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SJ61T
Skyjack SJ61T Service Manual
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T
elescopic Boom Series
Models SJ61T & SJ66T
194312
December 2007
P
age 207
Section 5 - Procedures
Service and Maintenance
5.6-4 Fuse Box (K
ubota WG2503)
15 A F
use
15 A F
use
15 A F
use
5 A Fuse
10 A F
use
5 A F
use
85
30
86
87
87A
Fuel P
ump
Relay
Pow
er Relay
Starter Relay
2
4
1
5
3
2
4
1
5
3
RED 8
PINK/T
AN 18
RED/T
AN 16
RED/T
AN 16
WHITE/
L
T_BLUE 18
L
T_BLUE/
PINK 18
PINK/BLACK 18
PINK/T
AN 18
T
AN/BLACK 18
9
8
7
6
5
4
1
2
3
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
RED 8
PINK 18
RED 16
RED 14
PINK/
DK_GREEN 16
PINK/
DK_GREEN 16
PINK/
DK_GREEN 16
PINK/
DK_GREEN 18
PINK/
DK_GREEN 18
PINK/
DK_GREEN 18
RED/T
AN 12
RED/T
AN 12
RED 12
WHITE 12
RED 16
PINK/
YELL
OW 16
PINK/
YELL
OW 16
PINK/
YELL
OW 16
POWER RELA
Y
ST
ARTER RELA
Y
DEPR 5A
FUEL_PUMP RELA
Y
FUEL_PUMP 15A
ST
ARTER 15A
IGNITION 15A
ECM 10A
VSW 5A
AL
TERNATOR 60A
206
208
Table of Contents
Section 1 Scheduled Maintenance
5
Table of Contents
5
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
Service and Maintenance
9
About this Section
9
Service Bulletins
9
Maintenance and Inspection
9
Maintenance Instructions
9
Table 1.1 Owner's Annual Inspection Record
10
Table 1.2 Pre-Delivery / Maintenance Inspection Checklist
11
Scheduled Maintenance Inspections
12
Function Tests
24
Section 2 Maintenance Tables and Diagrams
25
Table of Contents
25
Section 3 System Component Identification and Schematics
43
Hydraulic Symbol Chart
45
Electrical Symbol Chart
46
Wire Number and Color Code
47
Hydraulic Schematic Parts List
48
Electrical Component Parts List
51
Rotary Manifold and Port Identifications
54
Brake Manifold and Port Identifications
55
System and Drive Pumps and Port Identifications
56
System Pump and Port Identifications
57
Drive Pump and Port Identifications
58
Drive Motors and Port Identifications
59
Jib Valve and Port Identifications
60
No Jib Valve and Port Identifications
61
Pressure Reducing Valve Port Identifications
62
Main Manifold Port Identification
63
Main Manifold Electrical Component Identification
64
Main Manifold Hydraulic Component Identification
65
Generator Control Valves and Port Indentifcations
66
Main Harness Wiring Diagram
67
ECU Engine Wiring Diagram (Deutz Diesel Engine)
68
Glow Plug and EGR Harnesses (Deutz Diesel Engine)
69
Engine Interface Harness (Deutz TD2.9L Diesel)
70
Engine Interface Harness (GM Dual Fuel Engine)
71
Harnesses
72
Platform Control Cable Harnesses
73
Limit Switch Connections
74
Load Sensing Cable Connection (CE)
75
Generator and Oil Cooler Harness Connections
76
Generator Wire Kit Connections
77
12Kw Generator Connection Assembly
78
SGE Wiring Diagram
79
Telematics Wiring Diagram
80
Hydraulic Schematic Diagram
81
Platform Control Console Diagram (61T ANSI/CSA - Deutz Diesel Engine)
82
Platform Control Console Diagram (61T ANSI/CSA - GM Dual Fuel Engine)
83
Platform Control Console Diagram (66T ANSI/CSA - GM Dual Fuel Engine)
84
Platform Control Console Diagram (66T ANSI/CSA - Deutz Diesel Engine)
85
Platform Control Console Diagram (66T CE - Deutz Diesel Engine)
86
Platform Control Console Diagram (66T as - Deutz Diesel Engine)
87
Base Control Console Diagram (61T ANSI/CSA - GM Dual Fuel Engine)
88
Base Control Console Diagram (61T ANSI/CSA - Deutz D2011 Diesel Engine)
89
Base Control Console Diagram (61T ANSI/CSA - Deutz TD2.9L Diesel Engine)
90
Base Control Console Diagram
91
Base Control Console Diagram (66T ANSI/CSA - GM Dual Fuel)
92
Base Control Console Diagram (66T ANSI/CSA - Deutz D2011 Diesel Engine)
93
Base Control Console Diagram (66T CE - Deutz D2011 Diesel Engine)
94
Base Control Console Diagram (66T as - Deutz D2011 Diesel Engine)
95
Base Control Console Diagram (66T ANSI/CSA - Deutz TD2.9L Diesel Engine)
96
Base Control Console Diagram
97
Base Control Console Diagram (66T CE - Deutz TD2.9L Diesel Engine)
98
Electrical Schematic Diagram (ANSI/CSA - GM Dual Fuel Engine)
99
Electrical Schematic Diagram (ANSI/CSA - Kubota Dual Fuel Engine)
100
Electrical Schematic Diagram (ANSI/CSA - Deutz D2011 Diesel Engine)
101
Electrical Schematic Diagram (CE - Deutz D2011 Engine)
102
Electrical Schematic Diagram (as - Deutz D2011 Engine)
103
Electrical Schematic Diagram (ANSI/CSA - Deutz TD2.9L Diesel Engine)
104
Electrical Schematic Diagram (CE - Deutz TD2.9L Engine)
105
Interface & Engine Electrical Schematic - GM Dual Fuel Engine
106
Interface & Engine Electrical Schematic - Kubota Dual Fuel Engine
107
Interface & Engine Electrical Schematic - Deutz TD2.9L Diesel Engine
108
Section 4 Troubleshooting Information
109
Default Chapter
111
Introduction
111
Electrical System
112
All Controls Inoperative
112
No Power to Platform
112
No Power to Base
113
Engine will Not Crank from Base
113
Engine will Not Crank from Platform
113
Engine will Not Crank from Platform or Base (Deutz TD2.9L)
114
Engine Cranks but will Not Start (Deutz TD2.9L)
114
Engine will Not Crank from Platform or Base (Deutz Diesel D2011)
115
Engine Cranks but will Not Start (Deutz Diesel D2011)
115
10 Engine will Not Crank from Platform or Base Control (GM Dual Fuel)
116
11 Engine Cranks but will Not Start (GM Dual Fuel)
117
12 Glow Plug Circuit Inoperative
119
13 All Controls Inoperative from Base Console
119
14 No Boom up from Base Control Console
120
15 No Boom down from Base Control Console
120
16 No Turret Rotate Left from Base Control Console
120
17 No Turret Rotate Right from Base Control Console
121
18 No Telescope Retract from Base Control Console
121
19 No Telescope Extend from Base Control Console
121
20 No Platform Rotate Left from Base Control Console
122
21 No Platform Rotate Right from Base Control Console
122
22 No Platform Rotate Left or Right from Base Control Console
123
23 No Jib up from Base Control Console
123
24 No Jib down from Base Control Console
123
25 No Jib up or down from Base Control Console
124
26 No Manual Platform Level up from Base Control Console
124
27 No Manual Platform Level down from Base Control Console
125
28 No Manual Platform Level up from Platform Control Console
125
29 No Manual Platform Level down from Platform Control Console
126
30 All Controls Inoperative from Platform Control Console
126
31 No Boom up from Platform Control Console
127
32 No Boom down from Platform Control Console
127
33 No Turret Left from Platform Control Console
128
34 No Turret Right from Platform Control Console
129
35 No Telescope out from Platform Control Console
129
36 No Telescope out from Platform Control Console
130
37 No Platform Rotate or Jib Function from Platform Control Console
131
38 No Platform Rotate Left from Platform Control Console
131
39 No Platform Rotate Right from Platform Control Console
131
40 No Jib up from Platform Control Console
132
41 No Jib down from Platform Control Console
132
42 Throttle Inoperative, MID and High (Deutz TD2.9L Only)
132
43 MID Throttle Inoperative
133
44 High Throttle Inoperative
134
45 Brake will Not Release
135
46 No Drive and Steer
135
47 No Forward Drive
135
48 No Reverse Drive
135
49 No High Speed Drive
136
50 No Elevated Drive
137
51 No Left Steer
137
52 No Right Steer
138
53 Direction Sensing Inoperative
138
54 Steer Direction Sensing Inoperative
139
Hydraulic System 4.2-1 All Controls Inoperative
139
All Boom Functions Inoperative
139
No Main Boom up
139
No Main Boom down
140
No Turret Rotate Left
140
No Turret Rotate Right
140
No Boom Extend
141
No Boom Retract
141
No Jib up
142
10 No Jib down
142
11 No Platform Rotation Right
142
12 No Platform Rotation Left
143
13 Platform will Not Level down
143
14 Platform will Not Level up
143
15 Brake will Not Release
144
16 Brake will Not Engage
144
17 No Drive Forward or Reverse
144
18 No Forward Drive
145
19 No Reverse Drive
145
20 No High Speed Drive
145
21 No Right Steer
145
22 No Left Steer
145
23 Axle will Not Oscillate
145
24 Axle will Not Lock
146
Load Sensing System - CE
146
Green Power LED Is Not Flashing
146
Load Cell Red Alarm LED Is on (with Platform Empty)
146
Red Error LED Is on
147
Load Cell Red Alarm LED Is off (with Platform Overloaded)
147
Platform Indicator Light Does Not Turn on
147
Audible Alarm Does Not Turn on
147
Boom and Drive Functions Are Enabled (with Boom Extended)
147
Section 5 Procedures
149
General
151
Human Machine Interface (HMI)
151
Safety and Workmanship
151
User Interface Keys
152
How to Select Functionality
154
How to View OCM Operation
155
How to Unlock and Modify OCM Settings
156
OCM Pin Voltage Reference
157
Fly Boom Switch Voltage References
160
Platform Controller Voltage References
161
Boom
162
Cable Carrier Repair
162
Check Wear Pads
162
Shimming Wear Pads
162
Boom Section Wear Pad Replacement
163
Inspection and Replacement of Extension Cylinder and Boom Cables
176
Proper Wire Rope Tension
183
Wire Rope Inspection
184
Adjust Turret Rotation Gear Backlash
185
Check and Replace High Pressure Filter
185
Turret
185
Battery Replacement
186
Change Swing Drive Motor Oil
186
Check Swing Drive Motor Gearbox Oil
186
Bolt Torque Procedure
187
Electronic Tilt Switch Setup Procedure
188
Check Rotation Bearing for Axial Wear
191
Deutz Diesel Engine
192
Replace Engine Oil and Filter
192
Replace Fuel Filter
193
Check Engine Belt
193
Check Oil Cooler
193
Replace Air Filter
193
GM Dual Fuel Engine
194
GM Map and IAT Sensor
194
LPG Temperature Sensor
195
Throttle Actuator
196
Engine Coolant Temperature Sensor
197
ECU Pin Reference Chart
198
Fuse Block Layout
199
Engine Parameter Display (Kantrak 1700)
200
Kubota WG2503 Dual Fuel Engine
200
Diagnostic Trouble Codes
201
ECU Pin Reference Chart (Kubota WG2503)
206
Fuse Box (Kubota WG2503)
207
IAT Sensor (Kubota WG2503)
208
MAP Sensor (Kubota WG2503)
208
ECT (Kubota WG2503)
209
TPS & Engine Speed (Kubota WG2503)
209
10 Oil Pressure Sensor (Kubota WG2503)
210
Fuel Temperature Sensor (Kubota WG2503)
210
Change Hydraulic Oil
211
Change Hydraulic Tank Filter
211
Hydraulic Tank
211
Hydraulic Brake Pressure Adjustment
212
Manifold and Hydraulic Pumps
212
Hydraulic Standby Pressure Adjustment
213
Hydraulic High Pressure Adjustment
214
Hydraulic System Relief Valve Adjustment
215
Platform Level Relief Valve Adjustment
216
Turret Rotate Relief Valve Adjustment
216
Fly Boom Relief Valve Adjustment
217
Test Charge Pump Pressure on Drive Pump
217
10 Test Reverse Drive Pressure on Drive Pump
218
Test Forward Drive Pressure on Drive Pump
218
Change Oil in Axles
219
Check Oil Level in Torque Hub
219
Bleeding Oscillating Axle Cylinders
220
Change Oil in Axle Gearbox
220
Check Oil Level in Axle Gearbox
220
Pin Brake Adjustments
221
Grease Points
223
Grease Turret Rotation Bearing
223
Grease Turret Rotation Gear
223
Lubrication
223
Grease Drive Axle
224
Grease Drive Shaft
224
Load Sensing System - CE
225
Generator Troubleshooting
228
Generator Frequency/Voltage Check & Adjustment (3.5 Kw)
229
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Skyjack SJ61T Specifications
General
Brand
Skyjack
Model
SJ61T
Category
Lifting Systems
Language
English
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