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SJ63 AJ+
Skyjack SJ63 AJ+ Service Manual
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80
SJ63 AJ+, SJ63 AJ
229043AAA
3.24
Load
Sens
ing C
onne
ction
s -
CE &
AS
'B' PLUG
'A' PLUG
4
02
118
82
02
02
60
02
D118
5
1
GREEN/YELL
OW
3
2
24P
-FEMALE
24P
-MALE
1
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4
3
2
1
PLA
TFORM CONTOL B
O
X WIRING
4P
-MALE
4P
-FEMALE
3P
-FEMALE
4" PIGT
AIL
TYP
.
M152502AA
To
order
go
to
Discount-Equipment.com
78
80
Table of Contents
Table of Contents
5
Section 1 - Scheduled Maintenance
15
Read and Heed
15
Mobile Elevating Work Platform (MEWP) Definition
15
Purpose of Equipment
15
Use of Equipment
15
Manual
15
Service Policy and Warranty
15
Operator Safety Reminders, Warnings and Precautions
15
Maintenance and Service
15
Maintenance and Service Safety Tips
15
Maintenance and Inspection Schedule
16
Owner's Annual Inspection Record
16
Replacement Parts
16
Hydraulic System & Component Maintenance and Repair
17
Hydraulic Maintenance Hints
17
Railing Maintenance and Repair
17
Scheduled Maintenance
19
Service Bulletins
19
Maintenance and Inspection
19
Maintenance Instructions
19
Owner's Annual Inspection Record
19
Pre-Delivery/Maintenance Inspection Checklist
21
Scheduled Maintenance Inspections
21
Hydraulic
21
Labels
21
Limit Switches
21
Electrical
22
Engine Compartment
22
Base
28
Platform
30
Boom Assembly
31
Optional Equipment
32
Function Tests
33
Section 2 - Maintenance Tables and Diagrams
34
Standard Hose Numbering System
34
Torque Specifications for Fasteners (US Imperial)
36
Torque Specifications for Fasteners (Metric)
37
Torque Specifications for Hydraulic Couplings & Hoses
38
Axle Torque Specifications
39
Axles Maintenance Intervals
40
MEWP Torque Specifications
41
Maximum Platform Capacity
42
Tire Specifications
42
Floor Loading Pressure
43
Hydraulic Specifications & Gear Oil
44
Specifications & Features - Dimensions & Speeds
45
Engine Specifications
47
Dimension and Reach Diagrams - SJ63AJ
48
Axle Oscillation Diagrams
49
Section 3 - System Component Identification and Schematics
50
Electrical Symbol Chart
51
Hydraulic Symbol Chart
52
Wire Number and Color Code
53
Hydraulic Parts List
54
Electrical Component Parts List
58
Rotary Manifold Port Identification
61
Brake Manifold Port Identification
62
Drive and System Pump and Port Identifications
63
Drive Motor and Port Identifications
64
Jib Valve and Port Identifications
65
Main Manifold and Port Identifications
66
Main Manifold and Electrical Identifications
67
Main Manifold and Hydraulic Identifications
68
Main Electrical Harness and Fuel Level Switch Harness
69
ECU Engine Wiring Diagram - Deutz
70
Glow Plug Harnesses - Deutz D2011
71
Glow Plug Harnesses - Deutz TD2.9L
72
Engine Interface Harness - GM
73
Engine Interface Harness - Deutz TD2.9L
74
Lowering Throttle Valve Harness
75
Platform Harnesses
76
Platform Control Cables
77
Limit Switch Connections at the Base Control Box
78
Load Sensing Connections - CE & as
79
All Motion Alarm Connections - CE & as
80
SGE Wiring Diagram
81
Hydraulic Generator and Oil Cooler Wiring - Base Control Box
82
Generator Wiring - Upper Control Box
83
Welder Wiring - ANSI/CSA
84
Load Circuit Wiring
85
Positive Air Shutoff Harness
86
Hydraulic Schematic - ANSI/CSA
87
Hydraulic Schematic - CE & as
88
Platform Control Box Wiring - ANSI/CSA
89
Platform Conrol Box Wiring - CE - Deutz TCD2.2
90
Platform Control Box Wiring - CE - Deutz TD2.9L & D2011
91
Platform Control Box Wiring - CE - Kubota WG2503
92
Platform Control Box Wiring - as
93
Base Control Box Wiring - ANSI/CSA
94
Base Control Box Wiring - ANSI/CSA with Positive Air Shut-Off Option
95
Base Control Box Wiring - CE - Deutz TCD2.2
96
Base Control Box Wiring - CE - Deutz TD2.9L
97
Base Control Box Wiring - CE - Deutz D2011
98
Base Control Box Wiring - as
99
Electrical Schematic - ANSI/CSA
100
Electrical Schematic - CE - Deutz TCD2.2
101
Electrical Schematic - CE - Deutz TD2.9
102
Electrical Schematic - CE - Deutz D2011
103
Electrical Schematic - CE - Kubota WG2503
104
Electrical Schematic - as - Deutz D2011
105
Engine Electrical Schematic - Deutz TD2.9L
106
Engine Interface Wiring - Deutz TD2.9L
107
Engine Electrical Schematic - Deutz D2011
108
Engine Electrical Schematic - Kubota WG2503
109
Engine Electrical Schematic - Deutz TCD2.2
110
Engine Interface Harness - Deutz TCD2.2
111
Section 4 - Troubleshooting Information
112
Introduction
112
Electrical System - ANSI/CSA
113
All Controls Are Inoperative from the Base or Platform Console
113
All Controls Are Inoperative from the Base Console
115
The Engine will Not Crank from the Base or Platform
115
The Engine will Not Crank from the Base
116
The Engine will Not Crank from the Platform
116
The Boom Controls Are Inoperative (Drive Operates)
116
No Boom up from the Base or Platform Controls
117
No Boom up from the Base Console
117
No Boom up from the Platform Console
117
10 No Boom down from the Base or Platform Consoles
117
11 No Boom down from the Base Console
118
12 No Boom down from the Platform Console
118
13 No Turret Rotate Right from the Base or Platform Consoles
118
14 No Turret Rotate Right from the Base Console
118
15 No Turret Rotate Right from the Platform Console
119
16 No Turret Rotate Left from the Base or Platform Consoles
119
17 No Turret Rotate Left from the Base Console
119
18 No Turret Rotate Left from the Platform Console
119
19 No Riser up from the Base or Platform Consoles
120
20 No Riser up from the Base Console
120
21 No Riser up from the Platform Console
120
22 No Riser down from the Base or Platform Consoles
120
23 No Riser down from the Base Console
121
24 No Riser down from the Platform Console
121
25 No Telescope out from the Base or Platform Consoles
121
26 No Telescope out from the Base Console
121
27 No Telescope out from the Platform Console
122
28 No Telescope in from the Base or Platform Consoles
122
29 No Telescope in from the Base Console
122
30 No Telescope in from the Platform Console
122
31 No Platform Level up from the Base or Platform Consoles
123
32 No Platform Level up from the Base Console
123
33 No Platform Level up from the Platform Console
123
34 No Platform Level down from the Base or Platform Consoles
123
35 No Platform Level down from the Base Console
124
36 No Platform Level down from the Platform Console
124
37 No Platform Rotate or Jib Functions from the Base or Platform Consoles
124
38 No Platform Rotate Right from the Base or Platform Consoles
125
39 No Platform Rotate Right from the Base Console
125
40 No Platform Rotate Right from the Platform Console
125
41 No Platform Rotate Left from the Base or Platform Consoles
126
42 No Platform Rotate Left from the Base Console
126
43 No Platform Rotate Left from the Platform Console
126
44 No Jib up from the Base or Platform Consoles
126
45 No Jib up from the Base Console
127
46 No Jib up from the Platform Console
127
47 No Jib down from the Base or Platform Consoles
127
48 No Jib down from the Base Console
127
49 No Jib down from the Platform Console
128
50 No Drive or Steer Functions
128
51 No Forward or Reverse Drive
128
52 No Forward Drive
128
53 No Reverse Drive
129
54 The Brake will Not Release
129
55 No Left Steer
129
56 No Right Steer
130
57 The Directon Sensing Is Inoperative
130
Weight
131
59 The Overload Indicator Light Does Not Turn on When the Platform Is Overloaded
131
60 The Audible Alarm Does Not Turn on with the Platform Overloaded
131
Electrical System - CE & as
132
All Controls Are Inoperative
132
No Power to Platform
133
No Power to Base
133
The Engine will Not Crank from the Base
134
The Engine will Not Crank from the Platform
134
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 Ready
135
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 Inoperative
139
12 All Controls Are Inoperative from the Base Console
140
13 No Main Boom Down, Riser down or Turret Rotate from Base Control Console
141
14 No Boom up from the Base Control Console
141
15 No Boom down from the Base Control Console
142
16 No Riser up from the Base Control Console
142
17 No Riser down from the Base Control Console
143
18 No Turret Rotate Left from the Base Control Console
143
19 No Turret Rotate Right from the Base Control Console
144
20 No Telescope Retract from the Base Control Console
144
21 No Telescope Extend from the Base Control Console
145
22 No Platform Rotate Left or Right
145
23 Platform Rotates too Quickly
146
24 No Platform Rotate Left from the Base Control Console
146
25 No Platform Rotate Right from the Base Control Console
147
26 No Jib up from the Base Control Console
148
27 No Jib down from the Base Control Console
148
28 No Manual Platform Level up from the Base Control Console
149
29 No Manual Platform Level down from the Base Control Console
149
30 All Controls Are Inoperative from the Platform Control Console
149
31 No Boom up from the Platform Control Console
151
32 No Boom down from the Platform Control Console
151
33 No Riser up from the Platform Control Console
152
34 No Riser down from the Platform Control Console
153
35 No Turret Left from the Platform Control Console
154
36 No Turret Right from the Platform Control Console
154
37 No Toggle Switch Functions from the Platform Control Console
155
38 No Telescope in from the Platform Control Console
155
39 No Telescope out from the Platform Control Console
156
40 No Platform Rotate Left from the Platform Control Console
157
41 No Platform Rotate Right from the Platform Control Console
158
42 No Jib up from the Platform Control Console
159
43 No Jib down from the Platform Control Console
160
44 No Manual Platform Level up from the Platform Control Console
161
45 No Manual Platform Level down from the Platform Control Console
162
46 MID Throttle Inoperative
163
47 High Throttle Inoperative
164
48 Brake will Not Release
165
49 Differential Lock will Not Engage
165
50 Differential Lock Engages Momentarily but will Not Stay Engaged
166
51 No Drive and Steer
166
No Forward Drive
167
53 No Reverse Drive
167
54 No High Speed Drive
168
55 No Elevated Drive
169
56 No Left Steer
170
57 No Right Steer
170
58 Direction Sensing Inoperative
171
Load Sensing System - CE & as
172
Green Power LED Is Not Flashing
172
Load Cell Red Alarm LED Is on (with Platform Empty)
172
Red Error LED Is on
172
Load Cell Red Alarm LED Is off (with Platform Overloaded)
172
Platform Indicator Light Does Not Turn on
172
Audible Alarm Does Not Turn on
173
Boom and Drive Functions Are Enabled (with Boom Extended)
173
Hydraulic System - ANSI/CSA
174
All Controls Are Inoperative
174
All Boom Functions Are Inoperative
174
No Main Boom up
174
No Main Boom down
174
No Riser Boom up
175
No Riser Boom down
175
No Turret Rotate Left
176
No Turret Rotate Right
176
No Boom Extend
177
10 No Boom Retract
177
11 No Jib up
177
12 No Jib down
178
13 No Platform Rotation Right
178
14 No Platform Rotation Left
178
15 The Platform will Not Level down Manually
179
16 The Platform will Not Level up Manually
179
17 The Brake will Not Release
180
18 The Brake will Not Engage
180
19 The Differential Lock will Not Engage
181
20 No Drive Forward or Reverse
181
21 No Forward Drive
181
22 No Reverse Drive
181
23 No High Speed Drive
182
24 No Right Steer
182
25 No Left Steer
182
26 The Axle will Not Oscillate
182
27 Axle will Not Lock
183
Hydraulic System - CE & as
184
All Controls Are Inoperative
184
All Boom Functions Are Inoperative
184
No Main Boom up
184
No Main Boom down
184
No Riser Boom up
185
No Riser Boom down
185
No Turret Rotate Left
186
No Turret Rotate Right
186
No Boom Extend
187
10 No Boom Retract
187
11 No Jib up
187
12 Jib Up/ down Slow
188
13 No Jib down
188
14 No Platform Rotation Right
188
15 No Platform Rotation Left
188
16 Platform Rotates too Quickly
189
17 Platform will Not Level down Manually
189
18 Platform will Not Level up Manually
189
19 Brake will Not Release
190
20 Brake will Not Engage
190
21 Differential Lock will Not Engage
191
22 No Drive Forward or Reverse
191
23 No Forward Drive
191
24 No Reverse Drive
191
25 No High Speed Drive
192
26 No Right Steer
192
27 No Left Steer
192
28 The Axle will Not Oscillate
192
29 The Axle will Not Lock
193
Section 5 - Procedures
194
General
194
Safety and Workmanship
194
Platform
195
Human Machine Interface (HMI)
195
User Interface Keys
195
OCM Character Functions Charts
196
OCM Function Channel Names - CE & as
196
OCM Operating Values Chart - CE & as
197
How to Select Functionality - CE & as
198
How to View OCM Operation - CE & as
199
How to Unlock and Modify OCM Settings - CE & as
200
OCM Pin Reference - ANSI/CSA
201
10 OCM Pin Voltage Reference - CE & as
207
11 Platform Controller Voltage References
210
Load Sensing System - CE & as
212
Load Sensing System Overload Status
212
Verify Proper Operation of the Load Sensing System
213
Calibration of Load Sensing System (with "Teach In" Handset)
214
Boom
215
Check Wear Pads
215
Shim Wear Pads
215
Cable Carrier Repair
215
Rotary Actuator Bolt Torque Procedure
215
Boom Section Wear Pad Replacement
216
Platform and Jib Boom Removal
217
Operating Machine Functions from the Base Controls
218
Fly Boom Removal
218
Change Wear Pads on Extension Cylinder Support
220
10 Fly Boom Installation
221
11 Platform/Jib Installation
222
12 Platform Control Console Connection
222
13 Extension Cylinder Removal
223
14 Extension Cylinder Installation
226
15 Main Boom Lift Cylinder Removal
227
16 Lift Cylinder Installation
228
17 Riser Cylinder Removal
229
18 Riser Cylinder Installation
229
19 Replace Limit Switch - Main Boom
230
20 Test Main Boom Limit Switch
231
21 Replace Limit Switch - Riser Boom
231
22 Test Riser Boom Limit Switch
232
23 Replace Limit Switch - Fly Boom
232
24 Test Fly Boom Limit Switch
233
Turret
234
Check and Replace the High Pressure Filter
234
Adjust the Turret Rotation Gear Backlash
234
Swing Drive Motor Removal
235
Check the Swing Drive Oil
236
Change the Swing Drive Oil
236
Check Rotation Bearing for Axial Wear
237
Turret Rotation Gear Bolt Torque Sequence
237
Electronic Tilt Switch Setup Procedure
238
Battery Replacement
240
Deutz Diesel Engine
241
Replace Engine Oil and Filter
241
Replace the Fuel Filter
242
Replace the Air Filter
242
Check the Engine Belt
242
Check the Oil Cooler (Deutz D2011 Only)
242
Deutz TD2.9L Fault Codes
243
Kubota WG2503 Dual Fuel Engine
263
Engine Parameter Display (Kantrak 1700)
263
Diagnostic Trouble Codes
264
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 Tank
274
Change the Hydraulic Tank Filter
274
Change the Hydraulic Oil
274
Manifold and Hydraulic Pumps
275
Hydraulic Brake Pressure Adjustment
275
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 Pump
279
10 Test Reverse Drive Pressure on Drive Pump
280
11 Hydraulic Standby Pressure Adjustment
280
12 Hydraulic High Pressure Adjustment
281
Axles
282
Change the Oil in the Axles
282
Check the Oil Level in the Torque Hubs
282
Change the Oil in the Torque Hubs
282
Check the Oil Level in the Axle Gearbox
283
Change the Oil in the Axle Gearbox
283
Oscillating Cylinder Bolt Replacement
284
Oscillating Cylinder Replacement
284
Bleed the Oscillating Axle Cylinders
286
Pin Brake Adjustments
286
10 Brake Inspection
288
Grease Points
289
Grease the Turret Ring Gear
289
Grease the Turret Swing Drive
289
Grease the Axles
290
Grease the Drive Shaft
290
Options
291
Generator Troubleshooting
291
Generator Frequency/Voltage Check & Adjustment
292
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Skyjack SJ63 AJ+ Specifications
General
Brand
Skyjack
Model
SJ63 AJ+
Category
Boom Lifts
Language
English
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