Skyjack SJ61T SJ66T Telescopic Booms Service Manual 143871AJ – PDF DOWNLOAD

Description

Skyjack SJ61T SJ66T Telescopic Booms Service Manual 143871AJ – PDF DOWNLOAD

FILE DETAILS:

Skyjack SJ61T SJ66T Telescopic Booms Service Manual 143871AJ – PDF DOWNLOAD

Language : English
Pages :198 
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Skyjack SJ61T SJ66T Telescopic Booms Service Manual 143871AJ – PDF DOWNLOAD

Serial Number(s):
SJ61T & SJ66T 97 000 001 to 97 000 917

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Skyjack SJ61T SJ66T Telescopic Booms Service Manual 143871AJ – PDF DOWNLOAD

Cover 1
Table of Contents 3
Section 1 – Scheduled Maintenance 5
Operator’s Responsibility for Maintenance 7
Aerial Platform Definition 7
Railing Maintenance and Repair 16
Maintenance Hints 15
Hydraulic System & Component Maintenance and Repair 15
Maintenance and Service Safety Tips 14
Replacement Parts 14
Owner’s Annual Inspection Record 14
Maintenance and Inspection Schedule 14
Safety Precautions 10
Electrocution Hazard 9
Operator Safety Reminders 8
Scope of this Manual 8
Purpose of Equipment 7
Use of Equipment 7
Manuals 7
Operator 7
Service Policy and Warranty 7
Optional Accessories 7
Service and Maintenance 17
About this Section 17
Service Bulletins 17
Maintenance and Inspection 17
Maintenance Instructions 17
Tables 18
Table 1 1 Owner’s Annual Inspection Record 18
Table 1 2 Maintenance and Inspection Checklist 19
Scheduled Maintenance Inspections and Function Tests 20
1 1 Scheduled Maintenance Inspections 20
1 2 Function Tests 29
Section 2 – Maintenance Tables and Diagrams 39
Tables 40
Table 2 1 Standard Hose Numbering System 40
Table 2 2 Aerial Platform Torque Specifications 42
Table 2 3 Axles Torque Specifications 43
Table 2 4 Axles Maintenance Intervals 44
Table 2 5 Tire Specifications 45
Table 2 6 Floor Loading Pressure 46
Table 2 7 Hydraulic Specifications 47
Table 2 8 Specifications and Features 48
Diagrams 50
Diagram 2 1 Dimension and Reach Diagram – SJ 61T 50
Diagram 2 2 Dimension and Reach Diagram – SJ 66T 51
Diagram 2 3 Axle Oscillation Diagrams 52
Section 3 – System Component Identification and Schematics 53
Charts 55
3 1 Hydraulic Symbol Chart 55
3 2 Electrical Symbol Chart 56
3 3 Wire Number and Color Code 57
Parts Lists 58
3 4 Hydraulic Schematic Parts List 58
3 5 Electrical Component Parts List 61
Diagrams and Schematics 64
3 6 Rotary Manifold and Port Identifications (Dual Mount Plates) 64
3 7 Brake Manifold and Port Identifications 65
3 8 System Pump and Port Identifications 66
3 9 Drive Pump and Port Identifications 67
3 10 Drive Motors and Port Identifications 68
3 11 Jib Valve and Port Identifications 69
3 12 No Jib Valve and Port Identifications 70
3 13a Main Manifold and Port Identifications 71
3 13b Main Manifold and Electrical Identifications 72
3 13c Main Manifold and Hydraulic Identifications 73
3 14 Main Harness Wiring Diagram 74
3 15 ECU Engine Wiring Diagram (Deutz Diesel Engine) 75
3 16 Glow Plug and EGR Harnesses (Deutz Diesel Engine) 76
3 17 Engine Interface Harness (GM Dual Fuel Engine) 77
3 18 Harnesses 78
3 19 Platform Control Cable Harnesses 79
3 20 Limit Switch Connections 80
3 21 Load Sensing Cable Connection (CE) 81
3 22a Hydraulic Schematic Diagram 83
3 22b Hydraulic Schematic Diagram 84
3 23 Platform Control Console Diagram (ANSI/CSA SJ 66T – Deutz Diesel Engine) 85
3 24 Platform Control Console Diagram (ANSI/CSA SJ 61T – Deutz Diesel Engine) 86
3 25 Platform Control Console Diagram (CE & AS SJ 66T – Deutz Diesel Engine) 87
3 26 Platform Control Console Diagram (ANSI/CSA SJ 66T – GM Dual Fuel Engine) 88
3 27 Platform Control Console Diagram (ANSI/CSA SJ 61T – GM Dual Fuel Engine) 89
3 28 Base Control Console Diagram (ANSI/CSA SJ 66T – Deutz Diesel Engine) 90
3 29 Base Control Console Diagram (ANSI/CSA SJ 61T – Deutz Diesel Engine) 91
3 30 Base Control Console Diagram (CE SJ 66T – Deutz Diesel Engine) 92
3 31 Base Control Console Diagram (AS SJ 66T – Deutz Diesel Engine) 93
3 32a Base Control Console Diagram (ANSI/CSA SJ 66T – GM Dual Fuel Tier 3 Engine) 94
3 32b Base Control Console Diagram (ANSI/CSA SJ 66T – GM Dual Fuel Tier 2 Engine) 95
3 33a Base Control Console Diagram (ANSI/CSA SJ 61T – GM Tier 3 Dual Fuel Engine) 96
3 33b Base Control Console Diagram (ANSI/CSA SJ 61T – GM Tier 2 Dual Fuel Engine) 97
3 34 Electrical Schematic Diagram (ANSI/CSA – Deutz Diesel Engine) 98
3 35 Electrical Schematic Diagram (ANSI/CSA – Deutz Diesel Engine with Generator Convenience) 99
3 36 Electrical Schematic Diagram (CE SJ 66T – Deutz Diesel Engine) 100
3 37 Electrical Schematic Diagram (AS SJ 66T – Deutz Diesel Engine) 101
3 38a Electrical Schematic Diagram (ANSI/CSA – GM Dual Fuel Tier 3 Engine) 102
3 38b Electrical Schematic Diagram (ANSI/CSA – GM Dual Fuel Tier 2 Engine) 103
3 39 Interface & Engine Electrical Schematic – GM Dual Fuel 104
3 41 Generator Control Valves and Port Indentifcations 105
3 42 Generator and Oil Cooler Harness Connections 106
3 43 Generator Wire Kit Connections 107
3 44 12kW Generator Connection Assembly 108
Introduction 111
Section 4 – Troubleshooting Information 109
4 1 Electrical System 112
4 1-1 All Controls Inoperative 112
4 1-2 No Power To Platform 112
4 1-3 No Power to Base 112
4 1-4 Engine Will Not Crank from Base 113
4 1-5 Engine Will Not Crank from Platform 113
4 1-6 Engine Will Not Crank from Platform or Base (Deutz Diesel) 114
4 1-7 Engine Cranks but Will Not Start (Deutz Diesel) 114
4 1-8 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel) 115
4 1-9 Engine Cranks but Will Not Start (GM Dual Fuel) 115
4 1-10 Glow Plug Circuit Inoperative 118
4 1-11 All Controls Inoperative from Base Console 118
4 1-12 No Main Boom Down or Turret Rotate from Base Control Console 119
4 1-13 No Boom Up from Base Control Console 119
4 1-14 No Boom Down from Base Control Console 119
4 1-15 No Turret Rotate Left from Base Control Console 119
4 1-16 No Turret Rotate Right from Base Control Console 120
4 1-17 No Telescope Retract From Base Control Console 120
4 1-18 No Telescope Extend From Base Control Console 120
4 1-19 No Platform Rotate Left From Base Control Console 121
4 1-20 No Platform Rotate Right from Base Control Console 121
4 1-21 No Platform Rotate Left or Right from Base Control Console 122
4 1-22 No Jib Up from Base Control Console 122
4 1-23 No Jib Down from Base Control Console 123
4 1-24 No Jib Up Or Down From Base Control Console 123
4 1-25 No Manual Platform Level Up From Base Control Console 123
4 1-26 No Manual Platform Level Down From Base Control Console 124
4 1-27 No Manual Platform Level Up From Platform Control Console 124
4 1-28 No Manual Platform Level Down From Platform Control Console 125
4 1-29 All Controls Inoperative From Platform Control Console 126
4 1-30 No Boom Up From Platform Control Console 127
4 1-31 No Boom Down From Platform Control Console 127
4 1-32 No Turret Left from Platform Control Console 128
4 1-33 No Turret Right from Platform Control Console 128
4 1-34 No Toggle Switch Functions from Platform Control Console 129
4 1-35 No Telescope Out from Platform Control Console 129
4 1-36 No Telescope Out from Platform Control Console 130
4 1-37 No Platform Rotate or Jib Function from Platform Control Console 131
4 1-38 No Platform Rotate Left from Platform Control Console 131
4 1-39 No Platform Rotate Right from Platform Control Console 131
4 1-40 No Jib Up from Platform Control Console 132
4 1-41 No Jib Down from Platform Control Console 132
4 1-42 Mid Throttle Inoperative 132
4 1-43 High Throttle Inoperative 133
4 1-44 Brake will not Release 134
4 1-45 No Drive and Steer 134
4 1-46 No Forward Drive 135
4 1-47 No Reverse Drive 135
4 1-48 No High Speed Drive 136
4 1-49 No Elevated Drive 137
4 1-50 No Left Steer 137
4 1-51 No Right Steer 137
4 1-52 Direction Sensing Inoperative 138
4 1-53 Steer Direction Sensing Inoperative 138
4 2 Hydraulic System 139
4 2-1 All Controls Inoperative 139
4 2-2 All Boom Functions Inoperative 139
4 2-3 No Main Boom Up 139
4 2-4 No Main Boom Down 139
4 2-5 No Turret Rotate Left 140
4 2-6 No Turret Rotate Right 140
4 2-7 No Boom Extend 140
4 2-8 No Boom Retract 141
4 2-9 No Jib Up 141
4 2-10 No Jib Down 141
4 2-11 No Platform Rotation Right 142
4 2-12 No Platform Rotation Left 142
4 2-13 Platform will not Level Down 142
4 2-14 Platform will not Level Up 142
4 2-15 Brake will not Release 143
4 2-16 Brake will not Engage 143
4 2-17 No Drive Forward or Reverse 143
4 2-18 No Forward Drive 144
4 2-19 No Reverse Drive 144
4 2-20 No High Speed Drive 144
4 2-21 No Right Steer 144
4 2-22 No Left Steer 144
4 2-23 Axle Will Not Oscillate 145
4 2-24 Axle Will Not Lock 145
4 3 Load Sensing System – CE 146
4 3-1 Green Power LED is not Flashing 146
4 3-2 Load Cell red Alarm LED is ON (with platform empty) 146
4 3-3 Red Error LED is ON 146
4 3-4 Load Cell red Alarm LED is OFF (with platform overloaded) 146
4 3-5 Platform Indicator Light does not turn ON 146
4 3-6 Audible Alarm does not turn ON 146
4 3-7 Boom and Drive Functions are Enabled (with boom extended) 146
General 149
Safety and Workmanship 149
Section 5 – Procedures 147
Platform 149
5 1-1 Human Machine Interface (HMI) 149
5 1-2 User Interface Keys 150
5 1-3 How to Select Functionality 152
5 1-4 How to View OCM Operation 153
5 1-5 How to Unlock and Modify OCM Settings 154
5 1-6 OCM Pin Voltage Reference 155
5 1-7 Platform Controller Voltage References 158
Boom 159
5 2-1 Check Wear Pads 159
5 2-2 Shimming Wear Pads 159
5 2-3 Cable Carrier Repair 159
5 2-4 Inspection and Replacement of Extension Cylinder and Boom Cables (61T/66T) 159
5 2-5 Cable Inspection 163
5 2-6 Cable Tension (61T/66T) 166
Turret 166
5 3-1 Check and Replace High Pressure Filter 166
5 3-2 Adjust Turret Rotation Gear Backlash 167
5 3-3 Check Swing Drive Motor Gearbox Oil 167
5 3-4 Change Swing Drive Motor Oil 167
5 3-5 Battery Replacement 168
5 3-6 Bolt Torque Procedure 168
5 3-7 Electronic Tilt Switch Setup Procedure 169
5 3-8 Check Rotation Bearing for Axial Wear 172
Deutz Diesel Engine 173
5 4-1 Replace Engine Oil and Filter 173
5 4-2 Replace Fuel Filter 174
5 4-3 Replace Air Filter 174
5 4-4 Check Engine Belt 174
5 4-5 Check Oil Cooler 174
GM Dual Fuel Engine 175
5 5-1 GM Map and IAT Sensor 175
5 5-2 LPG Temperature Sensor 176
5 5-3 Throttle Actuator 177
5 5-4 Engine Coolant Temperature Sensor 178
5 5-5 ECU Pin Reference Chart 179
5 5-6 Fuse Block Layout 180
Hydraulic Tank 181
5 6-1 Change Hydraulic Tank Filter 181
5 6-2 Change Hydraulic Oil 181
Manifold and Hydraulic Pumps 182
5 7-1 Hydraulic Brake Pressure Adjustment 182
5 7-2 Hydraulic Standby Pressure Adjustment 183
5 7-3 Hydraulic High Pressure Adjustment 184
5 7-4 Hydraulic System Relief Valve Adjustment 185
5 7-5 Test Charge Pump Pressure on Drive Pump 186
5 7-6 Test Forward Drive Pressure on Drive Pump 186
5 7-7 Test Reverse Drive Pressure on Drive Pump 187
Axles 188
5 8-1 Change Oil in Rear Axle (including Front Axle – 61T/66T) 188
5 8-2 Change Oil in Front Axle (4WD) (40T/45T) 188
5 8-3 Check Oil Level in Torque Hub 188
5 8-4 Check Oil Level in Axle Gearbox 189
5 8-5 Change Oil in Axle Gearbox 189
5 8-6 Bleeding Oscillating Axle Cylinders 189
5 8-7 Pin Brake Adjustments 190
5 8-8 Brake Inspection 191
Grease Points 192
5 9-1 Lubrication 192
5 9-2 Grease Turret Rotation Bearing 192
5 9-3 Grease Turret Rotation Gear 192
5 9-4 Grease Drive Axle 193
5 9-5 Grease Drive Shaft 193
Options 194
5 10-1 Load Sensing System – CE 194

Need help? Contact: [email protected]

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M