SAFETY RELATED

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Service Bulletin #124 SJ 40T/45T/61T/66T/46AJ/51AJ Installation and Axle Drive Motor Replacement **********SAFETY RELATED********** March 28, 2014 Models Affected: SJ40T, SJ45 T, SJ 61T, SJ66T, SJ46

1 Service Bulletin #124 SJ 40T/45T/61T/66T/46AJ/51AJ Installation and Axle Drive Motor Replacement **********SAFETY RELATED********** March 28, 2014 Models Affected: SJ40T, SJ45 T, SJ 61T, SJ66T, SJ46 AJ, SJ 51AJ SJ40T , , , , , , , , , , , , SJ45 T , , , , , , , , , SJ 61T , , , , , SJ66T , , , , , , , , , , , , , SJ46 AJ , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , SJ 51AJ , , , , , , , , Page 1 of 4

2 Introduction: In our continuing effort to provide the best possible product to our customers and yours, it is necessary that this bulletin be completed on all machines with serial numbers listed above. Failure to implement this bulletin could potentially result in leakage of hydraulic fluid at the axle drive motor speed selector servo and a maximum drive speed that exceeds permissible limits. The units listed above must have this service bulletin completed immediately. This bulletin is also available on our website at: Procedure: 61T and 66T machines: All units with the above serial numbers must have the pressure reducing valve and replacement axle drive motor installed with Skyjack service kit # as per the attached procedure (Skyjack part # AC). Contact Skyjack Service to arrange for the removed drive motor(s) to be picked up. Please make sure that the motor(s) is drained and capped before shipping. 46AJ and 51AJ machines: All units with the above serial numbers must have the pressure reducing valve and replacement axle drive motor installed with Skyjack service kit # as per the attached procedure (Skyjack part # AB). Contact Skyjack Service to arrange for the removed drive motor(s) to be picked up. Please make sure that the motor(s) is drained and capped before shipping. 40T and 45T machines: All units with the above serial numbers must have the pressure reducing valve and replacement axle drive motor installed with Skyjack service kit # as per the attached procedure (Skyjack part # AC). Contact Skyjack Service to arrange for the removed drive motor(s) to be picked up. Please make sure that the motor(s) is drained and capped before shipping. Page 2 of 4

3 Parts and Warranty Policy: 61T and 66T machines: Skyjack will reimburse up to 5 hours of labor per machine to complete this bulletin, and up to 4 hours of travel. Skyjack will provide the necessary parts without charge. 46AJ, 51AJ, 40T and 45T machines: Skyjack will reimburse up to 3 hours of labor per machine to complete this bulletin, and up to 4 hours of travel. Skyjack will provide the necessary parts without charge. Replacement parts must be ordered through our Skyjack Warranty Department. Upon completion of this service bulletin, submit a warranty claim form for each machine stating that Service Bulletin #124 has been completed and arrange for the removed drive motor(s) to be picked up. Please make sure that the motor(s) is drained and capped before shipping. Reimbursement will be processed once the warranty claim has been received and the removed drive motor(s) returned. Ownership of Machines: Skyjack requires that you promptly notify us of a new owner s contact information if you have sold or transferred any machine. In particular, if you have sold or transferred a machine(s) with the serial numbers listed above, it is required that you promptly notify Skyjack of the new owner s contact information. This service bulletin must also be forwarded to the new machine owner. Contact Information: We regret any inconvenience and appreciate your cooperation. If you have any questions please call, Skyjack North America at , Skyjack Europe at , Skyjack Australia at 61 (0) or Skyjack Brasil at You may any questions to service@skyjack.com. Page 3 of 4

4 Service Bulletin #124 Parts Kit Shipment Request Form Customer Name: PO#: Customer Location: Address: Phone: City: Fax: State: Zip: Contact Name: We are requesting parts kit shipment for the following machines to comply with Service Bulletin #124. Please fill in the serial numbers of units in your possession that require a parts kit shipment for this bulletin to be completed. Machine Serial Number Machine Serial Number Machine Serial Number Please Fax or This Form To Skyjack Service: Fax: (630) or (Europe) service@skyjack.com If you have any questions please call Skyjack Service at , or (Europe). You can any questions to service@skyjack.com Skyjack requires that you promptly notify us of the new owner s contact information if you have sold or transferred any machine. If you have sold or transferred a machine(s) with the serial numbers listed above, it is required that you promptly notify Skyjack of the new owner s contact information. This service bulletin must also be forwarded to the new machine owner. Page 4 of 4

5 168169AC Models 61T & 66T AC

6 WARNING WARNING Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, USA Phone: Toll Free: Fax: Parts (North America) Toll Free: Toll Free Fax: Skyjack Australia Pty Ltd. 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel: +61 (0) Fax: +61(0) Parts & Service (Europe) Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK Phone: Fax: info@skyjackeurope.co.uk Skyjack Brasil Alameda Júpiter, 710 Loteamento American Park Empresarial Indaiatuba, SP, Brasil Tel: SKYJACK, Page AC

7 Table of Contents 1.0 Parts Inventory Machine Preparation Installation Procedure... 5 Install the Assembly (168170)... 5 Hydraulic Hose Connections... 6 Replace the Axle Motors (163596) Testing Procedure... 8 Test for Leaks... 8 Test Drive Speeds AC SKYJACK, Page 3

8 Skyjack PRESSURE REDUCING VALVE FIELD KIT SKYJACK, Page AC

9 1. 2. Chock or block the wheels. 3. and extend the boom upwards as far as possible (space permitting). Install the Assembly (168170) 1. the location indicated. 4. Push in control console and base control console. 5. position. Remove key. 6. Turn main power disconnect switch to position. 7. Throughout this procedure you will need to have several rags on hand to clean up leaking hydraulic oil. NOTE Prepare an oil pan or rags for the oil that may drip. Figure 1. Remove hardware CAUTION Dispose of oil in accordance with environmental regulations. 2. Place the new valve assembly on the manifold in the previous step. Figure 2. Install valve assembly AC SKYJACK, Page 5

10 Hydraulic Hose Connections 3. bottom left of the brake manifold. 5. Connect the straight end of new hose (H ) left of the brake manifold. Figure 3. Disconnect hose from brake manifold Figure 5. Connect new hose to brake manifold 4. pressure reducing valve manifold. 6. of the pressure reducing valve manifold. Figure 4. Connect hose to manifold Figure 6. Connect new hose to valve manifold SKYJACK, Page AC

11 7. Remove the end cap from one end of the supplied hose (H ) (131705) to the hose. Ensure the other end cap remains securely in place. 9. this port. Figure. ttach tting to hose 8. Remove the plug from the location indicated on the side of the hydraulic tank (second port from of rags on hand to catch leaking oil. Figure 9. Connect hose to tank port 10. Remove the end cap from the opposite end of the on the rear of the new valve manifold. Figure 8. Remove plug from hydraulic tank Figure 10. Connect hose to valve assembly 11. Tighten the hose ends on all three hoses. 12. Clean up all of the leaked hydraulic oil. 13. Fully lower and stow the boom AC SKYJACK, Page 7

12 Replace the Axle Motors (163596) 15. Replace both drive motors with the new motors provided (163596). Test for Leaks 1. Perform the functions tests given in your unit s 2. needed. Test Drive Speeds Equipment needed for this test: a. b. Assistant c. Stopwatch Figure 11. Replace the drive motors d. or other suitable objects. NOTE This test will require the boom operator to drive in a straight line at full speed. level driving surface and enough distance to complete the test. 3. This test will need to be completed a total of four with the steering axle in the forward direction. 4. starting point. Place a second marker Drive the boom forward ground markers. SKYJACK, Page AC

13 and note the travel time in seconds. 9. Repeat the test (steps 6 through 8) in reverse drive Move the second marker 30ft boom fully. Repeat the tests (steps 6 through 9). 11. The tested drive times must not be less than: 12. If any of the drive times are less than those are corrected. Start time Stop time 1st marker 2nd marker 15ft / 5m - Boom extended 30ft / 10m - Boom retracted AC SKYJACK, Page 9

15 168189AB Models 46AJ & 51AJ AB

16 WARNING WARNING Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, USA Phone: Toll Free: Fax: Parts (North America) Toll Free: Toll Free Fax: Skyjack Australia Pty Ltd. 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel: +61 (0) Fax: +61(0) Parts & Service (Europe) Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK Phone: Fax: info@skyjackeurope.co.uk Skyjack Brasil Alameda Júpiter, 710 Loteamento American Park Empresarial Indaiatuba, SP, Brasil Tel: SKYJACK, Page AB

17 Table of Contents 1.0 Parts Inventory Machine Preparation Installation Procedure... 5 Install the Manifold, Fittings and Hoses... 5 Replace the Axle Drive Motor (161964) Testing Procedure... 8 Test for Leaks... 8 Test Drive Speeds AB SKYJACK, Page 3

18 Skyjack PRESSURE REDUCING VALVE FIELD KIT - 46/51AJ SKYJACK, Page AB

19 Install the Manifold, Fittings and Hoses 1. hose (H ) (168167). 4. console NOTE Prepare an oil pan and rags for the oil that CAUTION Figure 1. Connect hose to 90 tting 2. Figure 2. Remove mounting hardware AB SKYJACK, Page 5

20 3. ( (103996) (103984). 5. Figure 5. Connect hose to new manifold Figure 3. Mount new manifold (702761) (155022) (707041) straight end of the second hose (H ) Figure 4. Disconnect 2SPD hose SKYJACK, Page 6 Figure 6. Connect ttings to hose AB

21 7. 9. Figure 7. Disconnect T port hose 8. Figure 9. Connect hose to Tee tting 10. Figure 10. Connect hose to new manifold Figure 8. Connect hose to T port AB SKYJACK, Page 7

22 11. Test for Leaks needed. Test Drive Speeds a. Assistant Figure 11. Connect hose to brake manifold Replace the Axle Drive Motor (161964) 15. provided (161964). c. d. NOTE starting point. Figure 12. Replace the drive motor SKYJACK, Page AB

23 9. Move the second are corrected. Start time Stop time 1st marker 2nd marker 15ft / 5m - Boom elevated 30ft / 10m - Boom stowed AB SKYJACK, Page 9

25 168188AC Models 40T & 45T AC

26 WARNING WARNING Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, USA Phone: Toll Free: Fax: Parts (North America) Toll Free: Toll Free Fax: Skyjack Australia Pty Ltd. 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel: +61 (0) Fax: +61(0) Parts & Service (Europe) Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK Phone: Fax: info@skyjackeurope.co.uk Skyjack Brasil Alameda Júpiter, 710 Loteamento American Park Empresarial Indaiatuba, SP, Brasil Tel: SKYJACK, Page AC

27 Table of Contents 1.0 Parts Inventory Machine Preparation Installation Procedure... 5 Install the Assembly (168191)... 5 Hydraulic Hose Connections... 5 Replace the Axle Drive Motor (161964) Testing Procedure... 8 Test for Leaks... 8 Test Drive Speeds AC SKYJACK, Page 3

28 Skyjack PRESSURE REDUCING VALVE FIELD KIT SKYJACK, Page AC

29 1. 2. Chock or block the wheels. 3. and extend the boom upwards as far as possible (space permitting). Install the Assembly (168191) 1. Mount the new pressure reducing valve assembly (168191) to the existing holes in the turret wall using the supplied bolts (103870) (103999) and (103472). 4. Push in the the platform control console and base control console Turn the main power disconnect switch to the 7. Throughout this procedure you will need to have several rags on hand to clean up leaking hydraulic oil. NOTE Prepare an oil pan and rags for the oil that may drip. Figure 1. Install valve assembly CAUTION Dispose of oil in accordance with environmental regulations. Hydraulic Hose Connections 2. 2SPD) on the bottom left of the brake manifold. Figure 2. Disconnect hose from brake manifold AC SKYJACK, Page 5

30 3. bottom right of the new pressure reducing valve manifold. 5. manifold. Figure 3. Connect hose to new manifold Figure 5. Connect new hose to valve manifold 4. (H ) brake manifold (port 2SPD). 6. Remove the end cap from one end of supplied hose (H ) (103070) to the hose. Ensure the other end cap remains securely in place. Figure 6. ttach tting to hose Figure 4. Connect new hose to brake manifold SKYJACK, Page AC

31 7. Remove the plug from the location indicated on the side of the hydraulic tank (port T7). Have plenty of rags on hand to catch leaking oil. 9. Remove the end cap from the opposite end of the on the bottom left of the new valve manifold. Figure 7. Remove plug from hydraulic tank Figure 9. Connect hose to valve assembly 10. Tighten the hose ends on all three hoses. 8. this port. 11. Clean up all of the leaked hydraulic oil. 12. Fully lower and stow the boom. 13. Figure 8. Connect hose to tank port AC SKYJACK, Page 7

32 Replace the Axle Drive Motor (161964) 14. Replace the drive motor with the new motor provided (161964). Test for Leaks 1. Perform the functions tests given in your unit s 2. needed. Test Drive Speeds Equipment needed for this test: a. b. Assistant c. Stopwatch Figure 10. Replace the drive motor d. or other suitable objects. NOTE This test will require the boom operator to drive in a straight line at full speed. level driving surface and enough distance to complete the test. 3. This test will need to be completed a total of four with the steering axle in the forward direction. 4. starting point. Place a second marker Drive the boom forward ground markers. SKYJACK, Page AC

33 and note the travel time in seconds. 9. Repeat the test (steps 6 through 8) in reverse drive Move the second marker 30ft boom fully. Repeat the tests (steps 6 through 9). 11. The tested drive times must not be less than: 12. If any of the drive times are less than those are corrected. Start time Stop time 1st marker 2nd marker 15ft / 5m - Boom extended 30ft / 10m - Boom retracted AC SKYJACK, Page 9

Service Bulletin #125 SJ 40T/45T/61T/66T/63AJ System Pump Replacement

Service Bulletin #125 SJ 40T/45T/61T/66T/63AJ April 16, 2014 Models Affected: SJ40T, SJ45 T, SJ 61T, SJ66T, SJ63 AJ SJ40T 98001175, 98001176, 98001177, 98001178, 98001179, 98001181, 98001187, 98001201,