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SJ85 AJ
Skyjack SJ85 AJ Service Manual
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94
SJ85 AJ
229044ADA
M224590AC-2
56ACR
105
104
A
G
H
54
PORT
78
79
79CR
78CR
1750 RPM
2000 RPM
DIAGNOSTIC
X22
R3=
120
ohm
60
R6=
3.9k
ohm
56B
56A
57A
74
105
104
76B
76A
99
90
68
54
00A
R5=
2.1k
ohm
R4=
2.2k
ohm
90
90
99A
99B
03A
B
02
76ACR
76B
76A
76
02
JMPR
MAIN P
ANEL
ENGINE P
ANEL
78
79
60
02
74
57A
03A
77CR1
00A
60
77
WA
TER 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
ACTUA
TOR
MPROP
U
n
ENGINE
SPEED
SENSOR
CAMSHAFT
U
P
FUEL
RAIL
PRESS.
SENSOR
U
n
ENGINE
SPEED
SENSOR
CRANKSHAFT
ST
ART
RELA
Y
EXHAUST GAS
RECIRCULA
TION
VAL
VE (EGR)
M
U
p&t°
BOOST
PRESSURE &
TEMPERA
TURE
SENSOR
OIL
PRESSURE
SENSOR
U
P
FUEL LOW
PRESSURE
SENSOR
U
P
U
n
COOLING
TEMPERA
TURE
SENSOR
D+
ST
ARTER
SOLENOID
ST
ARTER
B+
TO BA
TTERY
B- POST
03
TO S1 BA
TTERY
DISCONNECT SW.
00
30A
FU1
57A
77
TO BASE
P
ANEL
03A
76
74
78
79
02
60
00A1
Pin 1
Pin 2
Pin 3
Pin 4
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
Pin 5
Pin 1
Pin 2
Pin 3
Pin 4
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
Pin 5
84
96
230
CAN L
CAN H
68
96
84
J3
J4
00A1CR
00A
60
02
00A1
DEUTZ
T
CD 2.2
T5
ENGINE
CAN H
CAN L
EXHAUST
PRESSURE
SENSOR
U
P
U
P
DEL
T
A P
VENTURI
PRESS.
SENSOR
U
n
EXHAUST GAS
RECIRCULA
TION
TEMP
. SENSOR
THROTTLE
VAL
VE
M
U
n
EXHAUST GAS
TEMPERA
TURE
SENSOR 1
U
n
EXHAUST GAS
TEMPERA
TURE
SENSOR 2
U
P
SENT 1
231
ENGINE
U
n
AMBIENT
TEMPERA
TURE
SENSOR
232
09A
09A
D09
UPDA
TE NUMBERS
11A
233
3
1
2
6
5
4
8
7
10
9
12
11
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
CONNECTOR P1
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
A
T 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 BA
TTERY
TO BA
TTERY
CONNECTOR P2
K79-18 BK (46AJ ONLY)
K87-18 BK (46AJ ONLY)
K79-18 BK
6
7
3
1
2
6
5
4
8
7
10
9
12
11
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
2
1
8
7
1
3
5
6
2
60
59
49
53
52
2
1
X39-8 PIN
A
T 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
7
CONNECTOR P3
3
1
2
6
5
4
8
7
A34-18 BK
K15-18 BK
8
230
231
8
K72-18 BK
K68-18 BK
68
87
K87-18 BK
60
02
60
02
55
56
K56-18 BK
K55-18 BK
58
A58-16 WH
2
1
ENGINE DISPLA
Y - 12 PIN
MOUNTED ON ENGINE
4
3
5
6
7
8
02
60
CAN L-18
WH
CAN H-18 BK
A57-18 BK
A40-18 BK
2
1
2
1
K39-18 BK
K60-18 BK
39
60
K39-18 BK
K60-18 BK
42
K42-18 RD
232
(A40 GND)
09A-18 BK
A24-18 BK
A57-18 BK
K42-18 BK
233
K19-18 BK
49
A49-18 WH
10
9
11
12
R = 120 OHMS
G
M
3
3.39
Engin
e Sc
hemat
ic -
Deut
z T
CD2.2
3.39
Engine S
chematic
- Deutz T
CD2.2
To
order
go
to
Discount-Equipment.com
90
92
Table of Contents
Table of Contents
5
Section 1 - Scheduled Maintenance
10
Read and Heed
10
Mobile Elevating Work Platform (MEWP) Definition
10
Purpose of Equipment
10
Use of Equipment
10
Manual
10
Service Policy and Warranty
10
Operator Safety Reminders, Warnings and Precautions
10
Maintenance and Service
11
Maintenance and Inspection Schedule
11
Owner's Annual Inspection Record
11
Replacement Parts
11
Maintenance and Service Safety Tips
11
Hydraulic System & Component Maintenance and Repair
12
Hydraulic Maintenance Hints
12
Railing Maintenance and Repair
13
Scheduled Maintenance
14
Service Bulletins
14
Maintenance and Inspection
14
Maintenance Instructions
14
Owner's Annual Inspection Record
15
Pre-Delivery/Maintenance Inspection Checklist
16
Scheduled Maintenance Inspections
17
Electrical
17
Hydraulic
17
Labels
17
Limit Switches
17
Engine Compartment
18
Control Compartment
21
Platform Assembly
25
Boom Assembly
26
Optional Equipment/Attachments
27
Function Tests
28
Section 2 - Maintenance Tables and Diagrams
29
Standard Hose Numbering System
29
Torque Specifications for Fasteners (US)
31
Torque Specifications for Fasteners (Metric)
32
Torque Specifications for Hydraulic Couplings & Hoses
33
Axle Torque Specifications
34
Axle Maintenance Intervals
35
MEWP Torque Specifications
36
Tire Specifications
37
Floor Loading Pressure
38
Specifications & Features - Dimensional Data
39
Specifications and Features - Performance & Speeds
40
Hydraulic Specifications
41
Specifications and Features - Engines & Fluids
42
Reach
44
Dimensions
45
Axle Oscillation Zones
45
Section 3 - System Component Identification and Schematics
46
Electrical Symbol Chart
47
Hydraulic Symbol Chart
48
Wire Numbers and Color Codes
49
Wire Numbers and Color Codes - Additional
50
Hydraulic Parts List
51
Electrical Parts List
54
Brake Manifold Port Identification
58
Jib Manifold Port Identification
59
Main Manifold - Hose Port Identification
60
Main Manifold - Hydraulic Components
61
Main Manifold - Electrical Components
62
SGE Harness Connection
63
Jib and Platform Rotate Harness Connections
64
Footswitch Harness Connection
65
Main Manifold Harness
66
Platform to Base Control Cables
67
Engine Control Wiring - Deutz TD2.9L
68
Engine Control Wiring - Deutz D2011
69
Engine Control Wiring - Kubota WG3800
70
Deutz EDC-F Harness
71
Load Cell Wiring
72
Hydraulic Schematic
74
Electrical Schematic - ANSI/CSA
75
Electrical Schematic - CE with Deutz TCD2.2 Engine
76
Electrical Schematic - CE with Deutz TD2.9L, Deutz D2011 or Kubota Engines
77
Electrical Schematic - as
78
Platform Controls Wiring - Deutz TD2.9L, Deutz D2011, Kubota, Perkins
79
Platform Controls - Harness View - Deutz TD2.9L, Deutz D2011, Kubota, Perkins
80
Platform Controls - Schematic View - Deutz TD2.9L, Deutz D2011, Kubota, Perkins
81
Platform Controls Wiring - Deutz TCD2.2
82
Platform Controls - Harness View - Deutz TCD2.2
83
Platform Controls - Schematic View - Deutz TCD2.2
84
Base Controls Wiring - ANSI/CSA
85
Base Controls Wiring - ANSI/CSA with Positive Air Shut-Off Option
86
Base Controls Wiring - CE & as with Deutz TD2.9L or D2011 Engine
87
Base Controls Wiring - CE & as with Deutz TCD2.2 Engine
88
Engine Schematic - Deutz TD2.9L
89
Engine Schematic - Deutz D2011
90
Engine Schematic - Deutz TCD2.2
91
Engine Schematic - Kubota WG3800
92
Engine Harness - Deutz TD2.9L
93
Engine Harness - Deutz TCD2.2
94
Engine Harness - Kubota WG3800
95
Section 4 - Troubleshooting Information
96
Introduction
96
Electrical System
97
All Controls Inoperative
97
No Power
100
Engine will Not Crank
100
No Boom up or down
102
No Riser up or down
105
No Turret Rotate
107
No Telescope
109
No Platform Level
112
No Jib up or down
114
10 No Platform Rotate
116
11 No Platform Rotate or Jib Functions
118
12 No Drive or Steer
119
13 Direction Sensing Inoperative
121
14 Green LED on Load Sense/Dual Load Zone Module Is Not on
122
15 Load Sense Indicates Overload or Overload Warning with Platform Empty or below Weight
122
16 Load Sense/Dual Load Zone Module Error
123
17 No Light/Alarm When Platform Is Overloaded
124
Hydraulic System
125
All Controls Inoperative
125
All Boom Functions Inoperative
125
No Main Boom up or down
125
No Turret Rotate
127
No Boom Extend or Retract
128
No Riser up or down
129
No Platform Level
130
No Jib up or down
131
No Platform Rotate
132
10 No Steer
133
11 No Drive
134
12 No Brake Function
135
13 No Oscillating Axle Function
136
Section 5 - Procedures
137
General
137
Safety and Workmanship
137
Platform
138
Human Machine Interface (HMI)
138
User Interface Keys
138
SCM Character Functions Charts
139
SCM Operating Values Chart
140
How to Unlock and Modify SCM Settings
143
Check I/O Error
145
Fly Boom Switch Voltage References
146
Platform Controller Voltage References
147
Remove and Replace the Platform
149
Load Sensing System
151
Load Sensing System Overload Status
151
Dual Capacity Overload Module Function Table
152
Calibration of Load Sensing System
153
Boom
155
Check the Wear Pads
155
Shim the Wear Pads
155
Rotary Actuator Bolt Torque Procedure
155
Remove and Replace the Jib
156
Limit Switch Locations
157
Turret
158
Check and Replace the High Pressure Filter
158
Adjust the Turret Rotation Gear Backlash
158
Check the Swing Drive Oil
159
Change the Swing Drive Oil
159
Battery Replacement
160
Turret Rotation Gear Bolt Torque Sequence
160
Electronic Tilt Switch Setup Procedure
161
Check the Rotation Bearing for Axial Wear
163
Resetting the Emergency Lowering Counter (CE Only)
164
Deutz Diesel Engines
165
Replace Engine Oil and Filter
165
Replace the Fuel Filter
166
Replace the Air Filter
166
Check the Engine Belt
166
Check the Oil Cooler (Deutz D2011 Only)
166
Deutz TD2.9L Fault Codes
167
Diesel Particulate Filter (DPF) and Standstill Regeneration - Deutz TCD2.2 Engine
187
Hydraulic Tank
189
Change the Hydraulic Tank Filter
189
Change the Hydraulic Oil
189
Manifolds and Hydraulic Pumps
190
Hydraulic Brake Pressure Adjustment
190
Hydraulic Standby Pressure Adjustment
191
Hydraulic High Pressure Adjustment
192
Hydraulic System Relief Valve Adjustment
193
Turret Rotate Relief Valve Adjustment
194
Platform Level Relief Valve Adjustment
194
Riser Relief Valve Adjustment
195
Main Boom Relief Valve Adjustment
195
Fly Boom Relief Valve Adjustment
196
10 Test Charge Pump Pressure on Drive Pump
196
11 Test Forward Drive Pressure on Drive Pump
197
12 Test Reverse Drive Pressure on Drive Pump
197
Axles
198
Change the Oil in the Axles
198
Check the Oil Level in the Torque Hubs
198
Change the Oil in the Torque Hubs
198
Check the Oil Level in the Axle Gearbox
199
Change the Oil in the Axle Gearbox
199
Brake Inspection
200
Oscillating Cylinder Bolt Replacement
200
Oscillating Cylinder Replacement
201
Bleed the Oscillating Axle Cylinders
202
10 Test the Oscillating Axle Cylinders
203
Grease Points
204
Grease the Turret Ring Gear
204
Grease the Turret Swing Drive
204
Grease the Axles
205
Grease the Drive Shaft
205
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Skyjack SJ85 AJ Specifications
General
Brand
Skyjack
Model
SJ85 AJ
Category
Boom Lifts
Language
English
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