Skyjack SJ61T SJ66T Telescopic Booms Service Manual 207564AG – PDF DOWNLOAD

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Skyjack SJ61T SJ66T Telescopic Booms Service Manual 207564AG – PDF DOWNLOAD

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Skyjack SJ61T SJ66T Telescopic Booms Service Manual 207564AG – PDF DOWNLOAD

Language : English
Pages : 298
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Skyjack SJ61T SJ66T Telescopic Booms Service Manual 207564AG – PDF DOWNLOAD

• The operating manual is considered a fundamental part of the MEWP. 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 MEWP at all times. Service & Maintenance:
• 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

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TABLE OF CONTENTS:

Skyjack SJ61T SJ66T Telescopic Booms Service Manual 207564AG – PDF DOWNLOAD

Section 1 – Scheduled Maintenance 13
1 1 Read and Heed 13
1 1-1 Mobile Elevating Work Platform (MEWP) Definition 13
1 1-2 Purpose of Equipment 13
1 1-3 Use of Equipment 13
1 1-4 Manual 13
1 1-5 Service Policy and Warranty 13
1 1-6 Operator Safety Reminders, Warnings and Precautions 13
1 2 Maintenance and Service 14
1 2-1 Maintenance Inspection Schedule 14
1 2-2 Owner’s Annual Inspection Record 14
1 2-3 Replacement Parts 14
1 2-4 Maintenance and Service Safety Tips 14
1 2-5 Hydraulic System & Component Maintenance and Repair 15
1 2-6 Hydraulic Maintenance Hints 15
1 2-7 Railing Maintenance and Repair 16
1 3 Scheduled Maintenance 17
1 3-1 Service Bulletins 17
1 3-2 Maintenance and Inspection 17
1 3-3 Maintenance Instructions 17
1 4 Owner’s Annual Inspection Record 18
1 5 Pre-Delivery/Maintenance Inspection Checklist 19
1 6 Scheduled Maintenance Inspections 20
1 6-1 Electrical 20
1 6-2 Hydraulic 20
1 6-3 Manuals & Required Documents (B) 20
1 6-4 Labels (B) 20
1 6-5 Limit Switches (B) 21
1 6-6 Engine Compartment 21
1 6-7 Control Compartment 24
1 6-8 Base 26
1 6-9 Platform Assembly 28
1 6-10 Boom Assembly 29
1 6-11 Optional Equipment/Attachments 30
1 7 Function Tests 31
Section 2 – Maintenance Tables and Diagrams 33
2 1 Standard Hose Numbering System 33
2 2 MEWP Torque Specifications 35
2 3 Axle Torque Specifications 36
2 4 Torque Specifications for Fasteners (US) 37
2 5 Torque Specifications for Fasteners (Metric) 38
2 6 Torque Specifications for Hydraulic Couplings & Hoses 39
2 7 Axle Maintenance Intervals 40
2 8 Tire Specifications 41
2 9 Floor Loading Pressure 42
2 10 Hydraulic Specifications & Gear Oil 43
2 11 Specifications and Features – Dimensional Data 44
2 12 Specifications and Features – Performance & Speeds 45
2 13 Engine Specifications 46
2 14 Dimension and Reach Diagram – SJ61T 48
2 15 Dimension and Reach Diagram – SJ66T 49
2 16 Axle Oscillation Diagrams 50
Section 3 – System Component Identification and Schematics 51
3 1 Electrical Symbol Chart 52
3 2 Hydraulic Symbol Chart 53
3 3 Wire Number and Color Code 54
3 4 Wire Numbers and Color Codes – Additional 55
3 5 Hydraulic Parts List 56
3 6 Electrical Parts List 59
3 7 Rotary Manifold Port Identification 63
3 8 Brake Manifold Port Identification 64
3 9 System and Drive Pumps and Port Identifications 65
3 10 System Pump and Port Identifications 66
3 11 Drive Pump and Port Identifications 67
3 12 Drive Motors and Port Identifications 68
3 13 Platform Rotate Valve and Port Identification – SJ61T 69
3 14 Jib & Platform Rotate Valve and Port Identification – SJ66T 70
3 15 Main Manifold Port Identification 71
3 16 Main Manifold Electrical Component Identification 72
3 17 Main Manifold Hydraulic Component Identification 73
3 18 Generator Control Valves and Port Indentifcations 74
3 19 Main Harness Wiring Diagram 75
3 20 ECU Engine Wiring Diagram – Deutz 76
3 21 Glow Plug and EGR Harnesses – Deutz 77
3 22 Engine Interface Harness – Deutz TD2 9L 78
3 23 Harnesses 79
3 24 Platform Control Cables 80
3 25 Limit Switch Connections 81
3 26 Load Sensing Cable Connection – CE 82
3 27 Generator and Oil Cooler Harness Connections 83
3 28 Generator Wire Kit Connections 84
3 29 Generator Connection – 12 kW 85
3 30 SGE Wiring Diagram 86
3 31 Differential Lock Harness 87
3 32 Hydraulic Schematic 89
3 33 Platform Controls Wiring – SJ61T ANSI/CSA – Deutz & Perkins 90
3 34 Platform Controls Wiring – SJ61T ANSI/CSA – Kubota 91
3 35 Platform Controls Wiring – SJ66T ANSI/CSA – Deutz & Perkins 92
3 36 Platform Controls Wiring – SJ66T ANSI/CSA – Kubota 93
3 37 Platform Controls Wiring – SJ66T CE – Deutz TCD2 2 94
3 38 Platform Controls Wiring – SJ66T CE – Deutz TD2 9L & D2011 95
3 39 Platform Controls Wiring – SJ66T AS – Deutz 96
3 40 Base Controls Wiring – SJ61T ANSI/CSA – Deutz TD2 9L – S/N 97 003 631 & above 97
3 41 Base Controls Wiring – SJ61T ANSI/CSA – Deutz TD2 9L – S/N 97 003 630 & below 98
3 42 Base Controls Wiring – SJ61T ANSI/CSA – Deutz TD2 9L with Positive Air Shut-Off Option – S/N 97 003 631 & above 99
3 43 Base Controls Wiring – SJ61T ANSI/CSA – Deutz TD2 9L with Positive Air Shut-Off Option – S/N 97 003 630 & below 100
3 44 Base Controls Wiring – SJ61T ANSI/CSA – Deutz D2011 – S/N 97 003 631 & above 101
3 45 Base Controls Wiring – SJ61T ANSI/CSA – Deutz D2011 – S/N 97 003 630 & below 102
3 46 Base Controls Wiring – SJ61T ANSI/CSA – Deutz D2011with Positive Air Shut-Off Option – S/N 97 003 631 & above 103
3 47 Base Controls Wiring – SJ61T ANSI/CSA – Deutz D2011with Positive Air Shut-Off Option – S/N 97 003 630 & below 104
3 48 Base Controls Wiring – SJ61T ANSI/CSA – Perkins – S/N 97 003 631 & above 105
3 49 Base Controls Wiring – SJ61T ANSI/CSA – Perkins – S/N 97 003 630 & below 106
3 50 Base Controls Wiring – SJ61T ANSI/CSA – Kubota – S/N 97 003 631 & above 107
3 51 Base Controls Wiring – SJ61T ANSI/CSA – Kubota – S/N 97 003 630 & below 108
3 52 Base Controls Wiring – SJ66T ANSI/CSA – Deutz TD2 9L – S/N 97 003 631 & above 109
3 53 Base Controls Wiring – SJ66T ANSI/CSA – Deutz TD2 9L – S/N 97 003 630 & below 110
3 54 Base Controls Wiring – SJ66T ANSI/CSA – Deutz TD2 9L with Positive Air Shut-Off Option – S/N 97 003 631 & above 111
3 55 Base Controls Wiring – SJ66T ANSI/CSA – Deutz TD2 9L with Positive Air Shut-Off Option – S/N 97 003 630 & below 112
3 56 Base Controls Wiring – SJ66T ANSI/CSA – Deutz D2011 – S/N 97 003 631 & above 113
3 57 Base Controls Wiring – SJ66T ANSI/CSA – Deutz D2011 – S/N 97 003 630 & below 114
3 58 Base Controls Wiring – SJ66T ANSI/CSA – Deutz D2011 with Positive Air Shut-Off Option – S/N 97 003 631 & above 115
3 59 Base Controls Wiring – SJ66T ANSI/CSA – Deutz D2011 with Positive Air Shut-Off Option – S/N 97 003 630 & below 116
3 60 Base Controls Wiring – SJ66T ANSI/CSA – Perkins 2 2TA – S/N 97 003 631 & above 117
3 61 Base Controls Wiring – SJ66T ANSI/CSA – Perkins 2 2TA – S/N 97 003 630 & below 118
3 62 Base Controls Wiring – SJ66T ANSI/CSA – Kubota – S/N 97 003 631 & above 119
3 63 Base Controls Wiring – SJ66T ANSI/CSA – Kubota – S/N 97 003 630 & below 120
3 64 Base Controls Wiring – SJ66T CE – Deutz TCD2 2 121
3 65 Base Controls Wiring – SJ66T CE Deutz – TD2 9L 122
3 66 Base Controls Wiring – SJ66T CE – Deutz D2011 123
3 67 Base Controls Wiring – SJ66T AS – Deutz D2011 124
3 68 Electrical Schematic – ANSI/CSA – Deutz TD2 9L – S/N 97 003 631 & above 125
3 69 Electrical Schematic – ANSI/CSA – Deutz TD2 9L – S/N 97 003 630 & below 126
3 70 Electrical Schematic – ANSI/CSA – Deutz D2011 – S/N 97 003 631 & above 127
3 71 Electrical Schematic – ANSI/CSA – Deutz D2011 – S/N 97 003 630 & below 128
3 72 Electrical Schematic – ANSI/CSA – Perkins 2 2TA 129
3 73 Electrical Schematic – ANSI/CSA – Kubota – S/N 97 003 631 & above 130
3 74 Electrical Schematic – ANSI/CSA – Kubota – S/N 97 003 630 & below 131
3 75 Electrical Schematic – CE – Deutz TCD2 2 132
3 76 Electrical Schematic – CE – Deutz TD2 9L 133
3 77 Electrical Schematic – CE – Deutz D2011 134
3 78 Electrical Schematic – AS – Deutz D2011 135
3 79 Interface & Engine Electrical Schematic – Deutz TCD2 2 136
3 80 Engine OEM Harness Schematic – Deutz TCD2 2 137
3 81 Interface & Engine Electrical Schematic – Deutz TD2 9L 138
3 82 Engine Interface Harness Schematic – Perkins 139
3 83 Engine OEM Harness Schematic – Perkins 140
3 84 Engine Component Harness Schematic – Perkins 141
3 85 Interface & Engine Electrical Schematic – Kubota 142
Section 4 – Troubleshooting Information 143
4 1 Introduction 143
4 2 Electrical System 144
4 2-1 All Controls Inoperative 144
4 2-2 No Power 145
4 2-3 Engine Will Not Crank 146
4 2-4 Engine Cranks but Will Not Start 150
4 2-5 Glow Plug Circuit Inoperative – Deutz D2011 diesel engine 153
4 2-6 All Base Control Console Inoperative 154
4 2-7 No Movement from Base Control Console 155
4 2-8 All Controls Inoperative From Platform Control Console 162
4 2-9 Throttle Inoperative, Mid and High – Deutz D2 9L 170
4 2-10 Mid Throttle Inoperative 171
4 2-11 High Throttle Inoperative 172
4 2-12 Brake will not Release 173
4 2-13 Differential Lock will not Engage 174
4 2-14 No Drive and Steer 175
4 2-15 No High Speed Drive 177
4 2-16 No Elevated Drive 178
4 2-17 Direction Sensing Inoperative 179
4 2-18 Steer Direction Sensing Inoperative 179
4 3 Hydraulic System 180
4 3-1 All Controls Inoperative 180
4 3-2 All Boom Functions Inoperative 180
4 3-3 No Main Boom Up 180
4 3-4 No Main Boom Down 181
4 3-5 No Turret Rotate 181
4 3-6 No Boom Extend 182
4 3-7 No Boom Retract 183
4 3-8 No Jib Up 183
4 3-9 No Jib Down 184
4 3-10 No Platform Rotation 184
4 3-11 Platform will not Level 185
4 3-12 Brake will not Release 186
4 3-13 Brake will not Engage 186
4 3-14 No Drive 186
4 3-15 Differential Lock will not Engage 187
4 3-16 No High Speed Drive 187
4 3-17 No Steer 187
4 3-18 Axle Will Not Oscillate 188
4 3-19 Axle Will Not Lock 188
4 4 Load Sensing System – CE 189
4 4-1 Green Power LED is not Flashing 189
4 4-2 Load Cell red Alarm LED is ON (with platform empty) 189
4 4-3 Red Error LED is ON 189
4 4-4 Load Cell red Alarm LED is OFF (with platform overloaded) 189
4 4-5 Platform Indicator Light does not turn ON 189
4 4-6 Audible Alarm does not turn ON 190
4 4-7 Boom and Drive Functions are Enabled (with boom extended) 190
Section 5 – Procedures 191
5 1 General 191
5 1-1 Safety and Workmanship 191
5 2 Platform 192
5 2-1 Human Machine Interface (HMI) 192
5 2-2 User Interface Keys 192
5 2-3 SCM Character Functions Charts 193
5 2-4 SCM Operating Values Chart 194
5 2-5 How to Select Functionality 195
5 2-6 How to View OCM Operation 196
5 2-7 How to Unlock and Modify OCM Settings 197
5 2-8 OCM Pin Voltage Reference 198
5 2-9 Fly Boom Switch Voltage References 201
5 2-10 Platform Controller Voltage References 202
5 3 Boom 203
5 3-1 Check Wear Pads 203
5 3-2 Shim Wear Pads 203
5 3-3 Cable Carrier Repair 203
5 3-4 Rotary Actuator Bolt Torque Procedure 203
5 3-5 Boom Section Wear Pad Replacement 204
5 3-6 Platform and Jib Boom Removal 205
5 3-7 Platform Removal (no Jib Boom) 207
5 3-8 Operating Machine Functions from the Base Controls 209
5 3-9 Fly Boom Section Removal 210
5 3-10 Mid Boom Section Removal 211
5 3-11 Mid Boom Section Installation 213
5 3-12 Fly Boom Section Installation 214
5 3-13 Platform and Jib Boom Installation 214
5 3-14 Platform Installation (no Jib Boom) 215
5 3-15 Platform Control Console Connection 216
5 3-16 Inspection and Replacement of Extension Cylinder and Boom Cables 216
5 3-17 Extension Cylinder and Cable Assembly Removal 217
5 3-18 Extension Cylinder and Cable Assembly Installation 220
5 3-19 Proper Wire Rope Tension 223
5 3-20 Wire Rope Inspection 224
5 4 Turret 225
5 4-1 Check and Replace the High Pressure Filter 225
5 4-2 Adjust the Turret Rotation Gear Backlash 225
5 4-3 Check the Swing Drive Oil 226
5 4-4 Change the Swing Drive Oil 226
5 4-5 Battery Replacement 227
5 4-6 Turret Rotation Gear Bolt Torque Sequence 227
5 4-7 Electronic Tilt Switch Setup Procedure 228
5 4-8 Check the Rotation Bearing for Axial Wear 230
5 5 Deutz Diesel Engines 231
5 5-1 Replace the Engine Oil and Filter 231
5 5-2 Replace the Fuel Filter 232
5 5-3 Replace the Air Filter 232
5 5-4 Check the Engine Belt 232
5 5-5 Check the Oil Cooler (Deutz D2011 only) 232
5 5-6 Deutz TD2 9L Fault Codes 233
5 5-7 Deutz TCD2 2 Diagnoses and Error Codes 253
5 6 Kubota WG2503 Dual Fuel Engine 264
5 6-1 Engine Parameter Display (KAntrak 1700) 264
5 6-2 Diagnostic Trouble Codes 265
5 6-3 Diagnostic Trouble Codes 266
5 6-4 Diagnostic Trouble Codes 267
5 6-5 Diagnostic Trouble Codes 268
5 6-6 Diagnostic Trouble Codes 269
5 6-7 ECU Pin Reference Chart – Kubota WG2503 270
5 6-8 Fuse Box – Kubota WG2503 271
5 6-9 MAP Sensor – Kubota WG2503 272
5 6-10 IAT Sensor – Kubota WG2503 272
5 6-11 ECT – Kubota WG2503 273
5 6-12 TPS & Engine Speed – Kubota WG2503 273
5 6-13 Fuel Temperature Sensor – Kubota WG2503 274
5 6-14 Oil Pressure Sensor – Kubota WG2503 274
5 7 Hydraulic Tank 275
5 7-1 Hydraulic Oil Replacement 275
5 7-2 Hydraulic Filter Replacement 275
5 8 Manifold and Hydraulic Pumps 276
5 8-1 Hydraulic Brake Pressure Adjustment 276
5 8-2 Hydraulic Standby Pressure Adjustment 277
5 8-3 Hydraulic High Pressure Adjustment 278
5 8-4 Hydraulic System Relief Valve Adjustment 279
5 8-5 Turret Rotate Relief Valve Adjustment 280
5 8-6 Platform Level Relief Valve Adjustment 280
5 8-7 Fly Boom Relief Valve Adjustment 281
5 8-8 Test Charge Pump Pressure on Drive Pump 281
5 8-9 Test Forward Drive Pressure on Drive Pump 282
5 8-10 Test Reverse Drive Pressure on Drive Pump 282
5 9 Axles 283
5 9-1 Change the Oil in the Axles 283
5 9-2 Check the Oil Level in the Torque Hubs 283
5 9-3 Change the Oil in the Torque Hubs 283
5 9-4 Check the Oil Level in the Axle Gearbox 284
5 9-5 Change the Oil in the Axle Gearbox 284
5 9-6 Oscillating Cylinder Bolt Replacement 285
5 9-7 Oscillating Cylinder Replacement 285
5 9-8 Bleed the Oscillating Axle Cylinders 287
5 9-9 Test the Oscillating Axle Cylinders 287
5 9-10 Pin Brake Adjustments 288
5 9-11 Brake Inspection 289
5 10 Grease Points 290
5 10-1 Grease the Turret Ring Gear 290
5 10-2 Grease the Turret Swing Drive 290
5 10-3 Grease the Axles 291
5 10-4 Grease the Drive Shaft 291
5 11 Options 292
5 11-1 Load Sensing System – CE 292
5 11-2 Verify Proper Operation of the Load Sensing System 293
5 11-3 Calibration of the Load Sensing System (with the “Teach In” Handset) 294
5 11-4 Generator Troubleshooting 295
5 11-5 Generator Frequency/Voltage Check & Adjustment 296

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