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SJ82 T
Skyjack SJ82 T Service Manual
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108
SJ82 T
, SJ86 T
229040ABA
M224629AD-2
WATER IN
L1
L
COOLANT
L2
L
FUEL SWITCH
LEVEL
11CR
11
FP
FUEL
PUMP
SENSOR
100A
FU2
11C
11C
11C
11B
03
GP1
GP2
GP3
FUEL
INJ.
CYL.3
FUEL
INJ.
CYL.2
FUEL
INJ.
CYL.1
ACTUATOR
MPROP
U
n
ENGINE
SPEED
SENSOR
CAMSHAFT
U
P
FUEL
RAIL
PRESS.
SENSOR
U
n
ENGINE
SPEED
SENSOR
CRANKSHAFT
START
RELAY
EXHAUST GAS
RECIRCULATION
VAL
VE (EGR)
M
U
p&t°
BOOST
PRESSURE &
TEMPERATURE
SENSOR
OIL
PRESSURE
SENSOR
U
P
FUEL LOW
PRESSURE
SENSOR
U
P
U
t
COOLING
TEMPERATURE
SENSOR
D+
STARTER
SOLENOID
STARTER
B+
TO BATTERY
B- POST
03
TO S1 BATTERY
DISCONNECT SW
.
00
30A
FU1
EXHAUST
PRESSURE
SENSOR
U
P
U
P
DEL
TA P
VENTURI
PRESS.
SENSOR
U
t
EXHAUST GAS
RECIRCULATION
TEMP
. SENSOR
THROTTLE
VAL
VE
M
U
t
EXHAUST GAS
TEMPERATURE
SENSOR 1
U
t
EXHAUST GAS
TEMPERATURE
SENSOR 2
U
P
DPF
ENGINE
U
t
AMBIENT
TEMPERATURE
SENSOR
09A
11A
R=120 ohm
DIFFERENTIAL
PRESSURE
(BEFORE CAT)
(AF
TER CAT)
79
1
2
5
3
6
4
13
72
25
20
35
D2.2 - 94 PIN
48
53
65
70
92
52
19
75
57
15
73
88
71
X17.1-62 PIN
3
1
2
6
5
4
8
7
10
9
12
11
37
39
42
3
32
38
20
48
19
47
17
31
22
25
29
33
35
36
28
14
46
26
23
13
50
9
15
1
51
21
SPLK01
SPL00
(+)
(-)
2
3
1
2
5
4
8
10
9
12
11
B- POST
B+ POST
A20-16 BK
A19-16 BK
A54-18 BK
A39-18 WH
A38-18 RD
A52-18 BK
A37-18 WH
A53-18 RD
A33-16 BK
A16-16 BK
A05-16 BK
A04-16 BK
A48-16 BK
A18-16 BK
K68-18 BK
K20-18 BK
A09-18 BK
A25-18 BK
A27-18 BK
A57-18 BK
A26-18 BK
A42-18 BK
A43-18 BK
A44-18 BK
K13-18 RD
K87-18 BK
K68-18 BK
K13-18 RD
B+-12 RD
K01-12 RD
K01-14 RD
K01-14 RD
K01-14 RD
00-14 WH
00-12 WH
00-12 WH
00-14 WH
00-14 WH
00-14 WH
56B-14 RD
56B-14 RD
56A-18 WH
84-18 WH (T
-ONL
Y)
57A-16 BK
74-18 WH
105-18 WH
104-18 BK
A58-18 BK
A40-18 BK
76A-18 WH
96-18 WH (T
-ONL
Y)
76-18 BK
99-18 WH
90-18 BK
09-16 BK
54-18 BK
A49-18 WH
4
TO ECU
AT ENGINE
56A-18 WH
K72-18 BK
57A-18 BK
74-18 BK
105-18 WH
104-18 BK
76A-18 WH
96-18 WH
76-18 BK
99-18 BK
90-18 BK
54-18 BK
K15-18 BK
82
K82-18 BK
A40-18 BK
A22-18 BK
K20-18 BK
K19-18 BK
09-18 BK
K58-18 BK
A07-18 BK
A50-18 BK
A41-18 BK
39
38
24
54
44
41
57
22
19
12
40
59
20
50
28
29
25
07
D2.1 - 60 PIN
21
26
42
09
27
43
A44-18 BK
A57-18 BK
A43-18 BK
A09-18 BK
A27-18 BK
A26-18 BK
A25-18 BK
A42-18 BK
A07-18 BK
A29-18 BK
A28-18 BK
A50-18 BK
A41-18 BK
A54-18 BK
A39-18 WH
A38-18 RD
A24-18 BK
A22-18 BK
A12-18 BK
A19-16 BK
A20-16 BK
A59-18 BK
A40-18 BK
A21-18 BK
TO ECU
00-14 WH
4
3
2
1
2
3
1
A12-18 BK
5
3
1
2
6
2
1
3
24
A28-18 BK
3
2
1
4
3
2
1
4
3
2
1
4
2
1
TO BATTERY
TO BATTERY
K79-18 BK (46AJ ONL
Y)
K87-18 BK (46AJ ONL
Y)
K79-18 BK
6
7
CAN L
-18 WH
CAN H-18 BK
CAN H-18 BK
54
CAN L
-18 WH
76
53
52
33
37
16
05
32
04
02
48
11
18
34
15
A53-18 RD
A52-18 BK
A37-18 WH
A33-16 BK
A16-16 BK
A05-16 BK
A04-16 BK
A32-16 BK
A02-16 BK
A48-16 BK
A18-16 BK
A11-18 BK
A34-16 WH
84-18 WH (T
-ONL
Y)
3
2
1
4
30
43
44
45
2
1
3
6
4
5
27
1
2
8
7
1
3
5
6
2
60
59
49
53
52
2
1
X39-8 PIN
AT ENGINE
2
1
2
1
4
3
3
2
1
5
6
7
A32-16 BK
A02-16 BK
A11-18 BK
K23-18 BK
K81-18 BK
K82-18 BK
K08-18 BK
K64-18 BK
K09-18 BK
K33-18 BK
K07-18 BK
K80-18 BK
K46-18 BK
A59-18 BK
K55-18 BK
K56-18 BK
K91-18 BK
A21-18 BK
A24-18 BK
(A57 GND)
(A24 +5V)
18
34
A29-18 BK
K43-18 BK
K21-18 BK
33
07
23
81
43
58
09
21
91
K33-18 BK
K23-18 BK
K43-18 BK
K58-18 BK
K07-18 BK
K09-18 BK
K81-16 BK
K21-18 BK
K91-18 BK
64
80
08
46
K64-18 BK
K80-18 BK
K46-18 BK
K08-18 BK
3
1
2
6
5
4
A34-18 BK
K15-18 BK
8
K72-18 BK
K68-18 BK
68
87
K87-18 BK
60
02
55
56
K56-18 BK
K55-18 BK
58
A58-16 WH
2
1
ENGINE DISPLA
Y CONNECTOR
4
3
5
6
7
8
02
60
CAN L
-18 WH
CAN H-18 BK
A57-18 BK
A40-18 BK
1
2
2
1
K39-18 BK
K60-18 BK
39
60
K39-18 BK
K60-18 BK
42
K42-18 RD
(A40 GND)
09A-18 BK
A24-18 BK
A57-18 BK
K42-18 BK
K19-18 BK
49
A49-18 WH
P2
P1
P4
10
9
11
12
2
1
7
8
ENGINE DISPLA
Y
MOUNTED ON ENGINE
2
1
2
1
G
M
3
3.51
Engi
ne El
ectr
ical
Schem
atic
- De
utz
TCD
2.2
3.51
En
gine Elec
trical Sch
ematic -
Deutz
TCD2.2
To
order
go
to
Discount-Equipment.com
105
107
Table of Contents
Table of Contents
5
Section 1 - Scheduled Maintenance
11
Read and Heed
11
Aerial Platform and Mobile Elevating Work Platform Definition
11
Purpose of Equipment
11
Use of Equipment
11
Manual
11
Service Policy and Warranty
11
Operator Safety Reminders, Warnings and Precautions
11
Maintenance and Service
12
Maintenance and Inspection Schedule
12
Owner's Annual Inspection Record
12
Replacement Parts
12
Maintenance and Service Safety Tips
12
Hydraulic System & Component Maintenance and Repair
13
Hydraulic Maintenance Hints
13
Railing Maintenance and Repair
14
Scheduled Maintenance
15
Service Bulletins
15
Maintenance and Inspection
15
Maintenance Instructions
15
Owner's Annual Inspection Record
16
Pre-Delivery/Maintenance Inspection Checklist
17
Scheduled Maintenance Inspections
18
Electrical
18
Hydraulic
18
Labels
18
Limit Switches
18
Engine Compartment
19
Control Compartment
22
Base
24
Platform Assembly
26
Boom Assembly
27
10 Optional Equipment
29
Function Tests
30
Section 2 - Maintenance Tables and Diagrams
31
Standard Hose Numbering System
31
MEWP Torque Specifications
33
Axle Torque Specifications
34
Torque Specifications for Fasteners (US)
35
Torque Specifications for Fasteners (Metric)
36
Torque Specifications for Hydraulic Couplings & Hoses
37
Axles Maintenance Intervals
38
Tire Specifications
39
Floor Loading Pressure
40
Hydraulic Specifications & Gear Oil
41
Specifications & Features - Dimensional Data
42
Specifications & Features - Performance and Speeds
43
Engine Specifications
44
Axle Oscillation Diagrams
45
Dimension and Reach Diagram - SJ82 T
46
Dimension and Reach Diagram - SJ86 T
47
Section 3 - System Component Identification and Schematics
48
Electrical Symbol Chart
49
Hydraulic Symbol Chart
50
Wire Number and Color Code
51
Wire Numbers and Color Codes - Additional
52
Hydraulic Parts List
53
Electrical Parts List
56
Hourmeter/Counter Harness - CE
61
Rotary Manifold Port Identification
62
System and Drive Pump Port Identification
64
Drive Motors Port Identification
65
Jib Valve Port Identification
66
No Jib Valve Port Identification
67
Brake Manifold Port Identification
68
Main Manifold Port Identification
69
Main Manifold Electrical Component Identification
70
Main Manifold Hydraulic Component Identification
71
Main Harness Wiring Diagram
72
Boom Lift Valve Harness
73
Differential Lock Harness
74
Platform Rotate & Jib Harnesses
75
Platform to Base Control Cable Harnesses
76
Limit Switch Connections
77
Load Sensing Cable Connection - CE & as
78
ECU Engine Wiring Diagram - Deutz Diesel Engine
79
Glow Plug and EGR Harnesses - Deutz Diesel Engine
80
Generator and Oil Cooler Harness Connections
81
Generator Wiring
82
Platform Work Light
83
Dual Capacity Sensing Module
85
Load Circuit - ANSI/CSA with Deutz TD2.9L and Arctic Package
86
Hydraulic Schematic
87
Platform Controls Wiring - SJ82 T
88
Platform Controls Wiring - SJ86 T with Deutz TD2.9L or D2011 Engines
89
Platform Controls Wiring - SJ86 T with Deutz TCD2.2 Engine
90
Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L
91
Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off
92
Base Controls Wiring - SJ82 T ANSI/CSA - Deutz D2011
93
Base Controls Wiring - SJ86 T ANSI/CSA - Deutz TD2.9L
94
Base Controls Wiring - SJ86 T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off
95
Base Controls Wiring - SJ86 T ANSI/CSA & as - Deutz D2011
96
Base Controls Wiring - SJ86 T CE - Deutz TCD2.2
97
Base Controls Wiring - SJ86 T CE - Deutz D2011
98
Base Controls Wiring - SJ86 T CE - Deutz TD2.9L
99
Electrical Schematic - ANSI/CSA Deutz TD2.9L
100
Electrical Schematic - ANSI/CSA & as Deutz D2011
101
Electrical Schematic - CE Deutz TCD2.2
102
Electrical Schematic - CE Deutz D2011
103
Engine Electrical Schematic - Deutz TD2.9L
104
Engine Interface Harness Schematic - Deutz TD2.9L
105
Engine Electrical Schematic - Deutz TCD2.2
106
Engine Interface Harness Schematic - Deutz TCD2.2
107
Section 4 - Troubleshooting Information
108
Introduction
108
Electrical System
109
All Controls Inoperative
109
No Power
110
Engine will Not Crank
111
Engine Cranks but will Not Start
114
Glow Plug Circuit Inoperative - Deutz D2011 Diesel Engine
115
Glow Plug Circuit Inoperative - Deutz D2.9 Diesel Engine
115
All Base Control Console Inoperative
116
No Movement from Base Control Console
117
All Controls Inoperative from Platform Control Console
124
10 Throttle Inoperative, MID and High - Deutz D2.9L
133
11 MID Throttle Inoperative
134
12 High Throttle Inoperative
135
13 Brake will Not Release
136
14 No Drive and Steer
136
15 No High Speed Drive
139
16 No Elevated Drive
140
17 Direction Sensing Inoperative
141
18 Steer Direction Sensing Inoperative
141
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 System
145
All Controls Inoperative
145
All Boom Functions Inoperative
145
No Main Boom up
145
No Main Boom down
145
No Turret Rotate
146
No Boom Extend
147
No Boom Retract
147
No Jib up
148
No Jib down
149
10 No Platform Rotation
149
11 Platform will Not Level
150
12 Brake will Not Release
151
13 Brake will Not Engage
151
14 No Drive
152
15 Differential Lock will Not Engage
152
16 No High Speed Drive
152
17 No Steer
153
Load Sensing System - CE
155
Green LED on Load Sense/Dual Load Zone Module Is Not on
155
Load Sense Indicates Overload or Overload Warning with Platform Empty or below Weight
155
Load Sense/Dual Load Zone Module Error
156
No Light/Alarm When Platform Is Overloaded
157
Section 5 - Procedures
158
General
158
Safety and Workmanship
158
How to Install the Boom Maintenance Support
159
Platform
161
Human Machine Interface (HMI)
161
User Interface Keys
161
SCM Character Functions Charts
162
SCM Operating Values Chart
163
How to Select SCM Functionality
164
How to View SCM Operation
165
How to Unlock and Modify SCM Settings
166
SCM Pin Voltage Reference
167
Fly Boom Switch Voltage References
170
10 Platform Controller Voltage References
171
Load Sensing System
172
Load Sensing System Overload Status
172
Dual Capacity Overload Module Function Table
173
Calibration of Load Sensing System
174
Boom
176
Check Wear Pads
176
Shim Wear Pads
176
Cable Carrier Repair
176
Rotary Actuator Bolt Torque Procedure
176
Boom Section Wear Pad Replacement
177
Platform and Jib Boom Removal
178
Platform Removal (no Jib Boom)
180
Operating Machine Functions from Base Controls
182
Fly Boom Section Removal
183
10 MID Boom Section Removal
184
11 MID Boom Section Installation
185
12 Fly Boom Section Installation
186
13 Platform and Jib Boom Installation
186
14 Platform Installation (no Jib Boom)
187
15 Platform Control Console Connection
188
16 Extension Cylinder and Wire Rope Replacement
189
17 Extension Cylinder and Cable Assembly Removal
189
18 Extension Cylinder and Wire Rope Assembly Installation
192
19 Proper Wire Rope Tension
194
20 Wire Rope Inspection
195
21 Limit Switch Checking and Adjusting
196
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
Turret
207
Check and Replace the High Pressure Filter
207
Adjust the Turret Rotation Gear Backlash
207
Check the Swing Drive Oil
208
Change the Swing Drive Oil
208
Battery Replacement
209
Turret Rotation Gear Bolt Torque Sequence
209
Electronic Tilt Switch Setup Procedure
210
Check Rotation Bearing for Axial Wear
212
Resetting the Emergency Lowering Counter (CE Only)
213
Deutz Diesel Engines
214
Replace Engine Oil and Filter
214
Replace the Fuel Filter
215
Replace the Air Filter
215
Check the Engine Belt
215
Check the Oil Cooler (Deutz D2011 Only)
215
Deutz TD2.9L Fault Codes
216
Diesel Particulate Filter (DPF) and Standstill Regeneration - Deutz TCD2.2 Engine
236
Hydraulic Tank
238
Change the Hydraulic Tank Filter
238
Change the Hydraulic Oil
238
Manifolds and Hydraulic Pumps
239
Hydraulic Brake Pressure Adjustment
239
Hydraulic Standby Pressure Adjustment
240
Hydraulic High Pressure Adjustment
241
Hydraulic System Relief Valve Adjustment
242
Turret Rotate Relief Valve Adjustment
243
Platform Level Relief Valve Adjustment
243
Fly Boom Relief Valve Adjustment
244
Test Charge Pump Pressure on Drive Pump
244
Test Forward Drive Pressure on Drive Pump
245
10 Test Reverse Drive Pressure on Drive Pump
245
Axles
246
Change the Oil in the Axles
246
Check the Oil Level in the Torque Hubs
246
Change the Oil in the Torque Hubs
246
Check the Oil Level in the Axle Gearbox
247
Change the Oil in the Axle Gearbox
247
Brake Inspection
248
Oscillating Cylinder Bolt Replacement
248
Oscillating Cylinder Replacement
249
Bleed the Oscillating Axle Cylinders
250
10 Test the Oscillating Axle Cylinders
251
Grease Points
252
Grease the Turret Ring Gear
252
Grease the Turret Swing Drive
252
Grease the Axles
253
Grease the Drive Shaft
253
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Operation Manual
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Skyjack SJ82 T Specifications
General
Brand
Skyjack
Model
SJ82 T
Category
Boom Lifts
Language
English
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