Skyjack SJ82 T - Service Manual

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SERVICE

MANUAL

TELESCOPIC BOOMS

229040ABA

August 2020

ANSI/CSA, CE, AS

SJ82 T, SJ86 T

To order go to Discount-Equipment.com

Main Page

Table of Contents5
Section 1 - Scheduled Maintenance11
Read and Heed11
Aerial Platform and Mobile Elevating Work Platform Definition11
Purpose of Equipment11
Use of Equipment11
Manual11
Service Policy and Warranty11
Operator Safety Reminders, Warnings and Precautions11
Maintenance and Service12
Maintenance and Inspection Schedule12
Owner's Annual Inspection Record12
Replacement Parts12
Maintenance and Service Safety Tips12
Hydraulic System & Component Maintenance and Repair13
Hydraulic Maintenance Hints13
Railing Maintenance and Repair14
Scheduled Maintenance15
Service Bulletins15
Maintenance and Inspection15
Maintenance Instructions15
Owner's Annual Inspection Record16
Pre-Delivery/Maintenance Inspection Checklist17
Scheduled Maintenance Inspections18
Electrical18
Hydraulic18
Labels18
Limit Switches18
Engine Compartment19
Control Compartment22
Base24
Platform Assembly26
Boom Assembly27
10 Optional Equipment29
Function Tests30
Section 2 - Maintenance Tables and Diagrams31
Standard Hose Numbering System31
MEWP Torque Specifications33
Axle Torque Specifications34
Torque Specifications for Fasteners (US)35
Torque Specifications for Fasteners (Metric)36
Torque Specifications for Hydraulic Couplings & Hoses37
Axles Maintenance Intervals38
Tire Specifications39
Floor Loading Pressure40
Hydraulic Specifications & Gear Oil41
Specifications & Features - Dimensional Data42
Specifications & Features - Performance and Speeds43
Engine Specifications44
Axle Oscillation Diagrams45
Dimension and Reach Diagram - SJ82 T46
Dimension and Reach Diagram - SJ86 T47
Section 3 - System Component Identification and Schematics48
Electrical Symbol Chart49
Hydraulic Symbol Chart50
Wire Number and Color Code51
Wire Numbers and Color Codes - Additional52
Hydraulic Parts List53
Electrical Parts List56
Hourmeter/Counter Harness - CE61
Rotary Manifold Port Identification62
System and Drive Pump Port Identification64
Drive Motors Port Identification65
Jib Valve Port Identification66
No Jib Valve Port Identification67
Brake Manifold Port Identification68
Main Manifold Port Identification69
Main Manifold Electrical Component Identification70
Main Manifold Hydraulic Component Identification71
Main Harness Wiring Diagram72
Boom Lift Valve Harness73
Differential Lock Harness74
Platform Rotate & Jib Harnesses75
Platform to Base Control Cable Harnesses76
Limit Switch Connections77
Load Sensing Cable Connection - CE & as78
ECU Engine Wiring Diagram - Deutz Diesel Engine79
Glow Plug and EGR Harnesses - Deutz Diesel Engine80
Generator and Oil Cooler Harness Connections81
Generator Wiring82
Platform Work Light83
Dual Capacity Sensing Module85
Load Circuit - ANSI/CSA with Deutz TD2.9L and Arctic Package86
Hydraulic Schematic87
Platform Controls Wiring - SJ82 T88
Platform Controls Wiring - SJ86 T with Deutz TD2.9L or D2011 Engines89
Platform Controls Wiring - SJ86 T with Deutz TCD2.2 Engine90
Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L91
Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off92
Base Controls Wiring - SJ82 T ANSI/CSA - Deutz D201193
Base Controls Wiring - SJ86 T ANSI/CSA - Deutz TD2.9L94
Base Controls Wiring - SJ86 T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off95
Base Controls Wiring - SJ86 T ANSI/CSA & as - Deutz D201196
Base Controls Wiring - SJ86 T CE - Deutz TCD2.297
Base Controls Wiring - SJ86 T CE - Deutz D201198
Base Controls Wiring - SJ86 T CE - Deutz TD2.9L99
Electrical Schematic - ANSI/CSA Deutz TD2.9L100
Electrical Schematic - ANSI/CSA & as Deutz D2011101
Electrical Schematic - CE Deutz TCD2.2102
Electrical Schematic - CE Deutz D2011103
Engine Electrical Schematic - Deutz TD2.9L104
Engine Interface Harness Schematic - Deutz TD2.9L105
Engine Electrical Schematic - Deutz TCD2.2106
Engine Interface Harness Schematic - Deutz TCD2.2107
Section 4 - Troubleshooting Information108
Introduction108
Electrical System109
All Controls Inoperative109
No Power110
Engine will Not Crank111
Engine Cranks but will Not Start114
Glow Plug Circuit Inoperative - Deutz D2011 Diesel Engine115
Glow Plug Circuit Inoperative - Deutz D2.9 Diesel Engine115
All Base Control Console Inoperative116
No Movement from Base Control Console117
All Controls Inoperative from Platform Control Console124
10 Throttle Inoperative, MID and High - Deutz D2.9L133
11 MID Throttle Inoperative134
12 High Throttle Inoperative135
13 Brake will Not Release136
14 No Drive and Steer136
15 No High Speed Drive139
16 No Elevated Drive140
17 Direction Sensing Inoperative141
18 Steer Direction Sensing Inoperative141
19 No Boom down or Extend Functions from Base or Platform Consoles (ANSI)142
20 No Boom down Function from Base or Platform Consoles (ANSI)142
21 No Boom Extend Function from Base or Platform Consoles (ANSI)143
22 No Boom down Function from Base or Platform Consoles (CE, AS)143
23 No Boom Extend Function from Base or Platform Consoles (CE, AS)144
Hydraulic System145
All Controls Inoperative145
All Boom Functions Inoperative145
No Main Boom up145
No Main Boom down145
No Turret Rotate146
No Boom Extend147
No Boom Retract147
No Jib up148
No Jib down149
10 No Platform Rotation149
11 Platform will Not Level150
12 Brake will Not Release151
13 Brake will Not Engage151
14 No Drive152
15 Differential Lock will Not Engage152
16 No High Speed Drive152
17 No Steer153
Load Sensing System - CE155
Green LED on Load Sense/Dual Load Zone Module Is Not on155
Load Sense Indicates Overload or Overload Warning with Platform Empty or below Weight155
Load Sense/Dual Load Zone Module Error156
No Light/Alarm When Platform Is Overloaded157
Section 5 - Procedures158
General158
Safety and Workmanship158
How to Install the Boom Maintenance Support159
Platform161
Human Machine Interface (HMI)161
User Interface Keys161
SCM Character Functions Charts162
SCM Operating Values Chart163
How to Select SCM Functionality164
How to View SCM Operation165
How to Unlock and Modify SCM Settings166
SCM Pin Voltage Reference167
Fly Boom Switch Voltage References170
10 Platform Controller Voltage References171
Load Sensing System172
Load Sensing System Overload Status172
Dual Capacity Overload Module Function Table173
Calibration of Load Sensing System174
Boom176
Check Wear Pads176
Shim Wear Pads176
Cable Carrier Repair176
Rotary Actuator Bolt Torque Procedure176
Boom Section Wear Pad Replacement177
Platform and Jib Boom Removal178
Platform Removal (no Jib Boom)180
Operating Machine Functions from Base Controls182
Fly Boom Section Removal183
10 MID Boom Section Removal184
11 MID Boom Section Installation185
12 Fly Boom Section Installation186
13 Platform and Jib Boom Installation186
14 Platform Installation (no Jib Boom)187
15 Platform Control Console Connection188
16 Extension Cylinder and Wire Rope Replacement189
17 Extension Cylinder and Cable Assembly Removal189
18 Extension Cylinder and Wire Rope Assembly Installation192
19 Proper Wire Rope Tension194
20 Wire Rope Inspection195
21 Limit Switch Checking and Adjusting196
22 Directional Sensing Limit Switch (LS1)197
23 High Speed Drive / Tilt Override Limit Switch (LS2)198
24 Fly-In Limit Switch (LS3)200
25 Boom Angle (Dual Load) Limit Switch (LS4)201
26 Boom Extension (Dual Load) Limit Switch (LS5)203
27 Lift Cushion Limit Switch (LS6)205
Turret207
Check and Replace the High Pressure Filter207
Adjust the Turret Rotation Gear Backlash207
Check the Swing Drive Oil208
Change the Swing Drive Oil208
Battery Replacement209
Turret Rotation Gear Bolt Torque Sequence209
Electronic Tilt Switch Setup Procedure210
Check Rotation Bearing for Axial Wear212
Resetting the Emergency Lowering Counter (CE Only)213
Deutz Diesel Engines214
Replace Engine Oil and Filter214
Replace the Fuel Filter215
Replace the Air Filter215
Check the Engine Belt215
Check the Oil Cooler (Deutz D2011 Only)215
Deutz TD2.9L Fault Codes216
Diesel Particulate Filter (DPF) and Standstill Regeneration - Deutz TCD2.2 Engine236
Hydraulic Tank238
Change the Hydraulic Tank Filter238
Change the Hydraulic Oil238
Manifolds and Hydraulic Pumps239
Hydraulic Brake Pressure Adjustment239
Hydraulic Standby Pressure Adjustment240
Hydraulic High Pressure Adjustment241
Hydraulic System Relief Valve Adjustment242
Turret Rotate Relief Valve Adjustment243
Platform Level Relief Valve Adjustment243
Fly Boom Relief Valve Adjustment244
Test Charge Pump Pressure on Drive Pump244
Test Forward Drive Pressure on Drive Pump245
10 Test Reverse Drive Pressure on Drive Pump245
Axles246
Change the Oil in the Axles246
Check the Oil Level in the Torque Hubs246
Change the Oil in the Torque Hubs246
Check the Oil Level in the Axle Gearbox247
Change the Oil in the Axle Gearbox247
Brake Inspection248
Oscillating Cylinder Bolt Replacement248
Oscillating Cylinder Replacement249
Bleed the Oscillating Axle Cylinders250
10 Test the Oscillating Axle Cylinders251
Grease Points252
Grease the Turret Ring Gear252
Grease the Turret Swing Drive252
Grease the Axles253
Grease the Drive Shaft253

Skyjack SJ82 T - Service Manual

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