Skyjack SJ85 AJ - Service Manual

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SERVICE

MANUAL

ARTICULATING BOOM

August 2020

ANSI/CSA, CE, AS

229044ADA

SJ85 AJ

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Main Page

Table of Contents5
Section 1 - Scheduled Maintenance10
Read and Heed10
Mobile Elevating Work Platform (MEWP) Definition10
Purpose of Equipment10
Use of Equipment10
Manual10
Service Policy and Warranty10
Operator Safety Reminders, Warnings and Precautions10
Maintenance and Service11
Maintenance and Inspection Schedule11
Owner's Annual Inspection Record11
Replacement Parts11
Maintenance and Service Safety Tips11
Hydraulic System & Component Maintenance and Repair12
Hydraulic Maintenance Hints12
Railing Maintenance and Repair13
Scheduled Maintenance14
Service Bulletins14
Maintenance and Inspection14
Maintenance Instructions14
Owner's Annual Inspection Record15
Pre-Delivery/Maintenance Inspection Checklist16
Scheduled Maintenance Inspections17
Electrical17
Hydraulic17
Labels17
Limit Switches17
Engine Compartment18
Control Compartment21
Platform Assembly25
Boom Assembly26
Optional Equipment/Attachments27
Function Tests28
Section 2 - Maintenance Tables and Diagrams29
Standard Hose Numbering System29
Torque Specifications for Fasteners (US)31
Torque Specifications for Fasteners (Metric)32
Torque Specifications for Hydraulic Couplings & Hoses33
Axle Torque Specifications34
Axle Maintenance Intervals35
MEWP Torque Specifications36
Tire Specifications37
Floor Loading Pressure38
Specifications & Features - Dimensional Data39
Specifications and Features - Performance & Speeds40
Hydraulic Specifications41
Specifications and Features - Engines & Fluids42
Reach44
Dimensions45
Axle Oscillation Zones45
Section 3 - System Component Identification and Schematics46
Electrical Symbol Chart47
Hydraulic Symbol Chart48
Wire Numbers and Color Codes49
Wire Numbers and Color Codes - Additional50
Hydraulic Parts List51
Electrical Parts List54
Brake Manifold Port Identification58
Jib Manifold Port Identification59
Main Manifold - Hose Port Identification60
Main Manifold - Hydraulic Components61
Main Manifold - Electrical Components62
SGE Harness Connection63
Jib and Platform Rotate Harness Connections64
Footswitch Harness Connection65
Main Manifold Harness66
Platform to Base Control Cables67
Engine Control Wiring - Deutz TD2.9L68
Engine Control Wiring - Deutz D201169
Engine Control Wiring - Kubota WG380070
Deutz EDC-F Harness71
Load Cell Wiring72
Hydraulic Schematic74
Electrical Schematic - ANSI/CSA75
Electrical Schematic - CE with Deutz TCD2.2 Engine76
Electrical Schematic - CE with Deutz TD2.9L, Deutz D2011 or Kubota Engines77
Electrical Schematic - as78
Platform Controls Wiring - Deutz TD2.9L, Deutz D2011, Kubota, Perkins79
Platform Controls - Harness View - Deutz TD2.9L, Deutz D2011, Kubota, Perkins80
Platform Controls - Schematic View - Deutz TD2.9L, Deutz D2011, Kubota, Perkins81
Platform Controls Wiring - Deutz TCD2.282
Platform Controls - Harness View - Deutz TCD2.283
Platform Controls - Schematic View - Deutz TCD2.284
Base Controls Wiring - ANSI/CSA85
Base Controls Wiring - ANSI/CSA with Positive Air Shut-Off Option86
Base Controls Wiring - CE & as with Deutz TD2.9L or D2011 Engine87
Base Controls Wiring - CE & as with Deutz TCD2.2 Engine88
Engine Schematic - Deutz TD2.9L89
Engine Schematic - Deutz D201190
Engine Schematic - Deutz TCD2.291
Engine Schematic - Kubota WG380092
Engine Harness - Deutz TD2.9L93
Engine Harness - Deutz TCD2.294
Engine Harness - Kubota WG380095
Section 4 - Troubleshooting Information96
Introduction96
Electrical System97
All Controls Inoperative97
No Power100
Engine will Not Crank100
No Boom up or down102
No Riser up or down105
No Turret Rotate107
No Telescope109
No Platform Level112
No Jib up or down114
10 No Platform Rotate116
11 No Platform Rotate or Jib Functions118
12 No Drive or Steer119
13 Direction Sensing Inoperative121
14 Green LED on Load Sense/Dual Load Zone Module Is Not on122
15 Load Sense Indicates Overload or Overload Warning with Platform Empty or below Weight122
16 Load Sense/Dual Load Zone Module Error123
17 No Light/Alarm When Platform Is Overloaded124
Hydraulic System125
All Controls Inoperative125
All Boom Functions Inoperative125
No Main Boom up or down125
No Turret Rotate127
No Boom Extend or Retract128
No Riser up or down129
No Platform Level130
No Jib up or down131
No Platform Rotate132
10 No Steer133
11 No Drive134
12 No Brake Function135
13 No Oscillating Axle Function136
Section 5 - Procedures137
General137
Safety and Workmanship137
Platform138
Human Machine Interface (HMI)138
User Interface Keys138
SCM Character Functions Charts139
SCM Operating Values Chart140
How to Unlock and Modify SCM Settings143
Check I/O Error145
Fly Boom Switch Voltage References146
Platform Controller Voltage References147
Remove and Replace the Platform149
Load Sensing System151
Load Sensing System Overload Status151
Dual Capacity Overload Module Function Table152
Calibration of Load Sensing System153
Boom155
Check the Wear Pads155
Shim the Wear Pads155
Rotary Actuator Bolt Torque Procedure155
Remove and Replace the Jib156
Limit Switch Locations157
Turret158
Check and Replace the High Pressure Filter158
Adjust the Turret Rotation Gear Backlash158
Check the Swing Drive Oil159
Change the Swing Drive Oil159
Battery Replacement160
Turret Rotation Gear Bolt Torque Sequence160
Electronic Tilt Switch Setup Procedure161
Check the Rotation Bearing for Axial Wear163
Resetting the Emergency Lowering Counter (CE Only)164
Deutz Diesel Engines165
Replace Engine Oil and Filter165
Replace the Fuel Filter166
Replace the Air Filter166
Check the Engine Belt166
Check the Oil Cooler (Deutz D2011 Only)166
Deutz TD2.9L Fault Codes167
Diesel Particulate Filter (DPF) and Standstill Regeneration - Deutz TCD2.2 Engine187
Hydraulic Tank189
Change the Hydraulic Tank Filter189
Change the Hydraulic Oil189
Manifolds and Hydraulic Pumps190
Hydraulic Brake Pressure Adjustment190
Hydraulic Standby Pressure Adjustment191
Hydraulic High Pressure Adjustment192
Hydraulic System Relief Valve Adjustment193
Turret Rotate Relief Valve Adjustment194
Platform Level Relief Valve Adjustment194
Riser Relief Valve Adjustment195
Main Boom Relief Valve Adjustment195
Fly Boom Relief Valve Adjustment196
10 Test Charge Pump Pressure on Drive Pump196
11 Test Forward Drive Pressure on Drive Pump197
12 Test Reverse Drive Pressure on Drive Pump197
Axles198
Change the Oil in the Axles198
Check the Oil Level in the Torque Hubs198
Change the Oil in the Torque Hubs198
Check the Oil Level in the Axle Gearbox199
Change the Oil in the Axle Gearbox199
Brake Inspection200
Oscillating Cylinder Bolt Replacement200
Oscillating Cylinder Replacement201
Bleed the Oscillating Axle Cylinders202
10 Test the Oscillating Axle Cylinders203
Grease Points204
Grease the Turret Ring Gear204
Grease the Turret Swing Drive204
Grease the Axles205
Grease the Drive Shaft205

Skyjack SJ85 AJ - Service Manual

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