Skyjack SJ60 AJE+ Articulating Boom Lift Service Manual
194 pages · Publication 256673ACA
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- Models
- SJ60 AJE+
- Serial coverage
- SJ60 AJE+: B302200001 - B302209999
- Manual type
- Service Manual
- Pages
- 194
- Publication
- 256673ACA
- Condition
- Brand new
What's inside
From the manual's own table of contents: 5 sections, 253 entries. See sample pages (PDF, 742 KB)
Section 1 – Maintenance23 topics
- Read and Heed
- 1.1-1 Mobile Elevating Work Platform (MEWP) definition
- 1.1-2 Purpose of equipment
- 1.1-3 Use of equipment
- 1.1-4 Service Policy and Warranty
- 1.1-5 Ownership of MEWP
- 1.1-6 Optional equipment
- General information
- 1.2-1 Owner’s annual inspection record
- 1.2-2 Replacement parts
- 1.2-3 Maintenance and service safety tips
- 1.2-4 Hydraulic system & component maintenance and repair
- 1.2-5 Hydraulic oil maintenance
- 1.2-6 Hydraulic maintenance tips
- 1.2-7 Railing maintenance and repair
- 1.2-8 Multi-conduction control cable repair
- Scheduled maintenance and inspections
- 1.3-1 Service bulletins
- 1.3-2 Maintenance and inspections
- 1.3-3 Schedule and instructions
- 1.3-5 Pre-delivery/maintenance inspection checklist
- 1.3-6 Inspection points
- 1.3-7 Function tests
Section 2 – Maintenance Tables and Diagrams12 topics
- Standard Hose Numbering System
- Torque Specifications for Fasteners (Metric)
- Torque Specifications for Fasteners (US Imperial)
- Torque Specifications for Hydraulic Couplings & Hoses
- MEWP Torque Specifications
- Axle Torque Specifications
- Axle Maintenance Intervals
- Fluids
- Hydraulic Specifications
- MEWP Specifications
- Platform Capacities
- Reach Diagram
Section 3 – System Component Identification and Schematics30 topics
- Electrical Symbol Chart
- Hydraulic Symbol Chart
- Wire Number and Colour Chart
- Hydraulic Parts List
- Electrical Component Parts List
- Axle Manifold Port Identification
- System Pump Port Identification
- Jib Valve Port Identification
- Battery and Motor Controller Cables
- Main Manifold Port Identification
- Main Manifold Electrical Component Identification
- Main Manifold Hydraulic Component Identification
- Major Components
- Main Electrical Harness and Fuel Level Switch Harness
- Jib and Platform Rotate Harness
- Limit Switch Connections
- SGE Connections
- Moba Load Cell Connections
- Footswitch Connections
- CANbus Cable Connections
- Power Cable Connections
- All Motion Alarm Connections
- Flashing Amber Light Connections
- Inverter Interconnect Harness
- Inverter Panel Harness
- Inverter Panel Harness Schematic
- Hydraulic Schematic
- Platform Control Box Wiring
- Base Control Box Wiring
- Electrical Schematic
Section 4 – Troubleshooting Information81 topics
- Introduction
- Electrical System
- 4.2-1 All Controls are Inoperative from the Base or Platform Console
- 4.2-2 All Controls are Inoperative from the Base Console
- 4.2-3 Pump motor runs slow then stops
- 4.2-4 The Boom Controls are Inoperative (Drive Operates)
- 4.2-5 No Boom Up from the Base or Platform Controls
- 4.2-6 No Boom Up from the Base Console
- 4.2-7 No Boom Up from the Platform Console
- 4.2-8 No Boom Down from the Base or Platform Consoles
- 4.2-9 No Boom Down from the Base Console
- 4.2-10 No Boom Down from the Platform Console
- 4.2-11 No Turret Rotate Right from the Base or Platform Consoles
- 4.2-12 No Turret Rotate Right from the Base Console
- 4.2-13 No Turret Rotate Right from the Platform Console
- 4.2-14 No Turret Rotate Left from the Base or Platform Consoles
- 4.2-15 No Turret Rotate Left from the Base Console
- 4.2-16 No Turret Rotate Left from the Platform Console
- 4.2-17 No Riser Up from the Base or Platform Consoles
- 4.2-18 No Riser Up from the Base Console
- 4.2-19 No Riser Up from the Platform Console
- 4.2-20 No Riser Down from the Base or Platform Consoles
- 4.2-21 No Riser Down from the Base Console
- 4.2-22 No Riser Down from the Platform Console
- 4.2-23 No Telescope Out from the Base or Platform Consoles
- 4.2-24 No Telescope Out from the Base Console
- 4.2-25 No Telescope Out from the Platform Console
- 4.2-26 No Telescope In from the Base or Platform Consoles
- 4.2-27 No Telescope In from the Base Console
- 4.2-28 No Telescope In from the Platform Console
- 4.2-29 No Platform Level Up from the Base or Platform Consoles
- 4.2-30 No Platform Level Up from the Base Console
- 4.2-31 No Platform Level Up from the Platform Console
- 4.2-32 No Platform Level Down from the Base or Platform Consoles
- 4.2-33 No Platform Level Down from the Base Console
- 4.2-34 No Platform Level Down from the Platform Console
- 4.2-35 No Platform Rotate or Jib Functions from the Base or Platform Consoles
- 4.2-36 No Platform Rotate Right from the Base or Platform Consoles
- 4.2-37 No Platform Rotate Right from the Base Console
- 4.2-38 No Platform Rotate Right from the Platform Console
- 4.2-39 No Platform Rotate Left from the Base or Platform Consoles
- 4.2-40 No Platform Rotate Left from the Base Console
- 4.2-41 No Platform Rotate Left from the Platform Console
- 4.2-42 No Jib Up from the Base or Platform Consoles
- 4.2-43 No Jib Up from the Base Console
- 4.2-44 No Jib Up from the Platform Console
- 4.2-45 No Jib Down from the Base or Platform Consoles
- 4.2-46 No Jib Down from the Base Console
- 4.2-47 No Jib Down from the Platform Console
- 4.2-48 No Drive or Steer Functions
- 4.2-49 No Forward or Reverse Drive
- 4.2-50 The Brake will not Release
- 4.2-51 No Left Steer
- 4.2-52 No Right Steer
- 4.2-53 The Directon Sensing is Inoperative
- 4.2-54 The Load Sense Indicates Overload or Overload Warning with the Platform Empty or Below Weight
- 4.2-55 The Overload Indicator Light does not Turn On when the Platform is Overloaded
- 4.2-56 The Audible Alarm does not Turn On with the Platform Overloaded
- Hydraulic System
- 4.3-1 All Controls are Inoperative
- 4.3-2 All Boom Functions are Inoperative
- 4.3-3 No Main Boom Up
- 4.3-4 No Main Boom Down
- 4.3-5 No Riser Boom Up
- 4.3-6 No Riser Boom Down
- 4.3-7 No Turret Rotate Left
- 4.3-8 No Turret Rotate Right
- 4.3-9 No Boom Extend
- 4.3-10 No Boom Retract
- 4.3-13 No Platform Rotation Right
- 4.3-14 No Platform Rotation Left
- 4.3-15 The Platform will not Level Down Manually
- 4.3-16 The Platform will not Level Up Manually
- 4.3-17 The Brake will not Release
- 4.3-18 The Brake will not Engage
- 4.3-19 The Differential Lock will not Engage
- 4.3-20 Differential Lock will not Engage (pump runs when selected)
- 4.3-21 No Right Steer (pump running)
- 4.3-22 No Left Steer
- 4.3-23 The Axle will not Oscillate
- 4.3-24 Axle Will Not Lock
Section 5 – Procedures102 topics
- Safety and Workmanship
- System Control Module (SCM)
- 5.2-1 User Interface Keys
- 5.2-2 SCM Character Functions Charts
- 5.2-3 SCM Function Channel Names
- 5.2-4 SCM Model and Software Check
- 5.2-5 SCM Pin Reference
- 5.2-6 Unlock and Modify the SCM
- 5.2-7 SCM Model Select
- 5.2-8 Check I/O Error
- 5.2-9 SCM Calibration
- 5.2-10 SCM Calibration Flowchart
- 5.2-11 CAN Bus Communication Check
- Platform
- 5.3-1 Platform Level and Jib Up/Down Voltage References
- 5.3-2 Platform Controller Voltage References
- 5.3-3 Axle and Diff Lock Pressure Switches Voltage References
- 5.3-4 Replace the load cell
- Boom
- 5.4-1 Check Wear Pads
- 5.4-2 Shim Wear Pads
- 5.4-3 Cable Carrier Repair
- 5.4-4 Rotary Actuator Bolt Torque Procedure
- 5.4-5 Boom Section Wear Pad Replacement
- 5.4-6 Platform and Jib Boom Removal
- 5.4-7 Operating Machine Functions from the Base Controls
- 5.4-8 Fly Boom Removal
- 5.4-9 Change Wear Pads on Extension Cylinder Support
- 5.4-10 Fly Boom Installation
- 5.4-11 Platform/Jib Installation
- 5.4-12 Platform Control Console Connection
- 5.4-13 Extension Cylinder Removal
- 5.4-14 Extension Cylinder Installation
- 5.4-15 Main Boom Lift Cylinder Removal
- 5.4-16 Lift Cylinder Installation
- 5.4-17 Riser Cylinder Removal
- 5.4-18 Riser Cylinder Installation
- Limit Switches
- 5.5-1 Limit Switch Locations and Trip Points
- 5.5-2 Replace the Direction Sensing Limit Switch LS1
- 5.5-3 Test the Direction Sensing Limit Switch LS1
- 5.5-4 Replace the Fly Boom Limit Switch LS2
- 5.5-5 Test the Fly Boom Limit Switch LS2
- 5.5-6 Replace the Main Boom Limit Switch LS3
- 5.5-7 Test the Main Boom Limit Switch LS3
- 5.5-8 Replace the Dual Load Zone Main Boom Limit Switch LS4
- 5.5-9 Test the Dual Load Zone Main Boom Limit Switch LS4
- 5.5-10 Replace the Dual Load Zone Fly Boom Limit Switch LS5
- 5.5-11 Test the Dual Load Zone Fly Boom Limit Switch LS5
- 5.5-12 Replace the Riser Limit Switch LS6
- 5.5-13 Test the Riser Limit Switch LS6
- Curtis CAN Display Module
- 5.6-1 General information
- 5.6-2 Decode the faults displayed
- 5.6-3 Fault source indicators
- 5.6-4 System control module fault codes (BCS)
- 5.6-5 Traction controller fault codes (TRA)
- Turret
- 5.7-1 Check and Replace the High Pressure Filter
- 5.7-2 Adjust the Turret Rotation Gear Backlash
- 5.7-3 Swing Drive Motor Removal
- 5.7-4 Check the Swing Drive Oil
- 5.7-5 Change the Swing Drive Oil
- 5.7-6 Ring Gear Bolt Torque Sequence
- 5.7-7 Check the Ring Gear for Axial Wear
- 5.7-8 Replace the hydraulic oil
- Manifolds and Hydraulic Pump
- 5.8-1 RV1 Relief Valve Adjustment
- 5.8-2 Turret Rotate Relief Valve Adjustment (RV2)
- 5.8-3 Platform Level Relief Valve Adjustment (RV3)
- 5.8-4 Riser Boom Down Relief Valve Adjustment (RV4)
- 5.8-5 Main Boom Down Relief Valve Adjustment (RV5)
- 5.8-6 Fly Boom Relief Valve Adjustment (RV6)
- 5.8-7 Hydraulic Standby Pressure Adjustment
- 5.8-8 Hydraulic High Pressure Adjustment
- Batteries
- 5.9-1 Replace the batteries
- 5.9-2 Service the batteries
- Battery Charger
- 5.10-1 Charger operation
- 5.10-2 Charger maintenance
- 5.10-3 Charger profiles
- 5.10-4 Charger troubleshooting
- 5.10-5 Charger fault codes
- 5.10-6 Charger error codes
- Axles
- 5.11-1 Change the Oil in the Axles
- 5.11-2 Check the Oil Level in the Torque Hubs
- 5.11-3 Change the Oil in the Torque Hubs
- 5.11-4 Check the Oil Level in the Axle Gearbox
- 5.11-5 Change the Oil in the Axle Gearbox
- 5.11-6 Oscillating Cylinder Mount Inspection
- 5.11-7 Oscillating Cylinder Bolt Replacement
- 5.11-8 Oscillating Cylinder Replacement
- 5.11-9 Bleed the Oscillating Axle Cylinders
- 5.11-10 Test the Oscillating Axle Cylinders
- 5.11-11 Axle U-Bolt Torque
- Grease Points
- 5.12-1 Grease the Turret Ring Gear
- 5.12-2 Grease the Turret Swing Drive
- 5.12-3 Grease the Axles
- 5.12-4 Grease the Drive Shaft
Inside this manual
Real pages from this service manual (194 pages). Open the sample pages (PDF, 741 KB)
- Specifications, page 38: Platform Capacities
- Diagram, page 70: 3.26 Inverter Panel Harness Schematic
- Troubleshooting, page 160: Curtis CAN Display Module
- Color page, page 10: SJ60 AJE+
- Foldout diagram (color), page 74: SJ60 AJE+
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the SJ60 AJE+ are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 256673ACA$69.91
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 194 pages
Quantity one is the manual described above.
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