Skyjack SJ40T SJ45T Telescopic Boom Service Manual 207563AG – PDF DOWNLOAD
$28.95
Skyjack SJ40T SJ45T Telescopic Boom Service Manual 207563AG – PDF DOWNLOAD
SJ40T & SJ45T: 98001767 to 98999999
Description
Skyjack SJ40T SJ45T Telescopic Boom Service Manual 207563AG – PDF DOWNLOAD
FILE DETAILS:
Skyjack SJ40T SJ45T Telescopic Boom Service Manual 207563AG – PDF DOWNLOAD
Language : English
Pages : 250
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Skyjack SJ40T SJ45T Telescopic Boom Service Manual 207563AG – PDF DOWNLOAD
SJ40T & SJ45T: 98001767 to 98999999
1.1 Read and Heed:
Skyjack is continuously improving and expanding product features on its equipment, therefore,
specifications and dimensions are subject to change without notice.
A mobile device that has a positionable platform supported from ground level by a structure.
The Skyjack Telescopic Boom Series MEWPs are designed to transport and raise personnel, tools and
materials to overhead work areas.
The MEWP is a highly maneuverable, mobile work station. Work platform elevation and elevated
driving must only be done on a firm, level surface.
Operating Manual: The operating manual is considered a fundamental part of the MEWP. 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 MEWP 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.
Skyjack warrants each new product to be free of defective parts and workmanship for the first 2
years or 3000 hours, whichever occurs first. Any defective part will be replaced or repaired by
your local Skyjackdealer at no charge for parts or labor.
In addition, all products have a 5 year structural warranty. Contact the Skyjack Service Department
for warranty statement extensions or exclusions.
Operator safety is Skyjack’s priority. The operator should comply with all applicable
safety-related reminders, warnings and precautions found in the Operating Manual. They should be
read and understood completely before operating the MEWP.
TABLE OF CONTENTS:
Skyjack SJ40T SJ45T Telescopic Boom Service Manual 207563AG – PDF DOWNLOAD
Section 1 – Scheduled Maintenance 13
1 1 Read and Heed 13
1 1-1 Mobile Elevating Work Platform (MEWP) Definition 13
1 1-2 Purpose of Equipment 13
1 1-3 Use of Equipment 13
1 1-4 Manual 13
1 1-5 Service Policy and Warranty 13
1 1-6 Operator Safety Reminders, Warnings and Precautions 13
1 2 Maintenance and Service 14
1 2-1 Maintenance and Inspection Schedule 14
1 2-2 Owner’s Annual Inspection Record 14
1 2-3 Replacement Parts 14
1 2-4 Maintenance and Service Safety Tips 14
1 2-5 Hydraulic System & Component Maintenance and Repair 15
1 2-6 Hydraulic Maintenance Hints 15
1 2-7 Railing Maintenance and Repair 16
1 3 Scheduled Maintenance 17
1 3-1 Service Bulletins 17
1 3-2 Maintenance and Inspection 17
1 3-3 Maintenance Instructions 17
1 4 Owner’s Annual Inspection Record 18
1 5 Pre-Delivery/Maintenance Inspection Checklist 19
1 6 Scheduled Maintenance Inspections 20
1 6-1 Electrical 20
1 6-2 Hydraulic 20
1 6-3 Manuals & Required Documents 20
1 6-4 Labels 20
1 6-5 Limit Switches 21
1 6-6 Engine Compartment 21
1 6-7 Control Compartment 24
1 6-8 Base 26
1 6-9 Platform Assembly 28
1 6-10 Boom Assembly 29
1 6-11 Optional Equipment/Attachments 30
1 7 Function Tests 31
Section 2 – Maintenance Tables and Diagrams 33
2 1 Standard Hose Numbering System 33
Table of Contents
6
207563AG SJ40T, SJ45T
2 2 Aerial Platform Torque Specifications 35
2 3 Axle Torque Specifications 36
2 4 Torque Specifications for Fasteners (US) 37
2 5 Torque Specifications for Fasteners (Metric) 38
2 6 Torque Specifications for Hydraulic Couplings & Hoses 39
2 7 Axles Maintenance Intervals 40
2 8 Tire Specifications 41
2 9 Floor Loading Pressure 42
2 10 Hydraulic Specifications & Gear Oil 43
2 11 Specifications and Features – Dimensional Data 44
2 12 Specifications and Features – Performance and Speeds 45
2 13 Engine Specifications 46
2 14 Dimension and Reach Diagram – SJ40T 48
2 15 Dimension and Reach Diagram – SJ45T 49
2 16 Axle Oscillation Diagrams 50
Section 3 – System Component Identification and Schematics 51
3 1 Electrical Symbol Chart 52
3 2 Hydraulic Symbol Chart 53
3 3 Wire Number and Color Code 54
3 4 Hydraulic Parts List 55
3 5 Electrical Component Parts List 58
3 6 Rotary Manifold Port Identification 62
3 7 Brake Manifold Port Identification 63
3 8 System Pump Port Identification 64
3 9 Drive Pump Port Identification 65
3 10 Drive Motor Port Identification 66
3 11 Jib Valve Port Identification – SJ45T 67
3 12 No Jib Valve Port Identifications – SJ40T 68
3 13 Main Manifold Port Identification 69
3 14 Main Manifold Electrical Component Identification 70
3 15 Main Manifold Hydraulic Component Identification 71
3 16 Main Harness Wiring Diagram 72
3 17 ECU Engine Wiring Diagram – Deutz D2011 73
3 18 Engine Interface Harness – Deutz D2 9L 74
3 19 Engine Interface Harness – Kubota WG2503 75
3 20 Glow Plug Harness – Deutz D2 9L 76
3 21 Glow Plug Harness – Deutz D2011 77
3 22 Platform Harnesses 78
3 23 Platform Control Cables 79
3 24 Limit Switch Connections 80
3 25 Load Sensing Cable Connection (CE & AS) 81
3 26 Flashing Light Connection 82
7
SJ40T, SJ45T 207563AG
3 27 Oil Cooler Harness Connections 83
3 28 Generator Wire Kit Connections 84
3 29 SGE Wiring Diagram 85
3 30 Load Circuit Wiring 86
3 31 Differential Lock Harness 87
3 32 Hydraulic Schematic 89
3 33 Platform Controls Wiring – SJ40T ANSI/CSA Kubota 90
3 34 Platform Controls Wiring – SJ40T ANSI/CSA Deutz & Perkins 91
3 35 Platform Controls Wiring – SJ45T ANSI/CSA Kubota 92
3 36 Platform Controls Wiring – SJ45T ANSI/CSA Deutz & Perkins 93
3 37 Platform Controls Wiring – SJ45T CE Deutz 94
3 38 Platform Controls Wiring – SJ45T AS Deutz 95
3 39 Base Controls Wiring – SJ40T ANSI/CSA Kubota 96
3 40 Base Controls Wiring – SJ40T ANSI/CSA Deutz D2011 97
3 41 Base Controls Wiring – SJ40T ANSI/CSA Deutz D2011 with Positive Air Shut-Off Option 98
3 42 Base Controls Wiring – SJ40T ANSI/CSA Deutz D2 9L 99
3 43 Base Controls Wiring – SJ40T ANSI/CSA Deutz D2 9L with Positive Air Shut-Off Option 100
3 44 Base Controls Wiring – SJ40T ANSI/CSA Perkins 101
3 45 Base Controls Wiring – SJ45T ANSI/CSA Kubota 102
3 46 Base Controls Wiring – SJ45T ANSI/CSA Deutz D2011 103
3 47 Base Controls Wiring – SJ45T ANSI/CSA Deutz D2011 with Positive Air Shut-Off Option 104
3 48 Base Controls Wiring – SJ45T ANSI/CSA Deutz D2 9L 105
3 49 Base Controls Wiring – SJ45T ANSI/CSA Deutz D2 9L with Positive Air Shut-Off Option 106
3 50 Base Controls Wiring – SJ45T ANSI/CSA Perkins 107
3 51 Base Controls Wiring – SJ45T CE Deutz D2 2 108
3 52 Base Controls Wiring – SJ45T CE Deutz D2011 109
3 53 Base Controls Wiring – SJ45T AS Deutz D2011 110
3 54 Electrical Schematic – ANSI/CSA Kubota 111
3 55 Electrical Schematic – ANSI/CSA Deutz D2011 112
3 56 Electrical Schematic – ANSI/CSA Deutz D2 9L 113
3 57 Electrical Schematic – ANSI Perkins 114
3 58 Electrical Schematic – CE Deutz D2 2 115
3 59 Electrical Schematic – CE Deutz D2011 116
3 60 Electrical Schematic – AS Deutz D2011 117
3 61 Interface & Engine Electrical Schematic – Kubota WG2503 118
3 62 Interface & Engine Electrical Schematic – Deutz D2 9L 119
3 63 Interface & Engine Electrical Schematic – Deutz D2 2 120
3 64 OEM Engine Harness – Deutz D2 2 121
3 65 Engine Interface Harness Schematic – Perkins 122
3 66 Engine OEM Harness Schematic – Perkins 123
3 67 Engine Component Harness Schematic – Perkins 124
8
207563AG SJ40T, SJ45T
Section 4 – Troubleshooting Information 125
4 1 Introduction 125
4 2 Electrical System 126
4 2-1 All Controls Inoperative 126
4 2-2 No Power 127
4 2-3 Engine Will Not Crank 128
4 2-4 Engine Cranks but Will Not Start 132
4 2-5 Glow Plug Circuit Inoperative – Deutz D2011 diesel engine 136
4 2-6 All Base Control Console Inoperative 136
4 2-7 No Movement from Base Control Console 137
4 2-8 All Controls Inoperative From Platform Control Console 144
4 2-9 Throttle Inoperative, Mid and High – Deutz D2 9L 153
4 2-10 Mid Throttle Inoperative 153
4 2-11 High Throttle Inoperative 155
4 2-12 Brake will not Release 156
4 2-13 Differential Lock will not Engage 157
4 2-14 No Drive and Steer 158
4 2-15 No High Speed Drive 160
4 2-16 No Elevated Drive 162
4 2-17 Direction Sensing Inoperative 162
4 2-18 Steer Direction Sensing Inoperative 163
4 3 Hydraulic System 164
4 3-1 All Controls Inoperative 164
4 3-2 All Boom Functions Inoperative 164
4 3-3 No Main Boom Up 164
4 3-4 No Main Boom Down 165
4 3-5 No Turret Rotate 165
4 3-6 No Boom Extend 166
4 3-7 No Boom Retract 167
4 3-8 No Jib Up 167
4 3-9 No Jib Down 168
4 3-10 No Platform Rotation 168
4 3-11 Platform will not Level 169
4 3-12 Brake will not Release 170
4 3-13 Brake will not Engage 170
4 3-14 No Drive 170
4 3-15 Differential Lock will not Engage 171
4 3-16 No High Speed Drive 171
4 3-17 No Steer 171
4 3-18 Axle Will Not Oscillate 172
4 3-19 Axle Will Not Lock 172
4 4 Load Sensing System – CE 173
9
SJ40T, SJ45T 207563AG
4 4-1 Green Power LED is not Flashing 173
4 4-2 Load Cell red Alarm LED is ON (with platform empty) 173
4 4-3 Red Error LED is ON 173
4 4-4 Load Cell red Alarm LED is OFF (with platform overloaded) 173
4 4-5 Platform Indicator Light does not turn ON 173
4 4-6 Audible Alarm does not turn ON 174
4 4-7 Boom and Drive Functions are Enabled (with boom extended) 174
Section 5 – Procedures 175
5 1 General 175
5 1-1 Safety and Workmanship 175
5 2 Platform 176
5 2-1 Human Machine Interface (HMI) 176
5 2-2 User Interface Keys 176
5 2-3 SCM Character Functions Charts 177
5 2-4 SCM Operating Values Chart 178
5 2-5 How to Select Functionality 179
5 2-6 How to View OCM Operation 180
5 2-7 How to Unlock and Modify OCM Settings 181
5 2-8 OCM Pin Voltage Reference 182
5 2-9 Fly Boom Switch Voltage References 185
5 2-10 Platform Controller Voltage References 186
5 3 Boom 187
5 3-1 Check Wear Pads 187
5 3-2 Shim Wear Pads 187
5 3-3 Cable Carrier Repair 187
5 3-4 Rotary Actuator Bolt Torque Procedure 187
5 4 Turret 188
5 4-1 Check and Replace the High Pressure Filter 188
5 4-2 Adjust the Turret Rotation Gear Backlash 188
5 4-3 Check the Swing Drive Oil 189
5 4-4 Change the Swing Drive Oil 189
5 4-5 Battery Replacement 190
5 4-6 Turret Rotation Gear Bolt Torque Sequence 190
5 4-7 Electronic Tilt Switch Setup Procedure 191
5 4-8 Check Rotation Bearing for Axial Wear 193
5 5 Deutz Diesel Engines 194
5 5-1 Replace Engine Oil and Filter 194
5 5-2 Replace the Fuel Filter 195
5 5-3 Replace the Air Filter 195
5 5-4 Check the Engine Belt 195
5 5-5 Check the Oil Cooler (Deutz D2011 only) 195
5 5-6 Deutz D2 9L Fault Codes 196
5 6 Kubota WG2503 Dual Fuel Engine 216
5 6-1 Engine Parameter Display (KAntrak 1700) 216
5 6-2 Diagnostic Trouble Codes 217
5 6-3 Diagnostic Trouble Codes 218
5 6-4 Diagnostic Trouble Codes 219
5 6-5 Diagnostic Trouble Codes 220
5 6-6 Diagnostic Trouble Codes 221
5 6-7 ECU Pin Reference Chart (Kubota WG2503) 222
5 6-8 Fuse Box (Kubota WG2503) 223
5 6-9 MAP Sensor (Kubota WG2503) 224
5 6-10 IAT Sensor (Kubota WG2503) 224
5 6-11 ECT (Kubota WG2503) 225
5 6-12 TPS & Engine Speed (Kubota WG2503) 225
5 6-13 Fuel Temperature Sensor (Kubota WG2503) 226
5 6-14 Oil Pressure Sensor (Kubota WG2503) 226
5 7 Hydraulic Tank 227
5 7-1 Hydraulic Oil Replacement 227
5 7-2 Hydraulic Filter Replacement 227
5 8 Manifold and Hydraulic Pumps 228
5 8-1 Hydraulic Brake Pressure Adjustment 228
5 8-2 Hydraulic Standby Pressure Adjustment 229
5 8-3 Hydraulic High Pressure Adjustment 230
5 8-4 Hydraulic System Relief Valve Adjustment 231
5 8-5 Turret Rotate Relief Valve Adjustment 232
5 8-6 Platform Level Relief Valve Adjustment 232
5 8-7 Fly Boom Relief Valve Adjustment 233
5 8-8 Test Charge Pump Pressure on Drive Pump 233
5 8-9 Test Forward Drive Pressure on Drive Pump 234
5 8-10 Test Reverse Drive Pressure on Drive Pump 234
5 9 Axles 235
5 9-1 Change the Oil in the Axles 235
5 9-2 Check the Oil Level in the Torque Hubs 235
5 9-3 Change the Oil in the Torque Hubs 235
5 9-4 Check the Oil Level in the Axle Gearbox 236
5 9-5 Change the Oil in the Axle Gearbox 236
5 9-6 Oscillating Cylinder Bolt Replacement 237
5 9-7 Oscillating Cylinder Replacement 237
5 9-8 Bleed the Oscillating Axle Cylinders 239
5 9-9 Test the Oscillating Axle Cylinders 239
5 9-10 Pin Brake Adjustments 240
5 9-11 Brake Inspection 241
5 10 Grease Points 242
5 10-1 Grease the Turret Ring Gear 242
5 10-2 Grease the Turret Swing Drive 242
5 10-3 Grease the Axles 243
5 10-4 Grease the Drive Shaft 243
5 11 Options 244
5 11-1 Load Sensing System – CE 244
5 11-2 Verify Proper Operation of the Load Sensing System 245
5 11-3 Calibration of Load Sensing System (with “Teach In” Handset) 246
5 11-4 Generator Troubleshooting 247
5 11-5 Generator Frequency/Voltage Check & Adjustment 248
Customer Support: [email protected]
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V
