Skyjack SJ 800 Series SJ-8831 & SJ-8841 Rough Terrain Maintenance & Parts Manual - PDF DOWNLOAD

SJ-800 Series

MAINTENANCE & PARTS MANUAL

Printed in Canada

July 2013

Engine Powered

118938AJ

Model SJ-8831Serial #36952 & Above Model SJ-8841Serial #42029 & Above

For Service please call ........................................................................ 800 275-9522 Skyjack Inc. Service Center 3451, Swenson Ave., St. Charles, IL. 60174 FAX 630 262-0006 For Parts in North America and Asia please call ...................................... 800 965-4626 Skyjack Inc. Parts Center, 3451 Swenson Ave., St. Charles, IL. 60174 ........... FAX 888 782-4825 For Parts & Service in Europe please call ...................................................44-1691-676 236 Skyjack EuropeGlovers Meadow, Maesbury Road, Oswestry, Shropshire, UK .......... FAX 44-169- 676 238

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CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

MODELS

SERIAL NUMBER BREAKDOWN MANUAL PART # 112114

MANUAL PART # 118938

8831

36951 & BELOW

36952 & ABOVE

8841

42028 & BELOW

42029 & ABOVE

TABLE OF CONTENTS

Section - Paragraph

Page No.

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Section 1 - About Your Aerial Platform 1.1 Major Assemblies ..................................................................................................................... 1 1.2 Platform .................................................................................................................................... 1 1.3 Operator’s Control Box ........................................................................................................... 1 1.4 Manual Storage Box ................................................................................................................ 1 1.5 Lifting Mechanism .................................................................................................................. 1 1.6 Maintenance Support .............................................................................................................. 1 1.7 Base - (Models 71xx & 8xx) ..................................................................................................... 1 1.8 Base - (Model 9250) ................................................................................................................ 2 1.9 Tilt Sensing System ................................................................................................................ 2 1.10 Serial Number Nameplate ...................................................................................................... 2 1.11 Major Components ................................................................................................................ 3 1.12 Standard and Optional Features ............................................................................................ 4 1.13 Operator Safety Reminders .................................................................................................... 5 1.14 Electrocution Hazard .............................................................................................................. 5 1.15 Safety Precautions .......................................................................................................... 6, 7, 8

Section 2 - List of Tables

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Table Of Contents ............................................................................................................................. 1

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Section 3 - System component identification and schematics - Operation Table Of Contents ............................................................................................................................. 1

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Section 4 - Troubleshooting information - Operation Table Of Contents ............................................................................................................................. 1 Section 5 - Maintenance and service - Operation Table Of Contents ............................................................................................................................. 1

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Section 6 - Parts lists - Operation List Of Illustrations .............................................................................................................................2

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Mid Size & Full Size RT’s Engine Powered

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The Safety Alert Symbol identifies important safety messages on machines, safety signs in manuals or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

This Safety Alert Symbol Means Attention!

Become Alert! Your Safety Is Involved.

DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

IMPORTANT IMPORTANT indicates a procedure(s) essential for safe operation and which, if not followed, may result in a malfunction or damage to the machine.

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Mid Size & Full Size RT’s Engine Powered

Section 1 - About Your Aerial Platform

1. About Your Aerial Platform

1.5 Lifting Mechanism

This section provides the general information about your aerial platform. It describes the major components, table of standard features & optional equipment, safety reminders and precautions.

The lifting mechanism is constructed of formed steel or tube sections making up a scissor-type assembly. The scissor assembly is raised and lowered by single-acting hydraulic lift cylinders with holding valves. A two-section pump, driven by an engine, provides hydraulic power to the lift cylinders.

1.1 Major Assemblies 1.6 Maintenance Support The aerial platform consists of three major assemblies: the platform, the lifting mechanism and the base. An operator’s control box is mounted on the platform guardrail. Auxiliary and emergency controls are located at the base.

1.2 Platform The platform is constructed of a tubular support frame, a skid-resistant “diamond plate” deck surface and 43-1/2" hinged guardrails with 6" toe boards and midrails. The platform can be entered from either side through a spring returned gate for Full Size RT's and from the rear through a spring returned gate on Mid Size RT's.

The Mid Size RT's are equipped with a front extension platform. The Full Size RT's can be equipped with a front or both front and rear extension platforms.

1.3 Operator’s Control Box A removable control box, mounted at the front right of the platform, contains controls for aerial platform motion and emergency stopping.

1.4 Manual Storage Box This weather-resistant box is mounted to the inside of the hydraulic cabinet door at the base or at the front of the platform. It contains the Operating Manual, the Operating/Maintenance and Parts Manual and other important documentation. The Operating Manual for this make and model of aerial platform MUST remain with the aerial platform and should be stored in this box.

Mid Size & Full Size RT’s Engine Powered

A maintenance support is located inside the lifting mechanism. When properly positioned, it can support the scissor assembly and empty platform. The maintenance support MUST be used during inspection and maintenance or when repairs are being performed within the lifting mechanism.

1.7 Base - (Models 71xx & 8xxx) The base is a rigid, one-piece weldment which supports two side cabinets.

• One cabinet contains the hydraulic components, up/down controls and electrical components. The other cabinet contains the fuel and hydraulic tanks.

• The propane cylinder is either located behind the access ladder or behind the fuel cabinet.

• The front axle has two wheels, steerable by a hydraulic cylinder and is either non-driven (2WD models) or drive shaft/gear box driven (4WD models).

• The rear axle is drive shaft/gear box driven and has a spring-applied hydraulically-released disc parking brake.

A roll-out tray at the front of the base supports an • engine coupled with a two-section hydraulic pump providing power to the hydraulic system.

• An engine control panel is also located at the front of the base.

• The 12V starter battery is located in the hydraulic/ electric cabinet (Models 8831 & 8841) or at the front of the engine roll-out tray (Models 71xx, 8243 & 8850).

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Section 1 - About Your Aerial Platform

1.8 Base - (Model 9250)

1.10 Serial Number Nameplate

The base is a rigid, one-piece weldment which supports two side cabinets.

• One cabinet contains the hydraulic tank, hydraulic components, up/down controls, electrical components, emergency lowering battery and starter battery.

• The other cabinet contains the fuel tank and Liquid Propane (LP) tank (If Equipped).

• The front axle has two wheels, steerable by a hydraulic cylinder and is either non-driven (2WD models) or drive shaft/gear box driven (4WD models).

• The rear axle is drive shaft/gear box driven and has two spring-applied hydraulically-released parking brakes.

• A roll-out tray at the front of the base supports an engine coupled with a two-section hydraulic pump providing power to the hydraulic system.

• An engine control panel is also located at the front of the base.

The serial number nameplate, located at the rear of the machine, lists the following: • Model number • Serial number • Machine weight • Maximum drivable height • Maximum capacities • Maximum number of persons permissible on the platform • Voltage • System pressure • Lift pressure • Maximum platform height • Maximum wheel load • Date manufactured • Maximum wind speed (Australia only) • Maximum manual force (Australia only) • Maximum incline (Australia only) • Gradeability (Australia only)

1.9 Tilt Sensing System

Use this information for proper operation and maintenance and when ordering service parts.

The tilt sensing system located on the base of the aerial platform is designed to prevent lifting or driving when the machine is on a slope greater than a predetermined limit. If in this situation the platform must be lowered immediately.

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Mid Size & Full Size RT’s Engine Powered

Section 1 - About Your Aerial Platform

1.11 Major Components Entry Gate

Operator’s Control Box

Main Platform

Lifting Mechanism

Engine Tray

Hyd/Elect.

Component Cabinet

Base

SKYJACK Model 9250 Aerial Platform Mid Size & Full Size RT’s Engine Powered

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Section 1 - About Your Aerial Platform

1.12 Standard and Optional Features

ROUGH TERRAIN SERIES SPECIFICATIONS ANSI & CSA Mid Size RT's

Models Joystick control Dual range (torque/speed) selector Operator horn Diamond pattern, all steel platform deck construction Hinged guardrail system Lanyard attachment rings Front mounted manual extension deck Rear mounted manual extension deck Front mounted powered extension deck Rear mounted powered extension deck Access ladders and gates at both sides of platform AC outlet on platform Self-centering scissors design Flashing amber bacon Motion alarm Cabinets with lockable swing-out door Hourmeter Tilt alarm with lift/drive cut out Color-coded, numbered wiring system Engine-mounted on roll-out tray 52 hp Nissan dual fuel - gasoline/propane engine 25 hp Kubota diesel water-cooled engine Tie down points Grip lug air-filled tires Grip lug foam-filled tires 4-wheel drive 2-wheel drive Independently operated hydraulic outriggers 1500 watt AC Inverter 3500 watt hydraulic AC generator Spring-applied hydraulically-released disc brake system Dual spring-applied hydraulically-released parking brakes

Full Size RT's

7127

7135

8243

8850

8831

8841

9250

* * * * * * * N/A OPT N/A N/A * N/A * * * * * * * * OPT * * OPT * OPT OPT OPT OPT

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* * * * * * OPT OPT OPT OPT * * * * * * * * * * * OPT * * OPT * OPT OPT OPT OPT

* * * * * N/A N/A N/A OPT OPT * * * * * * * * * * * OPT * * OPT * OPT * OPT OPT

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N/A

N/A

N/A

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N/A

N/A

N/A

* 60375AA-ANSI

* OPT N/A

Standard equipment on these models Optional equipment on these models Not available on these models

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Mid Size & Full Size RT’s Engine Powered

Section 1 - About Your Aerial Platform

Warning Failure to comply with your required responsibilities in the use and operation of the aerial platform could result in death or serious injury!

1.13 Operator Safety Reminders A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to follow simple and fundamental safety rules and precautions.

You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this aerial platform is mandatory. The following pages of this manual should be read and understood completely before operating the aerial platform.

Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety devices to protect your eyes, ears, hands, feet and body.

Any modifications from the original design are strictly forbidden without written permission from SKYJACK Inc. 1.14 Electrocution Hazard This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from energized power lines and parts as listed below. The operator must allow for platform sway, rock or sag. This aerial platform does not provide protection from contact with or proximity to an electrically charged conductor.

DO NOT USE THE MACHINE AS A GROUND FOR WELDING. DO NOT OPERATE THE MACHINE DURING LIGHTNING OR STORMS.

DANGER Avoid Power Lines Minimum Safe Approach Distance Voltage Range (Phase to Phase) 0 To 300V Over 300V to 50KV Over 50KV to 200KV Over 200KV to 350KV Over 350KV to 500KV Over 500KV to 750KV Over 750KV to 1000KV

ANSI/SIA A92.6-1999 & CSA B354.2-01 Requirements Minimum Safe Approach Distance Feet Avoid Contact 10 15 20 25 35 45

FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY! 60023AC-ANSI

Mid Size & Full Size RT’s Engine Powered

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Section 1 - About Your Aerial Platform

1.15 Safety Precautions Know And Understand The Safety Precautions Before Going On To Next Section.

Warning Failure to heed the following safety precautions could result in tip over, falling, crushing, or other hazards leading to death or serious injury

• KNOW all Federal, State, Provincial and local rules which apply to your MACHINE and JOBSITE. • TURN the emergency main power disconnect switch OFF when leaving the machine unattended.

Remove the key to prevent unauthorized use of the aerial platform.

• WEAR all the protective clothing and personal safety devices issued to you or called for by job conditions.

• DO NOT wear loose clothing, dangling neckties, scarves, rings, wristwatches or other jewelry while operating this lift.

• DO NOT increase the lateral surface area of the platform. Increasing the area exposed to the wind will decrease machine stability.

• DO NOT drive or elevate the aerial platform if it is not on a firm level surface. Do not drive elevated near depressions or holes of any type, loading docks, debris, drop-offs and surfaces that may affect the stability of the aerial platform.

• If Operation In Areas With Holes Or Drop-offs Is Absolutely Necessary, elevated driving shall not be allowed. Position the aerial platform horizontally only with the platform fully lowered. After ensuring that all 4 wheels or outriggers have contact with level firm surface, the aerial platform can be elevated.

After elevation, the drive function must not be activated.

• AVOID entanglement with ropes, cords or hoses.

• Elevated driving must only be done on a firm level surface.

• AVOID falling. Stay within the boundaries of the guardrails.

• DO NOT raise the aerial platform in windy or gusty conditions.

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• DO NOT Ascend or descend a grade steeper than 25% (Model 9250), 30% (Models 8831 & 8841) or 35% (Models 71xx, 8243 & 8850). When fully lowered, ascending or descending, only grades up to the above maximums are permissible.

Mid Size & Full Size RT’s Engine Powered

Section 1 - About Your Aerial Platform

1.15 Safety Precautions (Continued) Know And Understand The Safety Precautions Before Going On To Next Section.

• DO NOT operate on surfaces not capable of holding the weight of the aerial platform including the rated load, e.g. covers, drains, and trenches.

• DO NOT operate an aerial platform that has ladders, scaffolding or other devices mounted on it to increase its size or work height. It is prohibited.

• DO NOT raise the aerial platform while the machine is on a truck, fork lift or other device or vehicle.

• BE AWARE of crushing hazards.

Keep all body parts inside platform guardrail.

• DO NOT exert side forces on aerial platform while elevated.

• DO NOT lower the platform unless the area below is clear of personnel and obstructions.

• DO NOT use the aerial platform as a crane. It is prohibited.

• ENSURE that there are no personnel or obstructions in the path of travel, including blind spots.

• DO NOT sit, stand or climb on the guardrails. It is prohibited.

• BE AWARE of blind spots when operating the aerial platform.

• STUNT driving and horseplay are prohibited.

• DO NOT climb on scissor arm assembly. It is prohibited.

• ENSURE ALL tires are in good condition and lug nuts are properly tightened.

• DO NOT alter or disable limit switches or other safety devices.

• BE AWARE of overhead obstructions or other possible hazards around the aerial platform when driving or lifting.

Mid Size & Full Size RT’s Engine Powered

• DO NOT use the aerial platform without guardrails, lock pins and the entry gate/chain/bar in place.

• DO NOT exceed the rated capacity of the aerial platform. Do make sure the load is evenly distributed on the platform.

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Section 1 - About Your Aerial Platform

1.15 Safety Precautions (Continued) Know And Understand The Safety Precautions Before Going On To Next Section.

• DO NOT overload the platform, the lift relief valve does not protect against overloading when the platform is elevated.

• DO NOT attempt to free a snagged platform with lower controls until personnel are removed from the platform.

• DO NOT position the aerial platform against another object to steady the platform.

Jobsite Inspection • Do not use in hazardous locations.

• Perform a thorough jobsite inspection prior to operating the aerial platform, to identify potential hazards in your work area.

• Be aware of moving equipment in the area. Take appropriate actions to avoid collision.

Warning Entering and Exiting the aerial platform should only be done using the three points of contact system.

• Use only equipped access openings and ladders.

• Enter and exit only when the aerial platform is in the fully retracted position.

• Do Use Three Points of Contact to Enter and Exit the Platform. Enter and exit the platform from the ground only. Face the machine when entering or exiting the platform.

• Three Points of Contact means that two hands and one foot OR one hand and two feet are in contact with the aerial platform or the ground at all times during entering and exiting.

Warning An operator should not use any aerial platform that : • Does not have a clean, uncluttered work area.

• Does not appear to be working properly.

• Has been damaged or appears to have worn or missing parts.

• Has alterations or modifications not approved by the manufacturer.

• Has safety devices which have been altered or disabled.

Failure to avoid these hazards could result in death or serious injury.

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Mid Size & Full Size RT’s Engine Powered

Section 2 - Operation

TABLE OF CONTENTS List of Tables Table 2-1A. Specifications and Features - ANSI/CSA ...................................................................................................2 Table 2-1B. Specifications and Features - CE .............................................................................................................3 Table 2-2A. Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA ................................................................4 Table 2-2B. Maximum Platform Capacities (Evenly Distributed) - CE ..........................................................................5 Table 2-3A. Maximum Platform Capacities (Evenly Distributed w/ #7 Tire Equiped) - ANSI/CSA ............................... 6 Table 2-3B. Maximum Platform Capacities (Evenly Distributed w/ #7 Tire Equiped) - CE ........................................... 7 Table 2-4. Tire Specifications .......................................................................................................................................8 Table 2-5. Owner’s Annual Inspection Record .............................................................................................................9 Table 2-6. Floor Loading Pressure ............................................................................................................................. 10 Table 2-7. Maintenance And Inspection Schedule ..................................................................................................... 11

Mid Size & Full Size RT’s Engine Powered

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

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