Service Bulletin #117 SJ7127 RT, SJ7135 RT, SJ8841 RT, SJ9250 RT Brake Manifold Assembly Replacement

Transcription

1 Service Bulletin #117 SJ7127 RT, SJ7135 RT, SJ8841 RT, SJ9250 RT September 4, 2013 Models Affected: SJ7127 RT, SJ7135 RT, SJ8841 RT, SJ9250 RT SJ7127 RT , , , SJ7135 RT , , , , , , SJ8841 RT , , , , , , , SJ9250 RT , , , , , , , , , , Introduction: In our continuing effort to provide the best possible product to our customers and yours, we require that the following Brake Manifold Replacement be completed for all machines with serial numbers listed above. Failure to implement this bulletin can potentially result in the inability to manually release the brakes during towing or winching. Procedure: All units with the above serial numbers must have the brake manifold assembly replaced as specified in the attached procedure (). Skyjack Corporation USA 3451 Swenson Ave St. Charles IL USA INDUSTRIAL GROUP Tel: Fax: linamar.com skyjack.com A Division of Linamar Holdings Inc.

2 Parts and Warranty Policy: Skyjack will reimburse up to 1 hour of labor per machine to complete this bulletin. Refer to Instructions part number # and order Field Kit # (Model 71XX/8841) or # (Model 9250) to complete this bulletin. To assist you with this process we have also attached a part request form. Upon completion of this service bulletin, submit a warranty claim form for each machine stating that Service Bulletin #117 has been completed and reimbursement will be processed. Ownership of Machines: 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. Contact Information: We regret any inconvenience and appreciate your cooperation. If you have any questions please call Skyjack North America at or Skyjack Europe at You may any questions to service@skyjack.com Skyjack Corporation USA 3451 Swenson Ave St. Charles IL USA INDUSTRIAL GROUP Tel: Fax: linamar.com skyjack.com A Division of Linamar Holdings Inc.

3 Service Bulletin #117 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 #117. 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 This Form To: Skyjack Service Fax: (630) or (Europe) 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. Skyjack Corporation USA 3451 Swenson Ave St. Charles IL USA INDUSTRIAL GROUP Tel: Fax: linamar.com skyjack.com A Division of Linamar Holdings Inc.

4 This page intentionally left Blank. Skyjack Corporation USA 3451 Swenson Ave St. Charles IL USA INDUSTRIAL GROUP Tel: Fax: linamar.com skyjack.com A Division of Linamar Holdings Inc.

5 Part Models SJ7127 / SJ7135 SJ8841 SJ9250

6 WARNING Only qualified and authorized personnel shall be permitted to service an aerial platform. WARNING Read all instructions closely before attempting each step of the procedure. If you have not received the complete parts inventory, contact the Skyjack Service Department to have the missing parts sent to you. Do not attempt installation without the complete package. 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 Canada) Cel: (USA) Cel: (Brasil) SKYJACK, Page 2

7 Table of Contents 1.0 Parts Inventory Preparation... 5 Machine Preparation... 5 Hydraulic Preparation Installation Procedure... 5 Remove Old Brake Manifold... 5 Disassemble Old Brake Manifold... 6 Assemble New Brake Manifold... 7 Cabinet Rework (Models 71XX and 9250)... 7 Install New Brake Manifold... 8 Install Gripper Clips and Pump Handle... 9 Replace Label Bleeding the Brake Caliper Manual Brake Pump Test and Caliper Adjustment SKYJACK, Page 3

8 1.0 Parts Inventory Index No. Skyjack Part No. Qty. Description A FIELD KIT, Manual Brake Pump - Model 71XX/8841 B FIELD KIT, Manual Brake Pump - Model MANIFOLD ASSEMBLY, Brake LABEL, Towing/Pushing procedure PLATE, Spacer, 92XX Brake Mount, B BOLT, Flat head cap screw (5/16-18 x 0.75 ), B WASHER, Flat (5/16 ), A WASHER, Flat (5/16 ), B BOLT, Hex head (5/16-18 x 1.00, Grade 5) WASHER, Lock (5/16 ) NUT, Hex head (5/16-18), B CAVITY HAND PUMP WITH LEVER HANDLE, Hand pump BOLT, Machine head (#8-32 x ) WASHER, Flat (#8) CLIP, Gripper (3/4 to 1-1/8 ) NUT, Nylon lock (#8-32) MANUAL, Operating, English (ANSI) (not shown) MANUAL, Operating, English (CE) (not shown) FIELD INSTALLATION INSTRUCTION, Manual Brake Pump (not shown) SKYJACK, Page 4

9 2.0 Preparation Machine Preparation 1. Ensure aerial platform is on a firm, level surface. 2. Chock or block the wheels to keep the aerial platform from rolling forward and backward. 3. Push in emergency stop button on platform control console and base control console. 4. Turn base/off/platform key switch to off position. Remove key. 3.0 Installation Procedure NOTE The Illustrations below show the SJ9250 model. Where steps differ per model, model numbers will be noted. Remove Old Brake Manifold 1. Locate the brake manifold on the wall (SJ8841/9250) or floor (SJ71XX) of the electrical/ hydraulic cabinet. 5. Turn main power disconnect switch to off position. Hydraulic Preparation NOTE When working with hydraulics, ensure the work area is clean and free from any contaminants, such as dust or dirt. NOTE Have several rags on hand to catch and clean up any leaking oil. 1. Cap and plug any disconnected hose ends and fittings. Caps and plugs required are: Figure 1. Locate Brake Manifold (9250 shown) 2. Label each of the brake manifold hoses with a piece of tape for ease of reassembly later. 3. Disconnect the wires leading from the solenoid. For 71XX and 8841 models - #6 plug (x3), #8 plug (x1), #6 cap (x3), #8 cap (x1) For 9250 model - #6 plug (x4), #6 cap (x4) B D C A Figure 2. Label Hoses and Disconnect Wires SKYJACK, Page 5

10 4. Remove the bolts, washers, and spacer plate securing the manifold to the cabinet. Retain the spacer plate for reinstallation later for models 71XX and 8841, but discard it for the Disassemble Old Brake Manifold 1. Take the manifold to a clean work area free of dirt, dust, and other contaminants, and secure it in a vice. 2. Remove all of the fittings, solenoid assembly, and valves from the manifold block. Keep the fittings (x4), solenoid assembly, and brake release valve (black knob), but discard the manifold block and hand pump (red knob). Cap the fittings. Remove hardware Keep Figure 3. Remove Manifold from Cabinet Wall 5. Using rags to catch any leaking oil, disconnect and plug the brake manifold hoses. Cap the exposed manifold fittings. Red Discard Disconnect and plug 4 hoses Black Keep Discard Figure 5. Disassemble Old Manifold Figure 4. Disconnect and Cap Hoses SKYJACK, Page 6

11 Assemble New Brake Manifold 1. Place the new manifold block (164795) in the vice. 2. Reinstall the fittings (x4) in the same ports as before. Reinstall the solenoid assembly. Reinstall the brake release valve (black knob). Install the new brake pump valve (164798). Hand-tighten the T fittting, but do not torque it yet. Torque the rest of the fittings and the valves 18 ft-lb / 24 Nm. Hand-tighten the solenoid coil nut, but do not torque it yet. Torque solenoid nut to 60 in-lb / 6.8 Nm Torque valves and fittings to 18 ft-lb / 24 Nm New part Cabinet Rework (Models 71XX and 9250) The brake manifold needs to be relocated on models 71XX and 9250, which requires drilling two holes in the cabinet weldment. 1. For 71XX - Using a 3/8 / 9.5 mm drill bit, drill two holes in the floor of the cabinet, 1.00 / 2.5 cm back from the existing manifold mount holes, as shown below. 2x 1.25 / 3.2 cm 3/8 / 9.5 mm Existing manifold mount holes / 43.8 cm New manifold mount holes 1 / 2.5 cm Figure 7. Drill Manifold Mounting Holes (71XX) 2. For Using a 3/8 / 9.5 mm drill bit, drill two holes in the wall of the cabinet, at the locations shown below. New part Figure 6. Assemble New Manifold A Existing manifold mounting holes 0.75 / 1.9 cm New manifold mounting holes 2 / 5.1 cm Detail A Scale 1 : 2 2x 3/8 / 9.5 mm Figure 8. Drill Manifold Mounting Holes (9250) 3. Clean the metal shavings out of the cabinet. SKYJACK, Page 7

12 Install New Brake Manifold 1. For 71XX and Remount the manifold to the cabinet (use the new holes for 71XX) using the spacer plate removed previously, bolts (103864), flat washers (103404), and lock washers (103996). 2. For First mount the manifold to the new spacer plate (164935) using bolts (704642). Orient the spacer plate so the countersunk holes are towards the back of the manifold (the spacer will be offset with the manifold). 4. Connect the brake manifold hoses (x4) to the same fittings as before, routing them so as to avoid sharp edges. Adjust the orientation of the T fitting as needed, and torque it to 18 ft-lb / 24 Nm. Torque the #6 hoses to 18 ft-lb / 24 Nm, and the #8 hoses 36 ft-lb / 49 Nm. Secure the hoses with tie wraps as needed. Torque to 36 ft-lb / 49 Nm (Models 71XX/8841) Torque to 18 ft-lb / 24 Nm Figure 11. Connect Hoses Countersunk holes toward back Figure 9. Mount Manifold to Spacer 5. Adjust the orientation of the solenoid as needed, and torque the nut to 60 in-lb / 6.8 Nm. Reconnect the solenoid wires, routing them to avoid sharp edges. Secure with tie wraps as needed. 3. For 9250 (continued) - Mount the manifold/ spacer assembly to the new holes in the cabinet using bolts (103864), flat washers (103404), lock washers (103996), and nuts (100397). Figure 11. Reconnect Wires New holes Figure 10. Mount Manifold to Cabinet SKYJACK, Page 8

13 Install Gripper Clips and Pump Handle 1. In the same cabinet where the brake manifold is located, place two gripper clips (164796) against the cabinet floor (71XX/8841) or right wall (9250), flush against the front inside lip of the cabinet. 2. For 71XX - Place the clips 6 and 13 (15 cm and 33 cm) from the inside of the right wall of the cabinet. Mark the holes with a marker, and remove the clips. 3. For Place the clips 6 and 13 (15 cm and 33 cm) from the inside left wall of the cabinet. Mark the holes with a marker, and remove the clips. 4. For Place the clips 2 and 10 (5 cm and 25.5 cm) from the inside top wall of the cabinet. Mark the holes with a marker, and remove the clips. 5. For all models - Using a 3/16 drill bit, drill two holes where marked in the previous steps. Clean up the metal shavings. Model 71XX 6. Install the clips using bolts (116192), flat washers (103991), and locknuts (138765). Install clips and hardware Figure 13. Install Clips 7. Mount the orange pump handle (164797) in the clips cm 6 15 cm FRONT (Overhead view) Model cm cm FRONT (Overhead view) TOP (Side View) 2 5 cm Figure 14. Mount Pump Handle in Clips (9250 shown) cm Model 9250 Figure 12. Drill Holes for Clips SKYJACK, Page 9

14 Replace Label 1. Remove the existing Towing/Pushing Procedure label from the cabinet wall/floor. Clean the cabinet surface until it is free of dirt and adhesive. Use a degreaser, if needed Apply the new label to the cabinet wall below the brake manifold. 2. Peel the backing off of the new Towing/Pushing Procedure label (164846), and apply it in the locations described below: 3. 71XX - Apply the label to the floor of the cabinet, to the right of the brake manifold, and behind the pump handle. Figure 17. Replace Label (Model 9250) Figure 15. Replace Label (Model 71XX) Apply the new label to the cabinet wall above, and in front of, the brake manifold. Figure 16. Replace Label (Model 8841) SKYJACK, Page 10

15 4.0 Bleeding the Brake Caliper 6. Open the bleeder screw 1/4 turn counterclockwise. 1. Chock or block the wheels. 2. Start the engine, raise the platform, and deploy the maintenance stand. 3. Shut off the engine. 4. Locate the brake caliper in front of the rear axle, then locate the bleeder screw on the top of the brake caliper, and remove the cap. Figure 20. Open Bleeder Screw 7. Refer to Section 5.0 Manual Brake Pump Test and Caliper Adjustment for details on using the manual brake pump, which is required for the next steps. 8. Push in the black brake release knob. Figure 18. Locate Brake Caliper Bleeder 5. Attach a piece of clear hose to a standard bleeder fitting, and attach the bleeder fitting to the bleeder screw. Place the other end of the hose into a container suitable for catching hydraulic oil. Bleeder fitting, hose and container Figure 21. Push in Brake Release Knob Figure 19. Attach Bleeder Fitting and Hose SKYJACK, Page 11

16 9. Slowly pump the brake pump repeatedly (see Section 5.0) until air bubbles are seen in the line. Continue pumping until there are no more air bubbles. Air bubbles in line 12. Follow the instructions in Section 5.0 Manual Brake Pump Test and Caliper Adjustment to test the brake manifold/pump. 13. Repeat steps 6 to 12 above if needed until the brake pump is working correctly. 14. Disconnect the bleeder fitting and hose, and replace the bleeder screw cap. Figure 22. Remove Air from Line 10. Close the bleeder screw. Figure 25. Replace Bleeder Cap 15. Stow the maintenance stand. Figure 23. Close Bleeder Screw 11. Pull out the black brake release knob. Figure 24. Reset Brake SKYJACK, Page 12

17 5.0 Manual Brake Pump Test and Caliper Adjustment 1. Prime the manifold by starting the engine and driving the aerial platform backward and forward approximately 10 ft / 3.05 m. 2. Deploy the maintenance stand, and shut off the engine. NOTE If the brake manifold requires more than 3 pumps, or the brake does not release, the brake caliper may need to be bled. See Section 4.0 Bleeding the Brake Caliper. 5. Remove the cap and turn the brake caliper adjusting screw clockwise until the calipers clamp onto the disc brake. 3. Remove the orange pump handle from the clips, and insert it in the pump valve socket. Turn screw clockwise Disc brake Calipers OVERHEAD VIEW Figure 28. Tighten the Brake Calipers Figure 26. Insert Handle 4. Push in the black knob on the brake release valve, then pump the handle on the pump valve back and forth 1 to 3 times until firm resistance is felt (approximately lb or kg force). The brake should now be released. 6. On the adjustment bolt, loosen the hex nut and turn the bolt clockwise until it makes contact with the bump stop, then back it off counterclockwise 1/4 turn. Loosen hex nut 2. Pump handle 1-3 times 1. Push in black knob Adjustment bolt Figure 29. Set Adjustment Bolt Figure 27. Release the Brake SKYJACK, Page 13

18 7. Hold the bolt in place while tightening the hex nut against the inner hex nut to ft-lb. 9. Remove the manual brake pump handle, and place it back in the retaining clips. Tighten nut OVERHEAD VIEW Figure 30. Tighten Adjustment Nut Figure 32. Return Handle to Clips 8. Back off the adjusting screw 1/2 turn counterclockwise. Replace the cap. 10. Pull out the black brake valve knob to reset the brake. Back off adjusting screw 1/2 turn Replace cap Figure 31. Back off the Adjusting Screw 1/2 turn Figure 33. Reset Brake 11. Start the engine, stow the maintenance stand, and lower the platform. 12. Shut off the engine. SKYJACK, Page 14

19 Notes SKYJACK, Page 15

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