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Skyjack SJ46AJ, SJ51AJ Articulating Booms Service Manual 194313AI – PDF DOWNLOAD
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Skyjack SJ46AJ, SJ51AJ Articulating Booms Service Manual 194313AI – PDF DOWNLOAD
SJ46AJ & SJ51AJ: 95 001 105 to 95 299 999
SJ46AJ & SJ51AJ: B301 000 001 to B301 999 999
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Description
Skyjack SJ46AJ, SJ51AJ Articulating Booms Service Manual 194313AI – PDF DOWNLOAD
FILE DETAILS:
Skyjack SJ46AJ, SJ51AJ Articulating Booms Service Manual 194313AI – PDF DOWNLOAD
Language : English
Pages : 252
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Skyjack SJ46AJ, SJ51AJ Articulating Booms Service Manual 194313AI – PDF DOWNLOAD
SJ46AJ & SJ51AJ: 95 001 105 to 95 299 999
SJ46AJ & SJ51AJ: B301 000 001 to B301 999 999
Read and Heed:
Skyjack is continuously improving and expanding product features on its equipment, therefore,
specifications and dimensions are subject to change without notice.
Skyjack is continuously improving and expanding product features on its equipment, therefore,
specifications and dimensions are subject to change without notice.
1.1-1 Mobile Elevating Work Platform (MEWP) Definition
A mobile device that has a positionable platform supported from ground level by a structure.
A mobile device that has a positionable platform supported from ground level by a structure.
1.1-2 Purpose of Equipment
The Skyjack Telescopic Boom Series MEWPs are designed to transport and raise personnel, tools and
materials to overhead work areas.
The Skyjack Telescopic Boom Series MEWPs are designed to transport and raise personnel, tools and
materials to overhead work areas.
1.1-3 Use of Equipment
The MEWP is a highly maneuverable, mobile work station. Work platform elevation and elevated
driving must only be done on a firm, level surface.
The MEWP is a highly maneuverable, mobile work station. Work platform elevation and elevated
driving must only be done on a firm, level surface.
1.1-4 Manual
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:
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.
1.1-5 Service Policy and Warranty
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.
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.
1.1-6 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 MEWP.
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 SJ46AJ, SJ51AJ Articulating Booms Service Manual 194313AI – PDF DOWNLOAD
Table of Contents............................................................................... 5 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 Manuals & Required Documents (B).................................................. 20 1.6-4 Labels (B)........................................................................ 20 1.6-5 Limit Switches (B)................................................................ 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 1.7 Function Tests......................................................................... 30 Section 2 – Maintenance Tables and Diagrams..................................................... 31 2.1 Standard Hose Numbering System......................................................... 31 2.2 Torque Specifications for Fasteners (US Imperial)...................................... 33 2.3 Torque Specifications for Fasteners (Metric)........................................... 34 2.4 Torque Specifications for Hydraulic Couplings & Hoses.................................. 35 2.5 MEWP Torque Specifications............................................................. 36 2.6 Axle Torque Specifications............................................................. 37 2.7 Axle Maintenance Intervals............................................................. 38 2.8 Maximum Platform Capacity.............................................................. 39 2.9 Tire Specifications.................................................................... 39 2.10 Floor Loading Pressure................................................................ 40 2.11 Hydraulic Specifications & Gear Oil................................................... 41 2.12 Specifications & Features - Dimensions & Speeds....................................... 42 2.13 Engine Specifications................................................................. 44 2.14 Dimension and Reach Diagrams - SJ46AJ................................................. 46 2.15 Dimension and Reach Diagrams - SJ51AJ................................................. 47 2.16 Axle Oscillation Diagram.............................................................. 48 Section 3 – System Component Identification and Schematics...................................... 49 3.1 Electrical Symbol Chart................................................................ 50 3.2 Hydraulic Symbol Chart................................................................. 51 3.3 Wire Number and Color Code............................................................. 52 3.4 Hydraulic Parts List................................................................... 53 3.5 Electrical Parts List.................................................................. 56 3.6 Brake Manifold Components and Ports.................................................... 59 3.7 Rotary Manifold Ports.................................................................. 60 3.8 Drive and System Pump Ports............................................................ 61 3.9 Drive and System Pump Ports............................................................ 62 3.10 Drive Motor Ports..................................................................... 63 3.11 Jib Valve Ports....................................................................... 64 3.12 Pressure Reducing Valve Ports......................................................... 65 3.13 Main Manifold Ports................................................................... 67 3.14 Generator Control Valve and Manifold.................................................. 70 3.15 Main Electrical Harness and Fuel Level Switch Harness................................ 71 3.16 ECU Engine Wiring Diagram - Deutz D2011............................................... 72 3.17 Glow Plug Harnesses - Deutz D2.9L..................................................... 73 3.18 Glow Plug Harnesses - Deutz D2011..................................................... 74 3.19 Engine Interface Harness - GM......................................................... 75 3.20 Platform Harnesses.................................................................... 76 3.21 Platform Control Cables............................................................... 77 3.22 Limit Switch Connections at Base Controls............................................ 78 3.23 Load Sensing Cable Connections - CE & AS.............................................. 79 3.24 All Motion Alarm Connections - CE & AS................................................ 80 3.25 Flashing Amber Light Connections...................................................... 81 3.26 SGE Wiring Diagram.................................................................... 82 3.27 Oil Cooler and 3.5 kW Generator Base Control Box Wiring............................... 83 3.28 Generator (3.5 kW) Platform Control Box Wiring........................................ 84 3.29 Oil Cooler and 12 kW Generator Base Control Box Wiring................................ 85 3.30 Generator (12 kW) Platform Control Box Wiring......................................... 86 3.31 12kW Generator Electrical Connections................................................. 87 3.32 Load Circuit Wiring................................................................... 88 3.33 Hydraulic Schematic (serial number 95 002 909 and above).............................. 89 3.34 Hydraulic Schematic (serial number 95 001 717 to 95 002 908).......................... 90 3.35 Hydraulic Schematic (serial number 95 001 716 and below).............................. 91 3.36 Platform Control Box Wiring - ANSI/CSA - GM........................................... 92 3.37 Platform Control Box Wiring - ANSI/CSA - Deutz & Perkins.............................. 93 3.38 Platform Control Box Wiring - CE - Deutz ............................................. 94 3.39 Platform Control Box Wiring - AS - Deutz.............................................. 95 3.40 Base Control Box Wiring - ANSI/CSA - GM............................................... 96 3.41 Base Control Box Wiring - ANSI/CSA - Kubota WG2503.................................... 97 3.42 Base Control Box Wiring - ANSI/CSA - Deutz D2011...................................... 98 3.43 Base Control Box Wiring - ANSI/CSA - Deutz D2011 with Positive Air Shut-Off Option.... 99 3.44 Base Control Box Wiring - ANSI/CSA - Deutz D2.9L......................................100 3.45 Control Box Wiring - ANSI/CSA - Perkins 2.2TA.........................................101 3.46 Base Control Box Wiring - CE - Deutz D2.2.............................................102 3.47 Base Control Box Wiring - CE - Deutz D2011............................................103 3.48 Base Control Box Wiring - AS - Deutz D2011............................................104 3.49 Electrical Schematic - ANSI/CSA - GM.................................................105 3.50 Electrical Schematic - ANSI/CSA - Kubota WG2503......................................106 3.51 Electrical Schematic - ANSI/CSA - Deutz D2011.........................................107 3.52 Electrical Schematic - ANSI/CSA - Deutz D2.9L.........................................108 3.53 Electrical Schematic - ANSI/CSA - Perkins 2.2TA.......................................109 3.54 Electrical Schematic - CE - Deutz D2.2................................................110 3.55 Electrical Schematic - CE - Deutz D2011...............................................111 3.56 Electrical Schematic - AS - Deutz D2011...............................................112 3.57 Interface & Engine Electrical Schematic - GM..........................................113 3.58 Interface & Engine Electrical Schematic - Kubota WG2503 .............................114 3.59 Interface & Engine Electrical Schematic - Deutz D2.9L.................................115 3.60 Engine Harness - Deutz D2.9L.........................................................116 3.61 Engine Interface Harness - Perkins 2.2T...............................................117 3.62 Engine OEM Harness - Perkins 2.2T.....................................................118 3.63 Engine Component Harness - Perkins 2.2T...............................................119 3.64 Engine Electrical Schematic - Deutz D2.2..............................................120 3.65 Engine Interface Harness - Deutz D2.2.................................................121 Section 4 – Troubleshooting Information.........................................................123 4.1 Introduction...........................................................................123 4.2 Electrical System......................................................................124 4.2-1 All Controls Inoperative..........................................................124 4.2-2 No Power..........................................................................125 4.2-3 Engine Will Not Crank.............................................................126 4.2-4 Engine Cranks but Will Not Start..................................................130 4.2-5 Glow Plug Circuit Inoperative - Deutz D2011 diesel engine.........................133 4.2-6 All Base Control Console Inoperative..............................................134 4.2-7 No Movement from Base Control Console.............................................135 4.2-8 All Controls Inoperative From Platform Control Console............................142 4.2-9 Throttle Inoperative, Mid and High - Deutz D2.9L..................................154 4.2-10 Mid Throttle Inoperative.........................................................155 4.2-11 High Throttle Inoperative........................................................156 4.2-12 Brake will not Release...........................................................157 4.2-13 Differential Lock will not Engage................................................158 4.2-14 Differential Lock Engages Momentarily but will not stay Engaged..................158 4.2-15 No Drive and Steer...............................................................159 4.2-16 No High Speed Drive..............................................................161 4.2-17 No Elevated Drive................................................................163 4.2-18 Direction Sensing Inoperative....................................................163 4.3 Hydraulic System.......................................................................165 4.3-1 All Controls Inoperative..........................................................165 4.3-2 All Boom Functions Inoperative....................................................165 4.3-3 No Main Boom Up...................................................................165 4.3-4 No Main Boom Down.................................................................166 4.3-5 No Riser Boom Up..................................................................166 4.3-6 No Riser Boom Down................................................................166 4.3-7 Riser Boom Down Jerky.............................................................167 4.3-8 No Turret Rotate Left.............................................................167 4.3-9 No Turret Rotate Right............................................................168 4.3-10 No Boom Extend...................................................................168 4.3-11 No Boom Retract..................................................................169 4.3-12 No Jib Up........................................................................169 4.3-13 No Jib Down......................................................................169 4.3-14 No Platform Rotation Right.......................................................170 4.3-15 No Platform Rotation Left........................................................170 4.3-16 Platform will not Level Down Manually............................................171 4.3-17 Platform will not Level Up Manually..............................................171 4.3-18 Brake will not Release...........................................................172 4.3-19 Brake will not Engage............................................................172 4.3-20 Differential Lock will not Engage................................................172 4.3-21 No Drive Forward or Reverse......................................................173 4.3-22 No Forward Drive.................................................................173 4.3-23 No Reverse Drive.................................................................173 4.3-24 No High Speed Drive..............................................................173 4.3-25 No Right Steer...................................................................173 4.3-26 No Left Steer....................................................................174 4.3-27 Axle Will Not Oscillate..........................................................174 4.3-28 Axle Will Not Lock...............................................................174 4.4 Load Sensing System - CE...............................................................175 4.4-1 Green Power LED is not Flashing...................................................175 4.4-2 Load Cell red Alarm LED is ON (with platform empty)...............................175 4.4-3 Red Error LED is ON...............................................................175 4.4-4 Load Cell red Alarm LED is OFF (with platform overloaded).........................175 4.4-5 Platform Indicator Light does not turn ON.........................................175 4.4-6 Audible Alarm does not turn ON....................................................175 4.4-7 Boom and Drive Functions are Enabled (with boom extended).........................176 Section 5 – Procedures..........................................................................177 5.1 General................................................................................177 5.1-1 Safety and Workmanship............................................................177 5.2 Platform...............................................................................178 5.2-1 Human Machine Interface (HMI).....................................................178 5.2-2 User Interface Keys...............................................................178 5.2-3 OCM Character Functions Charts....................................................179 5.2-4 OCM Operating Values Chart........................................................180 5.2-5 How to Select Functionality.......................................................181 5.2-6 How to View OCM Operation.........................................................182 5.2-7 How to Unlock and Modify OCM Settings.............................................183 5.2-8 OCM Pin Voltage Reference.........................................................184 5.2-9 Fly Boom Switch Voltage References................................................187 5.2-10 Platform Controller Voltage References...........................................188 5.3 Boom...................................................................................189 5.3-1 Check Wear Pads...................................................................189 5.3-2 Shim Wear Pads....................................................................189 5.3-3 Cable Carrier Repair..............................................................189 5.3-4 Rotary Actuator Bolt Torque Procedure.............................................189 5.3-5 Master Cylinder Replacement.......................................................190 5.4 Turret.................................................................................191 5.4-1 Check and Replace the High Pressure Filter........................................191 5.4-2 Adjust the Turret Rotation Gear Backlash..........................................191 5.4-3 Swing Drive Removal...............................................................192 5.4-4 Swing Drive Replacement...........................................................193 5.4-5 Check the Swing Drive Oil.........................................................193 5.4-6 Change the Swing Drive Oil........................................................193 5.4-7 Check Rotation Bearing for Axial Wear.............................................194 5.4-8 Turret Rotation Gear Bolt Torque Sequence.........................................194 5.4-9 Electronic Tilt Switch Setup Procedure............................................195 5.4-10 Battery Replacement..............................................................197 5.5 Deutz Diesel Engines...................................................................198 5.5-1 Replace Engine Oil and Filter.....................................................198 5.5-2 Replace the Fuel Filter...........................................................199 5.5-3 Replace the Air Filter............................................................199 5.5-4 Check the Engine Belt.............................................................199 5.5-5 Check the Oil Cooler (Deutz D2011 only)...........................................199 5.5-6 Deutz D2.9L Fault Codes...........................................................200 5.6 Hydraulic Tank.........................................................................220 5.6-1 Hydraulic Oil Replacement.........................................................220 5.6-2 Hydraulic Filter Replacement......................................................220 5.7 Kubota WG2503 Dual Fuel Engine.........................................................221 5.7-1 Engine Parameter Display (KAntrak 1700)...........................................221 5.7-2 Kubota WG2503 Diagnostic Trouble Codes............................................222 5.7-3 ECU Pin Reference Chart (Kubota WG2503)...........................................227 5.7-4 Fuse Box (Kubota WG2503)..........................................................228 5.7-5 MAP Sensor (Kubota WG2503)........................................................229 5.7-6 IAT Sensor (Kubota WG2503)........................................................229 5.7-7 ECT (Kubota WG2503)...............................................................230 5.7-8 TPS & Engine Speed (Kubota WG2503)................................................230 5.7-9 Fuel Temperature Sensor (Kubota WG2503)...........................................231 5.7-10 Oil Pressure Sensor (Kubota WG2503)..............................................231 5.8 Manifold and Hydraulic Pumps...........................................................232 5.8-1 Hydraulic Brake Pressure Adjustment...............................................232 5.8-2 Hydraulic System Relief Valve Adjustment..........................................233 5.8-3 Riser Down Relief Valve Adjustment................................................233 5.8-4 Turret Rotate Relief Valve Adjustment.............................................234 5.8-5 Platform Level Relief Valve Adjustment............................................234 5.8-6 Test Charge Pump Pressure on Drive Pump...........................................235 5.8-7 Test Forward Drive Pressure on Drive Pump.........................................235 5.8-8 Test Reverse Drive Pressure on Drive Pump.........................................236 5.9 Axles..................................................................................237 5.9-1 Change the Oil in the Axles ......................................................237 5.9-2 Check the Oil Level in the Torque Hubs............................................237 5.9-3 Change the Oil in the Torque Hubs.................................................237 5.9-4 Check the Oil Level in the Axle Gearbox...........................................238 5.9-5 Change the Oil in the Axle Gearbox................................................238 5.9-6 Oscillating Cylinder Bolt Replacement.............................................239 5.9-7 Oscillating Cylinder Replacement..................................................239 5.9-8 Bleed the Oscillating Axle Cylinders..............................................241 5.9-9 Test the Oscillating Axle Cylinders...............................................241 5.9-10 Pin Brake Adjustments............................................................242 5.9-11 Brake Inspection.................................................................243 5.10 Grease Points.........................................................................244 5.10-1 Grease the Turret Ring Gear......................................................244 5.10-2 Grease the Turret Swing Drive....................................................244 5.10-3 Grease the Axles.................................................................245 5.10-4 Grease the Drive Shaft...........................................................245 5.11 Options...............................................................................246 5.11-1 Load Sensing System - CE.........................................................246 5.11-2 Verify Proper Operation of the Load Sensing System...............................247 5.11-3 Calibration of Load Sensing System (with “Teach In” Handset).....................248 5.11-4 Generator Troubleshooting........................................................249 5.11-5 Generator Frequency/Voltage Check & Adjustment...................................250
Questions? Email us: [email protected]
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
