Skyjack SJ60AJ+ User manual

SERVICE
MANUAL
ARTICULATING BOOMS
238275AAA
March 2021
ANSI/CSA, CE, AS
SJ60AJ+
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This manual is for MEWPs with serial numbers:
SJ60 AJ+: A302 100 001 - A302 199 999
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SJ60AJ+ 238275AAA
The Safety Alert Symbol identifies important safety
messages on MEWPs, safety signs in manuals or
elsewhere. When you see this symbol, be alert to
the possibility of personal injury or death. Follow the
instructions in the safety message.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert
against unsafe practices.
IMPORTANT
IMPORTANT indicates a procedure essential for
safe operation and which, if not followed, may
result in a malfunction or damage to the MEWP.
THIS SAFETY ALERT SYMBOL MEANS ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED.
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SJ60AJ+ 238275AAA
Section 1 – Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Read and Heed ...................................................................13
1.1-1 Mobile Elevating Work Platform (MEWP) Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1-2 Purpose of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1-3 Use of Equipment ..............................................................13
1.1-4 Manual ......................................................................13
1.1-5 Service Policy and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1-6 Operator Safety Reminders, Warnings and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Maintenance and Service ...........................................................14
1.2-1 Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2-2 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2-3 Replacement Parts .............................................................14
1.2-4 Maintenance and Service Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2-5 Hydraulic System & Component Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2-6 Hydraulic Maintenance Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2-7 Railing Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Scheduled Maintenance ............................................................17
1.3-1 Service Bulletins ...............................................................17
1.3-2 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3-3 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Pre-Delivery/Maintenance Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.6 Scheduled Maintenance Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1.6-1 Electrical .....................................................................20
1.6-2 Hydraulic .....................................................................20
1.6-3 Labels .......................................................................20
1.6-4 Limit switches .................................................................20
1.6-5 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.6-6 Base ........................................................................26
1.6-7 Platform .....................................................................28
1.6-8 Boom Assembly ...............................................................29
1.6-9 Optional equipment ............................................................30
1.7 Function Tests ....................................................................31
Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Standard Hose Numbering System ...................................................33
2.2 Torque Specifications for Fasteners (US Imperial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Table of Contents
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2.4 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.5 Axle Torque Specifications ..........................................................38
2.6 Axles Maintenance Intervals .........................................................39
2.7 MEWP Torque Specifications ........................................................40
2.8 Maximum Platform Capacity .........................................................41
2.9 Tire Specifications .................................................................41
2.10 Floor Loading Pressure .............................................................42
2.11 Hydraulic Specifications ............................................................43
2.12 Fluids ...........................................................................44
2.13 Engines .........................................................................44
2.14 MEWP Specifications ..............................................................45
2.15 Platform Capacities ................................................................46
2.16 Reach Diagram ...................................................................47
2.17 Dimension Diagrams ...............................................................48
2.18 Axle Oscillation Diagrams ...........................................................50
Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 51
3.1 Electrical Symbol Chart .............................................................52
3.2 Hydraulic Symbol Chart ............................................................53
3.3 Wire Number and Color Code ........................................................54
3.4 Hydraulic Parts List ................................................................55
3.5 Electrical Component Parts List ......................................................59
3.6 Rotary Manifold Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3.7 Brake Manifold Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.8 Drive and System Pump and Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.9 Drive Motor and Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.10 Jib Valve and Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
3.11 Main Manifold Port Identification - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
3.12 Main Manifold Electrical Component Identification - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
3.13 Main Manifold Hydraulic Component Identification - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
3.14 Main Electrical Harness and Fuel Level Switch Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.15 Engine Harness - Kubota D1305 ......................................................71
3.16 Engine Harness Wiring Diagram - Kubota D1305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.17 Engine Harness - Kubota WG972 .....................................................73
3.18 Engine Harness Wiring Diagram - Kubota WG972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
3.19 Lowering Throttle Valve Harness .....................................................75
3.20 Platform Harnesses ................................................................76
3.21 Limit Switch Connections ...........................................................77
3.22 All Motion Alarm Connections - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
3.23 Welder Wiring - ANSI/CSA ..........................................................79
3.24 Positive Air Shutoff Harness .........................................................80
3.25 Hydraulic Schematic ...............................................................81
3.26 Platform Control Box Wiring .........................................................82
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SJ60AJ+ 238275AAA
3.27 Base Control Box Wiring - ANSI/CSA & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.28 Base Control Box Wiring - CE ........................................................84
3.29 Electrical Schematic - ANSI/CSA & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
3.30 Electrical Schematic - CE ...........................................................86
3.31 Engine Schematic - Kubota D1305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
3.32 Engine Schematic - Kubota WG972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.1 Introduction ......................................................................89
4.2 Electrical System ..................................................................90
4.2-1 All Controls are Inoperative from the Base or Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-2 All Controls are Inoperative from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2-3 The Engine will not Crank from the Base or Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2-4 The Engine will not Crank from the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-5 The Engine will not Crank from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-6 The Boom Controls are Inoperative (Drive Operates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-7 No Boom Up from the Base or Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-8 No Boom Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-9 No Boom Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-10 No Boom Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-11 No Boom Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-12 No Boom Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-13 No Turret Rotate Right from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-14 No Turret Rotate Right from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-15 No Turret Rotate Right from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-16 No Turret Rotate Left from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-17 No Turret Rotate Left from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-18 No Turret Rotate Left from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-19 No Riser Up from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2-20 No Riser Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2-21 No Riser Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2-22 No Riser Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2-23 No Riser Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-24 No Riser Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-25 No Telescope Out from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-26 No Telescope Out from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-27 No Telescope Out from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-28 No Telescope In from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-29 No Telescope In from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-30 No Telescope In from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-31 No Platform Level Up from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2-32 No Platform Level Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2-33 No Platform Level Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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SJ60AJ+238275AAA
4.2-34 No Platform Level Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2-35 No Platform Level Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2-36 No Platform Level Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2-37 No Platform Rotate or Jib Functions from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . 101
4.2-38 No Platform Rotate Right from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2-39 No Platform Rotate Right from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2-40 No Platform Rotate Right from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2-41 No Platform Rotate Left from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2-42 No Platform Rotate Left from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2-43 No Platform Rotate Left from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2-44 No Jib Up from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2-45 No Jib Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2-46 No Jib Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2-47 No Jib Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2-48 No Jib Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2-49 No Jib Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2-50 No Drive or Steer Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2-51 No Forward or Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2-52 No Forward Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2-53 No Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.2-54 The Brake will not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.2-55 No Left Steer .................................................................106
4.2-56 No Right Steer ................................................................107
4.2-57 The Directon Sensing is Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.3 Hydraulic System .................................................................108
4.3-1 All Controls are Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.3-2 All Boom Functions are Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.3-3 No Main Boom Up ............................................................108
4.3-4 No Main Boom Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.3-5 No Riser Boom Up ............................................................109
4.3-6 No Riser Boom Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.3-7 No Turret Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.3-8 No Turret Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.3-9 No Boom Extend ..............................................................111
4.3-10 No Boom Retract .............................................................111
4.3-11 No Jib Up ...................................................................111
4.3-12 No Jib Down .................................................................112
4.3-13 No Platform Rotation Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3-14 No Platform Rotation Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3-15 The Platform will not Level Down Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.3-16 The Platform will not Level Up Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.3-17 The Brake will not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.3-18 The Brake will not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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SJ60AJ+ 238275AAA
4.3-19 The Differential Lock will not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.3-20 No Drive Forward or Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.3-21 No Forward Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.3-22 No Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.3-23 No High Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.3-24 No Right Steer ................................................................116
4.3-25 No Left Steer .................................................................116
4.3-26 The Axle will not Oscillate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.3-27 Axle Will Not Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Section 5 – Procedures ...................................................119
5.1 General .........................................................................119
5.1-1 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.2 Platform ........................................................................120
5.2-1 Human Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.2-2 User Interface Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.2-3 OCM Character Functions Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.2-4 OCM Pin Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.2-5 SCM Calibration ..............................................................128
5.2-6 SCM Calibration Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2-7 Platform Controller Voltage References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.3 Boom ..........................................................................133
5.3-1 Check Wear Pads .............................................................133
5.3-2 Shim Wear Pads ..............................................................133
5.3-3 Cable Carrier Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.3-4 Rotary Actuator Bolt Torque Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.3-5 Boom Section Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.3-6 Platform and Jib Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.3-7 Operating Machine Functions from the Base Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.3-8 Fly Boom Removal ............................................................136
5.3-9 Change Wear Pads on Extension Cylinder Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.3-10 Fly Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.3-11 Platform/Jib Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.3-12 Platform Control Console Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.3-13 Extension Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.3-14 Extension Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.3-15 Main Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.3-16 Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.3-17 Riser Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.3-18 Riser Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.3-19 Replace Limit Switch - Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.3-20 Test Main Boom Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.3-21 Replace Limit Switch - Riser Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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SJ60AJ+238275AAA
5.3-22 Test Riser Boom Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.3-23 Replace Limit Switch - Fly Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.3-24 Test Fly Boom Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.3-25 Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.4 Turret ..........................................................................153
5.4-1 Check and Replace the High Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.4-2 Adjust the Turret Rotation Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.4-3 Swing Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.4-4 Check the Swing Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.4-5 Change the Swing Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.4-6 Check Rotation Bearing for Axial Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.4-7 Turret Rotation Gear Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.4-8 Electronic Tilt Switch Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.4-9 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.5 Engine .........................................................................160
5.5-1 Replace Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.5-2 Replace the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.5-3 Replace the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.5-4 Check the Engine Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.6 Hydraulic Tank ...................................................................162
5.6-1 Change the Hydraulic Tank Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.6-2 Change the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.7 Manifold and Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.7-1 Hydraulic Brake Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.7-2 Hydraulic System Relief Valve Adjustment (RV1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.7-3 Turret Rotate Relief Valve Adjustment (RV2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.7-4 Platform Level Relief Valve Adjustment (RV3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.7-5 Riser Boom Down Relief Valve Adjustment (RV4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.7-6 Main Boom Down Relief Valve Adjustment (RV5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.7-7 Fly Boom Relief Valve Adjustment (RV6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.7-8 Test Charge Pump Pressure on Drive Pump (RV10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.7-9 Test Forward Drive Pressure on Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.7-10 Test Reverse Drive Pressure on Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.7-11 Hydraulic Standby Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.7-12 Hydraulic High Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.8 Axles ...........................................................................170
5.8-1 Change the Oil in the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.8-2 Check the Oil Level in the Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.8-3 Change the Oil in the Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.8-4 Check the Oil Level in the Axle Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.8-5 Change the Oil in the Axle Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.8-6 Oscillating Cylinder Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.8-7 Oscillating Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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SJ60AJ+ 238275AAA
5.8-8 Bleed the Oscillating Axle Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.8-9 Pin Brake Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.8-10 Brake Inspection ..............................................................176
5.9 Grease Points ...................................................................177
5.9-1 Grease the Turret Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.9-2 Grease the Turret Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.9-3 Grease the Axles ..............................................................178
5.9-4 Grease the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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SJ60AJ+ 238275AAA
Section 1 – Scheduled Maintenance
1.1 Read and Heed
Skyjack is continuously improving and expanding
product features on its equipment, therefore,
specifications and dimensions are subject to change
without notice.
1.1-1 Mobile Elevating Work Platform
(MEWP) Definition
A MEWP is a mobile device that has a positionable
platform supported from ground level by a structure.
1.1-2 Purpose of Equipment
The Skyjack Articulating Boom Series MEWPs are
designed to transport and raise personnel, tools and
materials to overhead work areas.
1.1-3 Use of Equipment
The MEWP is a highly maneuverable, mobile work
station. Work platform elevation and elevated driving
must only be done on a firm surface.
1.1-4 Manual
Operating Manual: The operating manual is
considered a fundamental part of the MEWP. It is a
very important way to communicate necessary safety
information to users and operators. A complete
and legible copy of this manual must be kept in the
provided weather-resistant storage compartment on
the MEWP at all times.
Service & Maintenance: The purpose of this is
to provide the customer with the servicing and
maintenance procedures essential for the promotion
of proper machine operation for its intended purpose.
All information in this manual should be read and
understood before any attempt is made to service the
machine. The updated copy of the manuals are found
on the company’s website: www.skyjack.com.
1.1-5 Service Policy and Warranty
Skyjack warrants each new product to be free of
defective parts and workmanship for the first 2 years
or 3000 hours, whichever occurs first. Any defective
part will be replaced or repaired by your local Skyjack
dealer at no charge for parts or labor. In addition,
all products have a 5 year structural warranty.
Contact the Skyjack Service Department for warranty
statement extensions or exclusions.
1.1-6 Operator Safety Reminders,
Warnings and Precautions
Operator safety is Skyjack’s priority. The operator
should comply with all applicable safety-related
reminders, warnings and precautions found in
the Operating Manual. They should be read and
understood completely before operating the MEWP.
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SJ60AJ+238275AAA
Section 1 – Scheduled Maintenance Maintenance and Service
1.2 Maintenance and Service
1.2-1 Maintenance and Inspection
Schedule
The actual operating environment of the work platform
governs the use of the maintenance schedule.
The inspection points covered in 1.5 Pre-Delivery/
Maintenance Inspection Checklist, indicates the areas
of the MEWP to be maintained or inspected and at
what intervals the maintenance and inspections are to
be performed.
1.2-2 Owner’s Annual Inspection Record
It is the responsibility of the owner to arrange quarterly
and annual inspections of the MEWP. The Owner’s
Annual lnspection Record (1.4 Owner’s Annual
Inspection Record) is to be used to record the date
of the inspection, owner’s name, and the person
responsible for the inspection of the work platform.
1.2-3 Replacement Parts
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and
dimensions different from original parts will affect
stability of the MEWP and must not be used without
manufacturer’s consent.
All replacement tires must be of the same size and
load rating as originally supplied tires; to maintain
safety and stability of MEWP.
Consult Skyjack’s Service Department for optional
tires specifications and installation.
WARNING
Any unit that is damaged or not operating properly
must be immediately tagged and removed from
service until proper repairs are completed.
1.2-4 Maintenance and Service Safety
Tips
Maintenance and repair should only be performed by
personnel who are trained and qualified to service this
MEWP.
All maintenance and service procedures should be
performed in a well lighted and well ventilated area.
Anyone operating or servicing this MEWP must read
and completely understand all operating instructions
and safety hazards in this manual and operating
manual.
All tools, supports and lifting equipment to be used
must be of proper rated load and in good working
order before any service work begins. Work area
should be kept clean and free of debris to avoid
contaminating components while servicing.
Ensure personnel are clear from under unsupported
components/systems that are at risk of movement
during maintenance.
All service personnel must be familiar with employer
and governmental regulations that apply to servicing
this type of equipment.
Keep sparks and flames away from all flammable or
combustible materials.
Properly dispose of all waste material such as
lubricants, rags, and old parts according to the
relative law provisions obtaining in the country.
Before attempting any repair work, disconnect the
main power connectors.
Preventive maintenance is the easiest and least
expensive type of maintenance.
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SJ60AJ+ 238275AAA
Maintenance and Service Section 1 – Scheduled Maintenance
1.2-5 Hydraulic System & Component
Maintenance and Repair
The following points should be kept in mind when
working on the hydraulic system or any component:
WARNING
Escaping fluid from a hydraulic pressure leak can
damage your eyes, penetrate the skin and cause
serious injury. Use proper personal preotection at
all times.
1. Any structure has limits of strength and
durability. To prevent failure of structural parts of
hydraulic components, relief valves which limit
pressure to safe operating values are included in
the hydraulic circuits.
2. Tolerance of working parts in the hydraulic
system is very close. Even small amounts of dirt
or foreign materials in the system can cause
wear or damage to components, as well as
general faulty operation of the hydraulic system.
Every precaution must be taken to assure
absolute cleanliness of the hydraulic oil.
3. Whenever there is a hydraulic system failure
which gives reason to believe that there are
metal particles or foreign materials in the system,
drain and flush the entire system and replace the
filter cartridges. A complete change of oil must
be performed under these circumstances.
4. Whenever the hydraulic system is drained,
check the magnets in the hydraulic reservoir for
metal particles. If metal particles are present,
flush the entire system and add a new change
of oil. The presence of metal particles also may
indicate the possibility of imminent component
failure. A very small amount of fine particles is
normal.
5. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic
oil reservoir, and fill the reservoir only through
the filter opening. The use of cloth to strain the
oil should be avoided to prevent lint from getting
into the system.
6. When removing any hydraulic component,
be sure to cap and tag all hydraulic lines
involved. Also, plug the ports of the removed
components.
7. All hydraulic components must be disassembled
in spotlessly clean surroundings. During
disassembly, pay particular attention to
the identification of parts to assure proper
reassembly. Clean all metal parts in a clean
mineral oil solvent. Be sure to thoroughly clean
all internal passages. After the parts have been
dried thoroughly, lay them on a clean, lint-free
surface for inspection.
8. Replace all O-rings and seals when overhauling
any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
amounts of petroleum jelly to hold O-rings in
place during assembly.
9. Be sure to replace any lost hydraulic oil when
completing the installation of the repaired
component, and bleed any air from the system
when required.
10. All hydraulic connections must be kept tight. A
loose connection in a pressure line will permit
the oil to leak out or air to be drawn into the
system. Air in the system can cause damage
to the components and noisy or erratic system
operation.
1.2-6 Hydraulic Maintenance Hints
Three simple maintenance procedures have the
greatest effect on the hydraulic system performance,
efficiency and life. Yet, the very simplicity of them may
be the reason they are so often overlooked. They are
simply these:
1. Change filters annually. The filters will need
to be changed more often depending on the
operating conditions. Dirty, dusty, high moisture
environments may cause the hydraulic system
to be contaminated more quickly.
2. Maintain a sufficient quantity of clean hydraulic
oil of the proper type and viscosity in the
hydraulic reservoir.
3. Keep all connections tight.
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SJ60AJ+238275AAA
Section 1 – Scheduled Maintenance Maintenance and Service
1.2-7 Railing Maintenance and Repair
Skyjack MEWPs have been designed to ensure
compliance with the relevant design standards
applicable for that particular unit at the time of
manufacture. As such, any repairs made to the
guardrail or basket structure need to ensure this
compliance is not compromised and must return the
structure to its original condition.
Any damage must be repaired by returning the railing
assembly to its undamaged state. Damage includes,
but is not limited to, the items listed below:
▪bent/deformed guardrail sections
▪cracks or broken welds in railing sections
▪damaged pin connections
▪missing pins or broken pin lanyards
▪missing railing hardware
▪loose or missing parts
▪additional holes in guardrail sections other than
those approved by Skyjack
Additionally, the guardrails must be properly
positioned and secured, and the entry gate must be
in good working order.
The strength of the guardrail system, and therefore
its ability to provide fall protection for platform
occupants, depends upon the design being secure
and undamaged.
Skyjack railings are designed for modular
replacement, and Skyjack recommends replacement
of any damaged railing section. Skyjack-approved
replacement parts will meet this requirement.
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SJ60AJ+ 238275AAA
Scheduled Maintenance Section 1 – Scheduled Maintenance
1.3 Scheduled Maintenance
This section contains the maintenance and inspection
schedule that is to be performed.
References are made to the procedures in Section
5 that outline detailed step-by-step instructions for
checks and replacements.
1.3-1 Service Bulletins
Before performing any scheduled maintenance
inspection procedure, refer to service bulletins found
in our web site: www.skyjack.com for updates related
to service and maintenance of this MEWP.
1.3-2 Maintenance and Inspection
Death or injury can result if the MEWP is not kept in
good working order. Inspection and maintenance
should be performed by competent personnel who
are trained and qualified on maintenance of this
MEWP.
WARNING
Failure to perform each procedure as presented
and scheduled may cause death, serious injury or
substantial damage.
NOTE
Preventive maintenance is the easiest and least
expensive type of maintenance.
▪Unless otherwise specified, perform each
maintenance procedure with the MEWP in the
following configuration:
▪MEWP parked on a flat and level surface
▪Disconnect the batteries by disconnecting the
main power connectors.
▪Repair any damaged or malfunction
components before operating MEWP.
▪Keep records on all inspections.
1.3-3 Maintenance Instructions
This manual consists of four schedules to be done
for maintaining on an MEWP. Inspection schedule
frequency is shown below:
Issue or Symptom
PDI/Frequent BPerform PDI prior to each
delivery, or Frequent
Inspection every 200 days
or 200 hours.
Annual B + C Perform Scheduled
Maintenance Inspections
every year.
Additional *Perform at time sensitive
maintenance intervals.
▪Make copies of the maintenance and inspection
checklist to be used for each inspection.
▪Check the schedule on the checklist for the type
of inspection to be performed.
▪Place a check in the appropriate box after each
inspection procedure is completed.
▪Use the maintenance and inspection checklist
and step-by-step procedures in Section 1 –
Scheduled Maintenance.
▪If any inspection receives a fail, tag and remove
the MEWP from service.
▪If any MEWP component(s) has been repaired,
an inspection must be performed again before
removing the tag. Place a check in the repair
column.
Legend
Pass P
Fail F
Repaired R
Not applicable N/A
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SJ60AJ+238275AAA
Section 1 – Scheduled Maintenance Owner’s Annual Inspection Record
1.4 Owner’s Annual Inspection RecordTable
Inspection
Date
Inspector
Signature
WARNING
Do not use the MEWP if there is no inspection
recorded in the last 13 months. If you do not obey,
there is a risk of death or serious injury.
IMPORTANT
The Owner’s annual inspection record is located
on the scissor assembly. It must be filled out after
an annual inspection has been completed. Do
not use the MEWP if an inspection has not been
recorded in the last 13 months.
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19
SJ60AJ+ 238275AAA
Pre-Delivery/Maintenance Inspection Checklist Section 1 – Scheduled Maintenance
1.5 Pre-Delivery/Maintenance Inspection Checklist
Articulating Booms and Telescopic Booms
Items for Inspection P N/A
Service Bulletins. Make sure there are no open service bulletins. B
Annual Inspection. Make sure you complete it within 13 months. B
Labels. In place, correctly attached and you can read them. B
Limit Switches. Correctly installed and no obstructions or damage. B
ENGINE COMPARTMENT
Main Power Disconnect Switch. Cables and switch tight and in working order. B
Battery. No damage, tight connections and sufficient fluid levels. Clean
terminals and cable ends. B
Swing Drive. Tight fittings, hoses and bolts. No damage, missing components
or leaks. B
Hydraulic Pump and Motor. Tight fittings, hoses and bolts. No damage,
missing components or leaks. B
Engine and Components. Do a check of the engine and components for any
loose, missing, damaged, or failed items. Do a check of the oil and coolant
levels. Make sure you do not exceed the recommended oil and coolant change
intervals.
B
Air Filter. Do a check of the filter. Replace the air filter if necessary. C
Fuel Filter. Do a check of the filter. Replace the fuel filter if necessary. C
Radiator. Do a check of the coolant condition and replace if necessary. C
CONTROL COMPARTMENT
Turret Transportation Lock. Unlocked and no damage or missing
components. B
Base Control Console. Operate the switches and make sure they all operate
correctly. No damage or missing components. B
Hydraulic Tank. Filler cap closed tightly and no damage or leaks. B
Hydraulic Oil. Level between min. and max. marks. B
Hydraulic Oil. Do a check and replace oil and filters if necessary. C
Hydraulic Return Filter. Correctly attached and no damage, missing
components or leaks. B
Hydraulic Return Filter. Do a check of the filter. Replace the filter if necessary. C
Manifolds. Tight fittings and hoses and no damage or leaks. Tight wire
connections, no missing components and correctly working valves. B
High-pressure Filter. Do a check of the filter. Replace the filter if necessary.
Emergency Power Unit. Tight fittings and hoses. No leaks. Tight wire
connections and no damage or missing components. B
Fuel Tank and Lines. Filler cap, tank, fittings and hoses are closed tightly and
no damage or leaks. B
BASE
Base Weldment. No deformation or cracks. B
Rotary Manifold. Tight fittings and hoses, and no leaks. B
Turret Rotation Motor/Gear. Tight fittings, hoses and bolts. No damage,
missing components or leaks. Make sure the gears are lubricated. B
Turret Rotation Motor/Gear. Lubricate the gears. C
Items for Inspection P N/A
Axles. Correctly attached and no missing components. Tight fittings and hoses
and no leaks. B
Axles. Do a check of the brakes. C
Oscillating Cylinders. Correctly attached and no missing components. Tight
fittings and hoses and no leaks. B
Oscillating Cylinders. Correctly attached and no missing components. Tight
fittings and hoses and no leaks. Do a check of the mounting bolts torque seal. C
Steer Cylinder. Correctly attached and no missing components. Tight fittings
and hoses and no leaks. B
Steer Linkage. No damage/wear or missing components. B
Wheel/Tire Assembly. Do a check of all tires for damage, wear and
correctly aligned. B
Wheel/Tire Assembly. No loose bolts. Wheel nuts torqued as recommended. C
PLATFORM
Raillings and Gates. Correctly attached and no damage or missing
components. B
Platform Floor. Correctly attached and no damage or missing components. B
Footswitch. Correctly attached. Operates correctly with no modifications. B
Fall-Protection Anchorage. Anchorages are correctly attached and no damage. B
AC Power Socket. No obstructions, dirt, or damage. B
Platform Control Console. Operate the switches and make sure they all
operate correctly. No damage or missing components. B
Manual Storage Box. Manuals and documents are in the storage the box, in
good condition, and you can read them. B
BOOM
Rotary Actuator. No damage or missing components. Tight fittings, hoses and
bolts and no leaks. B
Jib. No damage or missing components. Tight hoses and bolts and no leaks. B
Boom. No damage or missing components. No deformation or cracks in welds.
Tight fittings, hoses, bolts, and pins. No leaks. B
Cable Track. No damage or missing components. B
Wear Pads. No damage, wear or missing components. Fasteners tight. B
Riser. No damage or missing components. No deformation or cracks in welds.
Tight fittings, hoses, bolts, and pins. No leaks. B
Cylinders. No damage or missing components. Tight fittings and hoses and no
leaks. Pins and bushing are tight and correctly installed. B
Control Cables and Hoses. No damage or missing components. No leaks. B
Wire Ropes. No damage or missing components. Tight jam nuts. No spring
gaps. Do not exceed the inspection interval. B
OPTIONAL EQUIPMENT
Special Options and Approved Attachments. Correctly attached and no
damage or missing components. B
Function Tests. Refer to the operating manual for your serial number for
information on how to run these tests.
PASS
FAIL
Comments:
Print Name
Print Name
Owner:
User:
199342AA
Signature
Signature
Date (DD/MM/YY)
Date (DD/MM/YY)
The undersigned has made sure that all areas in the list have received an inspection.
The undersigned has told the machine owner of all inconsistencies in the inspection and corrected them before machine operation.
Serial Number: Starting with serial number A000 000 000 or B000 000 000 and above
Use this table for pre-delivery inspections (PDI) before each rental, lease or sale and as an instruction for all frequent inspections and annual inspections.
Refer to the operation and service manuals for inspection instructions (for example, visual inspection and function tests, torque specs, engine oil, chain
inspection intervals, and more).
B - Do the pre-delivery inspection before the machine is sent out or during the frequent inspections at 200 days or 200 hour
intervals. For more instructions, refer to the operation and service manuals.
C - Do the scheduled maintenance Inspections each year. For more instructions, refer to the service manual.
P - Pass
N/A - Not Applicable
Put a check mark in the “Pass” column as you meet the requirements of the inspection for each item. Add a comment if the item does not pass inspection.
Model:
Hourmeter Reading:
Date/Time:
Inspection Type (Choose one): Pre-delivery Frequent Periodic Annual
Product User:
Product Owner:
Inspection Type Schedule
PDI/Frequent/Periodic B
Annual B+C
Frequent/Periodic/Annual/PDI Checklist
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20
SJ60AJ+238275AAA
Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections
1.6 Scheduled Maintenance
Inspections
Do an inspection of the MEWP in this sequence.
WARNING
Do not operate a MEWP until all malfunctions have
been corrected. If you do not obey, there is a risk
of death or serious injury.
WARNING
Turn the main power disconnect switch to the
off position before you do the visual and daily
maintenance inspections. If you do not obey, there
is a risk of death or serious injury.
1.6-1 Electrical
Do a check on these areas for chafed, corroded, and
loose wires:
▪Boom to platform cable harness
▪Engine compartment electrical panel
▪Engine wiring harness
▪Rotary manifold wiring
1.6-2 Hydraulic
Do a check on these areas and make sure there are
no signs of leakage:
▪Hydraulic tank filter, fittings, hoses, emergency-
power unit, turret and base surface
▪Engine compartment fittings, hoses, primary
pump, filter, turret and base surface
▪All hydraulic cylinders
▪All hydraulic manifolds
▪The ground area below the MEWP.
1.6-3 Labels (B)
Refer to the labels section in the Operating Manual.
Make sure all the labels are in the correct location, are
in good condition, and you can read them.
1.6-4 Limit switches (B)
Do an inspection of all limit switches 1 located inside
the turret and on the boom. Inspect for the following:
▪ Broken or missing actuator arms
▪ Missing fasteners
▪ Loose wiring.
1
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SJ60AJ+ 238275AAA
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance
1.6-5 Engine Compartment
Do the inspection that follows:
Make sure all compartment latches are latched tightly
and in good condition.
1 Main power disconnect switch (B)
▪Turn the main power disconnect switch to the
off position.
▪Make sure the switch rotates and stays in the
on and off position.
▪Make sure the cables are not loose.
2 Battery (B)
WARNING
Explosion hazard. Keep flames and sparks away.
Do not smoke near the batteries. If you do not
obey, there is a risk of death or serious injury.
WARNING
Corrosion hazard. Do not touch battery acid. Wear
the correct PPE. If the battery acid touches you,
immediately flush the area with cold water and get
medical aid.
B - Frequent Inspection
1. Do an inspection of the battery case for damage.
▪Clean the battery terminals and cable ends
thoroughly with a terminal cleaning tool or wire
brush.
2. Make sure all the battery connections are tight.
3. If applicable, check the battery fluid level.
▪If the plates do not have a minimum 13 mm
(1/2 inch) of solution above them, add distilled
or demineralized water.
▪Replace the battery if it is damaged or cannot
hold a lasting charge.
WARNING
Only use original or manufacturer-approved parts
and components for the MEWP. If you do not obey,
there is a risk of death, serious injury, or machine
damage.
3 Charge Indicator - CE (B)
▪Make sure there are no loose or missing parts.
▪Make sure there is no visible damage.
4 Swing drive motor (B,C)
▪Make sure there are no loose or missing parts.
▪Make sure there is no visible damage.
▪Make sure all bolts are correctly tightened.
▪Make sure all fittings and hoses are correctly
tightened and there are no hydraulic leaks.
C - Annual Inspection
▪For the brake/motor oil replacement
procedure, refer to 5.4-5 Change the Swing
Drive Oil.
2
1
4
3
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