Skyjack SJKB-40-D Operating Maintenance Instructions & Part List
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Skyjack SJKB-40-D Operating Maintenance Instructions & Part List

Skyjack SJKB-40-D Operating Maintenance Instructions & Part List

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  • Page 2 Skyjack Inc. 55 Campbell Rd., Guelph, Ontario, Canada N1H 1B9 ..FAX 519 837-3883 31 297 255 526 For Parts & Service in Europe please call ..........Skyjack Europe Communicatieweg 29, 3641 SG Mijdrecht Netherlands... FAX 31 297 256 948 707093-AC Printed in Canada MARCH, 2000...
  • Page 3 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. JUN. 1999...

  • Page 4: Table Of Contents

    Figure 1-1. Front Panel Labels ....................Page 2 Table 1-1. Specifications and Features .................. Page 3 WORK PLATFORM MAJOR COMPONENTS IDENTIFICATION Figure 1-2. SKYJACK SJKB Boom Work Platform (Model SJKB-40-D Shown) ..... Page 4 SECTION 2 OPERATION OPERATOR QUALIFICATIONS .................... Page 1 OPERATOR RESPONSIBILITY FOR MAINTENANCE ............
  • Page 5 (Over 350KV to 500KV) CONTACT WITH OR PROXIMITY TO AN (Over 500KV to 750KV) 10.67 ELECTRICALLY CHARGED CON- DUCTOR. (Over 750KV to 1000KV) 13.72 FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY! Page ii SJKB-40-D, SJKB-40-D/F JUN. 1999...
  • Page 6 INJURY COULD RESULT FROM IMPROPER USE OF THIS EQUIPMENT! SERVICE POLICY AND WARRANTY SKYJACK, Inc. warrants each new work platform to be free of defective parts and workmanship during the first 12 months. Refer to Warranty Statement on Page iv for details. NOTE SKYJACK, Inc.
  • Page 7 Skyjack within 15 days from the time of billing. When specified territory, limited to a maximum of four (4) work platforms are put into stock, the warranty period hours.

  • Page 8: Section 1 Introduction

    The work platforms (Figure 1-2) are highly maneuverable electrical system failure. work stations. The SJKB-40-D/F and -40-D Models are designed for both slab-type and rough terrain TURRET - The turret rotates 360 degrees continuously.
  • Page 9 Also be aware of poorly lit areas that Has alterations or modifications not approved by the might hide overhead obstacles. manufacturer. Has safety devices which have been altered or disabled. Figure 1-1. Front Panel Labels DEC. 1999 SECTION 1, Page 2 JUN. 1999 SJKB-40-D, SJKB-40-D/F...

  • Page 10: Work Platform Major Components Identification

    Spring-Loaded Half Gate Spring-Loaded Full Gate Lifting Lugs Air or Hydraulic Line to Platform Cold Weather Start High Flotation Tires Foam Filled Tires Four Wheel Drive WORK PLATFORM MAJOR COMPONENT IDENTIFICATION DEC. 1999 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 1, Page 3...
  • Page 11 Figure 1-2. SKYJACK SJKB Boom Work Platform (Model SJKB-40-D Shown) OPERATOR’S CONTROL CONSOLE PLATFORM BOOM TELESCOPING BOOM ASSEMBLY RISER TURRET BASE CONTROL PANEL DRIVE CHASSIS DEC. 1999 SECTION 1, Page 4 JUN. 1999 SJKB-40-D, SJKB-40-D/F...

  • Page 12: Operator Qualifications

    Procedures for operating this work platform are detailed in the “OPERATING PROCEDURES’‘ section on Pages 7 through 9 in this manual. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 2, Page 1...

  • Page 13: Base Controls - Electrical

    When the switch is held (down) position. Release switch to stop. in the “ ” (base) position power is directed to the control station on the base. JUN. 1999 SECTION 2, Page 2 SJKB-40-D, SJKB-40-D/F...

  • Page 14: Base Controls - Mechanical

    FUEL SHUT OFF VALVE 1. FUEL SHUT OFF VALVE - This valve located in the fuel supply line near the bottom of the fuel tank turns off the supply of fuel to the fuel pump. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 2, Page 3...

  • Page 15: Base Controls - Hydraulic

    Turning the valve knob in this section). The machine is now ready to be counterclockwise allows the boom to gradually lower. loaded or unloaded using a winch line. JUN. 1999 SECTION 2, Page 4 SJKB-40-D, SJKB-40-D/F...

  • Page 16: Platform Controls - Electrical

    Before releasing the foot switch, the controllers should until pressure drops below 300 psi.) be returned to the neutral position. Work platform motion will stop when the foot switch is released. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 2, Page 5...
  • Page 17 To rotate the turret counterclockwise, position. The engine must be running before any push and hold this toggle switch to the “ ð “ (right) functions can be operated. position. Release switch to stop. JUN. 1999 SECTION 2, Page 6 SJKB-40-D, SJKB-40-D/F...

  • Page 18: Operating Procedures

    Make sure the entry midrail returns to midrail position. Close the gate (if so equipped). JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 2, Page 7...
  • Page 19 “ (down) (reverse) position. Release controller handle position. To stop release the switch. to stop. TO STEER: Depress the rocker on the Drive/ Steer Controller handle in the direction you wish to steer. JUN. 1999 SECTION 2, Page 8 SJKB-40-D, SJKB-40-D/F...

  • Page 20: Shutdown Procedure

    Push in the Emergency Stop Buttons. Rotate the Off/Platform/Base Key Switch to the ” “(off) position. Remove the key. Ma40-212 Figure 2-11. Recommended Tie Down Locations Rotate the Battery Disconnect Switch to the “OFF” position. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 2, Page 9...
  • Page 21 Table 2-1. Maintenance and Inspection Schedule Daily Weekly Monthly 3 Months 6 Months * Yearly Engine (11) Fuel leaks (1) Mt40c-200 JUN. 1999 SECTION 2, Page 10 SJKB-40-D, SJKB-40-D/F...

  • Page 22: Recommended Hydraulic Oils

    DO NOT use synthetic or fire resistant oil in this work platform. Use ATF Dexron III (ESSO) or equivalent hydraulic oil. For conditions causing oil temperatures below -31°F (-35° C) and above 122°F (50° C) consult Skyjack, Inc. RECOMMENDED AXLE LUBRICANT TWO WHEEL DRIVE: SAE 80W90 GL-5 gear oil.
  • Page 23 Boom Extend (S/N 95209 and below.) 30-34 Boom Retract 20-22 Jib Up 12-14 Jib Down 10-12 Platform Rotate Left Platform Rotate Right Turret Rotate Clockwise 57-63 Turret Rotate Counter Clockwise 57-63 Mt40-205 JUN. 1999 SECTION 2, Page 12 SJKB-40-D, SJKB-40-D/F...
  • Page 24 AND SCHEMATICS TABLE OF CONTENTS ELECTRICAL SYSTEM TABLE 3-1. SKYJACK BOOMS, ELECTRICAL SYMBOLS LEGEND ............. Page 2 TABLE 3-2. SKYJACK BOOMS, HYDRAULIC SYMBOLS LEGEND .............. Page 3 TABLE 3-3. RELAY SCHEDULE ........................Page 4 TABLE 3-4. WIRE NUMBER AND COLOR CODE..................Page 5 FIGURE 3-1./ FIGURE 3-2.
  • Page 25 Table 3-1. Skyjack Booms, Electrical Symbols Legend CIRCUITS CROSSING RELAY, SINGLE POLE EMERGENCY STOP NO CONNECTION SINGLE THROW BUTTON CIRCUITS RELAY, SINGLE POLE KEY SWITCH CONNECTED DOUBLE THROW RELAY, DOUBLE POLE FOOT SWITCH BATTERY SINGLE THROW RELAY, DOUBLE POLE GROUND...
  • Page 26 Table 3-2. Skyjack Booms, Hyraulic Symbols Legend ADJUSTABLE MAIN LINES Solid ROTARY ACTUATOR FLOW CONTROL FIXED DISPLACEMENT PILOT LINES Dashed CHECK VALVE HYDRAULIC MOTOR BIDIRECTIONAL VARIABLE LINES CROSSING NO DISPLACEMENT SHUTTLE VALVE CONNECTION HYDRAULIC MOTOR BIDIRECTIONAL ACCUMULATOR, SERIES PARELLEL LINES CONNECTED...
  • Page 27 Engine Shutdown Relay 54,02,76,77,54C Engine Panel 57ACR Starter Relay 57A,02,03,03A Engine Panel 60ACR Base Panel Power Relay 60A,02,07,09 Base Panel 74CR Choke Relay 74,02,54,74A Base Panel 114CR Steering Bypass Relay 114,114A,09,02 Base Panel Mt40-300 SJKB-40-D, SJKB-40-D/F SECTION 3, Page 4 JUN. 1999...
  • Page 28 This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red. SJKB-40-D, SJKB-40-D/F SECTION 3, Page 5...
  • Page 29 TERMINAL BLOCK, Diode 700187 FOOT SWITCH 707875 RECEPTACLE, 40 Pin connector 707847 • GASKET, Connector 705258 • PIN, Contact 707822 • • TOOL, Pin removal 707823 • • TOOL, Crimp 102921 DIODE, 6 Amp/1000PIV SJKB-40-D, SJKB-40-D/F SECTION 3, Page 6 JUN. 1999...
  • Page 30 FIGURE 3-1. OPERATOR’S CONTROL CONSOLE DIAGRAM (S/N 95088 AND ABOVE.) PLATFORM LEVELING FROM PLATFORM CONTROL CONSOLE IS NOT AVAILABLE ON EUROPEAN MACHINES MA40-306 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 3, Page 7...
  • Page 31 FIGURE 3-2. OPERATOR’S CONTROL CONSOLE DIAGRAM (S/N 95087 AND BELOW.) PLATFORM LEVELING FROM PLATFORM CONTROL CONSOLE IS NOT AVAILABLE ON EUROPEAN MACHINES MA40-300 SECTION 3, Page 8 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 32 FIGURE 3-3. BASE CONTROL/ELECTRICAL PANEL WIRING DIAGRAM (S/N 95088 AND ABOVE.) LEGEND MAIN CONTROL CABLE GOVERNOR WIRE HARNESS MAIN FUNCTION MANIFOLD NOT USED ENGINE WIRE HARNESS MA40-307 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 3, Page 9...
  • Page 33 FIGURE 3-4. BASE CONTROL/ELECTRICAL PANEL WIRING DIAGRAM (S/N 95087 AND BELOW.) LEGEND MAIN CONTROL CABLE GOVERNOR WIRE HARNESS MAIN FUNCTION MANIFOLD NOT USED ENGINE WIRE HARNESS MA40-301 SECTION 3, Page 10 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 34 CONTROL CABLE, 18/30 660” 105269 CABLE, 14/3 732” 706294 LIMIT SWITCH, Booted 700160 LIMIT SWITCH 702434 LIMIT SWITCH ASSEMBLY 700552 TILT SWITCH 704716 BRAKE MANIFOLD 702262 PLUG, 1/2” Knockout (All Ford Engines) SJKB-40-D, SJKB-40-D/F SECTION 3, Page 11 JUN. 1999...
  • Page 35 DIODE, 6 Amp/1000 PIV 701943 RELAY, 12 Volt sealed 707824 TACHOMETER SENSOR 104345 CONNECTOR, Directional valve 707677 THROTTLE ACTUATOR, Linear 115329 ALTERNATOR 707676 CHOKE ACTUATOR, Linear COIL, Ignition 115309 STARTER SJKB-40-D, SJKB-40-D/F SECTION 3, Page 12 OCT. 1999 JUN. 1999...
  • Page 36 FIGURE 3-5. ENGINE WIRING DIAGRAM (Kubota gas and Dual Fuel) MA40-302 SJKB-40-D, SJKB-40-D/F SECTION 3, Page 13 JUN. 1999...
  • Page 37 FIGURE 3-6. ENGINE WIRING DIAGRAM (Diesel) MA40-303 SECTION 3, Page 14 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 38 TEMPERATURE SENSOR, Coolant 103011 TERMINAL BLOCK, Large 102921 DIODE, 6 Amp/1000 PIV 701943 RELAY, 12 Volt sealed 707824 TACHOMETER SENSOR 104345 CONNECTOR, Directional valve 707675 THROTTLE ACTUATOR, Linear 115329 ALTERNATOR 115457 STARTER SJKB-40-D, SJKB-40-D/F JUN. 1999 OCT. 1999 SECTION 3, Page 15...
  • Page 39 FORD TERMINAL STRIP 115389 SENSOR, Magnetic tachometer 704616 RELAY, 12 Volt time delay FORD SWITCH, 6 PSI Oil pressure 701943 RELAY, 12 Volt sealed 707677 THROTTLE ACTUATOR, Linear 103256 CABLE, 18/2 76” SECTION 3, Page 16 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 40 FIGURE 3-7. ENGINE WIRING DIAGRAM (Ford Dual Fuel) MA40-305 JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 3, Page 17...
  • Page 41 THROTTLE ACTUATOR, Linear (gas and dual fuel) 707676 CHOKE ACTUATOR, Linear (gas and dual fuel only)(Kubota engine) LB1-LB3 (Ref.) LIGHT ASSEMBLY, Indicator 103202 • LIGHT HEAD 102671 • LIGHT BASE 703185 • • BULB DEC. 1999 SECTION 3, Page 18 SJKB-40-D, SJKB-40-D/F JUN. 1999...
  • Page 42 FIGURE 3-8. ELECTRICAL SCHEMATIC (Kubota Gas and Dual Fuel)(S/N 95088 and above.) 704372AF SJKB-40-D, SJKB-40-D/F AUG. 1999 SECTION 3, Page 19...
  • Page 43 FIGURE 3-9. ELECTRICAL SCHEMATIC (Kubota Gas and Dual Fuel)(S/N 95087 and below.) 704372AA SECTION 3, Page 20 JUN. 1999 SJKB-40-D,SJKB-40-D/F...
  • Page 44 FIGURE 3-10. ELECTRICAL SCHEMATIC (Diesel)(S/N 95088 and above.) 706969AF SJKB-40-D, SJKB-40-D/F AUG. 1999 SECTION 3, Page 21...
  • Page 45 FIGURE 3-11. ELECTRICAL SCHEMATIC (Diesel)(S/N 95087 and below.) 706969AA SECTION 3, Page 22 JUN. 1999 SJKB-40-D,SJKB-40-D/F...
  • Page 46 FIGURE 3-12. ELECTRICAL SCHEMATIC (Ford Dual Fuel) 708852 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 3, Page 23...
  • Page 47 FIGURE 3-13. HYDRAULIC SCHEMATIC 704667AA MAR. 2000 SECTION 3, Page 24 SJKB-40-D,SJKB-40-D/F...
  • Page 48 PUMP/MOTOR ASSEMBLY, Emergency 706814 FILTER, Medium pressure 708333 ELEMENT, Filter 704476 FILTER, High pressure 704559 ELEMENT, Filter 700763 VALVE, Turret rotation speed control 706026 VALVE, Needle 703725 GAUGE, Pressure (800 PSI) MARCH, 2000 SJKB-40-D, SJKB-40-D/F JUNE 1999 SECTION 3, Page 25...
  • Page 49 CYLINDERS (turn right) TO (C7/C8) STEER 700 PSI CYLINDERS TO (C2) BOOM LIFT TO (RA1) ROTARY TO (C2) BOOM LIFT TO (RA1) ROTARY (turn left) CYLINDER (up) ACTUATOR(left) CYLINDER (down) ACTUATOR(rightt) Mt40-304 Ma40-621 Ma40-619 AUG. 1999 SECTION 3, Page 26 SJKB-40-D, SJKB-40-D/F...
  • Page 50 VALVE PRESSURE 390 PSI RV7 - DRIVE PRESSURE T2 - FROM SYSTEM MANIFOLD RELIEF VALVE (PORT P&T)(LOW SPEED/TORQUE) S - TO HYDRAULIC TANK TO PROPORTIONAL FLOW CONTROL MA40-304 (PORT 1&2)(DRIVE PUMP) Mt40-302 SJKB-40-D, SJKB-40-D/F JUNE 1999 SECTION 3, Page 27...
  • Page 51 NOTES SECTION 3, Page 28 JUNE 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 52 Loose or broken wire #60A from Check Continuity. Replace if base terminal block TB3 to relay defective. 60ACR. Loose or broken wire #02 from Check Continuity. Replace if relay 60ACR to base terminal defective. block TB3. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 1...
  • Page 53 Replace if defective. Loose or broken wire 07A from key Check Continuity. Replace if select switch S3-3 to key select defective. switch S3-1. Defective key select switch S3-1. Check Switch. Replace if defective. SECTION 4, Page 2 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 54 TPS1 to defective. vacuum switch VS1. Defective vacuum switch VS1. Check Switch. Replace if defective. Loose or broken wire #54D from Check Continuity. Replace if vacuum switch VS1 to relay defective. 54DCR. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 3...
  • Page 55 TB1 to defective. footswitch S11. Defective footswitch S11. Check Switch. Replace if defective. Loose or broken wire #08 from Check Continuity. Replace if footswitch S11 to platform defective. terminal block TB1. SECTION 4, Page 4 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 56 FROM PLATFORM platform terminal block to boom defective. function control board BFC1. Loose or broken wire #02 from Check Continuity. Replace if platform terminal block TB1 to defective. boom function control board BFC1. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 5...
  • Page 57 TB2 to defective. relay 28CR. Loose or broken wire #02 from relay Check Continuity. Replace if 28CR to platform terminal block defective. TB1. Defective relay 28CR. Check Relay. Replace if defective. SECTION 4, Page 6 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 58 Replace if defective. Loose or broken wire #02 from riser Check Continuity. Replace if up valve coil 4H-14A to base defective. terminal block TB3. Open diode D14. Check Diode. Replace if defective. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 7...
  • Page 59 Loose or broken wire #09 from base Check Continuity. Replace if terminal block TB3 to relay 31CR. defective. Loose or broken wire #31A from Check Continuity. Replace if relay 31CR to main boom up valve defective. coil 4H-31A. SECTION 4, Page 8 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 60 Replace if defective. Loose or broken wire #02 from Check Continuity. Replace if turret rotate left valve coil 4H-32A defective. to base terminal block TB3. Open diode D32. Check Diode. Replace if defective. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 9...
  • Page 61 Check Continuity. Replace if turret rotate switch S20 to platform defective. terminal block TB2. Loose or broken wire #33 from Check Continuity. Replace if platform terminal block TB2 to defective. base terminal block TB3. SECTION 4, Page 10 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 62 Check Continuity. Replace if telescope switch S16 to platform defective. terminal block TB2. Loose or broken wire #38 from Check Continuity. Replace if platform terminal block TB2 to defective. base terminal block TB3. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 11...
  • Page 63 35A. Replace if defective. Loose or broken wire #02 from jib Check Continuity. Replace if down valve 4H-35A to base defective. terminal block TB3. Open diode D35. Check Diode. Replace if defective. SECTION 4, Page 12 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 64 Replace if defective. Loose or broken wire #02 from Check Continuity. Replace if platform rotate left valve coil 4H- defective. 36A to base terminal block TB3. Open diode D36. Check Diode. Replace if defective. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 13...
  • Page 65 Check Continuity. Replace if platform rotate switch S19 to defective. platform terminal block TB2. Loose or broken wire #37 from Check Continuity. Replace if platform terminal block TB2 to defective. base terminal block TB3. SECTION 4, Page 14 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 66 FROM PLATFORM CON- relay 30BCR. TROLS Defective relay 30BCR. Check relay. Replace if defective. Loose or broken wire #08A from Check Continuity. Replace if relay 30BCR to platform level defective. switch S17. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 15...
  • Page 67 Check Continuity. Replace if base terminal block TB3 to defective. platform terminal block TB2. Loose or broken wire #62B from Check Continuity. Replace if platform terminal block TB2 to defective. relay 08CR2. SECTION 4, Page 16 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 68 Check Continuity. Replace if base terminal block TB3 to EDA defective. board EDA1. Loose or broken wire #98 from Check Continuity. Replace if terminal #10 on EDA board EDA1 defective. to base terminal block TB3. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 17...
  • Page 69 Loose or broken wire #02 from Check Continuity. Replace if drive forward valve coil 4H-16 to defective. the drive pump case. Defective MDSD board MDSD1. Refer to section 5, MDSD board troubleshooting. SECTION 4, Page 18 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 70 Loose or broken wire #09 from Check Continuity. Replace if base terminal block TB3 to relay defective. 114CR. Open diode D114A-1. Check Diode. Replace if defective. Open diode D114A-2. Check Diode. Replace if defective. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 19...
  • Page 71 Replace if defective. Loose or broken wire #02 from Check Continuity. Replace if steer right valve coil 4H-24A to defective. base terminal block TB3. Open diode D23. Check Diode. Replace if defective. SECTION 4, Page 20 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 72 Check Continuity. Replace if relay 26ACR to base terminal defective. block TB3. Loose or broken wire #26B from Check Continuity. Replace if base terminal block TB3 to brake defective. valve coil 3H-26B. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 21...
  • Page 73 Replace if TIVE FROM BASE CON- switch S22. defective. TROLS Loose or broken wire #13(down) or Check Continuity. Replace if #14(up) from riser boom up/down defective. switch S22 to base terminal block TB3. SECTION 4, Page 22 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 74 08CR3 to base terminal block defective. TB3. Defective relay 08CR3. Check relay. Replace if defective. Loose or broken wire #28 from Check Continuity. Replace if base terminal block TB3 to relay defective. 08CR3. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 23...
  • Page 75 TB3. Loose or broken wire #79 from base Check Continuity. Replace if terminal block TB3 to barber/ defective. colman controller BCB1. Defective barber/colman controller Refer to section 5, "barber/colman BCB1. troubleshooting". SECTION 4, Page 24 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 76 74CR to choke solenoid CS1. defective. Defective choke solenoid CS1. Check Solenoid. Replace if defective. Loose or broken wire #00 from Check Continuity. Replace if choke solenoid to engine block. defective. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 25...
  • Page 77 TB3. Defective emergency pump motor Check Contactor. Replace if contactor 108CR. defective. Loose or broken battery cable from Check Continuity. Replace if battery 03 to emergency pump defective. contactor 108CR. SECTION 4, Page 26 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 78 S4. Defective emergency pump switch Check Switch. Replace if defective. Loose or broken wire #01 from Check Continuity. Replace if emergency pump switch S4 to defective. base terminal block TB3. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 27...
  • Page 79 Stuck or defective steer right Clean Valve. Replace if defective. valve 4H-23A. Blown seals in rotary manifold. Rebuild Rotary Manifold. Replace if defective. Steer cylinder bypassing Rebuild Cylinder. Replace if internally. damaged. SECTION 4, Page 28 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 80 Stuck or defective platform rotate Clean Valve. Replace if defective. LEFT left valve 4H-36A. Defective platform rotary actuator Check Actuator. Replace if defective. Stuck counter balance valve Clean Valve. Replace if defective. CB6. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 29...
  • Page 81 Stuck counter balance valve CB1. Clean Valve. Replace if defective. Leveling master cylinder by Rebuild cylinder. Replace if passing internally. damaged. Stuck counter balance valve Clean Valve. Replace if CB12. defective. SECTION 4, Page 30 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 82 4H-15 or 4H-16. defective. Defective main drive pump P1. Refer to section 5, "drive pump diagnostics. Defective drive motor M1. Refer to section 5, "drive motor test procedures". Replace if defective. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 4, Page 31...
  • Page 83 Refer to section 5, "drive pump test procedure". If pressure is lower than 300 PSI replace relief valve RV5. NO ELEVATED DRIVE Defective or misadjusted hi/low Check Valve. Replace if drive relief valve RV4. defective. SECTION 4, Page 32 JUN. 1999 SJKB-40-D, SJKB-40-D/F...

  • Page 84: General Maintenance Hints

    MUST be immediately flammable or combustible materials. tagged and removed from service until • Properly dispose of all waste material, i.e. used proper repairs are completed. oil, old parts etc. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 1...
  • Page 85 NOTES JUN. 1999 SECTION 5, Page 2 SJKB-40-D, SJKB-40-D/F...

  • Page 86: Table Of Contents

    LOW DRIVE PRESSURE ADJUSTMENT...................... Page 26 BRAKE SYSTEM PRESSURE ADJUSTMENT ..................... Page 27 MECHANICAL ADJUSTMENTS BRAKE ADJUSTMENT PROCEDURES ......................Page 28 WEAR PAD CLEARANCES ........................... Page 29 STANDARD HOSE NUMBERING SYSTEM ....................Page 30 JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 3...

  • Page 87: Hydraulic System And Component Maintenance And Repair

    For conditions causing hydraulic reservoir. oil temperatures below -31°F (-35° C) and above 122°F (50° C) consult Skyjack, Inc. Keep all connections tight. JUN. 1999 SECTION 5, Page 4...
  • Page 88 Table 5-1. Special Tools BRAKE ADJUSTMENT TOOL SKYJACK PART 707704 17mm ALLEN WRENCH PURCHASE LOCALLY PRESSURE GAUGE 0 - 5000 psi PURCHASE LOCALLY PRESSURE GAUGE 0 - 1000 psi PURCHASE LOCALLY CYLINDER ASSEMBLY TOOL - 2" Inside Diameter SKYJACK PART 706522 CYLINDER ASSEMBLY TOOL - 2-1/2"...

  • Page 89: Electrical System Diagnostics And Adjustments

    NOT USED MAGNETIC PICKUP GROUND MAGNETIC PICKUP SIGNAL NOT USED NOT USED Ma40-501 5.9 VOLTS WITH ENGINE AT HIGH RPM’s, BOOM FULLY RETRACTED AND BELOW HORIZONTAL Figure 5-1. Multi-Purpose Controller (EDA) Card. JUN. 1999 SECTION 5, Page 6 SJKB-40-D, SJKB-40-D/F...

  • Page 90: Mdsd Board Diagnostics

    If there is no reading, replace MDSD board. If reading is low, perform MDSD adjustments. Refer to Page 8 in this section for adjustment procedures. Remove meter from MDSD board and reinstall wire 15 to terminal 6. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 7...
  • Page 91 WIRE 15 DRIVE REVERSE NOT USED NOT USED NOT USED NOT USED WIRE 64 POTENTIOMETER WIPER SIGNAL WIRE 63 POTENTIOMETER CENTER SIGNAL NOT USED MA-66-502 Figure 5-2. Dual Solenoid Driver (MDSD) Card. JUN. 1999 OCT. 1999 SECTION 5, Page 8 SJKB-40-D, SJKB-40-D/F...

  • Page 92: Eda And Mdsd Board Adjustment Procedures

    NOTE The following steps can be used in the event that the MDSD board is extremely out of adjustment or there is not enough area to adjust using steps 19 through 32. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 9...
  • Page 93 1200 milliamps(1.2A) to obtain 50 feet in 9-1/2 to 10-1/2 seconds, check for binding in the drive system such as brakes dragging. 12 VOLT Ma40-503 Figure 5-3. Dual Solenoid Driver (MDSD) Card. JUN. 1999 SECTION 5, Page 10 SJKB-40-D, SJKB-40-D/F...
  • Page 94 CCW until you hear the pot click CW until you hear the pot click CCW until you hear the pot click CW until you hear the pot click Ma40-504 Figure 5-4. Base EDA Board Settings. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 11...

  • Page 95: Boom Function Board Diagnostics

    Page 13,”Boom Control Board Adjustment Procedure”. If amperage present refer to Page 5 in Section 4, “No Boom Functions from Platform”. STEP 6 STEP 9 STEP 11 STEP 4 Ma40-505 Figure 5-5. Boom Function Board Settings. JUN. 1999 SECTION 5, Page 12 SJKB-40-D, SJKB-40-D/F...

  • Page 96: Boom Function Board Adjustment Procedure

    Paint the potentiometer adjusting screws with nail polish or RTV Silicone to prevent vibration from changing settings. NOT USED ADJUST TO 1500mA ADJUST TO 550mA Ma40-505 Figure 5-6. Boom Function Board Adjustment Settings. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 13...

  • Page 97: Governor Diagnostics (Kubota Engines)

    Using a jumper wire from wire #09, jump to wire #79. If RPM’s rise, refer to “No High RPM” section of Electrical Trouble Shooting, section 4, page 24. If RPM’s do not rise replace Governor Control Box. GOVERNOR ACTUATOR Ma40-519 Figure 5-7. Governor Actuator JUN. 1999 SECTION 5, Page 14 SJKB-40-D, SJKB-40-D/F...
  • Page 98 Black 98 White White 98A Mt40-507 WHITE 78 PURPLE/BLUE 87 BLACK/WHITE 79 PURPLE/BLUE 86 BLACK 98 WHITE 98A RED 77 SHIELD 02 WHITE 02 SHIELDED WIRE Ma40-517 Figure 5-8. Governor Control Card JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 15...

  • Page 99: Governor Adjusting Procedure (Kubota Engines)

    TO 30% STEP 10 ADJUST TO: GAS AND DUAL FUEL (Kubota 750) 2200 RPM’s DIESEL & FORD 1.3 1800 RPM’s STEP 8 ADJUST TO 1400 Ma40-518 Figure 5-9. Governor Control Box RPM’s (ALL) JUN. 1999 SECTION 5, Page 16 SJKB-40-D, SJKB-40-D/F...
  • Page 100 NOTES JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 17...

  • Page 101: Governor Diagnostics (Ford Engines)

    Attach a volt/ohm meter to terminals 3 and 4. With the foot switch held down activate speed selector switch from low to high and from high to low and measure voltage. If no voltage present, replace governor control box. JUN. 1999 SECTION 5, Page 18 SJKB-40-D, SJKB-40-D/F...
  • Page 102 OHMS GOVERNOR ACTUATOR ACTUATOR CONNECTOR TO D.I.S. 12 VOLTS MODULES TO SPEED SWITCH “A” TO SPEED SWITCH “B” Ma40-507 Figure 5-10. Barber Colman Governor Control Diagnostics. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 19...

  • Page 103: Governor Adjusting Procedure (Ford Engines)

    “I” potentiometer counterclockwise until satisfied. TOUCH JUMPER WIRE BETWEEN TERMINALS 9 AND 10 TO INCREASE ENGINE RPM’s TOUCH JUMPER WIRE BETWEEN TERMINALS DECREASE ENGINE RPMs Ma40-508 Figure 5-11. Barber Colman Governor Control. JUN. 1999 SECTION 5, Page 20 SJKB-40-D, SJKB-40-D/F...

  • Page 104: Magnetic Pick Up Test Procedure

    5-12. It should read between 135 - 165 ohms. If reading is outside of this range, the pick up is defective. Terminal Block TB-3 Located in Lower Control Panel 135-165 OHMS S o l d e r Splice Ma40-506 Figure 5-12. Magnetic Tachometer Pickup. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 21...

  • Page 105: Magnetic Pickup Replacement Instructions

    Check voltage between terminal “L” on the EDA board and a good chassis ground (Refer to EDA/MDSD adjustment procedure for location). It should read 5.9 volts D.C. Perform EDA/MDSD adjustment procedure if voltage does not read 5.9 volts D.C. MAGNETIC PICKUP Figure 5-13. Magnetic Pickup. JUN. 1999 SECTION 5, Page 22 SJKB-40-D, SJKB-40-D/F...

  • Page 106: Hydraulic System Diagnostics And Adjustments

    Engage and hold the Riser Boom Down Toggle switch. Observe reading on Gauge. Adjust RV1 to 2600 PSI. Refer to Figure 5-14 for location. Shut Engine off, remove Gauge. HYDRAULIC ACCUMULATOR QUICK COUPLING Ma40-500 Figure 5-14. Boom Pump Pressure Settings. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 23...

  • Page 107: Drive Pump Test Procedure

    SLOWLY move drive joystick in the forward direction. Observe gauge reading. Gauge should read 4800 PSI. If 4800 PSI present drive pump is operating properly. If no pressure present, replace drive pump. JUN. 1999 SECTION 5, Page 24 SJKB-40-D, SJKB-40-D/F...
  • Page 108 RV3 CHARGE PRESSURE RELIEF VALVE FORWARD Ma40-512 PRESSURE GAUGE PORT Figure 5-15 Drive Pump Test Ports DRIVE MOTOR CASE DRAIN FORWARD DRIVE HOSE FRONT REVERSE DRIVE HOSE Ma40-513 Figure 5-16 Rotary Manifold JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 25...

  • Page 109: Low Drive Pressure Adjustment

    TEE A 1000 PSI GAUGE INTO HOSE AT Ps PORT PORT Ma40-516 PILOT PRESSURE HOSE TO TURRET MANIFOLD Figure 5-17. Drive Pump. HI/LOW RELIEF VALVE Ma40-510 Figure 5-18. Hi/Low Relief Valve Location. JUN. 1999 SECTION 5, Page 26 SJKB-40-D, SJKB-40-D/F...

  • Page 110: Brake System Pressure Adjustment

    Stop machine and adjust pressure reducing valve 1/4 turn at a time until 600 - 650 pressure reading is achived. Turn clockwise to increase or counterclockwise to decrease. BRAKE RELEASE OVERRIDE VALVE RELIEF VALVE PRESSURE REDUCING VALVE BRAKE Ma40-524 RELEASE HAND PUMP Figure 5-19. Brake System Manifold. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 27...

  • Page 111: Mechanical Adjustments

    Remove the Center Plug (17mm allen head) (Item #1) from each brake cover. Starting with the left brake, insert the shaft of the Dial Indicator(Item #2, Skyjack part #707704) through the hole in the brake cover and carefully tighten the gauge holder (clockwise) until no threads are exposed.

  • Page 112: Wear Pad Clearances

    Boom Wear Pad Clearances Main Boom wear pads = 0” - .010” Clearance. Telescopic Boom wear pads = 0” - 0.010” Clearance. Ma40-523 Figure 5-21. Boom Wear Pad Locations. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 5, Page 29...

  • Page 113: Standard Hose Numbering System

    100R2AT FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R2AT FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R13 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R4 JUN. 1999 SECTION 5, Page 30 SJKB-40-D, SJKB-40-D/F...

  • Page 114: Section 6 Parts List

    HOW TO ORDER REPAIR PARTS complete identification should also be used when requesting equipment information. 1. Address all orders to your local SKYJACK dealer. 2. Specify model and serial number of the work platform METHOD OF LISTING (found on the serial number plate).

  • Page 115: List Of Illustrations

    FIGURE 6-39. PLANETARY REDUCTION GEAR ASSEMBLY (Brevini) ............. 6-78 FIGURE 6-40. PLANETARY REDUCTION GEAR ASSEMBLY (Sige) ..............6-79 FIGURE 6-41. DRIVE AXLE (Standard 4x2) ....................... 6-80 FIGURE 6-42. STEER AXLE ASSEMBLY (Optional 4x4) ................... 6-82 JUN. 1999 SECTION 6, Page 2 SJKB-40-D, SJKB-40-D/F...
  • Page 116 FIGURE 6-53. PLATFORM WORK LIGHTS OPTION ..................6-94 FIGURE 6-54. AIRLINE TO PLATFORM OPTION ....................6-97 FIGURE 6-55. HYDRAULIC TOOL OPTION ......................6-98 FIGURE 6-56. PLATFORM TOOL TRAY/CONTROL COVER OPTION ..............6-100 JUN. 1999 AUG. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 3...
  • Page 117 FIGURE 6-1. PLATFORM ASSEMBLY - 30” x 66” Ma40-600 JUN. 1999 SECTION 6, Page 4 SJKB-40-D, SJKB-40-D/F...
  • Page 118 • BUMPER RUBBER 117277 • HINGE SPRING 112495 • • BOLT, HHCS 1/4-20x3/8” lg. 104000 • • WASHER, Lock 1/4 Ref. OPERATOR’S CONTROL CONSOLE (For components, refer to Figure 6-2.) JUN. 1999 AUG. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 5...

  • Page 119: Figure 6-2. Operator's Control Console Assembly

    FIGURE 6-2. OPERATOR’S CONTROL CONSOLE ASSEMBLY 17 16 30 31 Ma40-602 JUN. 1999 SECTION 6, Page 6 MAR. 2000 SJKB-40-D, SJKB-40-D/F...
  • Page 120 702662 • SWITCH, Toggle DPDT 3 pos. momentary 102853 • SWITCH, Toggle SPDT 3 pos. momentary 707177 • POTENTIOMETER, w/resistor board 707253 • KNOB Parts list continued on Page 9. JUN. 1999 MAR. 2000 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 7...
  • Page 121 FIGURE 6-2. OPERATOR’S CONTROL CONSOLE ASSEMBLY 17 16 30 31 Ma40-602 JUN. 1999 SECTION 6, Page 8 MAR. 2000 SJKB-40-D, SJKB-40-D/F...
  • Page 122 • • BOLT, Mach. HD #8-32 x .75” lg. 112249 • • WASHER, Lock #8 103986 • • NUT, Hex #8-32 707822 • • TOOL, Pin removal 707823 • • TOOL, Crimp JUN. 1999 MAR. 2000 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 9...
  • Page 123 • POTENTIOMETER 708998 • PINION GEAR 709386 • SWITCH, w/Roller Actuator (Not Shown) 709387 • CAM, for Neutral Switch (Not Shown) 709000 • GRIP ASSEMBLY, No’s 3-9 709388 • ELECTRICAL ASSEMBLY, No’s 10-14 JUN. 1999 SECTION 6, Page 10 SJKB-40-D, SJKB-40-D/F...
  • Page 124 • POTENTIOMETER 708998 • PINION GEAR 709386 • SWITCH, w/Roller Actuator (Not Shown) 709387 • CAM, for Neutral Switch (Not Shown) 709390 • GRIP ASSEMBLY, No’s 3-10 709388 • ELECTRICAL ASSEMBLY, No’s 11-15 JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 11...

  • Page 125: Figure 6-5. Boom Assembly

    FIGURE 6-5. BOOM ASSEMBLY Ma40-601 JUN. 1999 SECTION 6, Page 12 SJKB-40-D, SJKB-40-D/F...
  • Page 126 • BOLT, HHCS 5/16-18 x 3/4” lg. 103404 • WASHER, Lock 5/16 700344 PIN, Turret lower parallel 103887 • BOLT, HHCS 5/16-18 x 3/4” lg. 103404 • WASHER, Lock 5/16 JUN. 1999 FEB. 2000 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 13...

  • Page 127: Figure 6-6. Jib Lift Cylinder Assembly

    FIGURE 6-6. JIB LIFT CYLINDER ASSEMBLY Ma40-604 JUN. 1999 SECTION 6, Page 14 SJKB-40-D, SJKB-40-D/F...
  • Page 128 • WASHER, Lock 5/16 700568 VALVE, Counterbalance 701956 FITTING, Connector #6orb-#4 701635 O-RING, Valve block 103136 VALVE, Manual lowering 700456 KIT, Seal repair 706521 TOOL, Cylinder assembly 2-1/2” * Part of Seal Repair Kit. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 15...
  • Page 129 NOTES JUN. 1999 SECTION 6, Page 16 SJKB-40-D, SJKB-40-D/F...
  • Page 130 100309 • BUSHING, 1” x 1-1/4" x 1" lg. 103069 • FITTING, Connector #6orb-#6 703223 FITTING, Tee #6swv-#4-#4 700454 KIT, Seal repair 706522 TOOL, Cylinder assembly 2” * Part of Seal Repair. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 17...

  • Page 131: Figure 6-8. Boom Lift Cylinder Assembly

    FIGURE 6-8. BOOM LIFT CYLINDER ASSEMBLY Ma40-606 JUN. 1999 SECTION 6, Page 18 SJKB-40-D, SJKB-40-D/F...
  • Page 132 • WASHER, Lock 5/16 103136 VALVE, Manual lowering 700568 VALVE, Counterbalance 707234 FITTING, Elbow 45° #6orb-#4 701635 O-RING, Valve block 700452 KIT, Seal repair 703872 TOOL, Cylinder assembly 3-1/2” * Part of Seal Repair Kit. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 19...

  • Page 133: Figure 6-9. Riser Lift Cylinder Assembly

    FIGURE 6-9. RISER LIFT CYLINDER ASSEMBLY Ma40-607 JUN. 1999 SECTION 6, Page 20 SJKB-40-D, SJKB-40-D/F...
  • Page 134 • WASHER, Lock 5/16” 707694 PLUG, Cavity C10-2 700568 VALVE, Counterbalance 707234 FITTING, Elbow 45° #6orb-#4 701635 O-RING, Valve block 700452 KIT, Seal repair 703872 TOOL, Cylinder assembly 3-1/2” * Part of Seal Repair Kit. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 21...

  • Page 135: Figure 6-10. Rotary Actuator Assembly

    FIGURE 6-10. ROTARY ACTUATOR ASSEMBLY Ma40-608 JUN. 1999 SECTION 6, Page 22 SJKB-40-D, SJKB-40-D/F...
  • Page 136 • • SCREW, Self tapping 1/4-14x3/4” lg. 706002 • CYLINDER ASSEMBLY, Slave (For components refer to Figure 6-11.) 700386 • PIN, Jib Actuator bracket 103887 • • BOLT, HHCS 5/16-18x3/4” lg. 103404 • • WASHER, Lock 5/16 JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 23...
  • Page 137 NOTES JUN. 1999 SECTION 6, Page 24 SJKB-40-D, SJKB-40-D/F...
  • Page 138 • BOLT, HHCS 5/16-18 x 1.75 lg. 103404 • WASHER, Lock 5/16” 700568 VALVE, Counterbalance 701635 O-RING, Valve block 700454 KIT, Seal repair 706522 TOOL, Cylinder assembly 2” * Part of Seal Repair Kit. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 25...

  • Page 139: Figure 6-12. Boom Assembly (Main And Telescopic Section)

    FIGURE 6-12. BOOM ASSEMBLY (Main and Telescopic Section) Ma40-610 JUN. 1999 SECTION 6, Page 26 SJKB-40-D, SJKB-40-D/F...
  • Page 140 • WASHER, Flat #10 104185 • WASHER, Lock #10 (Ref.) • WEAR PADS, Telescopic Boom (For components refer to Figure 6-14.) (Ref.) • WEAR PADS, Main Boom (For components refer to Figure 6-15.) JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 27...

  • Page 141: Figure 6-13. Boom Telescoping Cylinder Assembly

    FIGURE 6-13. BOOM TELESCOPING CYLINDER ASSEMBLY Ma40-613 JUN. 1999 SECTION 6, Page 28 SJKB-40-D, SJKB-40-D/F...
  • Page 142 • BOLT, SHCS 5/16-18 x 3-1/2” lg. 103404 • WASHER, Lock 5/16” 700568 VALVE, Counterbalance 700455 KIT, Seal repair 706522 TOOL, Cylinder assembly 2” * Part of Seal Repair Kit. JUN. 1999 DEC. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 29...

  • Page 143: Figure 6-14. Telescopic Boom Wear Pads

    BRACKET, Wear Pad 101632 • BOLT, HHCS 3/8-16x3/4” lg. 103472 • WASHER, Flat SAE 3/8” 103999 • WASHER, Lock 3/8” 700097 SHIM, Wear pad (.059 thk.) 700580 SHIM, Wear pad (.023 thk.) JUN. 1999 SECTION 6, Page 30 SJKB-40-D, SJKB-40-D/F...

  • Page 144: Figure 6-15. Main Boom Wear Pads

    • PIN, Roll 1/4x1/2” lg. 701071 BRACKET, Wear Pad 702196 • SHIM, Wear pad (.024 thk.) 103473 • BOLT, HHCS 3/8-16x1” lg. 103472 • WASHER, Flat SAE 3/8” 103999 • WASHER, Lock 3/8” JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 31...

  • Page 145: Figure 6-16. Hydraulic Hose Connections - Boom Assembly

    FIGURE 6-16. HYDRAULIC HOSE CONNECTIONS - Boom Assembly Ma40-614 JUN. 1999 SECTION 6, Page 32 SJKB-40-D, SJKB-40-D/F...
  • Page 146 FITTING, Elbow 90° #4orb-#4 707234 FITTING, Elbow 45° #6orb-#4 701956 FITTING, Connector #6orb-#4 103069 FITTING, Connector #6orb-#6 NOTE: Refer to Standard Hose Numbering System (SECTION 5, Page 30) for explanation of hose numbering. JUN. 1999 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 33...

  • Page 147: Figure 6-17. Turret Assembly

    FIGURE 6-17. TURRET ASSEMBLY MA40-603 JUN. 1999 SECTION 6, Page 34 SJKB-40-D, SJKB-40-D/F...
  • Page 148 706403 • SET SCREW, 1/2-13 x 2-1/2” lg. 103471 • NUT, Hex 1/2-13 706429 • BOLT, SHCS 5/8-11 x 2” lg. 103998 • WASHER, Lock 5/8” Parts List Continued on Page 37. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 35...
  • Page 149 FIGURE 6-17. TURRET ASSEMBLY MA40-603 JUN. 1999 SECTION 6, Page 36 SJKB-40-D, SJKB-40-D/F...
  • Page 150 702116 • FITTING, Connector #8orb - #8 707995 • FITTING, Branch tee #8orb - #8 703658 PIN, Hitch 3/8” (SJKB-40-D, -40-D/F Kabota engine only) 707774 LANYARD, 8” lg. (SJKB-40-D, -40-D/F Kabota engine only) 103996 • WASHER, Flat 5/16” SAE 103984 •...

  • Page 151: Figure 6-18. Turret Covers, Doors And Counterweights

    FIGURE 6-18. TURRET COVERS, DOORS AND COUNTERWEIGHTS MA40-634 JUN. 1999 SECTION 6, Page 38 SJKB-40-D, SJKB-40-D/F...
  • Page 152 • BOLT, HHCS 1-8 x 3” lg. 107948 • WASHER, Lock 1” 700435 • WASHER, Flat 1” 111135 PAD, Riser rest 103980 • NUT, Hex 1/4-20 103995 • WASHER, Flat 1/4” SAE 104000 • WASHER,Lock 1/4” SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 39...

  • Page 153: Figure 6-19. Fuel Tank Assembly

    • FITTING, Elbow 90° brass barb (Diesel) 701458 • FITTING, Connector #4 - #4 702313 • FITTING, Pipe 1/4” full coupling 702308 • FITTING, Needle valve 103339 • PLUG, 3/4” magnetic zinc plated JUN. 1999 SECTION 6, Page 40 OCT. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 154 • • BOLT, HHCS 1/4-20 x 3/4” lg. grade 5 103995 • • WASHER, Flat 1/4” 104000 • • WASHER, Lock 1/4” 700506 • PLUG, Breather vent 702290 • STRAINER, Hydraulic tank filler cap 702291 • FILLER CAP, Hydraulic tank SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 41...

  • Page 155: Figure 6-21. Rotary Manifold Assembly

    FIGURE 6-21. ROTARY MANIFOLD ASSEMBLY MA40-618 JUN. 1999 SECTION 6, Page 42 SJKB-40-D, SJKB-40-D/F...
  • Page 156 • FITTING, Pipe nipple 1/4NPT x 4” lg. 702500 • FITTING, Elbow 90° female 1/4NPT - 1/4NPT 702821 • FITTING, Adaptor 3/4NPT - 3/8NPT 702239 • FITTING, Brass swivel #6orb - #4 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 43...

  • Page 157: Figure 6-22. System Manifold Assembly

    FIGURE 6-22. SYSTEM MANIFOLD ASSEMBLY 704269 SECTION 6, Page 44 AUG. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 158 • FITTING, Elbow 90° #6orb - #4 707234 • FITTING, Elbow 45° #6orb - #4 701956 • FITTING, Connector #6orb - #4 110669 • FITTING, Elbow 90° #6orb - #8 SJKB-40-D, SJKB-40-D/F AUG. 1999 JUN. 1999 SECTION 6, Page 45...
  • Page 159 • • PLUG, SAE #2 700765 • • PLUG, SAE #4 104437 • • PLUG, SAE #6 103069 • FITTING, Connector #6orb - #6 107742 • FITTING, Elbow 45° #6orb - #6 (Ford 1.3 Only) JUN. 1999 SECTION 6, Page 46 SJKB-40-D, SJKB-40-D/F...
  • Page 160 • • WASHER, Lock 1/2” 704237 KIT,Seal 704504 • ASSEMBLY, Hose (H1204 0009 00-0) (Not shown) NOTE: Refer to Standard Hose Numbering System (SECTION 5, Page 30) for explanation of hose numbering. OCT. 1999 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 47...

  • Page 161: Figure 6-25. Base Control/Electrical Panel Assembly

    FIGURE 6-25. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY 39 40 MA40-628 JUN. 1999 SECTION 6, Page 48 SJKB-40-D, SJKB-40-D/F...
  • Page 162 • BREAKER, 15 Amp circuit 703572 • COVER, 110 Volt outlet 700841 • • BOLT, Machine head #6-32 x 1/2” lg. 103985 • • NUT, Hex #6-32 Parts List Continued on Page 51. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 49...
  • Page 163 FIGURE 6-25. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY 39 40 MA40-628 JUN. 1999 SECTION 6, Page 50 SJKB-40-D, SJKB-40-D/F...
  • Page 164 • WIRE HARNESS, Governor (All Ford Engines) 707708 • WIRE HARNESS, Engine control 703720 • LIGHT, Indicator amber (diesel only) 708560 • SUB-ASSEMBLY DIODE 708559 • SUB-ASSEMBLY DIODE 702262 • PLUG, 1/2” Knockout (All Ford Engines) SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 51...
  • Page 165 FIGURE 6-26. ENGINE AND RELATED PARTS (Kubota - Gas and Dual Fuel) 34 35 MA40-640 JUN. 1999 SECTION 6, Page 52 SJKB-40-D, SJKB-40-D/F...
  • Page 166 • WASHER, Flat 3/8” 702119 • FITTING, Elbow 90° swivel #12 - #12 704582 • FITTING, Connector #10orb - #12 703533 • FITTING, Elbow 90° #10orb - #8 Parts List Continued on Page 55. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 53...
  • Page 167 FIGURE 6-26. ENGINE AND RELATED PARTS (Kubota - Gas and Dual Fuel) 34 35 MA40-640 JUN. 1999 SECTION 6, Page 54 SJKB-40-D, SJKB-40-D/F...
  • Page 168 • WASHER, Thrust 707046 • RETAINING RING, 2.25 Dia. 707698 PLATE, Door rest 702195 • BOLT, HHCS 3/8-16 x 1-1/2” lg. grade 5 103999 • WASHER, Lock 3/8” 702929 • NUT, Hex jam 3/8-16 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 55...
  • Page 169 FIGURE 6-27. DUAL FUEL SYSTEM(Kubota) MA40-645 JUN. 1999 SECTION 6, Page 56 SJKB-40-D, SJKB-40-D/F...
  • Page 170 FITTING, Pipe nipple 1/4”NPT x 2” lg. 702500 FITTING, Brass elbow 90° #4 - #4 707707 HOSE ASSEMBLY, 32” Propane 710320 PIPE NIPPLE, 1/4” Close 702237 FITTING, Brass female tee #4 $ Consult factory. SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 57...
  • Page 171 FIGURE 6-28. ENGINE AND RELATED PARTS (Ford - Gas and Dual Fuel) MA40-647 JUN. 1999 SECTION 6, Page 58 SJKB-40-D, SJKB-40-D/F...
  • Page 172 • FITTING, Elbow 90° #10orb - #6 707040 • FITTING, Elbow 90° #16orb - #16 708827 MOUNTING BRACKET, Oil cooler (right hand) 708826 MOUNTING BRACKET, Oil cooler (left hand) Parts List Continued on Page 61. MARCH, 2000 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 59...
  • Page 173 FIGURE 6-28. ENGINE AND RELATED PARTS (Ford - Gas and Dual Fuel) MA40-647 JUN. 1999 SECTION 6, Page 60 SJKB-40-D, SJKB-40-D/F...
  • Page 174 PLATE, Safety latch 709352 ENGINE BAFFLE, 40-RT and XRT 709451 CARRIER, Hose 701503 • BOLT, HHCS 1/4-20 x 2 1/2” lg. 103995 • WASHER, Flat 1/4” 700583 • NUT, Lock 1/4-20 SJKB-40-D, SJKB-40-D/F MARCH, 2000 JUN. 1999 SECTION 6, Page 61...
  • Page 175 FIGURE 6-29. DUAL FUEL SYSTEM(Ford) MA40-645 JUN. 1999 SECTION 6, Page 62 SJKB-40-D, SJKB-40-D/F...
  • Page 176 FITTING, Pipe nipple 1/4”NPT x 2” lg. 702500 FITTING, Brass elbow 90° #4 - #4 708856 HOSE ASSEMBLY, 36” Propane 710320 PIPE NIPPLE, 1/4” Close 702237 FITTING. Brass female tee #4 $ Consult factory. MARCH, 2000 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 63...
  • Page 177 FIGURE 6-30. ENGINE AND RELATED PARTS (Diesel)(Option) MA40-641 JUN. 1999 SECTION 6, Page 64 SJKB-40-D, SJKB-40-D/F...

  • Page 178: Figure 6-30. Engine And Related Parts (Diesel)(Option)

    • FITTING, Elbow 90° #10orb - #6 103472 • WASHER, Flat 3/8” 707040 • FITTING, Elbow 90° #16orb - #16 103999 • WASHER, Lock 3/8” 704957 PUMP, Hydraulic system 702929 • NUT, Hex jam 3/8-16 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 65 MARCH, 2000...

  • Page 179: Figure 6-31. Turret Hydraulic Connections

    FIGURE 6-31. TURRET HYDRAULIC CONNECTIONS 41 30 Ma40-642 SECTION 6, Page 66 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 180 FITTING, Connector, #16 - #12 109052 FITTING, Connector #12orb - #6 NOTE: Refer to Standard Hose Numbering System 707234 FITTING, Elbow 45° #6orb - #4 (SECTION 5, Page 30) for explanation of hose numbering. SJKB-40-D, SJKB-40-D/F JUN. 1999 JUL. 1999 SECTION 6, Page 67...
  • Page 181 FIGURE 6-32. BASE, AXLES, AND WHEELS (Standard 4x2) Ma40-615 SECTION 6, Page 68 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 182 NOTE - Items 18 thru 19 are for machines with Dual Fuel Option only. 702633 BRACKETS, LP 702253 LP TANK, 43.5 lb. 240PSI 704547 HOSE ASSEMBLY, LP 702236 FITTING, LP 3400-4 103006 FITTING, LP - Female tank JUN. 1999 SECTION 6, Page 69 SJKB-40-D,SJKB-40-D/F...

  • Page 183: Figure 6-33. Base, Axles And Wheels (Optional 4X4)

    FIGURE 6-33. BASE, AXLES, AND WHEELS (Optional 4x4) Ma40-620 JUN. 1999 SECTION 6, Page 70 SJKB-40-D,SJKB-40-D/F...
  • Page 184 NOTE - Items 11 thru 12 are for machines with Dual Fuel Option only. 702633 BRACKETS, LP 702253 LP TANK, 43.5 lb. 240PSI 704547 HOSE ASSEMBLY, LP 702236 FITTING, LP 3400-4 103006 FITTING, LP - Female tank AUG. 1999 JUN. 1999 SECTION 6, Page 71 SJKB-40-D,SJKB-40-D/F...
  • Page 185 HOSE ASSEMBLY (H212 0042 00-0) 704554 HOSE ASSEMBLY (H606 0024 00-0) 704530 HOSE ASSEMBLY (H606 0050 00-0) 704958 DRIVE MOTOR NOTE: Refer to Standard Hose Numbering System (SECTION 5, Page 30) for explanation of hose numbering. JUN. 1999 SECTION 6, Page 72 SJKB-40-D,SJKB-40-D/F...
  • Page 186 HOSE ASSEMBLY (H606 0024 00-0) 707819 HOSE ASSEMBLY (H106 0020 00-0) 707818 HOSE ASSEMBLY (H606 0034 00-0) NOTE: Refer to Standard Hose Numbering System (SECTION 5, Page 30) for explanation of hose numbering. JUN. 1999 SECTION 6, Page 73 SJKB-40-D,SJKB-40-D/F...
  • Page 187 700575 • NUT, Lock 3/4-10 Grade C 102025 BEARING, Spherical 104114 RING, Retaining 700510 NIPPLE, Grease 1/8NPT - 90° 103073 FITTING, 90° #6orb-#4 701076 KIT, Seal repair * Part of Seal Repair Kit. JUN. 1999 SECTION 6, Page 74 SJKB-40-D,SJKB-40-D/F...
  • Page 188 102646 • WASHER, Flat 104351 • NUT, Castle 1” 700508 • PIN, Cotter 3/16 x 2” lg. 700466 • SEAL, Grease 700468 WHEEL BOLT, 5/8-18x1-1/2 gr. 5 700782 WASHER, Flat SAE 5/8” hard JUN. 1999 SECTION 6, Page 75 SJKB-40-D,SJKB-40-D/F...
  • Page 189 NOTES JUN. 1999 SECTION 6, Page 76 SJKB-40-D,SJKB-40-D/F...

  • Page 190: Figure 6-38. Drive Axle Assembly (Standard 4X2)

    • DRIVE AXLE (For components, refer to Figure 6-41.) 702438 • FITTING, 90° #8orb-#12 707622 • FITTING, 45° #16orb-#12 700817 • FITTING, Connector #14orb-#6 702382 • FITTING, Swivel nut tee #6-#6 JUN. 1999 DEC. 1999 SECTION 6, Page 77 SJKB-40-D,SJKB-40-D/F...

  • Page 191: Figure 6-39. Planetary Reduction Gear Assembly (Brevini)

    1 2 3 4 5 6 7 Assy. 701841 LIP SEAL, Output housing HOUSING, Output 701849 O-RING SEAL RING GEAR HOUSING, Input 701942 O-RING SEAL, Input adapter 701842 LIP SEAL, Input adapter 701030 HOUSING, Input adapter $ Consult factory JUN. 1999 SECTION 6, Page 78 SJKB-40-D,SJKB-40-D/F...

  • Page 192: Figure 6-40. Planetary Reduction Gear Assembly (Sige)

    1 2 3 4 5 6 7 Assy. 701960 LIP SEAL, Output housing HOUSING, Output 701961 O-RING SEAL RING GEAR HOUSING, Input 701962 LIP SEAL, Input adapter HOUSING, Input adapter $ Consult factory JUN. 1999 SECTION 6, Page 79 SJKB-40-D,SJKB-40-D/F...
  • Page 193 FIGURE 6-41. DRIVE AXLE (Standard 4x2) Ma40-633 JUN. 1999 SECTION 6, Page 80 SJKB-40-D,SJKB-40-D/F...
  • Page 194 BRAKE DISK, Intermediate 701847 BRAKE DISK 701808 OIL SEAL, Wheel flange 701889 DUST COVER, Wheel flange 701809 O-RING, Wheel flange 702003 COVER, Torque hub (Ref.) BRAKE ASSEMBLY (For components, refer to Figure 6-46.) JUN. 1999 SECTION 6, Page 81 SJKB-40-D,SJKB-40-D/F...

  • Page 195: Figure 6-42. Steer Axle Assembly (Optional 4X4)

    FIGURE 6-42. STEER AXLE ASSEMBLY (Optional 4x4) Ma40-77 JUN. 1999 SECTION 6, Page 82 SJKB-40-D,SJKB-40-D/F...
  • Page 196 • CYLINDER ASSEMBLY, Steer 708408 • • KIT, Seal repair • JOINT, Axial • TIE ROD END • NUT, Steer arm (Ref.) • BRAKE ASSEMBLY (For components, refer to Figure 6-46.) $ Consult factory JUN. 1999 SECTION 6, Page 83 SJKB-40-D,SJKB-40-D/F...
  • Page 197 (Ref.) • • TRANSFER CASE (For components, refer to Figure 6-44.) 702438 • FITTING, 90° #8orb-#12 707622 • FITTING, 45° #16orb-#12 700817 • FITTING, Connector #14orb-#6 702382 • FITTING, Swivel nut tee #6-#6 JUN. 1999 SECTION 6, Page 84 SJKB-40-D,SJKB-40-D/F...

  • Page 198: Figure 6-44. Transfer Case Assembly (Optional 4X4)

    FIGURE 6-44. TRANSFER CASE ASSEMBLY (Optional 4x4) Ma40-82 Units Description Index Skyjack Part No. 1 2 3 4 5 6 7 Assy. 706540 SEAL, O-ring 706541 SEAL, Oil 701843 WASHER, Oil seal 706542 SEAL, Oil 706543 SEAL, O-ring JUN. 1999 SECTION 6, Page 85 SJKB-40-D,SJKB-40-D/F...

  • Page 199: Figure 6-45. Drive Axle (Optional 4X4)

    • BRAKE DISK, Intermediate • BRAKE DISK, Friction • SHAFT, Axle • SEAL, Hub oil • SEAL, O-ring • FLANGE ASSEMBLY (Ref.) • BRAKE ASSEMBLY (For components, refer to Figure 6-46.) $ Consult factory JUN. 1999 SECTION 6, Page 86 SJKB-40-D,SJKB-40-D/F...

  • Page 200: Figure 6-46. Brake Assembly

    710199 • SPRING, Inner 710200 • STEM 710201 • COVER 708986 SPRING 708987 BRAKE FORK 708988 SNAP RING 708989 THRUST WASHER 708990 SPRING CLIP 708991 708992 FORK 708993 SNAP RING E 9 SJKB-40-D, SJKB-40-D/F JUN. 1999 SECTION 6, Page 87...
  • Page 201 • MANUAL, Operator (Not shown) 706229 706229 706229 706229 706229 706229 706229 706229 706229 LABEL, Serial number nameplate (SJKB-40-D/F), (Kubota engine) A (Consult factory) 709053 709053 709053 709053 709053 709053 709053 709053 709053 LABEL, Serial number nameplate (SJKB-40-RT), (4 x 2 Ford engine) A (Consult factory)

  • Page 202: Figure 6-47. Labels And Nameplates

    FIGURE 6-47. LABELS AND NAMEPLATES 707335cad APRIL, 2000 SJKB-40-D, SJKB-40-D/F SECTION 6, Page 89...
  • Page 203 702482 • WIRE, 16 ga. blue/yellow 72” 702466 • WIRE, 16 ga. red/black 76” 102921 • DIODE, 6 amp/1000PIV 702465 • WIRE, 16 ga. white 50” 703926 • HEATSHRINK, 3/16” dia. black JUN. 1999 SECTION 6, Page 90 SJKB-40-D, SJKB-40-D/F...

  • Page 204: Figure 6-50. Descent Alarm Option

    • • WIRE, 16 ga. yellow/red 82” 701943 • RELAY, 12VDC, Sealed 702000 • • TERMINAL, 16 ga.x1/4 SPD F 702478 • • WIRE, 16 ga. yellow 5” 702465 • • WIRE, 16 ga. white 5” JUN. 1999 SECTION 6, Page 91 SJKB-40-D, SJKB-40-D/F...

  • Page 205: Figure 6-51. Flashing Light Option

    • CABLE, 18-2 Cabtire 710136 • HOSE COVER, Flashing light option (New Style) 709026 • HOSE COVER, Flashing light option (Old Style) NOTE: Seal wire entry holes with silicone sealant. SECTION 6, Page 92 JUN. 1999 AUG. 1999 SJKB-40-D, SJKB-40-D/F...

  • Page 206: Figure 6-52. Horn Option

    • • WIRE, 16 GA red 57” 702479 • • WIRE, 16 GA green/red 36” 702465 • • WIRE, 16 GA white 17” 702000 • • TERMINAL, 16 ga. x 1/4 SPD F JUN. 1999 SECTION 6, Page 93 SJKB-40-D, SJKB-40-D/F...

  • Page 207: Figure 6-53. Platform Work Lights Option

    FIGURE 6-53. PLATFORM WORK LIGHTS OPTION 02-WHT 02-WHT 02-WHT 02-WHT 02-WHT Terminal Block at Lower Control Panel Ma40-662 AUG. 1999 SECTION 6, Page 94 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 208 • BOLT, HHCS 1/4-20 x 1/2” lg. 104000 • WASHER, Lock 1/4” 103980 • NUT, Hex 1/4-20 707052 • PLATE, Switch box mount (Weld On) 703544 • BRACKET, Work light (Weld On) JUN. 1999 SECTION 6, Page 95 SJKB-40-D, SJKB-40-D/F AUG. 1999...
  • Page 209 NOTES SECTION 6, Page 96 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 210 703681 • FITTING, Bulk head connector (LN8) - female 703671 • LABEL, Air line NOTE: Refer to Standard Hose Numbering System (SECTION 5, Page 30) for explanation of hose numbering. JUN. 1999 SECTION 6, Page 97 SJKB-40-D, SJKB-40-D/F JUL. 1999...

  • Page 211: Figure 6-55. Hydraulic Tool Option

    FIGURE 6-55. HYDRAULIC TOOL OPTION Ma40-664 JUL. 1999 SECTION 6, Page 98 JUN. 1999 SJKB-40-D, SJKB-40-D/F...
  • Page 212 • FITTING, Straight thread connector #8 706715 • FITTING, Swivel nut run tee #8 710121 • VALVE, Pressure reducing 710122 • VALVE, Adj. needle 710120 • VALVE, Solenoid 710170 • VALVE, Cartridge relief JUN. 1999 SECTION 6, Page 99 SJKB-40-D, SJKB-40-D/F JUL. 1999...

  • Page 213: Figure 6-56. Platform Tool Tray/Control Cover Option

    • TOOL TRAY SUPPORT 710427 CONTROL COVER OPTION 710479 • CONTROL COVER WELDMENT 700583 • • NUT, lock nylon insert 1/4”-20 103995 • • WASHER, Flat 1/4” 103860 • • BOLT, HHCS 1/4”-20x1-3/4” AUG. 1999 SECTION 6, Page 100 JUN. 1999 SJKB-40-D, SJKB-40-D/F...

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