Skyjack SJ45 AJ+ Articulating Boom Lift Service Manual
269 pages · Publication 264830ABA
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- Models
- SJ45 AJ+
- Serial coverage
- SJ45 AJ+: A301102000-A301199999
- SJ45 AJ+: B301102000-B301199999
- Manual type
- Service Manual
- Pages
- 269
- Publication
- 264830ABA
- Condition
- Brand new
What's inside
From the manual's own table of contents: 5 sections, 198 entries. See sample pages (PDF, 722 KB)
Section 1 – Maintenance23 topics
- Read and Heed
- 1.1-1 Mobile Elevating Work Platform (MEWP) definition
- 1.1-2 Purpose of equipment
- 1.1-3 Use of equipment
- 1.1-4 Service Policy and Warranty
- 1.1-5 Ownership of MEWP
- 1.1-6 Optional equipment
- General information
- 1.2-1 Owner’s annual inspection record
- 1.2-2 Replacement parts
- 1.2-3 Maintenance and service safety tips
- 1.2-4 Hydraulic system & component maintenance and repair
- 1.2-5 Hydraulic oil maintenance
- 1.2-6 Hydraulic maintenance tips
- 1.2-7 Railing maintenance and repair
- 1.2-8 Multi-conduction control cable repair
- Scheduled maintenance and inspections
- 1.3-1 Service bulletins
- 1.3-2 Maintenance and inspections
- 1.3-3 Schedule and instructions
- 1.3-5 Pre-delivery/maintenance inspection checklist
- 1.3-6 Inspection points
- 1.3-7 Function tests
Section 2 – Maintenance Tables and Diagrams13 topics
- Standard Hose Numbering System
- Torque Specifications for Fasteners (Metric)
- Torque Specifications for Fasteners (US Imperial)
- Torque Specifications for Hydraulic Couplings & Hoses
- Axle Torque Specifications
- Axle Maintenance Intervals
- MEWP Torque Specifications
- Hydraulic Specifications
- MEWP Specifications
- Platform Capacities
- Fluids
- Engines
- Reach Diagram
Section 3 – System Component Identification and Schematics37 topics
- Electrical Symbol Chart
- Hydraulic Symbol Chart
- Wire Number and Colour Chart
- Hydraulic Parts List
- Electrical Parts List
- Brake Manifold Components and Ports
- Drive and System Pump Ports
- Drive Motor Ports
- Jib Valve Ports
- Main Manifold Ports
- Main Manifold Electrical Components
- Main Manifold Hydraulic Components
- Major Components
- Main Harness
- Engine Harness - D1305
- Engine Harness Wiring Diagram - D1305
- Engine Harness - WG972
- Engine Harness Wiring Diagram - WG972
- Jib and Platform Rotate Harness
- Limit Switch Connections
- SGE Connections - 2-wire version
- SGE Connections - 4-wire version
- Load Cell Connections
- Footswitch Connections
- CANbus Cable Connections
- Power Cable Connections
- All Motion Alarm Connections
- Flashing Amber Light Connections
- Positive Air Shut-off Harness - Kubota D1305
- Drive Pump Harness
- 3.31 7.5 kW Generator Connections
- Hydraulic Schematic
- Platform Control Box Wiring
- Base Control Box Wiring
- Electrical Schematic
- Engine Schematic - Kubota D1305
- Engine Schematic - Kubota WG972
Section 4 – Troubleshooting Information36 topics
- Introduction
- Electrical System
- 4.2-1 All Controls are Inoperative
- 4.2-2 All Controls Inoperative If Equipped with Elevate/Trackunit Telematics
- 4.2-3 All Functions Inoperative from Platform Control Console
- 4.2-4 All Functions Inoperative from Base Control Console
- 4.2-5 Missing Functions from Base Control Console (Missing Input from Base Controls)
- 4.2-6 Missing Functions from Platform Control Console (Missing Input from Platform Controls)
- 4.2-7 Missing Functions from Base and Platform Control Console (Missing Output to Function Coils)
- Hydraulic System
- 4.3-1 All Controls Inoperative
- 4.3-2 All Boom Functions Inoperative
- 4.3-3 No Main Boom Up
- 4.3-4 No Main Boom Down
- 4.3-5 No Riser Boom Up
- 4.3-6 No Riser Boom Down
- 4.3-7 Riser Boom Down Jerky
- 4.3-8 No Turret Rotate Left
- 4.3-9 No Turret Rotate Right
- 4.3-10 No Boom Extend
- 4.3-11 No Boom Retract
- 4.3-14 No Platform Rotation Right
- 4.3-15 No Platform Rotation Left
- 4.3-16 Platform will not Level Down Manually
- 4.3-17 Platform will not Level Up Manually
- 4.3-18 Brake will not Release
- 4.3-19 Brake will not Engage
- 4.3-20 Differential Lock will not Engage
- 4.3-21 No Drive Forward or Reverse
- 4.3-22 No Forward Drive
- 4.3-23 No Reverse Drive
- 4.3-24 No High Speed Drive
- 4.3-25 No Right Steer
- 4.3-26 No Left Steer
- 4.3-27 Axle Will Not Oscillate
- 4.3-28 Axle Will Not Lock
Section 5 – Procedures84 topics
- Safety and Workmanship
- Machine control systems
- 5.2-1 Controller locations
- 5.2-2 Joystick pin reference
- 5.2-3 Jib and platform switches voltage reference
- 5.2-4 Zapi GC9033 I/O expander module pin reference (platform control box)
- 5.2-6 NVR display module (base control box)
- 5.2-5 NVR display - User interface keys
- 5.2-7 NVR display - Pin reference
- 5.2-8 NVR display - Machine info menus
- 5.2-9 NVR display - Tester menu
- 5.2-10 NVR display - Tester menu table A
- 5.2-11 NVR display - Tester menu table B
- 5.2-12 NVR display - Parameter menu
- 5.2-13 NVR display - Parameter table A
- 5.2-14 NVR display - Parameter table B
- 5.2-15 NVR display - Machine setup menu
- 5.2-16 NVR display - Machine setup table A
- 5.2-17 NVR display - Machine setup table B
- 5.2-18 NVR display - Machine setup table C
- 5.2-19 NVR display - Engine menu
- 5.2-20 NVR display - Engine table
- 5.2-21 NVR display - Load cell calibration
- 5.2-22 Drive speed tests
- 5.2-23 Adjust the drive speeds
- 5.2-24 TTC-510 (CM1) machine controller pin reference (base control box)
- 5.2-25 TTC-510 (CM1) machine controller error codes
- Platform
- 5.3-1 Replace the load cell
- Boom
- 5.4-1 Check Wear Pads
- 5.4-2 Shim Wear Pads
- 5.4-3 Cable Carrier Repair
- 5.4-4 Rotary Actuator Bolt Torque Procedure
- 5.4-5 Master Cylinder Replacement
- Limit Switches
- 5.5-1 Limit Switch Locations and Trip Points
- Turret
- 5.6-1 Check and Replace the High Pressure Filter
- 5.6-2 Ring Gear Bolt Torque Sequence
- 5.6-3 Check the Ring Gear for Axial Wear
- 5.6-4 Battery Replacement
- 5.6-5 Tilt Switch Operation
- 5.6-6 Set Up a New Tilt Switch
- 5.6-7 Reprogram an Existing Tilt Switch
- Engines
- 5.7-1 Replace Engine Oil and Filter
- 5.7-2 Replace the Fuel Filter
- 5.7-3 Replace the Air Filter
- 5.7-4 Check the Engine Belt
- 5.7-6 Kubota D1305 Error Codes
- 5.7-7 Kubota WG972 Error Codes
- Generator
- 5.8-1 Tension the Generator Belt
- Hydraulic Tank
- 5.9-1 Hydraulic Oil Replacement
- 5.9-2 Hydraulic Filter Replacement
- Manifold and Hydraulic Pumps
- 5.10-1 Hydraulic Brake Pressure Adjustment
- 5.10-2 Hydraulic System Relief Valve Adjustment
- 5.10-3 Riser Down Relief Valve Adjustment
- 5.10-4 Turret Rotate Relief Valve Adjustment
- 5.10-5 Platform Level Relief Valve Adjustment
- 5.10-6 Test Charge Pump Pressure on Drive Pump
- 5.10-7 Test Forward Drive Pressure on Drive Pump
- 5.10-8 Test Reverse Drive Pressure on Drive Pump
- Axles
- 5.11-1 Change the Oil in the Axles
- 5.11-2 Check the Oil Level in the Torque Hubs
- 5.11-3 Change the Oil in the Torque Hubs
- 5.11-4 Check the Oil Level in the Axle Gearbox
- 5.11-5 Change the Oil in the Axle Gearbox
- 5.11-6 Oscillating Cylinder Mount Inspection
- 5.11-7 Oscillating Cylinder Bolt Replacement
- 5.11-8 Oscillating Cylinder Replacement
- 5.11-9 Bleed the Oscillating Axle Cylinders
- 5.11-10 Test the Oscillating Axle Cylinders
- 5.11-11 Pin Brake Adjustments
- 5.11-12 Brake Inspection
- 5.11-13 Axle U-Bolt Torque
- Grease Points
- 5.12-1 Grease the Turret Ring Gear
- 5.12-2 Grease the Axles
- 5.12-3 Grease the Drive Shaft
Inside this manual
Real pages from this service manual (269 pages). Open the sample pages (PDF, 721 KB)
- Specifications, page 29: Section 2 – Maintenance Tables and Diagrams
- Diagram, page 73: 3.29 Positive Air Shut-off Harness - Kubota D1305
- Troubleshooting, page 85: Section 4 – Troubleshooting Information
- Color page, page 107: Section 5 – Procedures
- Color page, page 235: Section 5 – Procedures
- Foldout diagram (color), page 78: 3.34 Base Control Box Wiring
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the SJ45 AJ+ are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
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This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 269 pages
Quantity one is the manual described above.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).