Skyjack SJ46AJ SJ51AJ Articulating Booms Parts Manual 163265AF – PDF DOWNLOAD

PARTS MANUAL

ARTICULATING BOOMS MODELS SJ46AJ SJ51AJ

163265AF November 2016

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This manual is based on Serial Numbers: SJ SJ 46AJ / SJ 51AJ: 95,000,510 to 95,000,656 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

Articulating 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 Assy.)

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!

Table of Contents 1.0 PLATFORM RELATED PARTS 1.1 Platform Railing Assembly - Side Gate .................................................................................................. 8 1.2 Platform Base Assembly (ANSI/CSA) .................................................................................................. 10 1.3 Platform Base Assembly (CE&AS) ....................................................................................................... 11 1.4 Platform Footswitch Assembly ............................................................................................................. 12 1.5 Platform Gate Assembly ....................................................................................................................... 13 1.6 Platform Control Console Assembly .................................................................................................... 14 1.7 Boom / Turret Controller Assembly (Dual Axis) ................................................................................... 18 1.8 Drive / Steer Controller Assembly (Single Axis)................................................................................... 20 1.9 Riser Boom Controller Assembly (Single Axis).................................................................................... 22 1.10 Platform Terminal Strip ....................................................................................................................... 23 2.0 BOOM RELATED PARTS 2.1a Main Boom Assembly ........................................................................................................................ 26 2.1b Main Boom Assembly ........................................................................................................................ 28 2.2 Main & Riser Boom Limit Switches ...................................................................................................... 30 2.3 Fly Boom Assembly ............................................................................................................................. 31 2.4a Riser Boom Assembly ........................................................................................................................ 32 2.4b Riser Boom Assembly ........................................................................................................................ 36 2.5 Power Track Carrier Assembly ............................................................................................................. 40 2.6 Jib Boom Assembly ............................................................................................................................. 42 2.7 Jib Lift / Platform Rotate Valve Assemblies .......................................................................................... 44 2.8 Rotary Actuator Hardware .................................................................................................................... 46 3.0 CYLINDER RELATED PARTS 3.1 Fly Boom Extension Cylinder Assembly .............................................................................................. 48 3.2 Main Boom Lift Cylinder Assembly ...................................................................................................... 50 3.3 Riser Lift Assembly ............................................................................................................................... 51 3.4 Riser Cylinder Assembly ...................................................................................................................... 52 3.5 Master Cylinder Assembly ................................................................................................................... 53 3.6 Slave Cylinder Assembly...................................................................................................................... 54 3.7 Jib Cylinder Assembly .......................................................................................................................... 55 3.8 Axle Lock Cylinder Assembly ............................................................................................................... 56 4.0 TURRET RELATED PARTS 4.1 Turret Assembly ................................................................................................................................... 58 4.2 Cowling Assembly - Engine Side ......................................................................................................... 60 4.3 Cowling Assembly - Controls Side ...................................................................................................... 62 4.4 Counterweight Assembly ..................................................................................................................... 65 4.5 Engine Tray Assembly .......................................................................................................................... 66 4.6 Main Manifold Assembly ...................................................................................................................... 68 4.7 Brake Manifold Assembly..................................................................................................................... 72 4.8 Rotary Manifold Assembly ................................................................................................................... 74 4.9 Turret Swing Drive Assembly ............................................................................................................... 76 4.10 Fuel Tank Assembly (Deutz Engine) .................................................................................................. 77 4.11 Fuel Tank Assembly (GM Dual Fuel Engine) ..................................................................................... 78 4.12a Hydraulic Tank Assembly ................................................................................................................. 80 4.12b Hydraulic Tank Assembly ................................................................................................................. 82 4.13a High Pressure Filter Assembly ......................................................................................................... 84 4.13b High Pressure Filter Assembly ......................................................................................................... 85

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Articulating Boom Series Models SJ 46AJ & 51AJ 163265

Table of Contents 4.14 Charge Pump Filter Assembly ........................................................................................................... 86 4.15 15 Degrees Limit Switch Assembly .................................................................................................... 87 4.16 Grease Line Hose Assembly .............................................................................................................. 88 4.17 Battery Assembly................................................................................................................................ 89 4.18 Emergency Power Unit....................................................................................................................... 90 4.19 Base Control Console Assembly (Deutz) .......................................................................................... 92 4.20 Base Control Console Assembly (GM) .............................................................................................. 96 4.21 Base Terminal Strip ............................................................................................................................ 98 5.0 ELECTRICAL HARNESS RELATED PARTS 5.1 Main Electrical Harness and Fuel Level Switch Harness................................................................... 100 5.2 Cable Harnesses ................................................................................................................................ 102 5.3 Control Cable Harnesses ................................................................................................................... 104 5.4 Valve Harness and Limit Switches ..................................................................................................... 105 5.5 110/220V Outlet Assembly ................................................................................................................. 106 5.6 ECU Harnesses ................................................................................................................................. 107 5.7 Glow Plug Harness (Deutz Diesel Engine) ........................................................................................ 108 5.8 Engine Interface Harness (GM Dual Fuel Engine) ............................................................................. 109 6.0 BASE RELATED PARTS 6.1 Base Assembly ................................................................................................................................... 112 6.2 Axle Assembly Hardware ................................................................................................................... 113 6.3 Rear Axle Assembly with Gear Box .................................................................................................... 114 6.4 Differential Assembly - Rear Axle Assembly with Gear Box .............................................................. 116 6.5 Brakes Assembly - Rear Axle ............................................................................................................. 118 6.6 Central Housing Assembly - Rear Axle Assembly with Gear Box ..................................................... 120 6.7 Gear Box - Rear Axle .......................................................................................................................... 122 6.8 Hydraulic Drive Motor......................................................................................................................... 124 6.9 Front Axle Assembly........................................................................................................................... 126 6.10 Differential Assembly - Front Axle .................................................................................................... 128 6.11 Central Housing Assembly - Front Axle ........................................................................................... 130 6.12 Steering Assembly ........................................................................................................................... 131 6.13 Trunnion Assembly - Front Axle ....................................................................................................... 132 6.14 Axle Drive Shaft (4WD) ..................................................................................................................... 133 6.15 Propane Tank Assembly................................................................................................................... 134 6.16 Tires .................................................................................................................................................. 136 7.0 ENGINE RELATED PARTS 7.1 Engine Assembly (Deutz Diesel)........................................................................................................ 140 7.2 Engine Coupling Assembly ................................................................................................................ 145 7.3 Engine Assembly (GM Dual Fuel) ...................................................................................................... 146 7.4 Drive and System Pump Assembly.................................................................................................... 150 7.5 Drive and System Pump Assembly (with Welder Option) ................................................................. 152 8.0 HOSE CONNECTION RELATED PARTS 8.1 Standard Hose Numbering System ................................................................................................... 156 8.2 Hydraulic Hose Connection - Boom Cylinders .................................................................................. 158 8.3 Hydraulic Hose Connection - Control Compartment ........................................................................ 160 8.4 Hydraulic Hose Connection - Engine Compartment ......................................................................... 162 8.5 Fuel Line Hose Connection - Deutz Diesel Engine ............................................................................ 164 8.6 Fuel Line Hose Connection - GM Dual Fuel Engine .......................................................................... 166

Articulating Boom Series Models SJ 46AJ & 51AJ 163265

SKYJACK, Page 5

Table of Contents

9.0 OPTIONAL EQUIPMENT 9.1 All Motion Alarm Assembly ............................................................................................................... 172 9.2 Air Hose To Platform Option ............................................................................................................... 173 9.3 Working Light Option - ANSI/CSA...................................................................................................... 174 9.4 Flashing Amber Light Option ............................................................................................................. 175 9.5 Cold Start Option - ANSI/CSA ............................................................................................................ 176 9.6 Rotary Actuator - Arctic Package ....................................................................................................... 177 9.7 Arctic Package Option (Deutz Diesel Engine) ................................................................................... 178 9.8 Arctic Package Option (GM Dual Fuel Engine) ................................................................................. 179 9.9 Generator with Oil Cooler Option - 3500W (SJ46AJ) ........................................................................ 180 9.10 Diesel Scrubber Option .................................................................................................................... 182 9.11 Hydraulic Hose Connection - Generator (SJ 46AJ) ......................................................................... 183 9.12 Generator with Oil Cooler Option - 3500W (SJ51AJ) ...................................................................... 184 9.13 Hydraulic Hose Connection - 3500W Generator (SJ 51AJ) ............................................................ 186 9.14 Generator Wiring (3500W) ............................................................................................................... 187 9.15 Oil Cooler Wiring .............................................................................................................................. 188 9.16 Welder Option (SJ 46AJ) .................................................................................................................. 190 9.17 Generator with Oil Cooler Option -12kW (SJ 46AJ with Welder Option) ........................................ 192 9.18 Circuit Breaker Assembly - 12kW Generator ................................................................................... 194 9.19 12kW Generator Wiring .................................................................................................................... 196 9.20 Hydraulic Hose Connections - 12kW Generator & Oil Cooler (SJ 46AJ) ........................................ 198 9.21 Glazier Package Assembly............................................................................................................... 200 9.22 External Platform Railing Assembly ................................................................................................. 202 10.0 LABELS 10.1 Label Kits .......................................................................................................................................... 205 10.2 Labels - Platform Control Console ................................................................................................... 206 10.3 Labels - Front and Back ................................................................................................................... 207 10.4 Labels - Engine Side ........................................................................................................................ 208 10.5 Labels - Controls Side ...................................................................................................................... 210 10.6 Labels - Controls Compartment ....................................................................................................... 212 10.7 Labels - Engine Compartment ......................................................................................................... 213 10.8 Labels - Operator Platform ............................................................................................................... 214 10.9 Labels - Fuel ..................................................................................................................................... 216 11.0 TABLES 11.1 Boom Fluids Table ............................................................................................................................ 218 11.2 Boom Grease Locations - Axle Grease Table .................................................................................. 219 11.3 Boom Grease Locations - Gear Grease Table ................................................................................. 220

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Articulating Boom Series Models SJ 46AJ & 51AJ 163265

1.0 PLATFORM RELATED PARTS

1 1.6

Platform Control Console

Gate Assembly 1.5

Side Gate Railing Assembly 1.1 (Includes manual box)

Platform Base Assembly 1.2 (ANSI/CSA) Platform Base Assembly 1.3 (CE) Footswitch Assembly 1.4

Articulating Boom Series Models SJ 46AJ & 51AJ 163265

SKYJACK, Page 7

1.1 Platform Railing Assembly - Side Gate

11 10 9

3

5

3

5

3 15

19 18 17 8 9

3

5

3

12 3

4

13

10 14 2 3 4 3

5

3

5

7

16 17 18 19 7 8

3

3

1

5

2

6 18 19

3

2 3 2

3

5

4

3

M148531AA

SKYJACK, Page 8

Articulating Boom Series Models SJ 46AJ & 51AJ 163265

AC

1.1 Platform Railing Assembly - Side Gate

Index No.

Skyjack Part No.

Qty.

A B C D

148868 148966 149490 149077

1 1 1 1

SIDE GATE PLATFORM ASSEMBLY (72” x 30”, ANSI/CSA) SIDE GATE PLATFORM ASSEMBLY (72” x 30”, CE & AS) SIDE GATE PLATFORM ASSEMBLY (60” x 30”, ANSI/CSA) SIDE GATE PLATFORM ASSEMBLY (60” x 30”, CE & AS)

1

149183 149171 103865 103996 103866 157770 104000 122006 148869 149083 139008 100702 149098 138697 103632 148872 149085 149172 117293 115649 103856 103995

1 1 12 52 6 28 6 4 1 1 4 7 1 1 6 1 1 1 1 8 14 18

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

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

Articulating Boom Series Models SJ 46AJ & 51AJ 163265

Description

SKYJACK, Page 9

1.2 Platform Base Assembly (ANSI/CSA)

2 3 4

5 6

1

M149239AA

Index No.

Skyjack Part No.

Qty.

1

149239 149491 139193 125959 138696 102646 138559

1 1 8 8 1 1 1

2 3 4 5 6

SKYJACK, Page 10

Description

WELDMENT, Platform base (72” x 30”, ANSI/CSA & AS) WELDMENT, Platform base (60” x 30”, ANSI/CSA & AS) BOLT, Hex head patch (3/8”-16 x 7/8” Grade 8, zinc) WASHER, Flat (3/8”) BOLT, Hex head (1”-8 x 10 1/2” Grade 8, zinc) WASHER, Flat (1”) NUT, Crownlock (1”-8 Grade 8)

Articulating Boom Series Models SJ 46AJ & 51AJ 163265

1.3 Platform Base Assembly (CE&AS) 1

5

4

11 12 9 13

3 7

8

2

10

7

6

6

7

4

5

14 15

Index No.

Skyjack Part No.

Qty.

1

148947 149078 148959 144363 144502 144329 144575 104379 144574 144365 138791 139193 125959 138696 102646 138559

1 1 1 1 8 8 4 8 4 2 4 8 8 1 1 1

2 3 4 5 6 7 8 9 10 11 12 13 14 15

Articulating Boom Series Models SJ 46AJ & 51AJ 163265

M148966AA-2

Description

WELDMENT, Platform base (72” x 30”, CE & AS - side gate) WELDMENT, Platform base (60” x 30”, CE & AS - side gate) MOUNTING, Rotary actuator LOAD CELL BOLT, Hex head patch (M16 x 1.5 x 45 Grade 8.8, ZP) WASHER, Flat hardened (M16) BOLT, Hex head (1/2”-13 x 2 1/2” Grade 8, ZP) WASHER, Flat hardened (1/2”) SPACER, Load cell WASHER, Safety NUT, Torque lock (1/2”-13, Grade C) BOLT, Hex head patch (3/8”-16 x 7/8” Grade 8, ZP) WASHER, Flat hardened (3/8”) BOLT, Hex head (1”-8 x 10 1/2 Grade 8, zinc) WASHER, Flat (1”) NUT, Crownlock (1”-8 Grade 8)

SKYJACK, Page 11

1.4 Platform Footswitch Assembly

2

3

4

1 7 6

8

9 10

5

M138721AB2

Index No.

Skyjack Part No.

Qty.

-

138721

-

FOOTSWITCH ASSEMBLY

1 2 3 4 5 6 7 8 9 10

700187 138374 138373 138372 300831 130017 156451 103856 700598 115649

1 1 1 1 2 2 1 4 4 4

• FOOTSWITCH • PLUG, 3 Pole screw (10A) • STRAIN RELIEF (M20) • HOOD, Top 7 pole (M20) • SCREW, Flat head machine (#10-32 x 5/8”) • NUT, K-lock (#10-32, zinc) • COVER, Footswitch BOLT, Hex head (1/4”-20 x 3/4” Grade 5) WASHER, Fender NUT, Hex lock (1/4”-20 Grade 5, nylon)

SKYJACK, Page 12

Description

Articulating Boom Series Models SJ 46AJ & 51AJ 163265

1.5 Platform Gate Assembly

5 1

9

8

7

6

5

4

3

2 M149089AA

Index No.

Skyjack Part No.

Qty.

-

149089

1

GATE ASSEMBLY

1 2 3 4 5 6 7 8 9

149090 138695 144048 139641 100702 117277 103856 104000 103995

1 1 1 6 2 2 6 6 6

• • • • • • • • •

Articulating Boom Series Models SJ 46AJ & 51AJ 163265

Description

WELDMENT, Gate LOCK, Cabin CAP, Round end RIVET, Pop (1/4”) CAP, Plastic end HINGE, Stanley spring BOLT, Hex head (1/4”-2 x 3/4” Grade 5) WASHER, Lock (1/4”) WASHER, Flat (1/4”)

SKYJACK, Page 13

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL