Skyjack SJ63 AJ+, SJ63 AJ Articulating Boom Lift Service Manual
333 pages · Publication 229043AGA
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What's inside
From the manual's own table of contents: 5 sections, 415 entries. See sample pages (PDF, 850 KB)
Section 1 – Scheduled Maintenance29 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
- 1.1-5 Service Policy and Warranty
- 1.1-6 Operator Safety Reminders, Warnings and Precautions
- Maintenance and Service
- 1.2-1 Maintenance and Inspection Schedule
- 1.2-2 Owner’s Annual Inspection Record
- 1.2-3 Replacement Parts
- 1.2-4 Maintenance and Service Safety Tips
- 1.2-5 Hydraulic System & Component Maintenance and Repair
- 1.2-6 Hydraulic Maintenance Hints
- 1.2-7 Railing Maintenance and Repair
- Scheduled Maintenance
- 1.3-1 Service Bulletins
- 1.3-2 Maintenance and Inspection
- 1.3-3 Maintenance Instructions
- Owner’s Annual Inspection Record
- Pre-Delivery/Maintenance Inspection Checklist
- Scheduled Maintenance Inspections
- 1.6-1 Electrical
- 1.6-2 Hydraulic
- 1.6-4 Limit switches
- 1.6-5 Engine Compartment
- 1.6-7 Platform
- 1.6-8 Boom Assembly
- 1.6-9 Optional equipment
- Function Tests
Section 2 – Maintenance Tables and Diagrams16 topics
- Standard Hose Numbering System
- Torque Specifications for Fasteners (US Imperial)
- Torque Specifications for Fasteners (Metric)
- Torque Specifications for Hydraulic Couplings & Hoses
- Axle Torque Specifications
- Axles Maintenance Intervals
- MEWP Torque Specifications
- Maximum Platform Capacity
- Tire Specifications
- Floor Loading Pressure
- Hydraulic Specifications & Gear Oil
- Hydraulic & Gear Oils
- Specifications & Features - Dimensions & Speeds
- Engine Specifications
- Dimension and Reach Diagrams - SJ63AJ
- Axle Oscillation Diagrams
Section 3 – System Component Identification and Schematics67 topics
- Electrical Symbol Chart
- Hydraulic Symbol Chart
- Wire Number and Colour Chart
- Hydraulic Parts List
- Electrical Component Parts List
- Rotary Manifold Port Identification
- Brake Manifold Port Identification
- Drive and System Pump and Port Identifications
- Drive Motor and Port Identifications
- Jib Valve and Port Identifications
- Main Manifold Port Identification - ANSI/CSA
- Main Manifold Electrical Component Identification - ANSI/CSA
- Main Manifold Hydraulic Component Identification - ANSI/CSA
- Main Manifold Port Identification - CE & AS
- Main Manifold Electrical Component Identification - CE & AS
- Main Manifold Hydraulic Component Identification - CE & AS
- Major Components
- Main Electrical Harness and Fuel Level Switch Harness
- ECU Engine Wiring Diagram - Deutz
- Glow Plug Harnesses - Deutz D2011
- Glow Plug Harnesses - Deutz TD2.9L
- Engine Interface Harness - Deutz TD2.9L
- Engine Interface Harness - Deutz TCD2.2
- Engine Interface Harness - Deutz D2011
- Engine Interface Harness - Kubota WG2503
- Lowering Throttle Valve Harness
- Platform Harnesses
- Platform Control Cables - CE & AS
- Limit Switch Connections - ANSI/CSA
- Limit Switch Connections - CE & AS
- Load Sensing Connections - CE & AS
- All Motion Alarm Connections - CE & AS
- SGE Wiring Diagram
- SGE Connections - ANSI/CSA
- Moba Load Cell Connections - ANSI/CSA
- Footswitch Connections - ANSI/CSA
- CANbus Cable Connections - ANSI/CSA
- Power Cable Connections - ANSI/CSA
- Hydraulic Generator and Oil Cooler Wiring - Base Control Box
- Generator Wiring - Upper Control Box
- Welder Wiring - ANSI/CSA
- Load Circuit Wiring
- Positive Air Shutoff Harness
- Hydraulic Schematic - ANSI/CSA
- Hydraulic Schematic - CE & AS
- Platform Control Box Wiring - ANSI/CSA
- Platform Conrol Box Wiring - CE - Deutz TCD2.2
- Platform Control Box Wiring - CE - Deutz TD2.9L & D2011
- Platform Control Box Wiring - CE - Kubota WG2503
- Platform Control Box Wiring - AS
- Base Control Box Wiring - ANSI/CSA
- Base Control Box Wiring - ANSI/CSA with Positive Air Shut-Off Option
- Base Control Box Wiring - CE - Deutz TCD2.2
- Base Control Box Wiring - CE - Deutz TD2.9L
- Base Control Box Wiring - CE - Deutz D2011
- Base Control Box Wiring - AS
- Electrical Schematic - ANSI/CSA
- Electrical Schematic - CE - Deutz TCD2.2
- Electrical Schematic - CE - Deutz TD2.9
- Electrical Schematic - CE - Deutz D2011
- Electrical Schematic - CE - Kubota WG2503
- Electrical Schematic - AS - Deutz D2011
- Interface & Engine Electrical Schematic - Deutz TD2.9L - ANSI/CSA
- Interface & Engine Electrical Schematic - Deutz D2011
- Interface & Engine Electrical Schematic - Kubota WG2503
- Engine Electrical Schematic - Deutz TCD2.2
- Engine Interface Harness - Deutz TCD2.2
Section 4 – Troubleshooting Information182 topics
- Introduction
- Electrical System - ANSI/CSA
- 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 The Engine will not Crank from the Base or Platform
- 4.2-4 The Engine will not Crank from the Base
- 4.2-5 The Engine will not Crank from the Platform
- 4.2-6 The Boom Controls are Inoperative (Drive Operates)
- 4.2-7 No Boom Up from the Base or Platform Controls
- 4.2-8 No Boom Up from the Base Console
- 4.2-9 No Boom Up from the Platform Console
- 4.2-10 No Boom Down from the Base or Platform Consoles
- 4.2-11 No Boom Down from the Base Console
- 4.2-12 No Boom Down from the Platform Console
- 4.2-13 No Turret Rotate Right from the Base or Platform Consoles
- 4.2-14 No Turret Rotate Right from the Base Console
- 4.2-15 No Turret Rotate Right from the Platform Console
- 4.2-16 No Turret Rotate Left from the Base or Platform Consoles
- 4.2-17 No Turret Rotate Left from the Base Console
- 4.2-18 No Turret Rotate Left from the Platform Console
- 4.2-19 No Riser Up from the Base or Platform Consoles
- 4.2-20 No Riser Up from the Base Console
- 4.2-21 No Riser Up from the Platform Console
- 4.2-22 No Riser Down from the Base or Platform Consoles
- 4.2-23 No Riser Down from the Base Console
- 4.2-24 No Riser Down from the Platform Console
- 4.2-25 No Telescope Out from the Base or Platform Consoles
- 4.2-26 No Telescope Out from the Base Console
- 4.2-27 No Telescope Out from the Platform Console
- 4.2-28 No Telescope In from the Base or Platform Consoles
- 4.2-29 No Telescope In from the Base Console
- 4.2-30 No Telescope In from the Platform Console
- 4.2-31 No Platform Level Up from the Base or Platform Consoles
- 4.2-32 No Platform Level Up from the Base Console
- 4.2-33 No Platform Level Up from the Platform Console
- 4.2-34 No Platform Level Down from the Base or Platform Consoles
- 4.2-35 No Platform Level Down from the Base Console
- 4.2-36 No Platform Level Down from the Platform Console
- 4.2-37 No Platform Rotate or Jib Functions from the Base or Platform Consoles
- 4.2-38 No Platform Rotate Right from the Base or Platform Consoles
- 4.2-39 No Platform Rotate Right from the Base Console
- 4.2-40 No Platform Rotate Right from the Platform Console
- 4.2-41 No Platform Rotate Left from the Base or Platform Consoles
- 4.2-42 No Platform Rotate Left from the Base Console
- 4.2-43 No Platform Rotate Left from the Platform Console
- 4.2-44 No Jib Up from the Base or Platform Consoles
- 4.2-45 No Jib Up from the Base Console
- 4.2-46 No Jib Up from the Platform Console
- 4.2-47 No Jib Down from the Base or Platform Consoles
- 4.2-48 No Jib Down from the Base Console
- 4.2-49 No Jib Down from the Platform Console
- 4.2-50 No Drive or Steer Functions
- 4.2-51 No Forward or Reverse Drive
- 4.2-52 No Forward Drive
- 4.2-53 No Reverse Drive
- 4.2-54 The Brake will not Release
- 4.2-55 No Left Steer
- 4.2-56 No Right Steer
- 4.2-57 The Directon Sensing is Inoperative
- 4.2-58 The Load Sense Indicates Overload or Overload Warning with the Platform Empty or Below Weight
- 4.2-59 The Overload Indicator Light does not Turn On when the Platform is Overloaded
- 4.2-60 The Audible Alarm does not Turn On with the Platform Overloaded
- Electrical System - CE & AS
- 4.3-1 All Controls are Inoperative
- 4.3-2 No Power To Platform
- 4.3-3 No Power to Base
- 4.3-4 The Engine Will Not Crank from the Base
- 4.3-5 The Engine Will Not Crank from the Platform
- 4.3-6 The Engine Will Not Crank from the Platform or Base (Deutz Diesel)
- 4.3-7 The Engine Will Not Crank from the Platform or Base when equipped with Elevate/Trackunit Telematics Ready
- 4.3-8 The Engine Cranks but Will Not Start (Deutz Diesel)
- 4.3-9 The Engine Will Not Crank from the Platform or Base Control (GM Dual Fuel)
- 4.3-10 The Engine Cranks but Will Not Start (GM Dual Fuel)
- 4.3-11 The Glow Plug Circuit is Inoperative
- 4.3-12 All Controls are Inoperative from the Base Console
- 4.3-13 No Main Boom Down, Riser Down or Turret Rotate from Base Control Console
- 4.3-14 No Boom Up from the Base Control Console
- 4.3-15 No Boom Down from the Base Control Console
- 4.3-16 No Riser Up from the Base Control Console
- 4.3-17 No Riser Down from the Base Control Console
- 4.3-18 No Turret Rotate Left from the Base Control Console
- 4.3-19 No Turret Rotate Right from the Base Control Console
- 4.3-20 No Telescope Retract from the Base Control Console
- 4.3-21 No Telescope Extend from the Base Control Console
- 4.3-22 No Platform Rotate Left or Right
- 4.3-23 Platform Rotates too Quickly
- 4.3-24 No Platform Rotate Left from the Base Control Console
- 4.3-25 No Platform Rotate Right from the Base Control Console
- 4.3-26 No Jib Up from the Base Control Console
- 4.3-27 No Jib Down from the Base Control Console
- 4.3-28 No Manual Platform Level Up from the Base Control Console
- 4.3-29 No Manual Platform Level Down from the Base Control Console
- 4.3-30 All Controls are Inoperative from the Platform Control Console
- 4.3-31 No Boom Up from the Platform Control Console
- 4.3-32 No Boom Down from the Platform Control Console
- 4.3-33 No Riser Up from the Platform Control Console
- 4.3-34 No Riser Down from the Platform Control Console
- 4.3-35 No Turret Left from the Platform Control Console
- 4.3-36 No Turret Right from the Platform Control Console
- 4.3-37 No Toggle Switch Functions from the Platform Control Console
- 4.3-38 No Telescope In from the Platform Control Console
- 4.3-39 No Telescope Out from the Platform Control Console
- 4.3-40 No Platform Rotate Left from the Platform Control Console
- 4.3-41 No Platform Rotate Right from the Platform Control Console
- 4.3-42 No Jib Up from the Platform Control Console
- 4.3-43 No Jib Down from the Platform Control Console
- 4.3-44 No Manual Platform Level Up from the Platform Control Console
- 4.3-45 No Manual Platform Level Down from the Platform Control Console
- 4.3-46 Mid Throttle Inoperative
- 4.3-47 High Throttle Inoperative
- 4.3-48 Brake will not Release
- 4.3-49 Differential Lock will not Engage
- 4.3-50 Differential Lock Engages Momentarily but will not stay Engaged
- 4.3-51 No Drive and Steer
- 4.3-52 No Forward Drive
- 4.3-53 No Reverse Drive
- 4.3-54 No High Speed Drive
- 4.3-55 No Elevated Drive
- 4.3-56 No Left Steer
- 4.3-57 No Right Steer
- 4.3-58 Direction Sensing Inoperative
- Load Sensing System - CE & AS
- 4.4-1 Green Power LED is not Flashing
- 4.4-2 Load Cell red Alarm LED is ON (with platform empty)
- 4.4-3 Red Error LED is ON
- 4.4-4 Load Cell red Alarm LED is OFF (with platform overloaded)
- 4.4-5 Platform Indicator Light does not turn ON
- 4.4-6 Audible Alarm does not turn ON
- 4.4-7 Boom and Drive Functions are Enabled (with boom extended)
- Hydraulic System - ANSI/CSA
- 4.5-1 All Controls are Inoperative
- 4.5-2 All Boom Functions are Inoperative
- 4.5-3 No Main Boom Up
- 4.5-4 No Main Boom Down
- 4.5-5 No Riser Boom Up
- 4.5-6 No Riser Boom Down
- 4.5-7 No Turret Rotate Left
- 4.5-8 No Turret Rotate Right
- 4.5-9 No Boom Extend
- 4.5-10 No Boom Retract
- 4.5-13 No Platform Rotation Right
- 4.5-14 No Platform Rotation Left
- 4.5-15 The Platform will not Level Down Manually
- 4.5-16 The Platform will not Level Up Manually
- 4.5-17 The Brake will not Release
- 4.5-18 The Brake will not Engage
- 4.5-19 The Differential Lock will not Engage
- 4.5-20 No Drive Forward or Reverse
- 4.5-21 No Forward Drive
- 4.5-22 No Reverse Drive
- 4.5-23 No High Speed Drive
- 4.5-24 No Right Steer
- 4.5-25 No Left Steer
- 4.5-26 The Axle will not Oscillate
- 4.5-27 Axle Will Not Lock
- Hydraulic System - CE & AS
- 4.6-1 All Controls are Inoperative
- 4.6-2 All Boom Functions are Inoperative
- 4.6-3 No Main Boom Up
- 4.6-4 No Main Boom Down
- 4.6-5 No Riser Boom Up
- 4.6-6 No Riser Boom Down
- 4.6-7 No Turret Rotate Left
- 4.6-8 No Turret Rotate Right
- 4.6-9 No Boom Extend
- 4.6-10 No Boom Retract
- 4.6-14 No Platform Rotation Right
- 4.6-15 No Platform Rotation Left
- 4.6-16 Platform Rotates too Quickly
- 4.6-17 Platform will not Level Down Manually
- 4.6-18 Platform will not Level Up Manually
- 4.6-19 Brake will not Release
- 4.6-20 Brake will not Engage
- 4.6-21 Differential Lock will not Engage
- 4.6-22 No Drive Forward or Reverse
- 4.6-23 No Forward Drive
- 4.6-24 No Reverse Drive
- 4.6-25 No High Speed Drive
- 4.6-26 No Right Steer
- 4.6-27 No Left Steer
- 4.6-28 The Axle Will Not Oscillate
- 4.6-29 The Axle Will Not Lock
Section 5 – Procedures116 topics
- General
- 5.1-1 Safety and Workmanship
- System Control Modules (OCM/SCM)
- 5.2-1 User Interface Keys
- 5.2-2 OCM Character Functions Charts
- 5.2-3 OCM Function Channel Names - CE & AS
- 5.2-4 OCM Operating Values Chart - CE & AS
- 5.2-5 How to Select Functionality - CE & AS
- 5.2-6 How to View OCM Operation - CE & AS
- 5.2-7 How to Unlock and Modify OCM Settings - CE & AS
- 5.2-8 OCM Pin Voltage Reference - CE & AS
- 5.2-9 SCM Pin Reference - ANSI/CSA
- 5.2-10 Check I/O Error - ANSI/CSA
- 5.2-11 How to Unlock and Modify the SCM - ANSI/CSA
- 5.2-12 SCM Select Model - ANSI/CSA
- 5.2-13 SCM Weight Calibration - ANSI/CSA
- 5.2-14 SCM Weight Calibration Flowchart - ANSI/CSA
- 5.2-15 CAN Bus Communication Check
- Platform
- 5.3-1 Platform Controller Voltage References
- 5.3-2 Replace the load cell
- Load Sensing System - CE & AS
- 5.4-1 Load Sensing System Overload Status
- 5.4-2 Verify Proper Operation of the Load Sensing System
- 5.4-3 Calibration of Load Sensing System (with “Teach In” Handset)
- Boom
- 5.5-1 Check Wear Pads
- 5.5-2 Shim Wear Pads
- 5.5-3 Cable Carrier Repair
- 5.5-4 Rotary Actuator Bolt Torque Procedure
- 5.5-5 Boom Section Wear Pad Replacement
- 5.5-6 Platform and Jib Boom Removal
- 5.5-7 Operating Machine Functions from the Base Controls
- 5.5-8 Fly Boom Removal
- 5.5-9 Change Wear Pads on Extension Cylinder Support
- 5.5-10 Fly Boom Installation
- 5.5-11 Platform/Jib Installation
- 5.5-12 Platform Control Console Connection
- 5.5-13 Extension Cylinder Removal
- 5.5-14 Extension Cylinder Installation
- 5.5-15 Main Boom Lift Cylinder Removal
- 5.5-16 Lift Cylinder Installation
- 5.5-17 Riser Cylinder Removal
- 5.5-18 Riser Cylinder Installation
- 5.5-19 Replace Limit Switch - Main Boom
- 5.5-20 Test Main Boom Limit Switch
- 5.5-21 Replace Limit Switch - Riser Boom
- 5.5-22 Test Riser Boom Limit Switch
- 5.5-23 Replace Limit Switch - Fly Boom
- 5.5-24 Test Fly Boom Limit Switch
- 5.5-25 Limit Switch Locations - SJ63 AJ+ ANSI/CSA
- 5.5-26 Limit Switch Locations - SJ63 AJ CE & AS
- Turret
- 5.6-1 Check and Replace the High Pressure Filter
- 5.6-2 Adjust the Turret Rotation Gear Backlash
- 5.6-3 Swing Drive Motor Removal
- 5.6-4 Check the Swing Drive Oil
- 5.6-5 Change the Swing Drive Oil
- 5.6-6 Ring Gear Bolt Torque Sequence
- 5.6-7 Check the Ring Gear for Axial Wear
- 5.6-8 Set Up a New Tilt Switch
- 5.6-9 Reprogram an Existing Tilt Switch
- 5.6-10 Tilt Switch Operation
- 5.6-11 Battery Replacement
- Deutz Diesel Engine
- 5.7-1 Replace Engine Oil and Filter
- 5.7-2 Replace the Fuel Filter
- 5.7-3 Replace the Air Filter
- 5.7-4 Check the Engine Belt
- 5.7-5 Check the Oil Cooler (Deutz D2011 only)
- 5.7-6 Retrieve Engine Fault Codes - Deutz TD2.9L
- 5.7-7 Deutz TD2.9L Fault Codes
- 5.7-8 Diesel Particulate Filter (DPF) and Standstill Regeneration - Deutz TCD2.2 Engine
- Kubota WG2503 Dual Fuel Engine
- 5.8-1 Engine Parameter Display (KAntrak 1700)
- 5.8-2 Diagnostic Trouble Codes
- 5.8-3 ECU Pin Reference Chart (Kubota WG2503)
- 5.8-8 TPS & Engine Speed (Kubota WG2503)
- 5.8-9 Fuel Temperature Sensor (Kubota WG2503)
- 5.8-10 Oil Pressure Sensor (Kubota WG2503)
- Hydraulic Tank
- 5.9-1 Change the Hydraulic Tank Filter
- 5.9-2 Change the Hydraulic Oil
- Manifold and Hydraulic Pumps
- 5.10-1 Hydraulic Brake Pressure Adjustment
- 5.10-2 Hydraulic System Relief Valve Adjustment (RV1)
- 5.10-3 Turret Rotate Relief Valve Adjustment (RV2)
- 5.10-4 Platform Level Relief Valve Adjustment (RV3)
- 5.10-5 Riser Boom Down Relief Valve Adjustment (RV4)
- 5.10-6 Main Boom Down Relief Valve Adjustment (RV5)
- 5.10-7 Fly Boom Relief Valve Adjustment (RV6)
- 5.10-8 Test Charge Pump Pressure on Drive Pump (RV10)
- 5.10-9 Test Forward Drive Pressure on Drive Pump
- 5.10-10 Test Reverse Drive Pressure on Drive Pump
- 5.10-11 Hydraulic Standby Pressure Adjustment
- 5.10-12 Hydraulic High Pressure Adjustment
- 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 Bolt Replacement
- 5.11-7 Oscillating Cylinder Replacement
- 5.11-8 Bleed the Oscillating Axle Cylinders
- 5.11-9 Pin Brake Adjustments
- 5.11-10 Brake Inspection
- 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
- Options
- 5.13-1 Generator Troubleshooting
- 5.13-2 Generator Frequency/Voltage Check & Adjustment
Inside this manual
Real pages from this service manual (333 pages). Open the sample pages (PDF, 848 KB)
- Specifications, page 46: Maximum Platform Capacity
- Diagram, page 166: Electrical System - CE & AS
- Troubleshooting, page 296: Deutz Diesel Engine
- Color page, page 300: SJ63 AJ+, SJ63 AJ
- Color page, page 15: SJ63 AJ+, SJ63 AJ
- Foldout diagram (color), page 123: SJ63 AJ+, SJ63 AJ
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This is a service manual
Here's how it compares to the other manual types.
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, 333 pages
Quantity one is the manual described above.
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