Skyjack SJ61T Service Manual Download

Page: 45 / 232

Telescopic Boom Series

Models SJ61T & SJ66T

194312

December 2007

Page 45

Section 3 - System Component Identification and Schematics

Service and Maintenance

3.1 Hydraulic Symbol Chart

LINE CROSSING

VARIABLE
DISPLACEMENT
PUMP

SHUTTLE VALVE

VELOCITY FUSE

HAND PUMP

LINE JOINED

ACCUMULATOR,
GAS CHARGED

SINGLE ACTING
CYLINDER

RELIEF VALVE

HYDRAULIC

TANK

CUSHION
CYLINDER

DOUBLE ACTING
CYLINDER

PRESSURE
REDUCING
VALVE

HYDRAULIC
FILTER WITH
BYPASS

PRESSURE
SWITCH

DOUBLE ACTING
DOUBLE
RODDED

FIXED ORIFICE

ELECTRIC
MOTOR

MOTION
CONTROL VALVE

SPRING APPLIED
HYDRAULIC
RELEASED
BRAKE

ADJUSTABLE
FLOW CONTROL

ENGINE

FLOW DIVIDER
COMBINER

BRAKE
CYLINDER

CYLINDER

CHECK VALVE

FIXED
DISPLACEMENT
PUMP

COUNTER
BALANCE VALVE

ROTARY
ACTUATOR

OIL COOLER

THREE POSITION
FOUR WAY
PROPORTIONAL

VALVE COIL

BI DIRECTIONAL
HYDRAULIC
MOTOR

TWO POSITION
TWO WAY
NORMALLY
CLOSED VALVE

SERIES
PARALLEL
HYDRAULIC
MOTOR

TWO POSITION
THREE WAY VALVE

THREE  POSITION
FOUR  WAY
CLOSED  CENTER
OPEN  PORT

TWO POSITION
THREE WAY VALVE

TWO POSITION
TWO WAY
NORMALLY
OPEN VALVE

THREE  POSITION
FOUR  WAY
CLOSED  CENTER
CLOSED  PORT

THREE POSITION
FOUR WAY
PROPORTIONAL

PRESSURE
TRANSDUCER

MAIN LINES Solid

PILOT LINES Dashed

SERVO

VARIABLE
DISPLACEMENT
HYDRAULIC MOTOR

Charts

Summary of Contents for SJ61T

Page 1: ...TELESCOPIC BOOMS MODELS SJ61T SJ66T 194312AE February 2017 SERVICE MANUAL...

Page 2: ...2164 Australia Tel 61 0 28786 3200 Fax 61 0 28786 3222 Skyjack Brasil Indaiatuba SP Brasil 13347 653 Tel 55 19 3936 0132 Alameda J piter 710 Loteamento American Park Empresarial Skyjack Service Cente...

Page 3: ...NCE Table of Contents Section 1 Scheduled Maintenance Table of Contents Section 2 Maintenance Tables and Diagrams Table of Contents Section 3 System Component Identification and Schematics Table of Co...

Page 4: ...s involved DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if no...

Page 5: ...Record 7 Replacement Parts 7 Maintenance and Service Safety Tips 7 Hydraulic System Component Maintenance and Repair 8 Maintenance Hints 8 Service and Maintenance About this Section 9 Service Bulletin...

Page 6: ...ion to users and operators A complete and legible copy of this manual must be kept in the provided weather resistant storage compartment on the aerial platform at all times Service Maintenance Manuals...

Page 7: ...ntain safety and stability of aerial platform Consult SKYJACK s Service Department for optional tires specifications and installation WARNING Any unit that is damaged or not operating properly must be...

Page 8: ...filling the hydraulic oil reservoir and fill the reservoir only through the filter opening The use of cloth to strain the oil should be avoided to prevent lint from getting into the system 6 When rem...

Page 9: ...ng configuration Aerial platform parked on a flat and level surface Disconnect the battery by turning the main power disconnect switch to off position Repair any damaged or malfunction components befo...

Page 10: ...ent cowling It must be completed after an annual inspection has been completed Do not use the aerial platform if an inspection has not been recorded in the last 6 months 20__ 20__ 20__ Model Number __...

Page 11: ...and hoses no leaks Main Power Disconnect Switch Cables secure in working order B Base Weldment No cracks or deformation Brake Main Manifolds Tight fittings and hoses no leaks Tight wire connections B...

Page 12: ...harness rotary manifold wiring Hydraulic Maintaining hydraulic components is essential to good performance and service life of the aerial platform Perform a visual inspection around the following are...

Page 13: ...ttery B Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazard...

Page 14: ...e refer to 1 1 Scheduled Maintenance Inspections High Pressure Filter B C see Control Compartment for 61T 66T Ensure housing is secure and shows no visible damage or leakage C Annual Inspection For fi...

Page 15: ...age B Frequent Inspection For engine air filter maintenance procedure refer to engine manual C Annual Inspection For engine air filter replacement procedure refer to engine manual Engine Fuel Leaks B...

Page 16: ...s needed Refer to Table 2 12 Specifications and Features for recommended oil type Bi Annual Inspection For hydraulic oil replacement procedure refer to 5 7 2 Change Hydraulic Oil Hydraulic Return Filt...

Page 17: ...o evidence of fuel leakage Fuel Tank Leaks B Ensure that there no fuel leaks at tank DANGER Engine fuels are combustible Inspect the aerial platform in an open well ventilated area away from heaters s...

Page 18: ...here is no evidence of hydraulic leakage Oscillating Cylinder Assembly B C Ensure oscillating cylinder assembly is properly secured there are no loose or missing parts all fittings and hoses are prope...

Page 19: ...information refer to Table 2 2 Aerial Platform Torque Specifications To maximize stability it is essential to maintain proper pressure in all air filled tires Check each tire with an air pressure gau...

Page 20: ...ned and secured Ensure gate drop bar s are in good working order Ensure footswitch is in good working order and has not been modified disabled or blocked Ensure lanyard attachment anchorages are secur...

Page 21: ...eakage 1 1 11 Boom B Ensure there are no loose or missing parts and there is no visible damage Ensure all bolts and pins are properly tightened Ensure there are no visible cracks in welds or structure...

Page 22: ...c leakage Cable Carrier B Ensure there are no loose or missing parts and there is no visible damage Cables B Ensure there are no loose or missing parts with no signs of visible damage Ensure that nuts...

Page 23: ...hydraulic leakage Arctic Weather Package If Equipped B Ensure battery hydraulic oil engine oil heater plug is properly secured with no signs of visible damage and hydraulic leakage Welder If Equipped...

Page 24: ...ice Repairs to aerial platform may only be made by a qualified service technician After repairs are completed operator must perform a pre operation inspection and a series of function tests again befo...

Page 25: ...ions 29 Table 2 7 Axles Maintenance Intervals 33 Table 2 8 Tire Specifications 34 Table 2 9 Floor Loading Pressure 35 Table 2 10 Hydraulic Specifications 36 Table 2 11 Specifications and Features 37 D...

Page 26: ...1 4 1 1 2 2 2 1 2 3 3 1 2 4 Hose Size Chart HOSE PREFIX HOSE END FITTING HOSE END FITTING S A E HOSE SPECIFICATION H01 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H02 FEMALE 37 JIC SWIVEL FEMALE...

Page 27: ...28 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H29 SHORT 45 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H30 MEDIUM 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H31 FEMALE 37 JIC SWIVE...

Page 28: ...4 10 x 4 zinc Grade 5 280 380 Deutz Engine Mount BOLT Hex head 1 2 13 x 3 75 Grade 5 55 75 Coupling Assembly Deutz BOLT M10 29 33 39 45 Muffler NUT 40 55 GM Engine Mount NUT Hex head 1 2 13 Grade 5 50...

Page 29: ...M10 x 1 25 49 4 54 6 55 2 61 0 71 5 78 5 78 0 86 0 86 0 94 0 93 0 103 0 M12 x 1 25 90 100 98 109 128 142 139 154 152 168 166 184 M12 x 1 5 86 95 94 104 120 132 133 147 143 158 159 175 M14 x 1 5 143 1...

Page 30: ...lb 280 210 730 540 1020 760 Nm 15 11 23 18 34 24 Nm 380 285 990 732 1383 1030 ft lb 12 9 19 14 25 20 ft lb 350 270 800 600 1280 960 Nm 16 12 26 19 34 27 Nm 475 366 1085 813 1735 1302 ft lb 20 15 30 23...

Page 31: ...3 ft lb 222 167 318 238 Nm 301 226 431 323 ft lb 314 235 449 337 Nm 426 319 609 457 ft lb 428 321 613 460 Nm 580 435 831 624 ft lb 543 407 776 582 Nm 736 552 1052 789 ft lb 796 597 1139 854 Nm 1079 80...

Page 32: ...lic Couplings Hoses Min Max Min Max Min Max Min Max 4 1 4 10 11 13 15 5 6 6 75 9 6 3 8 17 19 23 26 12 15 17 20 8 1 2 34 38 47 52 20 24 27 66 33 10 5 8 50 56 69 76 34 40 46 33 55 12 3 4 70 78 96 106 53...

Page 33: ...1000 hours Gear box screws bolts every 200 hours Wheel Nuts every 200 hours Initially after 100 working hours When it starts sounding noisy Operation Member Conditions Frequency Lubricants Normal work...

Page 34: ...tandards WARNING Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability Therefore replace tires only with...

Page 35: ...cally Concentrated Pressure is a measure of how hard the aerial platform tire tread presses on the area in direct contact with the floor The floor covering tile carpet etc must be able to withstand mo...

Page 36: ...m 14 4 CC 14 4 CC Displacement High 2 32 CIR 22 8 gpm 2600 rpm 38 CC 38 CC Motor Displacement 4 CIR 39 4 gpm 2600 rpm 65 56 CC 65 56 CC Maximum Swing Pressure 1400 psi 96 bar 96 bar Bore 2 5 in 6 35 c...

Page 37: ...s 76 84 seconds 62 68 seconds 62 68 seconds 50 70 seconds 50 70 seconds 37 43 seconds 37 43 seconds 40 50 seconds 40 50 seconds 18 28 seconds 25 45 seconds 25 45 seconds 10 16 seconds 16 20 seconds 16...

Page 38: ...High 45 5 kW 61 Hp Gasoline Propane 45 gal 170 3 L Standard Lube Oil 40 F to 115 F 40 C to 45 C SAE 5W 30 API SL Approved Alternates See Engine Manual 2 5 gal 9 L Standard Coolant 20 F to 115 F 29 C...

Page 39: ...0 16 76 55 0 18 29 60 0 19 81 65 0 0 0 0 1 52 5 0 3 05 10 0 4 57 15 0 1 52 5 0 3 05 10 0 4 57 15 0 6 10 20 0 7 62 25 0 9 14 30 0 10 67 35 0 12 19 40 0 13 72 45 0 21 34 70 0 19 81 65 0 18 29 60 0 16 76...

Page 40: ...0 16 76 55 0 18 29 60 0 19 81 65 0 0 0 0 1 52 5 0 3 05 10 0 4 57 15 0 1 52 5 0 3 05 10 0 4 57 15 0 6 10 20 0 7 62 25 0 9 14 30 0 10 67 35 0 12 19 40 0 13 72 45 0 21 34 70 0 19 81 65 0 18 29 60 0 16 76...

Page 41: ...s WARNING Do not raise the platform in work mode if it is not on a firm level surface Axle oscillation free travel mode drive speed 4 5 mph max Axle oscillation locked work mode drive speed 0 5 mph ma...

Page 42: ...Page 42 December 2007 Telescopic Boom Series Models SJ61T SJ66T 194312 Notes...

Page 43: ...ons 66 3 19 Main Harness Wiring Diagram 67 3 20 ECU Engine Wiring Diagram Deutz Diesel Engine 68 3 21 Glow Plug and EGR Harnesses Deutz Diesel Engine 69 3 22 Engine Interface Harness Deutz TD2 9L Dies...

Page 44: ...66T ANSI CSA Deutz TD2 9L Diesel Engine with Positive Air Shut Off 97 3 50 Base Control Console Diagram 66T CE Deutz TD2 9L Diesel Engine 98 3 51 Electrical Schematic Diagram ANSI CSA GM Dual Fuel Eng...

Page 45: ...MOTION CONTROL VALVE SPRING APPLIED HYDRAULIC RELEASED BRAKE ADJUSTABLE FLOW CONTROL ENGINE FLOW DIVIDER COMBINER BRAKE CYLINDER CYLINDER CHECK VALVE FIXED DISPLACEMENT PUMP COUNTER BALANCE VALVE ROTA...

Page 46: ...DIODE CIRCUITS CROSSING NO CONNECTION CIRCUITS CONNECTED BATTERY FUSE GROUND CIRCUIT BREAKER VOLT METER CAPACITOR POTENTIOMETER SINGLE POLE DOUBLE THROW RELAY TRIPLE POLE DOUBLE THROW RELAY RELAY REL...

Page 47: ...N RED 76 BRN BLU 104 GRN ORG 08 PUR WHT 31 RED WHT 54 PUR RED 77 BRN GREY 105 GRN BRN 09 YEL 32 GRN BLK 55 YEL PUR 78 RED BLU 106 GRN PINK 10 BLU WHT 33 GRN WHT 56 YEL BLK 79 BRN PUR 107 BLK BLU 11 WH...

Page 48: ...166036 1 VALVE Control Jib Up 4H 36 166036 1 VALVE Control Platform Rotate Left 4H 37 166036 1 VALVE Control Platform Rotate Right 4H 38 166040 1 VALVE Control Boom Retract 4H 39 166040 1 VALVE Contr...

Page 49: ...LVE Check Generator CV18 168243 1 VALVE Check 2 SPD DCV1 159817 1 VALVE Check Double Steering DCV2 159817 1 VALVE Check Double Platform Level DSV1 166062 1 COMPENSATOR Swing DSV2 166061 1 COMPENSATOR...

Page 50: ...ELIEF Main Manifold RV2 166049 1 RELIEF Swing RV3 166047 1 RELIEF Platform Level RV4 166048 1 RELIEF Boom Extend RV5 166045 1 RELIEF Brake Manifold RV6 N A 1 RELIEF Drive RV7 N A 1 RELIEF Drive RV8 N...

Page 51: ...CR 127131 1 RELAY 12 Volt 40 Amp Dump valve 49CR 127131 1 RELAY 12 Volt 40 Amp Horn 51CR 127131 1 RELAY 12 Volt 40 Amp Drive enable 51CR1 127131 1 RELAY 12 Volt 40 Amp Tilt alarm 54ACR 138844 1 RELAY...

Page 52: ...rm right rotate valve 4H 37 141421 1 COIL 12 Volt Platform left rotate valve 4H 38 143964 1 COIL 12 Volt Telescope in valve 4H 39 143964 1 COIL 12 Volt Telescope out valve 4H 40 143969 1 COIL 12 Volt...

Page 53: ...ency pump toggle Base control console S6 138278 1 SWITCH Ignition emergency toggle Platform control console S7 102853 1 SWITCH Function enable toggle Base control console S8 102853 1 SWITCH Diagnose t...

Page 54: ...1 To Steer Cylinder Port 2 To Axle Lockout Valve Port 4 To Brake Manifold Port 3 To Hydraulic Tank Port 3 To Axle Lockout Cylinder Port 4 To Brake Cylinder Port 6 To Brake Manifold Port 5 To Main Mani...

Page 55: ...M 3H 26 Brake Valve 3H 65 Axle Lockout Valve 3H 45 2 Speed Valve 2 SPD To Rotary Manifold BR To Rotary Manifold AL To Rotary Manifold BRG Pressure Gauge V3 Hand Pump Release Valve T To Hydraulic Tank...

Page 56: ...mps and Port Identifications For pressure adjustment refer to Section 5 M162661AA_SM Port B To High Pressure Filter S To Hydraulic Tank LS To Main Manifold 3H V2 Load Sense Adjusting Stem 3H V1 Pressu...

Page 57: ...12 December 2007 Page 57 Section 3 System Component Identification and Schematics Service and Maintenance 3 9 System Pump and Port Identifications Port P To High Pressure Filter L To Hydraulic Tank S...

Page 58: ...ice and Maintenance Section 3 System Component Identification and Schematics A To Rotary Manifold B To Rotary Manifold C1 To Rotary Manifold Ma To Brake Manifold M154119AA D1 To Hydraulic Tank S To Hy...

Page 59: ...December 2007 Page 59 Section 3 System Component Identification and Schematics Service and Maintenance 3 11 Drive Motors and Port Identifications A To Rotary Manifold D2 To Rotary Manifold CONTROL To...

Page 60: ...ponent Identification and Schematics 3 12 Jib Valve and Port Identifications 2A To Bulkhead 2 1A To Bulkhead 2 4 T To Bulkhead 1 2B To Jib Cylinder 1B To Jib Cylinder 3 P To Bulkhead 1 M165018AB_Valve...

Page 61: ...n 3 System Component Identification and Schematics Service and Maintenance 3 13 No Jib Valve and Port Identifications 165009AA_Valve_Explode 1A To Bulkhead 2 3 To Bulkhead 2 2 P To Bulkhead 1 4 T To B...

Page 62: ...1T SJ66T 194312 Service and Maintenance Section 3 System Component Identification and Schematics 3 14 Pressure Reducing Valve Port Identifications 3 Hydraulic Tank M169008AA 1 2 Brake Manifold CV18 Ch...

Page 63: ...Main Boom LS To System Pump without Generator option BLS To Brake Manifold P2 To Emergency Power Unit P1 To High Pressure Filter EB To Fly Boom PLA To Bulkhead Main Boom SB To Rotary Manifold RB To Sw...

Page 64: ...evel Up Valve 2H 42 Flow Enable Valve 4H 38 Boom Retract Valve 4H 39 Boom Extend Valve 4H 13 Boom Down Valve 4H 14 Boom Up Valve 2H 21A Dump Valve 4H 32 Turret Rotate Left Valve 4H 33 Turret Rotate Ri...

Page 65: ...Valve CV8 Check Valve CV9 Check Valve CV6 Check Valve CV5 Check Valve CV4 Check Valve DCV2 Platform Level Check Valve CV10 Check Valve CV11 Check Valve DCV2 Steering Check Valve RV4 Boom Extend Relie...

Page 66: ...r Control Valves and Port Indentifcations M138405AB_M163543AB LS To Shuttle Valve 2H 85 Generator Valve IN To High Pressure Filter 8 GPM Flow Regulator OUT To Generator 1 To Shuttle Valve 1 To Generat...

Page 67: ...PIN 1 26 BL YL PIN 2 02 5 WH SPLICE 3 PIN 1 45 YL OR PIN 2 02 6 WH SPLICE 3 PIN 1 55 YL PR PIN 2 02 9 WH SPLICE 3 PIN 1 15 BL PIN 2 02 7 WH SPLICE 3 PIN 3 02 8 WH SPLICE 3 PIN D 16 WH BK 00 WH 12GA 03...

Page 68: ...A 74 02 02 PIN 1 02 WHITE PIN 2 106 GREEN PINK PIN 3 96 WHITE GREY PIN 4 76 BROWN BLUE PIN 5 74 GREEN GREY PIN 6 PLUGGED PIN 7 PLUGGED PIN 8 PLUGGED PIN 9 PLUGGED PIN 10 105 GREEN BROWN PIN 11 104 GRE...

Page 69: ...EGR Harnesses Deutz Diesel Engine M138849AB 03 11B RELAY CONNECTOR PIN OUT TO AIR BOX TO ENGINE GLOW PLUG POWER FEED STUD 30 11A RED 85 54A BLK EGR CONNECTOR PIN OUT CAVITY 1 07 WHITE CAVITY 2 02 BLA...

Page 70: ...Page 70 Telescopic Boom Series Model SJ61T SJ66T 194312 A B C D E F G H V Z Y X W 3 22 Engine Interface Harness Deutz TD2 9L Diesel M165023AA_SM D2 2 D2 1 X17 1 P1 P2 P3 P5 P4 P6 30A...

Page 71: ...N U BACK VIEW ENGINE CONNECTOR 2 BACK VIEW ENGINE CONNECTOR 1 ENGINE CONNECTOR 1 PIN A 54A PURPLE RED PIN B 77 BROWN GREY PIN C 3002 WHITE PIN D 3056 BLACK PIN F 57A BROWN GREEN PIN G 76 BROWN BLUE P...

Page 72: ...OUND CAVITY WIRE NO COLOUR DESCRIPTION 1 35 ORANGE WHITE JIB UP 2 02 WHITE SPLICE 2 GROUND CAVITY WIRE NO COLOUR DESCRIPTION 1 37 WHITE RED BLK ROTATE CCW 2 02 WHITE SPLICE 1 GROUND CAVITY WIRE NO COL...

Page 73: ...TION 18 BROWN BLUE POSITION 19 RED BLUE POSITION 20 BROWN PURPLE POSITION 21 GREY BLUE POSITION 22 BLACK YELLOW POSITION 23 BLUE WHITE YELLOW POSITION 24 BLUE WHITE BLACK BASE PLATFORM CONNECTIONS POS...

Page 74: ...4312 A B C D E F G H V Z Y X W 3 26 Limit Switch Connections M165674AB_M167237AA LS2 Fly Boom Limit Switch 09 17 59 09 LS1 Rotary Manifold Limit Switch Base Control Box Terminal Strip Black 09 White 5...

Page 75: ...ls SJ61T SJ66T 194312 Page 75 A B C D E F G H V Z Y X W 3 27 Load Sensing Cable Connection CE M167781AC 4 BLACK 2 22 BLACK 3 23 GREEN YELLOW 02 BLACK 1 60 BLACK 5 82 BLACK 4 118 Platform Control Box L...

Page 76: ...BLK IF EQUIPPED WITH GFI PIN 1 PURPLE BLUE PIN 2 WHITE TO COOLER FAN CONNECTOR 00 03 86A 86 86CR 03B 03 03B TOP VIEW RELAY SOCKET 86 02 03B 86A TO TEMPERATURE SWITCH CONNECTOR TO EMERGENCY PUMP POWER...

Page 77: ...51 60 10 21 20 29 17 02 23A 21 85 TOP OF CABINET 13 20 24 12 1 NEAR DOOR 20 S22 GEN 04A 04 34 35 08 S21 JIB S19 LEV S20 ROT S18 TELE 78 79 08C 04 57 S10 THROT S6 IGN 08 38A 39A S48 TORQ 08 1 12 24 20...

Page 78: ...H V Z Y X W GND NEUT BLACK JUMPER WHITE GREEN BLACK RED ORANGE X Y G Z WHITE RED BLACK GREEN BLACK RED WHITE GREEN WHITE JUMPER WHITE ORANGE RED BLACK GREEN WHITE BLACK 3 30 12kW Generator Connection...

Page 79: ...1 ANGLETRANSDUCER TILT SWITCH 12A WAS 09 161 PINK WH 12A WAS 09 TO 24 POLE PLUG A POSITION 22 12A START E pump BASETOGGLE SW 12A 162A 09 59 59CR 02 NEW DIODE D162B BASE CONTROLS MODIFICATION AJ Models...

Page 80: ...iagram M171104AA_M170989AB 09B 09B KEY TELEMATICS 09CR TO MASTER DISCCONET BATTERY SIDE DETAIL A 02 03B 09B 02 KEY 09B KEY DETAIL A SCALE 4 1 02 09B 02 KEY USESEALINGPLUGFORALLUNUSEDCONNECTOR CAVITIES...

Page 81: ...AE 06 SAE 06 SAE 04 SAE 04 SAE 04 SAE 04 SAE 04 SAE 12 SAE 20 SAE 12 SAE 10 SAE 16 SAE 12 SAE 04 SAE 04 SAE 04 SAE 08 SAE 04 SAE 04 SAE 08 P2 SYSTEM PUMP 28 CC 1 71 CIR 19 2 GPM 2600 RPM 3H V1 PRESSUR...

Page 82: ...38C 04B 49 37 08 36 RED BLK WHT X BLU Y 1 2 3 4 VIO GRN SIG WHT 1 2 3 RED BLK YEL SIG 1 2 3 4 WHT RED LEFT 5 WHT YEL RIGHT 08 RED YEL WHT RED BLU YEL WHT BLK BLU WHT 24 BLU BLK 23 60 27A 08 24 R10 R11...

Page 83: ...37 08 36 RED BLK WHT X BLU Y 1 2 3 4 VIO GRN SIG WHT 1 2 3 RED BLK YEL SIG 1 2 3 4 WHT RED LEFT 5 WHT YEL RIGHT 08 RED YEL WHT RED BLU YEL WHT BLK BLU WHT 24 BLU BLK 23 60 27A 08 24 R10 R11 R8 R9 04...

Page 84: ...9 08 78 02 12 04 10 04 04B 04B 57 41 08 40 38B 38A 38C 34 08 35 04B 49 37 08 36 RED BLK WHT X BLU Y 1 2 3 4 VIO GRN SIG WHT 1 2 3 RED BLK YEL SIG 1 2 3 4 WHT RED LEFT 5 WHT YEL RIGHT 08 RED YEL WHT RE...

Page 85: ...59 45 79 08 78 02 12 04 10 04 04B 04B 57 41 08 40 38B 38A 38C 34 08 35 04B 49 37 08 36 RED BLK WHT X BLU Y 1 2 3 4 VIO GRN SIG WHT 1 2 3 RED BLK YEL SIG 1 2 3 4 WHT RED LEFT 5 WHT YEL RIGHT 08 RED YE...

Page 86: ...10 04 04B 04B 57 41 26A 40 38B 38A 38C 34 08 35 04B 49 37 08 36 RED BLK WHT X BLU Y 1 2 3 4 VIO GRN SIG WHT 1 2 3 RED BLK YEL SIG 1 2 3 4 WHT RED LEFT 5 WHT YEL RIGHT 08 RED YEL WHT RED BLU YEL WHT B...

Page 87: ...4B 57 41 26B 40 38B 38A 38C 34 08 35 04B 49 37 08 36 RED BLK WHT X BLU Y 1 2 3 4 VIO GRN SIG WHT 1 2 3 RED BLK YEL SIG 1 2 3 4 WHT RED LEFT 5 WHT YEL RIGHT 08 RED YEL WHT RED BLU YEL WHT BLK BLU WHT 2...

Page 88: ...6 5 4 3 2 1 07A 14Ga 01 07A 14Ga 10 14 12 32 33 36 37 65 161 26 24A 23A 20 FROM STR RELIEF L 6 L 6 02 49A 128A 05 10 02 07 SetPt 12 ohm 37A 35A 37A D36A 1 1 D37A 20 38 16 17 78 79 128A 42 13 45 02 09...

Page 89: ...0A 02 02 02 14ga 00 12ga E F H D C A B G 54A 77 02 161 1 2 3 4 5 6 7 8 9 10 11 12 24 23 22 21 20 19 18 17 16 15 14 13 74 76 59 60 57A 55 02 49 15 28 39 02 13 14 15 16 17 18 19 20 21 22 23 24 12 11 10...

Page 90: ...07A 14ga 07A 14ga 01 10 12 26 24A 23A 20 14 165 32 33 36 45 65 37 42 03 00 02 03 05 56 76B 02 76 76A 4 3 NOEM 2 1 NCLB 2 1 NC 35A 07A 12 12 GREEN AMBER AMBER RED RED AMBER D12 D7A KEY 77 09B 09 09B 0...

Page 91: ...05 56 J1 J2 76B 02 76 76A GREEN AMBER AMBER RED RED AMBER 77 09 09B 09 D12 D7A KEY 76 09B 56C 02 403A 56 02 403A 402 403 POSI AIR RED D09 1 TT1 HOURMETER S2 KSW S3 E STOP COOLER 24P FEMALE AT1 ANGLE T...

Page 92: ...2 11 10 9 8 7 6 5 4 3 2 1 07A 14Ga 01 07A 14Ga 10 14 12 32 33 34 35 36 37 65 161 162 26 24A 23A 20 FROM STR RELIEF L 6 L 6 02 49A 128A 05 10 02 07 SetPt 12 ohm 37A 35A 37A D36A 1 1 D37A 20 38 16 17 78...

Page 93: ...2 02 02 02 02 00A 02 02 02 14ga 00 12ga E F H D C A B G 54A 77 02 161 1 2 3 4 5 6 7 8 9 10 11 12 24 23 22 21 20 19 18 17 16 15 14 13 74 76 59 60 57A 55 02 49 15 28 39 02 13 14 15 16 17 18 19 20 21 22...

Page 94: ...9 10 11 12 24 23 22 21 20 19 18 17 16 15 14 13 74 76 59 60 57A 55 02 49 15 28 39 02 13 14 15 16 17 18 19 20 21 22 23 24 12 11 10 9 8 7 6 5 4 3 2 1 07A 14Ga 01 07A 14Ga 10 14 12 32 33 34 35 36 37 65 16...

Page 95: ...E F H D C A B G 54A 77 02 02 161 D108 2 162 D108 1 D108 108 20C 108 1 2 3 4 5 6 7 8 9 10 11 12 24 23 22 21 20 19 18 17 16 15 14 13 74 76 59 60 57A 55 02 49 15 28 39 02 13 14 15 16 17 18 19 20 21 22 2...

Page 96: ...02 49 15 16 17 28 39 02 40 41 55 78 79 74 76 60 59 57A 128A 128A 13 07A 14ga 07A 14ga 01 10 12 26 24A 23A 20 14 165 32 33 34 35 36 45 65 37 42 03 00 02 03 05 56 76B 02 76 76A GREEN AMBER AMBER RED RED...

Page 97: ...TRANS 78CR 60CR 21CR 49CR 79CR S13 TUR S12 BOOM S14 TEL S17 JIB S15 LEVEL S16 ROT DIAGNOSE S8 CB3 CB2 CB1 24P MALE 24P FEMALE SPARE 45CR1 45CR2 R7 250 01ACR 59CR CE 86CR 10A 09 01A 55 09 74 13 14 10 2...

Page 98: ...59 57A 128A 128A 13 07A 14ga 07A 14ga 01 10 12 26 24A 23A 20 14 165 32 33 34A 35A 36A 45 65 37A 42 03 00 02 03 56 76ACR 76B 02 76 76A D07A D12 07A 162A 162 161 161 D162 C 59 09 162A 4 3 NOEM 2 1 NCLB...

Page 99: ...E BROWN PURPLE YELLOW BLUE YELLOW ORANGE ORANGE BLUE GRAY BLUE RED WHITE POSITION 13 A BLUE BLACK BLACK WHITE BLACK ORANGE POSITION 6 A POSITION 7 A BLUE GREEN BLUE WHITE BLACK BLUE YELLOW GREEN BLACK...

Page 100: ...BLUE BROWN GREEN GREEN RED WHITE YELLOW PURPLE WHITE RED BLUE BROWN PURPLE YELLOW BLUE YELLOW ORANGE ORANGE BLUE GRAY BLUE RED WHITE POSITION 13 A BLUE BLACK BLACK WHITE BLACK ORANGE POSITION 6 A POSI...

Page 101: ...GREEN WHITE BLUE PURPLE PINK POSITION 24 B BLUE RED BLACK RED ORANGE RED WHITE RED BLACK RED PURPLE ORANGE WHITE ORANGE BLACK R2 12 ohm 45T SUPPR 20 110C 110A 110B CB6 15 AMP OPTION WELDER GENERATOR M...

Page 102: ...B BLUE RED BLACK RED ORANGE RED WHITE RED BLACK RED PURPLE ORANGE WHITE ORANGE BLACK SUPPR 20 UP DN S15 PLATFORM LEVELING SPARE SPARE 20A 128A 128A 45CR2 45 128B R7 250 ohm 128A 128 02 09 AT1 ANGLE T...

Page 103: ...CK WHITE BLACK ORANGE POSITION 6 A POSITION 7 A BLUE GREEN BLUE WHITE BLACK BLUE YELLOW GREEN BLACK GREEN WHITE BLUE PURPLE PINK POSITION 24 B BLUE RED BLACK RED ORANGE RED WHITE RED BLACK RED PURPLE...

Page 104: ...CT AT LINE 3 FROM S2 10A 09 65 WHITE RED BLACK RED PURPLE ORANGE WHITE ORANGE BLACK R2 10 ohm W JIB SUPPR OPTIONAL OIL COOLER 110C 110A 110B CB6 15 AMP OPTION WELDER GENERATOR MALE AND FEMALE PLUGS AR...

Page 105: ...3 1 2 6 5 4 8 7 10 9 12 11 76B 96 76A 99 90 09 54 81 77 09A PREHEAT TEMP MIL R5 3 3k ohm R4 1 0k ohm 02 90 90 99A 99B W I F 09 49CR 49 02 CB4 20A M TSW1 86 03B 86A 86CR 09 02 56 00 ENGINE DETAIL HERE...

Page 106: ...OW EGOH 2 L BLACK LT GREEN M LT GREEN RED 19 LT GREEN RED 5V EXT 1 14 BLUE PINK CAN 1 15 BLUE WHITE CAN 1 P BLUE WHITE N BLUE PINK 13 WHITE ORANGE CAN TERM CONNECTOR 1 CONNECTOR 2 55 DK GREEN PC TX 56...

Page 107: ...K LT GREEN M LT GREEN RED 19 LT GREEN RED 5V EXT 1 14 DK BLUE PINK CAN 1 15 BLUE WHITE CAN 1 P BLUE WHITE N DK BLUE PINK CONNECTOR VIC1 CONNECTOR VIC2 A C D B MS1 36 YELLOW GRAY IAT 23 LT GREEN MAP SP...

Page 108: ...18 BK 103A 18 WH 56A 18 WH 84 18 WH 57A 16 BK 74 18 WH 105 18 WH 104 18 BK 201 18 WH 200 18 BK 76A 18 WH 96 18 WH 76 18 BK 99 18 WH 90 18 BK 103 18 BK 54 18 BK 81 18 WH 77 18 WH K85 18 BK K44 18 BK 8...

Page 109: ...t From Base Control Console 122 4 1 21 No Platform Rotate Right from Base Control Console 122 4 1 22 No Platform Rotate Left or Right from Base Control Console 123 4 1 23 No Jib Up from Base Control C...

Page 110: ...Boom Extend 141 4 2 8 No Boom Retract 141 4 2 9 No Jib Up 142 4 2 10 No Jib Down 142 4 2 11 No Platform Rotation Right 142 4 2 12 No Platform Rotation Left 143 4 2 13 Platform will not Level Down 143...

Page 111: ...e quickly than any other method This manual cannot cover all possible troubles and deficiencies that may occur If a specific trouble is not listed isolate the major component in which the trouble oc c...

Page 112: ...nal block to relay 60CR Check continuity Replace if defective 11 Loose or broken wire 07 from base emergency stop switch S3 to relay 60CR Check continuity Replace if defective 12 Loose or broken wire...

Page 113: ...ors Check for continuity between pins 4 on cable A Check for loose or corroded connections on cable connectors Replace if wire is defective 9 Loose or broken wire 10 from plug A pin 4 to base terminal...

Page 114: ...r 3 places pins 2 4 and 6 Check continuity Replace if defective 4 1 7 Engine Cranks but Will Not Start Deutz TD2 9L 1 Loose or broken wire 54 from 94 pin ECU connector pin90 to 12 pin connector P2 pin...

Page 115: ...CR Check relay Replace if defective 12 Loose or broken wire 54A from relay 09CR to base terminal block Check continuity Replace if defective 13 Loose or broken wire 54A from base terminal block to rel...

Page 116: ...ective fuse F8 Check fuse Replace if defective 8 Loose or broken red tan wire from fuse F8 to ECU connector pin 60 and pin 79 Check continuity Replace if defective 9 Loose or broken black wire from en...

Page 117: ...e 11 Loose or broken black wire from ignition module IGM1 pin C to engine ground Check continuity Replace if defective 12 Loose or broken yellow wire from ignition module IGM1 pin B to ECU connector p...

Page 118: ...ock to fuel select switch S26 Check continuity Replace if defective 32 Defective fuel select switch S26 Check switch Replace if defective 33 Loose or broken wire 11 from fuel select switch S26 to plug...

Page 119: ...ntinuity Replace if defective 2 Defective ignition pump switch S5 Check continuity through switch when activated Replace if defective 3 Loose or broken wire 10A from ignition pump switch S5 to basket...

Page 120: ...1 15 No Boom Down from Base Control Console 1 Loose or broken wire 10A from ignition pump switch S5 to boom switch S12 Check continuity Replace if defective 2 Defective boom switch S12 Check continuit...

Page 121: ...33 from turret harness plug pin 10 to turret rotate right valve 4H 33 Check continuity Replace if defective 8 Loose or broken wire 02 from turret harness plug to turret rotate right valve 4H 33 Check...

Page 122: ...boom cable A or its connectors Check for continuity between pins 18 on cable A Check for loose or corroded connections on cable connectors Replace if wire is defective 7 Loose or broken wire 36 plug...

Page 123: ...ugh coil Replace if defective 4 1 23 No Jib Up from Base Control Console 1 Loose or broken wire 10A from ignition pump switch S5 to jib switch S17 Check continuity Replace if defective 2 Defective jib...

Page 124: ...e 4 Loose or broken wire 42 from turret harness plug pin 16 to proportional flow enable valve 2H 42 Check continuity Replace if defective 5 Loose or broken wire 02 from turret harness plug to proporti...

Page 125: ...l down valve 4H 40 Check continuity Replace if defective 7 Defective platform level down valve coil 4H 40 Check continuity and resistance through coil Replace if defective 8 Loose or broken wire 40 fr...

Page 126: ...Replace if defective 5 Loose or broken wire 04 from platform terminal block to generator switch S22 generator option only Check continuity Replace if defective 6 Generator switch S22 in generator mod...

Page 127: ...22 to plug A pin 7 in platform control console Check continuity Replace if defective 8 Loose or broken wire 14 in boom cable A or its connectors Check for continuity between pins 7 on cable A Check f...

Page 128: ...oose or broken wire 02 from platform terminal block to joystick controller A1 Check continuity Replace if defective 3 No output on x axis of joystick controller A1 Refer to joystick test procedure in...

Page 129: ...ase terminal block to turret harness plug pin 11 Check continuity Replace if defective 11 Loose or broken wire 33 from turret harness plug pin 11 to turret right valve 4H 33 Check continuity Replace i...

Page 130: ...e switch S18 Check continuity through switch while activating the function between wires 38C and 38A 6 Loose or broken wire 38A from telescope switch S18 to valve driver pin 32 Check continuity Replac...

Page 131: ...te Left from Platform Control Console 1 Defective platform rotate switch S20 Check continuity through switch while activating rotate left function between wires 08 and 36 2 Loose or broken wire 36 fro...

Page 132: ...4 on platform terminal block Check continuity Replace if defective 4 Open or defective diode D34 in platform terminal block Check diode Replace if defective 5 Loose or broken wire 34A from platform te...

Page 133: ...eplace if defective 9 Loose or broken wire 99B from relay 79CR to base terminal block Check continuity Replace if defective 10 9 Defective relay 79CR Check relay Replace if defective Deutz D2011 Diese...

Page 134: ...wire 99A from relay 78CR to base terminal block Check continuity Replace if defective 9 Defective relay 78CR Check relay Replace if defective Deutz D2011 Diesel Only 10 Loose or broken wire 78 from ba...

Page 135: ...platform terminal block to drive joystick A2 Check continuity Replace if defective 3 Defective drive joystickA2 See drive joystick test procedure in section 5 4 1 47 No Forward Drive 1 No output on D...

Page 136: ...required 3 Loose or broken wire 29 from limit switch LS2 to base terminal block Check continuity Replace if defective 4 Loose or broken wire 29 from base terminal block to limit switch LS3 Check conti...

Page 137: ...ity Replace if defective 2 Misadjusted no output or defective angle transducer tilt switch AT1 Adjust angle transducer tilt switch if required Check for 12 volts on wire 28 If no voltage present with...

Page 138: ...n platform control console Check continuity Replace if defective 6 Loose or broken wire 23A in boom cable A or its connectors Check for continuity between pins 9 on cable A Check for loose or corroded...

Page 139: ...to proper level 4 2 2 All Boom Functions Inoperative 1 Open or defective dump enable valve 2H 21A Clean valve Check O rings on valve Check operation of valve Repair or replace valve as required 2 Stu...

Page 140: ...1 Clean valve Check O rings on valve Check operation of valve Repair or replace valve as required 2 Stuck or defective rotate left valve 4H 32 Clean valve Check operation of valve Repair or replace va...

Page 141: ...tion of valve Repair or replace valve as required 3 Stuck or defective check valve CV11 Clean valve Check O rings on valve Check operation of valve Repair or replace valve as required 4 Stuck or defec...

Page 142: ...e valve as required 4 Stuck or defective counterbalance valve CB9 Clean valve Check O rings on valve Repair or replace valve as required 5 Defective jib cylinder C5 Check seals on cylinder Replace as...

Page 143: ...s required 3 Stuck or defective check valve CV8 Clean valve Check O rings on valve Check operation of valve Repair or replace valve as required 4 Stuck or defective shuttle valve SV3 Clean valve Check...

Page 144: ...as required 5 Defective or misadjusted relief valve RV5 Set valve to specifications Check O rings and clean valve Repair or replace valve as required 6 Stuck or defective brake release override valve...

Page 145: ...V2 Clean valve Check O rings on valve Check operation of valve Repair or replace valve as required 3 Stuck or defective check valve CV2 Clean valve Check O rings on valve Check operation of valve Repa...

Page 146: ...eck O rings on valve Check operation of valve Repair or replace valve as required 2 Bypassing or defective axle cylinders C6 and C7 Check seals on cylinder Replace as necessary Replace cylinder if def...

Page 147: ...rip and relay 82CR and wire 82 at platform terminal block and relay 82CR 4 Defective load cell Defective if 0V is measured between wire 82 and 02 from platform terminal block 4 3 6 Audible Alarm does...

Page 148: ...Page 148 December 2007 Telescopic Boom Series Models SJ61T SJ66T 194312 Section 4 Troubleshooting Information Service and Maintenance...

Page 149: ...of Extension Cylinder and Boom Cables 176 5 2 6 Proper Wire Rope Tension 183 5 2 7 Wire Rope Inspection 184 Turret 5 3 1 Check and Replace High Pressure Filter 185 5 3 2 Adjust Turret Rotation Gear B...

Page 150: ...Adjustment 213 5 8 3 Hydraulic High Pressure Adjustment 214 5 8 4 Hydraulic System Relief Valve Adjustment 215 5 8 5 Turret Rotate Relief Valve Adjustment 216 5 8 6 Platform Level Relief Valve Adjustm...

Page 151: ...off platform key switch to platform position 3 Pull out emergency stop button WARNING Ensure that you maintain three points of contact to mount dismount platform 3 Enter platform and close gate WARNIN...

Page 152: ...M permanent memory storage 1 4 Simultaneously press UP and DOWN will reset the HMI to menu screen 0 OCM Character Functions Charts Keys Short Form THRESH Threshold Menu Select M S RAMPDN Ramp Down RAM...

Page 153: ...ib Toggle Enabled DI 6 0 or 1 Platform Rotation Toggle Enabled DI 11 0 or 1 High Speed Drive Enable Limit Switch Output Adjustable Parameter Description PWM 1 25 to 75 Drive Reverse PWM 2 25 to 75 Dri...

Page 154: ...NCT PRESS SELECT FLASHING NOTE SOFTWARE REVISION MODEL SERIAL NUMBER ENTER PASSWORD 51 1 FLASHING ENTER PASSWORD 510 0 FLASHING SET LRNG B C PRESS SELECT FLASHING SELECT MODEL PRESS SELECT FLASHING ME...

Page 155: ...o Di5 DISPLAYED Di6 to Di10 DISPLAYED Di11 to Di12 DISPLAYED Ai1 to Ai3 DISPLAYED Ai4 to Ai6 DISPLAYED Do1 to Do5 DISPLAYED Do6 to Do8 DISPLAYED PWM1 to PWM2 DISPLAYED PWM3 to PWM4 DISPLAYED PWM5 to P...

Page 156: ...DOWN THRESH Fn03A VALUE BOOM UP THRESH Fn03B VALUE FLY IN THRESH Fn04A VALUE FLY OUT THRESH Fn04B VALUE PROP FLOW THRESH Fn05A VALUE PROP FLOW THRESH Fn05B VALUE LR REV THRESH Fn06A VALUE LR FWD THRES...

Page 157: ...7ACR2 for directional sensing 0 volts Platform over drive axle 12 volts Platform over steer axle Test between pin 4 and 02 wire Pin 5 12 volt output on wire 20B to load sense dump valve when any funct...

Page 158: ...volt input from wire 36A Test between pin 17 and 02 wire Pin 18 12 volt input from angle sensor on wire 28 12V 5 degrees Test between pin 18 and 02 wire Pin 19 Not used Pin 20 Turret rotate left selec...

Page 159: ...om boom speed controller Proportional voltage 5 volts slow speed up to 7 5 volts fast speed Test between pin 30 and 02 wire while operating telescope in out jib up down or basket rotate Pin 31 12 volt...

Page 160: ...References TELESCOPE SWITCH WORKSHEET VOLTAGE DIVIDER CIRCUIT 7 25V WIRE L GND O2 WIRE L GND O2 TELESCOPE IN TELESCOPE OUT 250 OHMS 250 OHMS R9 R8 R10 R11 250 OHMS 250 OHMS P1 32 FLY TOGGLE SWITCH WIR...

Page 161: ...ation X axis Neutral Position 4 2 4 9 Volts Right 4 9 8 5 Volts full stroke Left 4 1 0 5 Volts full stroke Boom Elevation Y axis Neutral Position 4 2 4 8 Volts Up 4 9 8 5 Volts full stroke Down 4 1 0...

Page 162: ...main boom to a comfortable working height chest high and then extend fly boom approximately 1 ft 30 cm 4 Measure the thickness of each wear pad and replace wear pad if it is less than 7 16 11 mm 5 If...

Page 163: ...l when sliding the boom sections out See Platform and Jib Boom Removal on page 164 If the machine does not have a jib boom just the platform is removed Before beginning place the machine in the proper...

Page 164: ...ox M62067AA 24 pin Control Cables 2 Remove the auxiliary AC receptacle box as equipped if its harness is bundled with the other harnesses Remove the harness clamps M62191AA Auxiliary AC Receptacle Box...

Page 165: ...sconnect the hydraulic hoses for the jib cylinder and the platform rotary actuator Provide a suitable container or rags to catch any oil spillage Cap hoses and ports to keep them clean 9 Remove the ho...

Page 166: ...the machine Set it down on suitable blocking nearby Place it close enough to the end of the main boom so the control cables can be reconnected in the event boom repositioning is required Platform Rem...

Page 167: ...b and platform rotate harness 4 Remove tie wraps and make note of wire labels for reinstallation 5 To release each wire insert a small flat screwdriver into the slot beside it in the terminal strip 02...

Page 168: ...iliary power engine off to reposition safely If boom repositioning is necessary with the platform removed reconnect the two cable harnesses and the jib as equipped and platform rotate harness to the p...

Page 169: ...gency power Fly Boom Section Removal Procedure 1 On the platform end of the boom mark and remove the slave cylinder hoses on the top side of the fly boom tip Crack the lines slowly to relieve any resi...

Page 170: ...243 on the wear pad fasteners M62060AA Wear Pads on Fly Boom Mid Boom Section Removal Procedure 1 Place blocking inside the cable hose tube to support the e chain track when the main support bolt is r...

Page 171: ...on the stand and re sling to lift from two points 9 Remove bottom wear pad from the main boom M62236AA Remove Bottom Wear Pad NOTE All the wear pads must be removed from the platform end of the main...

Page 172: ...the bottom wear pad Apply Loctite 242 or 243 to the wear pad fasteners 3 Place a suitable stand under the end of the boom Lower it onto the stand and remove one lifting sling 4 Continue sliding the bo...

Page 173: ...until the holes in the boom tip and the e chain support bracket line up 5 Install the top and side wear pads and shims in the mid boom nose Apply Loctite 242 or 243 to the wear pad fasteners 6 Install...

Page 174: ...on no Jib Boom For torque specifications refer to Table 2 2 Aerial Platform Torque Specifications on page 28 Procedure 1 Connect lifting slings to the platform assembly 2 Using suitable lift equipment...

Page 175: ...orm is installed make sure all harnesses to be connected to the platform control box are routed through the guard hoop on the platform base 1 Connect the two platform control cable harnesses 2 Pull th...

Page 176: ...ust be provided to do so See 5 2 7 Wire Rope Inspection on page 184 CAUTION Risk of personal injury or equipment damage if repositioning boom during this procedure Use base controls with auxiliary pow...

Page 177: ...upport to the fly boom The upper flanges connect the cylinder base to the mid boom M62032AA Make sure the e stops are pushed in and the key is off Turn main power disconnect switch off Lock out the sw...

Page 178: ...e the washers then put the hex nut back on one full nut thread to temporarily hold the cable in place 5 Once the cables are slackened remove the boom flange pins and fasteners NOTE The flange pins may...

Page 179: ...e extension cylinder guide M62039AA 12 Place a lifting strap on the extension cylinder rod Pull the cylinder out along with the upper cables to about 1 3 of the way The cable ends can be tie wrapped t...

Page 180: ...stallation Procedure 1 Attach two lifting slings to the extension cylinder Using suitable lifting equipment raise and slide the end slowly into the counterweight end of the boom assembly The upper cab...

Page 181: ...rm end Install one hex nut on each cable end M62058AA Cables Routed to Platform End 8 Install the mid boom pulleys Pull the cable slack and fit it onto the pulleys Install the cable stops M62053AA Ins...

Page 182: ...ry bar 13 Install the upper flange pins onto the pin of the cylinder base end M62055AA 14 Remove the hex nut on each cable end and install the 12 spring discs The orientation of the spring discs is im...

Page 183: ...r hydraulic hoses Route the hoses through the hanger on the cylinder link M62056AA 18 Tighten all cable ends at the anchors 5 2 6 Proper Wire Rope Tension 19 Tighten each hex nut until all the spring...

Page 184: ...h broken wires severe corrosion excessive stretch deformed strands variations in diameter necking or any change from its normal appearance must be replaced If any cable is found to be in need of repla...

Page 185: ...nd re tighten bolt For torque specification refer to Section 2 5 3 2 Adjust Turret Rotation Gear Backlash The swing drive motor is located in the engine com partment NOTE The adjustment of the backlas...

Page 186: ...drain port to drain the oil 4 Reinstall the drain plug 5 Refill gearbox with oil 32oz 80W90 6 Reinstall plug at fill port Change Brake Oil 1 Remove plug at fill port 2 Place suitable container under...

Page 187: ...ss pattern sequence 1 2 3 4 5 6 7 8 Bolt Torque Sequence 4 Set torque wrench to 35 ft Ib and tighten mounting bolts with the same sequence 5 Torque the center bolt to 480 ft lb Turret Rotation Gear Bo...

Page 188: ...n connector NOTE Ensure part number of old and new tilt switch are the same 6 Remove old tilt switch from mount 7 Install new switch to mount and connect switch plug to 4 pin connector NOTE The tilt c...

Page 189: ...rogramming Existing Tilt Switch Red LED Green LED Light Indicators Set up button is located on this face next to harness 1 Ensure aerial platform is parked on a firm level surface 2 Fully lower platfo...

Page 190: ...2 seconds Results The switch is verifying the new zero position Red LED Green LED Red LED Green LED i The green LED will turn on solid Results The switch is ready for normal operation Red LED Green LE...

Page 191: ...Wear of the Rotation Bearing 5 Zero the dial indicator 6 Rotate the turret 180 in the clockwise direction until the boom is centered over the rear axle Rotating the turret in the counterclockwise dir...

Page 192: ...3 Remove bolts from engine tray 4 Pull locking pin down and swing the engine tray away from the turret until it locks in place 5 Place suitable container under engine 6 Remove oil drain plug and allow...

Page 193: ...of used filter and oil 5 4 3 Replace Air Filter Engine specifications require that this procedure be performed more often if dusty conditions exist Refer to engine manual CAUTION Perform this procedur...

Page 194: ...rvice life of the aerial platform 5 5 1 GM Map and IAT Sensor 1 2 3 4 YEL GRY 5 VOLTS INTAKE AIR TEMPERATURE SIGNAL IAT LT GRN RED 5 VOLTS LT GRN MANIFOLD ABSOLUTE PRESSURE SIGNAL MAP SENSOR GROUND BL...

Page 195: ...mperature Sensor A WHITE RED 5 VOLTS SENSOR GROUND BLK LT GREEN B Temperature Sensor Resistance TEMPERATURE SENSOR RESISTANCE TEMPERATURE DEGREES F TOLERANCE 10 OHMS 220 153 7 200 214 6 190 255 4 180...

Page 196: ...Series Models SJ61T SJ66T 194312 Section 5 Procedures Service and Maintenance 5 5 3 Throttle Actuator 4 DBW PNK WHT TAN ORG PPL LT BLU BLK LT GRN LT BLU DK BLU LT GRN RED DBW SIGNAL MOTOR TPS1 TPS1 S...

Page 197: ...Temperature Sensor A TAN WHITE 5 VOLTS SENSOR GROUND BLK LT GREEN B Temperature Sensor Resistance TEMPERATURE SENSOR RESISTANCE TEMPERATURE F TOLERANCE 10 OHMS 242 4 101 231 9 121 211 6 175 201 4 209...

Page 198: ...injector 4 19 LT GRN RED 5 volt from ECU to sensors 64 BRN WHT To injector 2 20 BLK LT GREEN 5 volt to ECU from sensors 65 EMPTY 21 PPL WHT V from crank position sensor 66 EMPTY 22 WHT PPL V from cra...

Page 199: ...Page 199 Section 5 Procedures Service and Maintenance 5 5 6 Fuse Block Layout 2002CR POWER RELAY 56CR FUEL PUMP RELAY 57ACR STARTER RELAY EMPTY F13 60A ALT EMPTY F7 5 AMP VSW F8 20 AMP ECU F10 15 AMP...

Page 200: ...nd a bar graph 2 Dual Screen This mode is used to monitor two parameters at a time The screen also displays the associated parameter icon and units 3 Multi Screen This mode is used to monitor a list o...

Page 201: ...nsor Wiring Harness Short To Ground Sensor Malfunction 118 110 3 Sensor Wiring Harness Short To Power Sensor Malfunction 121 51 1 Throttle Position Sensor Malfunction 122 51 4 Throttle Position Sensor...

Page 202: ...ly Injector driver circuit shorted to voltage between injector and ECM 264 652 5 Loss of 12 0 V feed to injector Open injector coil Open or shorted to ground injector driver circuit in engine harness...

Page 203: ...ircuit in engine harness 628 1347 5 Relay pull in coil shorted internally Relay driver circuit shorted to ground in wire harness 629 1347 6 Shorted relay pull in coil Relay driver circuit shorted to v...

Page 204: ...o the fuel injection system a non responsive HEGO sensor an injector that is stuck open 1161 4237 0 exhaust leaks upstream or near the HEGO sensor reduced fuel supply pressure to the gaseous fuel cont...

Page 205: ...S malfunction 2140 29 1 Wiring harness open short damage FPP malfunction IVS malfunction 2300 1268 5 a short to ground or open circuit in the harness an open internal to the primary coil 2301 1268 6 a...

Page 206: ...LT_GREEN 18 5 V RTN 1 65 BROWN LT_GREEN 18 INJ2 LS 21 DK_GREEN ORANGE 18 EGO 1 66 BROWN YELLOW 18 INJ3 LS 22 DK_GREEN WHITE 18 EGO 2 67 BROWN WHITE 18 INJ4 LS 23 LT_GREEN 18 MAP 68 BLANK INJ5 LS 24 B...

Page 207: ...D TAN 16 RED TAN 16 WHITE LT_BLUE 18 LT_BLUE PINK 18 PINK BLACK 18 PINK TAN 18 TAN BLACK 18 9 8 7 6 5 4 1 2 3 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 RED 8 PINK 18 RED 16 RED 14 PINK DK_...

Page 208: ...ls SJ61T SJ66T 194312 Section 5 Procedures Service and Maintenance 5 6 5 MAP Sensor Kubota WG2503 V V 5v ECM 5V ext 1 MAP Signal 5V rtn 1 19 23 20 B D C TAMP Sensor 5 6 6 IAT Sensor Kubota WG2503 5v E...

Page 209: ...Procedures Service and Maintenance 5 6 7 ECT Kubota WG2503 V ECM ECT 5V rtn 1 5v 37 20 A B ECT Sensor Thermistor 5 6 8 TPS Engine Speed Kubota WG2503 Motor Electronic Throttle Body TPS1 TPS2 5v 5V ex...

Page 210: ...194312 Section 5 Procedures Service and Maintenance 5 6 9 Fuel Temperature Sensor Kubota WG2503 FP FT Sensor ECM V V V 5V ext 1 FRP Signal 5V rtn 1 FRP Signal 5v 5v 19 13 20 38 5 6 10 Oil Pressure Sen...

Page 211: ...disconnect switch to off position 4 Place suitable container under the hydraulic tank 5 Remove oil drain plug and allow all hydraulic oil to drain into container 6 Install oil drain plug with new sea...

Page 212: ...e platform control console and extend the boom slightly to achieve low speed drive 6 Drive aerial platform forward or reverse The pressure gauge reading should be 550 psi Stop the aerial platform Foll...

Page 213: ...gine from the base control console and let it run for 2 5 minutes 4 Check the reading on the gauge standard pressure should be 330 psi and follow the next steps for adjusting pressure if needed 5 Loca...

Page 214: ...he engine from the base control console and let it run for 2 5 minutes 4 Steer fully to one direction and then check the reading on the gauge Standard pressure should be 3050 psi Follow the next steps...

Page 215: ...he GP2 port 4 Start the engine from the base control console and let it run for 2 5 minutes 5 Steer fully to one direction and then check the reading on the gauge Standard pressure should be 3250 psi...

Page 216: ...is observed on the gauge You must activate turret rotate to obtain pressure reading on gauge 10 Disengage turret transport lock 5 8 6 Platform Level Relief Valve Adjustment 1 Locate the GP2 port on t...

Page 217: ...ase pressure and counterclockwise to decrease pressure 7 Tighten the lock nut on fly boom relief valve RV4 once 1500 psi is observed on the gauge You must fully extend boom to activate pressure readin...

Page 218: ...essure is achieved 7 Replace pump if pressure is not achieved 8 Turn engine off 9 Remove pressure gauge from port cap the port and re plug brake solenoid power cable 5 8 10 Test Reverse Drive Pressure...

Page 219: ...Ports Check Port FIll Port Rear Axle shown 6 Reinstall all drain plugs 7 Remove check plug NOTE Axle is filled when oil is leaking from the check port 8 Refill axle with new oil as per specifications...

Page 220: ...il is leaking from the check port 7 Refill gearbox with new oil as per specifications Refer to Section 2 of this manual 8 Reinstall fill check plug 5 9 5 Bleeding Oscillating Axle Cylinders If the axl...

Page 221: ...e elimination loosen jam nut and back out adjustment stem a few turns 3 Apply a 2lb force 1Kg in the direction of brake application and turn adjusting stem so that it touches the stop 4 Tighten the Ja...

Page 222: ...Release the pressure from the cylinder and check that the rod returns and stops in a position where it projects out from the cylinder head by 3 16 5mm 8 If adjustment is needed loosen the jam nut pres...

Page 223: ...grease fitting beside the hydraulic tank 3 Pump grease into the turret rotation bearing and continue pumping until new lube appears continuously around the grease seal lip Refer to the Race column in...

Page 224: ...n the drive shaft and pump grease Refer to the Table below GREASE Model Recommended Grease Type SJ40T 45T SJ61T 66T Mobil Mobillux EP2 Texaco Multifax EP2 Sun Prestige 742 EP Shell Alvania EP2 Exxon R...

Page 225: ...of the process set the overload limit as regulated by applicable safety standards for Mobile Elevated Work Platforms Load Cell LED Display Error LED Alarm LED Interface Connector Zero Tare LED Power L...

Page 226: ...Error OFF Alarm ON red Zero Tare OFF Power FLASHING green Error OFF Alarm FLASHING red Zero Tare OFF Power FLASHING green PULSING ENABLED 1 Ensure aerial platform is on firm level ground 2 Fully retr...

Page 227: ...5Hz If not recheck that power is on and handset is properly connected WARNING Do not disconnect handset at any point of the following steps until instructed 8 On Teach in handset depress 4 button for...

Page 228: ...n windings Check winding resistance High no load voltage Excessive speed Check and adjust speed High capacity of capacitor Check and replace Low no load voltage Low speed Check and adjust RPM Faulty r...

Page 229: ...tch until the engine starts 4 Turn the generator on off switch to the on position 5 Connect a multimeter to the platform power outlet 6 Note the voltage and frequency Adjust the Frequency and Voltage...

Page 230: ...Page 230 December 2007 Telescopic Boom Series Models SJ61T SJ66T 194312 Notes...

Page 231: ......

Page 232: ...www skyjack com P litelig lift l sninger av folk som bryr seg...

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