Skyjack SJ45 AJ+ Service Manual
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Skyjack SJ45 AJ+ Service Manual

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SERVICE
MANUAL
SJ45 AJ+
ARTICULATING BOOMS
238274AAA
March 2021
ANSI/CSA, CE, AS

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Summary of Contents for Skyjack SJ45 AJ+

  • Page 1 SERVICE MANUAL SJ45 AJ+ ARTICULATING BOOMS 238274AAA 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: SJ45 AJ+: A301 100 001 - A301 199 999 SJ45 AJ+: B301 100 001 - B301 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 ......... . 11 Read and Heed .
  • Page 6 Torque Specifications for Fasteners (Metric) ..........34 Torque Specifications for Hydraulic Couplings &...
  • Page 7 3.27 Base Control Box Wiring - CE ............84 3.28 Electrical Schematic - ANSI/CSA &...
  • Page 8 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 4.3-16 Platform will not Level Down Manually ..........115 4.3-17 Platform will not Level Up Manually .
  • Page 10 5.5-3 Replace the Air Filter ............144 5.5-4 Check the Engine Belt .

  • Page 11: 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 12: Maintenance And Service

    MEWP . Before attempting any repair work, disconnect the main power conenctors. Consult Skyjack’s Service Department for optional tires specifications and installation. Keep personnel clear of components, systems or unsupported loads that may move unexpectedly WARNING during maintenance procedures.

  • Page 13: 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 14: 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 15: Scheduled Maintenance

    Scheduled Maintenance Section 1 – Scheduled Maintenance 1.3 Scheduled Maintenance 1.3-3 Maintenance Instructions This manual consists of four schedules to be done This section contains the maintenance and inspection for maintaining on a MEWP . Inspection schedule schedule that is to be performed. frequency is shown below: References are made to the procedures in Section 5 that outline detailed step-by-step instructions for...

  • Page 16: 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 17: 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 18: Scheduled Maintenance Inspections

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-2 Hydraulic 1.6 Scheduled Maintenance 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 19: Engine Compartment

    Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance 1.6-5 Engine Compartment B - Frequent Inspection 1. Do an inspection of the battery case for damage. Do the inspection that follows: Clean the battery terminals and cable ends ▪ Make sure all compartment latches are latched tightly thoroughly with a terminal cleaning tool or wire and in good condition.
  • Page 20 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 21 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 22: Control Compartment

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-6 Control Compartment C - Annual Inspection For the hydraulic oil replacement procedure, ▪ Do the inspection that follows: refer to 5.6-1 Hydraulic Oil Replacement. Make sure all compartment latches are latched tightly Hydraulic Return Filter (B,C) and in good condition.
  • Page 23 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 24: Base

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-7 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 25 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 26: Platform

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-8 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 27: Boom Assembly

    Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance 1.6-9 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 28: 10 Optional Equipment

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-10 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 29: 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 step-by-step instructions to test all MEWP functions. IMPORTANT Never use a malfunctioning MEWP . If malfunctions are discovered, the MEWP must be tagged and placed out of service.

  • Page 30: 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 31 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 32: 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 33: 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 34: 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 35: Mewp Torque Specifications

    Section 2 – Maintenance Tables and Diagrams MEWP Torque Specifications 2.5 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 36: Axle Torque Specifications

    Axle Torque Specifications Section 2 – Maintenance Tables and Diagrams 2.6 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: Axle Maintenance Intervals

    Section 2 – Maintenance Tables and Diagrams Axle Maintenance Intervals 2.7 Axle 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: Tire Specifications

    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 the proper functioning of each axle differential, all four wheels must have same tire size installed at all times.

  • Page 39: Floor Loading Pressure

    Section 2 – Maintenance Tables and Diagrams Floor Loading Pressure 2.9 Floor Loading Pressure Weights Pressures Model Gross MEWP Weight Weight per Wheel** LCP*** OFL*** min* 5075 11 190 1450 3200 SJ45 AJ+ max* 5375 11 850 2725 6000 1026 2152AA * Min: Minimum MEWP weight (Unloaded platform, no options/attachments) Max: Maximum MEWP weight (Platform loaded to capacity with options/attachments)

  • Page 40: Hydraulic Specifications

    Hydraulic Specifications Section 2 – Maintenance Tables and Diagrams 2.10 Hydraulic Specifications Description Metric Pumps Displacement - 2000 rpm 46 CC 2.8 CIR 24.3 gpm @ 2000 rpm Drive Pump Pressure 345 bar 5000 psi Drive Pump Charge Pump Displacement 13.9 CC 0.85 CIR Charge Pump Pressure...

  • Page 41: Mewp Specifications

    Section 2 – Maintenance Tables and Diagrams MEWP Specifications 2.11 MEWP Specifications Working Height - maximum 15.54 m 51 ft 0 in Platform Height - maximum 13.72 m 45 ft 0 in Horizontal Reach - maximum 6.93 m 22 ft 9 in Horizontal Reach - at maximum height 2.98 m 9 ft 10 in...

  • Page 42: Platform Capacities

    Platform Capacities Section 2 – Maintenance Tables and Diagrams 2.11 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 43: Fluids

    Section 2 – Maintenance Tables and Diagrams Fluids 2.13 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 44: Reach Diagram

    Reach Diagram Section 2 – Maintenance Tables and Diagrams 2.15 Reach Diagram 16.76 (55) 15.24 (50) 13.72 (45) 12.19 (40) 10.67 (35) 9.14 (30) 7.62 (25) 6.10 (20) 4.57 (15) 3.05 (10) 1.52 -1.52 (-5) -3.05 (-10) -3.05 -1.52 1.52 3.05 4.57 6.10...

  • Page 45: Dimension Diagrams

    Section 2 – Maintenance Tables and Diagrams Dimension Diagrams 2.16 Dimension Diagrams 13.72 m 2.98 m (45 ft) (9 ft 10 in) 6.93 m (22 ft 9 in) 5.23 m (17 ft 2 in) 62° 15.54 m (51 ft) 7.53 m (19 ft 8 in) (24 ft 8-3/4 in) 4.75 m...
  • Page 46 Dimension Diagrams Section 2 – Maintenance Tables and Diagrams Dimension Diagrams (continued) 1.52 m 1.83 m (60 in) (72 in) 175º 0.76 m (30 in) 1.14 m (45 in) 75º 2.7 m (106-1/2 in) 70º 2.29 m 0.61 m (7 ft 6 in) (2 ft) 1.11 m (44 in)

  • Page 47: Axle Oscillation Diagram

    Section 2 – Maintenance Tables and Diagrams Axle Oscillation Diagram 2.17 Axle Oscillation Diagram WARNING Do not raise the platform in work mode if the MEWP it is not on a firm level surface. Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max. Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max.

  • Page 48: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJ45 AJ+ 238274AAA...

  • Page 49: Electrical Symbol Chart

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

  • Page 50: Hydraulic Symbol Chart

    Hydraulic Symbol Chart Section 3 – System Component Identification and Schematics Table 3.2 Hydraulic Symbol Chart THREE POSITION FIXED FOUR WAY LINE CROSSING SHUTTLE VALVE DISPLACEMENT CLOSED CENTER PUMP OPEN PORT VARIABLE CUSHION PRESSURE LINE JOINED DISPLACEMENT CYLINDER SWITCH PUMP DOUBLE ACTING MAIN LINES MOTION...

  • Page 51: 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 52: Hydraulic Parts List

    Hydraulic Parts List Section 3 – System Component Identification and Schematics 3.4 Hydraulic Parts List Index Skyjack Description Part No. 2H-21A 166039 VALVE (Dump) 2H-42 231438 VALVE, Proportional 3H-21 195036 VALVE, Control (Load Circuit) 3H-26 159827 VALVE, Control (Brake Release)
  • Page 53 Section 3 – System Component Identification and Schematics Hydraulic Parts List 3.4 Hydraulic Parts List Index Skyjack Description Part No. 149488 VALVE, Counterbalance (Riser Down) 149488 VALVE, Counterbalance (Riser Down) 149228 VALVE, Counterbalance (Platform Level, Slave) 149228 VALVE, Counterbalance (Platform Level, Slave)
  • Page 54 Hydraulic Parts List Section 3 – System Component Identification and Schematics 3.4 Hydraulic Parts List Index Skyjack Description Part No. 160800 COOLER, Oil (Oil Cooler Option) 167353 ORIFICE, Main Control (Platform Rotate) 167352 ORIFICE, Main Control (Jib) 166056 ORIFICE, Main Control (Boom Extend)

  • Page 55: Electrical 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 56 Electrical Parts List Section 3 – System Component Identification and Schematics 3.5 Electrical Parts List Index Skyjack Description Part No. 4H-13 159819 COIL, 12 Volt (Boom down valve) 4H-14 159819 COIL, 12 Volt (Boom up valve) 4H-23A 159819 COIL, 12 Volt (Right steer valve)
  • Page 57 Section 3 – System Component Identification and Schematics Electrical Parts List 3.5 Electrical Parts List Index Skyjack Description Part No. 122420 QUICK DISCONNECT (CE & AS) 110999 RESISTOR, 5 ohm 25 W 151643 RESISTOR, 250 ohm 1 W 163021 RESISTOR, 120 ohm 1/2 W 164859 RESISTOR, 2.2k ohm 1/2 W...

  • Page 58: Brake Manifold Components And Ports

    Brake Manifold Components and Ports Section 3 – System Component Identification and Schematics 3.6 Brake Manifold Components and Ports 3H-65 Axle Lock Valve 3H-45 2 Speed Valve 3H-26 Brake Valve 3H-165 Differential Lock Valve To Rotary Manifold To Rotary Manifold To Rotary Manifold To Hydraulic...

  • Page 59: Rotary Manifold Ports

    Section 3 – System Component Identification and Schematics Rotary Manifold Ports 3.7 Rotary Manifold Ports Port 7 To Drive Pump Port 8 To Drive Pump Port 9 To Hydraulic Tank Port 1 To Main Manifold Port 5 To Main Manifold Port 3 To Axlelock Cylinder Port 2...

  • Page 60: Drive And System Pump Ports

    Drive and System Pump Ports Section 3 – System Component Identification and Schematics 3.8 Drive and System Pump Ports To Brake Manifold To Hydraulic Tank To Hydraulic Tank To Rotary Manifold To Rotary Manifold To Rotary Manifold To High Pressure Filter To Brake Manifold To Hydraulic Tank SJ45 AJ+...

  • Page 61: Drive And System Pump Ports

    Section 3 – System Component Identification and Schematics Drive and System Pump Ports 3.9 Drive and System Pump Ports For machines with the Welder Option To Brake Manifold To Hydraulic Tank (Pump Case Drain) To Rotary Manifold To Hydraulic Tank (System Suction) To Rotary Manifold...

  • Page 62: Drive Motor Ports

    Drive Motor Ports Section 3 – System Component Identification and Schematics 3.10 Drive Motor Ports To Rotary Manifold To Rotary Manifold To Rotary Manifold To Rotary Manifold SJ45 AJ+ 238274AAA...

  • Page 63: Jib Valve Ports

    Section 3 – System Component Identification and Schematics Jib Valve Ports 3.11 Jib Valve Ports 4H-34 4H-37 Jib Down Valve Platform Right Rotate Valve 4H-35 4H-36 Jib Up Valve Platform Left Rotate Valve To Jib Cylinder To Bulkhead #2 To Jib Cylinder To Bulkhead #1 To Bulkhead #2 To Bulkhead #1...

  • Page 64: Pressure Reducing Valve Ports

    Pressure Reducing Valve Ports Section 3 – System Component Identification and Schematics 3.12 Pressure Reducing Valve Ports To Rotary Manifold Port 6 To Hydraulic Tank To Brake Manifold 2SPD Port SJ45 AJ+ 238274AAA...

  • Page 65: Main Manifold Ports

    3.13 Main Manifold Ports TEST 1 TEST 3 TEST 5 TEST 2 TEST 4 To Lift Cylinder To Jib Valve To Jib Valve To Boom Extension Cylinder To Hi Pressure Filter To Boom Extension Cylinder To Master Cylinder To Emergency Power Unit To Lift Cylinder To Master Cylinder To Brake Manifold...
  • Page 66 3.13 Main Manifold Electrical Components 4H-40 Platform Leveling Valve 3H-38 2H-34A Boom Retract Valve Jib Boom Valve 4H-41 Platform Leveling Valve 4H-32 3H-39 Turret Rotate Left Valve Boom Extend Valve 4H-30 Riser Down Valve 2H-36A 4H-33 Platform Rotate Valve Turret Rotate Right Valve 4H-31 Riser Up Valve 4H-24A...
  • Page 67 3.13 Main Manifold Hydraulic Components Check Valve DSV5 Differential Sensing Valve DSV4 Differential Sensing Valve Shuttle Valve Shuttle Valve Check Valve Relief Valve PFC1 Check Valve Priority Flow Check Valve Control Valve Relief Valve CV10 Check Valve CV11 Check Valve CV12 Check Valve Shuttle Valve...

  • Page 68: Generator Control Valve And Manifold

    3.14 Generator Control Valve and Manifold 3500W Generator 12kW Generator (Welder option) 2H-85 Generator Valve To High Pressure Filter To Hydraulic Tank To Oil Cooler MAIN 3H-85 To Main Manifold Generator Valve CV15 Check Valve 3H-85 Generator Valve To Shuttle Valve To Generator To Drive/System Pump RV11...

  • Page 69: Main Harness And Fuel Level Switch Harness

    3.15 Main Harness and Fuel Level Switch Harness PIN 24 THIS CORNER PIN 1 - 13 - ORANGE PIN 13 - 38 - ORANGE/RED PIN 2 - 14 - BLACK PIN 14 - 39 - BLACK/RED PIN 3 - 21A - WHITE/RED PIN 15 - 40 - BLUE/RED PIN 4 - 23A - BLACK/WHITE PIN 16 - 41 - BLUE/PURPLE...

  • Page 70: Engine Harness - D1305

    3.16 Engine Harness - D1305 POSI AIR OPTION BACK VIEW BACK VIEW J4 - TO MACHINE CONTROLLER HARNESS PIN 1 - 57A - BRN/GRN -16 J3 - TO SPEED SENSOR PIN 2 - 74- GRN/GY -16 PIN 1 - 1104 - BLUE PIN 3 - 68 -GREY-16 PIN 2 - 1105 - WHITE PIN 4 - 76-BRN/BLU-16...

  • Page 71: Engine Harness Wiring Diagram - D1305

    3.17 Engine Harness Wiring Diagram - D1305 TO STARTER TO STARTER TO ACTUATOR SOLENOID TO SPEED SENSOR TO ENGINE GROUND TO ALTERNATOR IGNITION TO TEMP. SENSOR TO GLOW PLUG POSI AIR OPTION RELAY B+ POST TO OIL PRESSURE SW. TO B+ ON ALTERNATOR L = 661mm/26 "...

  • Page 72: Engine Harness - Wg972

    3.18 Engine Harness - 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 M224673AF-3...

  • Page 73: Engine Harness Wiring Diagram - Wg972

    3.19 Engine Harness Wiring Diagram - 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 RELAY...

  • Page 74: Platform Harnesses

    3.20 Platform Harnesses JIB / PLATFORM ROTATE VALVE HARNESS CAVITY WIRE COLOUR DESCRIPTION ORANGE/BLK JIB DOWN WHITE (SPLICE 2) GROUND PLATFORM CONTROL BOX WIRING CAVITY WIRE COLOUR DESCRIPTION ORANGE/WHITE JIB UP 02 WHITE (SPLICE 2) GROUND CAVITY WIRE COLOUR DESCRIPTION RED/PURPLE ROTATE CW 02 WHITE (SPLICE 1)

  • Page 75: Limit Switch Connections

    3.21 Limit Switch Connections Base Control Box Terminal Strip Black (09) Black/White (17) Black (09) Black/White (29A) Black (09) Black/White (59) Black (29) Black/White (29A) LS1 - Direction Sensing LS2 - Fly Stowed Limit LS3 - Main Boom LS6 - Riser Stowed Limit Switch Switch Limit Switch...

  • 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 238274AAA SJ45 AJ+...

  • Page 77: Flashing Amber Light Connections

    3.23 Flashing Amber Light Connections WHITE-02 BLACK - 20 CONTROL COMPARTMENT BASE CONTROL BOX LAYOUT TO LAMP CONNECTOR M148528AA_S3 SJ45 AJ+ 238274AAA...
  • Page 78 238274AAA SJ45 AJ+...

  • Page 79: Hydraulic Schematic

    3.24 Hydraulic Schematic RISER RISER CYLINDER CYLINDER PLATFORM LEVELING JIB LIFT SLAVE CYLINDER CYLINDER BOOM ROTATE SWING DRIVE C2/C11 MASTER MAIN BOOM LIFT FLY BOOM EXTENSION CYLINDER CYLINDER CYLINDER PLATFORM ROTARY ACTUATOR RELIEF VALVE 2500 PSI CB14 500 PSI 500 PSI CB15 3300 PSI 3300 PSI...

  • Page 80: Platform Control Box Wiring

    3.25 Platform Control Box Wiring A3 JOYSTICK A2 JOYSTICK 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) WHT/YEL RIGHT S20-PLTF DUAL FUEL READY S19-LEVEL S18-TELE S21-JIB NOTE:...

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

    3.26 Base Control Box Wiring - ANSI/CSA & AS (31) (4) S15- LEVEL -JIB 24P-FEMALE J6 BACK VIEW J4 BACK VIEW 3.26 Base Control Box Wiring - ANSI/CSA & AS M238013AD SJ45 AJ+ 238274AAA...

  • Page 82: Base Control Box Wiring - Ce

    3.27 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

    3.28 Electrical Schematic - ANSI/CSA & AS 10 11 3.28 Electrical Schematic - ANSI/CSA & AS M238035AA-1 SJ45 AJ+ 238274AAA...

  • Page 84: Electrical Schematic - Ce

    3.29 Electrical Schematic - CE 10 11 3.29 Electrical Schematic - CE M238036AA SJ45 AJ+ 238274AAA...

  • Page 85: Engine Schematic - Kubota D1305

    3.30 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

    3.31 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: 59 The Overload Indicator Light Does Not Turn On When The Platform Is Overloaded

    Section 4 – Troubleshooting Information Electrical System 4.2-58 The Load Sense Indicates Overload or Overload Warning with the Platform Empty or Below Weight 1. Load sense mis-calibration Refer to calibration procedure for recalibration of load cell 2. Load cell circuit not operating Check wiring from load cell to platform control module.

  • Page 107: Hydraulic System

    Hydraulic System Section 4 – Troubleshooting Information 4.3 Hydraulic System 4.3-1 All Controls 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 Inoperative 1.

  • Page 108: No Main Boom Down

    Section 4 – Troubleshooting Information Hydraulic System 4.3-4 No Main Boom Down 1. Stuck or defective lift down valve 4H-13. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV6. Clean valve. Check O-rings on valve. Check operation of valve.

  • Page 109: No Riser Boom Down

    Hydraulic System Section 4 – Troubleshooting Information 4.3-6 No Riser Boom Down 1. Stuck or defective riser down valve 4H-30. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV5. Clean valve. Check O-rings on valve. Check operation of valve.

  • Page 110: No Turret Rotate Right

    Section 4 – Troubleshooting Information Hydraulic System 4. Stuck or defective differential pressure sensing Clean valve. Check O-rings on valve. Check valve DSV2. operation of valve. Repair or replace valve as required. 5. Stuck or defective shuttle valve SV3. Clean valve. Check O-rings on valve. Check operation of valve.

  • Page 111: 10 No Boom Extend

    Hydraulic System Section 4 – Troubleshooting Information 4.3-10 No Boom Extend 1. Stuck or defective boom extend valve 3H-39. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Plugged, incorrectly adjusted or defective orifice Check orifice. Replace if plugged or defective. OR3.

  • Page 112: 13 No Jib Down

    Section 4 – Troubleshooting Information Hydraulic System 4.3-13 No Jib Down 1. Stuck or defective jib enable valve 2H-42. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective differential pressure sensing Clean valve.

  • Page 113: 15 No Platform Rotation Left 4

    Hydraulic System Section 4 – Troubleshooting Information 4.3-15 No Platform Rotation Left 4 1. Stuck or defective platform rotate enable valve Clean valve. Check O-rings on valve. Check 2H-42. operation of valve. Repair or replace valve as required. 2. Stuck or defective differential pressure sensing Clean valve.

  • Page 114: 17 Platform Will Not Level Up Manually

    Section 4 – Troubleshooting Information Hydraulic System 4.3-17 Platform will not Level Up Manually 1. Plugged, incorrectly adjusted or defective orifice Check orifice. Replace if plugged or defective. OR4. 2. Stuck or defective platform level down valve 4H- Clean valve. Check operation of valve. Repair or replace valve as required.

  • Page 115: 19 Brake Will Not Engage

    Hydraulic System Section 4 – Troubleshooting Information 4.3-19 Brake will not Engage 1. Brake cylinder defective. Check cylinders. Repair or replace as necessary. 2. Brake valve 3H-26 stuck in shifted position. Check valve. Replace if defective. 3. Brake inside axle out of adjustment. See section 5 for brake adjustment procedure.

  • Page 116: 23 No Reverse Drive

    Section 4 – Troubleshooting Information Hydraulic System 4.3-23 No Reverse Drive 1. Defective pump displacement control 4H-15. Check control. Replace if defective. 2. Defective or misadjusted drive relief valve RV2. See section 5 for drive pump set up procedures. 3. Drive pump servo stuck or not shifting. Check pump.

  • Page 117: 28 Axle Will Not Lock

    Hydraulic System Section 4 – Troubleshooting Information 4.3-28 Axle Will Not Lock NOTE Axle is in constant float if 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 118: 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 119: Platform

    Section 5 – Procedures Platform 5.2 Platform 5.2-1 Human Machine Interface (HMI) Maintaining proper calibration is essential for 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 120: 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 5.2-4 OCM Function Channel Names SCM Function (Channel) Names DRIVE REV Fn01A Drive Reverse...

  • Page 121: Ocm Pin Reference

    Section 5 – Procedures Platform 5.2-5 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 122 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 123 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 124 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 125 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 126 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 127: Scm Calibration - Ansi/Csa

    Section 5 – Procedures Platform 5.2-6 SCM Calibration - ANSI/CSA 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.

  • Page 128: Scm Calibration Flowchart - Ansi/Csa

    Platform Section 5 – Procedures 5.2-7 SCM Calibration Flowchart - ANSI/CSA START SCREEN BASE PLATFORM Press the + or - button until you see the weight calibration screen. Continued on the next page SJ45 AJ+ 238274AAA...
  • Page 129 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 130: Fly Boom Switch Voltage References

    Platform Section 5 – Procedures 5.2-8 Fly Boom Switch Voltage References TELESCOPE SWITCH WORKSHEET VOLTAGE DIVIDER CIRCUIT 250 OHMS 250 OHMS TELESCOPE IN WIRE WIRE#38A > >> 7.25V 4.83V P1-32 FLY TOGGLE SWITCH TELESCOPE OUT 250 OHMS 250 OHMS 250 OHMS 250 OHMS TELESCOPE IN WIRE...

  • Page 131: Platform Controller Voltage References

    Section 5 – Procedures Platform 5.2-9 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 132: 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 133: Master Cylinder Replacement

    Section 5 – Procedures Boom 5.3-5 Master Cylinder Replacement 5. Secure the master cylinder with straps. See below for an example. 1. Ensure the MEWP is parked on a firm and level surface. WARNING Ensure that there is sufficient room for boom to swing and elevate.

  • Page 134: Limit Switch Locations

    Boom Section 5 – Procedures 5.3-6 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 LS6 - Riser Stowed SJ45 AJ+ 238274AAA...

  • Page 135: Turret

    Section 5 – Procedures Turret 5.4 Turret 5.4-1 Check and Replace the High Pressure Filter 1. Start the engine from the base control console. 2. Inspect the filter restriction indicator gauge The filter should operate with the gauge pointing to the green area. If it is in the red area, the filter needs to be replaced.

  • Page 136: Check Rotation Bearing For Axial Wear

    Turret Section 5 – Procedures 5.4-2 Check Rotation Bearing for Axial 5.4-3 Turret Rotation Gear Bolt Torque Wear Sequence 1. Position the boom so that it is centered over the WARNING front drive and steer axle and is horizontal with the ground.

  • Page 137: Electronic Tilt Switch Setup Procedure

    Section 5 – Procedures Turret 5.4-4 Electronic Tilt Switch Setup 7. Pull out both emergency stop buttons Procedure 8. Verify the switch is powered (red or green LED will be continually blinking). Tilt Switch Replacement Red LED Red LED Y AXIS Green LED Green LED X AXIS...
  • Page 138 Turret Section 5 – Procedures 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 Light Indicators on this face next to the harness program mode and return to normal operation using the previously stored data.

  • Page 139: Battery Replacement

    Section 5 – Procedures Turret Verify Tilt Circuit 5.4-5 Battery Replacement 1. Turn the main power disconnect switch to the off Light Indicators 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 2.

  • Page 140: Diesel Engine

    Diesel Engine Section 5 – Procedures 5.5 Diesel Engine 13. Check for oil leakage. 14. Check the engine oil level on the dipstick and add oil if needed. Maintaining the engine components is essential to good performance and service life of the MEWP . 5.5-1 Replace Engine Oil and Filter Periodic replacement of the engine oil and filter is essential to good engine performance.

  • Page 141: Replace The Fuel Filter

    Section 5 – Procedures Diesel Engine 5.5-2 Replace the Fuel Filter 5.5-4 Check the Engine Belt 1. Close the fuel shut-off valve. 2. Place a suitable container under the fuel filter. The MEWP will not operate properly with a loose or defective belt.

  • Page 142: Hydraulic Tank

    Hydraulic Tank Section 5 – Procedures 5.6 Hydraulic Tank 5.6-2 Hydraulic Filter Replacement 1. Turn the MEWP off. Maintaining the hydraulic components and hydraulic 2. Place a suitable container under the filter. oil at the proper level are essential to the good performance and service life of the MEWP .

  • Page 143: Manifold And Hydraulic Pumps

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.7 Manifold and Hydraulic WARNING Pumps Ensure there are no personnel or obstructions in test area and there is sufficient room for forward or 5.7-1 Hydraulic Brake Pressure reverse travel. Adjustment 6. Start the engine from the platform control console and extend the boom slightly to achieve Maintaining accurate hydraulic brake pressure is low speed drive.

  • Page 144: Hydraulic System Relief Valve Adjustment

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7-2 Hydraulic System Relief Valve 5.7-3 Riser Down Relief Valve Adjustment Adjustment 1. Locate Test Port 5 on the main manifold. 1. Locate Test Port 1 on the main manifold. 2. Connect a pressure gauge (345 bar 5000 psi) to Remove the cap.

  • Page 145: Turret Rotate Relief Valve Adjustment

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.7-4 Turret Rotate Relief Valve 5.7-5 Platform Level Relief Valve Adjustment Adjustment 1. Locate Test Port 5 on the main manifold. 1. Locate the Test 5 Port on the main manifold. 2. Connect a pressure gauge (345 bar / 5000 psi) 2.

  • Page 146: Test Charge Pump Pressure On Drive Pump

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7-6 Test Charge Pump Pressure on 5.7-7 Test Forward Drive Pressure on Drive Pump Drive Pump 1. Locate test port TP3 on the drive pump. NOTE 2. Connect a pressure gauge 41.5 bar (600 psi) to Make sure the charge pump pressure test is the test port.

  • Page 147: Test Reverse Drive Pressure On Drive Pump

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.7-8 Test Reverse Drive Pressure on Drive Pump NOTE Make sure the charge pump pressure test is completed first. 1. Locate test port TP2 on the drive pump. 2. Connect a pressure gauge (690 bar / 10 000 psi) to test port TP2.

  • Page 148: Axles

    Axles Section 5 – Procedures 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 149: Check The Oil Level In The Axle Gearbox

    Section 5 – Procedures Axles 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 150: Oscillating Cylinder Bolt Replacement

    Axles Section 5 – Procedures 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 151 Section 5 – Procedures Axles 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 152: Bleed The Oscillating Axle Cylinders

    Axles Section 5 – Procedures 9. Reinstall the cylinder fittings, torquing the larger 5.8-9 Test the Oscillating Axle Cylinders one to 33 Nm (24 ft-lb) and the smaller one to 20 Nm (15 ft-lb). 10. Remove the plugs and reconnect the hoses to 1.

  • Page 153: 10 Pin Brake Adjustments

    Section 5 – Procedures Axles 5.8-10 Pin Brake Adjustments 4. Tighten the Jam nut. Repeat this procedure for the other side. 1. To manually release the brake give a light blow to the external ring of the check unit. 2. To adjust the idle elimination loosen jam nut and back out adjustment stem a few turns.

  • Page 154: 11 Brake Inspection

    Axles Section 5 – Procedures 7. Release the pressure from the cylinder and 5.8-11 Brake Inspection check that the rod returns and stops in a position where it projects out from the cylinder 1. Remove the oil level plug from one of the head by 5 mm (3/16").

  • Page 155: Grease Points

    Section 5 – Procedures Grease Points 5.9 Grease Points Maintaining proper lubrication is essential for 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 156: Grease The Axles

    Grease Points Section 5 – Procedures 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. SJ45 AJ+ 238274AAA...
  • Page 157 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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