Skyjack SJ60AJ+ Service Manual
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Skyjack SJ60AJ+ Service Manual

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SERVICE
MANUAL
SJ60AJ+
ARTICULATING BOOMS
238275AAA
March 2021
ANSI/CSA, CE, AS

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  • Page 1 SERVICE MANUAL SJ60AJ+ ARTICULATING BOOMS 238275AAA March 2021 ANSI/CSA, CE, AS...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.
  • Page 3 This manual is for MEWPs with serial numbers: SJ60 AJ+: A302 100 001 - A302 199 999...
  • Page 4 THIS SAFETY ALERT SYMBOL MEANS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The Safety Alert Symbol identifies important safety messages on MEWPs, safety signs in manuals or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

  • Page 5: Table Of Contents

    Table of Contents Section 1 – Scheduled Maintenance ......... . 13 Read and Heed .
  • Page 6 Torque Specifications for Hydraulic Couplings & Hoses ........37 Axle Torque Specifications .
  • Page 7 3.27 Base Control Box Wiring - ANSI/CSA & AS ..........83 3.28 Base Control Box Wiring - CE .
  • Page 8 4.2-34 No Platform Level Down from the Base or Platform Consoles ......100 4.2-35 No Platform Level Down from the Base Console ........101 4.2-36 No Platform Level Down from the Platform Console .
  • Page 9 4.3-19 The Differential Lock will not Engage ..........115 4.3-20 No Drive Forward or Reverse .
  • Page 10 5.3-22 Test Riser Boom Limit Switch ........... . 150 5.3-23 Replace Limit Switch - Fly Boom .
  • Page 11 5.8-8 Bleed the Oscillating Axle Cylinders ..........174 5.8-9 Pin Brake Adjustments .

  • Page 12: Section 1 - Scheduled Maintenance

    3000 hours, whichever occurs first. Any defective specifications and dimensions are subject to change part will be replaced or repaired by your local Skyjack without notice. dealer at no charge for parts or labor. In addition, all products have a 5 year structural warranty.

  • Page 13: Maintenance And Service

    MEWP . Before attempting any repair work, disconnect the main power connectors. Consult Skyjack’s Service Department for optional tires specifications and installation. Preventive maintenance is the easiest and least expensive type of maintenance.

  • Page 14: Hydraulic System & Component Maintenance And Repair

    Maintenance and Service Section 1 – Scheduled Maintenance 1.2-5 Hydraulic System & Component 7. All hydraulic components must be disassembled in spotlessly clean surroundings. During Maintenance and Repair disassembly, pay particular attention to The following points should be kept in mind when the identification of parts to assure proper working on the hydraulic system or any component: reassembly.

  • Page 15: Railing Maintenance And Repair

    Section 1 – Scheduled Maintenance Maintenance and Service 1.2-7 Railing Maintenance and Repair Skyjack MEWPs have been designed to ensure compliance with the relevant design standards applicable for that particular unit at the time of manufacture. As such, any repairs made to the...

  • Page 16: Scheduled Maintenance

    Inspection every 200 days Before performing any scheduled maintenance or 200 hours. inspection procedure, refer to service bulletins found in our web site: www.skyjack.com for updates related Annual B + C Perform Scheduled to service and maintenance of this MEWP .

  • Page 17: Owner's Annual Inspection Record

    Section 1 – Scheduled Maintenance Owner’s Annual Inspection Record Table 1.4 Owner’s Annual Inspection Record Inspection Date Inspector Signature WARNING Do not use the MEWP if there is no inspection recorded in the last 13 months. If you do not obey, there is a risk of death or serious injury.

  • Page 18: Pre-Delivery/Maintenance Inspection Checklist

    Pre-Delivery/Maintenance Inspection Checklist Section 1 – Scheduled Maintenance 1.5 Pre-Delivery/Maintenance Inspection Checklist Frequent/Periodic/Annual/PDI Checklist Articulating Booms and Telescopic Booms Serial Number: Product Owner: Starting with serial number A000 000 000 or B000 000 000 and above Product User: Date/Time: Model: Hourmeter Reading: Inspection Type (Choose one): Pre-delivery...

  • Page 19: Scheduled Maintenance Inspections

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6 Scheduled Maintenance 1.6-2 Hydraulic Do a check on these areas and make sure there are Inspections no signs of leakage: Do an inspection of the MEWP in this sequence. Hydraulic tank filter, fittings, hoses, emergency- ▪...

  • Page 20: Engine Compartment

    Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance 1.6-5 Engine Compartment 2. Make sure all the battery connections are tight. 3. If applicable, check the battery fluid level. Do the inspection that follows: If the plates do not have a minimum 13 mm ▪...
  • Page 21 Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections Hydraulic pump and motor Muffler and exhaust Make sure there are no loose or missing parts. Make sure that the muffler and exhaust ▪ ▪ systems are correctly attached with no visible Make sure there is no visible damage.
  • Page 22 Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance Radiator (B, C) Air filter (B,C) Make sure there are no loose or missing parts. Make sure there are no loose or missing parts. ▪ ▪ Make sure there is no visible damage. Make sure there is no visible damage.
  • Page 23 Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections Do the inspection that follows: Hydraulic Return Filter (B,C) Make sure all compartment latches are latched tightly Make sure the filter element is attached and ▪ and in good condition. tight. Turret transportation lock Make sure there is no visible damage or ▪...
  • Page 24 Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance Emergency Power Unit WARNING Make sure there are no loose or missing parts. ▪ Environmental hazard. Immediately remove Make sure there are no loose wires or missing ▪ gasoline, diesel fuel, engine oil, and hydraulic fasteners.

  • Page 25: Base

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-6 Base Brake Cylinder Base weldment Make sure there are no loose or missing parts. ▪ Make sure there are no visible cracks in Make sure all the fittings and hoses are ▪...
  • Page 26 Oscillating Cylinder Bolt Replacement. WARNING NOTE Do not use tires other than the tires that Skyjack The oscillating axle is locked when the MEWP is specifies for this MEWP . Do not mix different types in the elevated travel position or at the elevated of tires or use tires that are not in good condition.

  • Page 27: Platform

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-7 Platform Platform control console Railings and gates Make sure all switches and controllers are in ▪ the neutral position. Make sure there are no loose or missing parts, ▪ and there is no visible damage. Make sure there are no loose or missing parts, ▪...

  • Page 28: Boom Assembly

    Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance 1.6-8 Boom Assembly Wear Pads Rotary actuator All fasteners are correctly tightened. ▪ There are no loose or missing parts, and there There are no loose or missing parts, and there ▪ ▪...

  • Page 29: Optional Equipment

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-9 Optional equipment Cold or arctic weather package Do the inspection that follows, and make sure: The heater plugs are correctly attached with ▪ no visible damage. Generator There is no sign of engine oil leakage. ▪...

  • Page 30: Function Tests

    Function Tests Section 1 – Scheduled Maintenance 1.7 Function Tests Function tests are designed to discover any malfunctions before a MEWP is put into service. The operator must understand and follow the step-by-step instructions to test all MEWP functions. IMPORTANT Never use a malfunctioning MEWP .

  • Page 31: Section 2 - Maintenance Tables And Diagrams

    Section 2 – Maintenance Tables and Diagrams 2.1 Standard Hose Numbering System H1104 0081 2 LENGTH IN FRACTIONS FITTING (1/4" INCREMENTS) LENGTH OF HOSE IN ARRANGEMENT 1=1/4" WHOLE INCHES (See Schedule Below) HOSE SIZE 2=1/2" (See Chart Below) 3=3/4" Using the number above as an example, NOTE H1104 0081 2, this hose requires a 37°...
  • Page 32 Section 2 – Maintenance Tables and Diagrams Standard Hose Numbering System Hose S.A.E. Hose Hose End Fitting Hose End Fitting Prefix Specification REUSABLE FEMALE, 37° JIC, SWIVEL REUSABLE FEMALE, 37° JIC, SWIVEL 300 PSI NO FITTING NO FITTING 100R4 NO FITTING NO FITTING 300 PSI REUSABLE, FEMALE, 37°...

  • Page 33: Torque Specifications For Fasteners (Us Imperial)

    Torque Specifications for Fasteners (US Imperial) Section 2 – Maintenance Tables and Diagrams 2.2 Torque Specifications for Fasteners (US Imperial) SAE2 SAE 5 SAE 8 SAE2 SAE 5 SAE 8 Torque Torque Size Size Type Type Lubed Lubed Lubed Dry Lubed Dry Lubed Dry Lubed ft-lb (in-lb)

  • Page 34: Torque Specifications For Fasteners (Metric)

    Section 2 – Maintenance Tables and Diagrams Torque Specifications for Fasteners (Metric) 2.3 Torque Specifications for Fasteners (Metric) SAE2 SAE 5 SAE 8 Torque Size Type Lubed Lubed Lubed (in-lb) (54) (41) (78) (59) (12) M5 x 0.80 (in-lb) (92) (69) (133) (99)

  • Page 35: Torque Specifications For Hydraulic Couplings & Hoses

    Torque Specifications for Hydraulic Couplings & Hoses Section 2 – Maintenance Tables and Diagrams 2.4 Torque Specifications for Hydraulic Couplings & Hoses Hydraulic Coupling Torque Chart O-Ring Port Connectors Steel Ports Non-ferrous Ports SAE Size ft-lb ft-lb 14-16 20-22 9-10 12-13 24-26 33-35...

  • Page 36: Axle Torque Specifications

    Section 2 – Maintenance Tables and Diagrams Axle Torque Specifications 2.5 Axle Torque Specifications Type of Bolt 10.9 12.9 Size of Bolt Normali Normali Normali Loctite 270 Loctite 270 Loctite 270 Loctite 242 Loctite 242 Loctite 242 (Nm) (Nm) (Nm) (Nm) (Nm) (Nm)

  • Page 37: Axles Maintenance Intervals

    Axles Maintenance Intervals Section 2 – Maintenance Tables and Diagrams 2.6 Axles Maintenance Intervals Operation Component Frequency Lubricants Differential monthly Check Levels Planetary reduction every 200 hours SAE 80W-90 API GL-5 Gear box monthly Differential every 800 hours * Planetary reduction every 1000 hours * Oil Change SAE 80W-90 API GL-5...

  • Page 38: Mewp Torque Specifications

    Section 2 – Maintenance Tables and Diagrams MEWP Torque Specifications 2.7 MEWP Torque Specifications Location Description Torque (ft-lb) Torque (Nm) Base Trunnion Mount BOLT, Hex head (3/4"-10 x 5", Grade 8) Rear Axle Mount NUT, Torque lock (3/4"-10, Grade C) Axle Lock BOLT, Hex head (1/2"-13 x 2.25", Grade 8) Swing Drive Motor...

  • Page 39: Maximum Platform Capacity

    Do not use tires other than those specified for this machine. Do not mix different types of tires. Tires other than those specified can adversely affect stability. Failure to operate with matched, approved tires in good condition can result in death or serious injury. Replace tires with the exact, Skyjack-approved types only. IMPORTANT For proper function of each axle differential, all four wheels must have same tire size installed at all times.

  • Page 40: Floor Loading Pressure

    Section 2 – Maintenance Tables and Diagrams Floor Loading Pressure 2.10 Floor Loading Pressure Weights Pressures Model Gross MEWP Weight Weight per Wheel** LCP*** OFL*** min* 8530 18 800 2177 4800 11.2 SJ60 AJ+ max* 8980 19 800 4082 9000 1087 11.8 2153AA...

  • Page 41: Hydraulic Specifications

    Hydraulic Specifications Section 2 – Maintenance Tables and Diagrams 2.11 Hydraulic Specifications Description Metric Pumps Displacement - 2675 rpm 13.5 CC 2.48 CIR 28.7 gpm @ 2675 rpm Drive Pump Pressure 344.7 bar 5000 psi Drive Pump Charge Pump Displacement 13.8 CC 0.84 CIR Charge Pump Pressure...

  • Page 42: Fluids

    Section 2 – Maintenance Tables and Diagrams Fluids 2.12 Fluids Fluid Temperature Range Recommended Type Petro-Canada ATF D3M, Standard / Cold -26°C to 38°C (-15°F to 100°F) Shell ATF Donax TG Hydraulic Oil Biodegradable -29°C to 32°C (-20°F to 90°F) Shell Naturelle HF-E 46 Arctic -40°C to 38°C (-40°F to 100°F)

  • Page 43: Mewp Specifications

    MEWP Specifications Section 2 – Maintenance Tables and Diagrams 2.14 MEWP Specifications Working Height - maximum 20.11 m 66 ft 0 in Platform Height - maximum 18.29 m 60 ft 0 in Horizontal Reach - maximum 11.56 m 37 ft 11 in Horizontal Reach - at maximum height 6.2 m 20 ft 4 in...

  • Page 44: Platform Capacities

    Section 2 – Maintenance Tables and Diagrams Platform Capacities 2.14 MEWP Specifications (continued) Gradeability - maximum Drive Speed - stowed / low torque 4 km/h 2.5 mph Drive Speed - stowed / high torque 1.9 km/h 1.2 mph Drive Speed - elevated / low torque 0.6 km/h 0.36 mph Drive Speed - elevated / high torque...

  • Page 45: Reach Diagram

    Reach Diagram Section 2 – Maintenance Tables and Diagrams 2.16 Reach Diagram 21.34 (70) 19.81 (65) 18.29 96.09in (60) 16.76 (55) 15.24 (50) 13.72 (45) 12.19 (40) 45° 10.67 (35) 9.14 (30) 7.62 (25) 6.10 (20) 4.57 (15) 3.05 (10) 1.52 -1.52 (-5)

  • Page 46: Dimension Diagrams

    Section 2 – Maintenance Tables and Diagrams Dimension Diagrams 2.17 Dimension Diagrams 20.11 m (66 ft) 6.2 m (20 ft 4 in) 11.56 m (37 ft 11 in) 7.7 m (25 ft 3 in) 56° 8.31 m 18.29 m (27 ft 2 in) (60 ft) 6.6 m (21 ft 8 in)
  • Page 47 Dimension Diagrams Section 2 – Maintenance Tables and Diagrams Dimensions - SJ60 AJ+ (continued) 2.44 or 1.83 m (96 or 72 in) 0.91m 175˚ (36 in) 1.14 m (45 in) 2.81 m (9 ft 2-1/2 in) 65º 60º 1.11 m (44 in) 2.21m 0.64 m...

  • Page 48: Axle Oscillation Diagrams

    Section 2 – Maintenance Tables and Diagrams Axle Oscillation Diagrams 2.18 Axle Oscillation Diagrams WARNING Do not raise the platform in work mode if it is not on a firm level surface. Axle oscillation free (travel mode) - drive speed 7.3 km/h (4.5 mph) max. Axle oscillation locked (work mode) - drive speed 0.8 km/h (0.5 mph) max.

  • Page 49: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJ60AJ+ 238275AAA...

  • Page 50: Electrical Symbol Chart

    Section 3 – System Component Identification and Schematics Electrical Symbol Chart Table 3.1 Electrical Symbol Chart CIRCUITS CROSSING LIMIT SWITCH KEY SWITCH HOURMETER NO CONNECTION LIMIT SWITCH CIRCUITS LIGHT FOOT SWITCH CONNECTED CLOSED LIMIT SWITCH HYDRAULIC BATTERY TOGGLE SWITCH VALVE COIL PROPORTIONAL LIMIT SWITCH PUSH BUTTON...

  • Page 51: Hydraulic Symbol Chart

    Hydraulic Symbol Chart Section 3 – System Component Identification and Schematics Table 3.2 Hydraulic Symbol Chart VARIABLE DISPLACEMENT SHUTTLE VALVE VELOCITY FUSE LINE CROSSING PUMP ACCUMULATOR, SINGLE ACTING LINE JOINED HAND PUMP GAS CHARGED CYLINDER HYDRAULIC CUSHION DOUBLE ACTING RELIEF VALVE CYLINDER CYLINDER TANK...

  • Page 52: Wire Number And Color Code

    Section 3 – System Component Identification and Schematics Wire Number and Color Code 3.3 Wire Number and Color Code WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE COLOR COLOR COLOR COLOR COLOR ORG/BLU YEL/WHT ORG/BRN GRN SHLD WHT/RED YEL/ORG GREY BLK SHLD...

  • Page 53: Hydraulic Parts List

    Hydraulic Parts List Section 3 – System Component Identification and Schematics 3.4 Hydraulic Parts List Index Skyjack Description Part No. 2H-13A 159838 VALVE, Flow Control (Main boom lowering) 2H-21A 159821 VALVE, Control (Enable) 2H-21B 194492 VALVE, Control (Load Circuit Select)
  • Page 54 Section 3 – System Component Identification and Schematics Wire Number and Color Code 3.4 Hydraulic Parts List Index Skyjack Description Part No. 159841 VALVE, Counterbalance (Main boom) CB10 710088 VALVE, Counterbalance (Platform levelling cylinder - slave) CB11 710088 VALVE, Counterbalance (Platform levelling cylinder - slave)
  • Page 55 Wire Number and Color Code Section 3 – System Component Identification and Schematics 3.4 Hydraulic Parts List Index Skyjack Description Part No. 139092 OIL COOLER, Hydraulic ORIFICE, Motor swash plate (0.015”) 159825 ORIFICE, Differential sensing (0.030”) 159824 ORIFICE, Platform override speed (0.040”) 159823 ORIFICE, Jib boom speed (0.078”)
  • Page 56 Section 3 – System Component Identification and Schematics Wire Number and Color Code 3.4 Hydraulic Parts List Index Skyjack Description Part No. 159804 VALVE, Fly boom 159803 VALVE, Platform level override 238275AAA SJ60AJ+...

  • Page 57: Electrical Component Parts List

    Closed Normally Open Ground (B-) NORMALLY NORMALLY CLOSED OPEN CONTACT CONTACT Index Skyjack Description Part No. 01ACR 931298 RELAY, Micro 12 V DC, 30 amp Base control console) (ANSI) 01ACR 127131 RELAY, 12 Volt 40 Amp (Base control console - E-pump) (CE &...
  • Page 58 Section 3 – System Component Identification and Schematics Electrical Component Parts List 3.5 Electrical Parts List Index Skyjack Description Part No. 3H-26 159827 COIL, 12 Volt (Brake valve) 3H-45 159827 COIL, 12 Volt (Motor 2-speed valve) 3H-65 159827 COIL, 12 Volt (Axle lock valve)
  • Page 59 Electrical Component Parts List Section 3 – System Component Identification and Schematics 3.5 Electrical Parts List Index Skyjack Description Part No. 147229 LED BLOCK, Red (12 volts) (Base control console) 147229 LED BLOCK, Red (12 volts) (Platform control console) 138229...

  • Page 60: Rotary Manifold Port Identification

    Section 3 – System Component Identification and Schematics Rotary Manifold Port Identification 3.6 Rotary Manifold Port Identification Port 6 To Brake Manifold Port 2 To Brake Manifold Port 2 To Axle Lock Cylinder Port 4 To Brake Manifold Port 3 Port 9 To Drive Pump To Drive Motor...

  • Page 61: Brake Manifold Port Identification

    Brake Manifold Port Identification Section 3 – System Component Identification and Schematics 3.7 Brake Manifold Port Identification 3H-165 Differential Lock Valve 3H-45 2 Speed Motor Valve 3H-65 Axle Lock Valve 3H-26 Brake Release Valve To Rotary Manifold 2SPD To Rotary Manifold Brake Hand Pump To Rotary Manifold To Hydraulic Tank...

  • Page 62: Drive And System Pump And Port Identifications

    Section 3 – System Component Identification and Schematics Drive and System Pump and Port Identifications 3.8 Drive and System Pump and Port Identifications To High Pressure Shuttle To Rotary Manifold To Rotary Manifold To Rotary Manifold To Hydraulic Tank To High Pressure Shuttle To Hydraulic Tank To High Pressure Filter To Main Manifold...

  • Page 63: Drive Motor And Port Identifications

    Drive Motor and Port Identifications Section 3 – System Component Identification and Schematics 3.9 Drive Motor and Port Identifications To Rotary Manifold To Rotary Manifold To Rotary Manifold To Rotary Manifold M154138AC-SM SJ60AJ+ 238275AAA...

  • Page 64: Jib Valve And Port Identifications

    Section 3 – System Component Identification and Schematics Jib Valve and Port Identifications 3.10 Jib Valve and Port Identifications 3H-36 Platform Rotate Select To Bulkhead #1 To Platform Rotary Actuator To Platform Rotary Actuator To Bulkhead #1 M154206AC 238275AAA SJ60AJ+...

  • Page 65: Main Manifold Port Identification - Ansi/Csa

    3.11 Main Manifold Port Identification - ANSI/CSA To brake manifold T To emergency power unit EP2 To system pump X To union (master cylinder E) To union (master cylinder R) To bulkhead 2 (extend cylinder E) To bulkhead 2 (extend cylinder R) To bulkhead 1(to jib manifold P1) To return filter To bulkhead 1(to jib manifold T)

  • Page 66: Main Manifold Electrical Component Identification - Ansi/Csa

    3.12 Main Manifold Electrical Component Identification - ANSI/CSA 2H-13A Flow control 5H-23A/5H-24A Steer right/left 5H-31/5H-30 2H-42 Riser up/down Platform flow 5H-14/5H-13 Boom up/down 5H-39/5H-38 Boom extend/retract 5H-41/5H-40 Platform up/down 5H-33/5H-32 Turret right/left 2H-21A Enable M218406AB_SM-2 238275AAA SJ60AJ+...

  • Page 67: Main Manifold Hydraulic Component Identification - Ansi/Csa

    3.13 Main Manifold Hydraulic Component Identification - ANSI/CSA DSV3 DSV2 Flow control valve Flow control valve DSV1 Flow control valve RV 1 Relief valve DSV4 Check valve Flow control valve CV11 Check valve Relief valve Relief valve Orifice (0.030") Relief valve Relief valve Check valve Relief valve...

  • Page 68: Main Electrical Harness And Fuel Level Switch Harness

    3.14 Main Electrical Harness and Fuel Level Switch Harness STEER RIGHT JIB UP PLATFORM LEVEL DOWN RISER UP RISER DOWN PIN 1 - 23A BLACK/WHITE PIN 1 - 35 ORANGE/WHITE PIN 1 - 40 BLUE/RED PIN 1 - 31 RED/WHITE PIN 1 - 30 RED/GREEN PIN 2 - 02 WHITE (SPLICE #1) PIN 2 - 02 WHITE (SPLICE #2)

  • Page 69: Engine Harness - Kubota D1305

    3.15 Engine Harness - Kubota D1305 PIN 1 - 02 - WHITE PIN 2 - 106 - GREEN/PINK PIN 3 - PLUGGED PIN 4 - 76 - BROWN/BLUE PIN 5 - 74 - GREEN/GREY PIN 6 - PLUGGED PIN 7 - PLUGGED PIN 8 - PLUGGED PIN 9 - PLUGGED...

  • Page 70: Engine Harness Wiring Diagram - Kubota D1305

    3.16 Engine Harness Wiring Diagram - Kubota D1305 11 - WHITE RELAY CONNECTOR PIN-OUT 30 - 11A - RED 85 - 54A - BLACK 86 - 11 - WHITE 87 - 11B - RED BASE CONTROL BOX TERMINAL STRIP WIRING 11 - WHITE 54A - BLACK M148472AB-SM...

  • Page 71: Engine Harness - Kubota Wg972

    3.17 Engine Harness - Kubota WG972 00,00,57E,11,11A,77,1002, 76,1005,1008,1009,1017, TO ALTERNATOR 1030,1044,1054,1060, 1060,3002,CANH,CANL TO STARTER 1060,3002 1060, 1009, 1005, 1060, 1060, 1008, 57A, 57A,68,76, 1002,1030, 11A, 1070, 1060 1017 1054,1060 CANL,CANH, 1070 1060 TO PRE O2 77,11 57A, 1070 SENSOR 00,00 1044 (5A) SEE NOTE 4...

  • Page 72: Engine Harness Wiring Diagram - Kubota Wg972

    3.18 Engine Harness Wiring Diagram - Kubota WG972 GND ON TO FUEL TO CTRL PNL TO BATT. TO ENGINE HARNESS ENGINE PUMP BLOCK S1060-1 1054-PUR/RED-18 1030-YL/BLU-18 PRE O2 1060-BLK-18 SENSOR 1002-WHT-18 1044-RD/WHT-18 68-GREY-18 57E-BRN/GRN-18 57A-BRN/GRN-14 68-GREY-18 ALTERNATOR 1060-BLK-14 103 FLK-12 57A-BRN/GRN-14 57ACR STARTER...

  • Page 73: Lowering Throttle Valve Harness

    3.19 Lowering Throttle Valve Harness TO EVDR MODULE BACK VIEW PIN 1 - 09 - BLACK PIN 2 - 13 - GREEN PIN 3 - PLUGGED PIN 4 - PLUGGED PIN 5 - PLUGGED PIN 6 - PLUGGED PIN 7 - 02 - WHITE (SPLICE) PIN 8 - 02 - WHITE (SPLICE) M154357AA-SM SJ60AJ+...

  • Page 74: Platform Harnesses

    3.20 Platform Harnesses FOOT SWITCH TB 04A TB 08A 3H-36 PLATF. ROTATE SELECT SOL. TB 36A TB 02 PLATFORM CONTROL BOX WIRING SUPPR. D36-1 NOTE: DIODE D36-1 AND CAPACITOR CAP3 REMOVED ON 63AJ CE MACHINES TO JIB CYLINDER MANIFOLD SUPPR. ELECTRICAL SCHEMATIC (NOT COIL SPECIFIC) FOOT SWITCH...

  • Page 75: Limit Switch Connections

    3.21 Limit Switch Connections Base Control Box Terminal Strip Black (09) Black/White (122) Black (09) Black/White (17) Black (09) Blue/White (121) Black/ Black (29A) White Black (09) Black/White (29) Black (09) Black/White (59) (29) LS1 - Direction Sensing LS2 - Fly Stowed Limit LS3 - Main Boom LS4 - Boom Down LS5 - Fly Out...

  • Page 76: All Motion Alarm Connections - Ce & As

    3.22 All Motion Alarm Connections - CE & AS ALARM PASS WIRES THROUGH TOP-MOST STRAIN RELIEF (LOOSEN GLAND FIRST) 02-WHITE 20-ORANGE/BLUE -WIRE INSTALLATION- M152361AA_S3 238275AAA SJ60AJ+...

  • Page 77: Welder Wiring - Ansi/Csa

    3.23 Welder Wiring - ANSI/CSA WHITE 8 GA GREEN 8 GA WHITE RED 8 GA BLACK 50AMP BLACK 8 GA 50AMP GREEN 50AMP LOCATED ON PLATFORM VIEW UNDER BREAKER BOX LID PLUGS INTO 110V POWER CORD TO PLATFORM M154353AB SJ60AJ+ 238275AAA...

  • Page 78: Positive Air Shutoff Harness

    3.24 Positive Air Shutoff Harness TO ELECTRICAL PANEL BACK VIEW 403A RED POSITIVE AIR SHUT OFF MODULE 10 PIN CONNECTOR PLUG 402 GREEN PIN 1 -BLACK (401) PIN 6 -BLUE (403) 403 RED PIN 2 -EMPTY PIN 7 -WHITE (02) 02 WHITE (GROUND) PIN 3 -RED (403A) PIN 8 -WHITE (408)

  • Page 79: Hydraulic Schematic

    3.25 Hydraulic Schematic JIB LIFT BULKHEAD LOCATIONS #1 - AT RISER KNUCKLE #2 - TOP OF MAIN BOOM - AT EXT. CYL. ACCESS PLATFORM ROTATE #3 - TOP OF FLYBOOM - AT TIP Bore BULKHEAD #1 Stroke 29.5 POWER TRACK CARRIER ASSEMBLY SAE06 SAE06 CB13...

  • Page 80: Platform Control Box Wiring

    3.26 Platform Control Box Wiring LOAD LOW CAP A3 JOYSTICK ZONE A2 JOYSTICK BORDER HIGH CAP GLAZIER JOYSTICK ACTIVE 04(RED) POWER 04 (RED/YELLOW) POWER 02 (WHITE) GROUND 02 (WHITE) GROUND BLACK D-SIGNAL R(RED/GREEN) R-SIGNAL 24A (BLUE/BLACK) LEFT WHT/RED 23A (BLACK/WHITE) RIGHT WHT/YEL S20-PLTF...

  • Page 81: Base Control Box Wiring - Ansi/Csa & As

    3.27 Base Control Box Wiring - ANSI/CSA & AS CONNECTOR J1 - TO ENGINE DISPLAY SOCKET 1 - 02 SOCKET 2 - 09 09-YL-18 SOCKET 3 - CANH 02-WH-18 SOCKET 4 - CANL CANH-BK-18 SOCKET 5 - N/A CANL-WH-18 SOCKET 6 - N/A BACK VIEW BLACK...

  • Page 82: Base Control Box Wiring - Ce

    3.28 Base Control Box Wiring - CE CONNECTOR J1 - TO ENGINE DISPLAY SOCKET 1 - 02 SOCKET 2 - 09 09-YL-18 SOCKET 3 - CANH 02-WH-18 SOCKET 4 - CANL CANH-BK-18 SOCKET 5 - N/A CANL-WH-18 SOCKET 6 - N/A BACK VIEW J3 WHITE...

  • Page 83: Electrical Schematic - Ansi/Csa & As

    3.29 Electrical Schematic - ANSI/CSA & AS 10 11 3.29 Electrical Schematic - ANSI/CSA & AS M238035AA-1 SJ60AJ+ 238275AAA...

  • Page 84: Electrical Schematic - Ce

    3.30 Electrical Schematic - CE 10 11 3.30 Electrical Schematic - CE M238036AA SJ60AJ+ 238275AAA...

  • Page 85: Engine Schematic - Kubota D1305

    3.31 Engine Schematic - Kubota D1305 57E-BN/GN-12 DIESEL ENGINE STARTER RELAY TO MAIN TO BATTERY DISCONNECT B- POST POSI AIR OPTION STARTER ACTUATOR SOLENOID SPEED SENSOR OIL PRESSURE SW. SOLENOID TEMP. SENSOR GLOW PLUG STARTER CB40 AUTOMATIC REV. SHUT OFF LIMITER SOLENOID 403A...

  • Page 86: Engine Schematic - Kubota Wg972

    3.32 Engine Schematic - Kubota WG972 DUAL FUEL ENGINE FUEL PUMP TO BASE CONTROL BOX CUT-OFF TO BATT. B+ TO ECU GND ON ENGINE BLOCK 1054-PU/RD-18 1030-YL/BU-18 PRE O2 1060-BK-18 SENSOR 1002-WH-18 1044-RD/WH-18 68-GY-18 57E-BN/GN-18 57A-BN/GN-14 STARTER 1017-BN/WH-18 RELAY 57A-BN/GN-14 57ACR STARTER STARTER...

  • Page 87: Section 4 - Troubleshooting Information

    Section 4 – Troubleshooting Information 4.1 Introduction The following pages contain a table of Troubleshooting for locating and correcting most service trouble which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting will localize the trouble more quickly than any other method.

  • Page 88: Electrical System

    Section 4 – Troubleshooting Information Electrical System 4.2 Electrical System 4.2-1 All Controls are Inoperative from the Base or Platform Console NOTE Functions may be disabled by the dual load zone system or the overload system. Please first make sure the boom is at or below level and fully retracted, the platform is level and free of added weight, and there are no faults in the dual load or overload systems.
  • Page 89 Electrical System Section 4 – Troubleshooting Information 17. Loose or broken wire #09 from base terminal Check continuity. Replace if defective. block to base control module connector J1 pins 1, 2, 3, and/or 4. 18. Loose or broken wire #02 from base control Check continuity.

  • Page 90: All Controls Are Inoperative From The Base Console

    Section 4 – Troubleshooting Information Electrical System 34. Loose, broken, or defective 120 ohm CAN Check that resistance between CAN H and CAN L termination resistor(s) between CAN H and is appoximately 60 ohms (2 x 120 ohm in parallel). CAN L teminals in platform and/or base terminal Check connections.

  • Page 91: The Engine Will Not Crank From The Base

    Electrical System Section 4 – Troubleshooting Information 7. Defective relay 57DCR. Check relay. Replace if defective. 8. Loose or broken 57A wire from connector P4 Check schematic applicable to the engine equipped pin 8 to start input on ECU or 57ACR relay if on the machine to determine ECU pin # or relay if equipped.

  • Page 92: No Boom Up From The Base Or Platform Controls

    Section 4 – Troubleshooting Information Electrical System 4.2-7 No Boom Up from the Base or Platform Controls 1. Loose or broken wire #14 from base control Check continuity. Replace if defective module connector J2 pin 5 base terminal block to turret harness plug pin #2 2.

  • Page 93: 11 No Boom Down From The Base Console

    Electrical System Section 4 – Troubleshooting Information 4.2-11 No Boom Down from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to boom switch S12 2. Defective boom switch S12 Check continuity through switch while activating boom down function between wires #10A and #13B.

  • Page 94: 15 No Turret Rotate Right From The Platform Console

    Section 4 – Troubleshooting Information Electrical System 4.2-15 No Turret Rotate Right from the Platform Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective block to joystick controller A1 2. Loose or broken wire #02 from platform terminal Check continuity.

  • Page 95: 19 No Riser Up From The Base Or Platform Consoles

    Electrical System Section 4 – Troubleshooting Information 4.2-19 No Riser Up from the Base or Platform Consoles 1. Loose or broken wire #31 from base control Check continuity. Replace if defective module connector J2 pin 3 to turret harness plug pin #8 2.

  • Page 96: 23 No Riser Down From The Base Console

    Section 4 – Troubleshooting Information Electrical System 4.2-23 No Riser Down from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to boom switch S25 2. Defective riser switch S25 Check continuity through switch while activating riser down function between wires #10A and #30B.

  • Page 97: 27 No Telescope Out From The Platform Console

    Electrical System Section 4 – Troubleshooting Information 4.2-27 No Telescope Out from the Platform Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective block totelescope switch S18 2. Defective boom switch S18 Check continuity through switch while activating telescope out function between wires #04 and #39A.

  • Page 98: 31 No Platform Level Up From The Base Or Platform Consoles

    Section 4 – Troubleshooting Information Electrical System 4.2-31 No Platform Level Up from the Base or Platform Consoles 1. Loose or broken wire #41 from base control Check continuity. Replace if defective module connector J2 pin #7 to turret harness plug pin #16 2.

  • Page 99: 35 No Platform Level Down From The Base Console

    Electrical System Section 4 – Troubleshooting Information 4.2-35 No Platform Level Down from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to platform level switch S16 2. Defective platfrom level switch S16 Check continuity through switch while activating platfrom level down function between wires #10A and #40B.

  • Page 100: 38 No Platform Rotate Right From The Base Or Platform Consoles

    Section 4 – Troubleshooting Information Electrical System 4.2-38 No Platform Rotate Right from the Base or Platform Consoles 1. Loose or broken wire #37 from platform control Check continuity. Replace if defective module connector J12 pin #1 to platform terminal strip 2.

  • Page 101: 41 No Platform Rotate Left From The Base Or Platform Consoles

    Electrical System Section 4 – Troubleshooting Information 4.2-41 No Platform Rotate Left from the Base or Platform Consoles 1. Loose or broken wire #36 from platform control Check continuity. Replace if defective module connector J12 pin #2 to platform terminal strip 2.

  • Page 102: 45 No Jib Up From The Base Console

    Section 4 – Troubleshooting Information Electrical System 4.2-45 No Jib Up from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to jib switch S17 2. Defective jib switch S17 Check continuity through switch while activating jib up function between wires #10A and #35B.

  • Page 103: 49 No Jib Down From The Platform Console

    Electrical System Section 4 – Troubleshooting Information 4.2-49 No Jib Down from the Platform Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective block to jib switch S21 2. Defective jib switch S21 Check continuity through switch while activating jib down function between wires #04 and #34A.

  • Page 104: 53 No Reverse Drive

    Section 4 – Troubleshooting Information Electrical System 4.2-53 No Reverse Drive 1. No output from base control module at connector Check for correct output voltage. J2 pin #2 to wire #15 2. Loose or broken wire 15 from base control Check continuity.

  • Page 105: 56 No Right Steer

    Electrical System Section 4 – Troubleshooting Information 5. Loose or broken wire #02 from turret harness Check continuity. Replace if defective plug to left steer valve 4H-24 6. Defective left steer valve coil 4H-24 Check continuity and resistance through coil. Replace if defective 4.2-56 No Right Steer 1.

  • Page 106: Hydraulic System

    Section 4 – Troubleshooting Information Hydraulic System 4.3 Hydraulic System 4.3-1 All Controls are Inoperative 1. Broken or defective drive pump shaft or coupling. Check pump shaft and coupling. Replace if defective. 2. Hydraulic oil level low. Check oil level. Fill to proper level. 4.3-2 All Boom Functions are Inoperative 1.

  • Page 107: No Riser Boom Up

    Hydraulic System Section 4 – Troubleshooting Information 4. Stuck or defective check valve CV5. Clean valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective relief valve RV5. Set valve to specifications. Check o-rings and clean valve.

  • Page 108: No Turret Rotate Left

    Section 4 – Troubleshooting Information Hydraulic System 4.3-7 No Turret Rotate Left 1. Stuck or defective rotate left valve 5H-32. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Plugged or defective orifice OR2. Check orifice. Replace if plugged or defective. 3.

  • Page 109: No Boom Extend

    Hydraulic System Section 4 – Troubleshooting Information 4.3-9 No Boom Extend 1. Stuck or defective extend valve 5H-39. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective check valve CV6. Clean valve. Check operation of valve. Repair or replace valve as required.

  • Page 110: 12 No Jib Down

    Section 4 – Troubleshooting Information Hydraulic System 4.3-12 No Jib Down 1. Stuck or defective flow enable valve 2H-42. Clean valve. Check O-rings on valve. Check opera- tion of valve. Repair or replace valve as required. 2. Stuck or defective check valve CV8. Clean valve.

  • Page 111: 15 The Platform Will Not Level Down Manually

    Hydraulic System Section 4 – Troubleshooting Information 4.3-15 The Platform will not Level Down Manually 1. Plugged or defective orifice OR3. Check orifice. Replace if plugged or defective. 2. Stuck or defective platform level down valve 5H- Clean valve. Check operation of valve. Repair or replace valve as required.

  • Page 112: 17 The Brake Will Not Release

    Section 4 – Troubleshooting Information Hydraulic System 8. Stuck or defective check valve CV4. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 9. Defective leveling cylinder C4 or slave cylinder Check seals on cylinder. Replace as necessary. Replace cylinder if defective.

  • Page 113: 19 The Differential Lock Will Not Engage

    Hydraulic System Section 4 – Troubleshooting Information 4.3-19 The Differential Lock will not Engage 1. Stuck or defective shuttle valve SV3. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Defective or misadjusted pressure reducing valve Set valve to specifications.

  • Page 114: 23 No High Speed Drive

    Section 4 – Troubleshooting Information Hydraulic System 4.3-23 No High Speed Drive 1. Stuck or defective 2 speed valve 3H-45. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Defective shift valve V5 in drive motor M1. Check motor.

  • Page 115: 27 Axle Will Not Lock

    Hydraulic System Section 4 – Troubleshooting Information 4.3-27 Axle Will Not Lock NOTE The axle is in constant float if the boom is fully retracted and is horizontal or below. 1. Axle lockout valve 3H-65 is stuck in shifted Clean valve. Check O-rings on valve. Check position or is defective.

  • Page 116: Section 5 - Procedures

    Before performing routine maintenance underneath the riser, support it using a suitably rated lifting device (refer to Figure 01), or cylinder chocks on both riser cylinders. Contact Skyjack Parts to order chocks. WARNING Remove all material and personnel from the platform while using the maintenance support(s).

  • Page 117: Platform

    Section 5 – Procedures Platform 5.2 Platform 5.2-1 Human Machine Interface (HMI) Maintaining proper calibration is essential for the good performance of the MEWP . To access the OC1-1 console, open the platform control cover. The OCI-1 has an integrated multi segment, two line display with membrane keys that allow it to be used as the main interface to system controls and adjustments.

  • Page 118: Ocm Character Functions Charts

    Platform Section 5 – Procedures 5.2-3 OCM Character Functions Charts SCM Keypad Function Attribute Keys Short Form THRESH Threshold Menu/Select (M/S) RAMPDN Ramp Down /- RAMPUP Ramp Up LOWRNG Low Range /+ Save/Exit (S/E) MAXOUT Maximum Output 1345AA SJ60AJ+ 238275AAA...

  • Page 119: Ocm Pin Reference

    Section 5 – Procedures Platform 5.2-4 OCM Pin Reference P3/P13 WHITE P1/P11 BLACK P2/P12 GREY P1 (Black) Master Controller: SMB1-105 Wire Function Input/Output Type I/O Name Label Power Power Power Power Not used Vreg 5v CAN H CANH to Engine ECU & Telematics J1939 CAN CAN L CANL to Engine ECU &...
  • Page 120 Platform Section 5 – Procedures P2 (Grey) Master Controller: SMB1-105 Wire Function Input/Output Type I/O Name Label Drive Forward Analog Output PWM01 PWM02 Drive Reverse Analog Output PWM00 PWM01 Riser Up Analog Output PWM07 PWM08 Riser Down Analog Output PWM06 PWM07 Boom Up Analog Output...
  • Page 121 Section 5 – Procedures Platform P3 (White) Master Controller: SMB1-105 Wire Function Input/Output Type I/O Name Label Load Zone Border Lamp Digital Output DOUT1 Emergency Pump Relay Digital Output DOUT8 Steer Right Digital Output DOUT7 118A Overload Alarm/lamp Digital Output DOUT6 Axle Lock Digital Output...
  • Page 122 Platform Section 5 – Procedures P11 (Black) Slave Controller: SMB1-106 Wire Function Input/Output Type I/O Name Label Power Power Power Power Speed control supply (T Booms) Vreg 5v Not Used J1939 CAN Not Used J1939 CAN CAN 2H CANH To PLTF SMB1-106 CANopen CAN 2L CANL To PLTF SMB1-106...
  • Page 123 Section 5 – Procedures Platform P12 (Grey) Slave Controller: SMB1-106 Wire Function Input/Output Type I/O Name Label Platform Rotation Right PWM01 PWM17 Platform Rotation Left PWM00 PWM16 Not Used PWM07 PWM23 Not Used PWM06 PWM22 Not Used PWM05 PWM21 Not Used PWM04 PWM20 Not Used...
  • Page 124 Platform Section 5 – Procedures P13 (White) Slave Controller: SMB1-106 Wire Function Input/Output Type I/O Name Label Not Used DOUT19 Low Fuel Indicator Lamp DOUT26 EcoStart Indicator Light DOUT25 Tilt Audible Indicator DOUT24 Regen Lamp (EU Stage 5 engine) DOUT23 SGE Alarm DOUT30 O/L Lamp...

  • Page 125: Scm Calibration

    Section 5 – Procedures Platform 5.2-5 SCM Calibration 4. Do the calibration procedure from the SCM in the base control box. Follow the flowchart on the next two pages. Tare weight calibration sets the unladen weight of the platform. It is the weight of an empty platform that the SCM subtracts from the gross weight reading of the load cell, giving a new zero (net) weight to start from when measuring the contents of the platform.

  • Page 126: Scm Calibration Flowchart

    Platform Section 5 – Procedures 5.2-6 SCM Calibration Flowchart START SCREEN BASE PLATFORM Press the + or - button until you see the weight calibration screen. Continued on the next page SJ60AJ+ 238275AAA...
  • Page 127 Do not reset Set Points 1 or 2 unless directed to do so by Skyjack. Value = Net weight: the weight Calibration Save/Exit screen. currently on the platform. Press the Save exit button to...

  • Page 128: Platform Controller Voltage References

    Platform Section 5 – Procedures 5.2-7 Platform Controller Voltage References Boom/Turret (A1) Controller Boom Up 12 Volts RED (+) POWER 04 RED/YEL Neutral BLK(-) GROUND 02 WHT Position Turret Rotate Left Turret Rotate Right WHT(X) X-SIGNAL 4.2 - 4.8 Pin 28 Volts BLU(Y) Y-SIGNAL...
  • Page 129 Section 5 – Procedures Platform Drive (A2) Controller  12 Volts Drive Forward 04 YEL POWER 02 WHT GROUND Neutral  Position     D‐SIGNAL Pin 27 4.2 ‐ 4.8  Volts 24 BLU/BLK LEFT WHT/RED Pin 17 23 BLK/WHT RIGHT WHT/YEL Pin 18 Drive Reverse Reference Analog Input AI 1 Neutral Position = 4.2 ‐ 4.8 Volts 12 Volts  12 Volts   Forward = 4.9 ‐ 8.5 Volts @ full stroke Right Steer  Left Steer  Reverse = 4.1 ‐ 0.5 Volts @ full stroke Selected Selected Riser (A3) Controller Riser Up 04 RED/YEL POWER...

  • Page 130: Boom

    Boom Section 5 – Procedures 5.3 Boom 5.3-3 Cable Carrier Repair To repair the cable carrier, simply use a screwdriver. 5.3-1 Check Wear Pads Snap each crossbar off from either side of the chain, either by hand or by using the screwdriver as a lever. Install new crossbars by snapping the links together.

  • Page 131: Boom Section Wear Pad Replacement

    Section 5 – Procedures Boom 5.3-5 Boom Section Wear Pad CAUTION Replacement There is a risk of personal injury or equipment damage if repositioning the boom during this If wear pads inside the boom sections are worn and procedure. Use the base controls with auxiliary cannot be shimmed to meet the specification, they power (engine off) to reposition safely.

  • Page 132: Platform And Jib Boom Removal

    Boom Section 5 – Procedures 5.3-6 Platform and Jib Boom Removal 5. Mark and disconnect the jib cylinder hoses from the jib/platform rotate manifold. Cap hoses and fittings to prevent contamination 6. Connect lifting slings to the jib boom and NOTE platform.

  • Page 133: Operating Machine Functions From The Base Controls

    Section 5 – Procedures Boom 5.3-7 Operating Machine Functions from 5.3-8 Fly Boom Removal the Base Controls CAUTION There is a risk of personal injury or equipment CAUTION damage if repositioning boom with the platform removed. Use the base controls. There is a risk of personal injury or equipment damage if repositioning boom with platform removed.
  • Page 134 Boom Section 5 – Procedures 4. Locate the limit switch on the side of the main 6. Remove the cover plate on the counterweight boom at the platform end of the lower e-chain end of the upper pivot. tube. Pull in the limit switch arm and place a 7.

  • Page 135: Change Wear Pads On Extension Cylinder Support

    Section 5 – Procedures Boom 9. Place a 5 cm (2 in) wooden block under the 5.3-9 Change Wear Pads on Extension base end of the cylinder to support it. Cylinder Support 10. Place a suitable stand ahead of the machine that can bear the weight of the fly boom.

  • Page 136: 10 Fly Boom Installation

    Boom Section 5 – Procedures 5.3-10 Fly Boom Installation 5. Install top and side wear pads in the main boom. Apply Loctite 242 or 243 to the wear pad fasteners on assembly. 1. Put the end of the fly boom / extension cylinder assembly into the platform end of the main boom.

  • Page 137: 11 Platform/Jib Installation

    Section 5 – Procedures Boom 5.3-11 Platform/Jib Installation 5.3-12 Platform Control Console Connection Procedure: 1. Lift the platform/jib assembly and slide it into CAUTION place so the fly boom nose and slave cylinder There is a risk of personal injury or equipment holes line up.

  • Page 138: 13 Extension Cylinder Removal

    Boom Section 5 – Procedures 5.3-13 Extension Cylinder Removal Procedure: 1. Extend the fly boom outward to access the rod end pin on the extension cylinder. NOTE If removing the cylinder to service it or change the wear pads, follow this procedure rather than removing the fly boom section.
  • Page 139 Section 5 – Procedures Boom 7. Remove the master cylinder rod end pin. Lay 10. Remove the extension cylinder base-end pin the end of the cylinder down to rest on the cross and spacers. tube. Retract the cylinder rod so it is out of the way.
  • Page 140 Boom Section 5 – Procedures 13. Pull the cylinder out until the mounting bolts 15. Once the cylinder support is removed, the wear for the cylinder support on the rod end are pads can be replaced. Apply Loctite 242 or 243 accessible inside the main boom support to the wear pad fasteners on assembly.

  • Page 141: 14 Extension Cylinder Installation

    Section 5 – Procedures Boom 5.3-14 Extension Cylinder Installation 6. Continue sliding the cylinder inwards until the pin for the base end can be installed. 7. Use a pry bar to lift the end of the cylinder up to 1. Begin sliding the extension cylinder into the align the hole.

  • Page 142: 15 Main Boom Lift Cylinder Removal

    Boom Section 5 – Procedures 9. Reconnect the master cylinder hydraulic hoses. 5.3-15 Main Boom Lift Cylinder Removal CAUTION There is a risk of personal injury or equipment damage. Always use suitable lifting equipment and safe rigging practices when performing the following procedure.

  • Page 143: 16 Lift Cylinder Installation

    Section 5 – Procedures Boom 8. Place a lifting strap that straddles the boom 5.3-16 Lift Cylinder Installation under the rod end of the cylinder. Lift it lightly to tighten the strap. 1. Attach the lifting sling to the cylinder. Lift and guide it into the riser assembly from the platform end of the machine.

  • Page 144: 17 Riser Cylinder Removal

    Boom Section 5 – Procedures 5.3-17 Riser Cylinder Removal 5.3-18 Riser Cylinder Installation CAUTION 1. Lift the cylinder into the riser assembly. Line There is a risk of personal injury or equipment up and insert the base-end pin. Install the pin damage.

  • Page 145: 19 Replace Limit Switch - Main Boom

    Section 5 – Procedures Boom 5.3-19 Replace Limit Switch - Main Boom 9. Install the new main boom limit switch and retaining hardware. The main boom limit switch is located at the base of NOTE the main boom where the main boom connects to Ensure proper contact is made between the the upper pivot assembly.

  • Page 146: 20 Test Main Boom Limit Switch

    Boom Section 5 – Procedures 5.3-20 Test Main Boom Limit Switch 5.3-21 Replace Limit Switch - Riser Boom 1. In the engine compartment, turn the main power The riser boom limit switch is located on the inside disconnect switch to the on position . face of the lower pivot weldment where the third 2.

  • Page 147: 22 Test Riser Boom Limit Switch

    Section 5 – Procedures Boom 5.3-22 Test Riser Boom Limit Switch 5.3-23 Replace Limit Switch - Fly Boom The fly boom limit switch is located on the outside 1. Turn the main power disconnect switch to the on face of the main boom weldment and is mounted in position between the cable track assembly and the main boom 2.

  • Page 148: 24 Test Fly Boom Limit Switch

    Boom Section 5 – Procedures 9. Install the new fly boom limit switch and 5.3-24 Test Fly Boom Limit Switch retaining hardware. 1. In the engine compartment, turn the main power disconnect switch to the on position . NOTE 2. On the base control console, turn the base/off/ Ensure proper contact is made between the steel platform key switch to the platform position roller lever and the cam surface of the fly boom.

  • Page 149: 25 Limit Switch Locations

    Section 5 – Procedures Boom 5.3-25 Limit Switch Locations Limit Switch LS1 - Direction Sensing Limit Switch LS2 - Fly Stowed (high speed cut-out) Limit Switch LS3 - Main Boom (high speed cut-out) Limit Switch LS4 - Boom Down (dual load zone) Limit Switch LS5 - Fly Out (dual load zone) Limit Switch LS6 - Riser Stowed (high speed cut-out) 238275AAA...

  • Page 150: Turret

    Turret Section 5 – Procedures 5.4 Turret 5.4-2 Adjust the Turret Rotation Gear Backlash Adjusting the backlash clearance will allow proper mating between the turret rotation gear and the swing 5.4-1 Check and Replace the High drive motor gear. Pressure Filter WARNING 1.

  • Page 151: Swing Drive Motor Removal

    Section 5 – Procedures Turret 4. Support the boom with an overhead crane or other suitably rated supporting device. Do not lift the boom. 5. Turn the main power disconnect switch to the off position 6. Loosen the mounting fastener on the swing drive motor.

  • Page 152: Check The Swing Drive Oil

    Turret Section 5 – Procedures 5.4-4 Check the Swing Drive Oil 5.4-5 Change the Swing Drive Oil 1. Remove the plug from the fill port on the NOTE back of the swing drive. The oil change must be performed on a flat, level 2.

  • Page 153: Check Rotation Bearing For Axial Wear

    Section 5 – Procedures Turret 5.4-6 Check Rotation Bearing for Axial 5.4-7 Turret Rotation Gear Bolt Torque Wear Sequence WARNING 1. Position the boom so that it is centered over the front drive and steer axle and is horizontal to the Maintaining proper torque is essential to safe ground.

  • Page 154: Electronic Tilt Switch Setup Procedure

    Turret Section 5 – Procedures 5.4-8 Electronic Tilt Switch Setup 8. Verify the switch is powered (the red or green LED will be continually blinking). Procedure Tilt Switch Replacement Red LED Red LED Y AXIS Green LED Green LED X AXIS 9.
  • Page 155 Section 5 – Procedures Turret Reprogramming the Existing Tilt Switch IMPORTANT Step “c” must be completed within a 5 second The set to zero button is located period, or the switch will automatically exit Indicators Lights on this face next to the harness program mode and return to normal operation using the previously stored data.

  • Page 156: Battery Replacement

    Turret Section 5 – Procedures Verify Tilt Circuit 5.4-9 Battery Replacement Indicator Lights 1. Turn the main power disconnect switch to the off position Operations of the Tilt Switch The following describes the LED’s and what they indicate. Illuminated whenever both tilt axes are within the specified degrees of the zero/ home learned position.

  • Page 157: Engine

    Section 5 – Procedures Engine 5.5 Engine 5.5-2 Replace the Fuel Filter 1. Close the fuel shut-off valve. Maintaining the engine components is essential to the 2. Place a suitable container under the fuel filter. good performance and service life of the MEWP . 3.

  • Page 158: Check The Engine Belt

    Engine Section 5 – Procedures 5.5-4 Check the Engine Belt The MEWP will not operate properly with a loose or defective belt. Continuous usage may cause component damage. WARNING Do not inspect the fan belt while the engine is running. Remove the key to prevent accidental operation.

  • Page 159: Hydraulic Tank

    Section 5 – Procedures Hydraulic Tank 5.6 Hydraulic Tank 5.6-2 Change the Hydraulic Oil 1. Turn the engine on and allow the hydraulic oil to Maintaining the hydraulic components and warm up. hydraulic oil at the proper level are essential to good 2.

  • Page 160: Manifold And Hydraulic Pumps

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7 Manifold and Hydraulic 3. Drive the MEWP forward or reverse. The pressure gauge reading should be 38 bar (550 Pumps psi). Stop the MEWP . Follow the next steps for adjusting the relief valve pressure if needed. If no adjustment is required continue to step 8.

  • Page 161: Hydraulic System Relief Valve Adjustment (Rv1)

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.7-2 Hydraulic System Relief Valve 5.7-3 Turret Rotate Relief Valve Adjustment (RV1) Adjustment (RV2) 1. Adjust the pressure compensator valve on the 1. Locate the GP port on the main manifold and System pump to 220 bar (3200 psi).

  • Page 162: Platform Level Relief Valve Adjustment (Rv3)

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7-4 Platform Level Relief Valve 5.7-5 Riser Boom Down Relief Valve Adjustment (RV3) Adjustment (RV4) 1. Locate the GP port on the main manifold, 1. Locate the GP Port on the main manifold, and remove the cap.

  • Page 163: Main Boom Down Relief Valve Adjustment (Rv5)

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.7-6 Main Boom Down Relief Valve 5.7-7 Fly Boom Relief Valve Adjustment Adjustment (RV5) (RV6) 1. Locate the GP Port on the main manifold, 1. Locate the GP Port on the main manifold, and remove the cap.

  • Page 164: Test Charge Pump Pressure On Drive Pump (Rv10)

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7-8 Test Charge Pump Pressure on 5.7-9 Test Forward Drive Pressure on Drive Pump (RV10) Drive Pump NOTE 1. Locate test port TP3 on the drive pump. Make sure charge pump pressure test is 2.

  • Page 165: 10 Test Reverse Drive Pressure On Drive Pump

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.7-10 Test Reverse Drive Pressure on 5.7-11 Hydraulic Standby Pressure Drive Pump Adjustment NOTE 1. Locate the GP port on the main manifold. Make sure the charge pump pressure test is completed first. 1.

  • Page 166: 12 Hydraulic High Pressure Adjustment

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7-12 Hydraulic High Pressure 5. Adjust the system pump pressure by turning the Adjustment adjusting stem either clockwise to increase the pressure, or counterclockwise to decrease the pressure. 1. Locate the GP Port on the main manifold.

  • Page 167: Axles

    Section 5 – Procedures Axles 5.8 Axles 5.8-2 Check the Oil Level in the Torque Hubs 5.8-1 Change the Oil in the Axles 1. Drive the MEWP to rotate the hub until the plug is in the 3 or 9 o’clock position. Shut off the 1.

  • Page 168: Check The Oil Level In The Axle Gearbox

    Axles Section 5 – Procedures 5.8-4 Check the Oil Level in the Axle 5.8-5 Change the Oil in the Axle Gearbox Gearbox 1. Place a suitable container under the gearbox. 1. Remove the fill plug from the gear box. 2. Remove the fill plug. 2.

  • Page 169: Oscillating Cylinder Bolt Replacement

    Section 5 – Procedures Axles 5.8-6 Oscillating Cylinder Bolt 5.8-7 Oscillating Cylinder Replacement Replacement CAUTION The oscillating axle cylinder weighs approximately If upon inspection it is determined that the oscillating 19.5 kg (43 lb), so a second person to assist with cylinder bolts have missing or damaged torque seal, the removal and replacement would be helpful.
  • Page 170 Axles Section 5 – Procedures 4. Remove and set aside the cylinder fittings, 7. Adjust the oscillating cylinder position until ensuring they stay clean. there is continuous contact between the cylinder mounting surface and the mounting plate, and between the mounting plate and the cylinder shoulder, with no gaps.

  • Page 171: Bleed The Oscillating Axle Cylinders

    Section 5 – Procedures Axles 10. Remove the plugs and reconnect the hoses to 5.8-9 Pin Brake Adjustments the cylinder fittings, torquing the larger hose end to 28 Nm (21 ft-lb) and the smaller hose end to 1. To manually release the brake give a light blow 16 Nm (12 ft-lb).
  • Page 172 Axles Section 5 – Procedures 4. Tighten the jam nut. Repeat this procedure on 7. Release the pressure from the cylinder and the other side. check that the rod returns and stops in a position where it projects out from the cylinder head by 5 mm (3/16").

  • Page 173: 10 Brake Inspection

    Section 5 – Procedures Axles 5.8-10 Brake Inspection 1. Remove the oil level plug from one of the braking axle arms, as shown below. 2. Insert a 4.5 mm feeler gauge into the drain port. 3. Use the gauge to check the gap between the disks (A).

  • Page 174: Grease Points

    Grease Points Section 5 – Procedures 5.9 Grease Points Maintaining proper lubrication is essential for the good performance and service life of the MEWP . If the bearing and gear of the MEWP are improperly greased, it could result in component damage. 5.9-1 Grease the Turret Ring Gear 1.

  • Page 175: Grease The Axles

    Section 5 – Procedures Grease Points 5.9-3 Grease the Axles 1. Open the axle cover plates and locate the grease fittings. 2. Pump grease into the grease fittings. 5.9-4 Grease the Drive Shaft 1. Locate the grease fittings on the drive shaft u-joints, and pump grease into the fittings. 238275AAA SJ60AJ+...
  • Page 176 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.

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