Skyjack SJ61T SJ66T Telescopic Booms Service Manual 168895AG – PDF DOWNLOAD
$28.95
Skyjack SJ61T SJ66T Telescopic Booms Service Manual 168895AG – PDF DOWNLOAD
Serial Number(s):
SJ61T & SJ66T: 97 001 136 through 97 001 395
Description
Skyjack SJ61T SJ66T Telescopic Booms Service Manual 168895AG – PDF DOWNLOAD
FILE DETAILS:
Skyjack SJ61T SJ66T Telescopic Booms Service Manual 168895AG – PDF DOWNLOAD
Language : English
Pages :220
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Skyjack SJ61T SJ66T Telescopic Booms Service Manual 168895AG – PDF DOWNLOAD
Serial Number(s):
SJ61T & SJ66T: 97 001 136 through 97 001 395
and dimensions are subject to change without notice.
Aerial Platform Definition
A mobile device that has an adjustable position platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK Telescopic Boom Series (Models SJ 40T, 45T, 61T & 66T) aerial platform is designed to transport
and raise personnel, tools and materials to overhead work areas
Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level,
compacted surface. It can be driven over uneven terrain only when the platform is fully lowered.
Manuals
Operating Manuals
The operating manual is considered a fundamental part of the aerial platform. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the aerial platform at all times.
Service & Maintenance Manuals
The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.
All information in this manual should be read and understood before any attempt is made to service the machine.
The updated copy of the manuals are found on the company’s
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Skyjack SJ61T SJ66T Telescopic Booms Service Manual 168895AG – PDF DOWNLOAD
Cover 1
Table of Contents 3
Section 1 – Scheduled Maintenance 5
Operator’s Responsibility for Maintenance 6
Aerial Platform Definition 6
Purpose of Equipment 6
Use of Equipment 6
Manuals 6
Service Policy and Warranty 6
Operator Safety Reminders, Warnings, and Precautions 6
Maintenance and Inspection Schedule 7
Owner’s Annual Inspection Record 7
Replacement Parts 7
Maintenance and Service Safety Tips 7
Hydraulic System & Component Maintenance and Repair 8
Maintenance Hints 8
Railing Maintenance and Repair 9
Service and Maintenance 10
About this Section 10
Service Bulletins 10
Maintenance and Inspection 10
Maintenance Instructions 10
Tables 11
Table 1 1 Owner’s Annual Inspection Record 11
Table 1 2 Pre-Delivery / Maintenance Inspection Checklist 12
Scheduled Maintenance Inspections and Function Tests 13
1 1 Scheduled Maintenance Inspections 13
1 2 Function Tests 25
Section 2 – Maintenance Tables and Diagrams 27
Tables 28
Table 2 1 Standard Hose Numbering System 28
Table 2 2 Aerial Platform Torque Specifications 30
Table 2 3 Axles Torque Specifications 31
Table 2 4 Torque Specifications for Fasteners (Imperial) 32
Table 2 5 Torque Specifications for Fasteners (Metric) 33
Table 2 6 Torque Specifications for Hydraulic Couplings & Hoses 34
Table 2 7 Axles Maintenance Intervals 35
Table 2 8 Tire Specifications 36
Table 2 9 Floor Loading Pressure 37
Table 2 10 Hydraulic Specifications 38
Table 2 11 Specifications and Features 39
Diagrams 41
Diagram 2 1 Dimension and Reach Diagram – SJ 61T 41
Diagram 2 2 Dimension and Reach Diagram – SJ 66T 42
Diagram 2 3 Axle Oscillation Diagrams 43
Section 3 – System Component Identification and Schematics 45
Charts 47
3 1 Hydraulic Symbol Chart 47
3 2 Electrical Symbol Chart 48
3 3 Wire Number and Color Code 49
Parts Lists 50
3 4 Hydraulic Schematic Parts List 50
3 5 Electrical Component Parts List 53
Diagrams and Schematics 56
3 6 Rotary Manifold and Port Identifications 56
3 7 Brake Manifold and Port Identifications 57
3 8 System and Drive Pumps and Port Identifications 58
3 9 System Pump and Port Identifications 59
3 10 Drive Pump and Port Identifications 60
3 11 Drive Motors and Port Identifications 61
3 12 Jib Valve and Port Identifications 62
3 13 No Jib Valve and Port Identifications 63
3 14 Pressure Reducing Valve Port Identifications 64
3 15 Main Manifold Port Identification 65
3 16 Main Manifold Electrical Component Identification 66
3 17 Main Manifold Hydraulic Component Identification 67
3 18 Generator Control Valves and Port Indentifcations 68
3 19 Main Harness Wiring Diagram 69
3 20 ECU Engine Wiring Diagram (Deutz Diesel Engine) 70
3 21 Glow Plug and EGR Harnesses (Deutz Diesel Engine) 71
3 22 Engine Interface Harness (Deutz TD2 9L Diesel) 72
3 23 Engine Interface Harness (GM Dual Fuel Engine) 73
3 24 Harnesses 74
3 25 Platform Control Cable Harnesses 75
3 26 Limit Switch Connections 76
3 27 Load Sensing Cable Connection (CE) 77
3 28 Generator and Oil Cooler Harness Connections 78
3 29 Generator Wire Kit Connections 79
3 30 12kW Generator Connection Assembly 80
3 31 SGE Wiring Diagram 81
3 32 Telematics Wiring Diagram 82
3 33 Hydraulic Schematic Diagram 83
3 34 Platform Control Console Diagram (61T ANSI/CSA – Deutz Diesel Engine) 84
3 35 Platform Control Console Diagram (61T ANSI/CSA – GM Dual Fuel Engine) 85
3 36 Platform Control Console Diagram (66T ANSI/CSA – GM Dual Fuel Engine) 86
3 37 Platform Control Console Diagram (66T ANSI/CSA – Deutz Diesel Engine) 87
3 38 Platform Control Console Diagram (66T CE – Deutz Diesel Engine) 88
3 39 Platform Control Console Diagram (66T AS – Deutz Diesel Engine) 89
3 40 Base Control Console Diagram (61T ANSI/CSA – GM Dual Fuel Engine) 90
3 41 Base Control Console Diagram (61T ANSI/CSA – Deutz D2011 Diesel Engine) 91
3 42 Base Control Console Diagram (61T ANSI/CSA – Deutz TD2 9L Diesel Engine) 92
3 43 Base Control Console Diagram (66T ANSI/CSA – GM Dual Fuel) 93
3 44 Base Control Console Diagram (66T ANSI/CSA – Deutz D2011 Diesel Engine) 94
3 45 Base Control Console Diagram (66T CE – Deutz D2011 Diesel Engine) 95
3 46 Base Control Console Diagram (66T AS – Deutz D2011 Diesel Engine) 96
3 47 Base Control Console Diagram (66T ANSI/CSA – Deutz TD2 9L Diesel Engine) 97
3 48 Base Control Console Diagram (66T CE – Deutz TD2 9L Diesel Engine) 98
3 49 Electrical Schematic Diagram (ANSI/CSA – GM Dual Fuel Engine) 99
3 50 Electrical Schematic Diagram (ANSI/CSA – Deutz D2011 Diesel Engine) 100
3 51 Electrical Schematic Diagram (CE – Deutz D2011 Engine) 101
3 52 Electrical Schematic Diagram (AS – Deutz D2011 Engine) 102
3 53 Electrical Schematic Diagram (ANSI/CSA – Deutz TD2 9L Diesel Engine) 103
3 54 Electrical Schematic Diagram (CE – Deutz TD2 9L Engine) 104
3 55 Interface & Engine Electrical Schematic – GM Dual Fuel Engine 105
3 56 Interface & Engine Electrical Schematic – Deutz TD2 9L Diesel Engine 106
Introduction 109
Section 4 – Troubleshooting Information 107
4 1 Electrical System 110
4 1-1 All Controls Inoperative 110
4 1-2 No Power To Platform 110
4 1-3 No Power to Base 111
4 1-4 Engine Will Not Crank from Base 111
4 1-5 Engine Will Not Crank from Platform 111
4 1-6 Engine Will Not Crank from Platform or Base (Deutz TD2 9L) 112
4 1-7 Engine Cranks but Will Not Start (Deutz TD2 9L) 112
4 1-8 Engine Will Not Crank from Platform or Base (Deutz Diesel D2011) 113
4 1-9 Engine Cranks but Will Not Start (Deutz Diesel D2011) 113
4 1-10 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel) 114
4 1-11 Engine Cranks but Will Not Start (GM Dual Fuel) 115
4 1-12 Glow Plug Circuit Inoperative 117
4 1-13 All Controls Inoperative from Base Console 117
4 1-14 No Boom Up from Base Control Console 118
4 1-15 No Boom Down from Base Control Console 118
4 1-16 No Turret Rotate Left from Base Control Console 118
4 1-17 No Turret Rotate Right from Base Control Console 119
4 1-18 No Telescope Retract From Base Control Console 119
4 1-19 No Telescope Extend From Base Control Console 119
4 1-20 No Platform Rotate Left From Base Control Console 120
4 1-21 No Platform Rotate Right from Base Control Console 120
4 1-22 No Platform Rotate Left or Right from Base Control Console 121
4 1-23 No Jib Up from Base Control Console 121
4 1-24 No Jib Down from Base Control Console 121
4 1-25 No Jib Up Or Down From Base Control Console 122
4 1-26 No Manual Platform Level Up From Base Control Console 122
4 1-27 No Manual Platform Level Down From Base Control Console 123
4 1-28 No Manual Platform Level Up From Platform Control Console 123
4 1-29 No Manual Platform Level Down From Platform Control Console 124
4 1-30 All Controls Inoperative From Platform Control Console 124
4 1-31 No Boom Up From Platform Control Console 125
4 1-32 No Boom Down From Platform Control Console 125
4 1-33 No Turret Left from Platform Control Console 126
4 1-34 No Turret Right from Platform Control Console 127
4 1-35 No Telescope Out from Platform Control Console 127
4 1-36 No Telescope Out from Platform Control Console 128
4 1-37 No Platform Rotate or Jib Function from Platform Control Console 129
4 1-38 No Platform Rotate Left from Platform Control Console 129
4 1-39 No Platform Rotate Right from Platform Control Console 129
4 1-40 No Jib Up from Platform Control Console 130
4 1-41 No Jib Down from Platform Control Console 130
4 1-42 Throttle Inoperative, Mid and High (Deutz TD2 9L only) 130
4 1-43 Mid Throttle Inoperative 131
4 1-44 High Throttle Inoperative 132
4 1-45 Brake will not Release 133
4 1-46 No Drive and Steer 133
4 1-47 No Forward Drive 133
4 1-48 No Reverse Drive 133
4 1-49 No High Speed Drive 134
4 1-50 No Elevated Drive 135
4 1-51 No Left Steer 135
4 1-52 No Right Steer 136
4 1-53 Direction Sensing Inoperative 136
4 1-54 Steer Direction Sensing Inoperative 137
4 2 Hydraulic System 138
4 2-1 All Controls Inoperative 138
4 2-2 All Boom Functions Inoperative 138
4 2-3 No Main Boom Up 138
4 2-4 No Main Boom Down 138
4 2-5 No Turret Rotate Left 139
4 2-6 No Turret Rotate Right 139
4 2-7 No Boom Extend 140
4 2-8 No Boom Retract 140
4 2-9 No Jib Up 140
4 2-10 No Jib Down 141
4 2-11 No Platform Rotation Right 141
4 2-12 No Platform Rotation Left 141
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 142
4 2-16 Brake will not Engage 143
4 2-17 No Drive Forward or Reverse 143
4 2-18 No Forward Drive 143
4 2-19 No Reverse Drive 143
4 2-20 No High Speed Drive 143
4 2-21 No Right Steer 144
4 2-22 No Left Steer 144
4 2-23 Axle Will Not Oscillate 144
4 2-24 Axle Will Not Lock 144
4 3 Load Sensing System – CE 145
4 3-1 Green Power LED is not Flashing 145
4 3-2 Load Cell red Alarm LED is ON (with platform empty) 145
4 3-3 Red Error LED is ON 145
4 3-4 Load Cell red Alarm LED is OFF (with platform overloaded) 145
4 3-5 Platform Indicator Light does not turn ON 145
4 3-6 Audible Alarm does not turn ON 145
4 3-7 Boom and Drive Functions are Enabled (with boom extended) 145
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 Fly Boom Switch Voltage References 158
5 1-8 Platform Controller Voltage References 159
Boom 160
5 2-1 Check Wear Pads 160
5 2-2 Shimming Wear Pads 160
5 2-3 Cable Carrier Repair 160
5 2-4 Inspection and Replacement of Extension Cylinder and Boom Cables 160
5 2-5 Cable Inspection 164
5 2-6 Cable Tension 167
Turret 167
5 3-1 Check and Replace High Pressure Filter 167
5 3-2 Adjust Turret Rotation Gear Backlash 168
5 3-3 Check Swing Drive Motor Gearbox Oil 168
5 3-4 Change Swing Drive Motor Oil 168
5 3-5 Battery Replacement 169
5 3-6 Bolt Torque Procedure 169
5 3-7 Electronic Tilt Switch Setup Procedure 170
5 3-8 Check Rotation Bearing for Axial Wear 173
Deutz Diesel Engine 174
5 4-1 Replace Engine Oil and Filter 174
5 4-2 Replace Fuel Filter 175
5 4-3 Replace Air Filter 175
5 4-4 Check Engine Belt 175
5 4-5 Check Oil Cooler 175
5 4-6 Deutz D2 9L Fault Codes 176
GM Dual Fuel Engine 196
5 5-1 GM Map and IAT Sensor 196
5 5-2 LPG Temperature Sensor 197
5 5-3 Throttle Actuator 198
5 5-4 Engine Coolant Temperature Sensor 199
5 5-5 ECU Pin Reference Chart 200
5 5-6 Fuse Block Layout 201
Hydraulic Tank 202
5 6-1 Change Hydraulic Tank Filter 202
5 6-2 Change Hydraulic Oil 202
Manifold and Hydraulic Pumps 203
5 7-1 Hydraulic Brake Pressure Adjustment 203
5 7-2 Hydraulic Standby Pressure Adjustment 204
5 7-3 Hydraulic High Pressure Adjustment 205
5 7-4 Hydraulic System Relief Valve Adjustment 206
5 7-5 Turret Rotate Relief Valve Adjustment 207
5 7-6 Platform Level Relief Valve Adjustment 207
5 7-7 Fly Boom Relief Valve Adjustment 208
5 7-8 Test Charge Pump Pressure on Drive Pump 208
5 7-9 Test Forward Drive Pressure on Drive Pump 209
5 7-10 Test Reverse Drive Pressure on Drive Pump 209
Axles 210
5 8-1 Change Oil in Axles 210
5 8-2 Check Oil Level in Torque Hub 210
5 8-3 Check Oil Level in Axle Gearbox 211
5 8-4 Change Oil in Axle Gearbox 211
5 8-5 Bleeding Oscillating Axle Cylinders 211
5 8-6 Pin Brake Adjustments 212
5 8-7 Brake Inspection 213
Grease Points 214
5 9-1 Lubrication 214
5 9-2 Grease Turret Rotation Bearing 214
5 9-3 Grease Turret Rotation Gear 214
5 9-4 Grease Drive Axle 215
5 9-5 Grease Drive Shaft 215
Options 216
5 10-1 Load Sensing System – CE 216
Customer Support: [email protected]
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S.M
