Page 1 SERVICE MANUAL SJ82 T, SJ86 T TELESCOPIC BOOMS 229040ABA August 2020 ANSI/CSA, CE, AS...
Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.
Page 3 This manual is for MEWPs with serial numbers: SJ82 T: A402 000 001 - A402 999 999 SJ86 T: A402 000 001 - A402 999 999...
Page 4 It may also be used to alert against unsafe practices. IMPORTANT IMPORTANT indicates a procedure essential for safe operation and which, if not followed, may result in a malfunction or damage to the MEWP . SJ82 T, SJ86 T 229040ABA...
Page 5: Table Of Contents
MEWP Torque Specifications ............33 SJ82 T, SJ86 T...
Page 6 Dimension and Reach Diagram - SJ82 T ........
Page 7 Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L .......
Page 8 How to Unlock and Modify SCM Settings ......... . . 171 SJ82 T, SJ86 T...
Page 9 Electronic Tilt Switch Setup Procedure ..........215 SJ82 T, SJ86 T...
Page 10 5.10-4 Grease the Drive Shaft ............258 SJ82 T, SJ86 T...
Page 11: Section 1 - Scheduled Maintenance
SKYJACK dealer at no charge for parts or labor. In addition, all products have a 5 year structural 1.1-1 Aerial Platform and Mobile warranty.
Page 12: Maintenance And Service
MEWP . Before attempting any repair work, disconnect the main power conenctors. Consult SKYJACK’s Service Department for optional tires specifications and installation. Keep personnel clear of components, systems or unsupported loads that may move unexpectedly WARNING during maintenance procedures.
Page 13: Hydraulic System & Component Maintenance And Repair
6. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also, plug the ports of the removed components. SJ82 T, SJ86 T 229040ABA...
Page 14: Railing Maintenance And Repair
Section 1 – Scheduled Maintenance Maintenance and Service 1.2-7 Railing Maintenance and Repair Skyjack MEWPs have been designed to ensure compliance with the relevant design standards applicable for that particular unit at the time of manufacture. As such, any repairs made to the...
Page 15: Scheduled Maintenance
MEWP parked on a flat and level surface ▪ Legend Disconnect the batteries by disconnecting the ▪ Pass main power connectors. Fail Repair any damaged or malfunction ▪ components before operating MEWP . Repaired Keep records on all inspections. ▪ Not applicable SJ82 T, SJ86 T 229040ABA...
Page 16: Owner's Annual Inspection Record
The Owner’s annual inspection record is located on the scissor assembly. It must be filled out after an annual inspection has been completed. Do not use the MEWP if an inspection has not been recorded in the last 13 months. SJ82 T, SJ86 T 229040ABA...
Page 17: Pre-Delivery/Maintenance Inspection Checklist
The undersigned has made sure that all areas in the list have received an inspection. The undersigned has told the machine owner of all inconsistencies in the inspection and corrected them before machine operation. Owner: User: SJ82 T, SJ86 T 229040ABA...
Page 18: Scheduled Maintenance Inspections
Inspect for the following: loose wires: Broken or missing actuator arms ▪ Boom to platform cable harness ▪ Missing fasteners ▪ Engine compartment electrical panel ▪ Loose wiring. ▪ Engine wiring harness ▪ Rotary manifold wiring ▪ SJ82 T, SJ86 T 229040ABA...
Page 19: Engine Compartment
Make sure all fittings and hoses are correctly ▪ tightened and there are no hydraulic leaks. C - Annual Inspection For the brake/motor oil replacement ▪ procedure, refer to 5.5-3 Check the Swing Drive Oil. SJ82 T, SJ86 T 229040ABA...
Page 20 (B,C) Check the coolant strength. For ▪ Make sure that there no fuel leaks at the recommended coolant change intervals, refer ▪ engine. to the engine manual. Make sure there is no visible damage. ▪ SJ82 T, SJ86 T 229040ABA...
Page 21 B - Frequent Inspection refer to the engine manual. For recommended oil change, refer to engine ▪ manual B - Frequent Inspection For the recommended oil change interval and ▪ procedure, refer to the engine manual. SJ82 T, SJ86 T 229040ABA...
Page 22: Control Compartment
Make sure the housing is attached and tight. ▪ Make sure there is no visible damage or ▪ hydraulic leaks. C - Annual Inspection For the filter element replacement procedure, ▪ refer to 5.5-1 Check and Replace the High Pressure Filter. SJ82 T, SJ86 T 229040ABA...
Page 23 (for example, a sewage system, Before you use the MEWP , make sure there is streams, rivers, or other surface water), they can sufficient fuel for the estimated task. kill aquatic life. SJ82 T, SJ86 T 229040ABA...
Page 24: Base
Make sure all the fittings and hose connections ▪ are tight. Make sure there is no sign of hydraulic ▪ leakage. C - Annual Inspection Check the brakes annually. Refer to the ▪ procedure 5.9-6 Brake Inspection. SJ82 T, SJ86 T 229040ABA...
Page 25 Replacement. WARNING NOTE Do not use tires other than the tires that Skyjack The oscillating axle is locked when the MEWP is in the specifies for this MEWP . Do not mix different types elevated travel position or at the elevated travel speed.
Page 26: Platform Assembly
Make sure there is no debris lodged between ▪ Make sure there is no visible damage. ▪ the platform and the boom adaptor. AC power socket Make sure that the socket is free of dirt or ▪ blockages. SJ82 T, SJ86 T 229040ABA...
Page 27: Boom Assembly
All hoses are correctly tightened and there is no ▪ sign of hydraulic leakage. Make sure there are no visible cracks in welds or ▪ structure and there are no signs of deformation. SJ82 T, SJ86 T 229040ABA...
Page 28 Make sure that there are no gaps between the ▪ springs. For the wire rope tension procedure, refer to 5.4-19 Proper Wire Rope Tension. With Gaps No Gaps Cable Disc Springs SJ82 T, SJ86 T 229040ABA...
Page 29: 10 Optional Equipment
The welder and the welder tray are correctly ▪ ▪ is no visible damage. attached. There are no loose or missing parts, and there ▪ is no visible damage. There are no loose wires or missing fasteners. ▪ SJ82 T, SJ86 T 229040ABA...
Page 30: Function Tests
Found there will be detailed instructions for which tests to perform, as well as how to properly and successfully perform them. NOTE The all-function motion alarm should sound while operating any boom and drive function. SJ82 T, SJ86 T 229040ABA...
Page 31: Section 2 - Maintenance Tables And Diagrams
MEDIUM 90°, FEMALE, 37° JIC, SWIVEL 100R13 SHORT 90°, FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R17 FEMALE, 37° JIC, SWIVEL REUSABLE MALE PIPE THREAD FITTING 300 PSI REUSABLE MALE PIPE THREAD FITTING NO FITTING 300 PSI SJ82 T, SJ86 T 229040ABA...
Page 32 FEMALE, 37° JIC, SWIVEL 100R19 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19 LONG 90°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R15 SJ82 T, SJ86 T 229040ABA...
Page 33: Mewp Torque Specifications
Load Cell Mounting BOLT, Hex head (1/2"-13 x 2.25", Grade 8) Special Options Generator Support BOLT, Hex head (1/2”-13 x 2”, Grade 8) Oil Cooler Support BOLT, Hex head (1/2”-13 x 2”, Grade 8) 1394AA SJ82 T, SJ86 T 229040ABA...
Page 34: Axle Torque Specifications
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength ▪ locking. Before using it, completely remove any lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80˚C approx. SJ82 T, SJ86 T 229040ABA...
Page 35: Torque Specifications For Fasteners (Us)
2360 1 1/2-6 ft-lb 1180 2630 1979 4284 3200 1/2-20 ft-lb 2200 1640 3560 2660 1 1/2-12 1329 2983 2224 4827 3606 NOTE: Lubed includes lubricants such as lubrizing, oil, grease, or uncured Loctite. 1374AA SJ82 T, SJ86 T 229040ABA...
Page 36: Torque Specifications For Fasteners (Metric)
1101 2101 1576 M33 x 3.50 1990 1493 2849 2137 ft-lb 1886 1415 2699 2024 M36 x 4.00 2557 1918 3659 2744 NOTE: Lubed includes lubricants such as lubrizing, oil, grease, or uncured Loctite. 1375AA SJ82 T, SJ86 T 229040ABA...
Page 37: Torque Specifications For Hydraulic Couplings & Hoses
Min. Max. Min. Max. Min. Max. 1/4" 6.75 1/4" 3/8" 3/8" 1/2" 27.66 1/2" 5/8" 46.33 5/8" 3/4" 72.33 3/4" 1" 100.5 1" 1 1/4" 101.5 1 1/4" 1 1/2 1 1/2 2" 2" 1276AA SJ82 T, SJ86 T 229040ABA...
Page 38: Axles Maintenance Intervals
Torque Wrench Settings (Nm) Size of Screw 8G/8.8 10K/10.9 12K/12.9 M10 X 1.25 M14 X 1.5 * Initially after 100 working hours & when it starts sounding noisy 1376AB NOTE 1 Nm = 0.7376 ft-lb SJ82 T, SJ86 T 229040ABA...
Page 39: Tire Specifications
Do not use tires other than those specified for this machine. Do not mix different types of tires. Tires other than those specified can adversely affect stability. Failure to operate with matched, approved tires in good condition can result in death or serious injury. Replace tires with the exact, Skyjack-approved types only. IMPORTANT For proper function of each axle differential, all four wheels must have same tire size installed at all times.
Page 40: Floor Loading Pressure
Foot Print Area identified by test Base Area = Length x Width Wheel Load Weight of MEWP + Capacity LCP = OUP = Foot Print Area Base Area Foot Print Area Base Width Base Length SJ82 T, SJ86 T 229040ABA...
Page 41: Hydraulic Specifications & Gear Oil
-20°F to 115°F (-29°C to 45°C) SAE 80W-90 API GL5 Arctic Gear Oil -40°F to 115°F (-40°C to 45°C) Duratran XL Synthetic Oil Gear Oil Capacity 10 gal (38 L) *For other component specifications, refer to the hydraulic schematic. 1397AB SJ82 T, SJ86 T 229040ABA...
Page 42: Specifications & Features - Dimensional Data
7.20 m 23' 7" 7.20 m 7.20 m Turret Rotation 360° 360° 360° 360° 360° 360° Weight Weight 17 055 kg 37,600 lb 17 145 kg 37,800 lb 17 550 kg 17 550 kg 2040AA SJ82 T, SJ86 T 229040ABA...
Page 43: Specifications & Features - Performance And Speeds
500 / 750 lb 227 / 340 kg 500 / 750 lb Maximum Number of Persons 2 / 3 2 / 3 Electrical System Voltage 12 V DC 12 V DC Battery Type Lead/Acid Lead/Acid 2040AA-1 SJ82 T, SJ86 T 229040ABA...
Page 44: Engine Specifications
Cold Lube Oil Option -20°F to 90°F (-29°C to 32°C) SAE 5W-30 API CF/CG/CH-6 Arctic Lube Oil Option -40°F to 115°F (-40°C to 45°C) SAE 0W-40 API CF/CG/CH-6 Lube Oil Sump Capacity 2.64 gal (10.0 L) 1399AB-1 SJ82 T, SJ86 T 229040ABA...
Page 45: Axle Oscillation Diagrams
Axle oscillation free (travel mode) - drive speed 3.0 mph (4.8 km/h) max Axle oscillation locked (work mode) - drive speed 0.5 mph (0.8 km/h) max Axle Oscillation - SJ82 T Axle oscillation free (travel mode) - drive speed 3.0 mph (4.8 km/h) max Axle oscillation locked (work mode) - drive speed 0.5 mph (0.8 km/h) max...
Page 46: Dimension And Reach Diagram - Sj82 T
Section 2 – Maintenance Tables and Diagrams Dimension and Reach Diagram - SJ82 T Diagram 2.15 Dimension and Reach Diagram - SJ82 T Feet (meters) (28.95) (27.43) (25.91) (24.38) (22.86) (21.34) (19.81) (18.29) (16.76) (15.24) (13.72) (12.19) (10.67) (9.14) (7.62) (6.10)
Page 47: Dimension And Reach Diagram - Sj86 T
HEIGHT 53” [1.35 m] PLATFORM RAILING HEIGHT 44” [1.12 m] JIB R.O.M. DOWN 60° BOOM R.O.M. - UP 72.5° 24” PLATFORM HEIGHT WHEEL BASE 132” [3.35 m] [0.61 m] STOWED 11” [0.28 m] 486” [12.34 m] SJ82 T, SJ86 T 229040ABA...
Page 48: Section 3 - System Component Identification And Schematics
Section 3 – System Component Identification and Schematics SJ82 T, SJ86 T 229040ABA...
Page 49: Electrical Symbol Chart
SINGLE POLE VOLT METER DOUBLE THROW BEEPER PUSH BUTTON RELAY DOUBLE POLE CAPACITOR DOUBLE THROW ROTARY SWITCH DIODE RELAY DOUBLE POLE EMERGENCY SINGLE THROW POTENTIOMETER STOP BUTTON RELAY TRIPLE POLE DOUBLE THROW RESISTOR RHEOSTAT RELAY SJ82 T, SJ86 T 229040ABA...
Page 50: Hydraulic Symbol Chart
TWO POSITION HYDRAULIC FIXED ORIFICE THREE WAY VALVE MOTOR VARIABLE ADJUSTABLE TWO POSITION DISPLACEMENT FLOW CONTROL THREE WAY VALVE HYDRAULIC MOTOR THREE POSITION SERIES PARALLEL FOUR WAY HYDRAULIC CHECK VALVE CLOSED CENTER MOTOR CLOSED PORT SJ82 T, SJ86 T 229040ABA...
Page 51: Wire Number And Color Code
This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red. SJ82 T, SJ86 T 229040ABA...
Page 52: Wire Numbers And Color Codes - Additional
Note: Standard colors referenced from IEC 60445:2010, Annex A: Table 1. 1789AA Load Cell Color Code Wire No. Wire Color Wire No. Wire Color Wire No. Wire Color Wire No. Wire Color Brown Yellow White unused Beige Blue Green unused Purple unused Black 1790AA SJ82 T, SJ86 T 229040ABA...
Page 53: Hydraulic Parts List
165486 VALVE, Counterbalance - boom extend 159841 VALVE, Counterbalance - platform level 159841 VALVE, Counterbalance - platform level 159841 VALVE, Counterbalance - jib 159841 VALVE, Counterbalance - jib CB10 141399 VALVE, Counterbalance - platform rotate SJ82 T, SJ86 T 229040ABA...
Page 54 ORIFICE, 0.090" - main manifold 171415 ORIFICE, 0.055” - main manifold 171416 ORIFICE, 0.020” - main manifold 171416 ORIFICE, 0.020” - main manifold 171416 ORIFICE, 0.020” - main manifold 171416 ORIFICE, 0.020” - main manifold SJ82 T, SJ86 T 229040ABA...
Page 55 VALVE, Control - brake hand pump 171387 VALVE, Control - pilot operated 171387 VALVE, Control - pilot operated 221775 VALVE, Control - pilot operated 221776 VALVE, Control - pilot operated 166053 VALVE, Control - loop flush SJ82 T, SJ86 T 229040ABA...
Page 56: Electrical Parts List
86CR 127131 RELAY, 12 Volt 40 Amp (Oil cooler) 120CR 127131 RELAY, 12 Volt 40 Amp (Low capacity enable) - ANSI/CSA 120CR 127131 RELAY, 12 Volt 40 Amp (High capacity light) - CE & AS SJ82 T, SJ86 T 229040ABA...
Page 57 BEEPER, 4-28 VDC Slow pulsing (Platform control console) 103056 BEEPER, 7.5-16 VDC (Base control console) - ANSI/CSA 144387 ALARM, Overload - CE & AS 117325 CIRCUIT BREAKER (15 Amp) 117325 CIRCUIT BREAKER (15 Amp) 117325 CIRCUIT BREAKER (15 Amp) SJ82 T, SJ86 T 229040ABA...
Page 58 RESISTOR, 3 ohm 25 W - ANSI/CSA Deutz D2011 168783 RESISTOR, 4 ohm 25 W - CE & AS Deutz D2011 164857 RESISTOR, 3.9k ohm 1/2 W - Deutz TD2.9L 151643 RESISTOR, 250 ohm 1 W SJ82 T, SJ86 T 229040ABA...
Page 59 SWITCH, Load zone toggle (Platform control console) 148988 SWITCH, Load zone select (Base control console) 148988 SWITCH, Differential lock (Platform control console) 115574 SWITCH, Drive torque toggle (Platform control console) 103336 HOUR METER - ANSI/CSA SJ82 T, SJ86 T 229040ABA...
Page 60 Electrical Parts List Section 3 – System Component Identification and Schematics Index Skyjack Description Part No. 170787 HOUR METER - CE & AS 138576 PORT, Diagnose - Deutz engine 138574 CONNECTOR, Engine - Deutz engine SJ82 T, SJ86 T 229040ABA...
Page 61: Hourmeter/Counter Harness - Ce
Hourmeter/Counter Harness - CE 3.7 Hourmeter/Counter Harness - CE SECTION A-A SCALE 2 : 1 SECTION B-B DESCRIPTION IDENTIFICATION COLOUR CAVITY ID. +12 VDC PURPLE HOURMETER COUTNER BLUE HOUR RESET RH-1 GREEN COUNTER RESET RC-1 WHITE GROUND WHITE SJ82 T, SJ86 T 229040ABA...
Page 62: Rotary Manifold Port Identification
Steer Left (SB) Port 6 To Front Drive Motor Port 2 To Axle Lock Cylinder Port 7 To Rear Drive Motor Port V9 Port 10 To Rear Drive Motor To Rear Axle Diﬀerential Lock M167068AH-1 SJ82 T, SJ86 T 229040ABA...
Page 63 Port 4: SAHR Brake Release Port 5: Steer Left Port 6: Hydraulic Motor 2 Speed, Port 10: Diﬀerential Lock (if equipped) Port 9: Hydraulic Motor Drain Port 7: Hydraulic Motor; Drive FWD Port 8: Hydraulic Motor; Drive REV SJ82 T, SJ86 T 229040ABA...
Page 64: System And Drive Pump Port Identification
To Hydraulic Tank To Pressure Filter To Hydraulic Tank To Rotary Manifold To Main Manifold To Rotary Manifold 3H-V2 To Rotary Manifold Load Sense Compensator To Brake Manifold 3H-V1 Pressure Compensator To Hydraulic Tank To Hydraulic Tank SJ82 T, SJ86 T 229040ABA...
Page 65: Drive Motors Port Identification
Section 3 – System Component Identification and Schematics Drive Motors Port Identification 3.10 Drive Motors Port Identification To Rotary Manifold To Rotary Manifold To Rotary Manifold To Rotary Manifold SJ82 T, SJ86 T 229040ABA...
Page 66: Jib Valve Port Identification
4H-36 4A-35 Platform Left Rotate Valve Jib Up Valve To Jib Cylinder (Extend) To Jib Cylinder (Retract) To Platform Rotator (Right) To Platform Rotator (Left) To Bulkhead #1 (to T3) To Bulkhead #1 (to PP) SJ82 T, SJ86 T 229040ABA...
Page 67: No Jib Valve Port Identification
No Jib Valve Port Identification 3.12 No Jib Valve Port Identification 4H-37 Platform Right Rotate Valve 4H-36 Platform Left Rotate Valve 2(P) To Bulkhead #1 To Bulkhead #2 4(T) To Bulkhead #1 To Bulkhead #2 SJ82 T, SJ86 T 229040ABA...
Page 68: Brake Manifold Port Identification
To Tank T4 Pressure Reducing Valve 2SPD To Rotary Manifold Brake Release Override To Drive Pump Shuttle Valve To Drive Pump Loop Flush Valve CV13 Check Valve To Rotary Manifold To Main Manifold Oriﬁce (0.073”) M216511AB_SM SJ82 T, SJ86 T 229040ABA...
Page 69: Main Manifold Port Identification
To Brake Manifold To System Pump To Rotary Manifold To Swing Drive To Emergency Pump To Swing Drive To Extend Cylinder To High Pressure Filter To Extend Cylinder To RBulkhead (Main Boom) To Bulkhead (Main Boom) M165487AG-PI SJ82 T, SJ86 T 229040ABA...
Page 70: Main Manifold Electrical Component Identification
Boom In Valve 2H-21A Dump Valve 2H-42 Flow Enable Valve 5H-33 Turret Rotate Right Valve 5H-32 Turret Rotate Left Valve 5H-23A 4H-13 Steer Right Valve Boom Lower Valve 4H-14 5H-24A Boom Up Valve Steer Left Valve M165487AH-EC SJ82 T, SJ86 T 229040ABA...
Page 71: Main Manifold Hydraulic Component Identification
Check Valves (CV) & Oriﬁces (OR) (Rear View of Manifold) Oriﬁce Relief Valve Right Shuttle Valve Front DSV3 Pressure Compensating Valve Check Valve Test Port DSV1 Pressure Check Valve Compensating Valve DSV2 Pressure Flow Compensating Valve Regulator Valve M165487AH-HC SJ82 T, SJ86 T 229040ABA...
Page 72: Main Harness Wiring Diagram
PIN 21 - 16 - WH/BK PIN 22 - 02(.1) - WH (SPLICE #1) [14 GA.] PIN 23 - 02(.2) - WH (SPLICE #2) [14 GA.] PIN 24 - 02(.3) - WH (SPLICE #3) [14 GA.] M165094AD-1 SJ82 T, SJ86 T 229040ABA...
Page 73: Boom Lift Valve Harness
3.18 Boom Lift Valve Harness IINSERT WIRE 02 TO TB 02 INSERT WIRE 19 TO AVAILABLE TB 19. INSERT WIRE 09 TO AVAILABLE TB 09. BASE CONTROL BOX LAYOUT TO BOOM LIFT VALVE M168763AA SJ82 T, SJ86 T 229040ABA...
Page 74: Differential Lock Harness
3.19 Differential Lock Harness IINSERT HARNESS WIRE 165 TO TB 165 80.1389 INSERT HARNESS WIRE 02 TO AVAILABLE TB 02. BASE CONTROL BOX LAYOUT TO DIFFLOCK VALVE M167195AB SJ82 T, SJ86 T 229040ABA...
Page 75: Platform Rotate & Jib Harnesses
CAVITY WIRE NO. COLOUR DESCRIPTION RED/PURPLE ROTATE CW WHITE (SPLICE) GROUND CAVITY WIRE NO. COLOUR DESCRIPTION WHITE/RED/BLK ROTATE CCW WHITE (SPLICE) GROUND PLATFORM ROTATE HARNESS - SJ81T BLACK (04A) WHITE (08A) FOOT PEDAL CONNECTIONS M168644AB_M167740AB_M168650AA SJ82 T, SJ86 T 229040ABA...
Page 76: Platform To Base Control Cable Harnesses
POSITION 18 - WIRE 18 POSITION 19 - WIRE 19 POSITION 20 - WIRE 20 POSITION 21 - WIRE 21 POSITION 22 - WIRE 22 POSITION 23 - WIRE 23 POSITION 24 - WIRE 24 FEMALE M165497AD_M165499AD SJ82 T, SJ86 T 229040ABA...
Page 77: Limit Switch Connections
LS4 - Boom Angle (Dual Load) Limit Switch LS5 - Boom Extension (Dual Load) Limit Switch LS6 - Lift Cushion Limit Switch Black Black Black/White Black Black/White Black/White Black Black/White (CE) (ANSI) (ANSI) (CE) M63752AA SJ82 T, SJ86 T 229040ABA...
Page 78: Load Sensing Cable Connection - Ce & As
3.23 Load Sensing Cable Connection - CE & AS 162 WHITE CSIG 161 GREEN YSIG XSIG DSIG 128A NOTE: UNUSED WIRES IN THE LOAD CELL CABLE BEIGE, PURPLE AND BLACK HAVE TO BE CUT AND PROPERLY INSULATED CABLE FROM LOAD CELL M168774AB SJ82 T, SJ86 T 229040ABA...
Page 79: Ecu Engine Wiring Diagram - Deutz Diesel Engine
PIN 4 - 57C - BROWN/GREEN [12 GA.] PIN 6 - 02 - WHITE (IF EQUIPPED) PIN 10 - 11 - WHITE/ORANGE PIN 11 - 00A - WHITE PIN 12 - 54A - PURPLE/RED (IF EQUIPPED) M138708AA SJ82 T, SJ86 T 229040ABA...
Page 80: Glow Plug And Egr Harnesses - Deutz Diesel Engine
87 - 11B RED CAVITY 1 = 07 WHITE CAVITY 2 = 02 BLACK BASE CONTROL BOX TERMINAL STRIP WIRING: TO ENGINE GLOW PLUG POWER FEED STUD 11 WHT 54A BLK TO ENGINE STARTER M138849AB SJ82 T, SJ86 T 229040ABA...
Page 81: Generator And Oil Cooler Harness Connections
INSERT WIRE 02 (FROM VALVE HARNESS) INTO TERMINAL BLOCK POSITION 02 TO EMERG. PUMP POWER STUD HARNESS TO TEMP. SWITCH GENERATOR VALVE CONNECTOR 148485 INSTALL UNDER COOLER HARNESS BRACKET MOUNTING BOLT 171441 148484 COOLER FAN M171443AA_1 SJ82 T, SJ86 T 229040ABA...
Page 82: Generator Wiring
3.27 Generator Wiring Platform Control Box Base Control Box SPEED CONTROL JOYSTICK JOYSTICK 56ACR 01ACR LEVEL TELE PLATFORM ROTATE 79CR OPTION 76ACR 60CR IGNITION HORN E-STOP ABCDEFGH THROTTLE TORQUE E-PUMP 08CR M169566AC_M166385AA SJ82 T, SJ86 T 229040ABA...
Page 83: Platform Work Light
3.28 Platform Work Light M168636AB SJ82 T, SJ86 T 229040ABA...
Page 84 PIN 8 -WHITE (408) PIN 4 -GREEN (402) PIN 9 -EMPTY PIN 5 -EMPTY PIN 10 -YELLOW (410) CONNECTOR TO POSI AIR CONTROLLER TO SOLENOID PIN A-WHITE (408) PIN B-RED (403A) PIN C-BLACK (401) M171529AA-2 SJ82 T, SJ86 T 229040ABA...
Page 85: Dual Capacity Sensing Module
TO BOOM DOWN BYPASS RELAYS NOTES : 1. OPERATING VOLTAGE 8 - 18 VDC 2. OPERATING TEMPERATURE -40C TO 70C 3. CONFORMAL COATED PCB WITHIN A PLASTIC HOUSING 4. 08-PIN TE CONNECTOR OR SIMILAR. M167280AE SJ82 T, SJ86 T 229040ABA...
Page 86: Load Circuit - Ansi/Csa With Deutz Td2.9L And Arctic Package
ONTO END OF INTO NORMALLY CLOSED RELAY STACK SOCKET ON 21CR 86CR 59CR(CE) 57ACR2 76ACR 60CR 77CR 78CR 79CR COOLER IGN. (WHITE) 02 (WHITE) 21B (BLACK) USE EXISTING CONNECT TO LOAD STRAIN RELIEF CIRCUIT SOLENOID M194713AB SJ82 T, SJ86 T 229040ABA...
Page 87: Hydraulic Schematic
3 1 3 PSI (40.6 CC/ 2.48 CIR) (28.7 GPM @ 2675 RPM) SAE 8 SAE 8 SAE 6 SAE 16 SAE 16 SAE 04 VIEW OF HYDRAULIC TANK PORT PHYSICAL LOCATIONS 3.32 Hydraulic Schematic M167056AA SJ82 T, SJ86 T 229040ABA...
Page 88: Platform Controls Wiring - Sj82 T
3.33 Platform Controls Wiring - SJ82 T PL10 PL15 LOW CAP LOAD SPEED ZONE CONTROL JOYSTICK JOYSTICK BORDER PL11 HIGH CAP WHT(-) GRN(SIG) DIFF VIO(+) LOCK PLATFORM LEVEL ROTATE TELE R10(250) PL16 R11(250) R8(250) R9(250) IGNITION HORN E-STOP ABCDEFGH THROTTLE...
Page 89: Platform Controls Wiring - Sj86 T With Deutz Td2.9L Or D2011 Engines
162ACR 17A 17A 162A 162B SUPP SUPP SCM-32 CSIG YSIG XSIG DSIG 128A SPLICE 02 BP3 OVERLOAD ALARM BP1 TILT ALARM 3.34 Platform Controls Wiring - SJ86 T with Deutz TD2.9L or D2011 Engines M231432AB SJ82 T, SJ86 T 229040ABA...
Page 90: Platform Controls Wiring - Sj86 T With Deutz Tcd2.2 Engine
165CR 162BCR1 162ACR 17A 17A 162A 162B SUPP SUPP CSIG YSIG XSIG DSIG 128A BP OVERLOAD ALARM BP TILT ALARM BP6 REGEN ALARM 3.35 Platform Controls Wiring - SJ86 T with Deutz TCD2.2 Engine M224640AD SJ82 T, SJ86 T 229040ABA...
Page 91: Base Controls Wiring - Sj82 T Ansi/Csa - Deutz Td2.9L
3.36 Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L 24P-MALE 'B' CONNECTOR-AXIOMATIC SOCKET 1 - CAN L SOCKET 2 - CAN H SOCKET 3 - PLUGGED SOCKET 4 - PLUGGED CANH SOCKET 5 - 26B 128A CANL SOCKET 6 - 26C...
Page 92: Base Controls Wiring - Sj82 T Ansi/Csa - Deutz Td2.9L With Positive Air Shut-Off
3.37 Base Controls Wiring - SJ82 T ANSI/CSA - Deutz TD2.9L with Positive Air Shut-Off TO SOLENOID PIN A-WHITE (408) PIN B-RED (403A) PIN C-BLACK (401) 24P-MALE 'B' 403A 403A POSITIVE AIR SHUT OFF MODULE 10 PIN CONNECTOR PLUG PIN 1 -BLACK (401)
Page 93: Base Controls Wiring - Sj82 T Ansi/Csa - Deutz D2011
3.38 Base Controls Wiring - SJ82 T ANSI/CSA - Deutz D2011 24P-MALE CABLE B CONNECTOR-AXIOMATIC SOCKET 1 - CAN L CANH SOCKET 2 - CAN H SOCKET 3 - PLUGGED CANL 03-12ga SOCKET 4 - PLUGGED 05-14ga 128A SOCKET 5 - 26B...
Page 94: Base Controls Wiring - Sj86 T Ansi/Csa - Deutz Td2.9L
SOCKET 7 - CANH SOCKET 8 - CANL SOCKET 9 - 57D SOCKET 10 - PLUGGED SOCKET 11 - 20 SOCKET 12 - 26D 3.39 Base Controls Wiring - SJ86 T ANSI/ CSA - Deutz TD2.9L M232010AB SJ82 T, SJ86 T 229040ABA...
Page 95: Base Controls Wiring - Sj86 T Ansi/Csa - Deutz Td2.9L With Positive Air Shut-Off
SOCKET 8 - CANL SOCKET 9 - 57D SOCKET 10 - PLUGGED SOCKET 11 - 20 SOCKET 12 - 26D 3.40 Base Controls Wiring - SJ86 T ANSI/ CSA - Deutz TD2.9L with Positive Air Shut-Off M231368AB SJ82 T, SJ86 T 229040ABA...
Page 96: Base Controls Wiring - Sj86 T Ansi/Csa & As - Deutz D2011
PIN 3 - 39A BLACK/RED PIN 2 - 162B PINK/PURPLE PIN 1 - 02 WHITE TO DEUTZ EDC HARNESS 168781 CANH CANL 3.41 Base Controls Wiring - SJ86 T ANSI/ CSA & AS - Deutz D2011 M231382AB SJ82 T, SJ86 T 229040ABA...
Page 97: Base Controls Wiring - Sj86 T Ce - Deutz Tcd2.2
SOCKET 7 - CANH SOCKET 8 - CANL SOCKET 9 - 57D SOCKET 10 - PLUGGED SOCKET 11 - 20E SOCKET 12 - 26D 3.42 Base Controls Wiring - SJ86 T CE - Deutz TCD2.2 M224636AD SJ82 T, SJ86 T 229040ABA...
Page 98: Base Controls Wiring - Sj86 T Ce - Deutz D2011
PIN 4 - 09 YELLOW PIN 3 - 39A BLACK/RED PIN 2 - 162B PINK/PURPLE PIN 1 - 02 WHITE TO DEUTZ EDC HARNESS 168781 CANH CANL 3.43 Base Controls Wiring - SJ86 T CE - Deutz D2011 M231385AB SJ82 T, SJ86 T 229040ABA...
Page 99: Base Controls Wiring - Sj86 T Ce - Deutz Td2.9L
SOCKET 7 - CANH SOCKET 8 - CANL SOCKET 9 - 57D SOCKET 10 - PLUGGED SOCKET 11 - 20 SOCKET 12 - 26D 3.44 Base Controls Wiring - SJ86 T CE - Deutz TD2.9L M231430AA SJ82 T, SJ86 T 229040ABA...
Page 100: Electrical Schematic - Ansi/Csa Deutz Td2.9L
3.45 Electrical Schematic - ANSI/CSA Deutz TD2.9L Refer to 3.49 Engine Electrical Schematic - Deutz TD2.9L JMPR4 R40=330K ohm ONLY WITH SGE OPTION 3.45 Electrical Schematic - ANSI/CSA Deutz TD2.9L M218476AA-1 SJ82 T, SJ86 T 229040ABA...
Page 101: Electrical Schematic - Ansi/Csa & As Deutz D2011
3.46 Electrical Schematic - ANSI/CSA & AS Deutz D2011 ONLY WITH SGE OPTION ONLY WITH SGE OPTION 3.46 Electrical Schematic - ANSI/CSA & AS Deutz D2011 M218473AA SJ82 T, SJ86 T 229040ABA...
Page 102: Electrical Schematic - Ce Deutz Tcd2.2
3.47 Electrical Schematic - CE Deutz TCD2.2 Refer to 3.51 Engine Electrical Schematic - Deutz TCD2.2 3.47 Electrical Schematic - CE Deutz TCD2.2 M224629AD-1 SJ82 T, SJ86 T 229040ABA...
Page 103: Electrical Schematic - Ce Deutz D2011
3.48 Electrical Schematic - CE Deutz D2011 ONLY WITH SGE OPTION ONLY WITH SGE OPTION 3.48 Electrical Schematic - CE Deutz D2011 M218474AB SJ82 T, SJ86 T 229040ABA...
Page 104: Engine Electrical Schematic - Deutz Td2.9L
A37-18 WH A48-16 BK A18-16 WH A33-16 BK A16-16 WH A05-16 BK A04-16 WH A46-16 BK A03-16 WH A32-16 BK A02-16 WH 00-12 WH 00-14 WH B+-12 RD 3.49 Engine Electrical Schematic - Deutz TD2.9L M218476AA-2 SJ82 T, SJ86 T 229040ABA...
Page 105: Engine Interface Harness Schematic - Deutz Td2.9L
A03-16 WH A32-16 BK A32-16 BK A02-16 WH A02-16 WH TO PRE-HEAT TO FUEL PUMP TO BATTERY TO CTRL PNL TO WATER SENSOR TO CTRL PNL 3.50 Engine Interface Harness Schematic - Deutz TD2.9L M195628AA SJ82 T, SJ86 T 229040ABA...
Page 106: Engine Electrical Schematic - Deutz Tcd2.2
VALVE RECIRCULATION SENSOR CAMSHAFT CRANKSHAFT SENSOR SENSOR (BEFORE CAT) (AFTER CAT) VALVE (EGR) START STARTER RELAY STARTER SOLENOID TO S1 BATTERY TO BATTERY DISCONNECT SW. B- POST 3.51 Engine Electrical Schematic - Deutz TCD2.2 M224629AD-2 SJ82 T, SJ86 T 229040ABA...
Page 107: Engine Interface Harness Schematic - Deutz Tcd2.2
AMBIENT TEMP . TO CTRL PNL TO WATER SENSOR TO CTRL PNL TO CTRL PNL TO ENGINE ENGINE DISPLAY UNIT - 12 PIN SENSOR TO ENGINE 3.52 Engine Interface Harness Schematic - Deutz TCD2.2 M224638AD-1 SJ82 T, SJ86 T 229040ABA...
Page 108: Section 4 - Troubleshooting Information
The content of this section is separated into “probable cause” and “remedy”. See the example below for clarification. 1. Probable cause Remedy SJ82 T, SJ86 T 229040ABA...
Page 109: Electrical System
CB2. 16. Circuit breaker CB2 tripped or defective. Reset breaker, check for defective wiring. Replace if defective. 17. Loose or broken wire #00 from circuit breaker Check continuity. Replace if defective. CB2 to battery negative. SJ82 T, SJ86 T 229040ABA...
Page 110: No Power
Replace if defective. 7. Loose or broken wire #10 from base terminal Check continuity. Replace if defective block to Ignition/E-pump (enable) switch S5. 8. Open or defective Ignition/E-pump (enable) Check switch. Replace if defective switch S5. SJ82 T, SJ86 T 229040ABA...
Page 111: Engine Will Not Crank
3. Loose or broken B+ wire from battery B+ to ECU Check continuity. Replace if defective. fuse connector P6 pin A. 4. ECU 30A fuse open or defective. Check for defective wiring. Replace if defective. Replace fuse. SJ82 T, SJ86 T 229040ABA...
Page 112 14. Defective contacts in relay 57BCR1. Check continuity between wires #54A and #57C when cranking. If no continuity, replace relay. 15. Loose or broken wire #57C from relay 57BCR1 to Check continuity. Replace if defective. X23 engine connector pin #4. SJ82 T, SJ86 T 229040ABA...
Page 113 Check relay. Replace if defective. 9. Loose or broken wire 57B from 57DCR pin 87 to Check continuity. Replace if defective. engine starter contactor coil. 10. Defective telematics module. Check telematics assembly; repair or replace as required. SJ82 T, SJ86 T 229040ABA...
Page 114: Engine Cranks But Will Not Start
2. Loose or broken wire #57A from relay 57ACR to Check continuity. Replace if defective. relay 57BCR. 3. Loose or broken wire #02 from base terminal Check continuity. Replace if defective. block to relay 57BCR. SJ82 T, SJ86 T 229040ABA...
Page 115: Glow Plug Circuit Inoperative - Deutz D2011 Diesel Engine
3. Loose or broken wire #11B from fuse holder Check continuity. Replace if defective. FU1 to relay 11CR. 4. Loose or broken wire #11C from relay 11CR to Check continuity. Replace if defective. glow plugs. SJ82 T, SJ86 T 229040ABA...
Page 116: All Base Control Console Inoperative
12. Missing or broken jumper JMPR3 on base Check for jumper. Replace if missing or broken. terminal block between wires #20 and #21. NOTE Jumper is removed if equipped with generator option. SJ82 T, SJ86 T 229040ABA...
Page 117: No Movement From Base Control Console
8. Loose or broken wire #02 from turret harness Check continuity. Replace if defective. plug to boom up valve 4H-14. 9. Defective boom up coil 4H-14. Check continuity and resistance through coil. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 118 8. Loose or broken wire #02 from turret harness Check continuity. Replace if defective. plug to turret rotate left valve 4H-32. 9. Defective turret rotate left valve coil 4H-32. Check continuity and resistance through coil. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 119 6. Loose or broken wire #02 from turret harness Check continuity. Replace if defective. plug to telescope retract valve 3H-38. 7. Defective telescope retract valve coil 3H-38. Check continuity and resistance through coil. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 120 9. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective. block to platform rotate left valve 4H-36. 10. Defective platform rotate left valve coil 4H-36. Check continuity and resistance through coil. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 121 6. Loose or broken wire #02 from turret harness Check continuity. Replace if defective plug to proportional flow enable valve 2H-42. 7. Defective proportional flow enable valve coil 2H- Check continuity and resistance through coil. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 122 7. Loose or broken wire #34 from plug A pin #16 to Check continuity. Replace if defective platform terminal block. 8. Loose or broken wire #34 from platform terminal Check continuity. Replace if defective block to jib down valve 4H-34. SJ82 T, SJ86 T 229040ABA...
Page 123 9. Loose or broken wire #41 in boom cable B or its Check for continuity between pins #11 on cable B. connectors. Check for loose or corroded connections on cable connectors. Replace if wire is defective. SJ82 T, SJ86 T 229040ABA...
Page 124: All Controls Inoperative From Platform Control Console
2. Loose or broken wire #4B from emergency stop Check continuity. Replace if defective. switch S4 to platform terminal block. 3. Loose or broken jumper wire #4B on Check continuity. Replace if defective. emergency stop switch S4. SJ82 T, SJ86 T 229040ABA...
Page 125 08CR1. 17. Loose or broken wire #20 from 08CR1 relay to Check continuity. Replace if defective. plug A pin #8 in platform control console. 18. Defective relay 08CR1. Check relay. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 126 5. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts. If no voltage present with #20B. foot on footswitch check section 5 for OCM pin voltage reference. SJ82 T, SJ86 T 229040ABA...
Page 127 8. Loose or broken wire #13 in boom cable A or its Check for continuity between pins #6 on cable A. connectors. Check for loose or corroded connections on cable connectors. Replace if wire is defective. SJ82 T, SJ86 T 229040ABA...
Page 128 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective. block to joystick controller A1. 2. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective. block to joystick controller A1. SJ82 T, SJ86 T 229040ABA...
Page 129 6. Voltage out of range at valve driver pin #32. Check voltage while operating telescope in. Voltage should be between 4.75 and 5.25 volts. Refer to telescope voltage reference table in section 5 if out of this range. SJ82 T, SJ86 T 229040ABA...
Page 130 7. Voltage out of range at valve driver pin #32. Check voltage while operating telescope out. Voltage should be between 2.25 and 2.75 volts. Refer to telescope voltage reference table in section 5 if out of this range. SJ82 T, SJ86 T 229040ABA...
Page 131 1. Defective platform rotate switch S20. Check continuity through switch while activating rotate left function between wires #08 and #36. 2. Loose or broken wire #36 from platform rotate Check continuity. Replace if defective. switch S20 to platform terminal block. SJ82 T, SJ86 T 229040ABA...
Page 132 6. Loose or broken wire #35 or #02 from platform Check continuity. Replace if defective. terminal block to jib up valve 4H-35. 7. Defective jib up valve coil 4H-35. Check continuity and resistance through coil. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 133: 10 Throttle Inoperative, Mid And High - Deutz D2.9L
Measure resistance (3.3KΩ) between 99A and 99B. terminal block. Check connections. Replace if defective. 7. Resistor R6 open or poor connection at base Measure resistance (3.9KΩ) between 99B and 90. terminal block. Check connections. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 134: 11 Mid Throttle Inoperative
Check continuity. Replace if defective. base terminal block. 15. Loose or broken wire #103 from base terminal Check continuity. Replace if defective. block to ECU connector pin #17. 16. Defective relay 79CR. Check relay. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 135: 12 High Throttle Inoperative
Check continuity. Replace if defective. base terminal block. 14. Loose or broken wire #103 from base terminal Check continuity. Replace if defective. block to ECU connector pin #17. 15. Defective relay 78CR. Check relay. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 136: 13 Brake Will Not Release
5 for OCM pin voltage reference. 4. Loose or broken wire #16 from valve driver pin Check continuity. Replace if defective. #34 to plug B pin #5 in platform control console. SJ82 T, SJ86 T 229040ABA...
Page 137 Check diode. Replace if defective. block. 3. Loose or broken wire #24 from platform terminal Check continuity. Replace if defective. block to relay 17ACR1. 4. Defective N/C contacts in relay 17ACR1. Check relay. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 138 9. Loose or broken wire #23A or #02 from turret Check continuity. Replace if defective. harness plug to right steer valve 4H-23A. 10. Defective left steer valve coil 4H-23A. Check continuity and resistance through coil. Re- place if defective. SJ82 T, SJ86 T 229040ABA...
Page 139: 15 No High Speed Drive
15. Loose or broken wire #45 in cable A or its Check for continuity between pins #20 on cable A. connectors. Check for loose or corroded connections on cable connectors. Replace if wire is defective. SJ82 T, SJ86 T 229040ABA...
Page 140: 16 No Elevated Drive
5. Loose or broken wire #28 from plug B pin #7 to Check continuity. Replace if defective. platform terminal block. 6. Loose or broken wire #28 from platform terminal Check continuity. Replace if defective. block to valve driver pin #18. SJ82 T, SJ86 T 229040ABA...
Page 141: 17 Direction Sensing Inoperative
17ACR1 and 17ACR2. 4. Defective relays 17ACR1 and 17ACR2. Check relay. Replace if defective. NOTE If only one relay is bad and one is OK, you will have steer in one direction only. SJ82 T, SJ86 T 229040ABA...
Page 142: 19 No Boom Down Or Extend Functions From Base Or Platform Consoles (Ansi)
6. Loose or broken wire #02 from turret harness Check continuity. Replace if defective. plug to boom down valve 4H-13A. 7. Defective boom down coil 4H-13A. Check continuity and resistance through coil. Re- place if defective SJ82 T, SJ86 T 229040ABA...
Page 143: 21 No Boom Extend Function From Base Or Platform Consoles (Ansi)
5. Loose or broken wire #02 from turret harness Check continuity. Replace if defective. plug to boom down valve 4H-13A. 6. Defective boom down coil 4H-13A. Check continuity and resistance through coil. Re- place if defective. SJ82 T, SJ86 T 229040ABA...
Page 144: 23 No Boom Extend Function From Base Or Platform Consoles (Ce, As)
5. Loose or broken wire #02 from turret harness Check continuity. Replace if defective. plug to boom down valve 4H-13A. 6. Defective boom down coil 4H-13A. Check continuity and resistance through coil. Re- place if defective. SJ82 T, SJ86 T 229040ABA...
Page 145: Hydraulic System
5. Stuck or defective counterbalance valve CB3. Clean valve. Check O-rings on valve. Repair or replace valve as required. 6. Defective lift cylinder C1. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. 4.3-4 No Main Boom Down SJ82 T, SJ86 T 229040ABA...
Page 146: No Turret Rotate
Clean valve. Check operation of valve. Repair or replace valve as required. 3. Stuck or defective shuttle valve SV1. Clean valve. Check O-rings on valve. Check opera- tion of valve. Repair or replace valve as required. SJ82 T, SJ86 T 229040ABA...
Page 147: No Boom Extend
8. Return valve V4 stuck in the closed position or is Clean valve. Check operation of valve. Repair or defective. replace valve as required. 9. Defective extension cylinder C2. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. 4.3-7 No Boom Retract SJ82 T, SJ86 T 229040ABA...
Page 148: No Jib Up
4. Stuck or defective counterbalance valve CB9. Clean valve. Check O-rings on valve. Repair or replace valve as required. 5. Defective jib cylinder C5. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. SJ82 T, SJ86 T 229040ABA...
Page 149: No Jib Down
Clean valve. Check O-rings on valve. Check opera- 2H-42. tion of valve. Repair or replace valve as required. 2. Stuck or defective check valve CV9. Clean valve. Check O-rings on valve. Check opera- tion of valve. Repair or replace valve as required. SJ82 T, SJ86 T 229040ABA...
Page 150: 11 Platform Will Not Level
7. Plugged orifice OR2. Check orifice. Clean if plugged or replace if defec- tive. 8. Defective leveling cylinder C3 or slave cylinder Check seals on cylinder. Replace as necessary. Replace cylinder if defective. Level Up SJ82 T, SJ86 T 229040ABA...
Page 151: 12 Brake Will Not Release
1. Brake return spring or defective cylinder. Check cylinder. Repair or replace as necessary. 2. Brake valve 3H-26 stuck in shifted position. Check valve. Replace if defective. 3. Brake in axle out of adjustment. See section 5 for brake adjustment procedure. SJ82 T, SJ86 T 229040ABA...
Page 152: 14 No Drive
1. Stuck or defective 2 speed valve 3H-45. Clean valve. Check O-rings on valve. Check opera- tion of valve. Repair or replace valve as required. 2. Defective shift spool in drive motor M1. Check motor. Repair or replace if necessary. SJ82 T, SJ86 T 229040ABA...
Page 153: 17 No Steer
Axle is in constant float if boom is fully retracted and is below 15 degrees of elevation. 1. Axle lockout valve 3H-65 is stuck in shifted Clean valve. Check O-rings on valve. Check opera- position or is defective. tion of valve. Repair or replace valve as required. SJ82 T, SJ86 T 229040ABA...
Page 154 Check seals on cylinder. Replace as necessary. Replace cylinder if defective. 3. Counterbalance valves (CB12 or CB13) out of Clean valve. Check O-rings on valve. Repair or adjustment or are defective. replace valve as required. SJ82 T, SJ86 T 229040ABA...
Page 155: Load Sensing System - Ce
500 lbs (227 kg) = 15.9 - 16.4 mV (0.0159 V - 0.0164 V) 748 lbs (339 kg) = 19.6 - 20.1 mV (0.0196 V - 0.0201 V) Voltage across 162 resistor should match voltage across 161. SJ82 T, SJ86 T 229040ABA...
Page 156: Load Sense/Dual Load Zone Module Error
Module Amber and Green diagnostic LEDs on the module flash alternately ▪ To reset the module hold the actuator button down for 5 seconds, or shut the MEWP platform power off using the ignition switch or e-stop.. SJ82 T, SJ86 T 229040ABA...
Page 157: No Light/Alarm When Platform Is Overloaded
Check continuity. Replace if defective. to alarm BP3 4. Loose or broken wire #2 from alarm BP3 to Check continuity. Replace if defective. platform terminal block. 5. Defective relay 162ACR1. Check relay. Replace if defective. SJ82 T, SJ86 T 229040ABA...
Page 158: Section 5 - Procedures
Refer to Figure 01 and 5.1-2 How to Install the Boom Maintenance Support. Contact Skyjack Parts to order a maintenance support. WARNING Remove all material and personnel from the platform while using the maintenance support(s).
Page 159: How To Install The Boom Maintenance Support
2. Open the engine side cowling. Remove and set aside the fixed cowling from the engine side of the boom. There are six sets of hardware to remove - one outside the cowling and five inside the cowling. SJ82 T, SJ86 T 229040ABA...
Page 160 The bottom of the turret. cylinder should stop just above the support. 7. Push the lock-pin through the hole in the maintenance support. Make sure the detent ball comes all the way out the other side. SJ82 T, SJ86 T 229040ABA...
Page 161: Platform
1.2-2 <UP> selects the next item in the current menu’s list. 1.3-1 <SAVE> saves the new data to EEPROM (permanent SAVE memory storage). ---- Simultaneously pressing <UP> and <DOWN> resets the HMI to menu screen 0. SJ82 T, SJ86 T 229040ABA...
Page 162: Scm Character Functions Charts
FLY IN Fn04A Boom Telescope Retract FLY OUT Fn04B Boom Telescope Extend PROP FLOW Fn05A Jib and Platform Rotate PROP FLOW Fn05B Unused Channel LR REV Fn06A Virtual Channel LR FEW Fn06B Virtual Channel 1369AA SJ82 T, SJ86 T 229040ABA...
Page 163: Scm Operating Values Chart
0 or 1 Load Sense Valve Enable DOUT 3 0 or 1 Footswitch Actuated Indicator DOUT 4 0 or 1 Holding Brake OFF (energize to release) DOUT 5 0 or 1 Manual Platform Level Enable 1371AA SJ82 T, SJ86 T 229040ABA...
Page 164: How To Select Scm Functionality
EXIT + (FLASHING)   RESTORE DEFAULTS SELECT MULTIFNCT SELECT MULTIFNCT MENU (FLASHING) PRESS SELECT STD LTD – SELECT (FLASHING) (FLASHING) SAVE NOTE EXIT USE THE CHART TO THE STD Machines for the North American market (ANSI/CSA models) LEFT TO DETERMINE THE LTD Machines for the European market (CE models) FUNCTIONALITY REQUIRED FOR YOUR MACHINE. PRESS SAVE/EXIT WHEN THE FUNCTIONALITY FOR YOUR MACHINE Recycle power to the OCM with E‐Stop to re‐enable password protection. CONFIGURATION IS If the OCM is inactive for more than 5 minutes, password must be re‐entered. FLASHING. SJ82 T, SJ86 T 229040ABA...
Page 165: How To View Scm Operation
DISPLAYED DISPLAYED DISPLAYED ┼ ┼ MENU ▬▬▬▬ SELECT MENU 8V SENSOR SUPPLY VDD POWER SUPPLY ▬▬▬▬ VALUE = VOLTS VALUE = VOLTAGE SELECT 5.2-4 SCM Operating Values Chart for operating values for the previous observations SJ82 T, SJ86 T 229040ABA...
Page 166: How To Unlock And Modify Scm Settings
+ (LR FWD) THRESH Fn06B VALUE= % ( FLASHING ) Recycle power to the SCM with the E-Stop to re-enable password protection. If the SCM is inactive for more than 5 minutes, password must be re-entered. SJ82 T, SJ86 T 229040ABA...
Page 167: Scm Pin Voltage Reference
Pin 9 - Telescope in selected. Proportional output on wire 38 to telescope in valve 3H-38. 0 volts to 4.65 volts depending on boom speed control potentiometer. Threshold= .95 volts. Test between pin 9 and 02 wire while operating telescope in. SJ82 T, SJ86 T 229040ABA...
Page 168 Pin 22 - Boom up selected. Proportional output on wire 14 to boom up valve 4H-14. 0 volts to 6.3 volts depending on joystick position. Threshold= 1.5 volts. Test between pin 22 and 02 wire while operating boom up. SJ82 T, SJ86 T 229040ABA...
Page 169 Pin 35 - Turret rotate right selected. Proportional output on wire 33 to turret rotate right valve 4H-33. 0 volts to 5 volts depending on position of joystick. Threshold= .5 volts. Test between pin 10 and 02 wire while operating turret rotate right. SJ82 T, SJ86 T 229040ABA...
Page 170: Fly Boom Switch Voltage References
>> 7.25V 4.83V P1-32 FLY TOGGLE SWITCH TELESCOPE OUT 250 OHMS 250 OHMS 250 OHMS 250 OHMS TELESCOPE IN WIRE WIRE#38A > >> 7.25V FLY TOGGLE SWITCH 2.41V P1-32 TELESCOPE OUT 250 OHMS 250 OHMS SJ82 T, SJ86 T 229040ABA...
Page 171: 10 Platform Controller Voltage References
Neutral Position = 4.2 - 4.8 Volts 12 Volts 12 Volts Forward = 4.9 - 8.5 Volts @ full stroke Right Steer Left Steer Reverse = 4.1 - 0.5 Volts @ full stroke Selected Selected SJ82 T, SJ86 T 229040ABA...
Page 172: Load Sensing System
Shut the MEWP off using either the ignition switch or the e-stop. Restart the engine. ▪ If the platform load sensing system remains in fault mode, the emergency power unit may be used to lower the platform from the base controls. Contact a qualified/competent person for repairs. SJ82 T, SJ86 T 229040ABA...
Page 173: Dual Capacity Overload Module Function Table
Section 5 – Procedures Load Sensing System 5.3-2 Dual Capacity Overload Module Function Table SJ82 T, SJ86 T 229040ABA...
Page 174: Calibration Of Load Sensing System
5. Make sure the platform is unloaded and is free from any surface contact. Remove all options from the platform. 6. Open the base control box door, and locate the dual capacity module on the inside right wall of the control box. SJ82 T, SJ86 T 229040ABA...
Page 175 14. The Green LED will become solid, which is normal operating mode. Model Trip Point 1 Trip Point 2 244 kg 244 kg + 94 kg = 339 kg SJ86 T (538 lbs) (538 lbs + 210 lbs = 748 lbs) SJ82 T, SJ86 T 229040ABA...
Page 176: Boom
NOTE Always maintain squareness between the boom’s outer and inner tubes. 2. Set the torque wrench to 35 ft-Iband tighten mounting bolts with the same sequence. 3. Torque the center bolt to 480 ft-lb. SJ82 T, SJ86 T 229040ABA...
Page 177: Boom Section Wear Pad Replacement
Before beginning, place the machine in the ▪ proper shut down position, parked on level ground. Make sure the e-stops are pushed in and the key ▪ is off. Turn the main power disconnect switch off. Lock ▪ out the switch. SJ82 T, SJ86 T 229040ABA...
Page 178: Platform And Jib Boom Removal
4. Remove tie wraps and make note of wire labels for reinstallation. 5. To release each wire, insert a small flat screwdriver into the slot beside it in the terminal strip. M62067AA M62321AA SJ82 T, SJ86 T 229040ABA...
Page 179 M62018AA 10. Using suitably rating lifting equipment and safe rigging practices, connect lifting slings to the jib boom and platform. Tension the slings enough to lightly take the weight off the mounting bracket pins. SJ82 T, SJ86 T 229040ABA...
Page 180: Platform Removal (No Jib Boom)
Place it close enough M62023AA to the end of the main boom so the control cables can be reconnected in the event boom repositioning is required. 1. Disconnect the two 24-pin control cables from the control box. M62022AA SJ82 T, SJ86 T 229040ABA...
Page 181 Set it down on suitable blocking nearby. Place it close enough to the end of the main boom so the control cables can be reconnected in the event boom repositioning is required. SJ82 T, SJ86 T 229040ABA...
Page 182: Operating Machine Functions From Base Controls
Shut down the machine. ▪ Turn the main electrical disconnect switch off. ▪ Lock out the switch. Connect the jib and platform rotate harness as shown on the Platform Controls Wiring diagrams in Section SJ82 T, SJ86 T 229040ABA...
Page 183: Fly Boom Section Removal
6. Slide the fly boom completely out of the mid boom and set it down on suitable blocking. 7. Replace the wear pads on the counterweight end of the fly boom. Use Loctite 242 or 243 on the wear pad fasteners. M62255AA M62257AA SJ82 T, SJ86 T 229040ABA...
Page 184: 10 Mid Boom Section Removal
4. Place a suitable stand that can bear the weight of the mid boom about 2/3 the boom length ahead of the machine. 5. Connect lifting slings to the platform end of the mid boom. SJ82 T, SJ86 T 229040ABA...
Page 185: 11 Mid Boom Section Installation
6. Install the main power track carrier bolt. Remove the blocking and strap supporting the cable/ hose tube. M62263AA M62258AA 7. Remove the tape from the limit switch hole on the left-hand side of the main boom. M62200AA SJ82 T, SJ86 T 229040ABA...
Page 186: 12 Fly Boom Section Installation
Apply Loctite 242 or 243 to the wear pad fasteners. 6. Install the fasteners for cable/hose tube support M62020AA in the fly boom. Connect the platform level hydraulic hoses. 3. Connect the hydraulic hoses for the jib cylinder. M62250AA M62253AA SJ82 T, SJ86 T 229040ABA...
Page 187: 14 Platform Installation (No Jib Boom)
Connect the platform control console. Refer to the Platform Controls Wiring diagrams in Section 3. CAUTION Risk of personal injury or equipment damage. Test equipment operation before putting machine into service. See Function Tests in the Operating Manual. SJ82 T, SJ86 T 229040ABA...
Page 188: 15 Platform Control Console Connection
3. Tighten the strain relief connector locknut to secure it. M62022AA 4. Note the color and markings for each wire. Connect the wires as shown on the wiring diagram. 5. Tie-wrap the harnesses inside the control box as before. SJ82 T, SJ86 T 229040ABA...
Page 189: 16 Extension Cylinder And Wire Rope Replacement
Remove the jam nut, then use the flat on the end of wire rope anchor to hold it while backing off the main nut. Leave the main nut on the wire rope anchor about one full nut thread. M62265AA SJ82 T, SJ86 T 229040ABA...
Page 190 Remove the washers and spacers, then put the hex nut back 9. Remove the hex nuts from all 4 wire rope on one full nut thread to temporarily hold the anchors. wire rope in place. SJ82 T, SJ86 T 229040ABA...
Page 191 Connect lifting straps at both ends of the extension cylinder. 17. Continue to slide the cylinder completely out of the boom. Balance the load as it is being removed. 18. Lower the cylinder onto suitable supports. M62271AA SJ82 T, SJ86 T 229040ABA...
Page 192: 18 Extension Cylinder And Wire Rope Assembly Installation
5. Carefully feed the wire ropes in as the cylinder is being pushed in. 6. Slide the cylinder 2/3 of the way in until the wire rope terminal plate has passed where the mid boom pulleys mount. M62275AA Wire Rope Terminal Plate SJ82 T, SJ86 T 229040ABA...
Page 193 12. Install the extension cylinder base-end pin. into the anchor points. Install one hex nut on Install the keeper pin to secure it. each anchor to secure it. 13. Install the extension cylinder hydraulic hoses. M62279AA Counterweight-end Wire Ropes SJ82 T, SJ86 T 229040ABA...
Page 194: 19 Proper Wire Rope Tension
See the Function Tests in the Operating Manual. M62280AA 15. Tighten all wire rope ends at the anchors until they are tensioned correctly. See 5.4-19 Proper Wire Rope Tension. 16. Install the boom end cover. SJ82 T, SJ86 T 229040ABA...
Page 195: 20 Wire Rope Inspection
(necking), Sheave Pins Inspection or any change from its normal appearance, must be Check for loose or missing sheave (pulley) pins. replaced. SJ82 T, SJ86 T 229040ABA...
Page 196: 21 Limit Switch Checking And Adjusting
5.4-21 Limit Switch Checking and Tools required: Adjusting Calibrated digital protractor (to measure boom ▪ angles) There are six limit switches on the SJ82 T and SJ86 T machines. Use the following procedures to check and Multi-meter with continuity setting ▪ adjust them. Level ▪...
Page 197: 22 Directional Sensing Limit Switch (Ls1)
Verify the machine operates as the controls indicate using the platform controls. Check that forward–reverse controls and left– right steering operate as indicated. 2. Locate the terminal strip inside the base control panel. Set the multi-meter to continuity-check mode. SJ82 T, SJ86 T 229040ABA...
Page 198: 23 High Speed Drive / Tilt Override Limit Switch (Ls2)
6 seconds or when the footswitch is released. 6. Verify the circuit is now closed with the multi- meter. Continuity is indicated when the turret is rotated past 90°. Check both clockwise and counterclockwise directions. M62366AA Limit switch arm and roller SJ82 T, SJ86 T 229040ABA...
Page 199 (continuity). Adjust the switch position if required. 7. Raise the boom to horizontal. Verify the switch roller now contacts the cam and the switch circuit is open (no continuity). SJ82 T, SJ86 T 229040ABA...
Page 200: 24 Fly-In Limit Switch (Ls3)
M62364AA slotted hole in the mid boom. Limit switch arm and roller 9. Perform a test drive to verify the machine drive speed is slowed with the boom extended. SJ82 T, SJ86 T 229040ABA...
Page 201: 25 Boom Angle (Dual Load) Limit Switch (Ls4)
(2) to further lift or extend the boom from the 750 lb (340 kg) zone into the 500 lb (227 kg) zone. M62366AA Limit switch arm and roller M62356AA Platform capacity selector switch SJ82 T, SJ86 T 229040ABA...
Page 202 (as equipped): Automatic platform Wire 121 Black/White load sensing and 09 Black (CE machines) Standard load sensing Wire 121 Black/White (ANSI machines) and 09B Black Black Black Black/White (CE) (ANSI) M62360AA LS4 terminal connections SJ82 T, SJ86 T 229040ABA...
Page 203: 26 Boom Extension (Dual Load) Limit Switch (Ls5)
(CE machines), an overload state is detected automatically when the switch trips. The system then does not allow the boom to extend into the 500 lb (227 kg) zone (1). M62354AA LS5 location on main boom M62357AA Automatic platform load sensing SJ82 T, SJ86 T 229040ABA...
Page 204 8. Extend the boom again and observe the multi- meter as the boom extends. It should change from showing continuity back to no continuity when the roller arm contacts the ramp. SJ82 T, SJ86 T 229040ABA...
Page 205: 27 Lift Cushion Limit Switch (Ls6)
2. Place a digital protractor on a clean surface on the underside of the main boom. Calibrate it to 0° (horizontal). 3. Locate the terminal strip inside the base control panel. Set the multi-meter to continuity-check mode. SJ82 T, SJ86 T 229040ABA...
Page 206 5. Test the switch function by raising and lowering the boom. 6. Adjust the switch position as required so that it trips at 57° and boom movement slows as it approaches full extension. 7. Check repeatability by raising and lowering the boom. SJ82 T, SJ86 T 229040ABA...
Page 207: Turret
7. Tighten the mounting fasteners on the swing pressure filter housing. drive. 8. Reinstall the housing, screwing it in fully, then 8. Rotate the turret 360° and check for a smooth backing it off by one quarter turn. rotation of the turret. SJ82 T, SJ86 T 229040ABA...
Page 208: Check The Swing Drive Oil
5. Reinstall the drain plug. 6. Refill the swing drive with approximately 32 oz (1 L) of oil (refer to 2.10 Hydraulic Specifications & Gear Oil for recommended oil types). 7. Reinstall the plug at the fill port. SJ82 T, SJ86 T 229040ABA...
Page 209: Battery Replacement
8. Clean the terminal posts and clamps of the batteries, and apply acid-free and acid-resistant grease. 9. Re-connect the batteries with the positive and negative connector cables (ensure the clamps make good contact). SJ82 T, SJ86 T 229040ABA...
Page 210: Electronic Tilt Switch Setup Procedure
10. Turn the main power disconnect switch to the off position position 6. Turn te base/off/platform key switch to the base 11. Push in the emergency stop buttons position 12. Proceed to Verify Tilt Circuit. SJ82 T, SJ86 T 229040ABA...
Page 211 OFF. 6. Turn the main power disconnect switch to the off position 7. Push in the emergency stop buttons b. Both LEDs will flash. Red LED 8. Proceed to Verify Tilt Circuit. Green LED SJ82 T, SJ86 T 229040ABA...
Page 212: Check Rotation Bearing For Axial Wear
This reading is the total amount of axial movement in the bearing assembly. If this reading is 0.100” (2.54 mm) or greater, the rotation bearing should be removed and replaced. SJ82 T, SJ86 T 229040ABA...
Page 213: Resetting The Emergency Lowering Counter (Ce Only)
To reset the counter: COUNTER 1. Locate the terminal block with the integrated fuse holder inside the base control box. 2. Using any standard automotive fuse, insert it into the slot in the terminal block. SJ82 T, SJ86 T 229040ABA...
Page 214: Deutz Diesel Engines
17. Check for oil leakage. turret. 18. Check the engine oil level on the dipstick and add oil if needed. 3. Swing the engine tray away from the turret. 4. Place a suitable container under the engine oil drain. SJ82 T, SJ86 T 229040ABA...
Page 215: Replace The Fuel Filter
2. Remove the filter from inside of the canister. 3. Clean the inside of the canister and gasket with a dry cloth. 4. Insert a new filter into the canister. 5. Reinstall the end cap. SJ82 T, SJ86 T 229040ABA...
Page 216: Deutz Td2.9L Fault Codes
Burner dosing valve (DV2); Short circuit high side powerstage. 523912 7-2-2 Burner dosing valve (DV2) downstream pressure sensor; plausibility error. Physical range check high for burner dosing valve (DV2) downstream 523912 7-2-2 pressure; Shut off regeneration. 1513AA-1 SJ82 T, SJ86 T 229040ABA...
Page 217 Sensor error coolant temperature; Signal range check low. 2-3-2 High coolant temperature; Warning threshold exceeded. 2-3-2 Coolant temperature; System reaction initiated. 2-3-5 Coolant level too low. 3-2-5 Plausibility check for clutch. 1109 3-4-1 Engine shut off demand ignored. 1513AA-2 SJ82 T, SJ86 T 229040ABA...
Page 218 523793 6-7-8 Timeout error of CAN-Receive-Frame UAA10. AGS sensor service message. 523794 6-7-8 Timeout error of CAN-Receive-Frame UAA11. AGS sensor data. 523803 6-7-8 Timeout error of CAN-Receive-Message RxEngPres. Status Burner Air Pump. 1513AA-3 SJ82 T, SJ86 T 229040ABA...
Page 219 Sensor error ambient air pressure. Signal range check high. 2-9-2 Sensor error ambient air pressure. Signal range check low. Environment temperature sensor, temperature above upper physical thresh- 3-1-2 old. 3-1-2 Environment temperature physical range check low. 1513AA-4 SJ82 T, SJ86 T 229040ABA...
Page 220 HCI dosing valve (DV1): Short circuit to battery. 523915 1-6-4 Short circuit to battery high side, HCI dosing valve (DV1). 523915 1-5-9 HCI dosing valve (DV1): Short circuit to ground. 523915 1-6-4 HCI dosing valve (DV1): Short circuit high side powerstage. 1513AA-5 SJ82 T, SJ86 T 229040ABA...
Page 221 Injector 6 (in firing order): Interruption of electric connection. 523756 1-5-5 Special pattern for special cases. No detailed information! 523757 1-5-6 Special pattern for special cases. No detailed information! 523758 1-6-1 Special pattern for special cases. No detailed information! 1513AA-6 SJ82 T, SJ86 T 229040ABA...
Page 222 ECU reported internal software error. 523612 ECU reported internal software error. 523612 Injection system,electrical error injectors. 523612 ECU reported internal software error. 523612 ECU reported internal software error. 523612 ECU reported internal software error. 1513AA-7 SJ82 T, SJ86 T 229040ABA...
Page 223 Diagnostic fault check to report ABE active due to undervoltage detection. 523612 5-5-5 Diagnostic fault check to report ABE active due to overvoltage detection. 523612 5-5-5 Diagnostic fault check to report WDA/ABE active due to unknown reason. 1513AA-8 SJ82 T, SJ86 T 229040ABA...
Page 224 Pressure downstream charge air cooler, short circuit to ground. 523699 1-1-3 Boost pressure control; negative governor deviation below limit. 523699 1-1-3 Learning value too high. No detailed information! Over temperature of device driver of pressure control valve. No detailed 523889 1-1-3 information! 1513AA-9 SJ82 T, SJ86 T 229040ABA...
Page 225 Pressure sensor upstream turbine, Physical Range Check low. 1176 1-4-1 Pressure sensor upstream turbine, signal range check (SRC) high. 1176 1-4-1 Pressure sensor upstream turbine, signal range check (SRC) low. 523613 1-3-4 Rail pressure metering unit, Positive governor deviation. 1513AA-10 SJ82 T, SJ86 T 229040ABA...
Page 226 Sensor SCR catalyst upstream temperature too high; plausibility error. 3361 8-8-6 DEF dosing valve blocked (SCR). 523720 1-4-8 DEF supply module heater temperature; plausibility error (normal condition). Sensor DEF supply module heater temperature; plausibility error (cold start 523720 1-4-8 condition). 1513AA-11 SJ82 T, SJ86 T 229040ABA...
Page 227 Starter relay powerstage over temperature. 5-1-2 Starter relay low side short circuit to battery. 5-1-2 Starter relay low side short circuit to ground. 523922 7-1-5 Burner shut of valve; short circuit to battery. 5-1-3 SVS lamp; open load. 1513AA-12 SJ82 T, SJ86 T 229040ABA...
Page 228 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); signal range 1015 520521 5-9-4 check low. Actuator position for EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8) not 1016 5-9-4 plausible. Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); signal range 1022 5-9-4 check high 1513AA-13 SJ82 T, SJ86 T 229040ABA...
Page 229 523980 7-8-4 Bad quality of reduction agent detected. 1193 1180 5-5-6 Physical range check high for exhaust gas temperature upstream turbine. 1194 1180 5-5-6 Physical range check low for exhaust gas temperature upstream turbine. 1513AA-14 SJ82 T, SJ86 T 229040ABA...
Page 230 Burner Control; Shut-off Valve - Blocked closed Burner Shut Off Valve; 1262 523922 8-5-4 blocked closed. Burner Control; Fuel line ShutOff downstream - broken Burner fuel line pipe 1263 524021 8-6-4 leak behind Shut Off Valve. 1513AA-15 SJ82 T, SJ86 T 229040ABA...
Page 231 Timeout of Short-Circuit Ground Diagnosis Cyl. Bank 1;_ 1338 2798 5-6-6 IVDiaShCirGndToutBnk_1. 1339 2797 5-6-5 Injector diagnostic; Short circuit to ground cylinder bank 0. 1340 2798 5-6-6 Injector diagnostic; Short circuit to ground cylinder bank 1. 1513AA-16 SJ82 T, SJ86 T 229040ABA...
Page 232 Timeout Error of CAN-Receive-Frame ComEGRActr - exhaust gas 1432 524029 8-1-5 recirculation positioner. 1436 524034 8-1-6 Disc separator; open load. 1437 524034 8-1-6 Disc separator; powerstage over temperature. 1438 524034 8-1-6 Disc separator; short circuit to battery. 1513AA-17 SJ82 T, SJ86 T 229040ABA...
Page 233 Timeout error of CAN-Transmit-Frame ComETVActrTO. 1671 524112 9-3-6 Timeout ComIntake Throttle Valve Actr. 1672 524118 9-4-2 Timeout error of CAN-Receive-Frame ComRxCM1. 1675 524103 9-2-7 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp. 1676 524104 9-2-8 Timeout error of CAN-Receive-Frame ComRxDPFCtl. 1513AA-18 SJ82 T, SJ86 T 229040ABA...
Page 234 EGR Actuator, internal electrical fault. 1756 2791 4-1-5 EGR actuator, learning process aborted. 1757 2791 4-1-5 EGR actuator current is above maximum threshold. 1758 2791 4-1-5 EGR actuator supply voltage is above the maximum threshold. 1513AA-19 SJ82 T, SJ86 T 229040ABA...
Page 235 1188 8-1-4 Turbocharger wastegate, temperature critical high. 1827 524141 1-9-2 DEF dosing valve, dosing valve blocked. 1857 523612 5-5-5 Engine starter, plausibility error of starter release condition. 1858 524147 9-6-6 SCR-System, reverting valve blocked. 1513AA-20 SJ82 T, SJ86 T 229040ABA...
Page 236: Diesel Particulate Filter (Dpf) And Standstill Regeneration - Deutz Tcd2.2 Engine
Deutz engine l l b b k k g g display module (found below the engine control console) and identified by the flashing standstill lights on the base and platform controls. REGENERATION NEEDED REGENERATION REGENERATION COMPLETE SJ82 T, SJ86 T 229040ABA...
Page 237 Use of the derate override switch can cause diesel speed can change. particulate filter failure. 6. Standstill regeneration takes approximately 45 minutes. During this time you must not use the MEWP . SJ82 T, SJ86 T 229040ABA...
Page 238: Hydraulic Tank
Dirt and/or moisture cotamination will dictate that the oil should be changed more often. Under normal use and operating conditions, the hydraulic oil should be changed every two years. SJ82 T, SJ86 T 229040ABA...
Page 239: Manifolds And Hydraulic Pumps
2. Remove the wiring from two valves: axle lockout valve wires 65 and 02, and two speed valve wires 45 and 02. Mark the valves to ensure you put the wiring back in the correct positions later. SJ82 T, SJ86 T 229040ABA...
Page 240: Hydraulic Standby Pressure Adjustment
3. Start the ngine from the base control console and let it run for 2-5 minutes. 4. Check the reading on the gauge (standard pressure should be 330 psi) and follow the next steps for adjusting pressure if needed. SJ82 T, SJ86 T 229040ABA...
Page 241: Hydraulic High Pressure Adjustment
2-5 minutes. 4. Without driving, steer fully to one direction and then check the reading on the gauge. Standard pressure should be 3050 psi. Follow the next steps for adjusting the pressure, if needed. SJ82 T, SJ86 T 229040ABA...
Page 242: Hydraulic System Relief Valve Adjustment
2-5 minutes. 4. Steer fully to one direction and then check the reading on the gauge. Standard pressure should be 3250 psi. Follow the next steps for adjusting pressure if needed. SJ82 T, SJ86 T 229040ABA...
Page 243: Turret Rotate Relief Valve Adjustment
RV2 once 1250 psi is observed on the level to activate a pressure reading on the gauge. You must activate the turret rotate to gauge. obtain a pressure reading on the gauge. 10. Disengage the turret transport lock. SJ82 T, SJ86 T 229040ABA...
Page 244: Fly Boom Relief Valve Adjustment
RV4 once 1500 psi is observed on the gauge. relief valve is replaced. You must fully extend the boom to activate a 7. If the pressure is still not in range, repair or pressure reading on the gauge. replace the pump as necessary. SJ82 T, SJ86 T 229040ABA...
Page 245: Test Forward Drive Pressure On Drive Pump
6. Replace the pump if the pressure is not achieved. achieved. 8. Turn the engine off. 7. Turn the engine off. 9. Remove the pressure gauge from the port, cap the port, and re-plug the brake solenoid power cable. SJ82 T, SJ86 T 229040ABA...
Page 246: Axles
The axle is full when oil is leaking from the check port. 6. Refill the axle with new oil as per specifications Refer to 2.10 Hydraulic Specifications & Gear Oil Drain Fill 7. Reinstall both of the fill and check plugs. SJ82 T, SJ86 T 229040ABA...
Page 247: Check The Oil Level In The Axle Gearbox
The gearbox is full when oil is leaking from the check port. 5. Refill the gearbox with new oil as per specifications. Refer to 2.10 Hydraulic Specifications & Gear Oil. 6. Reinstall the fill plug. SJ82 T, SJ86 T 229040ABA...
Page 248: Brake Inspection
4.5 mm (front) or 5.2 mm (rear) between the disks of either arm (i.e. the gauge doesn’t fit), the brake disks must be replaced on both arms. 5. Repeat the procedure on the opposite axle. SJ82 T, SJ86 T 229040ABA...
Page 249: Oscillating Cylinder Replacement
Slowly loosen the oscillating axle cylinder hoses to release the pressure, then disconnect them fully, being sure to plug the hose ends. SJ82 T, SJ86 T 229040ABA...
Page 250: Bleed The Oscillating Axle Cylinders
2. Connect a hose to the bleeder nipple. 3. Start the engine and slowly open the bleeder to allow the oil to flow in a continuous stream. 4. Close the bleeder. 5. Repeat the procedure with the other oscillating axle cylinder. SJ82 T, SJ86 T 229040ABA...
Page 251: 10 Test The Oscillating Axle Cylinders
Result: An appropriate tilt of the MEWP ▪ chassis should occur. 3. Retract the fly boom while in tilt position. Result: The steer axles should unlock and ▪ the MEWP chassis should level itself to the ground. SJ82 T, SJ86 T 229040ABA...
Page 252: Grease Points
3. Rotate the turret in increments of 4 to 5 inches (10 to 13 cm) at a time, and repeat step 2 until the entire bearing has been greased. 5.10-2 Grease the Turret Swing Drive 1. Apply open gear lube to each tooth of the swing drive gear, located under the turret. SJ82 T, SJ86 T 229040ABA...
Page 253: Grease The Axles
1. Open the axle cover plates and locate the grease fittings. 2. Pump grease into the grease fittings. 5.10-4 Grease the Drive Shaft 1. Locate the grease fittings on the drive shaft u-joints, and pump grease into the fittings. SJ82 T, SJ86 T 229040ABA...
Page 254 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.

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Skyjack SJ82 T Service Manual

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