Skyjack SJ40T SJ45T Telescopic Booms Parts Manual 170945AE – PDF DOWNLOAD

PARTS MANUAL

TELESCOPIC BOOMS MODELS SJ40T SJ45T

170945AE November 2016

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This manual is based on Serial Number(s): SJ40T / SJ45T: 98 001 501 to 98 001 766 Please refer to the website - www.skyjack.com for older Serial Numbers.

Skyjack Service Center

Parts & Service (Europe)

3451 Swenson Ave. St. Charles, Illinois, 60174 USA Phone: 630-262-0005 Toll Free: 1-800-275-9522 Fax: 630-262-0006 Email: service@skyjack.com

Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK Phone: +44-1691-676-235 Fax: +44-1691-676-238 E-mail: info@skyjackeurope.co.uk

Parts (North America)

Skyjack Brasil

Toll Free: 1-800-965-4626 Toll Free Fax: 1-888-782-4825 E-mail: parts@skyjack.com

Alameda Júpiter, 710 Loteamento American Park Empresarial Indaiatuba, SP, Brasil 13347-653 Tel: +55 19 3936 0132

Skyjack Australia Pty Ltd. 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel: +61 (0) 28786 3200 Fax: +61(0) 28786 3222

Telescopic Boom Series Parts Manual General The information contained in this section is designed to aid the user in locating and identifying replacement parts. Component parts of various assemblies and sub-assemblies comprising the work platform are illustrated and accompanied by a descriptive parts list.

Exploded drawings are used to show relative location of component parts in disassembly order. If a part cannot be found in this section, order by work platform model number and serial number, giving a complete description of the part.

Parts Ordering Information

an index number initially starts with the letter “K”, for example “K1”, means it’s a kit. Any item(s) included in a kit will not have an index number.

Quantities (Units Per Assyembly) The quantities of each part that are required to complete the assembly. If quantity is (AR), it is understood that the quantity may vary when machine is equipped with certain options. Order quantity as needed.

Hardware

When ordering replacement parts, the complete part number and description should be used to ensure proper identification and delivery of the desired item.

This complete identification should also be used when requesting equipment information.

Standard screws, washers, nuts, etc. are not identified by a reference number. These parts are known as COMMON HARDWARE items and appear indented under the major items with which they are used. They should be ordered separately as listed, since they are not component parts of the pieces they attach to.

Method Of Listing

How To Order Repair Parts

Parts are listed in order according to the reference number shown in the illustration, followed by a full description based upon the “NOUN FIRST” method.

That is, the noun name of the part is listed first, then the modifying description information which serves to specifically identify the item. For example: PIN, Clevis.

Assemblies or groups are shown at the beginning of a parts list and are identified with the letter references A, B, C, etc. Individual parts in these lists have corresponding letters after their description to identify which assembly or group it is used in. Individual parts without identifying letters are used in all the assemblies or group shown at the beginning of the parts list. Descriptions preceded with an (•) indicates a serviceable component or attaching hardware for the higher level assembly. If

1. Address all orders to your local SKYJACK dealer.

2. Specify model and serial number of the work platform (found on the serial number plate).

3. List the quantity needed.

4. List the length needed (if bulk item).

5. List the part number and description as shown in this manual for each item.

6. Show billing and shipping address and name of individual if possible.

7. Suggest best routing.

CUSTOMER___________________________________________________________________ DEALER______________________________________________________________________ MODEL NUMBER ______________________________________________________________ SERIAL NUMBER ______________________________________________________________ DATE PURCHASED ____________________________________________________________

Use Only Skyjack Authorized Replacement Parts!

Telescopic Boom Series Models SJ40T & SJ45T 170945

SKYJACK, Page 3

Table Of Contents 1.0 PLATFORM 1.1 Platform ................................................................................................................................................ 10 1.2 Railings ................................................................................................................................................. 12 1.3 Platform Base (ANSI/CSA) ................................................................................................................... 14 1.4 Platform Base (CE & AS)...................................................................................................................... 15 1.5 Swing Gate .......................................................................................................................................... 16 1.6 Drop Bar Gate ...................................................................................................................................... 17 1.7 Railing Extension (No Gate) ................................................................................................................. 18 1.8 Footswitch ............................................................................................................................................ 19 1.9 Platform Control Box ............................................................................................................................ 20 1.10 Boom / Turret Controller (Dual Axis) .................................................................................................. 24 1.11 Drive / Steer Controller (Single Axis) ................................................................................................. 26 1.12 Platform Terminal Strip ....................................................................................................................... 28

2.0 BOOM 2.1 Boom Assembly ................................................................................................................................... 30 2.2 Main & Fly Boom Assemblies .............................................................................................................. 32 2.3 E-Chain Assembly ................................................................................................................................ 34 2.4 Jib Lift / Platform Rotate Valve Assembly............................................................................................. 36 2.5 Jib Assembly - 45T ............................................................................................................................... 38 2.6 Rotary Actuator Mounting - 40T ........................................................................................................... 40 2.7 Rotary Actuator Assembly .................................................................................................................... 41 2.8 Extension Cylinder Support Assembly ................................................................................................ 42

3.0 CYLINDERS 3.1 Lift Cylinder Assembly .......................................................................................................................... 44 3.2 Extension Cylinder Assembly .............................................................................................................. 46 3.3 Master Cylinder Assembly ................................................................................................................... 48 3.4 Slave Cylinder Assembly...................................................................................................................... 49 3.5 Jib Cylinder Assembly .......................................................................................................................... 50 3.6 Axle Lockout Cylinder Assembly ......................................................................................................... 51

4.0 TURRET 4.1 Turret Assembly .................................................................................................................................... 54 4.2 Cowling Assembly - Engine Side ......................................................................................................... 56 4.3 Cowling Assembly - Controls Side ...................................................................................................... 58 4.4 Cowling Assembly - Centre .................................................................................................................. 60 4.5 Counterweight Assembly ..................................................................................................................... 61 4.6 Lift Cylinder Bracket Assembly ............................................................................................................ 62 4.7 High Pressure Filter Assembly ............................................................................................................. 63 4.8 Swing Drive Assembly.......................................................................................................................... 64 4.9 Boom Lift Limit Switch .......................................................................................................................... 65 4.10 Manifold Hardware ............................................................................................................................. 66 4.11 Main Manifold Assembly .................................................................................................................... 68 4.12 Brake Manifold ................................................................................................................................... 70 4.13 Rotary Manifold .................................................................................................................................. 72 4.14 Pressure Reducing Manifold ............................................................................................................. 75 4.15 Hydraulic Tank Assembly ................................................................................................................... 76 4.16 Fuel Tank - GM Dual Fuel Engine....................................................................................................... 78 SKYJACK, Page 4

Telescopic Boom Series Models SJ40T & SJ45T 170945

Table Of Contents 4.17 Fuel Tank - Kubota Duel Fuel Engine ................................................................................................. 80 4.18 Fuel Tank - Deutz Diesel Engine ........................................................................................................ 82 4.19 Auxiliary Pump Assembly ................................................................................................................... 84 4.20 Battery Assembly................................................................................................................................ 85 4.21 Base Control Box - Deutz D2.9L Engine ............................................................................................ 86 4.22 Base Control Box - Deutz D2011 Engine ........................................................................................... 90 4.23 Base Control Box - GM & Kubota Dual Fuel Engines ........................................................................ 94 4.24 Base Terminal Strip - Deutz D2.9L Engine ......................................................................................... 98 4.25 Base Terminal Strip - Deutz D2011, GM & Kubota Engines .............................................................. 99

5.0 ELECTRICAL HARNESSES 5.1 Main Electrical Harness ...................................................................................................................... 102 5.2 Battery Cables .................................................................................................................................... 104 5.3 Control Cables.................................................................................................................................... 106 5.4 Jib and Platform Rotate Harnesses ................................................................................................... 107 5.5 110/220V Outlet Cable ....................................................................................................................... 108 5.6 ECU Harnesses .................................................................................................................................. 109 5.7 Glow Plug Harness - Deutz D2.9L...................................................................................................... 110 5.8 Glow Plug Harness - Deutz D2011 .................................................................................................... 111 5.9 Engine Interface Harness - Deutz D2.9L ............................................................................................ 112 5.10 Engine Interface Harness - Kubota WG2503 ................................................................................... 114 5.11 Engine Interface Harness - GM Engine ........................................................................................... 116

6.0 BASE 6.1 Base Assembly ................................................................................................................................... 118 6.2 Axle Assembly Hardware ................................................................................................................... 120 6.3 Rear Axle Assembly with Gear Box .................................................................................................... 122 6.4 Differential Assembly .......................................................................................................................... 124 6.5 Central Housing Assembly................................................................................................................. 126 6.6 Gear Box - Rear Axle .......................................................................................................................... 128 6.7 Brakes - Rear Axle .............................................................................................................................. 130 6.8 Front Axle Assembly........................................................................................................................... 132 6.9 Differential Assembly .......................................................................................................................... 134 6.10 Central Housing Assembly............................................................................................................... 136 6.11 Steering Assembly ........................................................................................................................... 137 6.12 Trunnion Assembly ........................................................................................................................... 138 6.13 Axle Drive Shaft ............................................................................................................................... 139 6.14 Propane Tank Assembly................................................................................................................... 140 6.15 Tires .................................................................................................................................................. 142

7.0 ENGINES 7.1 Deutz D2.9L Engine ........................................................................................................................... 144 7.2 Deutz D2011 Engine .......................................................................................................................... 150 7.3 GM Dual Fuel Engine ......................................................................................................................... 152 7.4 Kubota WG2503 Dual Fuel Engine .................................................................................................... 156 7.5 Drive & System Pumps ...................................................................................................................... 164 7.6 Engine Coupling - Deutz .................................................................................................................... 166 7.7 Engine Coupling - Kubota WG2503 ................................................................................................... 167

Telescopic Boom Series Models SJ40T & SJ45T 170945

SKYJACK, Page 5

Table Of Contents 8.0 HOSE CONNECTIONS 8.1 Standard Hose Numbering System ................................................................................................... 170 8.2 Hydraulic Hose Connection - Cylinders............................................................................................. 172 8.3 Hydraulic Hose Connection - Control Compartment ........................................................................ 174 8.4 Hydraulic Hose Connection - Engine Compartment ......................................................................... 176 8.5 Hydraulic Hose Connection - Base and Axles ................................................................................... 178 8.6 Fuel Line Hose Connection - Deutz D2.9L Engine ............................................................................ 180 8.7 Fuel Line Hose Connection - Deutz D2011 Engine ........................................................................... 182 8.8 Fuel Line Hose Connection - GM Dual Fuel Engine .......................................................................... 184 8.9 Fuel Line Hose Connection - Kubota WG2503 Dual Fuel Engine ..................................................... 186 8.10 Propane Line Hose Connections - Kubota WG2503 Engine ........................................................... 188 8.11 Hydraulic Hose Connection - Turret Grease Fittings ....................................................................... 190

9.0 OPTIONAL EQUIPMENT 9.1 Air Hose To Platform Option ............................................................................................................... 194 9.2 Flashing Amber Light Option ............................................................................................................. 195 9.3 Generator and Oil Cooler - 3.5 kW..................................................................................................... 196 9.4 Oil Cooler Assembly ........................................................................................................................... 198 9.5 Generator Assembly - 3.5 kW ............................................................................................................ 199 9.6 Generator and Oil Cooler Wiring........................................................................................................ 200 9.7 Hydraulic Hose Connection - Generator and Oil Cooler - 3.5 kW..................................................... 202 9.8 Generator and Oil Cooler Assembly - 12 kW ..................................................................................... 204 9.9 Generator Assembly - 12 kW ............................................................................................................. 206 9.10 Hydraulic Hose Connection - Generator and Oil Cooler - 12 kW.................................................... 208 9.11 Welder and Mounting Assembly ...................................................................................................... 210 9.12 Cold Start Assembly ......................................................................................................................... 214 9.13 Arctic Package Assembly ................................................................................................................. 215 9.14 Cold Start & Arctic Packages - Load Circuit (Deutz D2.9L) ............................................................. 216 9.15 Block Heater - Deutz D2.9L .............................................................................................................. 218 9.16 Oil Quick Drain ................................................................................................................................. 219 9.17 Diesel Scrubber - Deutz D2011 Engine ........................................................................................... 220 9.18 External Railing Assembly ................................................................................................................ 221 9.19 Glazier Rack Assembly .................................................................................................................... 222 9.20 SGM Assembly ................................................................................................................................. 224 9.21 SGE Assembly.................................................................................................................................. 226 9.22 Control Box Cover ............................................................................................................................ 228 9.23 Positive Air Shut-Off Option.............................................................................................................. 230 9.24 Telematics - Morey ........................................................................................................................... 232 9.25 Telematics - ZTR ............................................................................................................................... 233

10.0 LABELS 10.1 Label Kit ............................................................................................................................................ 237 10.2 Labels - Platform Control Box .......................................................................................................... 238 10.3 Labels - Front and Back ................................................................................................................... 239 10.4 Labels - Engine Side ........................................................................................................................ 240 10.5 Labels - Controls Side ...................................................................................................................... 242 10.6 Labels - Controls Compartment ....................................................................................................... 244 10.7 Labels - Engine Compartment ......................................................................................................... 245 10.8 Labels - Engine Fuel ........................................................................................................................ 246 10.9 Labels - Platform............................................................................................................................... 248 SKYJACK, Page 6

Telescopic Boom Series Models SJ40T & SJ45T 170945

Table Of Contents 11.0 TABLES 11.1 Fluids ................................................................................................................................................ 252 11.2 Turret and Axle Grease ..................................................................................................................... 253 11.3 Gear Grease ..................................................................................................................................... 254 11.4 Filters ................................................................................................................................................ 255

Telescopic Boom Series Models SJ40T & SJ45T 170945

SKYJACK, Page 7

Notes

SKYJACK, Page 8

Telescopic Boom Series Models SJ40T & SJ45T 170945

1.0 PLATFORM

1

Platform Control Box 1.9 Boom/Turret Controller 1.10 Drive/Steer Controller 1.11 Platform Terminal Strip 1.12

1.1 Platform 1.7

Railing Extension (No Gate)

Railing Assembly 1.2

1.8 Footswitch

1.3 Platform Base (ANSI/CSA) 1.4 Platform Base (CE & AS) 1.5 Swing Gate 1.6 Drop Bar Gate

Telescopic Boom Series Models SJ40T & SJ45T 170945

SKYJACK, Page 9

1.1 Platform

1

4

2

4

M166483AA

SKYJACK, Page 10

Telescopic Boom Series Models SJ40T & SJ45T 170945

1.1 Platform Index No.

Skyjack Part No.

Qty.

A B C D E F G H

166483 166484 166485 166486 166487 166488 166489 166490

-

PLATFORM ASSEMBLY - 8’ Swing Gate (ANSI/CSA) PLATFORM ASSEMBLY - 8’ Swing Gate (CE & AS) PLATFORM ASSEMBLY - 8’ Drop Bar (ANSI/CSA) PLATFORM ASSEMBLY - 8’ Drop Bar (CE & AS) PLATFORM ASSEMBLY - 6’ Swing Gate (ANSI/CSA) PLATFORM ASSEMBLY - 6’ Swing Gate (CE & AS) PLATFORM ASSEMBLY - 6’ Drop Bar (ANSI/CSA) PLATFORM ASSEMBLY - 6’ Drop Bar (CE& AS)

1

(Ref.)

-

2

(Ref.)

-

3

(Ref.)

-

4

(Ref.)

-

• RAILING ASSEMBLY (For components, refer to Section 1.2) • PLATFORM BASE ASSEMBLY (For components, refer to Section 1.3) A, C, E, G (For components, refer to Section 1.4) B, D, F, H • GATE ASSEMBLY (For components, refer to Section 1.5) A, B, E, F (For components, refer to Section 1.6) C, D, G, H • RAILING EXTENSION (No Gate) (For components, refer to Section 1.7) A, B, E, F

Telescopic Boom Series Models SJ40T & SJ45T 170945

Description

SKYJACK, Page 11

1.2 Railings

8

8

7

6

7

11 10 2 11

7

7

10 7

7

5

4

9 12

1 17 18 19 20 9 12 7 3

13 16

16 15

16 15 14

16

2 PLACES

6 PLACES M154309AB-Railings

SKYJACK, Page 12

Telescopic Boom Series Models SJ40T & SJ45T 170945

1.2 Railings Index No.

Skyjack Part No.

Qty.

A B

154293 154334

-

RAILING ASSEMBLY (36” x 96”) RAILING ASSEMBLY (36” x 72”)

1

159581 154319 159585 154318 159583 154321 159584 154320 159586 149098 100702 103865 103632 103984 103996 700598 103865 103866 103984 103996 117293 103856 103995 115649

1 1 1 1 1 1 1 1 1 1 8 4 4 4 8 4 12 4 16 32 1 4 4 4

• WELDMENT, Railing (Left/Front) A • WELDMENT, Railing (Left/Front) B • WELDMENT, Railing (Right/Front) A • WELDMENT, Railing (Right/Front) B • WELDMENT, Railing (Left/Back) A • WELDMENT, Railing (Left/Back) B • WELDMENT, Railing (Right/Back) A • WELDMENT, Railing (Right/Back) B • PLATE, Front guard • RAILING, Front • CAP, Plastic end • BOLT, Hex head (5/16”-18 x 2” Grade 5) • SCREW, Hex head self-tapping (1/4”-14 x 3/4”) • NUT, Hex lock (5/16”-18 Grade 5, nylon) • WASHER, Flat (5/16”) • WASHER, Fender BOLT, Hex head (5/16”-18 x 2” Grade 5) BOLT, Hex head (5/16”-18 x 2 1/4” Grade 5) NUT, Hex head nylon lock (5/16”-18 Grade 5) WASHER, Flat (5/16”) MANUAL BOX BOLT, Hex head (1/4”-20 x 3/4” Grade 5) WASHER, Flat (1/4”) NUT, Hex lock (1/4”-20 Grade 5, nylon)

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Telescopic Boom Series Models SJ40T & SJ45T 170945

Description

SKYJACK, Page 13

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