Skyjack SJ40 T+ Service Manual
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Skyjack SJ40 T+ Service Manual

Skyjack SJ40 T+ Service Manual

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SERVICE
MANUAL
SJ40 T+, SJ45 T+
TELESCOPIC BOOMS
238273AAA
March 2021
ANSI/CSA, CE, AS

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Summary of Contents for Skyjack SJ40 T+

  • Page 1 SERVICE MANUAL SJ40 T+, SJ45 T+ TELESCOPIC BOOMS 238273AAA 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 based on serial numbers: SJ40 T+: A400 000 263 - A400 999 999 SJ45 T+: A400 000 263 - A400 999 999...
  • 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 Axle Torque Specifications ............34 Torque Specifications for Fasteners (US) .
  • Page 7 3.25 Platform Controls Wiring - SJ45 T+ ........... 79 3.26 Base Controls Wiring - SJ40 T+ .
  • Page 8 4.2-32 No Platform Rotate Right from the Base or Platform Consoles ......98 4.2-33 No Platform Rotate Right from the Base Console ........99 4.2-34 No Platform Rotate Right from the Platform Console .
  • Page 9 4.3-19 Axle Will Not Lock ............. 114 Section 5 –...
  • Page 10 5.7-7 Fly Boom Relief Valve Adjustment ..........144 5.7-8 Test Charge Pump Pressure on Drive Pump .

  • Page 11: Section 1 - Scheduled Maintenance

    Section 1 – Scheduled Maintenance 1.1 Read and Heed 1.1-5 Service Policy and Warranty Skyjack warrants each new product to be free of Skyjack is continuously improving and expanding defective parts and workmanship for the first 2 product features on its equipment, therefore, years or 3000 hours, whichever occurs first.

  • Page 12: 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 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

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

  • 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 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 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 WARNING Hydraulic pump and motor Explosion or fire hazard. Do not smoke near the Make sure there are no loose or missing parts. ▪ fuel system. If you do not obey, there is a risk of Make sure there is no visible damage.
  • Page 21 Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance Engine oil level Air filter (B,C) Make sure there are no loose or missing parts. ▪ WARNING Make sure there is no visible damage. ▪ Burn hazard. Do not touch hot engine components Squeeze the lips of the vacuator valve to ▪...

  • Page 22: Control Compartment

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-6 Control Compartment Hydraulic Return Filter (B,C) Do the inspection that follows: Make sure the filter element is attached and ▪ tight. Make sure all compartment latches are latched tightly and in good condition. Make sure there is no visible damage or ▪...
  • 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 Replacement. WARNING NOTE Do not use tires other than the tires that Skyjack The oscillating axle is locked when the MEWP is in the specifies for this MEWP . Do not mix different types elevated travel position or at the elevated travel speed.

  • 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 (B)

    Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance 1.6-9 Boom Assembly Cable Track Rotary actuator There are no loose or missing parts, and there ▪ is no visible damage. There are no loose or missing parts, and there ▪ is no visible damage. Wear Pads All fasteners are correctly tightened.

  • Page 28: 10 Optional Equipment (B)

    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: Mewp Torque Specifications

    2.2 MEWP Torque Specifications Location Description Torque (ft-lb) Torque (Nm) Base Trunnion Mount BOLT, Hex head (3.4"-10 x 4.5", Grade 8) Rear Axle Mount BOLT, Hex head (M20 x 2.5 120mm, Grade 10.9) Oscillating axle Mount BOLT, Hex head (M20 x 2.5 120mm, Grade 10.9) Lockout Cylinder Pin BOLT, Hex head (3/8"-16 x 1", Grade 5) Swing Drive Motor...

  • Page 33: Axle Torque Specifications

    2.3 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) M6 x 1 9.5-10.5 10.5-11.5 14.3-15.7 15.2-16.8 16.2-17.8 18.1-20.0 M8 x 1.25...

  • Page 34: Torque Specifications For Fasteners (Us)

    2.4 Torque Specifications for Fasteners (US) 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) (12) 9/16-12 4-40 ft-lb (in-lb) (13) (10) 9/16-18 4-48 ft-lb...

  • Page 35: Torque Specifications For Fasteners (Metric)

    2.5 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) (13) (10) M6 x 1.00 10.4 11.2 (in-lb) (156) (116) (222) (167)

  • Page 36: Torque Specifications For Hydraulic Couplings & Hoses

    2.6 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 15-16 20-21 50-60 68-78 30-36 41-47 72-80 98-110 43-48 60-66 125-135 170-183 75-81 102-110...

  • Page 37: Axles Maintenance Intervals

    2.7 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 Self-locking differential gear every 700 hours * &...

  • Page 38: Tires

    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 39: Floor Loading Pressure

    2.9 Floor Loading Pressure Weights Pressures Model MEWP Weight Weight per Wheel** LCP*** OFL*** Min* 6,586 14,520 1,905 4,200 SJ40 T+ Max* 7,041 15,520 3,495 7,700 1,223 Min* 7,120 15,700 2,041 4,500 SJ45 T+ Max* 7,575 16,700 4,082 9,000 1,414 2106AA Gross MEWP Weight = Weight + platform capacity ▪...

  • Page 40: Hydraulic Specifications

    2.10 Hydraulic Specifications Description Metric Pumps Displacement - 2600 rpm 46 CC 2.8 CIR 30 gpm @2600 rpm Drive Pump Pressure 345 bar 5000 psi Drive Pump Charge Pump Displacement 13.9 CC 0.85 CIR Charge Pump Pressure 22 bar 313 psi Displacement - Static 30 CC 1.83 CIR / 20.6 gpm @ 2600 rpm...

  • Page 41: Fluids

    2.11 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) Esso Univis HVI 26 Standard / Cold -29°C to 45°C (-20°F to 115°F)

  • Page 42: Mewp Specifications

    2.13 MEWP Specifications SJ40 T+ SJ45 T+ Working Height - maximum 14.19 m 46 ft 6.5 in 15.58 m 51 ft 1.5 in Platform Height - maximum 12.36 m 40 ft 6.5 in 13.75 m 45 ft 1.5 in Horizontal Reach - maximum 10.34 m 33 ft 11 in 12.10 m...

  • Page 43: Maximum Platform Capacities

    2.14 Maximum Platform Capacities SJ40 T+ Regular Platform Capacity Derated Platform Capacity* Capacity 454 kg 1000 lb 454 kg 1000 lb High-capacity zone Maximum number of people Manual side force 400 N 90 lbf 200 N 45 lbf Capacity 340 kg 750 lb 318 kg 700 lb...

  • Page 44: Reach Diagram - Sj40 T

    2.15 Reach diagram - SJ40 T+ Meters (feet) 16.76 (55) 15.24 (50) 13.72 (45) 2.13m 12.19 (40) 10.67 (35) 9.14 (30) 7.62 (25) 60° (20) 4.57 (15) 3.05 (10) 1.52 -1.52 (-5) -3.05 (-10) -4.57 -3.05 1.52 1.52 3.05 4.57 7.62 9.14 10.67...

  • Page 45: Dimension Diagrams - Sj40 T

    2.17 Dimension Diagrams - SJ40 T+ 10.34 m [33ft 11 in] 2.69 m [8 ft 9.75 in] 14.19 m [46 ft 6.5 in] 12.36 m 5.93 m [40 ft 6.5 in] [19 ft 5.25 in] 7.73 m [25 ft 4.25 in] 75°...

  • Page 46: Dimension Diagrams - Sj45 T

    2.18 Dimension DIagrams - SJ45 T+ 12.10 m [39 ft 8-1/4 in] 3.61 m [11 ft 10-1/4 in] 15.58 m [51 ft 1-1/2 in] 7.68 m 13.75 m [25 ft 2-1/2 in] [45 ft 1-1/2 in] 8.83 m [28 ft 11-1/2 in] 75°...

  • Page 47: Axle Oscillation Diagrams

    Table 2.19 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 4.5 mph max. Axle oscillation locked (work mode) - drive speed 0.5 mph max. Axle Oscillation - SJ40 T+ Axle oscillation free (travel mode) - drive speed 4.5 mph max.

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

    Section 3 – System Component Identification and Schematics SJ40 T+, SJ45 T+ 238273AAA...

  • 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 103656 VALVE, Control (Pressure Dump) 2H-21B 194492 VALVE, Control (Load Circuit) 2H-42 166050 VALVE, Control (Flow Enable) 2H-85 168056 VALVE, Control (Flow Enable, 3.5 kW Generator)
  • 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 (Jib) 149488 VALVE, Counterbalance (Jib) CB10 141399 VALVE, Counterbalance (Platform Rotate) CB11 141399 VALVE, Counterbalance (Platform Rotate)
  • Page 54 Hydraulic Parts List Section 3 – System Component Identification and Schematics 3.4 Hydraulic Parts List Index Skyjack Description Part No. 168400 MANIFOLD (Generator 3.5 kW) 168401 MANIFOLD (Generator 12 kW) 171437 MANIFOLD (Generator 7.5 kW) 210105 MANIFOLD (dual relief valve)

  • Page 55: Electrical Component Parts List

    Electrical Component Parts List 3.5 Electrical Component Parts List Control B+ Normally Supply (B+) Closed Normally Open Ground (B-) Index Skyjack Description Part No. 00ACR 931298 RELAY, Micro 12 V DC, 30 amp 01ACR 931298 RELAY, Micro 12 V DC, 30 amp...
  • Page 56 Electrical Component Parts List Section 3 – System Component Identification and Schematics 3.5 Electrical Component Parts List Index Skyjack Description Part No. 4H-40 143969 COIL, 12 Volt (Platform level down valve) 4H-41 143969 COIL, 12 Volt (Platform level up valve)
  • Page 57 Section 3 – System Component Identification and Schematics Electrical Component Parts List 3.5 Electrical Component Parts List Index Skyjack Description Part No. 151643 RESISTOR, 250 ohm 1 W 151643 RESISTOR, 250 ohm 1 W 119725 SWITCH, Main power disconnect 218354 KEYSWITCH, Base/Off/Platform (Base control) (ANSI/CSA &...

  • Page 58: Rotary Manifold Port Identification

    Rotary Manifold Port Identification Section 3 – System Component Identification and Schematics 3.6 Rotary Manifold Port Identification Port 7 To Drive Pump Port 8 To Drive Pump Port 4 To Brake Cylinder Port 2 To Brake Manifold Port V9 To Hydraulic Tank Port 4 To Brake Manifold Port 3...

  • Page 59: Brake Manifold Port Identification

    Section 3 – System Component Identification and Schematics Brake Manifold Port Identification 3.7 Brake Manifold Port Identification To Main Manifold To Rotary Manifold Shuttle Valve Pressure Gauge Brake Valve To Hydraulic Tank To Rotary Manifold Brake Release To Drive Pump Override 2SPD To Rotary Manifold...

  • Page 60: System Pump Port Identification

    System Pump Port Identification Section 3 – System Component Identification and Schematics 3.8 System Pump Port Identification To Hydraulic Tank Port B To High Pressure Filter To Main Manifold To Shut-off Valve SJ40 T+, SJ45 T+ 238273AAA...

  • Page 61: Drive Pump Port Identification

    Section 3 – System Component Identification and Schematics Drive Pump Port Identification 3.9 Drive Pump Port Identification To Brake Manifold To Hydraulic Tank To Rotary Manifold To Hydraulic Tank To Rotary Manifold To Brake Manifold To Rotary Manifold 238273AAA SJ40 T+, SJ45 T+...

  • Page 62: Drive Motor Port Identification

    Drive Motor Port Identification Section 3 – System Component Identification and Schematics 3.10 Drive Motor Port Identification To Rotary Manifold To Rotary Manifold To Rotary Manifold To Rotary Manifold SJ40 T+, SJ45 T+ 238273AAA...

  • Page 63: Jib Valve Port Identification - Sj45 T

    Section 3 – System Component Identification and Schematics Jib Valve Port Identification - SJ45 T+ 3.11 Jib Valve Port Identification - SJ45 T+ 4A-34 4H-36 Jib Down Valve Platform Rotate Left Valve 4H-37 4A-35 Platform Rotate Right Valve Jib Up Valve To Jib Cylinder To Jib Cylinder To Bulkhead #2...

  • Page 64: No Jib Valve Port Identifications - Sj40 T

    No Jib Valve Port Identifications - SJ40 T+ Section 3 – System Component Identification and Schematics 3.12 No Jib Valve Port Identifications - SJ40 T+ 4H-36 Platform Rotate Left Valve 4H-37 Platform Rotate Right Valve 2(P) To Bulkhead #1 To Bulkhead #2 4(T) To Bulkhead #1 To Bulkhead #2...

  • Page 65: Main Manifold Port Identification

    3.13 Main Manifold Port Identification SJ40 T+, SJ45 T+ To Hydraulic Tank To Bulkhead (Main Boom) Test Port To System Pump (with generator option) To High Pressure Filter To Master/Slave Cylinders To Master/Slave Cylinders To Extension Cylinder To Lift Cylinder To Extension Cylinder To Swing Drive To Lift Cylinder...

  • Page 66: Main Manifold Electrical Component Identification

    3.14 Main Manifold Electrical Component Identification 229038AAA 4H-41 Platform Level Up 4H-40 Platform Level Down 4H-38 Boom Retract 2H-42 Flow Enable 4H-14 4H-39 Boom Up Boom Extend 4H-13 4H-33 Boom Down Turret Rotate Right 4H-32 Turret Rotate Left 2H-21A Dump 4H-23A 4H-24A Right Steer...

  • Page 67: Main Manifold Hydraulic Component Identification

    3.15 Main Manifold Hydraulic Component Identification SJ40 T+, SJ45 T+ Check Valve Check Valve Relief Valve DSV2 Check Valve Boom Lift Compensator Bottom Check Valve DSV3 Swing Relief Valve Boom Extend Check Valve Check Valve Compensator CV11 Check Valve CV10 Check Valve Check Valve Relief Valve...

  • Page 68: Main Harness Wiring Diagram

    3.16 Main Harness Wiring Diagram 229038AAA EMERGENCY PUMP 108 - YELLOW/BROWN 14 GA MAIN POWER 03 - GREEN PURPLE 12 GUAGE AXLE LOCK VALVE PIN 1 - 65 YELLOW/PINK PIN 2 - 02 WHITE (SPLICE #3) PIN 1 - 00 - WHITE [12 GA.] PIN 2 - 03 - GREEN/PURPLE [12 GA.] PIN 3 - 13 - ORANGE PIN 4 - 14 - BLACK...

  • Page 69: Engine Harness

    3.17 Engine Harness SJ40 T+, SJ45 T+ 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 70: Engine Harness Schematic

    3.18 Engine Harness Schematic 229038AAA TO STARTER TO STARTER TO ACTUATOR SOLENOID POSI AIR OPTION TO SPEED SENSOR TO OIL PRESSURE SW. TO B+ ON ALTERNATOR TO ENGINE GROUND TO ALTERNATOR IGNITION TO TEMP. SENSOR TO GLOW PLUG RELAY B+ POST L = 661mm/26 "...

  • Page 71: Platform Harnesses

    3.19 Platform Harnesses SJ40 T+, SJ45 T+ CAVITY WIRE NO. COLOUR DESCRIPTION ORANGE/BLK JIB DOWN WHITE (SPLICE 2) GROUND CAVITY WIRE NO. COLOUR DESCRIPTION ORANGE/WHITE JIB UP WHITE (SPLICE 2) GROUND CAVITY WIRE NO. COLOUR DESCRIPTION RED/PURPLE ROTATE CW WHITE (SPLICE 1) GROUND WHITE (02) CAVITY WIRE NO.

  • Page 72: Limit Switch Connections

    3.20 Limit Switch Connections 229038AAA Base Control Box Terminal Strip Black (09) Blue/White (121) Black/White Black (09) (17) Black (09) Black/White (122) Black (09) Black/White (29) Black (09) Black/White (59) LS1 - Direction Sensing LS2 - Fly Stowed Limit LS3 - Main Boom LS4 - Boom Down LS5 - Fly Out Limit Switch...

  • Page 73: Flashing Light Connection

    3.21 Flashing Light Connection SJ40 T+, SJ45 T+ BLACK - 20 WHITE - 02 BASE CONTROL CONSOLE TERMINAL STRIP M144026AA_S3 SJ40 T+, SJ45 T+ 238273AAA...

  • Page 74: Differential Lock Harness

    3.22 Differential Lock Harness 229038AAA IINSERT HARNESS WIRE 165 TO TB 165 80.1389 INSERT HARNESS WIRE 02 TO AVAILABLE TB 02. BASE CONTROL BOX LAYOUT TO DIFFLOCK VALVE M167195AB 238273AAA SJ40 T+, SJ45 T+...

  • Page 75: Hydraulic Schematic

    3.23 Hydraulic Schematic PLATFORM LEVELING JIB LIFT SLAVE CYLINDER PLATFORM FLY BOOM EXTENSION LEVELING BOOM ROTATE MAIN BOOM LIFT MASTER CYLINDER SWING DRIVE PLATFORM ROTATE Bore 3.25 Bore Stroke 11.63 Stroke 29.5 Bore Bore 3.75 Bore CB11 CB10 Stroke Stroke 12.06 3300 PSI 3300 PSI...

  • Page 76: Platform Controls Wiring - Sj40 T

    3.24 Platform Controls Wiring - SJ40 T+ LOAD LOW CAP ZONE A3 SPD CTRL A2 JOYSTICK BORDER HIGH CAP GLAZIER JOYSTICK ACTIVE 04(RED) POWER PIN 1 - L L (PURPLE) VIOLET 02 (WHITE) GROUND PIN 2 - C C (GREEN) GREEN BLACK D-SIGNAL...

  • Page 77: Platform Controls Wiring - Sj45 T

    3.25 Platform Controls Wiring - SJ45 T+ LOAD LOW CAP ZONE A3 SPD CTRL A2 JOYSTICK BORDER HIGH CAP GLAZIER JOYSTICK ACTIVE 04(RED) POWER PIN 1 - L L (PURPLE) VIOLET 02 (WHITE) GROUND C (GREEN) PIN 2 - C GREEN BLACK D-SIGNAL...

  • Page 78: Base Controls Wiring - Sj40 T

    3.26 Base Controls Wiring - SJ40 T+ J3 WHITE 165-PK/BK-18 120A 122-GY/YL-18 121-GY/RD-18 68-GY-18 85-GY/BU-18 118A 01-PU/BK-18 CAN2L-GN-18 CAN2H-YL-18 CANL-WH-18 118A D57D 09-YL-12 118A-PU/PK-18 57D-BN/GN-18 02-WH-14 02-WH-18 J2 GREY 57C-BN/GN-18 05-PU-14 22kµF LOAD PL13 ZONE BORDER 55-YL/PU-18 02-WH-18 PL14 PL15 HIGH 04-RD/YL-18 ADDWIRE LBL...

  • Page 79: Base Controls Wiring - Sj45 T+ Ansi/Csa & As

    3.27 Base Controls Wiring - SJ45 T+ ANSI/CSA & AS J3 WHITE 165-PK/BK-18 120A 122-GY/YL-18 121-GY/RD-18 68-GY-18 85-GY/BU-18 118A (10) 01-PU/BK-18 CAN2L-GN-18 CAN2H-YL-18 CANL-WH-18 118A 09-YL-12 118A-PU/PK-18 D57D 57D-BN/GN-18 02-WH-18 02-WH-14 J2 GREY 57C-BN/GN-18 05-PU-14 22kµF LOAD PL13 ZONE BORDER 55-YL/PU-18 02-WH-18 PL14...

  • Page 80: Base Controls Wiring - Sj45 T+ Ce

    3.28 Base Controls Wiring - SJ45 T+ CE 24P-FEMALE S15- LEVEL -JIB H1 HORN 3.28 Base Controls Wiring - SJ45 T+ CE M238413AC SJ40 T+, SJ45 T+ 238273AAA...

  • Page 81: Electrical Schematic - Ansi/Csa & As

    3.29 Electrical Schematic - ANSI/CSA & AS 10 11 3.29 Electrical Schematic - ANSI/CSA & AS M238037AA-1 SJ40 T+, SJ45 T+ 238273AAA...

  • Page 82: Electrical Schematic - Ce

    3.30 Electrical Schematic - CE 10 11 3.30 Electrical Schematic - CE M238037AA SJ40 T+, SJ45 T+ 238273AAA...

  • Page 83: 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 SOLENOID ACTUATOR SOLENOID SPEED SENSOR OIL PRESSURE SW. TEMP. SENSOR GLOW PLUG STARTER CB40 AUTOMATIC REV. SHUT OFF LIMITER SOLENOID 403A...

  • Page 84: Engine Schematic - Kuboa Wg972

    3.32 Engine Schematic - Kuboa WG972 DUAL FUEL ENGINE TO CTRL PNL TO BATT. B+ TO ECU FUEL PUMP CUT-OFF GND ON ENGINE BLOCK 1054 1030 PRE O2 1060 SENSOR 1002 1044 32ACR STARTER RELAY D1044 1044A 1044ACR STARTER 1017 STARTER SOLENOID RELAY...

  • Page 85: 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 86: 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 87 Electrical System Section 4 – Troubleshooting Information 18. Loose or broken wire #02 from base control Check continuity. Replace if defective. module connector J1 pins 10, 11, 12, and/or 13 to base terminal block. 19. Loose or broken wire #02 from base terminal Check continuity.

  • Page 88: All Controls Are Inoperative From The Base Console

    Section 4 – Troubleshooting Information Electrical System 35. Loose or broken wire #02 from platform control Check continuity. Replace if defective. module connector J11 pins 10, 11, 12, and/or 13 to platform terminal block. 36. Loose or broken wire #02 from platform terminal Check continuity.

  • Page 89: The Engine Will Not Crank From The Base

    Electrical System Section 4 – Troubleshooting Information 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 90: 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 #4 2.

  • Page 91: 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 92: 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. Missing output from telematics pin 9. Check for ground on pin 9. If no ground, contact the machine owner. 2. Defective relay 57DCR. Check relay.

  • Page 93: 19 No Telescope Out From The Base Or Platform Consoles

    Electrical System Section 4 – Troubleshooting Information 4.2-19 No Telescope Out from the Base or Platform Consoles 1. Loose or broken wire #39 from base control Check continuity. Replace if defective module connector J2 pin 5 base terminal block to turret harness plug pin #13 2.

  • Page 94: 22 No Telescope In From The Base Or Platform Consoles

    Section 4 – Troubleshooting Information Electrical System 4.2-22 No Telescope In from the Base or Platform Consoles 1. Loose or broken wire #38 from base control Check continuity. Replace if defective module connector J2 pin 9 to turret harness plug pin #12 2.

  • Page 95: 26 No Platform Level Up From The Base Console

    Electrical System Section 4 – Troubleshooting Information 4.2-26 No Platform Level Up from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to platform level switch S15 2. Defective platform level switch S15 Check continuity through switch while activating up function between wires #10A and #41B.

  • Page 96: 30 No Platform Level Down From The Platform Console

    Section 4 – Troubleshooting Information Electrical System 4.2-30 No Platform Level Down from the Platform Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective block to platform level switch S19 2. Defective platfrom level switch S19 Check continuity through switch while activating platfrom level down function between wires #04 and #40A.

  • Page 97: 33 No Platform Rotate Right From The Base Console

    Electrical System Section 4 – Troubleshooting Information 4.2-33 No Platform Rotate Right from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to platform rotate switch S16 2. Defective platform rotate switch S16 Check continuity through switch while activating platform rotate right function between wires #10A and #37B.

  • Page 98: 37 No Platform Rotate Left From The Platform Console

    Section 4 – Troubleshooting Information Electrical System 4.2-37 No Platform Rotate Left from the Platform Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective block to platform rotate switch S20 2. Defective platform level switch S20 Check continuity through switch while activating platform rotate left function between wires #04 and #36A.

  • Page 99: 41 No Jib Down From The Base Or Platform Consoles

    Electrical System Section 4 – Troubleshooting Information 4.2-41 No Jib Down from the Base or Platform Consoles 1. Loose or broken wire #34 from platform control Check continuity. Replace if defective module connector J12 pin #24 to platform terminal strip 2.

  • Page 100: 45 No Forward Or Reverse Drive

    Section 4 – Troubleshooting Information Electrical System 4.2-45 No Forward or Reverse Drive 1. No output on “D” when forward is selected on See drive joystick test procedure in section 5 drive joystick A2 2. Loose or broken wire ”D-signal” from drive Check continuity.

  • Page 101: 48 The Brake Will Not Release

    Electrical System Section 4 – Troubleshooting Information 4.2-48 The Brake will not Release 1. No output from base control module coneector Check for correct output voltage J3 pin #24 to wire #26 2. Loose or broken wire 26 from base control Check continuity.

  • Page 102: 50 No Right Steer

    Section 4 – Troubleshooting Information Electrical System 4.2-50 No Right Steer 1. Loose or broken wire #23P from drive joystick Check continuity. Replace if defective A2 to platform control module connector J12 pin 2. No output from base control module on Check pin #13 for 12 volts.

  • Page 103: 53 The Overload Indicator Light Does Not Turn On When The Platform Is Overloaded

    Electrical System Section 4 – Troubleshooting Information 4.2-53 The Overload Indicator Light does not Turn On when the Platform is Overloaded 1. Defective lamp Check lamp. Replace if defective 2. Load cell circuit not operating Check wiring from load cell to platform control module.

  • Page 104: 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 105: No Main Boom Down

    Hydraulic System Section 4 – Troubleshooting Information 4.3-4 No Main Boom Down 1. Stuck or defective differential sensing valve Clean valve. Check O-rings on valve. Check DSV2. operation of valve. Repair or replace valve as required. 2. Stuck or defective lift up valve 4H-13. Clean valve.

  • Page 106: No Boom Extend

    Section 4 – Troubleshooting Information Hydraulic System Right Rotate 1. Stuck or defective differential sensing valve Clean valve. Check O-rings on valve. Check DSV1. operation of valve. Repair or replace valve as required. 2. Stuck or defective rotate left valve 4H-33. Clean valve.

  • Page 107: No Boom Retract

    Hydraulic System Section 4 – Troubleshooting Information 8. Return valve V4 stuck in the closed position or is Clean valve. Check operation of valve. Repair or defective. replace valve as required. 9. Defective extension cylinder C2. Check seals on cylinder. Replace as necessary. Replace cylinder if defective.

  • Page 108: No Jib Down

    Section 4 – Troubleshooting Information Hydraulic System 4.3-9 No Jib Down 1. Stuck or defective proportional flow 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 check valve CV9. Clean valve.

  • Page 109: 11 Platform Will Not Level

    Hydraulic System Section 4 – Troubleshooting Information 4.3-11 Platform will not Level Level Down 1. Stuck or defective platform level down valve 4H- Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective dual check valve DCV2. Clean valve.

  • Page 110: 12 Brake Will Not Release

    Section 4 – Troubleshooting Information Hydraulic System 4.3-12 Brake will not Release 1. Stuck or defective shuttle valve SV5. 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 111: 15 Differential Lock Will Not Engage

    Hydraulic System Section 4 – Troubleshooting Information Forward Drive 1. Defective pump displacement control 4H-16. Check control. Replace if defective. 2. Defective or misadjusted drive relief valve RV6. See section 5 for drive pump set up procedures. Reverse Drive 1. Defective pump displacement control 4H-15. Check control.

  • Page 112: 18 Axle Will Not Oscillate

    Section 4 – Troubleshooting Information Hydraulic System Steer Left 1. Stuck or defective right steer valve 4H-24(A). Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective dual check valve DCV2. Clean valve. Check O-rings on valve. Check operation of valve.

  • Page 113: Section 5 - Procedures

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

  • Page 114: 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 aerial platform. To access the SCM console, open the platform control cover. The SCM 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 115: 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 SJ40 T+, SJ45 T+ 238273AAA...

  • Page 116: 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 117 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 118 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 119 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 120 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 121 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 122: 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 123: 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 SJ40 T+, SJ45 T+ 238273AAA...
  • Page 124 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 125: 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 126: Boom

    Section 5 – Procedures Boom 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 127: Limit Switch Locations

    Boom Section 5 – Procedures 5.3-5 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) SJ40 T+, SJ45 T+ 238273AAA...

  • Page 128: Turret

    Section 5 – Procedures Turret 5.4 Turret 5.4-2 Adjust the Turret Rotation Gear Backlash 5.4-1 Check and Replace the High The swing drive is located at the platform end of the turret, behind the battery. Pressure Filter NOTE 1. Start the engine from the base control console. The adjustment of the backlash must be 2.

  • Page 129: Check The Swing Drive Oil

    Turret Section 5 – Procedures 5.4-3 Check the Swing Drive Oil 5.4-4 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 130: Battery Replacement

    Section 5 – Procedures Turret 5.4-5 Battery Replacement 5.4-6 Turret Rotation Gear Bolt Torque Sequence 1. Turn the main power disconnect switch to the off WARNING position. Maintaining proper torque is essential to safe MEWP operation. Improper bolt torque could result in an unsafe operating condition and component damage.

  • Page 131: Electronic Tilt Switch Setup Procedure

    Turret Section 5 – Procedures 5.4-7 Electronic Tilt Switch Setup 8. Verify the switch is powered (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 132 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 Light Indicators on this face next to the harness program mode and return to normal operation using the previously stored data.

  • Page 133: Check Rotation Bearing For Axial Wear

    Turret Section 5 – Procedures Verify Tilt Circuit 5.4-8 Check Rotation Bearing for Axial Wear Light Indicators 1. Position the boom so that it is centered over the front drive and steer axle and is horizontal with the ground. 2. Extend the boom to its full extension length. 3.

  • Page 134: Engines

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

  • Page 135: Check The Engine Belt

    Engines 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 136: Hydraulic Tank

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

  • Page 137: Manifold And Hydraulic Pumps

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7 Manifold and Hydraulic 5. Start the engine from the platform control console and extend the boom slightly to achieve Pumps low speed drive. 6. Drive the MEWP forward or reverse. The 5.7-1 Hydraulic Brake Pressure pressure gauge reading should be 550 psi.

  • Page 138: Hydraulic Standby Pressure Adjustment

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.7-2 Hydraulic Standby Pressure 5. Locate the load sense compensator on the system pump. Adjustment 1. Locate the GP2 port on either the top or bottom of the main manifold and remove the cap.

  • Page 139: Hydraulic High Pressure Adjustment

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7-3 Hydraulic High Pressure 5. Locate the pressure compensator on the system pump. Adjustment 1. Locate GP2 port on the main manifold and remove the cap. 6. Loosen the lock nut. 7. Adjust the system pump pressure by turning the adjusting stem either clockwise to increase pressure or counterclockwise to decrease pressure.

  • Page 140: Hydraulic System Relief Valve Adjustment

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.7-4 Hydraulic System Relief Valve 5. Locate the system relief valve (RV1) Adjustment To adjust the system relief valve (RV1), you are required to temporarily adjust the high pressure setting on the system pump to 3300 psi. Refer to 5.7-3 Hydraulic High Pressure Adjustment.

  • Page 141: Turret Rotate Relief Valve Adjustment

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7-5 Turret Rotate Relief Valve 5.7-6 Platform Level Relief Valve Adjustment Adjustment 1. Locate the GP2 port on the main manifold. 1. Locate the GP2 port on the main manifold. 2. Connect a pressure gauge (5000 psi) to the GP2 2.

  • Page 142: Fly Boom Relief Valve Adjustment

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.7-7 Fly Boom Relief Valve Adjustment 5.7-8 Test Charge Pump Pressure on Drive Pump 1. Locate the GP2 port on the main manifold and remove the cap. 1. Locate test port TP3 on the drive pump.

  • Page 143: Test Forward Drive Pressure On Drive Pump

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.7-9 Test Forward Drive Pressure on 5.7-10 Test Reverse Drive Pressure on Drive Pump Drive Pump NOTE NOTE Make sure the charge pump pressure test is Make sure the charge pump pressure test is completed first.

  • Page 144: 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 145: 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 146: Oscillating Cylinder Bolt Replacement

    Section 5 – Procedures Axles 5.8-6 Oscillating Cylinder Bolt 5.8-7 Oscillating Cylinder Replacement Replacement CAUTION If upon inspection it is determined that the oscillating cylinder bolts have missing or damaged torque seal, The oscillating axle cylinder weighs approximately the affected bolts must be replaced. If replacing 43 lbs (19.5 kg), so a second person to assist with more than one bolt, do so one at a time to prevent the the removal and replacement would be helpful.
  • Page 147 Axles Section 5 – Procedures 3. With a rag in hand to catch any leaking oil, 7. Adjust the oscillating cylinder position until slowly loosen the bleeder screw to release any there is continuous contact between the cylinder trapped air within the cylinder, then tighten it mounting surface and the mounting plate, and again.

  • Page 148: Bleed The Oscillating Axle Cylinders

    Section 5 – Procedures Axles 10. Remove the plugs and reconnect the hoses to 5.8-9 Test the Oscillating Axle Cylinders the cylinder fittings, torquing the larger hose end to 21 ft-lbs [28 Nm] and the smaller hose end to 12 ft-lbs [16 Nm]. 1.

  • Page 149: 10 Pin Brake Adjustments

    Axles Section 5 – Procedures 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 the jam nut and back out the adjustment stem a few turns.

  • Page 150: 11 Brake Inspection

    Section 5 – Procedures Axles 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 a minimum of 3/16"...

  • Page 151: Grease Points

    Grease Points Section 5 – Procedures 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 MEWPare improperly greased, it could result in component damage. 5.9-1 Grease the Turret Ring Gear 1.

  • Page 152: 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. 238273AAA SJ40 T+, SJ45 T+...
  • Page 153 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 154 www.skyjack.com...

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