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SJ45 AJ+
Skyjack SJ45 AJ+ Service Manual
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73
238274AAA
SJ45 AJ+
3.17
Engin
e H
arne
ss
Wirin
g Di
agram -
D1
305
M236167AF-3
3
2
4
1
5
6
7
8
11
10
12
9
13
14
15
18
17
19
16
20
21
22
23
24
26
25
27
28
29
30
33
32
34
31
35
36
37
38
41
40
42
39
43
44
2
1
2
1
3
2
1
2
1
1
2
3
4
5
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8
9
10
11
12
106-BU/WH-18
1
105-WH-18
2A-WH-18
2005-BU-18
105-BU/BK-18
J1
TO ENGINE ECU
103C-RD-16
57F-BRN/GRN-16
00-WH-18
00-WH-18
1
104-BU-18
CANL-GN-18
CANH-YL-18
00-WH-18
00-WH-18
286-WH-16
86-PU/BU-16
232-WH-18
68B-GREY
-16
1
106-BN-18
74B-GRN/GY
-18
J2
TO ACTUATOR SOLENOID
86-PU/BU-16
286-WH-16
J3
TO SPEED SENSOR
1
105-WH-18
1
104-BU-18
1
106-BN-18
TO ENGINE GROUND
00-WH-12
TO B+ ON ALTERNATOR
S00
TO MAIN BATTERY
DISCONNECT
TO STARTER
RELAY
103A-FLK-12
103-RD-10
J6
TO ALTERNATOR IGNITION
2005-BU-18
68B-GREY
-18
74B-GRN/GY
-18
CANL-GN-18
CANH-YL-18
103-RD-10
74-GRN/GY
-12
J5
TO TEMP. SENSOR
106-BU/WH-18
105-BU/BK-18
57A-BRN/GRN-16
232-WH-18
57E--BRN/GRN-12
57E-BRN/GRN-12
2A-WH-18
TO OIL PRESSURE SW.
S68B
TO GLOW PLUG
103B-RD-12
103-RD-12
S103
103-RD-14
103C-RD-16
57A-BN/GN-18
57F-BRN/GRN-16
68-GREY
- 16
68B-GREY
-16
74BCR
57ACR
F6
F4
F3
F2
ENGINE FUSEBOX
S1105
1
105-WH-18
POSI AIR OPTION
103B-RD-12
10A
10A
5A
30A
103B-RD-12
00-WH-18
57A-BRN/GRN-16
74 GRN/GY
-16 (GLOW PLUG ON)
68- GREY
- 16
J4
TO BASE CONTROL BOX
CANL
CANH
76- BRN/BLU - 16
77- BRN/GRY
-16
77- BRN/GRY
-16
74-GRN/GY
-12
76-BRN/BLU - 16
68CR
103B-RD-16
00-WH-18
S00-1
68A-GREY
-16
S74
TO STARTER
B+ POST
103A-FLK-12
L = 661mm/26 "
S103B
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72
Table of Contents
Table of Contents
5
Section 1 - Scheduled Maintenance
11
Read and Heed
11
MEWP and Mobile Elevating Work Platform Definition
11
Purpose of Equipment
11
Use of Equipment
11
Manual
11
Service Policy and Warranty
11
Operator Safety Reminders, Warnings and Precautions
11
Maintenance and Service
12
Maintenance and Inspection Schedule
12
Owner's Annual Inspection Record
12
Replacement Parts
12
Maintenance and Service Safety Tips
12
Hydraulic System & Component Maintenance and Repair
13
Hydraulic Maintenance Hints
13
Railing Maintenance and Repair
14
Scheduled Maintenance
15
Service Bulletins
15
Maintenance and Inspection
15
Maintenance Instructions
15
Owner's Annual Inspection Record
16
Pre-Delivery/Maintenance Inspection Checklist
17
Scheduled Maintenance Inspections
18
Electrical
18
Hydraulic
18
Labels
18
Limit Switches
18
Engine Compartment
19
Control Compartment
22
Base
24
Platform
26
Boom Assembly
27
10 Optional Equipment
28
Function Tests
29
Section 2 - Maintenance Tables and Diagrams
30
Standard Hose Numbering System
30
Torque Specifications for Fasteners (US Imperial)
32
Torque Specifications for Fasteners (Metric)
33
Torque Specifications for Hydraulic Couplings & Hoses
34
MEWP Torque Specifications
35
Axle Torque Specifications
36
Axle Maintenance Intervals
37
Tire Specifications
38
Floor Loading Pressure
39
Hydraulic Specifications
40
MEWP Specifications
41
Platform Capacities
42
Fluids
43
Engines
43
Reach Diagram
44
Dimension Diagrams
45
Axle Oscillation Diagram
47
Section 3 - System Component Identification and Schematics
48
Electrical Symbol Chart
49
Hydraulic Symbol Chart
50
Wire Number and Color Code
51
Hydraulic Parts List
52
Electrical Parts List
55
Brake Manifold Components and Ports
58
Rotary Manifold Ports
59
Drive and System Pump Ports
60
Drive and System Pump Ports
61
Drive Motor Ports
62
Jib Valve Ports
63
Pressure Reducing Valve Ports
64
Main Manifold Ports
65
Generator Control Valve and Manifold
68
Main Harness and Fuel Level Switch Harness
69
Engine Harness - D1305
70
Engine Harness Wiring Diagram - D1305
71
Engine Harness - WG972
72
Engine Harness Wiring Diagram - WG972
73
Platform Harnesses
74
Limit Switch Connections
75
All Motion Alarm Connections - CE & as
76
Flashing Amber Light Connections
77
Hydraulic Schematic
79
Platform Control Box Wiring
80
Base Control Box Wiring - ANSI/CSA & as
81
Base Control Box Wiring - CE
82
Electrical Schematic - ANSI/CSA & as
83
Electrical Schematic - CE
84
Engine Schematic - Kubota D1305
85
Engine Schematic - Kubota WG972
86
Section 4 - Troubleshooting Information
87
Introduction
87
Electrical System
88
All Controls Are Inoperative from the Base or Platform Console
88
All Controls Are Inoperative from the Base Console
90
The Engine will Not Crank from the Base or Platform
90
The Engine will Not Crank from the Base
91
The Engine will Not Crank from the Platform
91
The Boom Controls Are Inoperative (Drive Operates)
91
No Boom up from the Base or Platform Controls
92
No Boom up from the Base Console
92
No Boom up from the Platform Console
92
10 No Boom down from the Base or Platform Consoles
92
11 No Boom down from the Base Console
93
12 No Boom down from the Platform Console
93
13 No Turret Rotate Right from the Base or Platform Consoles
93
14 No Turret Rotate Right from the Base Console
93
15 No Turret Rotate Right from the Platform Console
94
16 No Turret Rotate Left from the Base or Platform Consoles
94
17 No Turret Rotate Left from the Base Console
94
18 No Turret Rotate Left from the Platform Console
94
19 No Riser up from the Base or Platform Consoles
95
20 No Riser up from the Base Console
95
21 No Riser up from the Platform Console
95
22 No Riser down from the Base or Platform Consoles
95
23 No Riser down from the Base Console
96
24 No Riser down from the Platform Console
96
25 No Telescope out from the Base or Platform Consoles
96
26 No Telescope out from the Base Console
96
27 No Telescope out from the Platform Console
97
28 No Telescope in from the Base or Platform Consoles
97
29 No Telescope in from the Base Console
97
30 No Telescope in from the Platform Console
97
31 No Platform Level up from the Base or Platform Consoles
98
32 No Platform Level up from the Base Console
98
33 No Platform Level up from the Platform Console
98
34 No Platform Level down from the Base or Platform Consoles
98
35 No Platform Level down from the Base Console
99
36 No Platform Level down from the Platform Console
99
37 No Platform Rotate or Jib Functions from the Base or Platform Consoles
99
38 No Platform Rotate Right from the Base or Platform Consoles
100
39 No Platform Rotate Right from the Base Console
100
40 No Platform Rotate Right from the Platform Console
100
41 No Platform Rotate Left from the Base or Platform Consoles
101
42 No Platform Rotate Left from the Base Console
101
43 No Platform Rotate Left from the Platform Console
101
44 No Jib up from the Base or Platform Consoles
101
45 No Jib up from the Base Console
102
46 No Jib up from the Platform Console
102
47 No Jib down from the Base or Platform Consoles
102
48 No Jib down from the Base Console
102
49 No Jib down from the Platform Console
103
50 No Drive or Steer Functions
103
51 No Forward or Reverse Drive
103
52 No Forward Drive
103
53 No Reverse Drive
104
54 The Brake will Not Release
104
55 No Left Steer
104
56 No Right Steer
105
57 The Directon Sensing Is Inoperative
105
59 The Overload Indicator Light Does Not Turn on When the Platform Is Overloaded
106
60 The Audible Alarm Does Not Turn on with the Platform Overloaded
106
Hydraulic System
107
All Controls Inoperative
107
All Boom Functions Inoperative
107
No Main Boom up
107
No Main Boom down
108
No Riser Boom up
108
No Riser Boom down
109
Riser Boom down Jerky
109
No Turret Rotate Left
109
No Turret Rotate Right
110
10 No Boom Extend
111
11 No Boom Retract
111
12 No Jib up
111
13 No Jib down
112
14 No Platform Rotation Right
112
15 No Platform Rotation Left 4
113
16 Platform will Not Level down Manually
113
17 Platform will Not Level up Manually
114
18 Brake will Not Release
114
19 Brake will Not Engage
115
20 Differential Lock will Not Engage
115
21 No Drive Forward or Reverse
115
22 No Forward Drive
115
23 No Reverse Drive
116
24 No High Speed Drive
116
25 No Right Steer
116
26 No Left Steer
116
27 Axle will Not Oscillate
116
28 Axle will Not Lock
117
Section 5 - Procedures
118
General
118
Safety and Workmanship
118
Platform
119
Human Machine Interface (HMI)
119
User Interface Keys
119
OCM Character Functions Charts
120
OCM Function Channel Names
120
OCM Pin Reference
121
SCM Calibration - ANSI/CSA
127
SCM Calibration Flowchart - ANSI/CSA
128
Fly Boom Switch Voltage References
130
Platform Controller Voltage References
131
Boom
132
Check Wear Pads
132
Shim Wear Pads
132
Cable Carrier Repair
132
Rotary Actuator Bolt Torque Procedure
132
Master Cylinder Replacement
133
Limit Switch Locations
134
Turret
135
Check and Replace the High Pressure Filter
135
Check Rotation Bearing for Axial Wear
136
Turret Rotation Gear Bolt Torque Sequence
136
Electronic Tilt Switch Setup Procedure
137
Battery Replacement
139
Diesel Engine
140
Replace Engine Oil and Filter
140
Replace the Fuel Filter
141
Replace the Air Filter
141
Check the Engine Belt
141
Hydraulic Tank
142
Hydraulic Oil Replacement
142
Hydraulic Filter Replacement
142
Manifold and Hydraulic Pumps
143
Hydraulic Brake Pressure Adjustment
143
Hydraulic System Relief Valve Adjustment
144
Riser down Relief Valve Adjustment
144
Turret Rotate Relief Valve Adjustment
145
Platform Level Relief Valve Adjustment
145
Test Charge Pump Pressure on Drive Pump
146
Test Forward Drive Pressure on Drive Pump
146
Test Reverse Drive Pressure on Drive Pump
147
Axles
148
Change the Oil in the Axles
148
Check the Oil Level in the Torque Hubs
148
Change the Oil in the Torque Hubs
148
Check the Oil Level in the Axle Gearbox
149
Change the Oil in the Axle Gearbox
149
Oscillating Cylinder Bolt Replacement
150
Oscillating Cylinder Replacement
150
Bleed the Oscillating Axle Cylinders
152
Test the Oscillating Axle Cylinders
152
10 Pin Brake Adjustments
153
11 Brake Inspection
154
Grease Points
155
Grease the Turret Ring Gear
155
Grease the Turret Swing Drive
155
Grease the Axles
156
Grease the Drive Shaft
156
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Skyjack SJ45 AJ+ Specifications
General
Brand
Skyjack
Model
SJ45 AJ+
Category
Boom Lifts
Language
English
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