 Resistor - Voltage Divider ...................................................................................................................93
5.1-2 Troubleshooting - Diagnostic Switch .................................................................................................93
5.1-3 Tilt Switch Orientation .......................................................................................................................93
Hydraulic System
5.2 Pressure Adjustment .............................................................................................................................94
5.2-1 System Relief Pressure Adjustment ....................................................................................................94
5.2-2 Lift Pressure Adjustment ....................................................................................................................94
5.2-3 Steer Relief Pressure Adjustment .......................................................................................................95
Service Procedures
5.3 Electronic Tilt Switch Setup Procedure .................................................................................................96
5.3-1.0 Tilt Switch Replacement..................................................................................................................96
5.3-1.1 Reprogramming Existing Tilt Switch...............................................................................................97
5.4 Pothole Limit Switch (LS2) Replacement and Adjustment ...................................................................99
5.5 Mast Lubrication Procedure ................................................................................................................100
5.5-1 Outside Mast Lubrication..................................................................................................................100
5.5-2 Inner Mast Lubrication ......................................................................................................................101
5.5-3 Chains and rollers lubrication ...........................................................................................................101
5. 6 Mast Roller Inspection/Maintenance...................................................................................................102
5.6-1 Roller Operation Inspection ..............................................................................................................102
5.7 Mast Chain Visual Inspection ...............................................................................................................103
5.7-1 Chain Thorough examination ...........................................................................................................104
5.7-2 Condition inspection table ...............................................................................................................104
5.8 Mast Disassembly Procedure ..............................................................................................................105
5.8-1 Extending Platform Removal ............................................................................................................105
5.8-2 Mast Section 5 Removal (SJ16 Only) .................................................................................................107
5.8-3 Mast Section 4 Removal ....................................................................................................................108
5.9 Mast Roller Replacement ....................................................................................................................116
5.10 Mast Assembly Procedure .................................................................................................................117
5.10-1 Mast Section 1 Installation .............................................................................................................117
5.10-4 Mast Section 4 Installation. ............................................................................................................121
5.10-5 Mast Section 5 Installation (SJ16 Only) ..........................................................................................123
5.10-6 Extending Platform Installation ......................................................................................................124
5.11 Lift Cylinder Replacement .................................................................................................................126
5.11-1 Extending Platform Removal ..........................................................................................................126
5.11-2 Mast Assembly Removal .................................................................................................................126
5.11-3 Lift Cylinder Removal ......................................................................................................................129
5.11-4 Lift Cylinder Installation..................................................................................................................130
5
5.11-5 Mast Assembly Installation .............................................................................................................131

Models SJ12 & SJ16
157981
Service and Maintenance Section 5 - Procedures
General
The following information is provided to assist you in the use and application of servicing and maintenance procedures
contained in this section.
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.
Electrical System
5.1 Electrical System Adjustment
RST2,3,4,5 and 8
+ Resistor +
Voltage RST6 Voltage

In Resistor Out
- -
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%.

Models SJ12 & SJ16
157981
Section 5 - Procedures Service and Maintenance
5.1-1 Resistor - Voltage Divider 5.1-3 Tilt Switch Orientation
5.1-2 Troubleshooting - Diagnostic Switch The design of this equipment and the tilt switch require
it to be installed in a specific direction. Below you will
The SJ12 and SJ16 machines are equipped with a find a picture indicating the direction of TS1 Tilt Switch.
diagnostic switch for the purpose of troubleshooting. As indicated in the picture the tilt switch is oriented so
Once the deck is in the service position (deck fully that the wiring harness as well as the reset buttons face
extended out), the electric signal to the motor controller the center of the machine.
enable function is disengaged. All electrical wiring and
components can be checked in the service position Steer Cylinder
other than the signal to the enable of the motor TS1 - Tilt Switch
controller. To accomplish this you would be required
to engage the diagnostic switch.
Figure 5-2. Tilt Switch Orientation

Diagnostic Switch
Figure 5-1. Diagnostic and Horn Assembly

Models SJ12 & SJ16
157981
Hydraulic System 5.2-2 Lift Pressure Adjustment

All adjustments must be made with a calibrated gauge.
Refer to the serial number plate located on the rear of 1. Extend transverse deck to service position, then
the machine for system and lift pressure values. raise the service access door and secure in
position with the prop rod provided.
5.2 Pressure Adjustment 2. Locate the hose going to the lift cylinder on the
main manifold. Remove and plug the hose. Refer
5.2-1 System Relief Pressure Adjustment to Section 3 Main Manifold Assembly for location.
3. Install a calibrated 5000 PSI gauge to the port on
1. Extend transverse deck to service position, then the manifold where the hose was disconnected.
raise the service access door and secure in 4. At the main manifold, loosen the locknut on the
position with the prop rod provided. lift relief valve R3.
2. Locate system pressure test port on power pack 5. Select lift with the Lift/Drive select switch on the
manifold. Refer to Section 3 Power Pack and Port platform control box.
Identification for location. 6. Engage platform lift function and hold. Engage
3. Install a calibrated 5000 PSI gauge to the system diagnostic switch and hold.
pressure test port. 7. Observe reading on gauge. Adjust lift relief valve
4. Remove platform control box from guardrail and R3 to the value listed on the serial number plate.
locate it in the proximity of the work area of the Turn the stem of the relief valve clockwise to
power pack. increase pressure. Turn the stem counterclockwise
5. At the power pack manifold, loosen locknut on to decrease pressure.
system relief valve R1. Refer to Section 3 Power 8. Release platform lift function, diagnostic switch
pack and Port Identification for location. and then tighten the locknut.
6. Remove wires #15A and #16A from the valve 9. Remove the gauge from the lift port on the
coils. Refer to Section 3 Power Pack and Port manifold. Reattach lift cylinder hose and tighten.
Identification for location. 10. Store prop rod back to its holder, then lower
7. Select drive with the Lift/Drive switch on the Service access door and secure it. Push the
platform control box. transverse deck back to the working position.
8. Engage either forward or reverse drive and hold.
Engage diagnostic switch and hold. NOTE
9. Observe reading on gauge when drive is selected. Pressure setting may vary as machine components
Adjust system relief valve R1 value listed on the wear. The lift pressure should be set for rated load
serial number plate. Turn the stem on the relief only.
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.

Models SJ12 & SJ16
157981
5.2-3 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.

Models SJ12 & SJ16
157981
Service Procedures 9. Disconnect all wires #02 from motor contactor.
10. Remove base control console from the base.

5.3 Electronic Tilt Switch Setup Procedure Remove the cover plate on the base control console
to access the terminal strip.
The following information is supplied for replacement or
reprogramming of the electronic tilt switch. Also included 11. Install jumper wire between #7 and #19 to terminal
are test and verification instructions. Follow the appropri- strip.
ate procedures below.
12. Turn main disconnect switch to “ ” ON position. Pull
5.3-1.0 Tilt Switch Replacement out “ ” emergency stop buttons.
13. Verify switch is powered. (Red or green LED will

turn on solid)
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

1. Ensure aerial platform is parked on a firm level / stabilization time. (Only Red LED
surface. the red LED will blink for 4 Green LED
seconds)
2. Chock or block wheels to keep the aerial platform
from rolling forward or backward. c. Both LEDs will
flash for 1 second.
Red LED
3. Lower platform completely. Extend the transverse Results: The switch is
Green LED
deck to the service position. Open the base cover learning the new zero
and prop it in position using the rod provided. position.
4. Push in “ ” emergency stop buttons and turn d. Both LEDs will turn on
solid for 1 second.
main disconnect switch to “ ” off position. Results: The new zero
Red LED
Green LED
5. Remove any covers to locate and view the tilt switch. position has been learned.
6. Disconnect tilt switch from 6 pin connector. e. The green LED will flash and then the
red LED will turn on solid for 2 seconds.
7. Remove old tilt switch from mount.
NOTE
Ensure part number of old and new tilt Red LED Red LED
Green LED Green LED
switch are the same.
8. Install new switch to mount (in the same orientation Results: The switch is verifying the new zero
as the old switch) and connect switch plug to 6 pin position.
connector.
f. The green LED
NOTE will turn on solid. Red LED
The tilt circuit is only powered when Results: The switch is Green LED
activating a function. ready for normal operation.

Models SJ12 & SJ16
157981
6. Disconnect all wires #02 from motor contactor.

15. Turn main disconnect switch to “ ” off position.
7. Remove base control console from the base.
16. Remove jumper wire between #7 and #19 from
Remove the cover plate on the base control console
terminal block.
to access the terminal strip.
17. Reattach all wires #02 to motor contactor.
8. Install jumper wire between #7 and #19 to terminal
18. Reinstall cover plate on the base control console. strip.
Reinstall the base control console into the base of
the machine and secure with old hardware. 9. Turn main disconnect switch to “ ” ON position. Pull
out “ ” emergency stop buttons.
19. Reinstall any covers that were removed.
10. Verify switch is powered. (Red or green LED will
20. Close the base cover making sure it is secure. turn on solid)
Retract the transverse deck to the stored position.
21. Remove chock or wheel blocks.

Red LED Red LED
22. Proceed to Test and Verify Tilt Circuit. Green LED Green LED
5.3-1.1 Reprogramming Existing Tilt Switch

11. Reprogram the Tilt Switch
Set up button is located on this a. Press and hold the set
Light Indicators face next to harness up button for 3 seconds.
Results: Both LEDs will Red LED
be OFF. 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 period, or the switch will
automatically exit program mode and return
1. Ensure aerial platform is parked on a firm level
to normal operation using previously stored
surface.
data.
2. Chock or block wheels to keep the aerial platform
from rolling forward or backward. c. Press and release set up button 3 times.
3. Lower platform completely. Extend the transverse d. If 5 second period has expired prior completion,
deck to the service position. Open the base cover repeat Step “a”, “b” and “c”.
and prop it in position using the rod provided.
e. Observe program delay
4. Push in “ ” emergency stop buttons and turn / stabilization time. (Only
Red LED
the red LED will blink for
main disconnect switch to “ ” off position. Green LED
4 seconds)
NOTE
The tilt circuit is only powered when
activating a function.
5. Remove any covers to locate and view the tilt switch.

Models SJ12 & SJ16
157981
f. Both LEDs will 5.3-1.2 Test and Verify Tilt Circuit

flash for 1 second.
Results: The switch is Red LED
learning the new zero Green LED
Set up button is located on this
Light Indicators face next to harness
position.
g. Both LEDs will turn

on solid for 1 second.
Red LED
Results: The new zero Green LED R
Gre ed LE
position has been learned. en
LE
D
D
h. 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 Operations of Tilt Switch

Green LED Green LED The following describes the LED’s and what they indicate.
Illuminated whenever both tilt

i. The green LED will turn on solid. axes are within the specified
Results: The switch is ready for normal degrees of the zero/ home
operation. Green LED learned position.
Flashes when transitioning in or
out of tilt angle limits, but built in
time delay has not fully occurred.
13. Remove jumper wire between #7 and #19 from Illuminated whenever tilt on one
terminal block. or more axes is more than the
Red LED
specified degrees out from the
14. Reattach all wires #02 to motor contactor. zero/ home position.
On together, no blinking when
15. Reinstall cover plate on the base control console. Green & Red LED
fault detected.
Reinstall the base control console into the base of
the machine and secure with old hardware. Tilt Circuit Test
16. Reinstall any covers that were removed.
1. Refer to section 2 for test tilt sensor procedure.
17. Close the base cover making sure it is secure.
Retract the transverse deck to the stored position.
18. Remove chock or wheel blocks.
19. Proceed to Test and Verify Tilt Circuit.

Models SJ12 & SJ16
157981
5.4 Pothole Limit Switch (LS2) Replacement Limit Switch Electrical Connections
and Adjustment 2. Route the new limit switch cable along the same
path as the old one to the main harness. Use
Machine Preparation tie wraps as needed to secure them at regular
1. Make sure the MEWP is parked on a firm level intervals.
surface and fully lower the platform.
3. Plug the spade connectors into the same wire
2. Chock or block the wheels to keep the MEWP numbers. The #71A and #72 wires from the limit
from rolling forward or backward. switches connect to the respective wires on the
main harness.
Limit Switches Removal
1. Extend the platform to the service position. Limit Switch Setup
4. Loosen the hardware securing the limit switch
to the limit switch bracket. Adjust and move
2. Open the service cover door, and properly install the limit switch towards the lever bar until it
the prop bar. depresses the plunger roller.
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.
4. Remove the limit switch and free the limit switch
cable by cutting the tie wraps. Limit Switch Testing
1. Place a block, approximately 1.5” (3.75 cm),
5. Follow the cable into the main harness, and under the pothole bar and then raise the
disconnect the limit switch wire from the main platform to an approximate height of 7 feet
harness. Discard the limit switch. (2 meters) or until the pothole protection is
activated.
Limit Switch Replacement
1. Mount loosely the new limit switch assembly: , 2. Attempt to drive forward or reverse. The MEWP
using the hardware removed previously. should not move forward or backward when
pothole protection is on a block.

Models SJ12 & SJ16
157981
5.5 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.
5.5-1 Outside Mast Lubrication
1. Using the base controls,fully extend the mast.
2. Turn main disconnect switch to “ ” off position. Lubricate
IMPORTANT
The use of equipment suitable to provide
working access to the elevated mast sections is
necessary to complete this procedure.
3. Clean any existing lubricant on the sides of the vertical

mast.
Lubricate
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.
5. Allow 10 minutes for the lubricant to dry, then retract

the mast using the base controls.
Lubricate
Lubricate
Figure 5-1. Mast Lubrication Zone.

Models SJ12 & SJ16
157981
5.5-2 Inner Mast Lubrication 5.5-3 Chains and rollers lubrication

NOTE
1. Using the base controls, fully retract the mast. Make sure the proper type of lubrication is
used in the correct locations.
2. Turn main disconnect switch to off position.
1. Locate the roller assemblies inside the mast.
3. Remove top mast cover. 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 5-2. Top Cover Removal.
NOTE
Apply Lubricant
Make sure the proper type of lubrication is
used in the correct locations.
Figure 5-4. Chain & rollers lubrication
4. Apply DuPont Multi-Use Lubricant (158692) or any
PTFE wax based dry lubricant behind and around 2. For replacement rollers, pack the thrust washers
all top wear pads only, in each section of the mast. and the sides of the replacement rollers with grease
prior to installation.
Figure 5-3. Inner wear pads lubrication

Models SJ12 & SJ16
157981
AC
3. Locate the chain assemblies inside the mast. 5. 6 Mast Roller Inspection/Maintenance
Lubricate the entire length of chain and anchor
points using spray on industrial “Moly based” chain
lubricant (for example Crown Wire Rope, Chain and 5.6-1 Roller Operation Inspection
Cable Lube 7043).
1. Using the base controls, fully retract the mast.
Apply Lubricant
WARNING
Crushing/entrapment hazard due to moving
chains/rollers and mast components. Keep
all hands, other body parts and clothing
away from moving parts.
2. Enter the platform and remove top mast cover.
Figure 5-5. Chain & rollers lubrication

4. Exit the work platform.
5. Exit the work platform. 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 5-7. 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 5-6. Mast Top Cover Installation.

Models SJ12 & SJ16
157981
AC
4. Inspect rollers for uneven movement, rollers out 5.7 Mast Chain Visual Inspection
of alignment, uneven gaps on either side of the
rollers and excessive wear or gouging on the mast, NOTE
brackets or rollers. Replace brackets and rollers if When inspecting chains, wipe off any grease
damaged. 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 5.5-3 Chains and rollers lubrication
1. Using the base controls, fully retract the mast.
2. Turn main disconnect switch to off position.
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 5.7-2 Condition
inspection table for examples) Replace the chain
if required.
5. Mark each roller with an indelible marker. While NOTE
slowly raising the mast observe and ensure the Crushing/entrapment hazard due to moving
rollers rotate freely. chains/rollers and mast components. Keep
all hands, other body parts and clothing away
6. Fully retract the mast. from moving parts.
5. Turn on the Main Power Disconnect and pull out
7. Install the mast cover at the top. 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 chain links
for broken, cracked, corroded or worn links, with
particular attention to wear on the links that have
traveled over the rollers.
Figure 5-8. Mast Top Cover Installation. If during any of the inspections outlined above, a chain
8. Exit the work platform. shows any signs of degradation, perform a thorough
chain examination as per 5.7-1 Chain Thorough ex-
NOTE
amination as well as mast roller inspection as per 5.6-1
When rollers are replaced for any reason,
Roller Operation Inspection.
perform a full inspection on the chain for
If there is any reason to suspect a chain of damage, or if
damage as described in section 5.7-1 Chain
the mast is apart for other repairs then a thorough chain
Thorough examination
examination or replacement is recommended.

Models SJ12 & SJ16
157981
5.7-1 Chain Thorough examination

1. Remove all chains from the masts following section 5.8 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 5.7-2
Condition inspection table.
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 5.7-2 Condition inspection table.
8. Replace chain if necessary.
5.7-2 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

Models SJ12 & SJ16
157981
5.8 Mast Disassembly Procedure 5. Disconnect the platform control cable quick
connector from the mast.
6. Remove the control cable enclosure that houses the

CAUTION hour meter from the side of the mast.
Risk of personal injury or equipment
damage. Always use suitable lifting 7. Disconnect the wires for the platform limit switch
equipment and safe lifting practices when harness with the contact pin extraction tool (208767).
performing the following procedure.
Control
Cable Quick
CAUTION Connector
Risk of personal injury or equipment
Hourmeter
damage. The use of an assistant is required
Enclosure
to safely complete this procedure.
WARNING
Risk of personal injury. Do not stand or pass
under a suspended load. Limit
Switch
NOTE Harness
It is recommended that 2 lifting straps (or
similar) be used for a straight, even lift.
Figure 5-9. Harnesses Disconnection
NOTE
SJ16 machines have one more mast section 8. Pull the limit switch harness through the strain
than the SJ12 machines. Some of the connector and out of the box. Tie the harness and
following steps (as indicated) apply only to the platform control cable to the platform.
the SJ16 machines.
Control
Cable Quick
Connector Limit Switch
5.8-1 Extending Platform Removal Harness
1. With the platform fully-lowered, enter the 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 5-10. Harnesses Secured

Models SJ12 & SJ16
157981
9. From a position outside of the work platform, remove 11. Raise the platform slightly then carefully and slowly
the mast cover. slide the platform towards the back of the machine
to clear the mast.
Figure 5-13. Platform Positioning
12. Raise the platform over the mast and set aside.
Figure 5-11. Top Cover Removal
10. Support the platform using suitable lifting straps.

Remove the hardware securing the platform to the
mast. Set aside.
Remove
Figure 5-12. Platform Hardware Removal
Figure 5-14. Platform Removal

Models SJ12 & SJ16
157981
13. On the side of the mast disconnect the AC power 5.8-2 Mast Section 5 Removal (SJ16 Only)
supply cable from the weatherproof outlet box, then
loosen strain relief and remove the harness (ANSI/ NOTE
CSA Only). It is recommended that 2 lifting straps (or
similar) be attached evenly to mast section 5
14. Remove the 3 harness clamps at the top of the mast for a straight, even lift.
assembly. Secure the harnesses to the cylinder
mounting bracket with cable ties. NOTE
Attach lifting straps away from mast grab
handle and receptacle box.
Clamp
1. Disconnect the chains by removing the hardware

securing the chain mounts inside mast section 5
as shown.
Cable Wrap
Figure 5-15. Harness Clamps
Figure 5-16. Chain Tensioner Disconnection (Section 5)

Models SJ12 & SJ16
157981
2. Once the chains are disconnected, raise the mast 5.8-3 Mast Section 4 Removal
section and remove the lower wear pads. Mark the
location of each wear pad. 1. (SJ16 Only) Pull the chains laying on the outside
of section 4 up and over the single rollers so they
3. Lift mast section 5 up and away from the mast drop into the mast column. Ensure they do not
column, ensure the harnesses and the control cable tangle.
enclosure box are clear at the top of the mast. Set
the mast section aside.
Section 4
Figure 5-18. Section 3 to Section 5 Chains (SJ16 Only)
NOTE
Figure 5-17. Wear Pads Removal (Section 5)
for a straight, even lift.
NOTE
For SJ12 - Attach lifting straps away from
mast grab handle and receptacle box.

Models SJ12 & SJ16
157981
2. Carefully lift mast section 4, just enough so that the 4. Pry/push the bottom of the mast section forward to
chains are not in tension. Remove the hardware allow the chain tensioner to drop past the bottom
securing the chain tensioner block inside mast 4. edge of the mast section.
Chain
Tensioner
Block
Figure 5-21. 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 5-22. Mast Section 4 Removal

Models SJ12 & SJ16
157981
5.8-4 Mast Section 3 Removal 2. Pull the chains attached to mast section 2 up and
over the double rollers so they can drop into the
1. (SJ16 Only) Pull the chains attached to mast mast column. Ensure they do not tangle.
section 3 out of the mast column and lay them
against the front of mast section 3.
Figure 5-23. Section 3 Chains (SJ16 Only)
Figure 5-24. Section 2 to Section 4 Chains
NOTE

Models SJ12 & SJ16
157981
3. Carefully lift mast section 3 evenly, just enough so 5. Lift mast section 3 up and away from the mast
that chains are not in tension. Remove the hardware column. Ensure the harnesses and the control cable
securing the chain tensioner block inside mast 4. enclosure box are clear. Set the mast section aside.
Chain
Tensioner
Block
4. Lift the mast section up to a suitable working height

and remove the lower wear pads. Mark location of
each wear pad.

Section 2

Models SJ12 & SJ16
157981
5.8-5 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
1. Remove the hydraulic cylinder rod pin securing the mast section 2.
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 5-28. Rod Pin Removal
Figure 5-29. Section 2 Chains

Models SJ12 & SJ16
157981
4. Pull the chains attached to mast section 1 up and NOTE

over the double rollers so they drop into the mast It is recommended that 2 lifting straps (or
column. Ensure they do not tangle. similar) be attached evenly to mast section 2
5. Lift the mast section up to a comfortable working

height and remove the lower wear pads. Mark the
location of each wear pad.
Section 2
Section 1

Models SJ12 & SJ16
157981
6. Lift mast section 2 up and away from the mast 5.8-6 Mast Section 1 Removal
column. Ensure the harnesses and the control cable
enclosure box are clear. Set the mast section aside. 1. Pull the chains attached to mast section 1 out of
the mast.
Figure 5-32. Section 2 Removal

Models SJ12 & SJ16
157981
NOTE 2. Remove the 4 clamps that secure the harnesses

It is recommended that 2 lifting straps (or to the mast base, then disconnect the two harness
similar) be attached evenly to mast section 1 plug connectors and the mast limit switch harness.
Top View
Clamp Clamp
Main
Harness
Platform
Control Limit Switch
Harness Harness
Figure 5-35. 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)
Figure 5-34. Mast Section 1 Secured Rivet
Figure 5-36. Power Inlet Removal
NOTE
Disconnect the harness ground wire
connected to a mast mounting bolt at the
base of the mast.

Models SJ12 & SJ16
157981
4. Remove all hardware securing the mast to the base. 5.9 Mast Roller Replacement
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 5-37. Mast Hardware Removal
5. Lift mast section 1 up and away from the lift cylinder. Dowel
Ensure all harnesses are clear. Set the mast section Pin
aside.
Pin
Roll Pin
Figure 5-39. 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.

Models SJ12 & SJ16
157981
5.10 Mast Assembly Procedure
5.10-1 Mast Section 1 Installation

Clamp Clamp
CAUTION
A second person to assist will be required
to complete this procedure.
WARNING
Do not stand or pass under a suspended
load.
Figure 5-41. Harness Routing
4. Connect the mast control cable and limit switch

1. Ensure the main power disconnect switch is in the harness plugs.
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 5-42. 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 5-40. 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 5-43. Power Inlet Installation

Models SJ12 & SJ16
157981
6. Locate the limit switch at the top of the mast, then 2. Lift mast section 2 over the mast column, then slowly
press and hold the plunger away from the opening and carefully lower the section in place. Ensure the
with a piece of tape to avoid any potential damage harnesses and the control cable enclosure box are
when the next section passes over it. 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 using
3/16'' x 1/4''-3/8'' rivets.
Figure 5-44. Mast Limit Switch

Rear Wear
5.10-2 Mast Section 2 Installation Pads
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.
Section 1
Front Wear
Pads
Figure 5-46. Wear Pads Installation (Mast Section 2)
5. Fully lower the section in place.
6. Remove tape to release the limit switch.
Figure 5-45. Mast Section 1 Chains
NOTE

Models SJ12 & SJ16
157981
5.10-3 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
1. Pull the chains attached to mast section 1 out of column. Ensure they do not tangle.
mast section 2.
Section 2
Section 2
NOTE

Models SJ12 & SJ16
157981
3. Lift mast section 3 over the mast column, then slowly 6. Continue lowering until the chain block tensioner
and carefully lower the section in place. Ensure the inside the mast section can be attached. Apply
harnesses and the control cable enclosure box are Loctite 242 (blue) to the threads of the six bolts and
clear at the top. 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.
5. Install the rear (short) wear pads with the 10-32 x Chain Block
3/8” screws. Install the front (long) wear pads using Tensioner
3/16” rivets.
Rear Wear
Pads
Section 2
Figure 5-50. Chain Tensioner Installation (Section 3)
Front Wear 7. Fully lower mast section 3. Guide the electrical

Pads harnesses and the control cable enclosure out of
the mast column.
Figure 5-49. Wear Pads Installation (Section 3)

Models SJ12 & SJ16
157981
5.10-4 Mast Section 4 Installation. 2. (SJ16 Only) Pull the chains attached to mast
section 3 up and over the double rollers so they
1. Pull the chains attached to mast section 2 out of can drop into the mast column. Ensure they do
the mast column and lay them against the front of not tangle.
mast section 3.
Figure 5-52. Section 3 Chains (SJ16 Only)
NOTE

Models SJ12 & SJ16
157981
3. Lift mast section 4 over the mast column, then slowly 5. Lower the section until the bottom end of the mast
and carefully lower the section in place, ensure the is in a suitable working height to install the lower
harnesses and the control cable enclosure box are wear pads.
clear at the top.
4. Lower mast section 4 enough to connect the chain 3/8” screws. Install the front (long) wear pads using
block tensioner. Push the mast section slightly 3/16’’ x 1/4’’-3/8’’ rivets.
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
Tensioner
7. Fully lower mast section 4. Guide the electrical
harnesses and the control cable enclosure out of
the mast column.

Models SJ12 & SJ16
157981
5.10-5 Mast Section 5 Installation (SJ16 Only) NOTE

1. Pull the chains attached to mast section 3 out of similar) be attached evenly to mast section 5
the mast column and lay them against the front of for a straight, even lift.
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.

3/8” screws. Install the front (long) wear pads using
3/16” rivets.
Rear Wear
Pads
Section 4
Front Wear
Pads


Models SJ12 & SJ16
157981
5. Lower mast section 5 enough to connect the chain 5.10-6 Extending Platform Installation
tensioner. Apply Loctite 242 (blue) to the threads of
the four bolts and install them with the flat washers. 1. Secure the harnesses with the clamps at the top of
the mast as shown in figure below.

Figure 5-58. Harness and Clamps Installation
6. Fully lower mast section 5. Guide the electrical
harnesses and the control cable enclosure out of 2. Route the AC power supply harness through the
the mast column. strain relief to the inside of to the receptacle box on
the side of the mast and connect the harness to the
outlet (ANSI/CSA Only).
Strain
Relief
AC Power
Supply
Harness
Receptacle
Box
Outlet
Figure 5-59. AC Power Supply Harness Connection

Models SJ12 & SJ16
157981
3. Lift platform in position over the mast then slowly 4. Apply Loctite 242 (blue) to the threads of the upper
and carefully lower it in place. 4 bolts then install them with the washers. Torque
to 23 ft-lb (31 N·m).
Figure 5-61. 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 5-60. Platform Installation
Manual Box
Figure 5-62. Platform Harnesses Installation

Models SJ12 & SJ16
157981
8. Raise the platform into position using the base 5.11 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 (41 N·m). CAUTION
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.
5.11-1 Extending Platform Removal
Figure 5-63. Platform Lower Bolts Installation 1. See Section 5.7.1 for platform removal.
9. Fully lower the platform. 5.11-2 Mast Assembly Removal
10. Install the mast cover 1. Remove the cover on the top of the mast.
Figure 5-64. Mast Cover Installation
11. Perform a full function test before putting machine

into service as outlined in section 2.4 of the operating Figure 5-65. Mast Top Cover Removal
manual.

Models SJ12 & SJ16
157981
2. Remove the hydraulic cylinder rod pin securing the 3. Lift the mast enough to reach the harness plug
cylinder to the mount bracket. connectors at the base.
Rod Pin
Cotter Pin
Figure 5-66. Rod Pin Removal
NOTE
similar) be attached evenly to the cylinder
mounting bracket on mast section 2 for a Figure 5-67. Mast Positioning
straight, even lift.
4. Turn the main power disconnect switch to the off
position.

Models SJ12 & SJ16
157981
5. Disconnect the two harness plug connectors and 9. Remove all hardware securing the mast to the base
the mast limit switch harness. as shown.
6. Remove all clamps securing the harnesses to the

mast base.
Top View
Disconnect
Harness Figure 5-70. 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 5-68. 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 5-69. Power Inlet Removal
8. Lower the mast so that is slightly supported by the

Figure 5-71. Mast Removal
lifting straps.

Models SJ12 & SJ16
157981
5.11-3 Lift Cylinder Removal 3. Carefully raise the cylinder approximately 4 in (10
cm). Ensure the valve at the base of the cylinder is
1. Attach appropriate slings at the top of the cylinder clear.
to secure it.
Figure 5-74. 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 (hose and valve).
Figure 5-72. Cylinder Secured
2. Remove the 2 socket head screws and flat washers

at the base of the cylinder.
Disconnect
Hose
Disconnect
Harness
Figure 5-73. Cylinder Hardware
Figure 5-75. 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.

Models SJ12 & SJ16
157981
5.11-4 Lift Cylinder Installation 2. Lower the cylinder so there is a distance of

approximately 4 in (10 cm) between the cylinder
1. Attach appropriate slings at the top of the cylinder manifold and the base plate. Ensure the valve on
then carefully lift the cylinder over the base plate. the base of the cylinder is clear
Cylinder
Manifold
Base
Plate
Figure 5-77. 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 5-76. Cylinder Positioning
Figure 5-78. Manifold Hose and Harness Connection

Models SJ12 & SJ16
157981
5. Fully lower the cylinder in place. Apply loctite 242 5.11-5 Mast Assembly Installation
(blue) to the threads of 2 socket head screws then
install with flat washers at the base of the cylinder NOTE
as shown. Torque to 18ft-lb (24.4 N·m). It is recommended that 2 lifting straps (or
similar) 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 5-79. Cylinder Hardware Installation
Figure 5-80. Mast Installation

Models SJ12 & SJ16
157981
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 5-81. Mast Hardware Installation Figure 5-83. Mast Harness Connection
3. Lift the mast enough to connect the harness plug 4. Connect the AC power supply harness to the power
connectors at the base. 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 5-84. Power Inlet and Harness Installation
Figure 5-82. Mast Positioning

Models SJ12 & SJ16
157981
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 5-85. Mast Base Clamps Installation
6. Fully lower the mast and remove the lifting straps.
7. Secure the lift cylinder to the cylinder mount bracket

on section 2 with the rod pin and cotter pin. Figure 5-87. Mast Top Cover Installation
9. Refer to section 5.9.6 for platform installation.

Rod Pin
10. Perform a full function test as outlined in section 2.4
of the operating manual.
Cotter Pin
Figure 5-86. Rod Pin Installation

Models SJ12 & SJ16
157981
Notes

Models SJ12 & SJ16
157981
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SERVICE MANUAL (ALL STANDARDS)

157981AG January 2022

Please refer to the website - www.skyjack.com for older Serial Numbers.

Skyjack Service Center Parts & Service (Europe)

Parts (North America) Skyjack Brasil

Section 1 - Scheduled Maintenance

Section 2 - Maintenance Tables

Section 3 - System Component Identification and Schematics

Section 4 - Troubleshooting Information

Vertical Mast Series Page 3

Page 4 Vertical Mast Series

Operator’s Responsibility for Maintenance

Vertical Mast Series Page 5

Page 6 Vertical Mast Series

Aerial Platform and Mobile Elevating Work Platform (MEWP) Definition

Service & Maintenance

Service Policy and Warranty

For non-standard components or systems, contact the SKYJACK Service Department at

North America & Asia: Europe:

Vertical Mast Series Page 7

Scope of this Manual

- Equipment identified with “ANSI” meets the ANSI SIA-A92.6-2006 standard.

b. CSA (Canada) and CE (Europe)

c. ANSI/SIA (United States)

Operator Safety Reminders

Page 8 Vertical Mast Series

Per ANSI A92.5-2006 8.10(7)

As per CSA B354.4-02

Refer to CFR 1910.333 or the authority having jurisdiction.

DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING.

Minimum Safe Approach Distance

Over 300V to 50KV 10

Over 750KV to 1000KV 45 Greater than 133KV 10 8

FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!

Vertical Mast Series Page 9

• DO NOT increase the lateral surface area of the

• KNOW all national, state or territorial/provincial • DO NOT drive or elevate the

• WEAR all the protective clothing and personal

equipped) have contact with

• Elevated driving must only

• DO NOT ascend or descend

• DO NOT operate on surfaces

Page 10 Vertical Mast Series

Safety Precautions (Continued)

is on a truck, fork lift or other

• DO NOT operate an aerial platform that has

• DO NOT exert side forces on

• DO NOT use the aerial plat-

• DO NOT sit, stand or climb on

• DO NOT climb on base and • DO NOT use with improp-

• BE AWARE of overhead ob-

• DO NOT raise the aerial plat-

Vertical Mast Series Page 11

Safety Precautions (Continued)

• BE AWARE of blind spots when operating the

• DO NOT place materials on the guardrails or ma-

• DO NOT operate if aerial

• DO NOT leave aerial plat-

• DO NOT use under influence

• DO NOT access the