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

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Colin Davis
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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,

1 Service Bulletin #125 SJ 40T/45T/61T/66T/63AJ April 16, 2014 Models Affected: SJ40T, SJ45 T, SJ 61T, SJ66T, SJ63 AJ SJ40T , , , , , , , , , , , , , , , , SJ45 T , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , SJ 61T , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , SJ66T , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , SJ63 AJ , , , , , , , , Page 1 of 4

2 Introduction: In our continuing effort to provide the best possible product to our customers and yours, Skyjack requests that this bulletin be completed on all machines with serial numbers listed above. Failure to implement this bulletin could potentially result in slow or intermittent system pump function. This bulletin is also available on our website at: Procedure: 40/45T and 61/66T machines: All units with the above serial numbers must have the replacement system pump installed utilizing Skyjack service kit # as per the attached procedure (Skyjack part # ). Upon completion, contact Skyjack Service to arrange for the removed pump to be picked up. Please make sure that the pump is drained and capped before shipping. 63AJ machines: All units with the above serial numbers must have the replacement system pump installed utilizing Skyjack service kit # as per the attached procedure (Skyjack part # ). Upon completion, contact Skyjack Service to arrange for the removed pump to be picked up. Please make sure that the pump is drained and capped before shipping. Page 2 of 4

3 Parts and Warranty Policy: 40/45T, 61/66T and 63AJ machines: Skyjack will provide the necessary parts, without charge, and will reimburse up to 2 hours of labor, per machine, for the completion of this bulletin. 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 #125 has been completed and arrange for the removed system pump to be picked up. Please make sure that the pump is drained and capped before shipping. Reimbursement will be processed once the warranty claim has been received and the removed pump 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 #125 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 #125. 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 Models 40T & 45T 61T & 66T 63AJ

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, Page 2

7 Table of Contents 1.0 Parts Inventory Machine Preparation Replacement Procedure... 5 Remove the Old System Pump... 5 Prepare the New System Pump (163595)... 6 Install the New System Pump... 7 Replace the High Pressure Filter Element ( / ) Testing Procedure... 8 Check the Hydraulic Standby Pressure... 8 Adjust the Hydraulic Standby Pressure... 8 Check the Hydraulic High Pressure... 8 Adjust the Hydraulic High Pressure... 9 Function Test... 9 SKYJACK, Page 3

8 1.0 Parts Inventory Index No. Skyjack Part No. Qty. Description A SYSTEM PUMP AND HIGH PRESSURE FILTER FIELD KIT (40/45T & 61/66T) B SYSTEM PUMP AND HIGH PRESSURE FILTER FIELD KIT (63AJ) SYSTEM PUMP SEAL, O-Ring, A SEAL, O-Ring, B FILTER ELEMENT, High Pressure, A FILTER ELEMENT, High Pressure, B INSTRUCTION, SKYJACK, Page 4

9 2.0 Machine Preparation 1. Ensure the aerial platform is on a firm, level surface. 2. Push in the emergency stop button on the platform control console and base control console. 3.0 Replacement Procedure Remove the Old System Pump 1. Disconnect and cap the large case drain hose on the underside of the drive pump. Cap the fitting. 3. Turn the base/off/platform key switch to the off position. Remove the key. 4. Turn the main power disconnect switch to the off position. 5. Chock or block the wheels. NOTE Prepare an oil pan and rags for the oil that may drip. NOTE When working with hydraulics, ensure the work area is clean and free from any contaminants, such as dust or dirt. Cap fitting Disconnect and cap hose Figure 1. Disconnect & cap drive pump case drain 2. Disconnect and cap the hoses (x4) connected to the system pump. Note: Cap the large suction hose immediately, as it will drain the hydraulic tank otherwise. 3. Remove and set aside the hardware securing the system pump to the drive pump. Figure 2. Remove hoses and hardware SKYJACK, Page 5

10 4. Pull the system pump away from the drive pump until it is free, and place it on a workbench. 5. Remove the old o-ring seal from the drive pump and discard it. 8. Apply lubricant to the new o-ring seal ( for 40/45T and 61/66T or for 63AJ). Install the new o-ring on the lubricated boss of the system pump. Prepare the New System Pump (163595) 6. At the workbench, transfer the hydraulic fittings (x4) from the old pump to the new pump (163595). Torque them to the values shown below. 70 ft-lbs 108 ft-lbs Figure 5. Install new o-ring 15 ft-lbs Install the New System Pump 166 ft-lbs Figure 3. Transfer and torque fittings 7. Apply lubricant to the outside diameter and chamfer of the new system pump. 9. Align the shaft of the new system pump with the teeth of the drive pump, and push it in, stopping about 2 short. 10. Rotate the pump to align the mounting holes, then push it in fully, ensuring the o-ring does not get pinched. 11. Secure the system pump to the drive pump using the hardware removed earlier. Torque the bolts to 55 ft-lbs. Figure 4. Apply lubricant Figure 6. Align and secure the pump SKYJACK, Page 6

11 12. Reconnect the system pump hoses (x4) removed earlier, torquing them to the values shown below. 84 ft-lbs 55 ft-lbs Replace the High Pressure Filter Element ( / ) 14. Using the nut on the bottom of the high pressure filter housing, loosen and remove the housing from the filter head. 15. Remove and discard the old filter element, and install the new filter element ( for 40/45T & 61/66T or for 63AJ). 16. Reinstall the filter housing. For the 40/45T and 61/66T, tighten the filter housing fully hand-tight, then back it off 1/8 of a turn. For the 63AJ, torque it to 15 ft-lbs. 12 ft-lbs Figure 7. Reconnect & torque system pump hoses 13. Reconnect the drive pump hose removed earlier. Figure 8. Reconnect drive pump hose Figure 9. Replace the filter element SKYJACK, Page 7

12 4.0 Testing Procedure Check the Hydraulic Standby Pressure 1. Locate the GP2 port on either the top or bottom of the main manifold and remove the cap. Adjust the Hydraulic Standby Pressure 7. Loosen the lock nut on the load sense compensator on the system pump. 2. Connect a 600 psi pressure gauge to the GP2 port. Cap Load sense compensator Pressure Gauge GP2 Port Figure 11. Replace filter element Figure 10. Locate the GP2 port Main Manifold 8. Adjust the load sensing pressure by turning the adjusting stem either clockwise to increase pressure or counterclockwise to decrease pressure. 9. Tighten the lock nut after pressure is set to 330 psi. 3. Start the engine from the base control console. 4. Check for leaks at each of the newly installed/ reconnected hoses, fittings, and filter. Retighten if needed. 5. Let the engine run for 2-5 minutes. 6. Check the reading on the gauge. The standard pressure should be 330 psi. If the reading is 330 psi, skip to step 10. If the reading is not 330 psi, proceed to the next step to adjust the pressure. Check the Hydraulic High Pressure 10. Turn the engine off. 11. Replace the 600 psi pressure gauge on the GP2 port with a 5000 psi pressure gauge. 12. Start the engine from the base control console and let it run for 2-5 minutes. 13. Steer fully to one direction and then check the reading on the gauge. Standard pressure should be 3050 psi. If the reading is 3050 psi, skip to step 19. If the reading is not 3050 psi, proceed to the next step to adjust the pressure. SKYJACK, Page 8

13 Adjust the Hydraulic High Pressure 14. Loosen the lock nut on the pressure compensator on the system pump. Function Test 19. Perform the functions tests given in your unit s Operating manual. Pressure compensator Figure 12. Replace filter element 15. Adjust the system pump pressure by turning adjusting stem either clockwise to increase pressure or counterclockwise to decrease pressure. 16. Tighten the lock nut after pressure is set to 3050 psi. 17. Turn engine off. 18. Remove the pressure gauge from the GP2 port and cap the port. SKYJACK, Page 9

SAFETY RELATED

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,