Skyjack SJ85 AJ Service Manual
  1. Manuals
  2. Brands
  3. Skyjack Manuals
  4. Boom Lifts
  5. SJ85 AJ
  6. Service manual
Skyjack SJ85 AJ Service Manual

Skyjack SJ85 AJ Service Manual

Articulating boom
Hide thumbs Also See for SJ85 AJ:
Table of Contents

Advertisement

Quick Links

Download this manual
SERVICE
MANUAL
SJ85 AJ
ARTICULATING BOOM
229044ADA
August 2020
ANSI/CSA, CE, AS

Advertisement

Table of Contents
loading

Related Manuals for Skyjack SJ85 AJ

Summary of Contents for Skyjack SJ85 AJ

  • Page 1 SERVICE MANUAL SJ85 AJ ARTICULATING BOOM 229044ADA 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: SJ85 AJ: A303 000 001 - A303 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 . SJ85 AJ 229044ADA...

  • Page 5: Table Of Contents

    Torque Specifications for Fasteners (Metric) ..........34 SJ85 AJ...
  • Page 6 Platform Controls Wiring - Deutz TD2.9L, Deutz D2011, Kubota, Perkins ..... 82 3.28 Platform Controls - Harness View - Deutz TD2.9L, Deutz D2011, Kubota, Perkins ....83 229044ADA SJ85 AJ...
  • Page 7 No Riser Up or Down ............132 SJ85 AJ...
  • Page 8 Replace Engine Oil and Filter ........... . 169 229044ADA SJ85 AJ...
  • Page 9 5.10-4 Grease the Drive Shaft ............209 SJ85 AJ...

  • Page 10: Section 1 - Scheduled Maintenance

    3000 hours, whichever occurs first. Any defective specifications and dimensions are subject to change part will be replaced or repaired by your local Skyjack without notice. dealer at no charge for parts or labor. In addition, all products have a 5 year structural warranty.

  • Page 11: Maintenance And Service

    MEWP . Before attempting any repair work, disconnect the main power connectors. Consult SKYJACK’s Service Department for optional tires specifications and installation. Preventive maintenance is the easiest and least expensive type of maintenance.

  • Page 12: Hydraulic System & Component Maintenance And Repair

    The use of cloth to strain the oil should be avoided to prevent lint from getting into the system. 6. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also, plug the ports of the removed components. SJ85 AJ 229044ADA...

  • Page 13: 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 14: 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 SJ85 AJ 229044ADA...

  • Page 15: 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. 229044ADA SJ85 AJ...

  • Page 16: Pre-Delivery/Maintenance Inspection Checklist

    Comments: 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: SJ85 AJ 229044ADA...

  • Page 17: 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 ▪ 229044ADA SJ85 AJ...

  • Page 18: Engine Compartment

    ▪ 1. Do an inspection of the battery case for damage. procedure, refer to 5.5-4 Change the Swing Clean the battery terminals and cable ends Drive Oil. ▪ thoroughly with a terminal cleaning tool or wire brush. SJ85 AJ 229044ADA...
  • Page 19 Engine fuel leaks (B,C) Make sure that there no fuel leaks at the ▪ engine. Make sure there is no visible damage. ▪ 229044ADA SJ85 AJ...
  • Page 20 2.13 Specifications and Features - C - Annual Inspection Engines & Fluids. For the engine air filter replacement procedure, ▪ B - Frequent Inspection refer to the engine manual. For recommended oil change intervals, refer to ▪ the engine manual. SJ85 AJ 229044ADA...

  • Page 21: Control Compartment

    Add oil if it is necessary. Refer to tightened and there is no evidence of hydraulic 2.13 Specifications and Features - Engines & leakage. Fluids C - Annual Inspection For the hydraulic oil replacement procedure, ▪ refer to 5.7-2 Change the Hydraulic Oil. 229044ADA SJ85 AJ...
  • Page 22 Make sure that the fuel filler cap closes tightly. ▪ Make sure there is no visible damage to the ▪ tank, gauge, hoses, or fittings. Make sure there is no indication of fuel ▪ leakage from the tank, gauge, hoses, fittings, pump, and filter. SJ85 AJ 229044ADA...
  • Page 23 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. 229044ADA SJ85 AJ...
  • Page 24 Oscillating Cylinder Bolt Replacement. WARNING NOTE Do not use tires other than the tires that Skyjack The oscillating axle is locked when the MEWP is specifies for this MEWP . Do not mix different types in the elevated travel position or at the elevated of tires or use tires that are not in good condition.

  • Page 25: 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. 229044ADA SJ85 AJ...

  • Page 26: Boom Assembly

    All hoses are correctly tightened and there is ▪ deformation. no sign of hydraulic leakage. Cable Track There are no loose or missing parts, and there ▪ is no visible damage. SJ85 AJ 229044ADA...

  • Page 27: Optional Equipment/Attachments

    Welder The welder and the welder tray are correctly ▪ attached. There are no loose or missing parts, and there ▪ is no visible damage. There are no loose wires or missing fasteners. ▪ 229044ADA SJ85 AJ...

  • Page 28: Function Tests

    After repairs are completed, the operator must ▪ perform a pre-operation inspection and a series of function tests again before putting the MEWP into service. NOTE The all-function motion alarm should sound while operating any boom and drive function. SJ85 AJ 229044ADA...

  • Page 29: 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 SJ85 AJ 229044ADA...
  • Page 30 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 229044ADA SJ85 AJ...

  • Page 31: Torque Specifications For Fasteners (Us)

    1460 3160 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 SJ85 AJ 229044ADA...

  • Page 32: Torque Specifications For Fasteners (Metric)

    1468 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 229044ADA SJ85 AJ...

  • Page 33: Torque Specifications For Hydraulic Couplings & Hoses

    Min. Max. 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 SJ85 AJ 229044ADA...

  • Page 34: Axle Torque Specifications

    M22 x 1.5 581-642 637-704 822-908 903-998 998-1103 1078-1191 M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507 M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210 M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082 1373AA 229044ADA SJ85 AJ...

  • Page 35: Axle Maintenance Intervals

    Normal work monthly Grease Articulations MOLIKOTE Awkward work weekly 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 SJ85 AJ 229044ADA...

  • Page 36: Mewp Torque Specifications

    BOLT, Hex head (1"-8 x 10.5", Grade 8) Rotary Manifold BOLT, Hex head (1/2"-13 x 2", Grade 8) BOLT, Hex head patch (M16 x 1.5 x 4.5", Grade 8.8) Load Cell Mounting BOLT, Hex head (1/2"-13 x 2.5", Grade 8) 1711AA 229044ADA SJ85 AJ...

  • Page 37: 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. SJ85 AJ...

  • Page 38: Floor Loading Pressure

    Total Aerial Platform Load Gross Aerial Model Platform Weight Wheel 36,300 lb 16,535 lb 171 psi 355 psf SJ85 AJ ANSI/CSA 16 465 kg 7500 kg 1179 kPa 17 kPa SJ85 AJ CE 16 965 kg 7500 kg 1179 kPa 17.5 kPa...

  • Page 39: Specifications & Features - Dimensional Data

    Table 2.10 Specifications & Features - Dimensional Data SJ85 AJ Working Height - maximum 27.66 m 91' 9" Platform Height - maximum 25.83 m 84' 9" Horizontal Reach - maximum 17.22 m 56' 3" Horizontal Reach - at maximum height 7.62 m...

  • Page 40: Specifications And Features - Performance & Speeds

    Table 2.11 Specifications and Features - Performance & Speeds SJ85 AJ Gradeability - maximum Drive Speed - stowed / low torque 4.83 km/h 3.0 mph Drive Speed - stowed / high torque 1.93 km/h 1.2 mph Drive Speed - elevated / low torque 0.80 km/h...

  • Page 41: Hydraulic Specifications

    10 cm Lift Cylinder Stroke 84.06 in 213.5 cm Maximum Lift Pressure 4000 psi 276 bar Bore 3.06 in 7.8 cm Steering Cylinder Stroke 4.31 in 11 cm For other component specifications, refer to the hydraulic schematic. 1281AA SJ85 AJ 229044ADA...

  • Page 42: Specifications And Features - Engines & Fluids

    Table 2.13 Specifications and Features - Engines & Fluids SJ85 AJ RPM Settings 900 Low / 1600 / 2600 High Horsepower @ 2600 rpm (intermittent) 55.4 kW / 75 hp Fuel Type Diesel Fuel Tank Capacity 30 gal Standard Oil Factory Fill 0°F to 115°F (-18°C to 45°C)
  • Page 43 Table 2.13 Specifications and Features - Engines & Fluids SJ85 AJ RPM Settings 927 Low / 2600 High Horsepower @ 2600 rpm (intermittent) 65 kW / 87.2 hp Fuel Type Dual - Gasoline / Propane Fuel Tank Capacity 45 gal (170 L) Standard Oil Factory Fill 0°F to 115°F (-18°C to 45°C)

  • Page 44: Reach

    (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) (4.57) (3.05) (1.52) (-1.52) (-3.05) feet (-1.52) (1.52) (12.19) (-3.05) (3.05) (4.57) (6.10) (7.62) (9.14) (10.67) (13.72) (15.24) (16.76) (18.29) (19.81) (metres) 229044ADA SJ85 AJ...

  • Page 45: Dimensions

    9 ft 4 in. (2.84 m) Diagram 2.16 Axle Oscillation Zones Axle oscillation free (lowered travel position) - drive speed 3.0 mph (4.8 km/h) max. Axle oscillation locked (elevated travel position) - drive speed 0.5 mph (0.8 km/h) max. SJ85 AJ 229044ADA...

  • Page 46: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJ85 AJ 229044ADA...

  • Page 47: Electrical Symbol Chart

    TILT SWITCH TRANSISTOR SINGLE POLE VACUUM POTENTIOMETER SINGLE THROWN LEVEL SENSOR SWITCH RELAY DOUBLE POLE TEMPERATURE SINGLE POLE DOUBLE POLE DOUBLE THROW SWITCH DOUBLE THROW SINGLE THROW RELAY RELAY RELAY TRIPLE POLE RHEOSTAT DIODE DOUBLE THROW RELAY 229044ADA SJ85 AJ...

  • Page 48: Hydraulic Symbol Chart

    THREE WAY VALVE MOTOR OPEN PORT CLOSED VALVE THREE POSITION TWO POSITION TWO POSITION FOUR WAY TWO WAY THREE WAY VALVE CLOSED CENTER NORMALLY CLOSED PORT OPEN VALVE PRESSURE PILOT LINES Dashed MAIN LINES Solid TRANSDUCER SERVO SJ85 AJ 229044ADA...

  • Page 49: Wire Numbers And Color Codes

    This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire numbers will retain their original color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red. 229044ADA SJ85 AJ...

  • Page 50: 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 SJ85 AJ 229044ADA...

  • Page 51: Hydraulic Parts List

    VALVE, Counterbalance - boom lift 165486 VALVE, Counterbalance - boom extend 165486 VALVE, Counterbalance - boom extend 159841 VALVE, Counterbalance - platform level 159841 VALVE, Counterbalance - platform level 216059 VALVE, Counterbalance - jib 216059 VALVE, Counterbalance - jib 229044ADA SJ85 AJ...
  • Page 52 PUMP , Emergency 161932 FILTER, High pressure 161933 FILTER, Return 166058 VALVE, Flow regulator 171944 MOTOR, Axle drive 171944 MOTOR, Axle drive 170930 MOTOR, Swing drive 171419 MOTOR, Generator 3.5 kW 171438 MOTOR, Generator 12 kW 198103 MANIFOLD, Main SJ85 AJ 229044ADA...
  • Page 53 VALVE, Shuttle - boom lift VALVE, Shuttle - swing drive brake 113752 VALVE, Brake release override 223204 VALVE, Pilot operated 159831 VALVE, Brake hand pump 212553 VALVE, Pilot operated 230202 VALVE, Pilot operated 212552 VALVE, Pilot operated 166053 VALVE, Loop flush 229044ADA SJ85 AJ...

  • Page 54: Electrical Parts List

    86CR 127131 RELAY, Oil cooler 108CR 127131 RELAY, Emergency pump 120CR 127131 RELAY 123ACR 127131 RELAY 123ACR1 127131 RELAY 123CR 127131 RELAY 162ACR1 127131 RELAY (platform controls) 162ACR2 127131 RELAY 403ACR 127131 RELAY, Positive air shut-off option SJ85 AJ 229044ADA...
  • Page 55 BREAKER, Circuit - 20 amp (positive air shut-off option) 146652 HORN 171888 LIGHT, Work 171888 LIGHT, Work 144078 LIGHT, Flashing 199546 SWITCH, Limit - direction sensing 207059 SWITCH, Limit - boom down 198390 SWITCH, Limit - fly in 229044ADA SJ85 AJ...
  • Page 56 SWITCH, Toggle - platform rotate 102853 SWITCH, Toggle - jib up/down 102853 SWITCH, Toggle - Telescope extend/retract 102853 SWITCH, Toggle - Platform levelling 102853 SWITCH, Toggle - platform rotate 102853 SWITCH, Toggle - Jib up/down 115747 SWITCH, Toggle - generator SJ85 AJ 229044ADA...
  • Page 57 SWITCH, Toggle - fuel select 115747 SWITCH, Toggle - Diff lock 115574 SWITCH, Toggle - positive air shut-off 115574 SWITCH, Toggle - drive torque TSW1 138278 SWITCH, Toggle - starter 195940 Hourmeter - ANSI/CSA & AS 170787 Hourmeter - 229044ADA SJ85 AJ...

  • Page 58: Brake Manifold Port Identification

    To Drive Motor S1 Pressure To Hydraulic Tank T4 Reducing Valve Shuttle Valve To Drive Pump Mb Brake Release Valve To Drive Pump Ma Shuttle Valve CV13 Check Valve To Main Manifold BLS To Axle Lock Cylinder M198368AB-SM SJ85 AJ 229044ADA...

  • Page 59: Jib Manifold Port Identification

    To Jib Cylinder (Retract) 4H-34 Jib down 4H-35 Jib up To Platform Rotator 4H-37 Platform right 4H-36 Platform left To Main Manifold (P) To Jib Cylinder (Extend) To Main Manifold (PT) Flow regulator valve To Platform Rotator M198369AB-SM 229044ADA SJ85 AJ...

  • Page 60: Main Manifold - Hose Port Identification

    To System Pump To Lift Cylinder (Retract) To Slave Cylinder (Retract) To Swing Drive (Left) High Pressure Filter To Extention Cylinder (Extend) To Brake Manifold (LS) To Extension Cylinder (Retract) To Slave Cylinder (Extend) To Emergency Pump M198103AF-PI SJ85 AJ 229044ADA...

  • Page 61: Main Manifold - Hydraulic Components

    Swing Compensator Valve Flow Regulator Valve Jib/Platofm Return Check Valve DSV3 Boom Lift Compensator Valve DSV4 Main LS Check Valve Riser Compensator Valve Main LS Check Valve 80 psi Pressure Reducing Valve Boom Lift Relief Valve M198103AF-HC 229044ADA SJ85 AJ...

  • Page 62: Main Manifold - Electrical Components

    Boom Extend 4H-38 R I S Boom Retract 2H-21A Dump 5H-33 Turret Right 5H-32 Turret Left 2H-42C Flow Enable 4H-14 Boom Up 4H-13 Boom Down 4H-30 Riser Down 4H-31 5H-24A 5H-23A Riser Up Steer Left Steer Right M198103AH-EC SJ85 AJ 229044ADA...

  • Page 63: Sge Harness Connection

    3.12 SGE Harness Connection BLACK (04) WHITE (61) M198350AB 229044ADA SJ85 AJ...

  • Page 64: Jib And Platform Rotate Harness Connections

    DESCRIPTION RED/PURPLE ROTATE CW WHITE (SPLICE 1) GROUND CAVITY WIRE NO. COLOUR DESCRIPTION WHITE/RED/BLK ROTATE CCW ORANGE BLACK(34) WHITE (SPLICE 1) GROUND ORANGE WHITE (35) WHITE (02) WHITE (02) RED PURPLE (36) WHITE RED BLACK (37) M198228AB_M168650AB SJ85 AJ 229044ADA...

  • Page 65: Footswitch Harness Connection

    3.14 Footswitch Harness Connection BLACK (04) WHITE (08A) M198227AB 229044ADA SJ85 AJ...

  • Page 66: Main Manifold Harness

    PIN 2 - 02 WHITE (SPLICE # 3) RISER DOWN STEER RIGHT PIN 1 - 30 RED/GREEN PIN 1 - 23A BLACK/WHITE PIN 2 - 02 WHITE (SPLICE #3) PIN 2 - 02 WHITE (SPLICE #3) M198133AE SJ85 AJ 229044ADA...

  • Page 67: Platform To Base Control Cables

    POSITION 20 - YELLOW/ORANGE POSITION 21 - GREY/BLUE POSITION 21 - YELLOW/PINK POSITION 22 - BLACK/YELLOW POSITION 22 - PINK/WHITE POSITION 23 - BLUE/WHITE/YELLOW POSITION 23 - PINK/PURPLE POSITION 24 - BLUE/WHITE/BLACK POSITION 24 - PINK/BLACK M168784AA_M165096AC_M165098AC 229044ADA SJ85 AJ...

  • Page 68: Engine Control Wiring - Deutz Td2.9L

    PIN 6 - 02 PIN 7 - PLUGGED PIN 8 - PLUGGED PIN 9 - PLUGGED PIN 10 -PLUGGED PIN 11 -PLUGGED PIN 12 -PLUGGED X22 CONN. A - 09 B - 02 G - 105 H - 104 M198135AG SJ85 AJ 229044ADA...

  • Page 69: Engine Control Wiring - Deutz D2011

    PIN 6 - 02 PIN 7 - PLUGGED PIN 8 - PLUGGED PIN 9 - PLUGGED PIN 10 -PLUGGED PIN 11 -PLUGGED PIN 12 -PLUGGED X22 CONN. A - 60 B - 106 K - 104 L - 105 M198392AF 229044ADA SJ85 AJ...

  • Page 70: Engine Control Wiring - Kubota Wg3800

    PIN 3 - 11 PIN 4 - 79 PIN 5 - 78 PIN 6 - 02 PIN 7 - PLUGGED PIN 8 - PLUGGED PIN 9 - PLUGGED PIN 10 -PLUGGED PIN 11 -PLUGGED PIN 12 -PLUGGED M198212AE SJ85 AJ 229044ADA...

  • Page 71: Deutz Edc-F Harness

    PIN 21 - 90 - RED/GREY PIN 22 - PLUGGED PIN 23 - JUMPER TO PIN 24 PIN 24 - JUMPER TO PIN 23 CAN H TWIST WITH CAN L PIN 25 - PLUGGED TWIST WITH CAN H CAN L M198394AE 229044ADA SJ85 AJ...

  • Page 72: Load Cell Wiring

    3.21 Load Cell Wiring 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 SJ85 AJ 229044ADA...
  • Page 73 229044ADA SJ85 AJ...

  • Page 74: Hydraulic Schematic

    DRIVE PUMP 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 3.22 Hydraulic Schematic M198217AJ SJ85 AJ 229044ADA...

  • Page 75: Electrical Schematic - Ansi/Csa

    3.23 Electrical Schematic - ANSI/CSA JMPR4 R4=330K ohm NOTE A JMPR5 D10-1 3.23 Electrical Schematic - ANSI/CSA M218403AC-1 SJ85 AJ 229044ADA...

  • Page 76: Electrical Schematic - Ce With Deutz Tcd2.2 Engine

    3.24 Electrical Schematic - CE with Deutz TCD2.2 Engine 3.24 Electrical Schematic - CE with Deutz TCD2.2 Engine M224590AC-1 SJ85 AJ 229044ADA...

  • Page 77: Electrical Schematic - Ce With Deutz Td2.9L, Deutz D2011 Or Kubota Engines

    3.25 Electrical Schematic - CE with Deutz TD2.9L, Deutz D2011 or Kubota Engines 3.25 Electrical Schematic - CE with Deutz TD2.9L, Deutz D2011 or Kubota Engines M223006AC SJ85 AJ 229044ADA...

  • Page 78: Electrical Schematic - As

    3.26 Electrical Schematic - AS JMPR4 R4=330K ohm NOTE A JMPR5 D10-1 3.26 Electrical Schematic - AS M223005AC SJ85 AJ 229044ADA...

  • Page 79: Platform Controls Wiring - Deutz Td2.9L, Deutz D2011, Kubota, Perkins

    ZIP TIE LOOSE END S48- S10- TORQ THROT S6-EPUMP S4-E STOP S23-HORN S30-SGE S9-IGN 82CR 162ACR1 27CR (12) 162B BP1 TILT ALARM BP3 OVERLOAD ALARM 3.27 Platform Controls Wiring - Deutz TD2.9L, Deutz D2011, Kubota, Perkins M198203AG-3 SJ85 AJ 229044ADA...

  • Page 80: Platform Controls - Harness View - Deutz Td2.9L, Deutz D2011, Kubota, Perkins

    PIN 16 - 23 BLK/WHT PIN 34 - N/U TO BP3 OVERLOAD ALARM PIN 17 - 45 YEL/ORG (-) - 02 WHT PIN 35 - 37 WHT/RED/BLK TD2.9L, Deutz D2011, (+) - 118 PUR/PINK Kubota, Perkins M198203AG-1 SJ85 AJ 229044ADA...

  • Page 81: Platform Controls - Schematic View - Deutz Td2.9L, Deutz D2011, Kubota, Perkins

    BORDER ZONE ELEC.GEN. - Deutz TD2.9L, TO BP1 TO PL6 TO S30 TO BP4 TO BP3 TILT ALARM SGE RESET OVERLOAD ALARM TO P3 ON CONTROL MODULE Deutz D2011, ALARM TO TERMINAL BLOCK (TB) Kubota, Perkins M198203AG-2 SJ85 AJ 229044ADA...

  • Page 82: Platform Controls Wiring - Deutz Tcd2.2

    LOOSE END S48- S10- TORQ THROT S6-EPUMP S4-E STOP S23-HORN S30-SGE S9-IGN 162BCR2 27CR 82CR 162B BP1 TILT ALARM BP6 REGENERATION ALARM BP3 OVERLOAD ALARM TO S32 OVERRIDE SWITCH 3.30 Platform Controls Wiring - Deutz TCD2.2 M224601AC-2 SJ85 AJ 229044ADA...

  • Page 83: Platform Controls - Harness View - Deutz Tcd2.2

    PIN 33 - 39A BLK/RED (+) - 118 PUR/PINK PIN 16 - 23 BLK/WHT PIN 34 - N/U PIN 17 - 45 YEL/ORG PIN 35 - 37 WHT/RED/BLK 3.31 Platform Controls - Harness View - Deutz TCD2.2 M224601AC-1 SJ85 AJ 229044ADA...

  • Page 84: Platform Controls - Schematic View - Deutz Tcd2.2

    ELEC.GEN. TO BP1 TO PL6 TO S30 TO BP4 TO BP3 TILT ALARM OVERLOAD ALARM SGE RESET TO P3 ON CONTROL MODULE ALARM TO TERMINAL BLOCK (TB) 3.32 Platform Controls - Schematic View - Deutz TCD2.2 M224601AA-3 SJ85 AJ 229044ADA...

  • Page 85: Base Controls Wiring - Ansi/Csa

    PIN 10 -PLUGGED SOCKET 8 - CAN L PIN 11 -PLUGGED SOCKET 9 - 57D PIN 12 -PLUGGED SOCKET 10 - PLUG 3.33 Base Controls SOCKET 11 - 20 SOCKET 12 - 26 Wiring - ANSI/CSA M218340AD SJ85 AJ 229044ADA...

  • Page 86: Base Controls Wiring - Ansi/Csa With Positive Air Shut-Off Option

    SOCKET 8 - CAN L PIN 11 -PLUGGED SOCKET 9 - 57D PIN 12 -PLUGGED SOCKET 10 - PLUG SOCKET 11 - 20 SOCKET 12 - 26 3.34 Base Controls Wiring - ANSI/CSA with Positive Air Shut-off Option M218341AD SJ85 AJ 229044ADA...

  • Page 87: Base Controls Wiring - Ce & As With Deutz Td2.9L Or D2011 Engine

    PIN 11 -PLUGGED SOCKET 9 - 57D PIN 12 -PLUGGED SOCKET 10 - PLUG SOCKET 11 - 20 SOCKET 12 - 26 3.35 Base Controls Wiring - CE & AS with Deutz TD2.9L or D2011 Engine M198355AL SJ85 AJ 229044ADA...

  • Page 88: Base Controls Wiring - Ce & As With Deutz Tcd2.2 Engine

    SOCKET 7 - CAN H SOCKET 8 - CAN L SOCKET 9 - 57D SOCKET 10 - PLUG SOCKET 11 - 20 SOCKET 12 - 26 3.36 Base Controls Wiring - CE & AS with Deutz TCD2.2 Engine M224593AC SJ85 AJ 229044ADA...

  • Page 89: Engine Schematic - Deutz Td2.9L

    PRESSURE & PRESSURE CYL.3 CYL.2 CYL.1 CYL.4 EXHAUST GAS SENSOR SENSOR SENSOR SENSOR PRESS. TEMPERATURE SENSOR RECIRCULATION CAMSHAFT CRANKSHAFT SENSOR SENSOR VALVE (EGR) START STARTER RELAY STARTER SOLENOID TO S1 BATTERY TO BATTERY DISCONNECT SW. B- POST M218403AC-2 SJ85 AJ 229044ADA...

  • Page 90: Engine Schematic - Deutz D2011

    Blatt 2 hinzu 06.01.05 Sachser 0421 3231 0138-48 2005 M0138-48-0085 DEUTZ AG 12.03.04 Sachser Zust. Aenderung Datum/Name Ursprung M0138-48-0085 Ers. fuer INDEX REVISION DATE/NAME ORIGIN. REPLACES 0109 9910 DIN A1 3.38 Engine Schematic - Deutz D2011 M218403AC-3 SJ85 AJ 229044ADA...

  • Page 91: Engine Schematic - Deutz Tcd2.2

    TEMPERATURE SENSOR SENSOR 1 SENSOR 2 SENSOR VALVE RECIRCULATION SENSOR CAMSHAFT CRANKSHAFT SENSOR SENSOR VALVE (EGR) START STARTER RELAY STARTER SOLENOID TO S1 BATTERY TO BATTERY DISCONNECT SW. B- POST 3.39 Engine Schematic - Deutz TCD2.2 M224590AC-2 SJ85 AJ 229044ADA...

  • Page 92: Engine Schematic - Kubota Wg3800

    FUSE 5A 32BCR ENGINE STARTER SOLENOID FUSE 15A STARTER ENGINE STARTER EL. MOTOR (RED/TAN) CAN H (PURPLE) CAN L (RED) ALTERNATOR FUSE 60A ALTERNATOR TO MAIN TO BATTERY DISCONNECT GROUND 3.40 Engine Schematic - Kubota WG3800 M218403AA-4 SJ85 AJ 229044ADA...

  • Page 93: Engine Harness - Deutz Td2.9L

    A03-16 WH A03-16 WH A32-16 BK A32-16 BK A02-16 WH A02-16 WH X17.1 (30A) TO BATTERY BATTERY TO FUEL PUMP DISCONNECT TO CTRL PNL TO WATER SENSOR TO CTRL PNL 3.41 Engine Harness - Deutz TD2.9L M198132AD SJ85 AJ 229044ADA...

  • Page 94: Engine Harness - Deutz Tcd2.2

    TO AMBIENT TEMP. SENSOR 50" K39, A40, TO WATER SENSOR TO EAT CONNECTOR A59, A57, K56, K55, K91, A40, TO ENGINE CONNECTOR X17.1 SPL04 SPLK68 SPLA24 SPLA57 2" (30A) K20, K68, 3.42 Engine Harness - Deutz TCD2.2 M224592AC-1 SJ85 AJ 229044ADA...

  • Page 95: Engine Harness - Kubota Wg3800

    FUEL PUMP (-) 3002 WHITE TO FUEL PUMP 3000-WHT-16 68-GREY-18 SCANH CAN H-YEL/BLU-18 68-GREY-16 SCANL CAN L-GRN-18 57A-BRN/GRN-18 11-WHT/ORG-18 76-BRN/BLU-18 78-RED/BLU-18 79-BRN/PUR-18 00B-WHT-18 00A-WHT-18 CAN L-GRN-18 CAN H-YEL/BLU-18 GND-BLK-18 FRT-GRN/WHT-18 5V-GRN/RED-18 FRP-WHT-18 3.43 Engine Harness - Kubota WG3800 M198216AE SJ85 AJ 229044ADA...

  • Page 96: 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. SJ85 AJ 229044ADA...

  • Page 97: Electrical System

    CB2. 17. Circuit breaker CB2 tripped or defective. Reset breaker, check for defective wiring. Replace if defective. 18. Loose or broken wire #00 from circuit breaker Check continuity. Replace if defective. CB2 to battery negative. 229044ADA SJ85 AJ...
  • Page 98 01ACR1 relay. 15. Defective relay 01ACR1. Check relay. Replace if defective. 16. Loose or broken wire #10B from 01ACR1 relay to Check continuity. Replace if defective. resistor R1. 17. Defective resistor R1. Check resistor, replace if defective. SJ85 AJ 229044ADA...
  • Page 99 13. Loose or broken wire #60 from plug B pin #16 to Check continuity. Replace if defective. base terminal block. 14. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective. block to base terminal block. 229044ADA SJ85 AJ...

  • Page 100: No Power

    Check continuity. Replace if defective. switch S5 to Engine electrical box connector J3 pin Pin 8. 2. Loose or broken wire #57A from base start Check continuity. Replace if defective. switch S5 to Engine electrical box connector J3 pin Pin 8. SJ85 AJ 229044ADA...
  • Page 101 3. Loose or broken wire 07 from S3 base Check continuity. Replace if defective. Emergency stop switch to 57DCR pin 86. 4. Loose or broken wire 57A from S5 ignition switch Check continuity. Replace if defective. to 57DCR pin 30. 229044ADA SJ85 AJ...

  • Page 102: No Boom Up Or Down

    6. No output on J2 pin #5 of the valve driver to wire Check for a minimum 3.5 volts. If no voltage #14. present with foot on footswitch check section 5 for OCM pin voltage reference. SJ85 AJ 229044ADA...
  • Page 103 5 for OCM pin voltage reference. 6. No output on J2 pin #6 of the valve driver to wire Check for a minimum 3.5 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 229044ADA SJ85 AJ...
  • Page 104 #3 to boom down valve 4H-13A. 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. Replace if defective. SJ85 AJ 229044ADA...

  • Page 105: No Riser Up Or Down

    Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #31 from base connector Check continuity. Replace if defective. plug A pin #13 to base terminal block. 229044ADA SJ85 AJ...
  • Page 106 Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #30 from base connector Check continuity. Replace if defective. plug A pin #12 to base terminal block. SJ85 AJ 229044ADA...

  • Page 107: No Turret Rotate

    Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #32 from base connector Check continuity. Replace if defective. plug A pin #14 to base terminal block. 229044ADA SJ85 AJ...
  • Page 108 Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #33 from base connector Check continuity. Replace if defective. plug A pin #15 to base terminal block. SJ85 AJ 229044ADA...

  • Page 109: No Telescope

    Check for loose or corroded connections on cable connectors. Replace if wire is defective. 8. Loose or broken wire #38 from base connector Check continuity. Replace if defective. plug B pin #8 to base terminal block. 229044ADA SJ85 AJ...
  • Page 110 Replace if wire is defective. 8. Loose or broken wire #39 from base connector Check continuity. Replace if defective. plug B pin #9 to base terminal block. Follow steps on No Boom Extend from Base or Platform Consoles: on page 114. SJ85 AJ 229044ADA...
  • Page 111 #13 to boom extend valve 4H-39A. 5. Loose or broken wire #02 from turret harness Check continuity. Replace if defective. plug to boom extend valve 4H-39A. 6. Defective boom extend coil 4H-39A. Check continuity and resistance through coil. Replace if defective. 229044ADA SJ85 AJ...

  • Page 112: No Platform Level

    Check for loose or corroded connections on cable connectors. Replace if wire is defective. 8. Loose or broken wire #41 from base connector Check continuity. Replace if defective. plug B pin #11 to base terminal block. SJ85 AJ 229044ADA...
  • Page 113 Check for loose or corroded connections on cable connectors. Replace if wire is defective. 8. Loose or broken wire #40 from base connector Check continuity. Replace if defective. plug B pin #10 to base terminal block. 229044ADA SJ85 AJ...

  • Page 114: No Jib Up Or Down

    Check for a minimum 3.5 volts. If no voltage #35. present with foot on footswitch check section 5 for OCM pin voltage reference. 6. Loose or broken wire 35 from J2 pin #7 of valve Check continuity. Replace if defective. driver to platform terminal strip. SJ85 AJ 229044ADA...
  • Page 115 Check for a minimum 3.5 volts. If no voltage #34. present with foot on footswitch check section 5 for OCM pin voltage reference. 6. Loose or broken wire 34 from J2 pin #8 of valve Check continuity. Replace if defective. driver to platform terminal strip. 229044ADA SJ85 AJ...

  • Page 116: 10 No Platform Rotate

    #37. present with foot on footswitch check section 5 for OCM pin voltage reference. 6. Loose or broken wire 37 from J2 pin #35 of valve Check continuity. Replace if defective. driver to platform terminal strip. SJ85 AJ 229044ADA...
  • Page 117 #36. present with foot on footswitch check section 5 for OCM pin voltage reference. 6. Loose or broken wire 36 from J2 pin #23 of valve Check continuity. Replace if defective. driver to platform terminal strip. 229044ADA SJ85 AJ...

  • Page 118: 11 No Platform Rotate Or Jib Functions

    9. loose or broken wire 42A from 42CR relay pin 87 Check continuity. Replace if defective. to turret harness pin 11. 10. loose or broken wire 42A from 42CR relay pin 87 Check continuity. Replace if defective. to turret harness plug pin 11. SJ85 AJ 229044ADA...

  • Page 119: 12 No Drive Or Steer

    2. Loose or broken wire ”D-signal” from drive Check continuity. Replace if defective. joystick A2 to J3 pin #14 of valve driver . 3. No output from valve driver J2 pin #2 to wire Check continuity. Replace if defective. #15. 229044ADA SJ85 AJ...
  • Page 120 J3 pin #3 to plug A pin #9. 4. Loose or broken wire #23A in boom cable A or Check for continuity between pins #9 on cable A. its connectors. Check for loose or corroded connections on cable connectors. Replace if wire is defective. SJ85 AJ 229044ADA...

  • Page 121: 13 Direction Sensing Inoperative

    6. Loose or broken wire #17 from base plug B Check continuity. Replace if defective. pin #6 to valve driver connector J2 pin #25 in platform control console. 7. Defective valve driver channel input for direction Replace if Defective. sense enable. 229044ADA SJ85 AJ...

  • Page 122: 14 Green Led On Load Sense/Dual Load Zone Module Is Not On

    Empty platform = 8 mV (0.008 V) 250 lbs (113 kg) = 12mV (0.012 V) 500 lbs (227 kg) = 16 mV (0.016 V) 748 lbs (339 kg) = 20 mV (0.02 V) Voltage across 162 resistor should match voltage across 161. SJ85 AJ 229044ADA...

  • Page 123: 16 Load Sense/Dual Load Zone Module Error

    Off limits: (boom extended and/or boom above 10°): No functions and overload alarm pulses with overload light. Module Amber and Green diagnostic LEDs on the module flash alternately ▪ To reset the module hold the actuator button down for 5 seconds. 229044ADA SJ85 AJ...

  • Page 124: 17 No Light/Alarm When Platform Is Overloaded

    3. Loose or broken wire #118 from relay 162ACR1 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. SJ85 AJ 229044ADA...

  • Page 125: Hydraulic System

    Repair or replace valve as required. 5. Stuck or defective check valve CV13. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 229044ADA SJ85 AJ...
  • Page 126 7. Return valve V6 stuck in the closed position or is Clean valve. Check operation of valve. Repair or defective. replace valve as required. 8. Defective lift cylinder C1. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. SJ85 AJ 229044ADA...

  • Page 127: No Turret Rotate

    Clean valve. Check operation of valve. Repair or replace valve as required. 7. Defective Swing Drive Brake BR1. Check seals and operation. Repair or replacelace as necessary. 8. Defective Swing Drive Motor M2. Check seals and operation. Repair or replace as necessary. 229044ADA SJ85 AJ...

  • Page 128: No Boom Extend Or Retract

    5. Return valve V2 stuck in the closed position or is Clean valve. Check operation of valve. Repair or defective. replace valve as required. 6. Defective lift cylinder C2. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. SJ85 AJ 229044ADA...

  • Page 129: No Riser Up Or Down

    6. Shuttle valve SV3 stuck or defective. Clean valve. Check operation of valve. Repair or replace valve as required. 7. Defective riser cylinder(s) C11 and/or C12. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. 229044ADA SJ85 AJ...

  • Page 130: No Platform Level

    CB7. replace valve as required. 8. Defective master cylinder C3. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. 9. Defective slave cylinder C4. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. SJ85 AJ 229044ADA...

  • Page 131: No Jib Up Or Down

    6. Stuck or defective counterbalance valves CB8 Clean valve. Check O-rings on valve. Repair or and/or CB9. replace valve as required. 7. Defective jib cylinder C5. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. 229044ADA SJ85 AJ...

  • Page 132: No Platform Rotate

    7. Stuck or defective counterbalance valves CB10 Clean valve. Check O-rings on valve. Repair or and/or CB11. replace valve as required. 8. Defective platform rotator RA1. Check seals on rotator Replace as necessary. Repair or replace rotator if defective. SJ85 AJ 229044ADA...

  • Page 133: 10 No Steer

    5. Stuck or defective counterbalance valve CB6 Clean valve. Check O-rings on valve. Repair or and/or CB7. replace valve as required. 6. Defective steer cylinder C8. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. 229044ADA SJ85 AJ...

  • Page 134: 11 No Drive

    1. Stuck or defective 2 speed valve 3H-45. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Defective shift spool in drive motor M1. Check motor. Repair or replace if necessary. SJ85 AJ 229044ADA...

  • Page 135: 12 No Brake Function

    2. Stuck or defective brake valve 3H-26. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 3. Brake in axle out of adjustment. See section 5 for brake adjustment procedure. 229044ADA SJ85 AJ...

  • Page 136: 13 No Oscillating Axle Function

    2. Bypassing or defective axle cylinders C6 and C7. 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. SJ85 AJ 229044ADA...

  • Page 137: Section 5 - Procedures

    Before performing routine maintenance underneath the riser, support it using a suitably rated lifting device (refer to Figure 01), or cylinder chocks on both riser cylinders. Contact Skyjack Parts to order chocks. WARNING Remove all material and personnel from the platform while using the maintenance support(s).

  • Page 138: 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. 229044ADA SJ85 AJ...

  • Page 139: Scm Character Functions Charts

    BOOM UP Fn03B Main Boom Up ROTATE L Fn04A Turret Rotate Left ROTATE R Fn04B Turret Rotate Right RISER DN Fn05A Riser Down RISER UP Fn05B Riser Up RISER UP Fn06A Virtual channel RISER UP Fn06B Virtual channel 1346AA SJ85 AJ 229044ADA...

  • Page 140: Scm Operating Values Chart

    Section 5 – Procedures Platform 5.1-4 SCM Operating Values Chart P1 (Black) Wire Function Input/Output Type IO Name Label Expected Value POWER POWER POWER POWER GROUND GND1 GROUND GND2 GROUND GND3 GROUND GND4 1342AA 229044ADA SJ85 AJ...
  • Page 141 DIGITAL INPUT DIN09 0V/12V Engine Start Request DIGITAL INPUT DIN11 0V/12V DIGITAL INPUT DIN13 0V/12V DIGITAL INPUT DIN15 0V/12V Fly Boom Out DIGITAL INPUT DIN17 0V/12V Platform Rotate Right ANALOG OUTPUT PWM12 PWM13 400 - 790mA 1343AA SJ85 AJ 229044ADA...
  • Page 142 DIGITAL INPUT DIN23 0V/12V Generator DIGITAL INPUT DIN24 0V/12V Sensing Bar ( SGE) DIGITAL INPUT DIN25 0V/12V Reset SGE DIGITAL INPUT DIN26 0V/12V Holding Brake Off DIGITAL OUTPUT DOUT17 0V/12V Diff Lock DIGITAL OUTPUT DOUT18 0V/12V 1344AA 229044ADA SJ85 AJ...

  • Page 143: How To Unlock And Modify Scm Settings

    ENTER PASSWORD PRESS SELECT SELECT MENU ENTER PASSWORD ENTER PASSWORD SELECT MENU ENTER PASSWORD ENTER PASSWORD SELECT MENU ENTER PASSWORD SETUP UNLOCKED PRESS – OR + SELECT SET DRIVE TIMER PRESS SELECT MODEL: 85AJ**** Continued on next page FUNCTIONS OFF SJ85 AJ 229044ADA...
  • Page 144 SELECT *func. name* RAMPDN Adjust value Fn # ##mA SAVE EXIT Recycle power to the SCM with the E-Stop to re-enable password protection. If the SCM is inactive for more than 5 minutes, the password must be re-entered. 229044ADA SJ85 AJ...

  • Page 145: Check I/O Error

    Example: JIB DOWN PE 6 7 8 9 10 JIB UP 0 1 0 0 0 PLATF RGT This example indicates an error (1) in channel 7, PLATF LFT which is the Riser Down PROP FLOW function. SJ85 AJ 229044ADA...

  • Page 146: Fly Boom Switch Voltage References

    WIRE#38A > >> 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 229044ADA SJ85 AJ...

  • Page 147: Platform Controller Voltage References

    Neutral Position = 4.2 - 4.8 Volts Right = 4.9 - 8.5 Volts @ full stroke Up = 4.9 - 8.5 Volts @ full stroke Left = 4.1 - 0.5 Volts @ full stroke Down = 4.1 - 0.5 Volts @ full stroke SJ85 AJ 229044ADA...
  • Page 148 RIGHT WHT/YEL Pin 18 Drive Reverse Reference Analog Input AI 1 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 Riser (A3) Controller Riser Up 04 RED/YEL POWER Neutral  Position      02 WHT GROUND 4.2 ‐ 4.8  Volts R RED/GRN R‐SIGNAL Pin  30 Reference Analog Input AI 4 RiserDown Neutral Position = 4.2 ‐ 4.8 Volts Forward = 4.9 ‐ 8.5 Volts @ full stroke 12 Volts Reverse = 4.1 ‐ 0.5 Volts @ full stroke 229044ADA SJ85 AJ...

  • Page 149: Remove And Replace The Platform

    3. Disconnect the two 24-pin control cables from locations for reinstallation. the bottom of the control box. 6. To release each wire, insert a small flat screwdriver into the slot beside it in the terminal strip. M62067AA M62321AA SJ85 AJ 229044ADA...
  • Page 150 CAUTION To avoid personal injury or equipment damage, perform all of the function tests given in your unit’s Operating Manual after reconnecting all of the M62252AA cables. 229044ADA SJ85 AJ...

  • Page 151: 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. SJ85 AJ 229044ADA...

  • Page 152: Dual Capacity Overload Module Function Table

    Section 5 – Procedures Load Sensing System 5.3-2 Dual Capacity Overload Module Function Table 229044ADA SJ85 AJ...

  • Page 153: 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. SJ85 AJ 229044ADA...
  • Page 154 14. The green LED will become solid, which is normal operating mode. Trip Point 1 Trip Point 2 538 lb 538 lb + 210 lb = 748 lb (244 kg) (244 kg + 94 kg = 339 kg) 229044ADA SJ85 AJ...

  • Page 155: Boom

    Fly Boom 1/32” Feeler Gauge Shim Wear Pad 5. Extend and retract the fly boom through the entire range of motion and observe for loose points. NOTE Always maintain squareness between the boom’s outer and inner tubes. SJ85 AJ 229044ADA...

  • Page 156: Remove And Replace The Jib

    7. To reinstall the jib boom, follow the preceeding steps in reverse order. M63408AA 4. Using suitable lift equipment and safe rigging practices, connect lifting slings to the jib boom. Tension the slings enough to lightly take the weight off the mounting bracket pins. 229044ADA SJ85 AJ...

  • Page 157: Limit Switch Locations

    Limit Switch LS5 - Fly Out (Dual Load Zone) Limit Switch LS3 - Fly In (High Speed Cut-out) Limit Switch LS1 - Direction Sensing Limit Switch LS6 - Riser Down (Elevated Drive) Limit Switch LS7 - Boom/Riser Interlock SJ85 AJ 229044ADA...

  • Page 158: Turret

    9. Tighten the mounting fasteners on the swing drive. 8. Reinstall the housing, screwing it in fully, then backing it off by one quarter turn. 10. Rotate the turret 360° and check for a smooth rotation of the turret. 229044ADA SJ85 AJ...

  • Page 159: Check The Swing Drive Oil

    7. Reinstall the drain plug. 8. Refill the swing drive with approximately 1 L (32 oz) of oil (refer to 2.13 Specifications and Features - Engines & Fluids for recommended oil types). 9. Reinstall the plug at the fill port. SJ85 AJ 229044ADA...

  • Page 160: 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). 229044ADA SJ85 AJ...

  • Page 161: Electronic Tilt Switch Setup Procedure

    4. Turn the main disconnect switch to the ON 9. Turn the main power disconnect switch to the off position position 5. Turn the base/off/platform key switch to the base 10. Push in the emergency stop buttons position 11. Proceed to Verify the Tilt Circuit. SJ85 AJ 229044ADA...
  • Page 162 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 the Tilt Circuit. Green LED 229044ADA SJ85 AJ...

  • Page 163: Check The Rotation Bearing For Axial Wear

    This reading is the total amount of axial movement in the bearing assembly. If this reading is 2.54 mm (0.100") or greater, the rotation bearing should be removed and replaced. SJ85 AJ 229044ADA...

  • Page 164: Resetting The Emergency Lowering Counter (Ce Only)

    HOUR METER 000000 To reset the counter: COUNTER 1. Locate the terminal block with the integrated fuse holder inside the base control box. 2. Insert a standard automotive fuse into the fuse slot in the terminal block. 229044ADA SJ85 AJ...

  • Page 165: Deutz Diesel Engines

    17. Check for oil leakage. 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. SJ85 AJ 229044ADA...

  • Page 166: 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. 229044ADA SJ85 AJ...

  • Page 167: 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 SJ85 AJ 229044ADA...
  • Page 168 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 229044ADA SJ85 AJ...
  • Page 169 523216 3-3-7 gine command. 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 SJ85 AJ 229044ADA...
  • Page 170 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 229044ADA SJ85 AJ...
  • Page 171 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 SJ85 AJ 229044ADA...
  • Page 172 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 229044ADA SJ85 AJ...
  • Page 173 ECU reported internal software error. 523612 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 SJ85 AJ 229044ADA...
  • Page 174 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 229044ADA SJ85 AJ...
  • Page 175 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 SJ85 AJ 229044ADA...
  • Page 176 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 229044ADA SJ85 AJ...
  • Page 177 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 SJ85 AJ 229044ADA...
  • Page 178 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 229044ADA SJ85 AJ...
  • Page 179 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 SJ85 AJ 229044ADA...
  • Page 180 Air inlet filter sensor out of physical range check. 1187 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 229044ADA SJ85 AJ...
  • Page 181 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 SJ85 AJ 229044ADA...
  • Page 182 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 229044ADA SJ85 AJ...
  • Page 183 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 SJ85 AJ 229044ADA...
  • Page 184 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 229044ADA SJ85 AJ...
  • Page 185 4-1-5 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 SJ85 AJ 229044ADA...
  • Page 186 Turbocharger wastegate, broken spring detected. 1799 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 229044ADA SJ85 AJ...

  • Page 187: Diesel Particulate Filter (Dpf) And Standstill Regeneration - Deutz Tcd2.2 Engine

    Deutz engine display module (located below the engine control console) and indicated by the flashing standstill lamps on the base and platform controls. REGENERATION NEEDED REGENERATION REGENERATION COMPLETE SJ85 AJ 229044ADA...
  • Page 188 6. Standstill regeneration takes approximately Be aware that use of the derate override switch 45 minutes. During this time, the MEWP must may result in diesel particulate filter failure. not be used. 229044ADA SJ85 AJ...

  • Page 189: Hydraulic Tank

    Dirt and/or moisture contamination 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. SJ85 AJ 229044ADA...

  • Page 190: 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. 229044ADA SJ85 AJ...

  • Page 191: Hydraulic Standby Pressure Adjustment

    10. Remove the pressure gauge from the GP1 port 4. Check the reading on the gauge (standard and cap the port. pressure should be 23 bar / 330 psi) and follow the next steps for adjusting the pressure, if needed. SJ85 AJ 229044ADA...

  • Page 192: 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 210 bar (3050 psi). Follow the next steps for adjusting the pressure, if needed. 229044ADA SJ85 AJ...

  • Page 193: 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 220 bar (3200 psi). Follow the next steps for adjusting pressure if needed. SJ85 AJ 229044ADA...

  • Page 194: Turret Rotate Relief Valve Adjustment

    9. Tighten the lock nut on the turret rotate relief the gauge. valve RV2 once 120 bar (1750 psi) is observed on the gauge. You must activate the turret rotate to obtain a pressure reading on the gauge. 10. Disengage the turret transport lock. 229044ADA SJ85 AJ...

  • Page 195: Riser Relief Valve Adjustment

    8. Tighten the lock nut on the riser boom relief activate a pressure reading on the gauge. valve RV4 once 138 bar (2000 psi) is observed on the gauge. You must fully lower the riser to activate a pressure reading on the gauge. SJ85 AJ 229044ADA...

  • Page 196: Fly Boom Relief Valve Adjustment

    7. Tighten the lock nut on the fly boom relief valve RV4 once 138 bar (2000 psi) is observed on the gauge. You must fully extend the boom to activate a pressure reading on the gauge. 229044ADA SJ85 AJ...

  • Page 197: 11 Test Forward Drive Pressure On Drive Pump

    9. Remove the pressure gauge from the port, cap pressure should be 345 bar (5000 psi). the port, and re-plug the brake solenoid power 7. Replace the pump if the pressure is not cable. achieved. 8. Turn the engine off. SJ85 AJ 229044ADA...

  • Page 198: 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 2.13 Specifications and Features - Engines & Fluids. 7. Reinstall both of the fill and check plugs. Drain Fill 229044ADA SJ85 AJ...

  • Page 199: 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 2.13 Specifications and Features - Engines & Fluids. 6. Reinstall the fill plug. SJ85 AJ 229044ADA...

  • Page 200: 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. 229044ADA SJ85 AJ...

  • Page 201: Oscillating Cylinder Replacement

    Loctite 2. Remove and set aside the base cover from the 242 or 243 to the lower half of the bolts before oscillating axle end of the chassis. installing them. Hand tighten the bolts. SJ85 AJ 229044ADA...

  • Page 202: Bleed The Oscillating Axle Cylinders

    4. Close the bleeder. 5. Repeat the procedure with the other oscillating axle cylinder. 9. Reinstall the cylinder fittings, torquing the larger one to 33 Nm (24 ft-lb) and the smaller one to 20 Nm (15 ft-lb). 229044ADA SJ85 AJ...

  • Page 203: 10 Test The Oscillating Axle Cylinders

    Result: An appropriate tilt of the MEWP ▪ chassis should occur. 3. Retract the fly boom while in the tilted position. Result: The steer axles should unlock and ▪ the MEWP chassis should level itself to the ground. SJ85 AJ 229044ADA...

  • Page 204: Grease Points

    3. Rotate the turret in increments of 10 to 13 cm (4 to 5 inches) 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. 229044ADA SJ85 AJ...

  • Page 205: 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. SJ85 AJ 229044ADA...
  • Page 206 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.

Table of Contents