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SkyJack SJ61T SJ66T Service Manual and Parts List Manual
This manual is based on Serial Number(s):
SJ61T & SJ66T97 001 396 to 97 001 832
Content for Service Manual:
Section 1. SCHEDULED MAINTENANCE
Operators Responsibility for Maintenance
Aerial Platform Definition
Purpose of Equipment
Use of Equipment
Manuals
Service Policy and Warranty
Operator Safety Reminders, Warnings, and Precautions
Maintenance and Inspection Schedule
Owners Annual Inspection Record
Replacement Parts
Maintenance and Service Safety Tips
Hydraulic System & Component Maintenance and Repair
Maintenance Hints
Service and Maintenance
About this Section
Service Bulletins
Maintenance and Inspection
Maintenance Instructions
Tables
Table 1.1 Owners Annual Inspection Record
Table 1.2 Pre-Delivery / Maintenance Inspection Checklist
Scheduled Maintenance Inspections and Function Tests
1.1 Scheduled Maintenance Inspections
1.2 Function Tests
Section 3. SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Charts
3.1 Hydraulic Symbol Chart
3.2 Electrical Symbol Chart
3.3 Wire Number and Color Code
Parts Lists
3.4 Hydraulic Schematic Parts List
3.5 Electrical Component Parts List
Diagrams and Schematics
3.6 Rotary Manifold and Port Identifications
3.7 Brake Manifold and Port Identifications
3.8 System and Drive Pumps and Port Identifications
3.9 System Pump and Port Identifications
3.10 Drive Pump and Port Identifications
3.11 Drive Motors and Port Identifications
3.12 Jib Valve and Port Identifications
3.13 No Jib Valve and Port Identifications
3.14 Pressure Reducing Valve Port Identifications
3.15 Main Manifold Port Identification
3.16 Main Manifold Electrical Component Identification
3.17 Main Manifold Hydraulic Component Identification
3.18 Generator Control Valves and Port Indentifcations
3.19 Main Harness Wiring Diagram
3.20 ECU Engine Wiring Diagram (Deutz Diesel Engine)
3.21 Glow Plug and EGR Harnesses (Deutz Diesel Engine)
3.22 Engine Interface Harness (Deutz TD2.9L Diesel)
3.23 Engine Interface Harness (GM Dual Fuel Engine)
3.24 Harnesses
3.25 Platform Control Cable Harnesses
3.26 Limit Switch Connections
3.27 Load Sensing Cable Connection (CE)
3.28 Generator and Oil Cooler Harness Connections
3.29 Generator Wire Kit Connections
3.30 12kW Generator Connection Assembly
3.31 SGE Wiring Diagram
3.32 Telematics Wiring Diagram
3.33 Hydraulic Schematic Diagram
3.34 Platform Control Console Diagram (61T ANSI/CSA - Deutz Diesel Engine)
3.35 Platform Control Console Diagram (61T ANSI/CSA - GM Dual Fuel Engine)
3.36 Platform Control Console Diagram (66T ANSI/CSA - GM Dual Fuel Engine)
3.37 Platform Control Console Diagram (66T ANSI/CSA - Deutz Diesel Engine)
3.38 Platform Control Console Diagram (66T CE - Deutz Diesel Engine)
3.39 Platform Control Console Diagram (66T AS - Deutz Diesel Engine)
3.40 Base Control Console Diagram (61T ANSI/CSA - GM Dual Fuel Engine)
3.41 Base Control Console Diagram (61T ANSI/CSA - Deutz D2011 Diesel Engine)
3.42 Base Control Console Diagram (61T ANSI/CSA - Deutz TD2.9L Diesel Engine)
3.43 Base Control Console Diagram (61T ANSI/CSA - Deutz TD2.9L Diesel Engine with Positive Air Shut-Off
3.44 Base Control Console Diagram (66T ANSI/CSA - GM Dual Fuel)
3.45 Base Control Console Diagram (66T ANSI/CSA - Deutz D2011 Diesel Engine)
3.46 Base Control Console Diagram (66T CE - Deutz D2011 Diesel Engine)
3.47 Base Control Console Diagram (66T AS - Deutz D2011 Diesel Engine)
3.48 Base Control Console Diagram (66T ANSI/CSA - Deutz TD2.9L Diesel Engine)
3.49 Base Control Console Diagram (66T ANSI/CSA - Deutz TD2.9L Diesel Engine with Positive Air Shut-Off
3.50 Base Control Console Diagram (66T CE - Deutz TD2.9L Diesel Engine)
3.51 Electrical Schematic Diagram (ANSI/CSA - GM Dual Fuel Engine)
3.52 Electrical Schematic Diagram (ANSI/CSA - Kubota Dual Fuel Engine)
3.53 Electrical Schematic Diagram (ANSI/CSA - Deutz D2011 Diesel Engine)
3.54 Electrical Schematic Diagram (CE - Deutz D2011 Engine)
3.55 Electrical Schematic Diagram (AS - Deutz D2011 Engine)
3.56 Electrical Schematic Diagram (ANSI/CSA - Deutz TD2.9L Diesel Engine)
3.57 Electrical Schematic Diagram (CE - Deutz TD2.9L Engine)
3.58 Interface & Engine Electrical Schematic - GM Dual Fuel Engine
3.59 Interface & Engine Electrical Schematic - Kubota Dual Fuel Engine
3.60 Interface & Engine Electrical Schematic - Deutz TD2.9L Diesel Engine
Section 4. TROUBLESHOOTING INFORMATION
Introduction
4.1 Electrical System
4.1-1 All Controls Inoperative
4.1-2 No Power To Platform
4.1-3 No Power to Base
4.1-4 Engine Will Not Crank from Base
4.1-5 Engine Will Not Crank from Platform
4.1-6 Engine Will Not Crank from Platform or Base (Deutz TD2.9L)
4.1-7 Engine Cranks but Will Not Start (Deutz TD2.9L)
4.1-8 Engine Will Not Crank from Platform or Base (Deutz Diesel D2011)
4.1-9 Engine Cranks but Will Not Start (Deutz Diesel D2011)
4.1-10 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel)
4.1-11 Engine Cranks but Will Not Start (GM Dual Fuel)
4.1-12 Glow Plug Circuit Inoperative
4.1-13 All Controls Inoperative from Base Console
4.1-14 No Boom Up from Base Control Console
4.1-15 No Boom Down from Base Control Console
4.1-16 No Turret Rotate Left from Base Control Console
4.1-17 No Turret Rotate Right from Base Control Console
4.1-18 No Telescope Retract From Base Control Console
4.1-19 No Telescope Extend From Base Control Console
4.1-20 No Platform Rotate Left From Base Control Console
4.1-21 No Platform Rotate Right from Base Control Console
4.1-22 No Platform Rotate Left or Right from Base Control Console
4.1-23 No Jib Up from Base Control Console
4.1-24 No Jib Down from Base Control Console
4.1-25 No Jib Up Or Down From Base Control Console
4.1-26 No Manual Platform Level Up From Base Control Console
4.1-27 No Manual Platform Level Down From Base Control Console
4.1-28 No Manual Platform Level Up From Platform Control Console
4.1-29 No Manual Platform Level Down From Platform Control Console
4.1-30 All Controls Inoperative From Platform Control Console
4.1-31 No Boom Up From Platform Control Console
4.1-32 No Boom Down From Platform Control Console
4.1-33 No Turret Left from Platform Control Console
4.1-34 No Turret Right from Platform Control Console
4.1-35 No Telescope Out from Platform Control Console
4.1-36 No Telescope Out from Platform Control Console
4.1-37 No Platform Rotate or Jib Function from Platform Control Console
4.1-38 No Platform Rotate Left from Platform Control Console
4.1-39 No Platform Rotate Right from Platform Control Console
4.1-40 No Jib Up from Platform Control Console
4.1-41 No Jib Down from Platform Control Console
4.1-42 Throttle Inoperative, Mid and High (Deutz TD2.9L only)
4.1-43 Mid Throttle Inoperative
4.1-44 High Throttle Inoperative
4.1-45 Brake will not Release
4.1-46 No Drive and Steer
4.1-47 No Forward Drive
4.1-48 No Reverse Drive
4.1-49 No High Speed Drive
4.1-50 No Elevated Drive
4.1-51 No Left Steer
4.1-52 No Right Steer
4.1-53 Direction Sensing Inoperative
4.1-54 Steer Direction Sensing Inoperative
4.2 Hydraulic System
4.2-1 All Controls Inoperative
4.2-2 All Boom Functions Inoperative
4.2-3 No Main Boom Up
4.2-4 No Main Boom Down
4.2-5 No Turret Rotate Left
4.2-6 No Turret Rotate Right
4.2-7 No Boom Extend
4.2-8 No Boom Retract
4.2-9 No Jib Up
4.2-10 No Jib Down
4.2-11 No Platform Rotation Right
4.2-12 No Platform Rotation Left
4.2-13 Platform will not Level Down
4.2-14 Platform will not Level Up
4.2-15 Brake will not Release
4.2-16 Brake will not Engage
4.2-17 No Drive Forward or Reverse
4.2-18 No Forward Drive
4.2-19 No Reverse Drive
4.2-20 No High Speed Drive
4.2-21 No Right Steer
4.2-22 No Left Steer
4.2-23 Axle Will Not Oscillate
4.2-24 Axle Will Not Lock
4.3 Load Sensing System - CE
4.3-1 Green Power LED is not Flashing
4.3-2 Load Cell red Alarm LED is ON (with platform empty)
4.3-3 Red Error LED is ON
4.3-4 Load Cell red Alarm LED is OFF (with platform overloaded)
4.3-5 Platform Indicator Light does not turn ON
4.3-6 Audible Alarm does not turn ON
4.3-7 Boom and Drive Functions are Enabled (with boom extended)
Section 5. PROCEDURES
General
Safety and Workmanship
Platform
5.1-1 Human Machine Interface (HMI)
5.1-2 User Interface Keys
5.1-3 How to Select Functionality
5.1-4 How to View OCM Operation
5.1-5 How to Unlock and Modify OCM Settings
5.1-6 OCM Pin Voltage Reference
5.1-7 Fly Boom Switch Voltage References
5.1-8 Platform Controller Voltage References
Boom
5.2-1 Cable Carrier Repair
5.2-2 Check Wear Pads
5.2-3 Shimming Wear Pads
5.2-4 Boom Section Wear Pad Replacement
5.2-5 Inspection and Replacement of Extension Cylinder and Boom Cables
5.2-6 Proper Wire Rope Tension
5.2-7 Wire Rope Inspection
Turret
5.3-1 Check and Replace High Pressure Filter
5.3-2 Adjust Turret Rotation Gear Backlash
5.3-3 Check Swing Drive Motor Gearbox Oil
5.3-4 Change Swing Drive Motor Oil
5.3-5 Battery Replacement
5.3-6 Bolt Torque Procedure
5.3-7 Electronic Tilt Switch Setup Procedure
5.3-8 Check Rotation Bearing for Axial Wear
Deutz Diesel Engine
5.4-1 Replace Engine Oil and Filter
5.4-2 Replace Fuel Filter
5.4-3 Replace Air Filter
5.4-4 Check Engine Belt
5.4-5 Check Oil Cooler
GM Dual Fuel Engine
5.5-1 GM Map and IAT Sensor
5.5-2 LPG Temperature Sensor
5.5-3 Throttle Actuator
5.5-4 Engine Coolant Temperature Sensor
5.5-5 ECU Pin Reference Chart
5.5-6 Fuse Block Layout
Kubota WG2503 Dual Fuel Engine
5.6-1 Engine Parameter Display (KAntrak 1700)
5.6-2 Diagnostic Trouble Codes
5.6-3 ECU Pin Reference Chart (Kubota WG2503)
5.6-4 Fuse Box (Kubota WG2503)
5.6-5 MAP Sensor (Kubota WG2503)
5.6-6 IAT Sensor (Kubota WG2503)
5.6-7 ECT (Kubota WG2503)
5.6-8 TPS & Engine Speed (Kubota WG2503)
5.6-9 Fuel Temperature Sensor (Kubota WG2503)
5.6-10 Oil Pressure Sensor (Kubota WG2503)
Hydraulic Tank
5.7-1 Change Hydraulic Tank Filter
5.7-2 Change Hydraulic Oil
Manifold and Hydraulic Pumps
5.8-1 Hydraulic Brake Pressure Adjustment
5.8-2 Hydraulic Standby Pressure Adjustment
5.8-3 Hydraulic High Pressure Adjustment
5.8-4 Hydraulic System Relief Valve Adjustment
5.8-5 Turret Rotate Relief Valve Adjustment
5.8-6 Platform Level Relief Valve Adjustment
5.8-7 Fly Boom Relief Valve Adjustment
5.8-8 Test Charge Pump Pressure on Drive Pump
5.8-9 Test Forward Drive Pressure on Drive Pump
5.8-10 Test Reverse Drive Pressure on Drive Pump
Axles
5.9-1 Change Oil in Axles
5.9-2 Check Oil Level in Torque Hub
5.9-3 Check Oil Level in Axle Gearbox
5.9-4 Change Oil in Axle Gearbox
5.9-5 Bleeding Oscillating Axle Cylinders
5.9-6 Pin Brake Adjustments
Grease Points
5.10-1 Lubrication
5.10-2 Grease Turret Rotation Bearing
5.10-3 Grease Turret Rotation Gear
5.10-4 Grease Drive Axle
5.10-5 Grease Drive Shaft
Options
5.11-1 Load Sensing System - CE
5.11-2 Generator Troubleshooting
5.11-3 Generator Frequency/Voltage Check & Adjustment (3.5 kW)
_______________
This manual is based on Serial Number(s):
SJ61T & SJ66T97 001 396 to 97 001 832
Content for Parts List Manual:
1.0 PLATFORM
1.1 Platform
1.2 Railing Assembly
1.3 Platform Base Assembly (ANSI/CSA)
1.4 Platform Base Assembly (CE)
1.5 Swing Gate Assembly
1.6 Drop Bar Gate
1.7 Railing Extension (No Gate)
1.8 Footswitch
1.9 Platform Control Console
1.10 Boom / Turret Controller Assembly (Dual Axis)
1.11 Drive / Steer Controller Assembly (Single Axis)
1.12 Platform Terminal Strip