Service Bulletin #119 SJ45T, SJ61T, SJ66T E-Chain System Replacement

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1 Service Bulletin #119 SJ45T, SJ61T, SJ66T E-Chain System Replacement September 4, 2013 Models Affected: SJ45T, SJ61T, SJ66T SJ45T , , , SJ61T , , SJ66T , , , , , , , , , , , , , , , , , , , , , Introduction: In our continuing effort to provide the best possible product to our customers and yours, we require that the following E-Chain System Replacement be completed for all machines with serial numbers listed above. Failure to implement this bulletin can potentially result in the detachment of cross-bars on the e-chains, as well as damage to the hoses and cables along the telescopic boom. Procedure: All units with the above serial numbers must have the e-chain system 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 4 hours of labor to complete this bulletin. Refer to Instructions part number # and order Field Kit # (Model 45T) or # (Model 61T/66T) 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 #119 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 #119 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 #119. 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 Model SJ45T SJ61T SJ66T

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 Installation Procedure... 5 Old E-Chain Removal... 5 New E-Chain Installation Testing SKYJACK, Page 3

8 1.0 Parts Inventory Index No. Skyjack Part No. Qty. Description A FIELD KIT, (Models 45T) B FIELD KIT, (Models 61T/66T) E-CHAIN ASSEMBLY (Models 45T), A E-CHAIN ASSEMBLY (Models 61T/66T), B PLATE, Adapter BOLT, Button head cap screw (5/16-18 x 1.00 ) BOLT, Flat head cap screw (5/16-18 x 1.00, Grade 5) WASHER, Flat (5/16 ) NUT, Nylon FIELD INSTRUCTION, (not shown) SKYJACK, Page 4

9 2.0 Preparation 1. Ensure aerial platform is on a firm, level surface. 2. Extend the boom until the turret end of the e-chain is within working distance. 3. Chock or block the wheels to keep the aerial platform from rolling forward and backward. 3.0 Installation Procedure Old E-Chain Removal 1. Support or suspend the e-chain tube weldment using blocks, a jack, sling, crane, or other supportive device. 4. Push in emergency stop button on platform control console and base control console. 5. Turn base/off/platform key switch to off position. Remove key. 6. Turn main power disconnect switch to off position. Figure 1. Support the Tube Weldment 2. Place wooden blocks where needed between the e-chain and lower cover to support the components. Figure 2. Remove Lower E-Chain Cover SKYJACK, Page 5

10 3. Remove the hardware securing the lower e-chain cover to the upper e-chain cover. Remove the lower cover and set it and the hardware aside. 5. Remove the upper/inside crossbars and dividers along the entire length of the e-chain. Discard. Figure 3. Remove Lower E-Chain Cover Figure 5. Remove Crossbars and Dividers 4. Remove the hardware securing the e-chain upper cover. Remove the cover and set it and the hardware aside. 6. Remove the hardware securing the e-chain feet at the turret end of the e-chain. Set aside the hardware for reuse later. Figure 4. Remove Upper E-Chain Cover Figure 6. Remove Hardware SKYJACK, Page 6

11 7. Carefully snip the zip ties securing the boom hoses and cables at each end of the e-chain. 9. Pull the freed e-chain up the boom towards the turret, until it is clear of the hoses. Remove and discard the e-chain. Figure 7. Cut Zip Ties Figure 9. Remove Old E-Chain 8. Reaching through the hoses and cables, remove the hardware (x4) securing the e-chain feet at the platform end of the e-chain. Discard the hardware. Figure 8. Remove Jib Resting Pad SKYJACK, Page 7

12 New E-Chain Installation 1. Take the new e-chain to the boom, and slide it under the hoses. Orient it so the end with the adapter plate and outer feet goes in first (towards the platform). 3. Neatly arrange the hoses and cables. Starting from the platform end, replace the upper/inside link crossbars in the e-chain, placing a divider under the first crossbar, and every other crossbar following. Arrange the hoses on one side of the divider, and the cables on the other side. Slide this end in first Figure 10. Place E-Chain Figure 12. Arrange New E-Chain 2. Fasten the adapter plate to the inserts (x4) in the lower e-chain carrier weldment, using new washers (103996) and button head bolts (111231). Use a bolt and washer combination in the holes on the feet. 4. Mount the inside feet to the turret end of the e-chain and to the tube weldment using the 1/4 hardware removed earlier. Figure 11. Fasten the New Mounting Plate Figure 13. Install Inside Feet SKYJACK, Page 8

13 5. Zip tie the hoses and cables where they enter and exit the e-chain (zip ties hoses to hoses, and cables to cables, not hoses to cables). Also zip tie them on the underside of the rounded end of the e-chain support. 7. Replace the lower e-chain cover, securing it in place with the 1/4 hardware removed earlier. Figure 16. Replace Lower Cover Figure 14. Zip Tie Hoses and Cables 6. Replace the upper e-chain cover, securing it in place with the 3/8 hardware removed earlier. 8. Remove the blocks, jack, sling, or other supporting device from the e-chain tube weldment. Figure 17. Remove the Sling Figure 15. Replace Upper Cover SKYJACK, Page 9

14 4.0 Testing 1. Turn the main power disconnect switch to the on position. 2. Pull out the emergency stop buttons on the platform control console and on the base control console. 3. Turn the base/off/platform key switch to the base position. 4. Start the engine. 5. Fully extend and retract the boom several times, checking that the e-chain moves smoothly. Also check that the hoses and cables are secure within the e-chain, and they are not twisting. Check for hydraulic leaks. SKYJACK, Page 10

15 Notes SKYJACK, Page 11

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