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Skyjack SJ40T SJ45T Telescopic Boom Service Manual 143872AI – PDF DOWNLOAD
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Skyjack SJ40T SJ45T Telescopic Boom Service Manual 143872AI – PDF DOWNLOAD
SJ40T & SJ45T 98000522 to 98001141
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Description
Skyjack SJ40T SJ45T Telescopic Boom Service Manual 143872AI – PDF DOWNLOAD
FILE DETAILS:
Skyjack SJ40T SJ45T Telescopic Boom Service Manual 143872AI – PDF DOWNLOAD
Language : English
Pages : 206
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Skyjack SJ40T SJ45T Telescopic Boom Service Manual 143872AI – PDF DOWNLOAD
SJ40T & SJ45T 98000522 to 98001141
SKYJACK is continuously improving and expanding product features on its equipment, therefore,
specifications and dimensions are subject to change without notice.
specifications and dimensions are subject to change without notice.
Aerial Platfrm Definition:
A mobile device that has an adjustable position platform supported from ground level by a
structure.
A mobile device that has an adjustable position platform supported from ground level by a
structure.
Purpose of Equipment:
The SKYJACK Telescopic Boom Series (Models SJ 40T, 45T, 61T & 66T) aerial platform is designed to
transport and raise personnel, tools and materials to overhead work areas
The SKYJACK Telescopic Boom Series (Models SJ 40T, 45T, 61T & 66T) aerial platform is 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. It can be driven over uneven terrain only when the platform is
fully lowered.
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a
flat, level, compacted surface. It can be driven over uneven terrain only when the platform is
fully lowered.
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.
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.
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.
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.
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 4.1 of the operating manual. Operating
instructions for these options (if equipped) are located in Section 3 of the operating manual.
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are
listed under “Standard and Optional Features” in Table 4.1 of the operating manual. Operating
instructions for these options (if equipped) are located in Section 3 of the operating manual.
TABLE OF CONTENTS:
Skyjack SJ40T SJ45T Telescopic Boom Service Manual 143872AI – PDF DOWNLOAD
Cover..................................................................................... 1 Table of Contents......................................................................... 3 Section 1 - Scheduled Maintenance......................................................... 5 Operator’s Responsibility for Maintenance............................................. 7 Aerial Platfrm Definition......................................................... 7 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 Safety Precautions................................................................ 10 Maintenance and Inspection Schedule............................................... 14 Owner’s Annual Inspection Record.................................................. 14 Replacement Parts................................................................. 14 Maintenance and Service Safety Tips............................................... 14 Hydraulic System & Component Maintenance and Repair............................... 15 Maintenance Hints................................................................. 15 Railing Maintenance and Repair.................................................... 16 Service and Maintenance............................................................... 17 About this Section................................................................ 17 Service Bulletins................................................................. 17 Maintenance and Inspection........................................................ 17 Maintenance Instructions.......................................................... 17 Tables................................................................................ 18 Table 1.1 Owner’s Annual Inspection Record....................................... 18 Table 1.2 Maintenance and Inspection Checklist................................... 19 Scheduled Maintenance Inspections and Function Tests.................................. 20 1.1 Scheduled Maintenance Inspections............................................ 20 1.2 Function Tests............................................................... 30 Section 2 - Maintenance Tables and Diagrams............................................... 39 Tables................................................................................ 40 Table 2.1 Standard Hose Numbering System......................................... 40 Table 2.2 Aerial Platform Torque Specifications.................................. 42 Table 2.3 Axles Torque Specifications............................................ 43 Table 2.4 Axles Maintenance Intervals............................................ 44 Table 2.5 Tire Specifications.................................................... 45 Table 2.6 Floor Loading Pressure................................................. 46 Table 2.7 Hydraulic Specifications............................................... 47 Table 2.8 Specifications and Features............................................ 48 Diagrams.............................................................................. 50 Diagram 2.1 Dimension and Reach Diagram - SJ 40T................................. 50 Diagram 2.2 Dimension and Reach Diagram - SJ 45T................................. 51 Diagram 2.3 Axle Oscillation Diagrams............................................ 52 Section 3 - System Component Identification and Schematics................................ 53 Charts................................................................................ 55 3.1 Hydraulic Symbol Chart....................................................... 55 3.2 Electrical Symbol Chart...................................................... 56 3.3 Wire Number and Color Code................................................... 57 3.4 Hydraulic Schematic Parts List .............................................. 58 3.5 Electrical Component Parts List.............................................. 61 Diagrams and Schematics............................................................... 64 3.6 Rotary Manifold and Port Identifications..................................... 64 3.7a Brake Manifold and Port Identifications..................................... 65 3.7b Brake Manifold and Port Identifications..................................... 66 3.8 System Pump and Port Identifications......................................... 67 3.9 Drive Pump and Port Identifications.......................................... 68 3.10 Drive Motor and Port Identifications........................................ 69 3.11 Jib Valve and Port Identifications.......................................... 70 3.12 No Jib Valve and Port Identifications....................................... 71 3.13 Axle Lockout Valve (If Equipped) and Port Identifications................... 72 3.14 Main Manifold and Port Identifications...................................... 73 3.15 Main Manifold and Electrical Identifications................................ 74 3.16 Main Manifold and Hydraulic Identifications................................. 75 3.17a Main Harness Wiring Diagram................................................ 76 3.17b Main Harness Wiring Diagram................................................ 77 3.18 ECU Engine Wiring Diagram (Deutz Diesel Engine)............................. 78 3.19 Engine Interface Harness (GM Dual Fuel Engine).............................. 79 3.20 Glow Plug Harness........................................................... 80 3.21 Harnesses................................................................... 81 3.22 Platform Control Cable Harnesses............................................ 82 3.23 Limit Switch Connections (ANSI/CSA)......................................... 83 3.24 Limit Switch Connections (CE & AS)........................................... 84 3.25 Load Sensing Cable Connection (CE & AS)..................................... 85 3.26a Deutz Diesel Engine Battery Cable Locations................................ 86 3.26b Deutz Diesel Engine Battery Cable Locations................................ 87 3.27a Hydraulic Schematic Diagram................................................ 89 3.27b Hydraulic Schematic Diagram................................................ 90 3.27c Hydraulic Schematic Diagram................................................ 91 3.28 Platform Control Console Diagram (ANSI/CSA SJ 45T - Deutz Diesel Engine).... 92 3.29 Platform Control Console Diagram (ANSI/CSA SJ 40T - Deutz Diesel Engine).... 93 3.30 Platform Control Console Diagram (CE & AS SJ 45T - Deutz Diesel Engine)..... 94 3.31 Platform Control Console Diagram (ANSI/CSA SJ 45T - GM Dual Fuel Engine).... 95 3.32 Platform Control Console Diagram (ANSI/CSA SJ 40T - GM Dual Fuel Engine).... 96 3.33 Base Control Console Diagram (ANSI/CSA SJ 45T - Deutz Diesel Engine)........ 97 3.34 Base Control Console Diagram (ANSI/CSA SJ 40T - Deutz Diesel Engine)........ 98 3.35 Base Control Console Diagram (CE SJ 45T - Deutz Diesel Engine).............. 99 3.36 Base Control Console Diagram (AS SJ 45T - Deutz Diesel Engine)..............100 3.37a Base Control Console Diagram (ANSI/CSA SJ 45T - GM Dual Fuel Engine).......101 3.37b Base Control Console Diagram (ANSI/CSA SJ 45T - GM Dual Fuel Engine).......102 3.38a Base Control Console Diagram (ANSI/CSA SJ 40T - GM Dual Fuel Engine).......103 3.38b Base Control Console Diagram (ANSI/CSA SJ 40T - GM Dual Fuel Engine).......104 3.39 Electrical Schematic Diagram (ANSI/CSA - Deutz Diesel Engine)...............105 3.40 Electrical Schematic Diagram (CE SJ 45T - Deutz Diesel Engine)..............106 3.41 Electrical Schematic Diagram (AS SJ 45T - Deutz Diesel Engine)..............107 3.42a Electrical Schematic Diagram (ANSI/CSA - GM Dual Fuel Engine).............108 3.42b Electrical Schematic Diagram (ANSI/CSA - GM Dual Fuel Engine).............109 3.43 Interface & Engine Electrical Schematic - GM Dual Fuel Engine .............110 3.44 Engine Harnesses - GM Dual Fuel Engine......................................111 3.45 Flashing Amber Light Connection.............................................113 3.46 Generator Control Valves and Port Indentifcations...........................114 3.47 Oil Cooler Harness Connections..............................................115 3.48 Generator Wire Kit Connections..............................................116 3.49 Generator and Oil Cooler Connection Locations...............................117 3.50 12 kW Generator Connection Assembly.........................................118 3.51 12 kW Generator Connection Locations........................................119 Introduction......................................................................123 Section 4 - Troubleshooting Information...................................................121 4.1 Electrical System................................................................124 4.1-1 All Controls Inoperative...................................................124 4.1-2 No Power To Platform.......................................................124 4.1-3 No Power to Base...........................................................124 4.1-4 Engine Will Not Crank from Base............................................125 4.1-5 Engine Will Not Crank from Platform........................................125 4.1-6 Engine Will Not Crank from Platform or Base (Deutz Diesel).................126 4.1-7 Engine Cranks but Will Not Start (Deutz Diesel)............................126 4.1-8 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel).........127 4.1-9 Engine Cranks but Will Not Start (GM Dual Fuel)............................128 4.1-10 Glow Plug Circuit Inoperative.............................................130 4.1-11 All Base Control Console Inoperative......................................130 4.1-12 No Main Boom Down or Turret Rotate from Base Control Console..............131 4.1-13 No Boom Up from Base Control Console......................................131 4.1-14 No Boom Down from Base Control Console....................................131 4.1-15 No Turret Rotate Left from Base Control Console...........................132 4.1-16 No Turret Rotate Right from Base Control Console..........................132 4.1-17 No Telescope Retract From Base Control Console............................132 4.1-18 No Telescope Extend From Base Control Console.............................133 4.1-19 No Platform Rotate Left From Base Control Console.........................133 4.1-20 No Platform Rotate Right from Base Control Console........................133 4.1-21 No Platform Rotate Left or Right from Base Control Console................134 4.1-22 No Jib Up from Base Control Console.......................................134 4.1-23 No Jib Down from Base Control Console.....................................135 4.1-24 No Jib Up Or Down From Base Control Console...............................135 4.1-25 No Manual Platform Level Up From Base Control Console.....................135 4.1-26 No Manual Platform Level Down From Base Control Console...................136 4.1-27 No Manual Platform Level Up From Platform Control Console.................136 4.1-28 No Manual Platform Level Down From Platform Control Console...............137 4.1-29 All Controls Inoperative From Platform Control Console....................137 4.1-30 No Boom Up From Platform Control Console..................................138 4.1-31 No Boom Down From Platform Control Console................................139 4.1-32 No Turret Left from Platform Control Console..............................139 4.1-33 No Turret Right from Platform Control Console.............................140 4.1-34 No Telescope In from Platform Control Console.............................140 4.1-35 No Telescope Out from Platform Control Console............................141 4.1-36 No Platform Rotate or Jib Function from Platform Control Console..........142 4.1-37 No Platform Rotate Left from Platform Control Console.....................142 4.1-38 No Platform Rotate Right from Platform Control Console....................142 4.1-39 No Jib Up from Platform Control Console...................................143 4.1-40 No Jib Down from Platform Control Console.................................143 4.1-41 Mid Throttle Inoperative..................................................143 4.1-42 High Throttle Inoperative.................................................144 4.1-43 Brake will not Release....................................................145 4.1-44 No Drive and Steer........................................................145 4.1-45 No Forward Drive..........................................................145 4.1-46 No Reverse Drive..........................................................146 4.1-47 No High Speed Drive.......................................................146 4.1-48 No Elevated Drive.........................................................148 4.1-49 No Left Steer.............................................................148 4.1-50 No Right Steer............................................................148 4.1-51 Direction Sensing Inoperative.............................................149 4.1-52 Steer Direction Sensing Inoperative.......................................149 4.2 Hydraulic System.................................................................150 4.2-1 All Controls Inoperative...................................................150 4.2-2 All Boom Functions Inoperative.............................................150 4.2-3 No Main Boom Up............................................................150 4.2-4 No Main Boom Down..........................................................150 4.2-5 No Turret Rotate Left......................................................151 4.2-6 No Turret Rotate Right.....................................................151 4.2-7 No Boom Extend.............................................................151 4.2-8 No Boom Retract............................................................152 4.2-9 No Jib Up..................................................................152 4.2-10 No Jib Down...............................................................152 4.2-11 No Platform Rotation Right................................................153 4.2-12 No Platform Rotation Left.................................................153 4.2-13 Platform will not Level Down..............................................153 4.2-14 Platform will not Level Up................................................153 4.2-15 Brake will not Release....................................................154 4.2-16 Brake will not Engage.....................................................154 4.2-17 No Drive Forward or Reverse...............................................154 4.2-18 No Forward Drive..........................................................154 4.2-19 No Reverse Drive..........................................................155 4.2-20 No High Speed Drive.......................................................155 4.2-21 No Right Steer............................................................155 4.2-22 No Left Steer.............................................................155 4.2-23 Axle Will Not Oscillate...................................................155 4.2-24 Axle Will Not Lock........................................................156 4.3 Load Sensing System - CE.........................................................157 4.3-1 Green Power LED is not Flashing............................................157 4.3-2 Load Cell red Alarm LED is ON (with platform empty)........................157 4.3-3 Red Error LED is ON........................................................157 4.3-4 Load Cell red Alarm LED is OFF (with platform overloaded)..................157 4.3-5 Platform Indicator Light does not turn ON..................................157 4.3-6 Audible Alarm does not turn ON.............................................157 4.3-7 Boom and Drive Functions are Enabled (with boom extended)..................157 General...........................................................................161 Safety and Workmanship............................................................161 Section 5 - Procedures....................................................................159 Platform..............................................................................161 5.1-1 Human Machine Interface (HMI)..............................................161 5.1-2 User Interface Keys........................................................162 OCM Character Functions Charts................................................162 OCM Operating Values Chart....................................................163 5.1-3 How to Select Functionality................................................164 5.1-4 How to View OCM Operation..................................................165 5.1-5 How to Unlock and Modify OCM Settings......................................166 5.1-6 OCM Pin Voltage Reference..................................................167 5.1-7 Platform Controller Voltage References.....................................171 Boom..................................................................................172 5.2-1 Check Wear Pads............................................................172 5.2-2 Shimming Wear Pads.........................................................172 5.2-3 Cable Carrier Repair.......................................................172 Turret................................................................................173 5.3-1 High Pressure Filter Replacement...........................................173 5.3-2 Check Swing Drive Motor Gearbox Oil........................................173 5.3-3 Turret Rotation Gear Backlash Adjustment...................................173 5.3-4 Change Swing Drive Motor Oil...............................................174 5.3-5 Battery Replacement........................................................174 5.3-6 Bolt Torque Procedure......................................................175 Rotary Actuator Bolt Torque Sequence..........................................175 Turret Rotation Gear Bolt Torque Sequence.....................................175 5.3-7 Electronic Tilt Switch Setup Procedure.....................................175 Tilt Switch Replacement.......................................................175 Reprogramming Existing Tilt Switch............................................177 Test and Verify Tilt Circuit..................................................178 5.3-8 Check Rotation Bearing for Axial Wear......................................178 Deutz Diesel Engine...................................................................179 5.4-1 Replace Engine Oil and Filter..............................................179 5.4-2 Replace Fuel Filter........................................................180 5.4-3 Replace Air Filter.........................................................180 5.4-4 Check Engine Belt..........................................................180 5.4-5 Check Oil Cooler...........................................................180 GM Dual Fuel Engine...................................................................181 5.5-1 GM Map and IAT Sensor......................................................181 5.5-2 LPG Temperature Sensor.....................................................182 5.5-3 Throttle Actuator..........................................................183 5.5-4 Engine Coolant Temperature Sensor..........................................184 5.5-5 ECU Pin Reference Chart....................................................185 5.5-6 Fuse Block Layout..........................................................186 Hydraulic Tank........................................................................187 5.6-1 Change Hydraulic Tank Filter...............................................187 5.6-2 Change Hydraulic Oil.......................................................187 Manifold and Hydraulic Pumps..........................................................188 5.7-1 Hydraulic Brake Pressure Adjustment........................................188 5.7-2 Hydraulic Standby Pressure Adjustment......................................189 5.7-3 Hydraulic High Pressure Adjustment.........................................190 5.7-4 Hydraulic System Relief Valve Adjustment...................................191 5.7-5 Test Charge Pump Pressure on Drive Pump....................................192 5.7-6 Test Forward Drive Pressure on Drive Pump..................................192 5.7-7 Test Reverse Drive Pressure on Drive Pump..................................193 Axles.................................................................................193 5.8-1 Change Oil in Rear Axle....................................................193 5.8-2 Change Oil in Front Axle (4WD).............................................193 5.8-3 Check Oil Level in Torque Hub..............................................194 5.8-4 Check Oil Level in Axle Gearbox............................................194 5.8-5 Change Oil in Axle Gearbox.................................................194 5.8-6 Bleeding Oscillating Axle Cylinders........................................195 5.8-7 Pin Brake Adjustments......................................................195 5.8-7 Brake Inspection...........................................................197 Grease Points.........................................................................198 5.9-1 Lubrication................................................................198 5.9-2 Grease Turret Rotation Bearing.............................................198 5.9-3 Grease Turret Rotation Gear................................................198 5.9-4 Grease Cylinder Brackets...................................................199 5.9-5 Grease Drive Axle..........................................................200 5.9-6 Grease Drive Shaft.........................................................200 Options...............................................................................201 5.10-1 Load Sensing System - CE..................................................201
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