Skyjack SJ46 AJ+ - Service Manual

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SERVICE

MANUAL

ARTICULATING BOOMS

SJ46 AJ+, SJ46 AJ, SJ51 AJ

229042ABA

August 2020

ANSI/CSA, CE, AS

To order go to Discount-Equipment.com

Main Page

Table of Contents5
Section 1 - Scheduled Maintenance13
Read and Heed13
MEWP and Mobile Elevating Work Platform Definition13
Purpose of Equipment13
Use of Equipment13
Manual13
Service Policy and Warranty13
Operator Safety Reminders, Warnings and Precautions13
Maintenance and Service14
Maintenance and Inspection Schedule14
Owner's Annual Inspection Record14
Replacement Parts14
Maintenance and Service Safety Tips14
Hydraulic System & Component Maintenance and Repair15
Hydraulic Maintenance Hints15
Railing Maintenance and Repair16
Scheduled Maintenance17
Service Bulletins17
Maintenance and Inspection17
Maintenance Instructions17
Owner's Annual Inspection Record18
Pre-Delivery/Maintenance Inspection Checklist19
Scheduled Maintenance Inspections20
Electrical20
Hydraulic20
Labels20
Limit Switches20
Engine Compartment21
Control Compartment24
Base26
Platform28
Boom Assembly29
10 Optional Equipment30
Function Tests31
Section 2 - Maintenance Tables and Diagrams32
Standard Hose Numbering System32
Torque Specifications for Fasteners (US Imperial)34
Torque Specifications for Fasteners (Metric)35
Torque Specifications for Hydraulic Couplings & Hoses36
MEWP Torque Specifications37
Axle Torque Specifications38
Axle Maintenance Intervals39
Maximum Platform Capacity40
Tire Specifications40
Floor Loading Pressure41
Hydraulic Specifications42
Hydraulic & Gear Oils43
Specifications & Features - Dimensions & Speeds44
Engine Specifications46
Reach & Dimension Diagrams - SJ46 AJ+ ANSI/CSA47
Reach & Dimension Diagrams - SJ46 AJ CE & as48
Reach & Dimension Diagrams - SJ51 AJ CE & as49
Axle Oscillation Diagram50
Section 3 - System Component Identification and Schematics51
Electrical Symbol Chart52
Hydraulic Symbol Chart53
Wire Number and Color Code54
Hydraulic Parts List55
Electrical Parts List58
Brake Manifold Components and Ports61
Rotary Manifold Ports62
Drive and System Pump Ports63
Drive and System Pump Ports64
Drive Motor Ports65
Jib Valve Ports66
Pressure Reducing Valve Ports67
Main Manifold Ports68
Generator Control Valve and Manifold71
Main Harness and Fuel Level Switch Harness72
Interface Harness - Deutz D2.9L73
Interface Harness - Deutz D201174
Engine Interface Harness - Deutz D2.275
Interface Harness - Kubota76
ECU Engine Wiring Diagram - Deutz D201177
Glow Plug Harnesses - Deutz D2.9L78
Glow Plug Harnesses - Deutz D201179
Platform Harnesses80
Platform Control Cables81
Limit Switch Connections - ANSI/CSA82
Limit Switch Connections - CE & as83
Load Sensing Cable Connections - CE & as84
All Motion Alarm Connections - CE & as85
Flashing Amber Light Connections86
SGE Wiring Diagram87
Oil Cooler and 3.5 Kw Generator Base Control Box Wiring88
Generator (3.5 Kw) Platform Control Box Wiring89
Oil Cooler and 12 Kw Generator Base Control Box Wiring90
Generator (12 Kw) Platform Control Box Wiring91
12Kw Generator Electrical Connections92
Load Circuit Wiring - no Generator93
Load Circuit Wiring - 3.5 Kw Generator94
Load Circuit Wiring - 7.5 or 12.5 Kw Generator95
Hydraulic Schematic - ANSI/CSA96
Hydraulic Schematic - CE & as97
Platform Control Box Wiring - ANSI/CSA98
Platform Control Box Wiring - CE99
Platform Control Box Wiring - as100
Base Control Box Wiring - ANSI/CSA101
Base Control Box Wiring - ANSI/CSA with Positive Air Shut-Off Option102
Base Control Box Wiring - CE Deutz D2.2103
Base Control Box Wiring - CE Deutz D2011104
Base Control Box Wiring - as105
Electrical Schematic - ANSI/CSA106
Electrical Schematic - CE with Deutz D2.2107
Electrical Schematic - CE & as with D2011108
Electrical Schematic - as109
Interface & Engine Electrical Schematic - Deutz D2.9L110
Interface & Engine Electrical Schematic - Deutz D2011111
Engine Electrical Schematic - Deutz D2.2112
Interface & Engine Electrical Schematic - Kubota WG2503113
Section 4 - Troubleshooting Information114
Introduction114
Electrical System - ANSI/CSA115
All Controls Are Inoperative from the Base or Platform Console115
All Controls Are Inoperative from the Base Console117
The Engine will Not Crank from the Base or Platform117
The Engine will Not Crank from the Base118
The Engine will Not Crank from the Platform118
The Boom Controls Are Inoperative (Drive Operates)118
No Boom up from the Base or Platform Controls119
No Boom up from the Base Console119
No Boom up from the Platform Console119
10 No Boom down from the Base or Platform Consoles119
11 No Boom down from the Base Console120
12 No Boom down from the Platform Console120
13 No Turret Rotate Right from the Base or Platform Consoles120
14 No Turret Rotate Right from the Base Console120
15 No Turret Rotate Right from the Platform Console121
16 No Turret Rotate Left from the Base or Platform Consoles121
17 No Turret Rotate Left from the Base Console121
18 No Turret Rotate Left from the Platform Console121
19 No Riser up from the Base or Platform Consoles122
20 No Riser up from the Base Console122
21 No Riser up from the Platform Console122
22 No Riser down from the Base or Platform Consoles122
23 No Riser down from the Base Console123
24 No Riser down from the Platform Console123
25 No Telescope out from the Base or Platform Consoles123
26 No Telescope out from the Base Console123
27 No Telescope out from the Platform Console124
28 No Telescope in from the Base or Platform Consoles124
29 No Telescope in from the Base Console124
30 No Telescope in from the Platform Console124
31 No Platform Level up from the Base or Platform Consoles125
32 No Platform Level up from the Base Console125
33 No Platform Level up from the Platform Console125
34 No Platform Level down from the Base or Platform Consoles125
35 No Platform Level down from the Base Console126
36 No Platform Level down from the Platform Console126
37 No Platform Rotate or Jib Functions from the Base or Platform Consoles126
38 No Platform Rotate Right from the Base or Platform Consoles127
39 No Platform Rotate Right from the Base Console127
40 No Platform Rotate Right from the Platform Console127
41 No Platform Rotate Left from the Base or Platform Consoles128
42 No Platform Rotate Left from the Base Console128
43 No Platform Rotate Left from the Platform Console128
44 No Jib up from the Base or Platform Consoles128
45 No Jib up from the Base Console129
46 No Jib up from the Platform Console129
47 No Jib down from the Base or Platform Consoles129
48 No Jib down from the Base Console129
49 No Jib down from the Platform Console130
50 No Drive or Steer Functions130
51 No Forward or Reverse Drive130
52 No Forward Drive130
53 No Reverse Drive131
54 The Brake will Not Release131
55 No Left Steer131
56 No Right Steer132
57 The Directon Sensing Is Inoperative132
Weight133
59 The Overload Indicator Light Does Not Turn on When the Platform Is Overloaded133
60 The Audible Alarm Does Not Turn on with the Platform Overloaded133
Electrical System - CE & as134
All Controls Are Inoperative134
No Power135
Engine will Not Crank136
Engine Cranks but will Not Start140
Glow Plug Circuit Inoperative - Deutz D2011 Diesel Engine143
All Base Control Console Inoperative144
No Movement from Base Control Console145
All Controls Inoperative from Platform Control Console152
Throttle Inoperative, MID and High - Deutz D2.9L164
10 MID Throttle Inoperative165
11 High Throttle Inoperative166
12 Brake will Not Release167
13 Differential Lock will Not Engage168
14 Differential Lock Engages Momentarily but will Not Stay Engaged168
15 No Drive and Steer169
16 No High Speed Drive171
17 No Elevated Drive173
18 Direction Sensing Inoperative173
Load Sensing System - CE & as175
Green Power LED Is Not Flashing175
Load Cell Red Alarm LED Is on (with Platform Empty)175
Red Error LED Is on175
Load Cell Red Alarm LED Is off (with Platform Overloaded)175
Platform Indicator Light Does Not Turn on175
Audible Alarm Does Not Turn on175
Boom and Drive Functions Are Enabled (with Boom Extended)176
Hydraulic System177
All Controls Inoperative177
All Boom Functions Inoperative177
No Main Boom up177
No Main Boom down178
No Riser Boom up178
No Riser Boom down179
Riser Boom down Jerky179
No Turret Rotate Left179
No Turret Rotate Right180
10 No Boom Extend181
11 No Boom Retract181
12 No Jib up - ANSI/CSA181
13 No Jib up - CE & as182
14 No Jib down - ANSI/CSA182
15 No Jib down - CE & as183
16 No Platform Rotation Right - ANSI/CSA183
17 No Platform Rotation Right - CE & as184
18 No Platform Rotation Left - ANSI/CSA184
19 No Platform Rotation Left - CE & as185
20 Platform will Not Level down Manually185
21 Platform will Not Level up Manually186
22 Brake will Not Release186
23 Brake will Not Engage187
24 Differential Lock will Not Engage187
25 No Drive Forward or Reverse187
26 No Forward Drive187
27 No Reverse Drive188
28 No High Speed Drive188
29 No Right Steer188
30 No Left Steer188
31 Axle will Not Oscillate188
32 Axle will Not Lock189
Section 5 - Procedures190
General190
Safety and Workmanship190
Platform191
Human Machine Interface (HMI) - CE & as191
User Interface Keys191
OCM Character Functions Charts192
OCM Function Channel Names192
OCM Operating Values Chart - CE & as193
How to Select OCM Functionality - CE & as194
How to View OCM Operation - CE & as195
How to Unlock and Modify OCM Settings - CE & as196
OCM Pin Reference197
10 OCM Pin Voltage Reference - CE & as203
11 SCM Calibration - ANSI/CSA206
12 SCM Calibration Flowchart - ANSI/CSA207
13 Fly Boom Switch Voltage References209
14 Platform Controller Voltage References210
Load Sensing System - CE & as211
Load Sensing System211
Verify Proper Operation of the Load Sensing System212
Calibration of Load Sensing System (with "Teach In" Handset)213
Boom214
Check Wear Pads214
Shim Wear Pads214
Cable Carrier Repair214
Rotary Actuator Bolt Torque Procedure214
Master Cylinder Replacement215
Limit Switch Locations - SJ46 AJ+ ANSI/CSA216
Limit Switch Locations - SJ46 AJ & SJ51 AJ CE & as217
Turret218
Check and Replace the High Pressure Filter218
Adjust the Turret Rotation Gear Backlash218
Swing Drive Removal219
Swing Drive Replacement220
Check the Swing Drive Oil220
Change the Swing Drive Oil220
Check Rotation Bearing for Axial Wear221
Turret Rotation Gear Bolt Torque Sequence221
Electronic Tilt Switch Setup Procedure222
10 Battery Replacement224
Deutz Diesel Engines225
Replace Engine Oil and Filter225
Replace the Fuel Filter226
Replace the Air Filter226
Check the Engine Belt226
Check the Oil Cooler (Deutz D2011 Only)226
Deutz D2.9L Fault Codes227
Hydraulic Tank247
Hydraulic Oil Replacement247
Hydraulic Filter Replacement247
Kubota WG2503 Dual Fuel Engine248
Engine Parameter Display (Kantrak 1700)248
Kubota WG2503 Diagnostic Trouble Codes249
ECU Pin Reference Chart (Kubota WG2503)254
Fuse Box (Kubota WG2503)255
MAP Sensor (Kubota WG2503)256
IAT Sensor (Kubota WG2503)256
ECT (Kubota WG2503)257
TPS & Engine Speed (Kubota WG2503)257
Fuel Temperature Sensor (Kubota WG2503)258
10 Oil Pressure Sensor (Kubota WG2503)258
Manifold and Hydraulic Pumps259
Hydraulic Brake Pressure Adjustment259
Hydraulic System Relief Valve Adjustment260
Riser down Relief Valve Adjustment260
Turret Rotate Relief Valve Adjustment261
Platform Level Relief Valve Adjustment261
Test Charge Pump Pressure on Drive Pump262
Test Forward Drive Pressure on Drive Pump262
Test Reverse Drive Pressure on Drive Pump263
Axles264
Change the Oil in the Axles264
Check the Oil Level in the Torque Hubs264
Change the Oil in the Torque Hubs264
Check the Oil Level in the Axle Gearbox265
Change the Oil in the Axle Gearbox265
Oscillating Cylinder Bolt Replacement266
Oscillating Cylinder Replacement266
Bleed the Oscillating Axle Cylinders268
Test the Oscillating Axle Cylinders268
10 Pin Brake Adjustments269
11 Brake Inspection270
Grease Points271
Grease the Turret Ring Gear271
Grease the Turret Swing Drive271
Grease the Axles272
Grease the Drive Shaft272
Options273
Generator Troubleshooting273
Generator Frequency/Voltage Check & Adjustment274

Skyjack SJ46 AJ+ - Service Manual

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