service bulletin 124 - global | skyjack€¦ · · 2016-03-28168189ab). contact skyjack service...

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Service Bulletin #124 SJ 40T/45T/61T/66T/46AJ/51AJ

Pressure Reducing Valve Installation and Axle Drive Motor Replacement

**********SAFETY RELATED**********

March 28, 2014 Models Affected: SJ40T, SJ45 T, SJ 61T, SJ66T, SJ46 AJ, SJ 51AJ SJ40T 98001181, 98001187, 98001175, 98001176, 98001177, 98001178, 98001179, 98001201, 98001202, 98001203, 98001204, 98001205, 98001206 SJ45 T 98001145, 98001161, 98001165, 98001166, 98001167, 98001153, 98001154, 98001182, 98001174, 98001192 SJ 61T 97000942, 97000944, 97000945, 97000947, 97000949, 97000962 SJ66T 97000936, 97000932, 97000933, 97000938, 97000939, 97000940, 97000943, 97000946, 97000948, 97000950, 97000951, 97000952, 97000953, 97000956 SJ46 AJ 95000657, 95000666, 95000667, 95000668, 95000669, 95000671, 95000672, 95000665, 95000675, 95000676, 95000698, 95000696, 95000697, 95000677, 95000683, 95000684, 95000690, 95000700, 95000701, 95000722, 95000723, 95000678, 95000680, 95000681, 95000682, 95000685, 95000687, 95000693, 95000694, 95000695, 95000702, 95000716, 95000713, 95000714, 95000715, 95000705, 95000709, 95000704, 95000712, 95000717, 95000718, 95000719, 95000720, 95000721, 95000724, 95000725, 95000727, 95000728, 95000729, 95000730 SJ 51AJ 95000679, 95000688, 95000689, 95000692, 95000706, 95000707, 95000708, 95000710, 95000711

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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: www.skyjack.com. 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 #168171 as per the attached procedure (Skyjack part # 168169AC). 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 #169176 as per the attached procedure (Skyjack part # 168189AB). 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 #168192 as per the attached procedure (Skyjack part # 168188AC). 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.

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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 1-800-275-9522, Skyjack Europe at 44-1691-676-2, Skyjack Australia at 61 (0) 2878 63200 or Skyjack Brasil at 55-19-3936-0136. You may e-mail any questions to [email protected].

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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 Email This Form To Skyjack Service: Fax: (630) 262-0006 or 44-1691-676-238 (Europe)

Email: [email protected] If you have any questions please call Skyjack Service at 800-275-9522, 630-262-0005 or 44-1691-676-235 (Europe). You can e-mail any questions to [email protected] 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.

March 2014Pressure Reducing ValveInstallation Instructions168169AC

168169AC

Models

Pressure Reducing ValveInstallation Instructions

61T & 66T

SKYJACK, Page 2March 2014


168169AC

WARNING

WARNING

Parts (North America)Toll Free: 1-800-965-4626Toll Free Fax: 1-888-782-4825E-mail: [email protected]

Skyjack Australia Pty Ltd.4 Coates PlaceWetherill ParkNew South Wales 2164AustraliaTel: +61 (0) 28786 3200Fax: +61(0) 28786 3222

Skyjack Brasil

Indaiatuba, SP, Brasil 13347-653Tel: +55 19 3936 0132

Alameda Júpiter, 710Loteamento American Park Empresarial

Skyjack Service Center 3451 Swenson Ave. St. Charles,

Phone: 630-262-0005Toll Free: 1-800-275-9522Fax: 630-262-0006Email: [email protected]

Illinois, 60174 USA

Parts & Service (Europe) Unit 1 Maes Y Clawdd

Oswestry, Shropshire SY10 8NN UKPhone: +44-1691-676-235Fax: +44-1691-676-238E-mail: [email protected]

Maesbury Road Industrial Estate

March 2014SKYJACK, Page 3Pressure Reducing Valve

Installation Instructions168169AC

Table of Contents

1.0 Parts Inventory ............................................................................................................................ 42.0 Machine Preparation ................................................................................................................... 53.0 Installation Procedure ................................................................................................................ 5

Install the Pressure Reducing Valve Assembly (168170) ............................................................................. 5Hydraulic Hose Connections ........................................................................................................................ 6Replace the Axle Motors (163596) ................................................................................................................ 8

5.0 Testing Procedure........................................................................................................................ 8Test for Leaks ................................................................................................................................................. 8Test Drive Speeds .......................................................................................................................................... 8



168169AC

Skyjack

- 168171 1 PRESSURE REDUCING VALVE FIELD KIT

1

2 3 4 5 6

1

3

4

2

5



1.

2. Chock or block the wheels.

3. and extend the boom upwards as far as possible (space permitting).

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.

NOTEPrepare an oil pan or rags for the oil that

may drip.

CAUTIONDispose of oil in accordance with

environmental regulations.

Install the Pressure Reducing Valve Assembly (168170)

1.

the location indicated.

Figure 1. Remove hardware

2. Place the new valve assembly on the manifold

in the previous step.

Figure 2. Install valve assembly



168169AC

Hydraulic Hose Connections

3. bottom left of the brake manifold.

Figure 3. Disconnect hose from brake manifold

4.

pressure reducing valve manifold.

Figure 4. Connect hose to manifold

5. Connect the straight end of new hose (H340600261) left of the brake manifold.

Figure 5. Connect new hose to brake manifold

6.

of the pressure reducing valve manifold.

Figure 6. Connect new hose to valve manifold



7. Remove the end cap from one end of the supplied hose (H310400150)

(131705) to the hose. Ensure the other end cap remains securely in place.

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 8. Remove plug from hydraulic tank

9.

this port.

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 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.

14.



168169AC

Replace the Axle Motors (163596)

15. Replace both drive motors with the new motors provided (163596).

Figure 11. Replace the drive motors

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

d. or other suitable objects.

NOTEThis 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.



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.

15ft / 5m - Boom extended30ft / 10m - Boom retracted

1st marker 2nd marker

Start time Stop time

www.skyjack.com

March 2014Pressure Reducing ValveInstallation Instructions168189AB

168189AB

Models


46AJ & 51AJ



168189AB

WARNING

WARNING



Skyjack Brasil





Illinois, 60174 USA





Installation Instructions168189AB

Table of Contents


Install the Manifold, Fittings and Hoses ........................................................................................................ 5Replace the Axle Drive Motor (161964) ........................................................................................................ 8




168189AB

Skyjack

- 168176 1 PRESSURE REDUCING VALVE FIELD KIT - 46/51AJ

1

2 3 4 5 6 7 8 9 10

7

4

2

5

3

6

8

1

9



1.

2.

3.

4.

console.

5.

6.

7.

NOTEPrepare an oil pan and rags for the oil that

CAUTION

Install the Manifold, Fittings and Hoses

1. hose (H060400160)

(168167).

Figure 1. Connect hose to 90 tting

2.

Figure 2. Remove mounting hardware



168189AB

3.

(138957 (103996)(103984).

Figure 3. Mount new manifold

4.

Figure 4. Disconnect 2SPD hose

5.

Figure 5. Connect hose to new manifold

6. (702761) (155022)

(707041)straight end of the second hose (H060400160)

Figure 6. Connect ttings to hose



7.

Figure 7. Disconnect T port hose

8.

Figure 8. Connect hose to T port

9.

Figure 9. Connect hose to Tee tting

10.




168189AB

11.

Figure 11. Connect hose to brake manifold

12.

13.

14.

Replace the Axle Drive Motor (161964)

15. provided (161964).

Figure 12. Replace the drive motor

Test for Leaks

1.

2.

needed.

Test Drive Speeds

a.

Assistant

c.

d.

NOTE

3.

4. starting point.



9.

Move the second

11.

12.

are corrected.

15ft / 5m - Boom elevated30ft / 10m - Boom stowed



www.skyjack.com

March 2014Pressure Reducing ValveInstallation Instructions168188AC

168188AC

Models


40T & 45T



168188AC

WARNING

WARNING



Skyjack Brasil





Illinois, 60174 USA






Table of Contents


Install the Pressure Reducing Valve Assembly (168191) ............................................................................. 5Hydraulic Hose Connections ........................................................................................................................ 5Replace the Axle Drive Motor (161964) ........................................................................................................ 8




168188AC

Skyjack

- 168192 1 PRESSURE REDUCING VALVE FIELD KIT

1

2 3 4 5 6 7 8 9

1

6

7

2

3

4

5

8



1.

2. Chock or block the wheels.

3. and extend the boom upwards as far as possible (space permitting).

4. Push in the “the platform control console and base control console.

5.

6. 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.

NOTEPrepare an oil pan and rags for the oil that

may drip.

CAUTIONDispose of oil in accordance with

environmental regulations.

Install the Pressure Reducing Valve 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).

Figure 1. Install valve assembly

Hydraulic Hose Connections

2. 2SPD) on the bottom left of the brake manifold.

Figure 2. Disconnect hose from brake manifold



168188AC

3. bottom right of the new pressure reducing valve manifold.


4. (H340600261)

brake manifold (port 2SPD).

Figure 4. Connect new hose to brake manifold

5.

manifold.

Figure 5. Connect new hose to valve manifold

6. Remove the end cap from one end of supplied hose (H310600160)(103070) to the hose. Ensure the other end cap remains securely in place.

Figure 6. ttach tting to hose



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.

Figure 7. Remove plug from hydraulic tank

8.

this port.

Figure 8. Connect hose to tank port

9. Remove the end cap from the opposite end of the

on the bottom left of the new valve manifold.

Figure 9. Connect hose to valve assembly

10. Tighten the hose ends on all three hoses.

11. Clean up all of the leaked hydraulic oil.

12. Fully lower and stow the boom.

13.



168188AC

Replace the Axle Drive Motor (161964)

14. Replace the drive motor with the new motor provided (161964).

Figure 10. Replace the drive motor

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

d. or other suitable objects.

NOTEThis 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.



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.

15ft / 5m - Boom extended30ft / 10m - Boom retracted



www.skyjack.com

service bulletin 124 - global | skyjack€¦ · · 2016-03-28168189ab). contact skyjack service...

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