Skyjack 37 004 671 Manuals

Manuals and User Guides for Skyjack 37 004 671. We have 1 Skyjack 37 004 671 manual available for free PDF download: Service Manual

Skyjack 37 004 671 Service Manual (154 pages)

Brand: Skyjack | Category: Lifting Systems | Size: 20 MB

Table of Contents
5
Section 1 - Scheduled Maintenance
11
Read and Heed
11
Aerial Platform and Mobile Elevating Work Platform Definition
11
Purpose of Equipment
11
Use of Equipment
11
Manual
11
Service Policy and Warranty
11
Operator Safety Reminders, Warnings and Precautions
11
Maintenance and Inspection Schedule
12
Owner's Annual Inspection Record
12
Replacement Parts
12
Maintenance and Service Safety Tips
12
Hydraulic System & Component Maintenance and Repair
13
Maintenance Hints
13
About this Section
14
Service Bulletins
14
Maintenance and Inspection
14
Maintenance Instructions
14
Owner's Annual Inspection Record
15
Scheduled Maintenance Inspections
17
Electrical
17
Hydraulic
17
Manuals (B)
18
Labels (B)
18
Limit Switches (B)
18
Engine Compartment
18
Hydraulic / Fuel Compartment
21
Platform Assembly
22
Lifting Mechanism
23
10 Base
27
Function Tests
29
Section 2 - Specifications
31
Specifications and Features
31
Floor Load Calculation
32
Floor Loading Pressure
33
Maximum Platform Capacities
33
Fluid Specifications
34
Torque Specifications
35
Torque Specifications for Fasteners (Imperial)
36
Torque Specifications for Fasteners (Metric)
37
Torque Specifications for Hydraulic Couplings & Hoses
38
Section 3 - System Component Identification and Schematics
39
Hydraulic Symbol Chart
40
Electrical Symbol Chart
41
AC Cord Color Code
42
Hydraulic Schematic Parts List
43
Electrical Parts List
45
Hydraulic Schematic S/N 37006450 and above
50
Hydraulic Schematic S/N 37006449 and below
51
Hydraulic Manifold Valve Port Identification
52
Hydraulic Manifold Valve Assemblies and Port Identification
53
Control Box Wiring Diagram
54
Outrigger / Hydraulic Generator Control Console Wiring Diagram
55
Scissor Arm Control Cable Wiring Diagram
56
Main Manifold Valve Harness Wiring Diagram
57
Kubota Engine Wiring Diagram - Dual Fuel System - S/N 37009728 and below
58
Kubota Engine Wiring Diagram - Dual Fuel System - S/N 37009729 and above
59
Kubota Engine Wiring Diagram (Diesel Fuel System)
60
Outrigger Harness Wiring Diagram
61
Hydraulic Generator Electrical Panel Assembly
62
All Motion Alarm Electrical Panel Diagram
63
Telematics Harness Wiring Diagram
64
Flashing Light Relay Harness
65
Electrical Panel Wiring Diagram S/N 37000235 and above
66
Electrical Panel Wiring Diagram S/N 37000234 and below
67
Electrical Panel Diagram with Positive Air Shut off Option S/N 37000235 and above
68
Electrical Panel Diagram with Positive Air Shut off Option S/N 37000234 and below
69
Positive Air Shut off Harness Wiring Diagram - Diesel Engine
70
Electrical Schematic (no Option with Kubota Dual Fuel Engine) S/N 37009565 and above
71
Electrical Schematic (no Option with Kubota Dual Fuel Engine) S/N 37000235 to 37009564
72
Electrical Schematic (no Option with Kubota Dual Fuel Engine) S/N 37000234 and below
73
Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37009565 and above
74
Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37000235 to 37009564
75
Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37000234 and below
76
Electrical Schematic (All Option with Kubota Diesel Engine) S/N 37000235 and above
77
Electrical Schematic (All Option with Kubota Diesel Engine) S/N 37000234 and below
78
Section 4 - Troubleshooting Guide
79
Introduction
79
Electrical System
80
All Controls Inoperative
80
No Power to Platform
80
All Functions Inoperative from the Platform
81
Engine will Not Crank from Platform or Base Control Console
81
Engine Cranks but Does Not Start - Kubota Diesel
82
Engine Cranks but Does Not Start - Kubota Dual Fuel
82
Glow Plugs Inoperative from Engine Controls or Platform (Diesel Models)
83
Choke Inoperative from Engine Controls or Platform (Kubota Dual Fuel)
84
High Throttle Inoperative
84
10 High Throttle on Demand Inoperative (Kubota Dual Fuel)
85
11 Drive and Steer Inoperative (Machines Without Outriggers Option)
86
12 Drive and Steer Inoperative (Machines with Outriggers Option)
87
13 Brakes Does Not Release
88
14 Steer Right Inoperative
88
15 Steer Left Inoperative
88
16 Reverse Drive Inoperative
88
17 Forward Drive Inoperative
89
18 First Drive Speed and Steering Inoperative
90
19 Second Drive Speed Inoperative
91
20 Third Drive Speed Inoperative
92
21 High Drive Speed Inoperative
92
22 Up Circuit Inoperative from Platform
93
23 Up Circuit Inoperative from Base Control Console
93
24 Up Circuit Inoperative from Platform or Base Control Console (Without Outriggers)
93
25 Platform Does Not Lift from Platform or Base Control Console with Outriggers Retracted (Lift Operates Correctly with Outriggers Extended)
94
26 Platform Does Not Lift from Platform or Base Control Console with Outriggers Extended
95
Retracted
96
28 Down Circuit Inoperative from Platform
96
29 Down Circuit Inoperative from Base
97
30 Hydraulic Generator Inoperative
97
31 Hydraulic Generator Does Not Shut off from Generator Switch
98
32 All Outriggers Inoperative (Auto-Level and Manual)
98
33 All Outriggers Inoperative (Auto-Level and Manual from Platform Controls)
99
34 All Outriggers Inoperative (Base Controls Only)
99
35 All Outriggers Inoperative (Auto Level Only)
99
36 All Outriggers Inoperative (Auto Level Only)
100
37 Left Front Outrigger Inoperative Manually
101
38 Right Front Outrigger Inoperative Manually
101
39 Right Rear Outriggers Inoperative Manually
101
40 Left Rear Outriggers Inoperative Manually
102
41 Individual Outrigger Functions Inoperative (Auto-Level)
102
42 Auto-Level Inoperative
103
43 Auto All up Inoperative (Retract)
103
Hydarulic System
104
All Functions Inoperative
104
Steering Inoperative
104
Lift, Steer and First Drive Speed Inoperative
104
Second Drive Speed Inoperative
104
Drive Inoperative
104
Drive Sluggish
104
Reverse Drive Inoperative
105
Forward Drive Inoperative
105
Drive Inoperative When in Low Drive
105
10 Drive Inoperative When in High Drive
105
11 Brakes Does Not Release
105
12 Up Circuit Inoperative
105
13 Down Circuit Inoperative
105
14 Hydraulic Generator Inoperative
106
15 All Outriggers Inoperative
106
16 Left Front Outriggers Inoperative
106
17 Right Front Outriggers Inoperative
106
18 Right Rear Outriggers Inoperative
106
19 Left Rear Outriggers Inoperative
106
20 Outriggers Drift in
106
Section 5 - Service Procedures
109
General
109
Safety and Workmanship
109
Platform
110
Adjust the Gate Spring Hinge
110
Platform Mounting Hardware
110
Scissors
111
Replace and Adjust the High Speed Cutout Limit Switch (LS5)
111
Test the High Speed Cutout Limit Switch
112
Engine
113
Kubota Dual Fuel (DF972 / WG752) Resistance Checks
113
Kubota Dual Fuel (DF972/WG752) Engine Throttle Setting
114
Kubota Diesel D902 Engine Throttle Setting
115
Replace the Fuel Filter Element - Kubota D902
117
Bleed the Fuel System of Air - Kubota D902
117
Replace and Adjust the Fan Belt
118
Replace the Air Cleaner Element
119
Replace the Oil Filter Cartridge
119
Change the Oil
120
10 Check and Replenish the Radiator Coolant Level
120
11 Drain and Refill the Radiator
121
Base
122
Inspect and Torque the Wheel Bolts and Nuts
122
Install and Torque the Wheels
122
Grease Points
123
Reconnect the Platform Control Box for Use from the Ground
124
Electronic Tilt Switch Set up Procedure
125
Hydraulics
128
Tightening and Torque Recommendations for Hydraulic Couplings and Hoses
128
Do a Check of the Holding Valve
129
Set the System Pressure
130
Set the Lift Pressure
131
Drive Circuit Flush Procedure
132
Drive Pressure and Wheel Motor Tests
133
Drive Motor Test
133
System Pressure Test
133
Drive Pressure Test
133
Outriggers
134
Outrigger Mechanical Limit Switch Wiring Diagram
134
Replace and Adjust the Outrigger Upper Limit Switches (LS61, LS62, LS63, LS64)
135
Replace and Adjust the Outrigger Lower Limit Switches (LS65, LS66, LS67, LS68)
136
Ezcal Diagnostic Tool
137
Hand Held Ezcal Calibration and Diagnostic Tool Key Functions
137
Flash the Controller
138
Outrigger Codes
139
OCM1 Control Module
140
Auto-Leveling Outrigger PC Board Layout
140
Outrigger Control Module (OCM1) Instructions
141
Auto-Leveling Outrigger Settings and Error Codes
144
Auto-Leveling Outrigger Error Code Breakdown
145
Control Module
146
Set up the GP-106 Outrigger Controller
146
GP-106 Outrigger Controller Pin Reference Table
147
Control Module
148
Set up the GP-108 Outrigger Controller
148
GP-108 Outrigger Controller Pin Reference Table
150
LED Error Codes
152

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Skyjack 37 004 671 Service Manual (154 pages)

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