Skyjack SJ46 AJ+, SJ46 AJ, SJ51 AJ Articulating Booms Service Manual 229042AAA – PDF DOWNLOAD
$28.95
Skyjack SJ46 AJ+, SJ46 AJ, SJ51 AJ Articulating Booms Service Manual 229042AAA – PDF DOWNLOAD
SJ46 AJ+: A301 000 001 – A301 999 999
SJ46 AJ: B301 000 001 – B301 999 999
SJ51 AJ: B301 000 001 – B301 999 999
Description
Skyjack SJ46 AJ+, SJ46 AJ, SJ51 AJ Articulating Booms Service Manual 229042AAA – PDF DOWNLOAD
FILE DETAILS:
Skyjack SJ46 AJ+, SJ46 AJ, SJ51 AJ Articulating Booms Service Manual 229042AAA – PDF DOWNLOAD
Language : English
Pages : 272
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Skyjack SJ46 AJ+, SJ46 AJ, SJ51 AJ Articulating Booms Service Manual 229042AAA – PDF DOWNLOAD
SJ46 AJ+: A301 000 001 – A301 999 999
SJ46 AJ: B301 000 001 – B301 999 999
SJ51 AJ: B301 000 001 – B301 999 999
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 SJ46 AJ+, SJ46 AJ, SJ51 AJ Articulating Booms Service Manual 229042AAA – PDF DOWNLOAD
Section 1 – Scheduled Maintenance 13
1 1 Read and Heed 13
1 1-1 MEWP and Mobile Elevating Work Platform 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 Labels 20
1 6-4 Limit switches 20
1 6-5 Engine Compartment 21
1 6-6 Control Compartment 24
1 6-7 Base 26
1 6-8 Platform 28
1 6-9 Boom Assembly 29
1 6-10 Optional equipment 30
1 7 Function Tests 31
Section 2 – Maintenance Tables and Diagrams 33
2 1 Standard Hose Numbering System 33
2 2 Torque Specifications for Fasteners (US Imperial) 35
Table of Contents
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229042AAA SJ46 AJ+, SJ46 AJ, SJ51 AJ
2 3 Torque Specifications for Fasteners (Metric) 36
2 4 Torque Specifications for Hydraulic Couplings & Hoses 37
2 5 MEWP Torque Specifications 38
2 6 Axle Torque Specifications 39
2 7 Axle Maintenance Intervals 40
2 8 Maximum Platform Capacity 41
2 9 Tire Specifications 41
2 10 Floor Loading Pressure 42
2 11 Hydraulic Specifications & Gear Oil 43
2 12 Specifications & Features – Dimensions & Speeds 44
2 13 Engine Specifications 46
2 14 Reach & Dimension Diagrams – SJ46 AJ+ ANSI/CSA 47
2 15 Reach & Dimension Diagrams – SJ46 AJ CE & AS 48
2 16 Reach & Dimension Diagrams – SJ51 AJ CE & AS 49
2 17 Axle Oscillation Diagram 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 Parts List 58
3 6 Brake Manifold Components and Ports 61
3 7 Rotary Manifold Ports 62
3 8 Drive and System Pump Ports 63
3 9 Drive and System Pump Ports 64
3 10 Drive Motor Ports 65
3 11 Jib Valve Ports 66
3 12 Pressure Reducing Valve Ports 67
3 13 Main Manifold Ports 69
3 14 Generator Control Valve and Manifold 72
3 15 Main Harness and Fuel Level Switch Harness 73
3 16 Interface Harness – Deutz D2 9L 74
3 17 Interface Harness – Deutz D2011 75
3 18 Interface Harness – Kubota 76
3 19 ECU Engine Wiring Diagram – Deutz D2011 77
3 20 Glow Plug Harnesses – Deutz D2 9L 78
3 21 Glow Plug Harnesses – Deutz D2011 79
3 22 Platform Harnesses 80
3 23 Platform Control Cables 81
3 24 Limit Switch Connections at Base Controls 82
3 25 Load Sensing Cable Connections – CE & AS 83
3 26 All Motion Alarm Connections – CE & AS 84
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SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042AAA
3 27 Flashing Amber Light Connections 85
3 28 SGE Wiring Diagram 86
3 29 Oil Cooler and 3 5 kW Generator Base Control Box Wiring 87
3 30 Generator (3 5 kW) Platform Control Box Wiring 88
3 31 Oil Cooler and 12 kW Generator Base Control Box Wiring 89
3 32 Generator (12 kW) Platform Control Box Wiring 90
3 33 12kW Generator Electrical Connections 91
3 34 Load Circuit Wiring – No Generator 92
3 35 Load Circuit Wiring – 3 5 kW Generator 93
3 36 Load Circuit Wiring – 7 5 or 12 5 kW Generator 94
3 37 Hydraulic Schematic – ANSI/CSA 95
3 38 Hydraulic Schematic – CE & AS 96
3 39 Platform Control Box Wiring – ANSI/CSA 97
3 40 Platform Control Box Wiring – CE 98
3 41 Platform Control Box Wiring – AS 99
3 42 Base Control Box Wiring – ANSI/CSA 100
3 43 Base Control Box Wiring – ANSI/CSA with Positive Air Shut-Off Option 101
3 44 Base Control Box Wiring – CE Deutz D2 2 102
3 45 Base Control Box Wiring – CE Deutz D2011 103
3 46 Base Control Box Wiring – AS 104
3 47 Electrical Schematic – ANSI/CSA 105
3 48 Electrical Schematic – CE with Deutz D2 2 106
3 49 Electrical Schematic – CE & AS with D2011 107
3 50 Electrical Schematic – AS 108
3 51 Interface & Engine Electrical Schematic – Kubota WG2503 109
3 52 Interface & Engine Electrical Schematic – Deutz D2 9L 110
3 53 Engine Harness – Deutz D2 9L 111
3 54 Engine Electrical Schematic – Deutz D2 2 112
3 55 Engine Interface Harness – Deutz D2 2 113
Section 4 – Troubleshooting Information 115
4 1 Introduction 115
4 2 Electrical System – ANSI/CSA 116
4 2-1 All Controls are Inoperative from the Base or Platform Console 116
4 2-2 All Controls are Inoperative from the Base Console 118
4 2-3 The Engine will not Crank from the Base or Platform 118
4 2-4 The Engine will not Crank from the Base 119
4 2-5 The Engine will not Crank from the Platform 119
4 2-6 The Boom Controls are Inoperative (Drive Operates) 119
4 2-7 No Boom Up from the Base or Platform Controls 120
4 2-8 No Boom Up from the Base Console 120
4 2-9 No Boom Up from the Platform Console 120
4 2-10 No Boom Down from the Base or Platform Consoles 120
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229042AAA SJ46 AJ+, SJ46 AJ, SJ51 AJ
4 2-11 No Boom Down from the Base Console 121
4 2-12 No Boom Down from the Platform Console 121
4 2-13 No Turret Rotate Right from the Base or Platform Consoles 121
4 2-14 No Turret Rotate Right from the Base Console 121
4 2-15 No Turret Rotate Right from the Platform Console 122
4 2-16 No Turret Rotate Left from the Base or Platform Consoles 122
4 2-17 No Turret Rotate Left from the Base Console 122
4 2-18 No Turret Rotate Left from the Platform Console 122
4 2-19 No Riser Up from the Base or Platform Consoles 123
4 2-20 No Riser Up from the Base Console 123
4 2-21 No Riser Up from the Platform Console 123
4 2-22 No Riser Down from the Base or Platform Consoles 123
4 2-23 No Riser Down from the Base Console 124
4 2-24 No Riser Down from the Platform Console 124
4 2-25 No Telescope Out from the Base or Platform Consoles 124
4 2-26 No Telescope Out from the Base Console 124
4 2-27 No Telescope Out from the Platform Console 125
4 2-28 No Telescope In from the Base or Platform Consoles 125
4 2-29 No Telescope In from the Base Console 125
4 2-30 No Telescope In from the Platform Console 125
4 2-31 No Platform Level Up from the Base or Platform Consoles 126
4 2-32 No Platform Level Up from the Base Console 126
4 2-33 No Platform Level Up from the Platform Console 126
4 2-34 No Platform Level Down from the Base or Platform Consoles 126
4 2-35 No Platform Level Down from the Base Console 127
4 2-36 No Platform Level Down from the Platform Console 127
4 2-37 No Platform Rotate or Jib Functions from the Base or Platform Consoles 127
4 2-38 No Platform Rotate Right from the Base or Platform Consoles 128
4 2-39 No Platform Rotate Right from the Base Console 128
4 2-40 No Platform Rotate Right from the Platform Console 128
4 2-41 No Platform Rotate Left from the Base or Platform Consoles 129
4 2-42 No Platform Rotate Left from the Base Console 129
4 2-43 No Platform Rotate Left from the Platform Console 129
4 2-44 No Jib Up from the Base or Platform Consoles 129
4 2-45 No Jib Up from the Base Console 130
4 2-46 No Jib Up from the Platform Console 130
4 2-47 No Jib Down from the Base or Platform Consoles 130
4 2-48 No Jib Down from the Base Console 130
4 2-49 No Jib Down from the Platform Console 131
4 2-50 No Drive or Steer Functions 131
4 2-51 No Forward or Reverse Drive 131
4 2-52 No Forward Drive 131
4 2-53 No Reverse Drive 132
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SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042AAA
4 2-54 The Brake will not Release 132
4 2-55 No Left Steer 132
4 2-56 No Right Steer 133
4 2-57 The Directon Sensing is Inoperative 133
4 2-58 The Load Sense Indicates Overload or Overload Warning with the Platform Empty or Below
Weight 133
4 2-59 The Overload Indicator Light does not Turn On when the Platform is Overloaded 134
4 2-60 The Audible Alarm does not Turn On with the Platform Overloaded 134
4 3 Electrical System – CE & AS 135
4 3-1 All Controls are Inoperative 135
4 3-2 No Power 136
4 3-3 Engine Will Not Crank 137
4 3-4 Engine Cranks but Will Not Start 141
4 3-5 Glow Plug Circuit Inoperative – Deutz D2011 diesel engine 144
4 3-6 All Base Control Console Inoperative 145
4 3-7 No Movement from Base Control Console 146
4 3-8 All Controls Inoperative From Platform Control Console 153
4 3-9 Throttle Inoperative, Mid and High – Deutz D2 9L 165
4 3-10 Mid Throttle Inoperative 166
4 3-11 High Throttle Inoperative 167
4 3-12 Brake will not Release 168
4 3-13 Differential Lock will not Engage 169
4 3-14 Differential Lock Engages Momentarily but will not stay Engaged 169
4 3-15 No Drive and Steer 170
4 3-16 No High Speed Drive 172
4 3-17 No Elevated Drive 174
4 3-18 Direction Sensing Inoperative 174
4 4 Load Sensing System – CE & AS 176
4 4-1 Green Power LED is not Flashing 176
4 4-2 Load Cell red Alarm LED is ON (with platform empty) 176
4 4-3 Red Error LED is ON 176
4 4-4 Load Cell red Alarm LED is OFF (with platform overloaded) 176
4 4-5 Platform Indicator Light does not turn ON 176
4 4-6 Audible Alarm does not turn ON 176
4 4-7 Boom and Drive Functions are Enabled (with boom extended) 177
4 5 Hydraulic System 178
4 5-1 All Controls Inoperative 178
4 5-2 All Boom Functions Inoperative 178
4 5-3 No Main Boom Up 178
4 5-4 No Main Boom Down 179
4 5-5 No Riser Boom Up 179
4 5-6 No Riser Boom Down 180
4 5-7 Riser Boom Down Jerky 180
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229042AAA SJ46 AJ+, SJ46 AJ, SJ51 AJ
4 5-8 No Turret Rotate Left 180
4 5-9 No Turret Rotate Right 181
4 5-10 No Boom Extend 182
4 5-11 No Boom Retract 182
4 5-12 No Jib Up – ANSI/CSA 182
4 5-13 No Jib Up – CE & AS 183
4 5-14 No Jib Down – ANSI/CSA 183
4 5-15 No Jib Down – CE & AS 184
4 5-16 No Platform Rotation Right – ANSI/CSA 184
4 5-17 No Platform Rotation Right – CE & AS 185
4 5-18 No Platform Rotation Left – ANSI/CSA 185
4 5-19 No Platform Rotation Left – CE & AS 186
4 5-20 Platform will not Level Down Manually 186
4 5-21 Platform will not Level Up Manually 187
4 5-22 Brake will not Release 187
4 5-23 Brake will not Engage 188
4 5-24 Differential Lock will not Engage 188
4 5-25 No Drive Forward or Reverse 188
4 5-26 No Forward Drive 188
4 5-27 No Reverse Drive 189
4 5-28 No High Speed Drive 189
4 5-29 No Right Steer 189
4 5-30 No Left Steer 189
4 5-31 Axle Will Not Oscillate 189
4 5-32 Axle Will Not Lock 190
Section 5 – Procedures 191
5 1 General 191
5 1-1 Safety and Workmanship 191
5 2 Platform 192
5 2-1 Human Machine Interface (HMI) – CE & AS 192
5 2-2 User Interface Keys 192
5 2-3 OCM Character Functions Charts 193
5 2-4 OCM Function Channel Names 193
5 2-5 OCM Operating Values Chart – CE & AS 194
5 2-6 How to Select OCM Functionality – CE & AS 195
5 2-7 How to View OCM Operation – CE & AS 196
5 2-8 How to Unlock and Modify OCM Settings – CE & AS 197
5 2-9 OCM Pin Reference 198
5 2-10 OCM Pin Voltage Reference – CE & AS 204
5 2-11 Fly Boom Switch Voltage References 207
5 2-12 Platform Controller Voltage References 208
5 3 Load Sensing System – CE & AS 209
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SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042AAA
5 3-1 Load Sensing System 209
5 3-2 Verify Proper Operation of the Load Sensing System 210
5 3-3 Calibration of Load Sensing System (with “Teach In” Handset) 211
5 4 Boom 212
5 4-1 Check Wear Pads 212
5 4-2 Shim Wear Pads 212
5 4-3 Cable Carrier Repair 212
5 4-4 Rotary Actuator Bolt Torque Procedure 212
5 4-5 Master Cylinder Replacement 213
5 5 Turret 214
5 5-1 Check and Replace the High Pressure Filter 214
5 5-2 Adjust the Turret Rotation Gear Backlash 214
5 5-3 Swing Drive Removal 215
5 5-4 Swing Drive Replacement 216
5 5-5 Check the Swing Drive Oil 216
5 5-6 Change the Swing Drive Oil 216
5 5-7 Check Rotation Bearing for Axial Wear 217
5 5-8 Turret Rotation Gear Bolt Torque Sequence 217
5 5-9 Electronic Tilt Switch Setup Procedure 218
5 5-10 Battery Replacement 220
5 6 Deutz Diesel Engines 221
5 6-1 Replace Engine Oil and Filter 221
5 6-2 Replace the Fuel Filter 222
5 6-3 Replace the Air Filter 222
5 6-4 Check the Engine Belt 222
5 6-5 Check the Oil Cooler (Deutz D2011 only) 222
5 6-6 Deutz D2 9L Fault Codes 223
5 7 Hydraulic Tank 243
5 7-1 Hydraulic Oil Replacement 243
5 7-2 Hydraulic Filter Replacement 243
5 8 Kubota WG2503 Dual Fuel Engine 244
5 8-1 Engine Parameter Display (KAntrak 1700) 244
5 8-2 Kubota WG2503 Diagnostic Trouble Codes 245
5 8-3 ECU Pin Reference Chart (Kubota WG2503) 250
5 8-4 Fuse Box (Kubota WG2503) 251
5 8-5 MAP Sensor (Kubota WG2503) 252
5 8-6 IAT Sensor (Kubota WG2503) 252
5 8-7 ECT (Kubota WG2503) 253
5 8-8 TPS & Engine Speed (Kubota WG2503) 253
5 8-9 Fuel Temperature Sensor (Kubota WG2503) 254
5 8-10 Oil Pressure Sensor (Kubota WG2503) 254
5 9 Manifold and Hydraulic Pumps 255
5 9-1 Hydraulic Brake Pressure Adjustment 255
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229042AAA SJ46 AJ+, SJ46 AJ, SJ51 AJ
5 9-2 Hydraulic System Relief Valve Adjustment 256
5 9-3 Riser Down Relief Valve Adjustment 256
5 9-4 Turret Rotate Relief Valve Adjustment 257
5 9-5 Platform Level Relief Valve Adjustment 257
5 9-6 Test Charge Pump Pressure on Drive Pump 258
5 9-7 Test Forward Drive Pressure on Drive Pump 258
5 9-8 Test Reverse Drive Pressure on Drive Pump 259
5 10 Axles 260
5 10-1 Change the Oil in the Axles 260
5 10-2 Check the Oil Level in the Torque Hubs 260
5 10-3 Change the Oil in the Torque Hubs 260
5 10-4 Check the Oil Level in the Axle Gearbox 261
5 10-5 Change the Oil in the Axle Gearbox 261
5 10-6 Oscillating Cylinder Bolt Replacement 262
5 10-7 Oscillating Cylinder Replacement 262
5 10-8 Bleed the Oscillating Axle Cylinders 264
5 10-9 Test the Oscillating Axle Cylinders 264
5 10-10 Pin Brake Adjustments 265
5 10-11 Brake Inspection 266
5 11 Grease Points 267
5 11-1 Grease the Turret Ring Gear 267
5 11-2 Grease the Turret Swing Drive 267
5 11-3 Grease the Axles 268
5 11-4 Grease the Drive Shaft 268
5 12 Options 269
5 12-1 Generator Troubleshooting 269
5 12-2 Generator Frequency/Voltage Check & Adjustment 270
Customer Support: [email protected]
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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