Skyjack SJ82T, SJ86T Telescopic Boom Lift Service Manual
297 pages · Publication 170454AO
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What's inside
From the manual's own table of contents: 5 sections, 269 entries. See sample pages (PDF, 831 KB)
Section 1 – Scheduled Maintenance31 topics
- Read and Heed
- 1.1-1 Aerial Platform and Mobile Elevating Work Platform 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
- 1.6-2 Electrical
- 1.6-3 Limit Switches
- 1.6-4 Hydraulic
- 1.6-5 Limit Switches (B)
- 1.6-6 Engine Compartment
- 1.6-7 Control Compartment
- 1.6-9 Platform Assembly
- 1.6-10 Boom Assembly
- 1.6-11 Optional Equipment/Attachments
- Function Tests
Section 2 – Maintenance Tables and Diagrams16 topics
- Standard Hose Numbering System
- MEWP Torque Specifications
- Axle Torque Specifications
- Torque Specifications for Fasteners (US)
- Torque Specifications for Fasteners (Metric)
- Torque Specifications for Hydraulic Couplings & Hoses
- Axles Maintenance Intervals
- Tire Specifications
- Floor Loading Pressure
- Hydraulic Specifications & Gear Oil
- Specifications & Features - Dimensional Data
- Specifications & Features - Performance and Speeds
- Engine Specifications
- Axle Oscillation Diagrams
- Dimension and Reach Diagram - SJ82T
- Dimension and Reach Diagram - SJ86T
Section 3 – System Component Identification and Schematics78 topics
- Electrical Symbol Chart
- Hydraulic Symbol Chart
- Wire Number and Color Code
- Wire Numbers and Color 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
- Pressure Reducing Valve Port Identification
- Main Manifold Port Identification
- Main Manifold Electrical Component Identification
- Main Manifold Hydraulic Component Identification
- Main Harness Wiring Diagram
- Boom Lift Valve Harness
- Differential Lock Harness
- Platform Rotate & Jib Harnesses
- Platform to Base Control Cable Harnesses
- Power Control Cable Connections
- Limit Switch Connections
- Load Sensing Cable Connection - CE & AS
- ECU Engine Wiring Diagram - Deutz Diesel Engine
- Glow Plug and EGR Harnesses - Deutz Diesel Engine
- Generator and Oil Cooler Harness Connections
- Generator Wiring
- SGE Wiring Diagrams
- Platform Work Light
- Positive Air Shut-Off Option Harness
- Dual Capacity Sensing Module
- Load Circuit - ANSI/CSA with Deutz TD2.9L
- Hydraulic Schematic
- Platform Controls Wiring - SJ82T ANSI/CSA
- Platform Controls Wiring - SJ86T ANSI/CSA
- Platform Controls Wiring - SJ86T CE - Deutz TCD2.2
- Platform Controls Wiring - SJ86T CE - Deutz TD2.9L
- Platform Controls Wiring - SJ86T AS
- Base Controls Wiring - SJ82T ANSI/CSA - Deutz D2011
- Base Controls Wiring - SJ82T ANSI/CSA - Deutz TD2.9L
- Base Controls Wiring - SJ82T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off
- Base Controls Wiring - SJ82T ANSI/CSA - Perkins 2.2TA
- Base Controls Wiring - SJ86T ANSI/CSA - Deutz D2011
- Base Controls Wiring - SJ86T ANSI/CSA - Deutz TD2.9L
- Base Controls Wiring - SJ86T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off
- Base Controls Wiring - SJ86T ANSI/CSA - Perkins 2.2TA
- Base Controls Wiring - SJ86T CE - Deutz TCD2.2
- Base Controls Wiring - SJ86T CE - Deutz D2011
- Base Controls Wiring - SJ86T CE - Deutz TD2.9L
- Base Controls Wiring - SJ86T AS - Deutz D2011
- Electrical Schematic - SJ82T & SJ86T ANSI/CSA Deutz D2011(S/N 97101144 & below)
- Electrical Schematic - SJ82T & SJ86T ANSI/CSA Deutz D2011(S/N 97101145 & above)
- Electrical Schematic - SJ82T & SJ86T ANSI/CSA Deutz TD2.9L (S/N 97101144 & below)
- Electrical Schematic - SJ82T & SJ86T ANSI/CSA Deutz TD2.9L (S/N 97101145 & above)
- Electrical Schematic - SJ82T & SJ86T ANSI/CSA Perkins 2.2TA (S/N 97101144 & below)
- Electrical Schematic - SJ82T & SJ86T ANSI/CSA Perkins 2.2TA (S/N 97101145 & above)
- Electrical Schematic - SJ86T CE Deutz TCD2.2
- Electrical Schematic - SJ86T CE Deutz D2011 (S/N 97101144 & below)
- Electrical Schematic - SJ86T CE Deutz D2011 (S/N 97101145 & above)
- Electrical Schematic - SJ86T CE Deutz TD2.9L (S/N 97101144 & below)
- Electrical Schematic - SJ86T CE Deutz TD2.9L (S/N 97101145 & above)
- Electrical Schematic - SJ86T AS Deutz D2011 (S/N 97101144 & below)
- Electrical Schematic - SJ86T AS Deutz D2011 (S/N: 97101145& above)
- Engine Electrical Schematic - Deutz TCD2.2
- Engine Interface Harness Schematic - Deutz TCD2.2
- Engine Electrical Schematic - Deutz TD2.9L (S/N 97101144 & below)
- Engine Electrical Schematic - Deutz TD2.9L (S/N 97101145 & above)
- Engine Electrical Schematic CE - Deutz TD2.9L (S/N 97101144 & below)
- Engine Electrical Schematic CE - Deutz TD2.9L (S/N 97101145 & above)
- Engine Interface Harness Schematic - Deutz TD2.9L
- Engine Interface Harness - Perkins 2.2TA (S/N 97101144 & below)
- Engine Interface Harness - Perkins 2.2TA (S/N 97101145 & above)
- Engine OEM Harness - Perkins 2.2TA (S/N 97101144 & below)
- Engine OEM Harness - Perkins 2.2TA (S/N 97101145 & above)
- Engine Component Harness - Perkins 2.2TA (S/N 97101144 & below)
- Engine Component Harness - Perkins 2.2TA (S/N 97101145 & above)
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 - CE
- 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 – Procedures96 topics
- General
- 5.1-1 Safety and Workmanship
- System Control Module (SCM)
- 5.2-1 User Interface Keys
- 5.2-2 SCM Character Functions Charts
- 5.2-3 SCM Operating Values Chart
- 5.2-4 How to Select SCM Functionality
- 5.2-5 How to View SCM Operation
- 5.2-6 How to Unlock and Modify SCM Settings
- 5.2-7 SCM Pin Voltage Reference
- Platform
- 5.3-1 Fly Boom Switch Voltage References
- 5.3-2 Platform Controller Voltage References
- 5.3-3 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 Platform Removal (no Jib Boom)
- 5.4-8 Operating Machine Functions from Base Controls
- 5.4-9 Fly Boom Section Removal
- 5.4-10 Mid Boom Section Removal
- 5.4-11 Mid Boom Section Installation
- 5.4-12 Fly Boom Section Installation
- 5.4-13 Platform and Jib Boom Installation
- 5.4-14 Platform Installation (no Jib Boom)
- 5.4-15 Platform Control Console Connection
- 5.4-16 Extension Cylinder and Wire Rope Replacement
- 5.4-17 Extension Cylinder and Cable Assembly Removal
- 5.4-18 Extension Cylinder and Wire Rope Assembly Installation
- 5.4-27 Wire Rope Tension
- 5.4-19 Wire Rope Inspection
- 5.4-28 Replace the Lift Cylinder
- Limit Switches
- 5.5-1 Limit Switch Locations and Trip Points
- 5.4-20 Check and Adjust the Limit Switches
- 5.4-21 Directional Sensing Limit Switch (LS1)
- 5.4-22 High Speed Drive / Tilt Override Limit Switch (LS2)
- 5.4-23 Fly-in Limit Switch (LS3)
- 5.4-24 Boom Angle (Dual Load) Limit Switch (LS4)
- 5.4-25 Boom Extension (Dual Load) Limit Switch (LS5)
- 5.4-26 Lift Cushion Limit Switch (LS6)
- Turret
- 5.6-1 Check and Replace the High Pressure Filter
- 5.6-2 Adjust the Turret Rotation Gear Backlash
- 5.6-3 Check the Swing Drive Oil
- 5.6-4 Change the Swing Drive Oil
- 5.6-5 Battery Replacement
- 5.6-6 Ring Gear Bolt Torque Sequence
- 5.6-7 Electronic Tilt Switch Setup Procedure
- 5.6-8 Check Rotation Bearing for Axial Wear
- 5.6-9 Resetting the Emergency Lowering Counter (CE only)
- Deutz Diesel Engines
- 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 Deutz TD2.9L Fault Codes
- Hydraulic Tank
- 5.8-1 Change the Hydraulic Tank Filter
- 5.8-2 Change the Hydraulic Oil
- Manifolds and Hydraulic Pumps
- 5.9-1 Hydraulic Brake Pressure Adjustment
- 5.9-2 Hydraulic Standby Pressure Adjustment
- 5.9-3 Hydraulic High Pressure Adjustment
- 5.9-4 Hydraulic System Relief Valve Adjustment
- 5.9-5 Turret Rotate Relief Valve Adjustment
- 5.9-6 Platform Level Relief Valve Adjustment
- 5.9-7 Fly Boom Relief Valve Adjustment
- 5.9-8 Test Charge Pump Pressure on Drive Pump
- 5.9-9 Test Forward Drive Pressure on Drive Pump
- 5.9-10 Test Reverse Drive Pressure on Drive Pump
- Axles
- 5.10-1 Change the Oil in the Axles
- 5.10-2 Check the Oil Level in the Torque Hubs
- 5.10-3 Change the Oil in the Torque Hubs
- 5.10-4 Check the Oil Level in the Axle Gearbox
- 5.10-5 Change the Oil in the Axle Gearbox
- 5.10-6 Brake Inspection
- 5.10-7 Oscillating Cylinder Bolt Replacement
- 5.10-8 Oscillating Cylinder Replacement
- 5.10-9 Bleed the Oscillating Axle Cylinders
- 5.10-10 Test the Oscillating Axle Cylinders
- Grease Points
- 5.11-1 Grease the Turret Ring Gear
- 5.11-2 Grease the Turret Swing Drive
- 5.11-3 Grease the Axles
- 5.11-4 Grease the Drive Shaft
- Load Sensing System
- 5.12-1 Load Sensing System Overload Status
- 5.12-2 Dual Capacity Overload Module Function Table
- 5.12-3 Calibration of Load Sensing System
Inside this manual
Real pages from this service manual (297 pages). Open the sample pages (PDF, 829 KB)
- Specifications, page 38: Torque Specifications for Fasteners (US)
- Troubleshooting, page 138: Section 4 – Troubleshooting Information
- Diagram, page 250: Turret
- Color page, page 11: SJ82T, SJ86T
- Color page, page 51: SJ82T, SJ86T
- Foldout diagram (color), page 116: SJ82T, SJ86T
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the SJ82T, SJ86T 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 170454AO$69.69
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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, 297 pages
Quantity one is the manual described above.
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