Skyjack SJ46AJ SJ51AJ Articulating Booms Service Manual 166876AF – PDF DOWNLOAD

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Skyjack SJ46AJ SJ51AJ Articulating Booms Service Manual 166876AF – PDF DOWNLOAD

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Skyjack SJ46AJ SJ51AJ Articulating Booms Service Manual 166876AF – PDF DOWNLOAD

Language : English
Pages : 210
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Skyjack SJ46AJ SJ51AJ Articulating Booms Service Manual 166876AF – PDF DOWNLOAD

SJ46AJ / SJ51AJ 95000657 to 95000852

SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Aerial Platform Definition
A mobile device that has an adjustable position platform supported from ground level by a structure.
Purpose of Equipment:
The SKYJACK Articulating Boom Series (Models SJ 46A, 46AJ, & 51AJ) 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.
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.
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.

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.
Operator Safety Reminders, Warnings, and Precautions:
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 aerial platform.

TABLE OF CONTENTS:

Skyjack SJ46AJ SJ51AJ Articulating Booms Service Manual 166876AF – PDF DOWNLOAD

Cover.........................................................................................  1
Table of Contents.............................................................................  3
Section 1 - Scheduled Maintenance.............................................................  5
	Operator’s Responsibility for Maintenance.................................................  6
		Aerial Platform Definition............................................................  6
		Purpose of Equipment .................................................................  6
		Use of Equipment......................................................................  6
		Manuals...............................................................................  6
		Service Policy and Warranty...........................................................  6
		Operator Safety Reminders, Warnings, and Precautions..................................  6
		Maintenance and Inspection Schedule...................................................  7
		Owner’s Annual Inspection Record......................................................  7
		Replacement Parts.....................................................................  7
		Maintenance and Service Safety Tips...................................................  7
		Hydraulic System & Component Maintenance and Repair...................................  8
		Maintenance Hints.....................................................................  8
		Railing Maintenance and Repair........................................................  9
	Service and Maintenance................................................................... 10
		About this Section.................................................................... 10
		Service Bulletins..................................................................... 10
		Maintenance and Inspection............................................................ 10
		Maintenance Instructions.............................................................. 10
	Tables.................................................................................... 11
		Table 1.1  Owner’s Annual Inspection Record........................................... 11
		Table 1.2  Pre-Delivery/Maintenance Inspection Checklist.............................. 12
	Scheduled Maintenance Inspections and Function Tests...................................... 13
		1.1 Scheduled Maintenance Inspections................................................. 13
		1.2 Function Tests.................................................................... 24
Section 2 - Maintenance Tables and Diagrams................................................... 25
	Tables.................................................................................... 26
		Table 2.1  Standard Hose Numbering System............................................. 26
		Table 2.2  Aerial Platform Torque Specifications...................................... 28
		Table 2.3  Axles Torque Specifications................................................ 29
		Table 2.4  Torque Specifications for Fasteners (Imperial)............................. 30
		Table 2.5  Torque Specifications for Fasteners (Metric)............................... 31
		Table 2.6  Torque Specifications for Hydraulic Couplings & Hoses...................... 32
		Table 2.7  Axles Maintenance Intervals................................................ 33
		Table 2.8  Tire Specifications........................................................ 34
		Table 2.9 Maximum Platform Capacities................................................. 34
		Table 2.10  Floor Loading Pressure.................................................... 35
		Table 2.11  Hydraulic Specifications.................................................. 36
		Table 2.12  Specifications and Features............................................... 37
	Diagrams.................................................................................. 39
		Diagram 2.1  Dimension and Reach Diagram - SJ 46AJ.................................... 39
		Diagram 2.2  Dimension and Reach Diagram - SJ 51AJ.................................... 40
		Diagram 2.3  Axle Oscillation Diagram................................................. 41
Section 3 - System Component Identification and SChematics.................................... 43
	Charts.................................................................................... 45
		3.1  Hydraulic Symbol Chart........................................................... 45
		3.2  Electrical Symbol Chart.......................................................... 46
		3.3  Wire Number and Color Code....................................................... 47
	Parts Lists............................................................................... 48
		3.4  Hydraulic Component Parts List................................................... 48
		3.5  Electrical Component Parts List.................................................. 51
	Diagrams and Schematics................................................................... 55
		3.6  Brake Manifold and Port Identifications.......................................... 54
		3.7  Rotary Manifold and Port Identifications......................................... 55
		3.8  Drive and System Pump and Port Identifications................................... 56
		3.9  Drive and System Pump and Port Identifications (with Welder Option).............. 57
		3.10  Drive Motors and Port Identifications........................................... 58
		3.11  Jib Valves and Port Identifications............................................. 59
		3.12  Main Manifold and Port Identifications.......................................... 61
		3.14  Main Electrical Harness  and Fuel Level Switch Harness.......................... 65
		3.15  ECU Engine Wiring Diagram (Deutz D2011 Diesel Engine)........................... 66
		3.16  Glow Plug Harnesses (Deutz D2.9L Diesel Engine)................................. 67
		3.17  Glow Plug Harnesses (Deutz D2011 Diesel Engine)................................. 68
		3.18  Engine Interface Harness (GM Dual Fuel Engine).................................. 69
		3.19  Engine Interface Harness (Deutz D2.9L Diesel Engine)............................ 70
		3.20  Harnesses....................................................................... 71
		3.21  Platform Control Cable Harnesses................................................ 72
		3.22  Limit Switch Connections at Base Control Console................................ 73
		3.23  Load Sensing Cable Connection (CE & AS)......................................... 74
		3.24  All Motion Alarm Connections (CE & AS).......................................... 75
		3.25  Flashing Amber Light Option..................................................... 76
		3.26  SGE Wiring Diagram.............................................................. 77
		3.27  Oil Cooler and 3.5kW Generator Base Control Console Wiring...................... 78
		3.28  Generator (3.5kW) Platform Control Box Wiring................................... 79
		3.29  12kW Generator Connection Assembly (with Welder Option)......................... 80
		3.30  Hydraulic Schematic Diagram..................................................... 81
		3.31  Platform Control Console Diagram (ANSI/CSA, SJ 46AJ - Deutz Diesel Engine)...... 82
		3.32  Platform Control Console Diagram (CE, SJ 46AJ/51AJ - Deutz Diesel Engine)....... 83
		3.33  Platform Control Console Diagram (AS, SJ 46AJ/51AJ - Deutz Diesel Engine)....... 84
		3.34  Platform Control Console Diagram (ANSI/CSA, SJ 46AJ - GM Dual Fuel Engine)...... 85
		3.35  Base Control Console Diagram (ANSI/CSA, SJ 46AJ - Deutz D2.9L Diesel Engine).... 86
		3.36  Base Control Console Diagram (ANSI/CSA, SJ 46AJ - Deutz D2011 Diesel Engine).... 87
		3.37  Base Control Console Diagram (CE, SJ 46AJ/51AJ - Deutz D2011 Diesel Engine)..... 88
		3.38  Base Control Console Diagram (AS, SJ 46AJ/51AJ - Deutz D2011 Diesel Engine)..... 89
		3.39  Base Control Console Diagram (ANSI/CSA, SJ 46AJ - GM Engine).................... 90
		3.40  Electrical Schematic Diagram (ANSI/CSA, SJ 46AJ - Deutz D2.9L Diesel Engine).... 91
		3.41  Electrical Schematic Diagram (ANSI/CSA, SJ 46AJ - Deutz D2011 Diesel Engine).... 92
		3.42  Electrical Schematic Diagram (CE, SJ 46AJ/51AJ - Deutz D2011 Diesel Engine)..... 93
		3.43  Electrical Schematic Diagram (AS, SJ 46AJ/51AJ - Deutz D2011 Diesel Engine)..... 94
		3.44  Electrical Schematic Diagram  (ANSI/CSA, SJ 46A/46AJ - GM Dual Fuel Engine) .... 95
		3.45  Interface & Engine Electrical Schematic - Deutz D2.9L Engine.................... 96
		3.46  Engine Harness  - Deutz D2.9L................................................... 97
		3.47  Interface & Engine Electrical Schematic - GM Dual Fuel Engine  ................. 98
Section 4 - Troubleshooting Information....................................................... 99
	Introduction..............................................................................101
	4.1  Electrical System....................................................................102
		4.1-1  All Controls Inoperative.......................................................102
		4.1-2  No Power To Platform...........................................................102
		4.1-3  No Power to Base...............................................................103
		4.1-4  Engine Will Not Crank from Base................................................103
		4.1-5  Engine Will Not Crank from Platform............................................103
		4.1-6  Engine Will Not Crank from Platform or Base (Deutz Diesel D2.9L................104
		4.1-7  Engine Cranks but Will Not Start (Deutz Diesel D2.9L)..........................104
		4.1-8 Engine Will Not Crank from Platform or Base (Deutz Diesel D2011)................105
		4.1-9 Engine Cranks but Will Not Start (Deutz Diesel D2011)...........................105
		4.1-10 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel).............106
		4.1-11  Engine Cranks but Will Not Start (GM Dual Fuel)...............................107
		4.1-12  Glow Plug Circuit Inoperative (Deutz Diesel D2011 Engine).....................109
		4.1-13  All Controls Inoperative from Base Console....................................109
		4.1-14 No Main Boom Down, Riser Down or Turret Rotate from Base Control Console.......110
		4.1-15 No Boom Up from Base Control Console...........................................110
		4.1-16 No Boom Down from Base Control Console.........................................110
		4.1-17 No Riser Up from Base Control Console..........................................111
		4.1-18 No Riser Down from Base Control Console........................................111
		4.1-19  No Turret Rotate Left from Base Control Console...............................111
		4.1-20  No Turret Rotate Right from Base Control Console..............................112
		4.1-21  No Telescope Retract from Base Control Console................................112
		4.1-22  No Telescope Extend from Base Control Console.................................112
		4.1-23  No Platform Rotate Left from Base Control Console.............................113
		4.1-24  No Platform Rotate Right from Base Control Console............................113
		4.1-25  No Jib Up from Base Control Console...........................................114
		4.1-26 No Jib Down from Base Control Console..........................................114
		4.1-27 No Manual Platform Level Up from Base Control Console..........................115
		4.1-28 No Manual Platform Level Down from Base Control Console........................115
		4.1-29  All Controls Inoperative from Platform Control Console........................116
		4.1-30  No Boom Up from Platform Control Console......................................117
		4.1-31  No Boom Down from Platform Control Console....................................117
		4.1-32  No Riser Up from Platform Control Console.....................................118
		4.1-33  No Riser Down from Platform Control Console...................................118
		4.1-34  No Turret Left from Platform Control Console..................................119
		4.1-35  No Turret Right from Platform Control Console.................................120
		4.1-36 No Toggle Switch Functions from Platform Control Console.......................120
		4.1-37 No Telescope In from Platform Control Console..................................120
		4.1-38 No Telescope Out from Platform Control Console.................................121
		4.1-39 No Platform Rotate Left from Platform Control Console..........................121
		4.1-40  No Platform Rotate Right from Platform Control Console........................122
		4.1-41  No Jib Up from Platform Control Console.......................................123
		4.1-42  No Jib Down from Platform Control Console.....................................123
		4.1-43  No Manual Platform Level Up from Platform Control Console.....................124
		4.1-44  No Manual Platform Level Down from Platform Control Console...................125
		4.1-45 Throttle Inoperative, Mid and High (Deutz D2.9L only)..........................125
		4.1-46 Mid Throttle Inoperative.......................................................126
		4.1-47 High Throttle Inoperative......................................................127
		4.1-48 Brake will not Release.........................................................127
		4.1-49  Differential Lock will not Engage.............................................128
		4.1-50  Differential Lock Engages Momentarily but will not stay Engaged...............128
		4.1-51  No Drive and Steer............................................................129
		4.1-52  No Forward Drive..............................................................129
		4.1-53  No Reverse Drive..............................................................129
		4.1-54  No High Speed Drive...........................................................130
		4.1-55  No Elevated Drive.............................................................131
		4.1-56  No Left Steer.................................................................131
		4.1-57  No Right Steer................................................................132
		4.1-58  Direction Sensing Inoperative.................................................132
	4.2  Hydraulic System.....................................................................133
		4.2-1 All Controls Inoperative........................................................133
		4.2-2 All Boom Functions Inoperative..................................................133
		4.2-3 No Main Boom Up.................................................................133
		4.2-4 No Main Boom Down...............................................................133
		4.2-5 No Riser Boom Up................................................................134
		4.2-6 No Riser Boom Down..............................................................134
		4.2-7 Riser Boom Down Jerky...........................................................134
		4.2-8 No Turret Rotate Left...........................................................135
		4.2-9 No Turret Rotate Right..........................................................135
		4.2-10 No Boom Extend.................................................................136
		4.2-11 No Boom Retract................................................................136
		4.2-12 No Jib Up......................................................................136
		4.2-13 No Jib Down....................................................................136
		4.2-14 No Platform Rotation Right.....................................................137
		4.2-15 No Platform Rotation Left......................................................137
		4.2-16 Platform will not Level Down Manually..........................................137
		4.2-17 Platform will not Level Up Manually............................................138
		4.2-18 Brake will not Release.........................................................138
		4.2-19 Brake will not Engage..........................................................139
		4.2-20 Differential Lock will not Engage..............................................139
		4.2-21 No Drive Forward or Reverse....................................................139
		4.2-22 No Forward Drive...............................................................139
		4.2-23 No Reverse Drive...............................................................140
		4.2-24 No High Speed Drive............................................................140
		4.2-25 No Right Steer.................................................................140
		4.2-26 No Left Steer..................................................................140
		4.2-27 Axle Will Not Oscillate........................................................140
		4.2-28 Axle Will Not Lock.............................................................141
	4.3 Load Sensing System - CE..............................................................142
		4.3-1 Green Power LED is not Flashing.................................................142
		4.3-2 Load Cell red Alarm LED is ON (with platform empty).............................142
		4.3-3 Red Error LED is ON.............................................................142
		4.3-4 Load Cell red Alarm LED is OFF (with platform overloaded).......................142
		4.3-5 Platform Indicator Light does not turn ON.......................................142
		4.3-6 Audible Alarm does not turn ON..................................................142
		4.3-7 Boom and Drive Functions are Enabled (with boom extended).......................142
Section 5 - Procedures........................................................................143
	General...................................................................................145
	Safety and Workmanship....................................................................145
	Platform..................................................................................145
		5.1-1 Human Machine Interface (HMI)...................................................145
		5.1-2 User Interface Keys.............................................................146
			OCM Character Functions Charts....................................................146
			OCM Operating Values Chart........................................................147
		5.1-3 How to Select Functionality.....................................................148
		5.1-4 How to View OCM Operation.......................................................149
		5.1-5 How to Unlock and Modify OCM Settings...........................................150
		5.1-6 OCM Pin Voltage Reference.......................................................151
		5.1-7 Platform Controller Voltage References..........................................154
	Boom......................................................................................156
		5.2-1 Check Wear Pads.................................................................156
		5.2-2 Shimming Wear Pads..............................................................156
		5.2-3 Cable Carrier Repair............................................................156
		5.2-4 Master Cylinder Replacement.....................................................156
	Turret....................................................................................158
		5.3-1 High Pressure Filter Replacement................................................158
		5.3-2 Check Swing Drive Motor Gearbox Oil.............................................158
		5.3-3  Turret Rotation Gear Backlash Adjustment.......................................158
		5.3-4  Swing Drive Motor Removal......................................................159
		5.3-5 Swing Drive Motor Replacement...................................................160
		5.3-6 Swing Drive Brake and Gearbox Oil Replacement...................................160
		5.3-7 Battery Replacement.............................................................160
		5.3-8 Bolt Torque Procedure...........................................................161
		5.3-9  Electronic Tilt Switch Setup Procedure.........................................162
			Tilt Switch Replacement...........................................................162
			Reprogramming Existing Tilt Switch................................................163
			Test and Verify Tilt Circuit......................................................164
		5.3-10  Check Rotation Bearing for Axial Wear.........................................165
	Deutz Diesel Engine.......................................................................166
		5.4-1 Engine Oil and Filter Replacement...............................................166
		5.4-2 Fuel Filter Replacement.........................................................167
		5.4-3 Air Filter Replacement..........................................................167
		5.4-4 Check Engine Belt...............................................................167
		5.4-5 Check Oil Cooler................................................................167
		5.4-6  Deutz D2.9L Fault Codes........................................................168
	GM Dual Fuel Engine.......................................................................188
		5.5-1 GM Map and IAT Sensor (3.0L GM Engine)..........................................188
		5.5-2 LPG Temperature Sensor (3.0L GM Engine).........................................189
		5.5-3 Throttle Actuator (3.0L GM Engine)..............................................190
		5.5-4 Engine Coolant Temperature Sensor (3.0L GM Engine)..............................191
		5.5-5 ECU Pin Reference Chart (3.0L GM Engine)........................................192
		5.5-6 Fuse Block Layout (3.0L GM Engine)..............................................193
	Hydraulic Tank............................................................................194
		5.6-1 Hydraulic Oil Replacement.......................................................194
		5.6-2 Hydraulic In-tank Filter Replacement............................................194
	Manifold and Hydraulic Pumps..............................................................195
		5.7-1 Hydraulic Brake Pressure Adjustment.............................................195
		5.7-2 Hydraulic System Relief Valve Adjustment........................................196
		5.7-3 Riser Down Relief Valve Adjustment..............................................196
		5.7-4 Turret Rotate Relief Valve Adjustment...........................................197
		5.7-5 Platform Level Relief Valve Adjustment..........................................197
		5.7-6 Test Charge Pump Pressure on Drive Pump.........................................198
		5.7-7 Test Forward Drive Pressure on Drive Pump.......................................198
		5.7-8 Test Reverse Drive Pressure on Drive Pump.......................................199
	Axles.....................................................................................199
		5.8-1 Rear Axle Oil Replacement.......................................................199
		5.8-2 Front Axle Oil Replacement......................................................199
		5.8-3 Check Torque Hub Oil Level......................................................200
		5.8-4 Check Axle Gearbox Oil Level....................................................200
		5.8-5 Axle Gearbox Oil Replacement....................................................200
		5.8-6 Bleeding Oscillating Axle Cylinders.............................................201
		5.8-7 Pin Brake Adjustments...........................................................201
		5.8-8 Brake Inspection................................................................203
	Grease Points.............................................................................204
		5.9-1 Lubrication.....................................................................204
			Grease Turret Rotation Bearing....................................................204
			Grease Turret Rotation Gear.......................................................204
			Grease Drive Axle.................................................................205
			Grease Drive Shaft................................................................205
	Options...................................................................................206
		5.10-1 Load Sensing System - CE.......................................................206

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