Skyjack SJ63AJ Articulating Booms Parts Manual 159762AG – PDF DOWNLOAD

PARTS MANUAL

ARTICULATING BOOMS MODEL SJ63AJ

159762AG November 2016

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This manual is based on Serial Numbers: SJ 63AJ: 95,300,001 to 95,300,267

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!

Articulating Boom Series Model SJ 63AJ 159762

SKYJACK, Page 3

Table of Contents 1.0 PLATFORM RELATED PARTS 1.1 Platform .................................................................................................................................................. 8 1.2 Railings ................................................................................................................................................. 10 1.3 Platform Base (ANSI/CSA) ................................................................................................................... 12 1.4 Platform Base (CE & AS)...................................................................................................................... 13 1.4 Gate Assembly - Swing ........................................................................................................................ 14 1.5 Drop Bar Gate ...................................................................................................................................... 16 1.7 Railing Extension (No Gate) ................................................................................................................. 18 1.8 Platform Control Console Assembly .................................................................................................... 20 1.9 Boom / Turret Controller Assembly ...................................................................................................... 24 1.10 Drive / Steer Controller Assembly ...................................................................................................... 26 1.11 Riser Boom Controller Assembly (Single Axis).................................................................................. 28 1.12 Platform Terminal Strip ....................................................................................................................... 29 2.0 BOOM RELATED PARTS 2.1 Riser Boom Assembly .......................................................................................................................... 32 2.2 Main and Fly Boom Assembly ............................................................................................................. 36 2.3 Jib Boom Assembly ............................................................................................................................. 42 2.4 Limit Switch Assemblies ....................................................................................................................... 44 2.5 Rotary Actuator Assembly .................................................................................................................... 46 3.0 CYLINDER RELATED PARTS 3.1 Riser Lift Assembly ............................................................................................................................... 48 3.2 Riser Boom Cylinder Assembly ........................................................................................................... 49 3.3 Main Boom Lift Cylinder Assembly ...................................................................................................... 50 3.4 Master Cylinder Assembly ................................................................................................................... 51 3.5 Slave Cylinder Assembly...................................................................................................................... 52 3.6 Axle Lock Cylinder Assembly ............................................................................................................... 53 3.7 Fly Boom Extension Cylinder Assembly .............................................................................................. 54 3.8 Jib Boom Cylinder Assembly ............................................................................................................... 56 4.0 TURRET RELATED PARTS 4.1 Turret Assembly .................................................................................................................................... 60 4.2 Cowling Assembly Mounting - Engine Side ........................................................................................ 62 4.3 Cowling Assembly Mounting - Controls Side ...................................................................................... 64 4.4 Cowling Assembly - Engine Side ......................................................................................................... 66 4.5 Cowling Assembly - Controls Side ...................................................................................................... 67 4.6 Counterweight Assembly ..................................................................................................................... 68 4.7 Additional Counterweight Assembly .................................................................................................... 69 4.8 Engine Tray Assembly .......................................................................................................................... 70 4.9 High Pressure Shuttle Valve Assembly ................................................................................................ 71 4.10 Main Manifold Assembly .................................................................................................................... 72 4.11 Brake Manifold Assembly................................................................................................................... 74 4.12 Fuel Tank Assembly - Deutz Engine .................................................................................................. 76 4.13 Fuel Tank Assembly - Dual Fuel Engine ............................................................................................ 79 4.14 Hydraulic Tank Assembly ................................................................................................................... 80 4.15 High Pressure Filter Assembly ........................................................................................................... 82 4.16 Turret Swing Drive Assembly ............................................................................................................. 83 4.17 Base Control Console Assembly ....................................................................................................... 84 4.18 Base Terminal Strip ............................................................................................................................ 88

SKYJACK, Page 4

Articulating Boom Series Model SJ 63AJ 159762

Table of Contents 4.19 Emergency Power Unit....................................................................................................................... 89 4.20 Battery Assembly................................................................................................................................ 90 4.21 Grease Line Hose Assembly .............................................................................................................. 91 5.0 ELECTRICAL HARNESS RELATED PARTS 5.1 Main Electrical Harness and Fuel Level Switch Harness..................................................................... 94 5.2 Lowering Throttle Valve Harness ......................................................................................................... 96 5.3 Deutz ECU Harness ............................................................................................................................. 97 5.4 Cable Harnesses .................................................................................................................................. 98 5.5 Control Cable Harnesses ................................................................................................................... 100 5.6 Glow Plug Harness - Deutz Engine.................................................................................................... 101 5.7 110/220V Outlet Assembly ................................................................................................................. 102 5.8 Engine Interface Harness - Dual Fuel Engine .................................................................................... 103 5.9 Rotate Select Harness ........................................................................................................................ 104 6.0 BASE RELATED PARTS 6.1 Base Assembly ................................................................................................................................... 106 6.2 Axle Assembly Hardware - Front........................................................................................................ 108 6.3 Axle Assembly Hardware - Rear......................................................................................................... 109 6.4 Front Axle Assembly........................................................................................................................... 110 6.5 Differential Assembly - Front Axle ...................................................................................................... 112 6.6 Central Housing Assembly - Front Axle ............................................................................................. 114 6.7 Steering Assembly - Front Axle .......................................................................................................... 115 6.8 Trunnion Assembly - Front Axle ......................................................................................................... 116 6.9 Axle Drive Shaft .................................................................................................................................. 117 6.10 Rear Axle Assembly (with Gear Box) ............................................................................................... 118 6.11 Differential Assembly - Rear Axle (with Gear Box) ........................................................................... 120 6.12 Central Housing Assembly - Rear Axle (with Gear Box).................................................................. 123 6.13 Gear Box - Rear Axle ........................................................................................................................ 124 6.14 Brakes Assembly - Front and Rear Axle .......................................................................................... 126 6.15 Rotary Manifold Assembly ............................................................................................................... 128 6.16 Propane Tank Assembly................................................................................................................... 130 6.17 Tire Assemblies ................................................................................................................................ 132 7.0 ENGINE RELATED PARTS 7.1 Engine Assembly - Deutz Engine....................................................................................................... 136 7.2 Engine Assembly - GM Engine .......................................................................................................... 140 7.3 Drive Pump and System Pump Assembly ......................................................................................... 144 7.4 Engine Coupling Assembly ................................................................................................................ 146 8.0 HOSE CONNECTION RELATED PARTS 8.1 Standard Hose Numbering System ................................................................................................... 148 8.2 Hydraulic Hose Connection - Turret ................................................................................................... 150 8.3 Hydraulic Hose Connection - Chassis ............................................................................................... 152 8.4 Hydraulic Hose Connection - Drive Pump and System Pump .......................................................... 154 8.5 Hydraulic Hose Connection - Boom .................................................................................................. 156 8.6 Fuel Line Connection - Deutz Engine ................................................................................................ 159 8.7 Fuel Line Connection - Dual Fuel Engine .......................................................................................... 160

Articulating Boom Series Model SJ 63AJ 159762

SKYJACK, Page 5

Table of Contents 9.0 OPTIONAL EQUIPMENT 9.1 Diesel Scrubber .................................................................................................................................. 164 9.2 All Motion Alarm ................................................................................................................................. 165 9.3 Air Hose to Platform ........................................................................................................................... 166 9.4 Hostile Environment Kit ...................................................................................................................... 168 9.5 Platform Control Box Cover ............................................................................................................... 170 9.6 Hydraulic Oil Cooler Assembly .......................................................................................................... 172 9.7 Hydraulic Hose Connection - Hydraulic Oil Cooler Assembly .......................................................... 173 9.8 Hydraulic Oil Cooler Wiring ................................................................................................................ 174 9.9 Generator Assembly (3,500W) ........................................................................................................... 176 9.10 Generator Assembly (12,000W) ....................................................................................................... 178 9.11 Hydraulic Hose Connection - Generator Assembly (3,500W) ......................................................... 180 9.12 Hydraulic Hose Connection - Generator Assembly (12,000W) ....................................................... 181 9.13 Generator Wiring .............................................................................................................................. 182 9.14 Welder and Mounting Assembly ...................................................................................................... 184 9.15 Glazier Package Assembly............................................................................................................... 188 9.16 Cold Start Assembly ......................................................................................................................... 190 9.17 Arctic Package Assembly ................................................................................................................. 191 9.18 Working Lights Assembly ................................................................................................................. 192 9.19 External Platform Railing Assembly ................................................................................................. 194 9.20 Pipe Rack Assembly......................................................................................................................... 196 9.21 Flashing Amber Light Assembly ...................................................................................................... 197 9.22 SGM Assembly ................................................................................................................................. 198 9.23 SGE Assembly.................................................................................................................................. 200 10.0 LABELS 10.1 Label Kits .......................................................................................................................................... 203 10.2 Labels - Platform Control Console ................................................................................................... 204 10.3 Labels - Front and Back ................................................................................................................... 205 10.4 Labels - Engine Side ........................................................................................................................ 206 10.5 Labels - Controls Side ...................................................................................................................... 208 10.6 Labels - Engine Compartment ......................................................................................................... 210 10.7 Labels - Controls Compartment ....................................................................................................... 211 10.8 Labels - Operator Platform ............................................................................................................... 212 11.0 TABLES 11.1 Boom Fluids Table ............................................................................................................................ 216 11.2 Boom Grease Locations - Axle Grease Table .................................................................................. 217 11.3 Boom Grease Locations - Gear Grease Table ................................................................................. 218

SKYJACK, Page 6

Articulating Boom Series Model SJ 63AJ 159762

1.0 PLATFORM RELATED PARTS

1 Platform Control 1.8 Console Assembly Swing Gate Assembly 1.5 Drop Bar Gate Assembly 1.6 Railing Extension Assembly 1.7

Railing Assembly 1.2

Platform Base Assembly 1.3 (ANSI/CSA) Platform Base Assembly 1.4 (CE & AS)

Articulating Boom Series Model SJ 63AJ 159762

SKYJACK, Page 7

1.1 Platform

AD

1

4

2

4

M166483AA

SKYJACK, Page 8

Articulating Boom Series Model SJ 63AJ 159762

1.1 Platform

AD 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

Articulating Boom Series Model SJ 63AJ 159762

Description

SKYJACK, Page 9

1.2 Railings

8

8

7

6

7

11 10 2 11

7

7

10 7

7

5

4

9

1

9 16 17 18 19 9 7 3

12 15

15 14

15 14 13

15

2 PLACES

6 PLACES M154309AB-Railings

SKYJACK, Page 10

Articulating Boom Series Model SJ 63AJ 159762

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 103865 103866 103984 103996 117293 103856 103995 115649

1 1 1 1 1 1 1 1 1 1 8 4 4 4 8 12 4 16 32 1 4 8 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”) BOLT, Hex head (5/16”-18 x 2” Grade 5) BOLT, Hex head (5/16”-18 x 2 1/4” Grade 5) NUT, Hex lock (5/16”-18 Grade 5, nylon) 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

Articulating Boom Series Model SJ 63AJ 159762

Description

SKYJACK, Page 11

1.3 Platform Base (ANSI/CSA)

1

2 4 3

5 6

M154309AB-Base

Index No.

Skyjack Part No.

Qty.

1

159431 154317 139193 138696 125959 102646 138559

1 1 8 1 8 1 1

2 3 4 5 6

SKYJACK, Page 12

Description

WELDMENT, Platform base (36” x 96”) WELDMENT, Platform base (36” x 72”) BOLT, Hex head patch (3/8”-16 x 7/8” Grade 8, Zinc) BOLT, Hex head (1”-8 x 10 1/2” Grade 8, Zinc) WASHER, Flat hardened (3/8”) WASHER, Flat (1”) NUT, Torque lock (1”-8 Grade C)

Articulating Boom Series Model SJ 63AJ 159762

1.4 Platform Base (CE & AS)

1 7 5

4 10

13

8

11 14 2

3

4 6

4 10

9 5

8

7 12 4 6

15

M154313AB-Base-2

Index No.

Skyjack Part No.

Qty.

A B

154292 154361

-

PLATFORM BASE ASSEMBLY (36” x 96”) PLATFORM BASE ASSEMBLY (36” x 72”)

1

154291 154310 144363 154289 104379 144329 144575 144502 144365 144574 138791 125959 102646 139193 138696 138559

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

• WELDMENT, Platform base (36” x 96”) • WELDMENT, Platform base (36” x 72”) • LOAD CELL, Moba • MOUNT, Rotary actuator • WASHER, Flat hardened (1/2”) • WASHER, Flat (M16) • BOLT, Hex head (1/2”-13 x 2 1/2” Grade 8, Zinc) • BOLT, Hex head patch (M16 x 1.5 x 45 Grade 8.8, Zinc) • WASHER, Safety • SPACER, Load cell • NUT, Torque lock (1/2”-13 Grade C) WASHER, Flat hardened (3/8”) WASHER, Flat (1”) BOLT, Hex head patch (3/8”-16 x 7/8” Grade 8, Zinc) BOLT, Hex head (1”-8 x 10 1/2” Grade 8, Zinc) NUT, Torque lock (1”-8 Grade C)

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

Articulating Boom Series Model SJ 63AJ 159762

Description

SKYJACK, Page 13

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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