Skyjack SJ45 AJ+ - Service Manual

To Next Page

SERVICE

MANUAL

ARTICULATING BOOMS

SJ45 AJ+

238274AAA

March 2021

ANSI/CSA, CE, AS

To order go to Discount-Equipment.com

Main Page

Table of Contents5
Section 1 - Scheduled Maintenance11
Read and Heed11
MEWP and Mobile Elevating Work Platform Definition11
Purpose of Equipment11
Use of Equipment11
Manual11
Service Policy and Warranty11
Operator Safety Reminders, Warnings and Precautions11
Maintenance and Service12
Maintenance and Inspection Schedule12
Owner's Annual Inspection Record12
Replacement Parts12
Maintenance and Service Safety Tips12
Hydraulic System & Component Maintenance and Repair13
Hydraulic Maintenance Hints13
Railing Maintenance and Repair14
Scheduled Maintenance15
Service Bulletins15
Maintenance and Inspection15
Maintenance Instructions15
Owner's Annual Inspection Record16
Pre-Delivery/Maintenance Inspection Checklist17
Scheduled Maintenance Inspections18
Electrical18
Hydraulic18
Labels18
Limit Switches18
Engine Compartment19
Control Compartment22
Base24
Platform26
Boom Assembly27
10 Optional Equipment28
Function Tests29
Section 2 - Maintenance Tables and Diagrams30
Standard Hose Numbering System30
Torque Specifications for Fasteners (US Imperial)32
Torque Specifications for Fasteners (Metric)33
Torque Specifications for Hydraulic Couplings & Hoses34
MEWP Torque Specifications35
Axle Torque Specifications36
Axle Maintenance Intervals37
Tire Specifications38
Floor Loading Pressure39
Hydraulic Specifications40
MEWP Specifications41
Platform Capacities42
Fluids43
Engines43
Reach Diagram44
Dimension Diagrams45
Axle Oscillation Diagram47
Section 3 - System Component Identification and Schematics48
Electrical Symbol Chart49
Hydraulic Symbol Chart50
Wire Number and Color Code51
Hydraulic Parts List52
Electrical Parts List55
Brake Manifold Components and Ports58
Rotary Manifold Ports59
Drive and System Pump Ports60
Drive and System Pump Ports61
Drive Motor Ports62
Jib Valve Ports63
Pressure Reducing Valve Ports64
Main Manifold Ports65
Generator Control Valve and Manifold68
Main Harness and Fuel Level Switch Harness69
Engine Harness - D130570
Engine Harness Wiring Diagram - D130571
Engine Harness - WG97272
Engine Harness Wiring Diagram - WG97273
Platform Harnesses74
Limit Switch Connections75
All Motion Alarm Connections - CE & as76
Flashing Amber Light Connections77
Hydraulic Schematic79
Platform Control Box Wiring80
Base Control Box Wiring - ANSI/CSA & as81
Base Control Box Wiring - CE82
Electrical Schematic - ANSI/CSA & as83
Electrical Schematic - CE84
Engine Schematic - Kubota D130585
Engine Schematic - Kubota WG97286
Section 4 - Troubleshooting Information87
Introduction87
Electrical System88
All Controls Are Inoperative from the Base or Platform Console88
All Controls Are Inoperative from the Base Console90
The Engine will Not Crank from the Base or Platform90
The Engine will Not Crank from the Base91
The Engine will Not Crank from the Platform91
The Boom Controls Are Inoperative (Drive Operates)91
No Boom up from the Base or Platform Controls92
No Boom up from the Base Console92
No Boom up from the Platform Console92
10 No Boom down from the Base or Platform Consoles92
11 No Boom down from the Base Console93
12 No Boom down from the Platform Console93
13 No Turret Rotate Right from the Base or Platform Consoles93
14 No Turret Rotate Right from the Base Console93
15 No Turret Rotate Right from the Platform Console94
16 No Turret Rotate Left from the Base or Platform Consoles94
17 No Turret Rotate Left from the Base Console94
18 No Turret Rotate Left from the Platform Console94
19 No Riser up from the Base or Platform Consoles95
20 No Riser up from the Base Console95
21 No Riser up from the Platform Console95
22 No Riser down from the Base or Platform Consoles95
23 No Riser down from the Base Console96
24 No Riser down from the Platform Console96
25 No Telescope out from the Base or Platform Consoles96
26 No Telescope out from the Base Console96
27 No Telescope out from the Platform Console97
28 No Telescope in from the Base or Platform Consoles97
29 No Telescope in from the Base Console97
30 No Telescope in from the Platform Console97
31 No Platform Level up from the Base or Platform Consoles98
32 No Platform Level up from the Base Console98
33 No Platform Level up from the Platform Console98
34 No Platform Level down from the Base or Platform Consoles98
35 No Platform Level down from the Base Console99
36 No Platform Level down from the Platform Console99
37 No Platform Rotate or Jib Functions from the Base or Platform Consoles99
38 No Platform Rotate Right from the Base or Platform Consoles100
39 No Platform Rotate Right from the Base Console100
40 No Platform Rotate Right from the Platform Console100
41 No Platform Rotate Left from the Base or Platform Consoles101
42 No Platform Rotate Left from the Base Console101
43 No Platform Rotate Left from the Platform Console101
44 No Jib up from the Base or Platform Consoles101
45 No Jib up from the Base Console102
46 No Jib up from the Platform Console102
47 No Jib down from the Base or Platform Consoles102
48 No Jib down from the Base Console102
49 No Jib down from the Platform Console103
50 No Drive or Steer Functions103
51 No Forward or Reverse Drive103
52 No Forward Drive103
53 No Reverse Drive104
54 The Brake will Not Release104
55 No Left Steer104
56 No Right Steer105
57 The Directon Sensing Is Inoperative105
59 The Overload Indicator Light Does Not Turn on When the Platform Is Overloaded106
60 The Audible Alarm Does Not Turn on with the Platform Overloaded106
Hydraulic System107
All Controls Inoperative107
All Boom Functions Inoperative107
No Main Boom up107
No Main Boom down108
No Riser Boom up108
No Riser Boom down109
Riser Boom down Jerky109
No Turret Rotate Left109
No Turret Rotate Right110
10 No Boom Extend111
11 No Boom Retract111
12 No Jib up111
13 No Jib down112
14 No Platform Rotation Right112
15 No Platform Rotation Left 4113
16 Platform will Not Level down Manually113
17 Platform will Not Level up Manually114
18 Brake will Not Release114
19 Brake will Not Engage115
20 Differential Lock will Not Engage115
21 No Drive Forward or Reverse115
22 No Forward Drive115
23 No Reverse Drive116
24 No High Speed Drive116
25 No Right Steer116
26 No Left Steer116
27 Axle will Not Oscillate116
28 Axle will Not Lock117
Section 5 - Procedures118
General118
Safety and Workmanship118
Platform119
Human Machine Interface (HMI)119
User Interface Keys119
OCM Character Functions Charts120
OCM Function Channel Names120
OCM Pin Reference121
SCM Calibration - ANSI/CSA127
SCM Calibration Flowchart - ANSI/CSA128
Fly Boom Switch Voltage References130
Platform Controller Voltage References131
Boom132
Check Wear Pads132
Shim Wear Pads132
Cable Carrier Repair132
Rotary Actuator Bolt Torque Procedure132
Master Cylinder Replacement133
Limit Switch Locations134
Turret135
Check and Replace the High Pressure Filter135
Check Rotation Bearing for Axial Wear136
Turret Rotation Gear Bolt Torque Sequence136
Electronic Tilt Switch Setup Procedure137
Battery Replacement139
Diesel Engine140
Replace Engine Oil and Filter140
Replace the Fuel Filter141
Replace the Air Filter141
Check the Engine Belt141
Hydraulic Tank142
Hydraulic Oil Replacement142
Hydraulic Filter Replacement142
Manifold and Hydraulic Pumps143
Hydraulic Brake Pressure Adjustment143
Hydraulic System Relief Valve Adjustment144
Riser down Relief Valve Adjustment144
Turret Rotate Relief Valve Adjustment145
Platform Level Relief Valve Adjustment145
Test Charge Pump Pressure on Drive Pump146
Test Forward Drive Pressure on Drive Pump146
Test Reverse Drive Pressure on Drive Pump147
Axles148
Change the Oil in the Axles148
Check the Oil Level in the Torque Hubs148
Change the Oil in the Torque Hubs148
Check the Oil Level in the Axle Gearbox149
Change the Oil in the Axle Gearbox149
Oscillating Cylinder Bolt Replacement150
Oscillating Cylinder Replacement150
Bleed the Oscillating Axle Cylinders152
Test the Oscillating Axle Cylinders152
10 Pin Brake Adjustments153
11 Brake Inspection154
Grease Points155
Grease the Turret Ring Gear155
Grease the Turret Swing Drive155
Grease the Axles156
Grease the Drive Shaft156

Skyjack SJ45 AJ+ - Service Manual

Table of Contents

Other manuals for Skyjack SJ45 AJ+

Related product manuals