Skyjack SJ61T SJ66T Telescopic Booms Service Manual 194312AG – PDF DOWNLOAD
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Skyjack SJ61T SJ66T Telescopic Booms Service Manual 194312AG – PDF DOWNLOAD
Serial Numbers:
SJ61T & SJ66T: 97 001 396 to 97 001 832
Description
Skyjack SJ61T SJ66T Telescopic Booms Service Manual 194312AG – PDF DOWNLOAD
FILE DETAILS:
Skyjack SJ61T SJ66T Telescopic Booms Service Manual 194312AG – PDF DOWNLOAD
Language : English
Pages :254
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Skyjack SJ61T SJ66T Telescopic Booms Service Manual 194312AG – PDF DOWNLOAD
Serial Numbers:
SJ61T & SJ66T: 97 001 396 to 97 001 832
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
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 194312AG – 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 (US 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 (61T ANSI/CSA – Deutz TD2 9L Diesel Engine with Positive Air Shut-Off Option) 93
3 44 Base Control Console Diagram (66T ANSI/CSA – GM Dual Fuel) 94
3 45 Base Control Console Diagram (66T ANSI/CSA – Deutz D2011 Diesel Engine) 95
3 46 Base Control Console Diagram (66T CE – Deutz D2011 Diesel Engine) 96
3 47 Base Control Console Diagram (66T AS – Deutz D2011 Diesel Engine) 97
3 48 Base Control Console Diagram (66T ANSI/CSA – Deutz TD2 9L Diesel Engine) 98
3 49 Base Control Console Diagram (66T ANSI/CSA – Deutz TD2 9L Diesel Engine with Positive Air Shut-Off Option) 99
3 50 Base Control Console Diagram (66T CE – Deutz TD2 9L Diesel Engine) 100
3 51 Electrical Schematic Diagram (ANSI/CSA – GM Dual Fuel Engine) 101
3 52 Electrical Schematic Diagram (ANSI/CSA – Kubota Dual Fuel Engine) 102
3 53 Electrical Schematic Diagram (ANSI/CSA – Deutz D2011 Diesel Engine) 103
3 54 Electrical Schematic Diagram (CE – Deutz D2011 Engine) 104
3 55 Electrical Schematic Diagram (AS – Deutz D2011 Engine) 105
3 56 Electrical Schematic Diagram (ANSI/CSA – Deutz TD2 9L Diesel Engine) 106
3 57 Electrical Schematic Diagram (CE – Deutz TD2 9L Engine) 107
3 58 Interface & Engine Electrical Schematic – GM Dual Fuel Engine 108
3 59 Interface & Engine Electrical Schematic – Kubota Dual Fuel Engine 109
3 60 Interface & Engine Electrical Schematic – Deutz TD2 9L Diesel Engine 110
Introduction 113
Section 4 – Troubleshooting Information 111
4 1 Electrical System 114
4 1-1 All Controls Inoperative 114
4 1-2 No Power To Platform 114
4 1-3 No Power to Base 115
4 1-4 Engine Will Not Crank from Base 115
4 1-5 Engine Will Not Crank from Platform 115
4 1-6 Engine Will Not Crank from Platform or Base (Deutz TD2 9L) 116
4 1-7 Engine Cranks but Will Not Start (Deutz TD2 9L) 116
4 1-8 Engine Will Not Crank from Platform or Base (Deutz Diesel D2011) 117
4 1-9 Engine Cranks but Will Not Start (Deutz Diesel D2011) 117
4 1-10 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel) 118
4 1-11 Engine Cranks but Will Not Start (GM Dual Fuel) 119
4 1-12 Glow Plug Circuit Inoperative 121
4 1-13 All Controls Inoperative from Base Console 121
4 1-14 No Boom Up from Base Control Console 122
4 1-15 No Boom Down from Base Control Console 122
4 1-16 No Turret Rotate Left from Base Control Console 122
4 1-17 No Turret Rotate Right from Base Control Console 123
4 1-18 No Telescope Retract From Base Control Console 123
4 1-19 No Telescope Extend From Base Control Console 123
4 1-20 No Platform Rotate Left From Base Control Console 124
4 1-21 No Platform Rotate Right from Base Control Console 124
4 1-22 No Platform Rotate Left or Right from Base Control Console 125
4 1-23 No Jib Up from Base Control Console 125
4 1-24 No Jib Down from Base Control Console 125
4 1-25 No Jib Up Or Down From Base Control Console 126
4 1-26 No Manual Platform Level Up From Base Control Console 126
4 1-27 No Manual Platform Level Down From Base Control Console 127
4 1-28 No Manual Platform Level Up From Platform Control Console 127
4 1-29 No Manual Platform Level Down From Platform Control Console 128
4 1-30 All Controls Inoperative From Platform Control Console 128
4 1-31 No Boom Up From Platform Control Console 129
4 1-32 No Boom Down From Platform Control Console 129
4 1-33 No Turret Left from Platform Control Console 130
4 1-34 No Turret Right from Platform Control Console 131
4 1-35 No Telescope Out from Platform Control Console 131
4 1-36 No Telescope Out from Platform Control Console 132
4 1-37 No Platform Rotate or Jib Function from Platform Control Console 133
4 1-38 No Platform Rotate Left from Platform Control Console 133
4 1-39 No Platform Rotate Right from Platform Control Console 133
4 1-40 No Jib Up from Platform Control Console 134
4 1-41 No Jib Down from Platform Control Console 134
4 1-42 Throttle Inoperative, Mid and High (Deutz TD2 9L only) 134
4 1-43 Mid Throttle Inoperative 135
4 1-44 High Throttle Inoperative 136
4 1-45 Brake will not Release 137
4 1-46 No Drive and Steer 137
4 1-47 No Forward Drive 137
4 1-48 No Reverse Drive 137
4 1-49 No High Speed Drive 138
4 1-50 No Elevated Drive 139
4 1-51 No Left Steer 139
4 1-52 No Right Steer 140
4 1-53 Direction Sensing Inoperative 140
4 1-54 Steer Direction Sensing Inoperative 141
4 2 Hydraulic System 141
4 2-1 All Controls Inoperative 141
4 2-2 All Boom Functions Inoperative 141
4 2-3 No Main Boom Up 141
4 2-4 No Main Boom Down 142
4 2-5 No Turret Rotate Left 142
4 2-6 No Turret Rotate Right 142
4 2-7 No Boom Extend 143
4 2-8 No Boom Retract 143
4 2-9 No Jib Up 144
4 2-10 No Jib Down 144
4 2-11 No Platform Rotation Right 144
4 2-12 No Platform Rotation Left 145
4 2-13 Platform will not Level Down 145
4 2-14 Platform will not Level Up 145
4 2-15 Brake will not Release 146
4 2-16 Brake will not Engage 146
4 2-17 No Drive Forward or Reverse 146
4 2-18 No Forward Drive 147
4 2-19 No Reverse Drive 147
4 2-20 No High Speed Drive 147
4 2-21 No Right Steer 147
4 2-22 No Left Steer 147
4 2-23 Axle Will Not Oscillate 147
4 2-24 Axle Will Not Lock 148
4 3 Load Sensing System – CE 148
4 3-1 Green Power LED is not Flashing 148
4 3-2 Load Cell red Alarm LED is ON (with platform empty) 148
4 3-3 Red Error LED is ON 149
4 3-4 Load Cell red Alarm LED is OFF (with platform overloaded) 149
4 3-5 Platform Indicator Light does not turn ON 149
4 3-6 Audible Alarm does not turn ON 149
4 3-7 Boom and Drive Functions are Enabled (with boom extended) 149
General 153
Safety and Workmanship 153
Section 5 – Procedures 151
Platform 153
5 1-1 Human Machine Interface (HMI) 153
5 1-2 User Interface Keys 154
5 1-3 How to Select Functionality 156
5 1-4 How to View OCM Operation 157
5 1-5 How to Unlock and Modify OCM Settings 158
5 1-6 OCM Pin Voltage Reference 159
5 1-7 Fly Boom Switch Voltage References 162
5 1-8 Platform Controller Voltage References 163
Boom 164
5 2-1 Cable Carrier Repair 164
5 2-2 Check Wear Pads 164
5 2-3 Shimming Wear Pads 164
5 2-4 Boom Section Wear Pad Replacement 165
5 2-5 Inspection and Replacement of Extension Cylinder and Boom Cables 178
5 2-6 Proper Wire Rope Tension 185
5 2-7 Wire Rope Inspection 186
Turret 187
5 3-1 Check and Replace High Pressure Filter 187
5 3-2 Adjust Turret Rotation Gear Backlash 187
5 3-3 Check Swing Drive Motor Gearbox Oil 188
5 3-4 Change Swing Drive Motor Oil 188
5 3-5 Battery Replacement 188
5 3-6 Bolt Torque Procedure 189
5 3-7 Electronic Tilt Switch Setup Procedure 190
5 3-8 Check Rotation Bearing for Axial Wear 193
Deutz Diesel Engine 194
5 4-1 Replace Engine Oil and Filter 194
5 4-2 Replace Fuel Filter 195
5 4-3 Replace Air Filter 195
5 4-4 Check Engine Belt 195
5 4-5 Check Oil Cooler 195
5 4-6 Deutz D2 9L Fault Codes 196
GM Dual Fuel Engine 216
5 5-1 GM Map and IAT Sensor 216
5 5-2 LPG Temperature Sensor 217
5 5-3 Throttle Actuator 218
5 5-4 Engine Coolant Temperature Sensor 219
5 5-5 ECU Pin Reference Chart 220
5 5-6 Fuse Block Layout 221
Kubota WG2503 Dual Fuel Engine 222
5 6-1 Engine Parameter Display (KAntrak 1700) 222
5 6-2 Diagnostic Trouble Codes 223
5 6-3 ECU Pin Reference Chart (Kubota WG2503) 228
5 6-4 Fuse Box (Kubota WG2503) 229
5 6-5 MAP Sensor (Kubota WG2503) 230
5 6-6 IAT Sensor (Kubota WG2503) 230
5 6-7 ECT (Kubota WG2503) 231
5 6-8 TPS & Engine Speed (Kubota WG2503) 231
5 6-9 Fuel Temperature Sensor (Kubota WG2503) 232
5 6-10 Oil Pressure Sensor (Kubota WG2503) 232
Hydraulic Tank 233
5 7-1 Change Hydraulic Tank Filter 233
5 7-2 Change Hydraulic Oil 233
Manifold and Hydraulic Pumps 234
5 8-1 Hydraulic Brake Pressure Adjustment 234
5 8-2 Hydraulic Standby Pressure Adjustment 235
5 8-3 Hydraulic High Pressure Adjustment 236
5 8-4 Hydraulic System Relief Valve Adjustment 237
5 8-5 Turret Rotate Relief Valve Adjustment 238
5 8-6 Platform Level Relief Valve Adjustment 238
5 8-7 Fly Boom Relief Valve Adjustment 239
5 8-8 Test Charge Pump Pressure on Drive Pump 239
5 8-9 Test Forward Drive Pressure on Drive Pump 240
5 8-10 Test Reverse Drive Pressure on Drive Pump 240
Axles 241
5 9-1 Change Oil in Axles 241
5 9-2 Check Oil Level in Torque Hub 241
5 9-3 Check Oil Level in Axle Gearbox 242
5 9-4 Change Oil in Axle Gearbox 242
5 9-5 Bleeding Oscillating Axle Cylinders 242
5 9-6 Pin Brake Adjustments 243
5 9-7 Brake Inspection 244
Grease Points 245
5 10-1 Lubrication 245
5 10-2 Grease Turret Rotation Bearing 245
5 10-3 Grease Turret Rotation Gear 245
5 10-4 Grease Drive Axle 246
5 10-5 Grease Drive Shaft 246
Options 247
5 11-1 Load Sensing System – CE 247
5 11-2 Generator Troubleshooting 250
5 11-3 Generator Frequency/Voltage Check & Adjustment (3 5 kW) 251
Contact us: [email protected]
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.M
