Skyjack SJ82T, SJ86T Telescopic Booms Service Manual 170454AI – PDF DOWNLOAD

Description

Skyjack SJ82T, SJ86T Telescopic Booms Service Manual 170454AI – PDF DOWNLOAD

FILE DETAILS:

Skyjack SJ82T, SJ86T Telescopic Booms Service Manual 170454AI – PDF DOWNLOAD

Language : English
Pages : 268
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Skyjack SJ82T, SJ86T Telescopic Booms Service Manual 170454AI – PDF DOWNLOAD

Scheduled Maintenance Operator’s Responsibility for Maintenance;
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Aerial Platform and Mobile Elevating Work Platform (MEWP) Definition
A mobile device that has a positionable platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK Veritcal Mast series aerial platform are 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.
Manuals:
Operating:
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:
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
Operator:
The operator must read and completely understand both this operating manual and the safety panel label located
on the platform and all other warnings in this manual and on the aerial platform. Compare the labels on the aerial
platform with the labels found within this manual. If any labels are damaged or missing, replace them immediately.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Skyjack SJ82T, SJ86T Telescopic Booms Service Manual 170454AI – PDF DOWNLOAD

Table of Contents 5
Section 1 – Scheduled Maintenance 13
1 1 Read and Heed 13
1 1-1 Aerial Platform and Mobile Elevating Work Platform 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 and 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 Labels 20
1 6-2 Electrical 20
1 6-3 Limit Switches 20
1 6-4 Hydraulic 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 Axles Maintenance Intervals 40
2 8 Tire Specifications 41
2 9 Floor Loading Pressure 42
2 10 Hydraulic Specifications & Gear Oil 43
2 11 Specifications & Features – Dimensional Data 44
2 12 Specifications & Features – Performance and Speeds 45
2 13 Engine Specifications 46
2 14 Axle Oscillation Diagrams 48
2 15 Dimension and Reach Diagram – SJ82T 49
2 16 Dimension and Reach Diagram – SJ86T 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 Hourmeter/Counter Harness – CE 64
3 8 Rotary Manifold Port Identification 65
3 9 System and Drive Pump Port Identification 67
3 10 Drive Motors Port Identification 68
3 11 Jib Valve Port Identification 69
3 12 No Jib Valve Port Identification 70
3 13 Brake Manifold Port Identification 71
3 14 Pressure Reducing Valve Port Identification 72
3 15 Main Manifold Port Identification 73
3 16 Main Manifold Electrical Component Identification 74
3 17 Main Manifold Hydraulic Component Identification 75
3 18 Main Harness Wiring Diagram 76
3 19 Boom Lift Valve Harness 77
3 20 Differential Lock Harness 78
3 21 Platform Rotate & Jib Harnesses 79
3 22 Platform to Base Control Cable Harnesses 80
3 23 Limit Switch Connections 81
3 24 Load Sensing Cable Connection – CE & AS 82
3 25 ECU Engine Wiring Diagram – Deutz Diesel Engine 83
3 26 Glow Plug and EGR Harnesses – Deutz Diesel Engine 84
3 27 Generator and Oil Cooler Harness Connections 85
3 28 Generator Wiring 86
3 29 SGE Wiring Diagrams 87
3 30 Platform Work Light 88
3 31 Positive Air Shut-Off Option Harness 89
3 32 Dual Capacity Sensing Module 90
3 33 Load Circuit – ANSI/CSA with Deutz TD2 9L 91
3 34 Hydraulic Schematic 93
3 35 Platform Controls Wiring – SJ82T ANSI/CSA 94
3 36 Platform Controls Wiring – SJ86T ANSI/CSA 95
3 37 Platform Controls Wiring – SJ86T CE – Deutz TCD2 2 96
3 38 Platform Controls Wiring – SJ86T CE – Deutz TD2 9L 97
3 39 Platform Controls Wiring – SJ86T AS 98
3 40 Base Controls Wiring – SJ82T ANSI/CSA – Deutz D2011 99
3 41 Base Controls Wiring – SJ82T ANSI/CSA – Deutz TD2 9L 100
3 42 Base Controls Wiring – SJ82T ANSI/CSA – Deutz TD2 9L with Positive Air Shut-Off 101
3 43 Base Controls Wiring – SJ82T ANSI/CSA – Perkins 2 2TA 102
3 44 Base Controls Wiring – SJ86T ANSI/CSA – Deutz D2011 103
3 45 Base Controls Wiring – SJ86T ANSI/CSA – Deutz TD2 9L 104
3 46 Base Controls Wiring – SJ86T ANSI/CSA – Deutz TD2 9L with Positive Air Shut-Off 105
3 47 Base Controls Wiring – SJ86T ANSI/CSA – Perkins 2 2TA 106
3 48 Base Controls Wiring – SJ86T CE – Deutz TCD2 2 107
3 49 Base Controls Wiring – SJ86T CE – Deutz D2011 108
3 50 Base Controls Wiring – SJ86T CE – Deutz TD2 9L 109
3 51 Base Controls Wiring – SJ86T AS – Deutz D2011 110
3 52 Electrical Schematic – SJ82T & SJ86T ANSI/CSA Deutz D2011 111
3 53 Electrical Schematic – SJ82T & SJ86T ANSI/CSA Deutz TD2 9L 112
3 54 Electrical Schematic – SJ82T & SJ86T ANSI/CSA Perkins 2 2TA 113
3 55 Electrical Schematic – SJ86T CE Deutz TCD2 2 114
3 56 Electrical Schematic – SJ86T CE Deutz D2011 115
3 57 Electrical Schematic – SJ86T CE Deutz TD2 9L 116
3 58 Electrical Schematic – SJ86T AS Deutz D2011 117
3 59 Engine Electrical Schematic – Deutz TCD2 2 118
3 60 Engine Interface Harness Schematic – Deutz TCD2 2 119
3 61 Engine Electrical Schematic – Deutz TD2 9L 120
3 62 Engine Interface Harness Schematic – Deutz TD2 9L 121
3 63 Engine Interface Harness – Perkins 2 2TA 122
3 64 Engine OEM Harness – Perkins 2 2TA 123
3 65 Engine Component Harness – Perkins 2 2TA 124
Section 4 – Troubleshooting Information 125
4 1 Introduction 125
4 2 Electrical System 126
4 2-1 All Controls Inoperative 126
4 2-2 No Power 127
4 2-3 Engine Will Not Crank 128
4 2-4 Engine Cranks but Will Not Start 131
4 2-5 Glow Plug Circuit Inoperative – Deutz D2011 diesel engine 132
4 2-6 Glow Plug Circuit Inoperative – Deutz D2 9 diesel engine 132
4 2-7 All Base Control Console Inoperative 133
4 2-8 No Movement from Base Control Console 134
4 2-9 All Controls Inoperative From Platform Control Console 141
4 2-10 Throttle Inoperative, Mid and High – Deutz D2 9L 150
4 2-11 Mid Throttle Inoperative 151
4 2-12 High Throttle Inoperative 152
4 2-13 Brake will not Release 153
4 2-14 No Drive and Steer 153
4 2-15 No High Speed Drive 156
4 2-16 No Elevated Drive 157
4 2-17 Direction Sensing Inoperative 158
4 2-18 Steer Direction Sensing Inoperative 158
4 2-19 No boom down or extend Functions from Base or Platform Consoles (ANSI) 159
4 2-20 No boom down Function from Base or Platform Consoles (ANSI) 159
4 2-21 No boom extend Function from Base or Platform Consoles (ANSI) 160
4 2-22 No boom down Function from Base or Platform Consoles (CE, AS) 160
4 2-23 No boom extend Function from Base or Platform Consoles (CE, AS) 161
4 3 Hydraulic System 162
4 3-1 All Controls Inoperative 162
4 3-2 All Boom Functions Inoperative 162
4 3-3 No Main Boom Up 162
4 3-4 No Main Boom Down 163
4 3-5 No Turret Rotate 163
4 3-6 No Boom Extend 164
4 3-7 No Boom Retract 165
4 3-8 No Jib Up 166
4 3-9 No Jib Down 166
4 3-10 No Platform Rotation 167
4 3-11 Platform will not Level 168
4 3-12 Brake will not Release 169
4 3-13 Brake will not Engage 169
4 3-14 No Drive 169
4 3-15 Differential Lock will not Engage 170
4 3-16 No High Speed Drive 170
4 3-17 No Steer 170
4 4 Load Sensing System – CE 172
4 4-1 Green LED on Load Sense/Dual Load Zone Module is not on 172
4 4-2 Load Sense indicates overload or overload warning with platform empty or below weight 172
4 4-3 Load Sense/Dual Load Zone Module Error 173
4 4-4 No Light/Alarm when Platform is Overloaded 174
Section 5 – Procedures 175
5 1 General 175
5 1-1 Safety and Workmanship 175
5 2 Platform 176
5 2-1 Human Machine Interface (HMI) 176
5 2-2 User Interface Keys 176
5 2-3 SCM Character Functions Charts 177
5 2-4 SCM Operating Values Chart 178
5 2-5 How to Select SCM Functionality 179
5 2-6 How to View SCM Operation 180
5 2-7 How to Unlock and Modify SCM Settings 181
5 2-8 SCM Pin Voltage Reference 182
5 2-9 Fly Boom Switch Voltage References 185
5 2-10 Platform Controller Voltage References 186
5 3 Boom 187
5 3-1 Check Wear Pads 187
5 3-2 Shim Wear Pads 187
5 3-3 Cable Carrier Repair 187
5 3-4 Rotary Actuator Bolt Torque Procedure 187
5 3-5 Boom Section Wear Pad Replacement 188
5 3-6 Platform and Jib Boom Removal 189
5 3-7 Platform Removal (no Jib Boom) 191
5 3-8 Operating Machine Functions from Base Controls 193
5 3-9 Fly Boom Section Removal 194
5 3-10 Mid Boom Section Removal 195
5 3-11 Mid Boom Section Installation 196
5 3-12 Fly Boom Section Installation 197
5 3-13 Platform and Jib Boom Installation 197
5 3-14 Platform Installation (no Jib Boom) 198
5 3-15 Platform Control Console Connection 199
5 3-16 Extension Cylinder and Wire Rope Replacement 200
5 3-17 Extension Cylinder and Cable Assembly Removal 200
5 3-18 Extension Cylinder and Wire Rope Assembly Installation 203
5 3-19 Proper Wire Rope Tension 205
5 3-20 Wire Rope Inspection 206
5 3-21 Limit Switch Checking and Adjusting 207
5 3-22 Directional Sensing Limit Switch (LS1) 208
5 3-23 High Speed Drive / Tilt Override Limit Switch (LS2) 209
5 3-24 Fly-in Limit Switch (LS3) 211
5 3-25 Boom Angle (Dual Load) Limit Switch (LS4) 212
5 3-26 Boom Extension (Dual Load) Limit Switch (LS5) 214
5 3-27 Lift Cushion Limit Switch (LS6) 216
5 4 Turret 218
5 4-1 Check and Replace the High Pressure Filter 218
5 4-2 Adjust the Turret Rotation Gear Backlash 218
5 4-3 Check the Swing Drive Oil 219
5 4-4 Change the Swing Drive Oil 219
5 4-5 Battery Replacement 220
5 4-6 Turret Rotation Gear Bolt Torque Sequence 220
5 4-7 Electronic Tilt Switch Setup Procedure 221
5 4-8 Check Rotation Bearing for Axial Wear 223
5 4-9 Resetting the Emergency Lowering Counter (CE only) 224
5 5 Deutz Diesel Engines 225
5 5-1 Replace Engine Oil and Filter 225
5 5-2 Replace the Fuel Filter 226
5 5-3 Replace the Air Filter 226
5 5-4 Check the Engine Belt 226
5 5-5 Check the Oil Cooler (Deutz D2011 only) 226
5 5-6 Deutz TD2 9L Fault Codes 227
5 6 Hydraulic Tank 247
5 6-1 Change the Hydraulic Tank Filter 247
5 6-2 Change the Hydraulic Oil 247
5 7 Manifolds and Hydraulic Pumps 248
5 7-1 Hydraulic Brake Pressure Adjustment 248
5 7-2 Hydraulic Standby Pressure Adjustment 249
5 7-3 Hydraulic High Pressure Adjustment 250
5 7-4 Hydraulic System Relief Valve Adjustment 251
5 7-5 Turret Rotate Relief Valve Adjustment 252
5 7-6 Platform Level Relief Valve Adjustment 252
5 7-7 Fly Boom Relief Valve Adjustment 253
5 7-8 Test Charge Pump Pressure on Drive Pump 253
5 7-9 Test Forward Drive Pressure on Drive Pump 254
5 7-10 Test Reverse Drive Pressure on Drive Pump 254
5 8 Axles 255
5 8-1 Change the Oil in the Axles 255
5 8-2 Check the Oil Level in the Torque Hubs 255
5 8-3 Change the Oil in the Torque Hubs 255
5 8-4 Check the Oil Level in the Axle Gearbox 256
5 8-5 Change the Oil in the Axle Gearbox 256
5 8-6 Brake Inspection 257
5 8-7 Oscillating Cylinder Bolt Replacement 257
5 8-8 Oscillating Cylinder Replacement 258
5 8-9 Bleed the Oscillating Axle Cylinders 259
5 8-10 Test the Oscillating Axle Cylinders 260
5 9 Grease Points 261
5 9-1 Grease the Turret Ring Gear 261
5 9-2 Grease the Turret Swing Drive 261
5 9-3 Grease the Axles 262
5 9-4 Grease the Drive Shaft 262
5 10 Load Sensing System 263
5 10-1 Load Sensing System Overload Status 263
5 10-2 Dual Capacity Overload Module Function Table 264
5 10-3 Calibration of Load Sensing System 265

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