Skyjack SJ63 AJ+

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This manual is for MEWPs with serial numbers:

SJ63 AJ+: A302 000 001 - A302 999 999

SJ63 AJ: A302 000 001 - A302 999 999

SJ63 AJ: B302 000 001 - B302 999 999

To order go to Discount-Equipment.com

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Table of Contents5
Section 1 - Scheduled Maintenance15
Read and Heed15
Mobile Elevating Work Platform (MEWP) Definition15
Purpose of Equipment15
Use of Equipment15
Manual15
Service Policy and Warranty15
Operator Safety Reminders, Warnings and Precautions15
Maintenance and Service15
Maintenance and Service Safety Tips15
Maintenance and Inspection Schedule16
Owner's Annual Inspection Record16
Replacement Parts16
Hydraulic System & Component Maintenance and Repair17
Hydraulic Maintenance Hints17
Railing Maintenance and Repair17
Scheduled Maintenance19
Service Bulletins19
Maintenance and Inspection19
Maintenance Instructions19
Owner's Annual Inspection Record19
Pre-Delivery/Maintenance Inspection Checklist21
Scheduled Maintenance Inspections21
Hydraulic21
Labels21
Limit Switches21
Electrical22
Engine Compartment22
Base28
Platform30
Boom Assembly31
Optional Equipment32
Function Tests33
Section 2 - Maintenance Tables and Diagrams34
Standard Hose Numbering System34
Torque Specifications for Fasteners (US Imperial)36
Torque Specifications for Fasteners (Metric)37
Torque Specifications for Hydraulic Couplings & Hoses38
Axle Torque Specifications39
Axles Maintenance Intervals40
MEWP Torque Specifications41
Maximum Platform Capacity42
Tire Specifications42
Floor Loading Pressure43
Hydraulic Specifications & Gear Oil44
Specifications & Features - Dimensions & Speeds45
Engine Specifications47
Dimension and Reach Diagrams - SJ63AJ48
Axle Oscillation Diagrams49
Section 3 - System Component Identification and Schematics50
Electrical Symbol Chart51
Hydraulic Symbol Chart52
Wire Number and Color Code53
Hydraulic Parts List54
Electrical Component Parts List58
Rotary Manifold Port Identification61
Brake Manifold Port Identification62
Drive and System Pump and Port Identifications63
Drive Motor and Port Identifications64
Jib Valve and Port Identifications65
Main Manifold and Port Identifications66
Main Manifold and Electrical Identifications67
Main Manifold and Hydraulic Identifications68
Main Electrical Harness and Fuel Level Switch Harness69
ECU Engine Wiring Diagram - Deutz70
Glow Plug Harnesses - Deutz D201171
Glow Plug Harnesses - Deutz TD2.9L72
Engine Interface Harness - GM73
Engine Interface Harness - Deutz TD2.9L74
Lowering Throttle Valve Harness75
Platform Harnesses76
Platform Control Cables77
Limit Switch Connections at the Base Control Box78
Load Sensing Connections - CE & as79
All Motion Alarm Connections - CE & as80
SGE Wiring Diagram81
Hydraulic Generator and Oil Cooler Wiring - Base Control Box82
Generator Wiring - Upper Control Box83
Welder Wiring - ANSI/CSA84
Load Circuit Wiring85
Positive Air Shutoff Harness86
Hydraulic Schematic - ANSI/CSA87
Hydraulic Schematic - CE & as88
Platform Control Box Wiring - ANSI/CSA89
Platform Conrol Box Wiring - CE - Deutz TCD2.290
Platform Control Box Wiring - CE - Deutz TD2.9L & D201191
Platform Control Box Wiring - CE - Kubota WG250392
Platform Control Box Wiring - as93
Base Control Box Wiring - ANSI/CSA94
Base Control Box Wiring - ANSI/CSA with Positive Air Shut-Off Option95
Base Control Box Wiring - CE - Deutz TCD2.296
Base Control Box Wiring - CE - Deutz TD2.9L97
Base Control Box Wiring - CE - Deutz D201198
Base Control Box Wiring - as99
Electrical Schematic - ANSI/CSA100
Electrical Schematic - CE - Deutz TCD2.2101
Electrical Schematic - CE - Deutz TD2.9102
Electrical Schematic - CE - Deutz D2011103
Electrical Schematic - CE - Kubota WG2503104
Electrical Schematic - as - Deutz D2011105
Engine Electrical Schematic - Deutz TD2.9L106
Engine Interface Wiring - Deutz TD2.9L107
Engine Electrical Schematic - Deutz D2011108
Engine Electrical Schematic - Kubota WG2503109
Engine Electrical Schematic - Deutz TCD2.2110
Engine Interface Harness - Deutz TCD2.2111
Section 4 - Troubleshooting Information112
Introduction112
Electrical System - ANSI/CSA113
All Controls Are Inoperative from the Base or Platform Console113
All Controls Are Inoperative from the Base Console115
The Engine will Not Crank from the Base or Platform115
The Engine will Not Crank from the Base116
The Engine will Not Crank from the Platform116
The Boom Controls Are Inoperative (Drive Operates)116
No Boom up from the Base or Platform Controls117
No Boom up from the Base Console117
No Boom up from the Platform Console117
10 No Boom down from the Base or Platform Consoles117
11 No Boom down from the Base Console118
12 No Boom down from the Platform Console118
13 No Turret Rotate Right from the Base or Platform Consoles118
14 No Turret Rotate Right from the Base Console118
15 No Turret Rotate Right from the Platform Console119
16 No Turret Rotate Left from the Base or Platform Consoles119
17 No Turret Rotate Left from the Base Console119
18 No Turret Rotate Left from the Platform Console119
19 No Riser up from the Base or Platform Consoles120
20 No Riser up from the Base Console120
21 No Riser up from the Platform Console120
22 No Riser down from the Base or Platform Consoles120
23 No Riser down from the Base Console121
24 No Riser down from the Platform Console121
25 No Telescope out from the Base or Platform Consoles121
26 No Telescope out from the Base Console121
27 No Telescope out from the Platform Console122
28 No Telescope in from the Base or Platform Consoles122
29 No Telescope in from the Base Console122
30 No Telescope in from the Platform Console122
31 No Platform Level up from the Base or Platform Consoles123
32 No Platform Level up from the Base Console123
33 No Platform Level up from the Platform Console123
34 No Platform Level down from the Base or Platform Consoles123
35 No Platform Level down from the Base Console124
36 No Platform Level down from the Platform Console124
37 No Platform Rotate or Jib Functions from the Base or Platform Consoles124
38 No Platform Rotate Right from the Base or Platform Consoles125
39 No Platform Rotate Right from the Base Console125
40 No Platform Rotate Right from the Platform Console125
41 No Platform Rotate Left from the Base or Platform Consoles126
42 No Platform Rotate Left from the Base Console126
43 No Platform Rotate Left from the Platform Console126
44 No Jib up from the Base or Platform Consoles126
45 No Jib up from the Base Console127
46 No Jib up from the Platform Console127
47 No Jib down from the Base or Platform Consoles127
48 No Jib down from the Base Console127
49 No Jib down from the Platform Console128
50 No Drive or Steer Functions128
51 No Forward or Reverse Drive128
52 No Forward Drive128
53 No Reverse Drive129
54 The Brake will Not Release129
55 No Left Steer129
56 No Right Steer130
57 The Directon Sensing Is Inoperative130
Weight131
59 The Overload Indicator Light Does Not Turn on When the Platform Is Overloaded131
60 The Audible Alarm Does Not Turn on with the Platform Overloaded131
Electrical System - CE & as132
All Controls Are Inoperative132
No Power to Platform133
No Power to Base133
The Engine will Not Crank from the Base134
The Engine will Not Crank from the Platform134
The Engine will Not Crank from the Platform or Base (Deutz Diesel)134
The Engine will Not Crank from the Platform or Base When Equipped with Elevate/Trackunit Telematics Ready135
The Engine Cranks but will Not Start (Deutz Diesel)136
The Engine will Not Crank from the Platform or Base Control (GM Dual Fuel)136
10 The Engine Cranks but will Not Start (GM Dual Fuel)137
11 The Glow Plug Circuit Is Inoperative139
12 All Controls Are Inoperative from the Base Console140
13 No Main Boom Down, Riser down or Turret Rotate from Base Control Console141
14 No Boom up from the Base Control Console141
15 No Boom down from the Base Control Console142
16 No Riser up from the Base Control Console142
17 No Riser down from the Base Control Console143
18 No Turret Rotate Left from the Base Control Console143
19 No Turret Rotate Right from the Base Control Console144
20 No Telescope Retract from the Base Control Console144
21 No Telescope Extend from the Base Control Console145
22 No Platform Rotate Left or Right145
23 Platform Rotates too Quickly146
24 No Platform Rotate Left from the Base Control Console146
25 No Platform Rotate Right from the Base Control Console147
26 No Jib up from the Base Control Console148
27 No Jib down from the Base Control Console148
28 No Manual Platform Level up from the Base Control Console149
29 No Manual Platform Level down from the Base Control Console149
30 All Controls Are Inoperative from the Platform Control Console149
31 No Boom up from the Platform Control Console151
32 No Boom down from the Platform Control Console151
33 No Riser up from the Platform Control Console152
34 No Riser down from the Platform Control Console153
35 No Turret Left from the Platform Control Console154
36 No Turret Right from the Platform Control Console154
37 No Toggle Switch Functions from the Platform Control Console155
38 No Telescope in from the Platform Control Console155
39 No Telescope out from the Platform Control Console156
40 No Platform Rotate Left from the Platform Control Console157
41 No Platform Rotate Right from the Platform Control Console158
42 No Jib up from the Platform Control Console159
43 No Jib down from the Platform Control Console160
44 No Manual Platform Level up from the Platform Control Console161
45 No Manual Platform Level down from the Platform Control Console162
46 MID Throttle Inoperative163
47 High Throttle Inoperative164
48 Brake will Not Release165
49 Differential Lock will Not Engage165
50 Differential Lock Engages Momentarily but will Not Stay Engaged166
51 No Drive and Steer166
No Forward Drive167
53 No Reverse Drive167
54 No High Speed Drive168
55 No Elevated Drive169
56 No Left Steer170
57 No Right Steer170
58 Direction Sensing Inoperative171
Load Sensing System - CE & as172
Green Power LED Is Not Flashing172
Load Cell Red Alarm LED Is on (with Platform Empty)172
Red Error LED Is on172
Load Cell Red Alarm LED Is off (with Platform Overloaded)172
Platform Indicator Light Does Not Turn on172
Audible Alarm Does Not Turn on173
Boom and Drive Functions Are Enabled (with Boom Extended)173
Hydraulic System - ANSI/CSA174
All Controls Are Inoperative174
All Boom Functions Are Inoperative174
No Main Boom up174
No Main Boom down174
No Riser Boom up175
No Riser Boom down175
No Turret Rotate Left176
No Turret Rotate Right176
No Boom Extend177
10 No Boom Retract177
11 No Jib up177
12 No Jib down178
13 No Platform Rotation Right178
14 No Platform Rotation Left178
15 The Platform will Not Level down Manually179
16 The Platform will Not Level up Manually179
17 The Brake will Not Release180
18 The Brake will Not Engage180
19 The Differential Lock will Not Engage181
20 No Drive Forward or Reverse181
21 No Forward Drive181
22 No Reverse Drive181
23 No High Speed Drive182
24 No Right Steer182
25 No Left Steer182
26 The Axle will Not Oscillate182
27 Axle will Not Lock183
Hydraulic System - CE & as184
All Controls Are Inoperative184
All Boom Functions Are Inoperative184
No Main Boom up184
No Main Boom down184
No Riser Boom up185
No Riser Boom down185
No Turret Rotate Left186
No Turret Rotate Right186
No Boom Extend187
10 No Boom Retract187
11 No Jib up187
12 Jib Up/ down Slow188
13 No Jib down188
14 No Platform Rotation Right188
15 No Platform Rotation Left188
16 Platform Rotates too Quickly189
17 Platform will Not Level down Manually189
18 Platform will Not Level up Manually189
19 Brake will Not Release190
20 Brake will Not Engage190
21 Differential Lock will Not Engage191
22 No Drive Forward or Reverse191
23 No Forward Drive191
24 No Reverse Drive191
25 No High Speed Drive192
26 No Right Steer192
27 No Left Steer192
28 The Axle will Not Oscillate192
29 The Axle will Not Lock193
Section 5 - Procedures194
General194
Safety and Workmanship194
Platform195
Human Machine Interface (HMI)195
User Interface Keys195
OCM Character Functions Charts196
OCM Function Channel Names - CE & as196
OCM Operating Values Chart - CE & as197
How to Select Functionality - CE & as198
How to View OCM Operation - CE & as199
How to Unlock and Modify OCM Settings - CE & as200
OCM Pin Reference - ANSI/CSA201
10 OCM Pin Voltage Reference - CE & as207
11 Platform Controller Voltage References210
Load Sensing System - CE & as212
Load Sensing System Overload Status212
Verify Proper Operation of the Load Sensing System213
Calibration of Load Sensing System (with "Teach In" Handset)214
Boom215
Check Wear Pads215
Shim Wear Pads215
Cable Carrier Repair215
Rotary Actuator Bolt Torque Procedure215
Boom Section Wear Pad Replacement216
Platform and Jib Boom Removal217
Operating Machine Functions from the Base Controls218
Fly Boom Removal218
Change Wear Pads on Extension Cylinder Support220
10 Fly Boom Installation221
11 Platform/Jib Installation222
12 Platform Control Console Connection222
13 Extension Cylinder Removal223
14 Extension Cylinder Installation226
15 Main Boom Lift Cylinder Removal227
16 Lift Cylinder Installation228
17 Riser Cylinder Removal229
18 Riser Cylinder Installation229
19 Replace Limit Switch - Main Boom230
20 Test Main Boom Limit Switch231
21 Replace Limit Switch - Riser Boom231
22 Test Riser Boom Limit Switch232
23 Replace Limit Switch - Fly Boom232
24 Test Fly Boom Limit Switch233
Turret234
Check and Replace the High Pressure Filter234
Adjust the Turret Rotation Gear Backlash234
Swing Drive Motor Removal235
Check the Swing Drive Oil236
Change the Swing Drive Oil236
Check Rotation Bearing for Axial Wear237
Turret Rotation Gear Bolt Torque Sequence237
Electronic Tilt Switch Setup Procedure238
Battery Replacement240
Deutz Diesel Engine241
Replace Engine Oil and Filter241
Replace the Fuel Filter242
Replace the Air Filter242
Check the Engine Belt242
Check the Oil Cooler (Deutz D2011 Only)242
Deutz TD2.9L Fault Codes243
Kubota WG2503 Dual Fuel Engine263
Engine Parameter Display (Kantrak 1700)263
Diagnostic Trouble Codes264
ECU Pin Reference Chart (Kubota WG2503)269
Fuse Box (Kubota WG2503)270
MAP Sensor (Kubota WG2503)271
IAT Sensor (Kubota WG2503)271
ECT (Kubota WG2503)272
TPS & Engine Speed (Kubota WG2503)272
Fuel Temperature Sensor (Kubota WG2503)273
10 Oil Pressure Sensor (Kubota WG2503)273
Hydraulic Tank274
Change the Hydraulic Tank Filter274
Change the Hydraulic Oil274
Manifold and Hydraulic Pumps275
Hydraulic Brake Pressure Adjustment275
Hydraulic System Relief Valve Adjustment (RV1)276
Turret Rotate Relief Valve Adjustment (RV2)276
Platform Level Relief Valve Adjustment (RV3)277
Riser Boom down Relief Valve Adjustment (RV4)277
Main Boom down Relief Valve Adjustment (RV5)278
Fly Boom Relief Valve Adjustment (RV6)278
Test Charge Pump Pressure on Drive Pump (RV10)279
Test Forward Drive Pressure on Drive Pump279
10 Test Reverse Drive Pressure on Drive Pump280
11 Hydraulic Standby Pressure Adjustment280
12 Hydraulic High Pressure Adjustment281
Axles282
Change the Oil in the Axles282
Check the Oil Level in the Torque Hubs282
Change the Oil in the Torque Hubs282
Check the Oil Level in the Axle Gearbox283
Change the Oil in the Axle Gearbox283
Oscillating Cylinder Bolt Replacement284
Oscillating Cylinder Replacement284
Bleed the Oscillating Axle Cylinders286
Pin Brake Adjustments286
10 Brake Inspection288
Grease Points289
Grease the Turret Ring Gear289
Grease the Turret Swing Drive289
Grease the Axles290
Grease the Drive Shaft290
Options291
Generator Troubleshooting291
Generator Frequency/Voltage Check & Adjustment292

Skyjack SJ63 AJ+ - Page 3

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