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SkyJack SJ61T SJ66T Service Manual and Parts List Manual

This manual is based on Serial Number(s):
SJ61T & SJ66T97 001 396 to 97 001 832

Content for Service Manual:
Section 1. SCHEDULED MAINTENANCE
Operators Responsibility for Maintenance
Aerial Platform Definition
Purpose of Equipment
Use of Equipment
Manuals
Service Policy and Warranty
Operator Safety Reminders, Warnings, and Precautions
Maintenance and Inspection Schedule
Owners Annual Inspection Record
Replacement Parts
Maintenance and Service Safety Tips
Hydraulic System & Component Maintenance and Repair
Maintenance Hints
Service and Maintenance
About this Section
Service Bulletins
Maintenance and Inspection
Maintenance Instructions
Tables
Table 1.1 Owners Annual Inspection Record
Table 1.2 Pre-Delivery / Maintenance Inspection Checklist
Scheduled Maintenance Inspections and Function Tests
1.1 Scheduled Maintenance Inspections
1.2 Function Tests

Section 2. MAINTENANCE TABLES AND DIAGRAMS
Tables
Table 2.1 Standard Hose Numbering System
Table 2.2 Aerial Platform Torque Specifications
Table 2.3 Axles Torque Specifications
Table 2.7 Axles Maintenance Intervals
Table 2.8 Tire Specifications
Table 2.9 Floor Loading Pressure
Table 2.10 Hydraulic Specifications
Table 2.11 Specifications and Features
Diagrams
Diagram 2.1 Dimension and Reach Diagram - SJ 61T
Diagram 2.2 Dimension and Reach Diagram - SJ 66T
Diagram 2.3 Axle Oscillation Diagrams

Section 3. SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Charts
3.1 Hydraulic Symbol Chart
3.2 Electrical Symbol Chart
3.3 Wire Number and Color Code
Parts Lists
3.4 Hydraulic Schematic Parts List
3.5 Electrical Component Parts List
Diagrams and Schematics
3.6 Rotary Manifold and Port Identifications
3.7 Brake Manifold and Port Identifications
3.8 System and Drive Pumps and Port Identifications
3.9 System Pump and Port Identifications
3.10 Drive Pump and Port Identifications
3.11 Drive Motors and Port Identifications
3.12 Jib Valve and Port Identifications
3.13 No Jib Valve and Port Identifications
3.14 Pressure Reducing Valve Port Identifications
3.15 Main Manifold Port Identification
3.16 Main Manifold Electrical Component Identification
3.17 Main Manifold Hydraulic Component Identification
3.18 Generator Control Valves and Port Indentifcations
3.19 Main Harness Wiring Diagram
3.20 ECU Engine Wiring Diagram (Deutz Diesel Engine)
3.21 Glow Plug and EGR Harnesses (Deutz Diesel Engine)
3.22 Engine Interface Harness (Deutz TD2.9L Diesel)
3.23 Engine Interface Harness (GM Dual Fuel Engine)
3.24 Harnesses
3.25 Platform Control Cable Harnesses
3.26 Limit Switch Connections
3.27 Load Sensing Cable Connection (CE)
3.28 Generator and Oil Cooler Harness Connections
3.29 Generator Wire Kit Connections
3.30 12kW Generator Connection Assembly
3.31 SGE Wiring Diagram
3.32 Telematics Wiring Diagram
3.33 Hydraulic Schematic Diagram
3.34 Platform Control Console Diagram (61T ANSI/CSA - Deutz Diesel Engine)
3.35 Platform Control Console Diagram (61T ANSI/CSA - GM Dual Fuel Engine)
3.36 Platform Control Console Diagram (66T ANSI/CSA - GM Dual Fuel Engine)
3.37 Platform Control Console Diagram (66T ANSI/CSA - Deutz Diesel Engine)
3.38 Platform Control Console Diagram (66T CE - Deutz Diesel Engine)
3.39 Platform Control Console Diagram (66T AS - Deutz Diesel Engine)
3.40 Base Control Console Diagram (61T ANSI/CSA - GM Dual Fuel Engine)
3.41 Base Control Console Diagram (61T ANSI/CSA - Deutz D2011 Diesel Engine)
3.42 Base Control Console Diagram (61T ANSI/CSA - Deutz TD2.9L Diesel Engine)
3.43 Base Control Console Diagram (61T ANSI/CSA - Deutz TD2.9L Diesel Engine with Positive Air Shut-Off
3.44 Base Control Console Diagram (66T ANSI/CSA - GM Dual Fuel)
3.45 Base Control Console Diagram (66T ANSI/CSA - Deutz D2011 Diesel Engine)
3.46 Base Control Console Diagram (66T CE - Deutz D2011 Diesel Engine)
3.47 Base Control Console Diagram (66T AS - Deutz D2011 Diesel Engine)
3.48 Base Control Console Diagram (66T ANSI/CSA - Deutz TD2.9L Diesel Engine)
3.49 Base Control Console Diagram (66T ANSI/CSA - Deutz TD2.9L Diesel Engine with Positive Air Shut-Off
3.50 Base Control Console Diagram (66T CE - Deutz TD2.9L Diesel Engine)
3.51 Electrical Schematic Diagram (ANSI/CSA - GM Dual Fuel Engine)
3.52 Electrical Schematic Diagram (ANSI/CSA - Kubota Dual Fuel Engine)
3.53 Electrical Schematic Diagram (ANSI/CSA - Deutz D2011 Diesel Engine)
3.54 Electrical Schematic Diagram (CE - Deutz D2011 Engine)
3.55 Electrical Schematic Diagram (AS - Deutz D2011 Engine)
3.56 Electrical Schematic Diagram (ANSI/CSA - Deutz TD2.9L Diesel Engine)
3.57 Electrical Schematic Diagram (CE - Deutz TD2.9L Engine)
3.58 Interface & Engine Electrical Schematic - GM Dual Fuel Engine
3.59 Interface & Engine Electrical Schematic - Kubota Dual Fuel Engine
3.60 Interface & Engine Electrical Schematic - Deutz TD2.9L Diesel Engine

Section 4. TROUBLESHOOTING INFORMATION
Introduction
4.1 Electrical System
4.1-1 All Controls Inoperative
4.1-2 No Power To Platform
4.1-3 No Power to Base
4.1-4 Engine Will Not Crank from Base
4.1-5 Engine Will Not Crank from Platform
4.1-6 Engine Will Not Crank from Platform or Base (Deutz TD2.9L)
4.1-7 Engine Cranks but Will Not Start (Deutz TD2.9L)
4.1-8 Engine Will Not Crank from Platform or Base (Deutz Diesel D2011)
4.1-9 Engine Cranks but Will Not Start (Deutz Diesel D2011)
4.1-10 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel)
4.1-11 Engine Cranks but Will Not Start (GM Dual Fuel)
4.1-12 Glow Plug Circuit Inoperative
4.1-13 All Controls Inoperative from Base Console
4.1-14 No Boom Up from Base Control Console
4.1-15 No Boom Down from Base Control Console
4.1-16 No Turret Rotate Left from Base Control Console
4.1-17 No Turret Rotate Right from Base Control Console
4.1-18 No Telescope Retract From Base Control Console
4.1-19 No Telescope Extend From Base Control Console
4.1-20 No Platform Rotate Left From Base Control Console
4.1-21 No Platform Rotate Right from Base Control Console
4.1-22 No Platform Rotate Left or Right from Base Control Console
4.1-23 No Jib Up from Base Control Console
4.1-24 No Jib Down from Base Control Console
4.1-25 No Jib Up Or Down From Base Control Console
4.1-26 No Manual Platform Level Up From Base Control Console
4.1-27 No Manual Platform Level Down From Base Control Console
4.1-28 No Manual Platform Level Up From Platform Control Console
4.1-29 No Manual Platform Level Down From Platform Control Console
4.1-30 All Controls Inoperative From Platform Control Console
4.1-31 No Boom Up From Platform Control Console
4.1-32 No Boom Down From Platform Control Console
4.1-33 No Turret Left from Platform Control Console
4.1-34 No Turret Right from Platform Control Console
4.1-35 No Telescope Out from Platform Control Console
4.1-36 No Telescope Out from Platform Control Console
4.1-37 No Platform Rotate or Jib Function from Platform Control Console
4.1-38 No Platform Rotate Left from Platform Control Console
4.1-39 No Platform Rotate Right from Platform Control Console
4.1-40 No Jib Up from Platform Control Console
4.1-41 No Jib Down from Platform Control Console
4.1-42 Throttle Inoperative, Mid and High (Deutz TD2.9L only)
4.1-43 Mid Throttle Inoperative
4.1-44 High Throttle Inoperative
4.1-45 Brake will not Release
4.1-46 No Drive and Steer
4.1-47 No Forward Drive
4.1-48 No Reverse Drive
4.1-49 No High Speed Drive
4.1-50 No Elevated Drive
4.1-51 No Left Steer
4.1-52 No Right Steer
4.1-53 Direction Sensing Inoperative
4.1-54 Steer Direction Sensing Inoperative
4.2 Hydraulic System
4.2-1 All Controls Inoperative
4.2-2 All Boom Functions Inoperative
4.2-3 No Main Boom Up
4.2-4 No Main Boom Down
4.2-5 No Turret Rotate Left
4.2-6 No Turret Rotate Right
4.2-7 No Boom Extend
4.2-8 No Boom Retract
4.2-9 No Jib Up
4.2-10 No Jib Down
4.2-11 No Platform Rotation Right
4.2-12 No Platform Rotation Left
4.2-13 Platform will not Level Down
4.2-14 Platform will not Level Up
4.2-15 Brake will not Release
4.2-16 Brake will not Engage
4.2-17 No Drive Forward or Reverse
4.2-18 No Forward Drive
4.2-19 No Reverse Drive
4.2-20 No High Speed Drive
4.2-21 No Right Steer
4.2-22 No Left Steer
4.2-23 Axle Will Not Oscillate
4.2-24 Axle Will Not Lock
4.3 Load Sensing System - CE
4.3-1 Green Power LED is not Flashing
4.3-2 Load Cell red Alarm LED is ON (with platform empty)
4.3-3 Red Error LED is ON
4.3-4 Load Cell red Alarm LED is OFF (with platform overloaded)
4.3-5 Platform Indicator Light does not turn ON
4.3-6 Audible Alarm does not turn ON
4.3-7 Boom and Drive Functions are Enabled (with boom extended)

Section 5. PROCEDURES
General
Safety and Workmanship
Platform
5.1-1 Human Machine Interface (HMI)
5.1-2 User Interface Keys
5.1-3 How to Select Functionality
5.1-4 How to View OCM Operation
5.1-5 How to Unlock and Modify OCM Settings
5.1-6 OCM Pin Voltage Reference
5.1-7 Fly Boom Switch Voltage References
5.1-8 Platform Controller Voltage References
Boom
5.2-1 Cable Carrier Repair
5.2-2 Check Wear Pads
5.2-3 Shimming Wear Pads
5.2-4 Boom Section Wear Pad Replacement
5.2-5 Inspection and Replacement of Extension Cylinder and Boom Cables
5.2-6 Proper Wire Rope Tension
5.2-7 Wire Rope Inspection
Turret
5.3-1 Check and Replace High Pressure Filter
5.3-2 Adjust Turret Rotation Gear Backlash
5.3-3 Check Swing Drive Motor Gearbox Oil
5.3-4 Change Swing Drive Motor Oil
5.3-5 Battery Replacement
5.3-6 Bolt Torque Procedure
5.3-7 Electronic Tilt Switch Setup Procedure
5.3-8 Check Rotation Bearing for Axial Wear
Deutz Diesel Engine
5.4-1 Replace Engine Oil and Filter
5.4-2 Replace Fuel Filter
5.4-3 Replace Air Filter
5.4-4 Check Engine Belt
5.4-5 Check Oil Cooler
GM Dual Fuel Engine
5.5-1 GM Map and IAT Sensor
5.5-2 LPG Temperature Sensor
5.5-3 Throttle Actuator
5.5-4 Engine Coolant Temperature Sensor
5.5-5 ECU Pin Reference Chart
5.5-6 Fuse Block Layout
Kubota WG2503 Dual Fuel Engine
5.6-1 Engine Parameter Display (KAntrak 1700)
5.6-2 Diagnostic Trouble Codes
5.6-3 ECU Pin Reference Chart (Kubota WG2503)
5.6-4 Fuse Box (Kubota WG2503)
5.6-5 MAP Sensor (Kubota WG2503)
5.6-6 IAT Sensor (Kubota WG2503)
5.6-7 ECT (Kubota WG2503)
5.6-8 TPS & Engine Speed (Kubota WG2503)
5.6-9 Fuel Temperature Sensor (Kubota WG2503)
5.6-10 Oil Pressure Sensor (Kubota WG2503)
Hydraulic Tank
5.7-1 Change Hydraulic Tank Filter
5.7-2 Change Hydraulic Oil
Manifold and Hydraulic Pumps
5.8-1 Hydraulic Brake Pressure Adjustment
5.8-2 Hydraulic Standby Pressure Adjustment
5.8-3 Hydraulic High Pressure Adjustment
5.8-4 Hydraulic System Relief Valve Adjustment
5.8-5 Turret Rotate Relief Valve Adjustment
5.8-6 Platform Level Relief Valve Adjustment
5.8-7 Fly Boom Relief Valve Adjustment
5.8-8 Test Charge Pump Pressure on Drive Pump
5.8-9 Test Forward Drive Pressure on Drive Pump
5.8-10 Test Reverse Drive Pressure on Drive Pump
Axles
5.9-1 Change Oil in Axles
5.9-2 Check Oil Level in Torque Hub
5.9-3 Check Oil Level in Axle Gearbox
5.9-4 Change Oil in Axle Gearbox
5.9-5 Bleeding Oscillating Axle Cylinders
5.9-6 Pin Brake Adjustments
Grease Points
5.10-1 Lubrication
5.10-2 Grease Turret Rotation Bearing
5.10-3 Grease Turret Rotation Gear
5.10-4 Grease Drive Axle
5.10-5 Grease Drive Shaft
Options
5.11-1 Load Sensing System - CE
5.11-2 Generator Troubleshooting
5.11-3 Generator Frequency/Voltage Check & Adjustment (3.5 kW)
_______________

This manual is based on Serial Number(s):
SJ61T & SJ66T97 001 396 to 97 001 832
Content for Parts List Manual:
1.0 PLATFORM
1.1 Platform
1.2 Railing Assembly
1.3 Platform Base Assembly (ANSI/CSA)
1.4 Platform Base Assembly (CE)
1.5 Swing Gate Assembly
1.6 Drop Bar Gate
1.7 Railing Extension (No Gate)
1.8 Footswitch
1.9 Platform Control Console
1.10 Boom / Turret Controller Assembly (Dual Axis)
1.11 Drive / Steer Controller Assembly (Single Axis)
1.12 Platform Terminal Strip

2.0 BOOM
2.1 Boom Assembly
2.2 Main Boom Assembly
2.3 Fly Boom Assembly
2.4 Mid Boom Assembly
2.5 Power Track Carrier Assembly
2.6 Jib Assembly - 66T
2.7 Rotary Actuator Mounting - 61T
2.8 Rotary Actuator Assembly
2.9 Jib Lift / Platform Rotate Valve Assemblies

3.0 CYLINDERS
3.1 Extension Cylinder Hardware
3.2 Extension Cylinder Assembly
3.3 Lift and Master Cylinder Hardware
3.4 Lift Cylinder Assembly
3.5 Master Cylinder Assembly
3.6 Slave Cylinder Assembly
3.7 Jib Cylinder Assembly
3.8 Axle Lockout Cylinder Assembly

4.0 TURRET
4.1 Cowling Assembly - Engine Side
4.2 Cowling Assembly - Control Side
4.3 Cowling Assembly - Center
4.4 High Pressure Filter Assembly
4.5 Turret Assembly
4.6 Manifold Hardware
4.7 Main Manifold Assembly
4.8 Brake Manifold Assembly
4.9 Pressure Reducing Manifold
4.10 Rotary Manifold Assembly
4.11 Hydraulic Tank Assembly
4.12 No Generator and Oil Cooler Hose Fittings
4.13 Turret Swing Drive Assembly
4.14 Fuel Tank Assembly (GM Dual Fuel Engine)
4.15 Fuel Tank Assembly - Kubota Engine
4.16 Fuel Tank Assembly - Deutz Diesel Engine
4.17 Battery Cable Assembly
4.18 Battery and Lockout Switch Assembly
4.19 Auxiliary Pump
4.20 Base Control Box - Deutz TD2.9L Engine
4.21 Base Control Box - Deutz D2011 & GM Engines
4.22 Base Terminal Strip - Deutz TD2.9L Engine
4.23 Base Terminal Strip - Deutz D2011 & GM Engines

5.0 ELECTRICAL HARNESSES
5.1 Main Electrical Harness
5.2 Battery Cables
5.3 Control Cable Harnesses
5.4 Jib & Platform Rotate Harnesses
5.5 110/220V Outlet Harness
5.6 ECU Harnesses - Deutz D2011
5.7 Glow Plug Harness (Deutz TD2.9L Engine)
5.8 Glow Plug Harness (Deutz D2011 Engine)
5.9 Engine Interface Harness - Deutz TD2.9L Engine
5.10 Engine Interface Harness - Kubota WG2503
5.11 Engine Interface Harness - GM Engine

6.0 BASE
6.1 Base Assembly
6.2 Counterweight Assembly
6.3 Axle Hardware
6.4 Rear Axle Assembly
6.5 Differential Assembly - Rear Axle
6.6 Central Housing Assembly - Rear Axle
6.7 Gear Box - Rear Axle
6.8 Hydraulic Drive Motor
6.9 Front Axle Assembly
6.10 Differential Assembly - Front Axle
6.11 Central Housing Assembly - Front Axle
6.12 Steering Assembly
6.13 Trunnion Assembly - Front Axle
6.14 Axle Drive Shaft
6.15 Brake Assembly - Front & Rear Axle
6.16 Propane Tank Assembly
6.17 Tires

7.0 ENGINES
7.1 Engine Assembly - Deutz TD2.9L
7.2 Radiator Assembly - Deutz TD2.9L
7.3 Engine Assembly - Deutz D2011
7.4 Engine Assembly - GM Dual Fuel
7.5 Engine Assembly - Kubota WG2503
7.6 Radiator & Air Intake Assemblies - Kubota WG2503
7.7 Engine Tray Assembly
7.8 Drive and System Pump Assembly
7.9 Engine Coupling - Deutz
7.10 Engine Coupling - Kubota WG2503

8.0 HOSE CONNECTIONS
8.1 Standard Hose Numbering System
8.2 Hydraulic Hose Connection - Cylinders
8.3 Hydraulic Hose Connection - Control Compartment
8.4 Hydraulic Hose Connection - Pumps & Swing Drive
8.5 Hydraulic Hose Connection - Base and Axles
8.6 Fuel Line Hose Connection - Deutz TD2.9L Engine
8.7 Fuel Line Hose Connection - Deutz D2011 Engine
8.8 Fuel Line Hose Connection - GM Engine
8.9 Fuel Line Hose Connection - Kubota WG2503 Engine
8.10 Turret Grease Hose Connections

9.0 OPTIONAL EQUIPMENT
9.1 Generator and Oil Cooler - 3.5kW
9.2 Generator Assembly - 3.5kW
9.3 Oil Cooler with No Generator
9.4 Oil Cooler Assembly
9.5 Hydraulic Hose Connection - Generator and Oil Cooler - 3.5kW
9.6 Generator and Oil Cooler Wiring
9.7 Generator and Oil Cooler -12 kW
9.8 Generator Assembly - 12kW
9.9 Hydraulic Hose Connection - 12kW Generator and Oil Cooler
9.10 Welder and Mounting Assembly
9.11 Glazier Package Option
9.12 Cold Start Engine Option
9.13 Arctic Package Option
9.14 Block Heater - Deutz TD2.9L
9.15 Oil Quick Drain
9.16 SGM Assembly
9.17 SGE Assembly
9.18 External Platform Railing Assembly
9.19 Flashing Light
9.20 Air Hose To Platform Option
9.21 Diesel Scrubber
9.22 Control Box Cover
9.23 Positive Air Shut-Off Valve - Deutz TD2.9L
9.25 Telematics - Morey
9.26 Telematics - ZTR

10.0 LABELS
10.1 Label Kits
10.2 Labels - Platform Control Console
10.3 Labels - Front and Bottom
10.4 Labels - Engine Side
10.5 Labels - Controls Side
10.6 Labels - Controls Compartment
10.7 Labels - Engine Compartment
10.8 Labels - Platform
10.9 Labels - Engine Fuel

11.0 TABLES
11.1 Fluids
11.2 Grease Locations - Axle
11.3 Grease Locations - Gears
11.4 Filters
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