Skyjack SJ82 T, SJ86 T Telescopic Boom Lift Service Manual
323 pages · Publication 229040AHA
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What's inside
From the manual's own table of contents: 5 sections, 262 entries. See sample pages (PDF, 893 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 Diagrams14 topics
- Standard Hose Numbering System
- Torque Specifications for Fasteners (Metric)
- Torque Specifications for Fasteners (US)
- Axle Torque Specifications
- Torque Specifications for Hydraulic Couplings & Hoses
- MEWP Torque Specifications
- Axles Maintenance Intervals
- Hydraulic Specifications & Gear Oil
- Specifications & Features - Dimensional Data
- Specifications & Features - Performance and Speeds
- Engine Specifications
- Platform Capacities
- Reach Diagram - SJ82 T
- Reach Diagram - SJ86 T
Section 3 – System Component Identification and Schematics72 topics
- Electrical Symbol Chart
- Hydraulic Symbol Chart
- Wire Number and Colour Code
- Wire Numbers and Colour Codes - Additional
- Hydraulic Parts List
- Electrical Parts List
- Hourmeter/Counter Harness - CE
- Rotary Manifold Port Identification
- System and Drive Pump Port Identification
- Drive Motors Port Identification
- Jib Valve Port Identification
- No Jib Valve Port Identification
- Brake Manifold Port Identification
- Main Manifold Port Identification
- Main Manifold Electrical Component Identification
- Main Manifold Hydraulic Component Identification
- Major Components
- Main Harness Wiring Diagram
- Boom Lift Valve Harness
- Differential Lock Harness
- Platform Rotate & Jib Harnesses
- Platform to Base Control Cable Harnesses
- Limit Switch Connections
- Load Cell Connections
- ECU Engine Wiring Diagram - Deutz Diesel Engine
- Glow Plug and EGR Harnesses - Deutz Diesel Engine
- Generator and Oil Cooler Harness Connections
- Generator Wiring
- Platform Work Light
- Positive Air Shut-Off Option Harness
- Dual Capacity Sensing Module
- Load Circuit - ANSI/CSA with Deutz TD2.9L and Arctic Package
- SGE Wiring Diagrams - ANSI/CSA
- SGE Wiring Diagrams - CE
- SGE Wiring Diagrams - AS
- Drive Pump Harness - Hengli
- Hydraulic Schematic - S/N A402 000 092 and above with an Eaton Drive Pump and Motors
- Hydraulic Schematic - S/N A402 000 092 and above with a Hengli Drive Pump and Motors
- Hydraulic Schematic - S/N A402 000 091 and below
- Platform Controls Wiring - SJ82 T with a single platform upper indicator light module
- Platform Controls Wiring - SJ82 T with individual platform upper indicator LEDs
- Platform Controls Wiring - SJ86 T with Deutz TD2.9L or D2011 engines with a single platform upper indicator light m
- Platform Controls Wiring - SJ86 T with Deutz TD2.9L or D2011 engines with individual platform upper indicator LEDs
- Platform Controls Wiring - SJ86 T with Deutz TCD2.2 engine with a single platform upper indicator light module
- Platform Controls Wiring - SJ86 T with Deutz TCD2.2 engine with individual platform upper indicator LEDs
- Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L serial number A402 001 124 and above
- Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L serial number A402 001 123 and below
- Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off serial number A402 001 124 and abo
- Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off serial number A402 001 123 and bel
- Base Controls Wiring - SJ82 T ANSI/CSA - Deutz D2011
- Base Controls Wiring - SJ86 T ANSI/CSA - Deutz TD2.9L serial number A402 001 124 and above
- Base Controls Wiring - SJ86 T ANSI/CSA - Deutz TD2.9L serial number A402 001 123 and below
- Base Controls Wiring - SJ86 T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off serial number A402 001 124 and abo
- Base Controls Wiring - SJ86 T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off serial number A402 001 123 and bel
- Base Controls Wiring - SJ86 T ANSI/CSA & AS - Deutz D2011
- Base Controls Wiring - SJ86 T CE - Deutz TCD2.2
- Base Controls Wiring - SJ86 T CE - Deutz D2011
- Base Controls Wiring - SJ86 T CE - Deutz TD2.9L
- Electrical Schematic - ANSI/CSA Deutz TD2.9L with a single platform upper indicator lights module
- Electrical Schematic - ANSI/CSA Deutz TD2.9L with individual platform upper indicator LEDs, serial number A402 001
- Electrical Schematic - ANSI/CSA & AS Deutz D2011 with a single platform upper indicator lights module
- Electrical Schematic - ANSI/CSA & AS Deutz D2011 with individual platform upper indicator LEDs
- Electrical Schematic - CE Deutz TCD2.2 with a single platform upper indicator lights module
- Electrical Schematic - CE Deutz TCD2.2 with individual platform upper indicator LEDs
- Electrical Schematic - CE Deutz D2011 with a single platform upper indicator lights module
- Electrical Schematic - CE Deutz D2011 with individual platform upper indicator LEDs
- Engine Electrical Schematic - Deutz TD2.9L serial number A402 001 123 and below
- Engine Electrical Schematic - Deutz TD2.9L serial number A402 001 124 and above
- Engine Interface Harness Schematic - Deutz TD2.9L serial number A402 001 124 and above
- Engine Interface Harness Schematic - Deutz TD2.9L serial number A402 001 123 and below
- Engine Electrical Schematic - Deutz TCD2.2
- Engine Interface Harness Schematic - Deutz TCD2.2
Section 4 – Troubleshooting Information43 topics
- Introduction
- Electrical System
- 4.2-1 All Controls Inoperative
- 4.2-3 Engine Will Not Crank
- 4.2-4 Engine Cranks but Will Not Start
- 4.2-5 Glow Plug Circuit Inoperative - Deutz D2011 diesel engine
- 4.2-6 Glow Plug Circuit Inoperative - Deutz D2.9 diesel engine
- 4.2-7 All Base Control Console Inoperative
- 4.2-8 No Movement from Base Control Console
- 4.2-9 All Controls Inoperative From Platform Control Console
- 4.2-10 Throttle Inoperative, Mid and High - Deutz D2.9L
- 4.2-11 Mid Throttle Inoperative
- 4.2-12 High Throttle Inoperative
- 4.2-13 Brake will not Release
- 4.2-14 No Drive and Steer
- 4.2-15 No High Speed Drive
- 4.2-16 No Elevated Drive
- 4.2-17 Direction Sensing Inoperative
- 4.2-18 Steer Direction Sensing Inoperative
- 4.2-19 No boom down or extend Functions from Base or Platform Consoles (ANSI)
- 4.2-20 No boom down Function from Base or Platform Consoles (ANSI)
- 4.2-21 No boom extend Function from Base or Platform Consoles (ANSI)
- 4.2-22 No boom down Function from Base or Platform Consoles (CE, AS)
- 4.2-23 No boom extend Function from Base or Platform Consoles (CE, AS)
- Hydraulic System
- 4.3-1 All Controls Inoperative
- 4.3-2 All Boom Functions Inoperative
- 4.3-3 No Main Boom Up
- 4.3-4 No Main Boom Down
- 4.3-5 No Turret Rotate
- 4.3-6 No Boom Extend
- 4.3-7 No Boom Retract
- 4.3-10 No Platform Rotation
- 4.3-11 Platform will not Level
- 4.3-12 Brake will not Release
- 4.3-13 Brake will not Engage
- 4.3-15 Differential Lock will not Engage
- 4.3-16 No High Speed Drive
- Load Sensing System
- 4.4-1 Green LED on Load Sense/Dual Load Zone Module is not on
- 4.4-2 Load Sense indicates overload or overload warning with platform empty or below weight
- 4.4-3 Load Sense/Dual Load Zone Module Error
- 4.4-4 No Light/Alarm when Platform is Overloaded
Section 5 – Procedures105 topics
- Safety and Workmanship
- 5.1-1 How to Install the Boom Maintenance Support
- System Control Module (SCM)
- 5.2-1 User Interface Keys
- 5.2-2 SCM Character Functions Charts
- 5.2-3 SCM Model and Software Check
- 5.2-4 SCM Recommended Settings
- 5.2-5 SCM Pin Reference
- 5.2-6 How to Select SCM Functionality
- 5.2-7 How to View SCM Operation
- 5.2-8 How to Unlock and Modify SCM Settings
- 5.2-9 SCM Pin Voltage Reference
- 5.2-10 Drive speed tests
- 5.2-11 Adjust the drive speeds
- Platform
- 5.3-1 Fly Boom Switch Voltage References
- 5.3-2 Platform Controller Voltage References
- 5.3-3 Replace the load cell
- Load Sensing System
- 5.4-1 Load Sensing System Overload Status
- 5.4-2 Dual Capacity Overload Module Function Table
- 5.4-3 Calibration of Load Sensing System
- 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 Mid Boom Abrasion Inspection
- 5.5-6 Boom Section Wear Pad Replacement
- 5.5-7 Platform and Jib Boom Removal
- 5.5-8 Platform Removal (no Jib Boom)
- 5.5-9 Operating Machine Functions from Base Controls
- 5.5-10 Fly Boom Section Removal
- 5.5-11 Mid Boom Section Removal
- 5.5-12 Mid Boom Section Installation
- 5.5-13 Fly Boom Section Installation
- 5.5-14 Platform and Jib Boom Installation
- 5.5-15 Platform Installation (no Jib Boom)
- 5.5-16 Platform Control Console Connection
- 5.5-17 Extension Cylinder and Wire Rope Replacement
- 5.5-18 Extension Cylinder and Cable Assembly Removal
- 5.5-19 Extension Cylinder and Wire Rope Assembly Installation
- 5.5-20 Wire Rope Tension
- 5.5-21 Wire Rope Inspection
- 5.5-22 Replace the Lift Cylinder
- Limit Switches
- 5.6-1 Limit Switch Locations and Trip Points
- 5.6-2 Check and Adjust the Limit Switches
- 5.6-3 Directional Sensing Limit Switch (LS1)
- 5.6-4 High Speed Drive / Tilt Override Limit Switch (LS2)
- 5.6-5 Fly-in Limit Switch (LS3)
- 5.6-6 Boom Angle (Dual Load) Limit Switch (LS4)
- 5.6-7 Test the Dual Load Zone Main Boom Limit Switch LS4
- 5.6-8 Boom Extension (Dual Load) Limit Switch (LS5)
- 5.6-9 Lift Cushion Limit Switch (LS6)
- Turret
- 5.7-1 Check and Replace the High Pressure Filter
- 5.7-2 Adjust the Turret Rotation Gear Backlash
- 5.7-3 Check the Swing Drive Oil
- 5.7-4 Change the Swing Drive Oil
- 5.7-5 Ring Gear Bolt Torque Sequence
- 5.7-6 Check the Rotation Bearing for Axial Wear
- 5.7-7 Battery Replacement
- 5.7-8 Electronic Tilt Switch Setup Procedure
- 5.7-9 Resetting the Emergency Lowering Counter (CE only)
- Deutz Diesel Engines
- 5.8-1 Replace Engine Oil and Filter
- 5.8-2 Replace the Fuel Filter
- 5.8-3 Replace the Air Filter
- 5.8-4 Check the Engine Belt
- 5.8-5 Check the Oil Cooler (Deutz D2011 only)
- 5.8-6 Deutz TD2.9L Fault Codes (EMR4) - serial number A402 001 123 and below
- 5.8-7 Deutz TD2.9L Fault Codes (EMR5) - serial number A402 001 124 and above
- 5.8-8 Diesel Particulate Filter (DPF) and Standstill Regeneration - Deutz TCD2.2 Engine
- Hydraulic Tank
- 5.9-1 Change the Hydraulic Tank Filter
- 5.9-2 Change the Hydraulic Oil
- Manifolds and Hydraulic Pumps
- 5.10-1 Hydraulic Brake Pressure Adjustment
- 5.10-2 Hydraulic Standby Pressure Adjustment
- 5.10-3 Hydraulic High Pressure Adjustment
- 5.10-4 Hydraulic System Relief Valve Adjustment
- 5.10-5 Turret Rotate Relief Valve Adjustment
- 5.10-6 Platform Level Relief Valve Adjustment
- 5.10-7 Fly Boom Relief Valve Adjustment
- 5.10-8 Test Charge Pump Pressure on Drive Pump
- 5.10-9 Test Forward Drive Pressure on Drive Pump
- 5.10-10 Test Reverse Drive Pressure on Drive Pump
- 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 Brake 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 (323 pages). Open the sample pages (PDF, 891 KB)
- Specifications, page 39: Section 2 – Maintenance Tables and Diagrams
- Diagram, page 83: 3.33 SGE Wiring Diagrams - ANSI/CSA
- Troubleshooting, page 279: Deutz Diesel Engines
- Color page, page 42: SJ82 T, SJ86 T
- Color page, page 302: SJ82 T, SJ86 T
- Foldout diagram (color), page 97: SJ82 T, SJ86 T
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the SJ82 T, SJ86 T 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 229040AHA$69.95
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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, 323 pages
Quantity one is the manual described above.
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