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SERVICE MANUAL TELESCOPIC BOOMS MODELS SJ40T SJ45T 168894AJ June 25 2025...
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This manual is for MEWPs with serial numbers: SJ40T & SJ45T: 98 001 331 through 98 001 500 Please refer to the website (www.skyjack.com) for older serial numbers.
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Section 2 - Maintenance Tables and Diagrams Table of Contents Section 3 - System Component Identification and Schematics Table of Contents Section 4 - Troubleshooting Table of Contents Section 5 - Procedures Table of Contents Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 3 168894...
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It may also be used to alert against unsafe practices. IMPORTANT IMPORTANT indicates a procedure essential for safe operation and which, if not followed, may result in a malfunction or damage to the aerial platform. Telescopic Boom Series Models SJ40T, SJ45T Page 4 December 2007 168894...
SKYJACK warrants each new SJT series work platform to be free of defective parts and workmanship for the first 24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor.
Consult SKYJACK’s Service Department for optional Before attempting any repair work, turn Battery tires specifications and installation. Disconnect Switch to “...
When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also, Keep all connections tight. plug the ports of the removed components. Telescopic Boom Series Models SJ40T, SJ45T Page 8 December 2007 168894...
Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance 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...
- Disconnect the battery by turning the main power disconnect switch to “ ”off position. • Repair any damaged or malfunction components before operating aerial platform. • Keep records on all inspections. Telescopic Boom Series Models SJ40T, SJ45T Page 10 December 2007 168894...
This decal is located on the control compartment cowling. It must be completed after an annual inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 6 months. Pictorial Description Inspection Date Inspector Signature Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 11 168894...
Owner: ________________________________________________ / _____________________________________________ / _________________________________________ Print Name Signature Date (DD/MM/YY) User: _______________________________________________ / _____________________________________________ / __________________________________________ Print Name Signature Date (DD/MM/YY) 167834AB Note: Visit www.skyjack.com for a printable copy of this form. Telescopic Boom Series Models SJ40T, SJ45T Page 12 December 2007 168894...
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Always return manuals to the manual storage box after use. 1.1-2 Labels Refer to the labels section in the Operating Manual and ensure that all labels are in place and are legible. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 13 168894...
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B - Frequent Inspection Improper fluid levels or damaged cables and Replace battery if damaged or incapable connections can result in engine component of holding a lasting charge. damage and hazardous conditions. Telescopic Boom Series Models SJ40T, SJ45T Page 14 December 2007 168894...
Ensure there are no loose or missing For lube procedure, refer to Section 5.9-3. parts and no visible damage to the engine pivot tray. Ensure that each tray-securing bolt is in place. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 15 168894...
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B - Frequent Inspection For engine air filter maintenance procedure, refer to engine manual. C - Annual Inspection For engine air filter replacement procedure, refer to engine manual. Telescopic Boom Series Models SJ40T, SJ45T Page 16 December 2007 168894...
Table 2.8 Specifications and Features hydraulic leakage. recommended oil type. * - Bi-Annual Inspection For hydraulic oil replacement procedure, refer to Section 5.6-2. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 17 168894...
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Ensure tank shows no visible damage reach. and no evidence of fuel leakage. Ensure fuel tank, shutoff valve, hoses and fittings show no visible damage and no evidence of fuel leakage. Telescopic Boom Series Models SJ40T, SJ45T Page 18 December 2007 168894...
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Check the brakes annually. Refer to procedure 5.8-8 Brake Inspection. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 19 168894...
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An over-inflated tire can explode and fore, replace tires ONLY with exact may cause death or serious injury. Skyjack-approved types. Failure to operate with matched, approved tires Check all tire treads and sidewalls for in good condition may result in death cuts, cracks, punctures and unusual or serious injury.
Ensure gate/drop-bar(s) are in good working order. Ensure footswitch is in good working order and has not been modified, disabled or blocked. Ensure lanyard attachment anchorages are secure and there is no visible damage. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 21 168894...
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Ensure there are no visible cracks in welds or structure and there are no signs of deformation. Ensure all hoses are properly tightened and there is no evidence of hydraulic leakage. Telescopic Boom Series Models SJ40T, SJ45T Page 22 December 2007 168894...
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• Arctic Weather Package (If Equipped) no signs of visible damage. Ensure battery/hydraulic oil/engine oil heater plug is properly secured with no signs of visible damage and hydraulic leakage. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 23 168894...
NOTE The all-function motion alarm should sound while operating any boom and drive function. Telescopic Boom Series Models SJ40T, SJ45T Page 24 December 2007 168894...
REUSABLE MALE PIPE THREAD FITTING NO FITTING 300 PSI REUSABLE FEMALE, 37° JIC, SWIVEL REUSABLE FEMALE, 37° JIC, SWIVEL 300 PSI Fitting Arrangement Schedule (Continued on the following page) Telescopic Boom Series Models SJ40T, SJ45T Page 26 December 2007 168894...
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SHORT 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17 MEDIUM 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 27 168894...
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BOLT, Hex head (1/2"-13 x 2.25", Grade 8) Special Options (If equipped) Generator Support (40T/45T) BOLT, Hex head (1/2"-13 x 2", Grade 8) Oil Cooler Support (40T/45T) BOLT, Hex head (1/2"-13 x 2", Grade 8) 60580AK Telescopic Boom Series Models SJ40T, SJ45T Page 28 December 2007 168894...
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Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength lock- ing. Before using it, completely remove any lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80˚C approx. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 29 168894...
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1708 3688 2766 ft‐lb ft‐lb 1940 1460 3160 2360 1/2-20 1 1/2‐6 1180 2630 1979 4284 3200 Inch‐Pound Force = in‐lb Foot‐Pound Force = ft‐lb Newton‐Meter = Nm ft‐lb 2200 1640 3560 2660 1 1/2‐12 NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite. 1329 2983 2224 4827 3606 Telescopic Boom Series Models SJ40T, SJ45T Page 30 December 2007 168894...
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1543 1158 M30 x 3.50 1463 1097 2092 1570 ft‐lb 1468 1101 2101 1576 M33 x 3.50 1990 1493 2849 2137 ft‐lb 1886 1415 2699 2024 M36 x 4.00 2557 1918 3659 2744 Inch‐Pound Force = in‐lb Foot‐Pound Force = ft‐lb Newton‐Meter = Nm NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 31 168894...
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Lubricant SAE 90 oil API GL3 Torque Wrench Settings (Nm) Size of Screw 8G/8.8 10K/10.9 12K/12.9 M10 x 1.25 M14 x 1.5 60572AA Note: 1 Nm = 0.7376 ft-lb Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 33 168894...
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Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability. Therefore, replace tires only with the exact original Skyjack-approved type. Failure to operate with matched approved tires in good condition may result in death or serious injury.
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Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability. Therefore, replace tires only with the exact original Skyjack-approved type. Failure to operate with matched approved tires in good condition may result in death or serious injury.
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Steering Cylinder Stroke 4.32 in. 10.9 cm 10.9 cm Cylinder Maximum Steering Pressure 2175 psi 150 bar 150 bar For other component specifications, refer to hydraulic schematic. 1085-ALL Standards Telescopic Boom Series Models SJ40T, SJ45T Page 36 December 2007 168894...
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Overall Uniform Pressure - OUP 181 psf (9 kPa) 190 psf (9.1 kPa) 9.5 kPa 9.5 kPa 1132AA NOTE: All dimensional values are nominal and do not account for tire deflection. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 37 168894...
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Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.11 Specifications and Features (Continued) MODEL SJ40T & SJ45T Engine Type Deutz D2.9L RPM Settings 900 Low / 1700 / 2600 High Horsepower @ 2000 rpm (intermittent) 29.8 kW / 40 Hp...
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Section 2 - Maintenance Tables and Diagrams Service and Maintenance Diagram 2.1 Dimension and Reach Diagram - SJ 40T Reach Diagram - 40T Dimensions - 40T Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 39 168894...
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Service and Maintenance Section 2 - Maintenance Tables and Diagrams Diagram 2.2 Dimension and Reach Diagram - SJ 45T Reach Diagram - 45T Dimensions - 45T Telescopic Boom Series Models SJ40T, SJ45T Page 40 December 2007 168894...
THREE POSITION TWO POSITION TWO POSITION FOUR WAY TWO WAY THREE WAY VALVE CLOSED CENTER NORMALLY CLOSED PORT OPEN VALVE PRESSURE PILOT LINES Dashed MAIN LINES Solid TRANSDUCER SERVO Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 45 168894...
SINGLE THROWN LEVEL SENSOR SWITCH RELAY DOUBLE POLE TEMPERATURE SINGLE POLE DOUBLE POLE DOUBLE THROW SWITCH DOUBLE THROW SINGLE THROW RELAY RELAY RELAY TRIPLE POLE RHEOSTAT DIODE DOUBLE THROW RELAY Telescopic Boom Series Models SJ40T, SJ45T Page 46 December 2007 168894...
This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 47...
CB11 141399 VALVE, Counterbalance (Platform Rotate) CB12 160028 VALVE, Counterbalance (Axle Lock) CB13 160028 VALVE, Counterbalance (Axle Lock) 166066 VALVE, Check (Auxiliary Pump) Parts list continued on following page. Telescopic Boom Series Models SJ40T, SJ45T Page 48 December 2007 168894...
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ORIFICE, 0.018” (Main Manifold) 166081 ORIFICE, 0.018” (Main Manifold) 166058 ORIFICE (Main Manifold) 166073 ORIFICE, 0.073” (Bleed Off) 168061 VALVE, Needle (3.5kW Generator) Parts list continued on following page. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 49 168894...
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VALVE, Control (Brake Hand Pump) 166060 VALVE, Control (Pilot Operated) 166060 VALVE, Control (Pilot Operated) 166060 VALVE, Control (Bypass, Towing) 166060 VALVE, Control (Pilot Operated) VALVE, Control (Bypass, Towing) Telescopic Boom Series Models SJ40T, SJ45T Page 50 December 2007 168894...
RELAY, 12 Volt 40 Amp (Low idle) 81CR 127131 RELAY, 12 Volt 40 Amp (Optional light) 82CR 127131 RELAY, 12 Volt 40 Amp (Overload alarm) (CE & AS) Parts list continued on following page. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 51 168894...
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SWITCH, Low fuel 146652 HORN, 12 Volt 143971 LIGHT, Optional strobe 144576 LIMIT SWITCH, High drive 138719 LIMIT SWITCH, High drive (if equipped) Parts list continued on following page. Telescopic Boom Series Models SJ40T, SJ45T Page 52 December 2007 168894...
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SWITCH, Platform rotate toggle (Platform control console) 102853 SWITCH, Jib up/down toggle (Platform control console) (SJ 45T) 144266 SWITCH, Electrical generator (Platform control console) Parts list continued on following page. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 53 168894...
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SWITCH, Fuel select (Platform control console) (GM engine) 115574 SWITCH, Drive torque toggle (Platform control console) 166163 SWITCH, Tilt (5°/ 5°) 103336 HOUR METER 138576 PORT, Diagnose (Deutz engine) 138574 CONNECTOR, Engine (Deutz engine) Telescopic Boom Series Models SJ40T, SJ45T Page 54 December 2007 168894...
To Steer Cylinder Port 5 To Steer Cylinder Port 6 To Drive Motor Port 9 To Drive Motor Port 8 Port 4 To Drive Motor To Brake Cylinder M158040AA_3 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 55 168894...
Section 3 - System Component Identification and Schematics Service and Maintenance 3.8 System Pump and Port Identifications To Hydraulic Tank Port B To High Pressure Filter To Main Manifold To Shut-off Valve M163595AA-SM Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 57 168894...
Section 3 - System Component Identification and Schematics 3.9 Drive Pump and Port Identifications To Brake Manifold To Hydraulic Tank To Rotary Manifold To Hydraulic Tank To Rotary Manifold To Brake Manifold To Rotary Manifold M154119AA-SM Telescopic Boom Series Models SJ40T, SJ45T Page 58 December 2007 168894...
Section 3 - System Component Identification and Schematics Service and Maintenance 3.10 Drive Motor and Port Identifications To Rotary Manifold To Rotary Manifold To Rotary Manifold To Rotary Manifold M162721AA_SM Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 59 168894...
4A-35 Platform Rotate Right Valve Jib Up Valve To Jib Cylinder To Jib Cylinder To Bulkhead #2 To Bulkhead #2 4(T) 3(P) To Bulkhead #1 To Bulkhead #1 M165018AB_Valve_Explode Telescopic Boom Series Models SJ40T, SJ45T Page 60 December 2007 168894...
3.12 No Jib Valve and Port Identifications 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 165009AA_Valve_Explode Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 61 168894...
Section 3 - System Component Identification and Schematics 3.13 Pressure Reducing Manifold Port Identifications CV18 Check Valve To Brake Manifold To Rotary Manifold To Hydraulic Tank Pressure Reducing Valve M139133AA_S3 Telescopic Boom Series Models SJ40T, SJ45T Page 62 December 2007 168894...
To Emergency Power Unit To Lift Cylinder To Shuttle Valve To Swing Drive To Brake Manifold To Rotary Manifold To Bulkhead (Turret) To Lift Cylinder To Rotary Manifold To Swing Drive M167894AB-1 Telescopic Boom Series SKYJACK, Page 63 Models SJ40T, SJ45T 168894...
PIN C - 3002 WHITE PIN D - 3056 BLACK PIN F - 57A BROWN/GREEN PIN G - 76 BROWN/BLUE PIN H - 11 WHITE/ORANGE PINS (E,J,K,L,M,N,P,R,S) - N/U M144265AD Telescopic Boom Series SKYJACK, Page 69 Models SJ40T, SJ45T 168894...
SOCKET 2 - 11C (10GA) 11-18 BK 11-18 BK TO 86 11A-18 BK 11A-18 BK TO 85 11C-18 RD 11C-10 RD 11C-10 RD 11C-8 RD TO 87 11B-8 RD 11B-8 RD TO 30 M165028AB SKYJACK, Page 70 Telescopic Boom Series Models SJ40T, SJ45T 168894...
3.22 Glow Plug Harness (Deutz D2011 Diesel Engine) TO AIR BOX LEFT CYLINDER RELAY SOCKET DETAIL CENTRE CYLINDER RIGHT CYLINDER SOCKET #87 BASE CONTROL BOX TERMINAL BLACK - 54A STRIP TO ENGINE STARTER M138849AB Telescopic Boom Series SKYJACK, Page 71 Models SJ40T, SJ45T 168894...
POSITION 21 - PINK/WHITE POSITION 22 - PINK/PURPLE POSITION 22 - PINK/PURPLE POSITION 23 - BLUE/WHITE/RED POSITION 23 - BLUE/WHITE/RED POSITION 24 - BLUE/WHITE/YELLOW POSITION 24 - BLUE/WHITE/YELLOW FEMALE M138758AA1 Telescopic Boom Series SKYJACK, Page 73 Models SJ40T, SJ45T 168894...
JMPR (BLK) FRAME SCREW JMPR (WHT) TO EMERG. PUMP POWER STUD JMPR TO TEMPERATURE SWITCH CONNECTOR TO COOLER FAN CONNECTOR INSTALL UNDER COOLER MOUNTING BOLT GENERATOR TERMINAL CONSOLE M144106AE, M144107AE Telescopic Boom Series SKYJACK, Page 77 Models SJ40T, SJ45T 168894...
(WAS 09) TO 24 POLE PLUG "A" 161 (PINK/WH) POSITION #22 (WAS 09) 59CR 162A NEW DIODE D162B BASE CONTROLS MODIFICATION - AJ Models BASE CONTROLS MODIFICATION - T Models M166133AC Telescopic Boom Series SKYJACK, Page 79 Models SJ40T, SJ45T 168894...
8 PIN CONNECTOR DETAIL A USE SEALING PLUG FOR ALL UNUSED CONNECTOR, CAVITIES, FOR THE FOLLOWING PINS # 5, 6, 7, 8. TO MASTER DISCCONET (BATTERY SIDE) DETAIL A SCALE 4:1 M171104AA_M170989AB SKYJACK, Page 80 Telescopic Boom Series Models SJ40T, SJ45T 168894...
A52-18 BK A37-18 WH A48-16 BK A18-16 WH A33-16 BK A16-16 WH A05-16 BK A04-16 WH A46-16 BK A03-16 WH A32-16 BK A02-16 WH 00-12 WH 00-18 WH B+-12 RD M169631AB-2_4XT Telescopic Boom Series SKYJACK, Page 102 Models SJ40T, SJ45T 168894...
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4.1-40 No Platform Rotate Right from Platform Control Console ................126 4.1-41 No Jib Up from Platform Control Console....................126 4.1-42 No Jib Down from Platform Control Console ....................126 4.1-43 Throttle Inoperative, Mid and High (Deutz D2.9L only) ................127 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 103 168894...
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4.3-4 Load Cell red Alarm LED is OFF (with platform overloaded) .................141 4.3-5 Platform Indicator Light does not turn ON .....................141 4.3-6 Audible Alarm does not turn ON ........................141 4.3-7 Boom and Drive Functions are Enabled (with boom extended) ..............141 Telescopic Boom Series Models SJ40T, SJ45T Page 104 December 2007 168894...
“probable cause.” The following line, noted by a dash represents the “remedy” to the “probable cause” directly above it. See example below for clarification. 1. Probable Cause Remedy Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 105 168894...
6. Loose or broken wire #57A in boom cable B or its connectors. Check for continuity between pin #14 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 107 168894...
11. Loose or broken ground wire #00 from fuel pump to battery B-. Check continuity. Replace if defective. 12. Engine pre-heat circuit inoperative. Refer to Engine manufacturer’s manual to diagnose. NOTE For other engine related problems, consult engine manufacturer’s manual. Telescopic Boom Series Models SJ40T, SJ45T Page 108 December 2007 168894...
3. Loose or broken wire #02 from base terminal block to relay 57BCR. Check continuity. Replace if defective. 4. Defective relay 57BCR. Check relay. Replace if defective. 5. Glow plug circuit not operating. See “Glow Plug Circuit Inoperative” in this section. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 109 168894...
18. Loose or broken battery cable from starter solenoid 32BCR to starter motor. Check continuity. Replace if defective. 19. Defective starter motor. Check motor. Repair or replace if defective. Telescopic Boom Series Models SJ40T, SJ45T Page 110 December 2007 168894...
19. Loose or broken light blue/dark blue wire from ECU connector pin #6 to throttle actuator RA1. Check continuity. Replace if defective. 20. Loose or broken purple/light blue wire from ECU connector pin #5 to throttle actuator RA1. Check continuity. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 111 168894...
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39. Loose or broken white/black wire from ECU connector pin #75 to propane lock off 2P-56. Check continuity. Replace if defective. 40. Defective propane lock off 2P-56. Check lock off. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T Page 112 December 2007 168894...
8. Missing or broken jumper JMPR3 on base terminal block between wires #20 and #21. Check for jumper. Replace if missing or broken. NOTE Jumper is removed if equipped with generator option. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 113 168894...
4. Loose or broken wire #13 from base terminal block to turret harness plug pin #3. Check continuity. Replace if defective. 5. Loose or broken wire #13 from turret harness plug pin #3 to boom down valve 4H-13. Telescopic Boom Series Models SJ40T, SJ45T Page 114 December 2007 168894...
4. Loose or broken wire #38 from base terminal block to turret harness plug pin #12. Check continuity. Replace if defective. 5. Loose or broken wire #38 from turret harness plug pin #12 to telescope retract valve 3H-38. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 115 168894...
9. Loose or broken wire #02 from platform terminal block to platform rotate left valve 4H-36. Check continuity. Replace if defective. 10. Defective platform rotate left valve coil 4H-36. Check continuity and resistance through coil. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T Page 116 December 2007 168894...
4. Loose or broken wire #35A from diode D35-1 to resistor R2. Check continuity. Replace if defective. 5. Loose or broken wire #35 from jib up switch S17 to base connector plug A pin #17. Check continuity. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 117 168894...
Check continuity and resistance through coil. Replace if defective. 4.1-27 No Manual Platform Level Up From Base Control Console 1. Loose or broken wire #10A from ignition/ pump switch S5 to platform level switch S15. Telescopic Boom Series Models SJ40T, SJ45T Page 118 December 2007 168894...
Check continuity. Replace if defective. 11. Open diode D40 located in platform terminal block. Check diode. Replace if defective. 4.1-29 No Manual Platform Level Up From Platform Control Console Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 119 168894...
Check continuity. Replace if defective. 8. Loose or broken wire #04A from platform terminal block to footswitch S11. Check continuity. Replace if defective. 9. Open or defective footswitch S11. Telescopic Boom Series Models SJ40T, SJ45T Page 120 December 2007 168894...
Check continuity. Replace if defective. 13. Defective boom up valve coil 4H-14. Check continuity and resistance through coil. Replace if defective. 4.1-33 No Boom Down From Platform Control Console Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 121 168894...
9. Loose or broken wire #32 from base connector plug A pin #14 to base terminal block. Check continuity. Replace if defective. 10. Loose or broken wire #32 from base terminal block to turret harness plug pin #10. Telescopic Boom Series Models SJ40T, SJ45T Page 122 December 2007 168894...
2. Open or defective resistor R9. Check resistor. Replace if defective. 3. Loose or broken wire #38B from resistor R9 to telescope switch S18. Check continuity. Replace if defective. 4. Defective telescope switch S18. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 123 168894...
10. Loose or broken wire #39 from valve driver pin #12 to plug B pin #9 in platform control console. Check continuity. Replace if defective. 11. Loose or broken wire #39 in boom cable B or its connectors. Telescopic Boom Series Models SJ40T, SJ45T Page 124 December 2007 168894...
6. Loose or broken wire #36 or #02 from platform terminal block to rotate left valve 4H-36. Check continuity. Replace if defective. 7. Defective rotate left valve coil 4H-36. Check continuity and resistance through coil. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 125 168894...
6. Loose or broken wire #34 or #02 from platform terminal block to jib down valve 4H-34. Check continuity. Replace if defective. 7. Defective jib down valve coil 4H-34. Check continuity and resistance through coil. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T Page 126 December 2007 168894...
14. Loose or broken wire #103 from base terminal block to ECU connector pin #17. Check continuity. Replace if defective. 15. Defective relay 79CR. Check relay. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 127 168894...
14. Loose or broken wire #103 from base terminal block to ECU connector pin #17. Check continuity. Replace if defective. 15. Defective relay 78CR. Check relay. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T Page 128 December 2007 168894...
5. Loose or broken wire #5 in cable B or its connectors. Check for continuity between pins #5 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 129 168894...
8. Loose or broken wire #59 in boom cable B or its connectors. Check for continuity between pins #15 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. Telescopic Boom Series Models SJ40T, SJ45T Page 130 December 2007 168894...
5. Loose or broken wire #28 from plug B pin #7 to platform terminal block. Check continuity. Replace if defective. 6. Loose or broken wire #28 from platform terminal block to valve driver pin #18. Check continuity. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 131 168894...
7. Loose or broken wire #23A from base plug A pin #9 to base terminal block. Check continuity. Replace if defective. 8. Loose or broken wire #23A from base terminal block to turret harness plug pin #6. Check continuity. Replace if defective. Telescopic Boom Series Models SJ40T, SJ45T Page 132 December 2007 168894...
4. Defective relays 17ACR1 and 17ACR2. Check relay. Replace if defective. NOTE If only one relay is bad and one is OK, you will have steer in one di- rection only. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 133 168894...
Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective check valve CV5. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. Telescopic Boom Series Models SJ40T, SJ45T Page 134 December 2007 168894...
8. Turret rotate brake BR1 not releasing. Inspect brake for worn seals or broken components. Repair and replace as necessary. 9. Worn or defective swing drive motor M2. Check motor. Repair or replace if defective. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 135 168894...
4.2-9 No Jib Up 1. Stuck or defective proportional flow enable valve 2H-42. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. Telescopic Boom Series Models SJ40T, SJ45T Page 136 December 2007 168894...
Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 3. Stuck or defective brake valve 3H-26. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. Telescopic Boom Series Models SJ40T, SJ45T Page 138 December 2007 168894...
4.2-19 No Reverse Drive 1. Defective pump displacement control 4H-15. Check control. Replace if defective. 2. Defective or misadjusted drive relief valve RV7. See section 5 for drive pump set up procedures. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 139 168894...
Check seals on cylinder. Replace as necessary. Replace cylinder if defective. 3. Counterbalance valves (CB12 or CB13) out of adjustment or are defective. Clean valve. Check O-rings on valve. Repair or replace valve as required. Telescopic Boom Series Models SJ40T, SJ45T Page 140 December 2007 168894...
Readjust limit switch if necessary. 2. Defective load cell. Safety contact remains closed. Check for voltage (0V) between wires #162A and #02 from base terminal block. Defective if 12V is measured. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 141 168894...
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Notes Telescopic Boom Series Models SJ40T, SJ45T Page 142 December 2007 168894...
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5.4-4 Check Engine Belt ............................166 5.4-5 Check Oil Cooler ............................166 5.4-6 Deutz D2.9L Fault Codes ..........................167 GM Dual Fuel Engine 5.5-1 GM Map and IAT Sensor ..........................187 5.5-2 LPG Temperature Sensor ..........................188 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 143 168894...
- Active Function Being Used - Part Number and Serial Number - Restore the Factory Default Settings - Output Calibrations (Tresh, Max, Ramp.etc) - I-O Status - CANBus Status Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 145 168894...
SELECT MULTIFNCT MENU SELECT MULTIFNCT RESTORE DEFAULTS (FLASHING) PRESS SELECT STD LTD – SELECT (FLASHING) (FLASHING) SAVE NOTE EXIT USE THE CHART TO THE STD Machines for the North American market (ANSI/CSA models) LEFT TO DETERMINE THE LTD Machines for the European market (CE models) FUNCTIONALITY REQUIRED FOR YOUR MACHINE. PRESS SAVE/EXIT WHEN THE FUNCTIONALITY FOR YOUR MACHINE Recycle power to the OCM with E‐Stop to re‐enable password protection. CONFIGURATION IS If the OCM is inactive for more than 5 minutes, password must be re‐entered. FLASHING. Telescopic Boom Series Models SJ40T, SJ45T Page 148 December 2007 168894...
MENU 8V SENSOR SUPPLY VDD POWER SUPPLY ▬▬▬▬ VALUE = VOLTS VALUE = VOLTAGE SELECT OCM Operating Values Chart on page 147 for operating valves for the previous observations. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 149 168894...
THRESH Fn06B VALUE= % (FLASHING) Recycle power to the OCM with the E-Stop to re-enable password protection. If the OCM is inactive for more than 5 minutes, password must be re-entered. Telescopic Boom Series Models SJ40T, SJ45T Page 150 December 2007 168894...
Test between pin 9 and 02 wire while operating telescope in. Pin 10 - 12 volt output on wire 26 to brake valve 3H-26 to release brakes. Test between pin 10 and 02 wire. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 151 168894...
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0 volts to 7.5 volts depending on joystick position. Threshold= 1.5 volts. Test between pin 23 and 02 wire while operating reverse drive. Pin 24 - Battery negative. Wire 02. Pin 25 - Battery negative. Wire 02. Telescopic Boom Series Models SJ40T, SJ45T Page 152 December 2007 168894...
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Pin 35 - Turret rotate right selected. Proportional output on wire 33 to turret rotate right valve 4H-33. 0 volts to 5 volts depending on position of joystick. Threshold= .5 volts. Test between pin 10 and 02 wire while operating turret rotate right. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 153 168894...
New crossbars may be installed by snapping links together. Female Side Male Side Crossbar Cable Carrier Assembly 14. Lift and install link weldment pin #2 at cylinder end. Telescopic Boom Series Models SJ40T, SJ45T Page 156 December 2007 168894...
7. If there is damage (such as gouging) to the pad mating surfaces or any other part of the boom structure, contact Skyjack service. General locations of the wear pads Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 157 168894...
6. Extend and retract fly boom through the entire range of motion and observe for loose Shim points. Wear Pad NOTE Shim & Feeler Gauge Always maintain squareness between the boom’s outer and inner tubes. Telescopic Boom Series Models SJ40T, SJ45T Page 158 December 2007 168894...
8. Tighten mounting fasteners on swing drive Section 2. motor. 7. Rotate turret through an entire rotation and check for a smooth rotation of the turret. Fill to here Gearbox Fill Port Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 159 168894...
2. Remove plug at drain port to drain the oil. clamps make good contact) 3. Reinstall the drain plug. 4. Refill brake with hydraulic oil (2.7oz, VG32) 5. Reinstall plug at fill port. Telescopic Boom Series Models SJ40T, SJ45T Page 160 December 2007 168894...
Ensure part number of old and new tilt 61T/66T) and tighten mounting bolts with switch are the same. the same sequence. Remove old tilt switch from mount. Bolt Torque Sequence Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 161 168894...
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The green LED will flash and then the red LED will turn on solid for 2 seconds. Results: The switch is verifying the new zero position. Red LED Red LED Green LED Green LED Telescopic Boom Series Models SJ40T, SJ45T Page 162 December 2007 168894...
T h e Red LED Green LED Results: Both LEDs Green LED s w i t c h i s r e a d y will be OFF. for normal operation. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 163 168894...
Refer to section 2 for test tilt sensor procedure. axial movement in the bearing assembly. If this reading is 0.100” (2.54 mm) or greater, the rotation bearing should be removed and replaced. Telescopic Boom Series Models SJ40T, SJ45T Page 164 December 2007 168894...
13. Clean up any oil that may have spilled during this procedure. 14. Refill engine with new oil as per specifications (Refer to engine manual). 15. Swing engine tray back to its original position. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 165 168894...
2. Remove filters from inside of canister. 3. Clean inside of canister and gasket with a dry cloth. 4. Insert new filters inside of canister. 5. Reinstall end cap. Telescopic Boom Series Models SJ40T, SJ45T Page 166 December 2007 168894...
Burner dosing valve (DV2); Short circuit high side powerstage. 523912 7-2-2 Burner dosing valve (DV2) downstream pressure sensor; plausibility error. Physical range check high for burner dosing valve (DV2) downstream 523912 7-2-2 pressure; Shut off regeneration. 1513AA-1 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 167 168894...
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High coolant temperature; Warning threshold exceeded. 2-3-2 Coolant temperature; System reaction initiated. 2-3-5 Coolant level too low. 3-2-5 Plausibility check for clutch. 1109 3-4-1 Engine shut off demand ignored. 1513AA-2 Telescopic Boom Series Models SJ40T, SJ45T Page 168 December 2007 168894...
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Timeout error of CAN-Receive-Frame UAA10. AGS sensor service message. 523794 6-7-8 Timeout error of CAN-Receive-Frame UAA11. AGS sensor data. 523803 6-7-8 Timeout error of CAN-Receive-Message RxEngPres. Status Burner Air Pump. 1513AA-3 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 169 168894...
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Sensor error ambient air pressure. Signal range check high. 2-9-2 Sensor error ambient air pressure. Signal range check low. Environment temperature sensor, temperature above upper physical thresh- 3-1-2 old. 3-1-2 Environment temperature physical range check low. 1513AA-4 Telescopic Boom Series Models SJ40T, SJ45T Page 170 December 2007 168894...
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Short circuit to battery high side, HCI dosing valve (DV1). 523915 1-5-9 HCI dosing valve (DV1): Short circuit to ground. 523915 1-6-4 HCI dosing valve (DV1): Short circuit high side powerstage. 1513AA-5 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 171 168894...
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Special pattern for special cases. No detailed information! 523757 1-5-6 Special pattern for special cases. No detailed information! 523758 1-6-1 Special pattern for special cases. No detailed information! 1513AA-6 Telescopic Boom Series Models SJ40T, SJ45T Page 172 December 2007 168894...
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Diagnostic fault check to report ABE active due to undervoltage detection. 523612 5-5-5 Diagnostic fault check to report ABE active due to overvoltage detection. 523612 5-5-5 Diagnostic fault check to report WDA/ABE active due to unknown reason. 1513AA-8 Telescopic Boom Series Models SJ40T, SJ45T Page 174 December 2007 168894...
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Boost pressure control; negative governor deviation below limit. 523699 1-1-3 Learning value too high. No detailed information! Over temperature of device driver of pressure control valve. No detailed 523889 1-1-3 information! 1513AA-9 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 175 168894...
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Pressure sensor upstream turbine, signal range check (SRC) high. 1176 1-4-1 Pressure sensor upstream turbine, signal range check (SRC) low. 523613 1-3-4 Rail pressure metering unit, Positive governor deviation. 1513AA-10 Telescopic Boom Series Models SJ40T, SJ45T Page 176 December 2007 168894...
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Starter relay low side short circuit to battery. 5-1-2 Starter relay low side short circuit to ground. 523922 7-1-5 Burner shut of valve; short circuit to battery. 5-1-3 SVS lamp; open load. 1513AA-12 Telescopic Boom Series Models SJ40T, SJ45T Page 178 December 2007 168894...
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5-9-4 check low. Actuator position for EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8) not 1016 5-9-4 plausible. Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); signal range 1022 5-9-4 check high 1513AA-13 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 179 168894...
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Bad quality of reduction agent detected. 1193 1180 5-5-6 Physical range check high for exhaust gas temperature upstream turbine. 1194 1180 5-5-6 Physical range check low for exhaust gas temperature upstream turbine. 1513AA-14 Telescopic Boom Series Models SJ40T, SJ45T Page 180 December 2007 168894...
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Burner Control; Shut-off Valve - Blocked closed Burner Shut Off Valve; 1262 523922 8-5-4 blocked closed. Burner Control; Fuel line ShutOff downstream - broken Burner fuel line pipe 1263 524021 8-6-4 leak behind Shut Off Valve. 1513AA-15 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 181 168894...
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1338 2798 5-6-6 IVDiaShCirGndToutBnk_1. 1339 2797 5-6-5 Injector diagnostic; Short circuit to ground cylinder bank 0. 1340 2798 5-6-6 Injector diagnostic; Short circuit to ground cylinder bank 1. 1513AA-16 Telescopic Boom Series Models SJ40T, SJ45T Page 182 December 2007 168894...
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524029 8-1-5 recirculation positioner. 1436 524034 8-1-6 Disc separator; open load. 1437 524034 8-1-6 Disc separator; powerstage over temperature. 1438 524034 8-1-6 Disc separator; short circuit to battery. 1513AA-17 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 183 168894...
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Timeout ComIntake Throttle Valve Actr. 1672 524118 9-4-2 Timeout error of CAN-Receive-Frame ComRxCM1. 1675 524103 9-2-7 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp. 1676 524104 9-2-8 Timeout error of CAN-Receive-Frame ComRxDPFCtl. 1513AA-18 Telescopic Boom Series Models SJ40T, SJ45T Page 184 December 2007 168894...
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4-1-5 EGR actuator, learning process aborted. 1757 2791 4-1-5 EGR actuator current is above maximum threshold. 1758 2791 4-1-5 EGR actuator supply voltage is above the maximum threshold. 1513AA-19 Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 185 168894...
Negative supply to fuel pump TAN/BRN Propane selected Not used TAN/RED Not used DK BLU Not used TAN/BLK Not used PNK/BLK Negative supply to starter relay 57ACR PNK/TAN 12 volt input EMPTY 60594AB Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 191 168894...
Under normal use and operating conditions, the hydraulic oil should be changed every two years. Refer to Table 1.2 of this manual. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 193 168894...
15. Test the brake and two speed functions. 4. Locate brake system pressure reducing valve PR1. Loosen the lock nut and turn the adjustment stem gently clockwise 2 full turns. Telescopic Boom Series Models SJ40T, SJ45T Page 194 December 2007 168894...
2-5 minutes. 4. Check the reading on the gauge (standard pressure should be 330 psi) and follow the next steps for adjusting pressure if needed. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 195 168894...
4. Steer fully to one direction and then check the reading on the gauge. Standard pressure should be 3050 psi. Follow the next steps for adjusting pressure if needed. Telescopic Boom Series Models SJ40T, SJ45T Page 196 December 2007 168894...
5. Steer fully to one direction and then check the reading on the gauge. Standard pressure should be 3250 psi. Follow the next steps for adjusting pressure if needed. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 197 168894...
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You must fully raise or lower gauge. You must activate turret rotate to platform level to activate pressure reading obtain pressure reading on gauge. on gauge. 10. Disengage turret transport lock. Telescopic Boom Series Models SJ40T, SJ45T Page 198 December 2007 168894...
7. Tighten the lock nut on the fly boom relief valve RV4 once 1500 psi is observed on the gauge. You must fully extend boom to activate pressure reading on gauge. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 199 168894...
9. Remove pressure gauge from port, cap 9. Remove pressure gauge from port, cap the port and re-plug brake solenoid power the port and re-plug brake solenoid power cable. cable. Telescopic Boom Series Models SJ40T, SJ45T Page 200 December 2007 168894...
2. Turn main power disconnect switch to off position. Drive Torque Hub 3. Place suitable container under the axle. Fill and Check Drain 4. Remove fill plug. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 201 168894...
Gearbox is filled when oil is leaking from the check port. 7. Refill gearbox wi th new oi l as per specifications. (Refer to Section 2 of this manual) 8. Reinstall fill/check plug. Telescopic Boom Series Models SJ40T, SJ45T Page 202 December 2007 168894...
3. Apply a 2lb. force (1Kg) in the direction of brake application and turn adjusting stem 6. Introduce pressure into the cylinder and so that it touches the stop. ensure that the check unit engages. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 203 168894...
If the gap is smaller than 4.5 mm between the disks of either arm (i.e. the gauge doesn’t fit), the brake disks must be replaced on both arms. Telescopic Boom Series Models SJ40T, SJ45T Page 204 December 2007 168894...
Model Race Gear Mobil Mobillux EP2 Mobil Mobiltac C Texaco Multifax EP2 Texaco Crater 2X or 3X SJ40T / 45T Sun Prestige 742 EP Sun Gear Compound 407 SJ61T / 66T Shell Alvania EP2 Shell Cardium EP Exxon Ronex WB...
(Refer to the Table below) *GREASE Model Recommended Grease Type Mobil Mobillux EP2 Texaco Multifax EP2 SJ40T / 45T Sun Prestige 742 EP Shell Alvania EP2 Exxon Ronex WB Refer to Service and Maintenance manual for greasing frequency and procedures.
(Refer to the Table below) *GREASE Model Recommended Grease Type Mobil Mobillux EP2 Texaco Multifax EP2 SJ40T / 45T Sun Prestige 742 EP SJ61T / 66T Shell Alvania EP2 Exxon Ronex WB Refer to Service and Maintenance manual for greasing frequency and procedures.
5.10-1 Load Sensing System - CE The Skyjack boom platform overload sensing system is based on load cell or electronic scale technology. The deck steel structure is isolated from the aerial platform. The load cell is permanently bolted between the deck and the rotary actuator mount.
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8. Remove load from platform. Result: All drive and boom function are enabled and all warning indicators are OFF. NOTE Refer to Section 4 for load sensing system troubleshooting. Telescopic Boom Series Models SJ40T, SJ45T December 2007 Page 209 168894...
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Result: Green power LED is flashing, orange LED is ON, red alarm LED is OFF, audible alarm is OFF and red error LED is OFF. 14. Re-cap interface connector and place provided “calibrated” label over interface connector. Telescopic Boom Series Models SJ40T, SJ45T Page 210 December 2007 168894...
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