Skyjack SJ 8831 SJ 8841 Full-Size Rough Terrain Series Parts Manual 143902AE – PDF DOWNLOAD

MODELS SJ 8831 SJ 8841

Parts Manual Full-Size Rough Terrain Series

Part No. 143902AE February 2014

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

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

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

This manual is based on Serial Numbers: SJ 8831 SJ 8841

ANSI/CSA & AS 36,000,194 TO 36,000,232 40,000,442 TO 40,000,727

SJ 8831 SJ 8841

CE 36,000,194 TO 36,000,228 40,000,442 TO 40,000,635

Please refer to the website www.skyjack.com for older Serial Numbers.

Skyjack Service Center

Parts & Service (Europe)

3451 Swenson Ave. St. Charles, Illinois, 60174 USA Phone: 630-262-0005 Toll Free: 1-800-275-9522 Fax: 630-262-0006 Email: service@skyjack.com

Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK Phone: +44-1691-676-235 Fax: +44-1691-676-238 E-mail: info@skyjackeurope.co.uk

Parts (North America)

Skyjack Brasil

Toll Free: 1-800-965-4626 Toll Free Fax: 1-888-782-4825 E-mail: parts@skyjack.com

Alameda Júpiter, 710 Loteamento American Park Empresarial Indaiatuba, SP, Brasil 13347-653 Tel: +55 19 3936 0132

Skyjack Australia Pty Ltd. 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel: +61 (0) 28786 3200 Fax: +61(0) 28786 3222

Full-Size Rough Terrain Series Parts Manual General The information contained in this section is designed to aid the user in locating and identifying replacement parts. Component parts of various assemblies and sub-assemblies comprising the work platform are illustrated and accompanied by a descriptive parts list.

Exploded drawings are used to show relative location of component parts in disassembly order. If a part cannot be found in this section, order by work platform model number and serial number, giving a complete description of the part.

Parts Ordering Information When ordering replacement parts, the complete part number and description should be used to ensure proper identification and delivery of the desired item.

This complete identification should also be used when requesting equipment information.

Method Of Listing Parts are listed in order according to the reference number shown in the illustration, followed by a full description based upon the “NOUN FIRST” method.

That is, the noun name of the part is listed first, then the modifying description information which serves to specifically identify the item. For example: PIN, Clevis.

Assemblies or groups are shown at the beginning of a parts list and are identified with the letter references A, B, C, etc. Individual parts in these lists have corresponding letters after their description to identify which assembly or group it is used in. Individual parts without identifying letters are used in all the assemblies or group shown at the beginning of the parts list. Descriptions preceded with an (•) indicates a serviceable component or attaching hardware for the higher level assembly. If

an index number initially starts with the letter “K”, for example “K1”, means it’s a kit. Any item(s) included in a kit will not have an index number.

Quantities (Units Per Assy.)

The quantities of each part that are required to complete the assembly. If quantity is (AR), it is understood that the quantity may vary when machine is equipped with certain options. Order quantity as needed.

Hardware Standard screws, washers, nuts, etc. are not identified by a reference number. These parts are known as COMMON HARDWARE items and appear indented under the major items with which they are used. They should be ordered separately as listed, since they are not component parts of the pieces they attach to.

How To Order Repair Parts 1. Address all orders to your local SKYJACK dealer.

2. Specify model and serial number of the work platform (found on the serial number plate).

3. List the quantity needed.

4. List the length needed (if bulk item).

5. List the part number and description as shown in this manual for each item.

6. Show billing and shipping address and name of individual if possible.

7. Suggest best routing.

CUSTOMER___________________________________________________________________ DEALER______________________________________________________________________ MODEL NUMBER ______________________________________________________________ SERIAL NUMBER ______________________________________________________________ DATE PURCHASED ____________________________________________________________

Use Only Skyjack Authorized Replacement Parts!

Full-Size Rough Terrain Series Models 8831 & 8841 143902

SKYJACK, Page 3

Table Of Contents Platform Related Parts Figure 1.1 Main Platform And Railings............................................................................................................ 8 Figure 1.2 4 Ft. Roll-out Extension Platform Assembly ................................................................................ 12 Figure 1.3 4 Ft. Powered Extension Platform Assembly .............................................................................. 14 Figure 1.4 Powered Extension Platform Control Console Assembly ........................................................... 18 Figure 1.5 Powered Extension Platform Cylinder Assembly ........................................................................ 19 Figure 1.6 Powered Extension Platform Electrical Panel .............................................................................. 20 Figure 1.7 Hydraulic Hose Connections - Single Powered Extension Platform........................................... 22 Figure 1.8 Hydraulic Hose Connections - Dual Powered Extension Platforms (Model 8831) .................... 23 Figure 1.9 Hydraulic Hose Connections - Dual Powered Extension Platforms (Model 8841) ..................... 24 Figure 1.10 Safety D-ring Assembly ............................................................................................................... 25 Figure 1.11 Platform Control Console Assembly - Hardware......................................................................... 26 Figure 1.12 Platform Control Console Assembly - Switches .......................................................................... 28 Figure 1.13 Drive/Steer Controller Assembly.................................................................................................. 30 Figure 1.14 Control Cable Assemblies ........................................................................................................... 32 Scissor Related Parts Figure 2.1 Scissor Arm Assembly - Model 8831........................................................................................... 34 Figure 2.2 Scissor Arm Assembly - Model 8841........................................................................................... 38 Figure 2.3 Scissor Stack Mounting Hardware Assemblies .......................................................................... 42 Figure 2.4 Scissor Arm Connecting Hardware Assemblies ......................................................................... 44 Figure 2.5 Horn, Light & Beeper Assemblies (ANSI/CSA) ........................................................................... 46 Figure 2.6 Horn, Light, Beeper, & Load Sensing Assemblies (CE) .............................................................. 49 Figure 2.7 Lift Cylinder Assembly ................................................................................................................. 50 Figure 2.8 Hydraulic Hose Connections- Scissors ....................................................................................... 52 Figure 2.9 Lift Cylinder Holding Valve Manifold Assembly ........................................................................... 54 Figure 2.10 Lift Cylinder Holding Valve Manifold Assembly with Transducer (CE) ........................................ 55 Base Related Parts Figure 3.1 Base, Axles and Wheels .............................................................................................................. 56 Figure 3.2 Hydraulic Hose Connections - Base (Cushman/Dana Axles) ..................................................... 62 Figure 3.3 Fuel/Tank Hydraulic Oil Tank Cabinet Assembly ........................................................................ 64 Figure 3.4 Hydraulic Oil Tank Assembly ....................................................................................................... 66 Figure 3.5 Fuel Tank Assembly ..................................................................................................................... 68 Figure 3.6 Hydraulic/Electric Cabinet Assembly .......................................................................................... 70 Figure 3.7 Hydraulic Hose Connections - Cabinet Assembly ..................................................................... 74 Figure 3.8 Auto Reset Brake Manifold Assembly ......................................................................................... 76 Figure 3.9 Motion Control Valve System....................................................................................................... 77 Figure 3.10 Main Manifold Assembly .............................................................................................................. 78 Figure 3.11 Base Control/Electrical Panel Assembly ..................................................................................... 80 Figure 3.12 Base Control/Electrical Panel Harnesses .................................................................................... 84 Figure 3.13 Base Control Console Assembly ................................................................................................. 86

SKYJACK, Page 4

Full-Size Rough Terrain Series Models 8831 & 8841 143902

Table Of Contents Axle Related Parts Figure 4.1 Front Idle Axle Assembly (For 2-wheel Drive Aerial platforms) ................................................... 88 Figure 4.2 Front Axle Hardware Assembly - All Wheel Drive Option (Cushman Axles) ............................. 90 Figure 4.3 Front Axle Assembly - All Wheel Drive Option (Cushman Axles)............................................... 92 Figure 4.4 Front Axle Assembly (Axle End) - All Wheel Drive Option (Cushman Axles) ............................. 94 Figure 4.5 Front Axle (Differential Assembly) - All Wheel Drive Option (Cushman Axles) ........................ 96 Figure 4.6 Front & Rear Axle (Wheel Hub Assembly) - All Wheel Drive Option (Cushman Axles) ............. 98 Figure 4.7 Front Axle (Axle Shaft Assembly) - All Wheel Drive Option (Cushman Axles) .......................... 99 Figure 4.8 Steer Cylinder Assembly (4WD / Cushman Front Axle - 4WD) (Cushman Axles) ................... 100 Figure 4.9 Front Axle Assembly (For 4-wheel Drive Aerial platforms) (Dana Axles) ................................. 102 Figure 4.10 Front Drive Axle Assembly - 4-wheel Drive (Dana Axles) .......................................................... 104 Figure 4.11 Steer Cylinder Assembly (Dana Axles) ...................................................................................... 108 Figure 4.12 Drive Shaft Assembly ................................................................................................................. 109 Figure 4.13 Drive Motor Assembly ................................................................................................................ 111 Figure 4.14 Center Drive Assembly .............................................................................................................. 112 Figure 4.15 Rear Axle Assembly - (Cushman Axles) .................................................................................... 114 Figure 4.16 Rear Axle (Differential Assembly) - (Cushman Axles) .............................................................. 116 Figure 4.17 Rear Axle (Brake Assembly) - (Cushman Axles) ....................................................................... 118 Figure 4.18 Rear Drive Axle Assembly (Dana Axles) .................................................................................... 120 Figure 4.19 Disc Brake Assembly (Dana Axles) .......................................................................................... 122 Figure 4.20 Disc Brake Cylinder Assembly (Dana Axles) ............................................................................. 125 Engine Related Parts Figure 5.1 Engine Roll Out Tray & Cover Assembly ................................................................................... 126 Figure 5.2 Engine Control Panel ................................................................................................................. 128 Figure 5.3 Engine Tray Lock Assembly ..................................................................................................... 131 Figure 5.4 Diesel Engine Assembly (Kubota Diesel Engine D1305) ......................................................... 132 Figure 5.5 Diesel Fuel System (Kubota Diesel Engine D1305) ................................................................. 138 Figure 5.6 Kubota Diesel Fuel Engine Harness .......................................................................................... 140 Figure 5.7 Air Intake Assembly (Kubota Diesel Engine D1305) ................................................................. 142 Figure 5.8 Hydraulic Pump Assembly ........................................................................................................ 143 Figure 5.9 Exhaust Manifold Assembly (Kubota Diesel Engine D1305) .................................................... 144 Figure 5.10 Engine Roll Out Accessories (GM Dual Fuel Engine) .............................................................. 146 Figure 5.11 Dual Fuel Engine Assembly (GM Dual Fuel Engine)................................................................ 148 Figure 5.12 Bell Housing Assembly (GM Dual Fuel Engine) ....................................................................... 154 Figure 5.13 Engine Interface Harness (GM Dual Fuel Engine) ................................................................... 156 Figure 5.14 Dual Fuel Hose Assembly (GM Dual Fuel Engine) .................................................................. 158

Full-Size Rough Terrain Series Models 8831 & 8841 143902

SKYJACK, Page 5

Table Of Contents Optional Equipment Figure 6.1 Hydraulic Outrigger Option - Hydraulic Hose Connections ...................................................... 160 Figure 6.2 Hydraulic Outrigger Option - Leg Assembly ............................................................................. 162 Figure 6.3 Hydraulic Outrigger Option - Cylinder Assembly ...................................................................... 164 Figure 6.4 Hydraulic Outrigger Option - Manifold Assembly ..................................................................... 165 Figure 6.5 Hydraulic Outrigger Option - Electrical Panel Assembly........................................................... 166 Figure 6.6 Hydraulic Outrigger Option (Auto level) - Electrical Panel Connections ................................. 168 Figure 6.7 Outrigger/Hydraulic Generator Control Console Assembly...................................................... 170 Figure 6.8 3500 Hydraulic Generator & Oil Cooler Option ......................................................................... 172 Figure 6.9 12kW Hydraulic Generator & Oil Cooler Option........................................................................ 174 Figure 6.10 Hydraulic Generator & Oil Cooler Assembly ............................................................................. 176 Figure 6.11 12kW Generator Mount & Breaker Box Assembly .................................................................... 179 Figure 6.12 Hydraulic Connections - 12kW Generator ................................................................................. 180 Figure 6.13 Hydraulic Valve Assembly - 12kW Generator ............................................................................ 181 Figure 6.14 Welder Option (ANSI/CSA) ........................................................................................................ 182 Figure 6.15 1500W Inverter Option ............................................................................................................... 184 Figure 6.16 Load Sensing Components (CE) .............................................................................................. 186 Figure 6.17 Air Hose to Platform Option ....................................................................................................... 188 Figure 6.18 Work Light Option ...................................................................................................................... 189 Figure 6.19 Platform AC Outlet ..................................................................................................................... 190 Figure 6.20 Scissor Guard Option ................................................................................................................ 192 Labels Figure 7.1 Figure 7.2 Figure 7.3 Figure 7.4 Figure 7.5

Label Kit ..................................................................................................................................... 197 Labels And Nameplates - Misc .................................................................................................. 198 Labels And Nameplates - Control Console Assemblies ........................................................... 200 Labels And Nameplates ............................................................................................................. 202 Labels - Outrigger ...................................................................................................................... 204

Tables Table 1.1

SJRT Scissor Fluids ................................................................................................................... 206

SKYJACK, Page 6

Full-Size Rough Terrain Series Models 8831 & 8841 143902

Notes

Figure 1.1 Main Platform And Railings

6

AD

12

4 4 7

11

5

5

7 8

6 28 10 9

2 3 9

17 16

21 1

20

22 23

19

13

24 18 15 14

25

26 27

M134041AC

SKYJACK, Page 8

Full-Size Rough Terrain Series Models 8831 & 8841 143902

Figure 1.1 Main Platform And Railings Index No.

Skyjack Part No.

Qty.

A B C

-

-

HINGED RAILING ASSEMBLY (with no extension platform) HINGED RAILING ASSEMBLY (with one extension platform) HINGED RAILING ASSEMBLY (with two extension platform)

1

107623 104625 103978 111845 111845 111842 111842 111808 111808 107621 107621 107615 111840 111840 107621 107621 107617 132814 132816 103865 103984 103996 124547 134355 115649 (Ref.)

1 16 16 2 1 2 1 2 1 1 2 2 2 1 1 2 2 1 1 2 2 2 1 1 1 -

107614 108791 101778 117290 117291 103873 104606 117289 117277 103856 104000 103983 103632 106915 103865 103984 104183

8 1 AR 2 2 4 4 2 4 12 12 12 12 2 4 4 54”

WELDMENT, Main platform SCREW, Set (3/8”-16 x 5/8”) NUT, Hex (3/8”-16) RAILING, Upper end, A RAILING, Upper end, B RAILING, Lower end, A RAILING, Lower end, B RAILING, Upper side, A RAILING, Upper (Rear left hand), B RAILING, Upper (Front right hand), B RAILING, Upper side, C RAILING, Lower side RAILING, Upper side, A RAILING, Upper (Rear right hand), B RAILING, Upper (Front left hand), B RAILING, Upper side, C RAILING, Lower side PLATFORM CONTROL CONSOLE MOUNTING ASSEMBLY • WELDMENT, Control console mount • BOLT, Hex head (5/16”-18 x 2”) • NUT, Lock (5/16”-18) • WASHER, Flat (5/16”) • PIN, Quick release assembly small loop • SCREW, Machine flat head (1/4”-20 x 3/4”) • NUT, Hex nylon lock (1/4”-20, Grade 5) RING KIT, Safety (For components, refer to Figure 1.10) PLATE, Railing retainer CLIP, Cable (stick-on) CLAMP, Entry railing GATE, Half (Hinged - top) GATE, Full (Hinged - top) BOLT, Hex head (3/8”-16 x 2.5”) NUT, Lock (3/8-16) GATE, Bottom (Hinged) HINGE, Spring return (Stanley) BOLT, Hex head (1/4”-20 x 3/4”) WASHER, Lock (1/4”) NUT, Jam (1/4”-20) SCREW, Self-tapping (1/4”-14 x 3/4”) RAILING, Gate top (Aerial platforms with half gate) BOLT, Hex head (5/16”-18 x 2”) NUT, Lock (5/16”-18) PAD, Entry insulation (with half gate)

2 3 4

5 6

7 8

9 10 11 12 13

14 15

16

17

AD

Description

Parts list continued on the following page.

Full-Size Rough Terrain Series Models 8831 & 8841 143902

SKYJACK, Page 9

Figure 1.1 Main Platform And Railings (Continued)

6

AD

12

4 4 7

11

5

5

7 8

6 28 10 9

2 3 9

17 16

21 1

20

22 23

19

13

24 18 15 14

25

26 27

M134041AC

SKYJACK, Page 10

Full-Size Rough Terrain Series Models 8831 & 8841 143902

Figure 1.1 Main Platform And Railings (Continued) Index No.

Skyjack Part No.

Qty.

AD

Description

Parts list continued from the previous page.

18 19 20 21 22 23 24 25 26 27 28

103107 105310 105307 105312 110693 103632 100702 109377 120143 119943 119945 100509 105807

2 2 2 2 2 4 AR 2 1 1 4 AR AR

Full-Size Rough Terrain Series Models 8831 & 8841 143902

SPRING, Compression PIN, Roll (1/8” x 1.25”) PLATE, Latch release GUIDE, Spring STOP, Latch SCREW, Self-tapping (1/4-14 x 3/4”) CAP, Tube end PIN, Latch (5/8” x 4-3/16”) Extension, Gate (CE) PLATE, Gate clamp (CE) RIVET, Pop Wide Head (CE) PIN, Locking (3/8”) CABLE, Lanyard (6”)

SKYJACK, Page 11

Figure 1.2 4 Ft. Roll-out Extension Platform Assembly 8

9

7 6 L 22

5

10

4 3 20

19

21 14 17 18

11 12 14

21

2

1 16

17

15 14

13

M10033AA

SKYJACK, Page 12

Full-Size Rough Terrain Series Models 8831 & 8841 143902

Figure 1.2 4 Ft. Roll-out Extension Platform Assembly Index No.

Skyjack Part No.

Qty.

Description

NOTE: Quantities shown are for a single extension platform.

1

107639 105829 100141 106432 117200 115531 117199 115015 112467 115543 115014 115016 117198 (Ref.)

1 2 2 2 1 AR 1 1 2 2 1 1 1 -

102237 110425 111136 114998 105673 101954 107057 112389 100509 105807 (Ref.)

2 8 2 2 AR AR 4 1 AR AR -

22

130229 103632

1 4

L

(Ref.)

-

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21

Full-Size Rough Terrain Series Models 8831 & 8841 143902

WELDMENT, Extension platform • PIN, Roller (3/4” x 2-3/8”) • ROLLER, Rear U-BOLT (1/4-20 x 3/4”ID) RAILING, Pivoting front LABEL, Falling hazard RAILING, Side RH TUBE, Push bar lower RH PLUNGER, Quick release pull ring LABEL, No step WELDMENT, Push bar upper TUBE, Push bar lower LH RAILING, Side LH WELDMENT, Main platform (For components, refer to Figure 1.1) PIN, Roller (3/4” x 3-11/32”) PAD, Platform slider (Ø 1”x 11/32”) ROLLER, Extension platform PAD, Extension stop PAD, Slider (Ø 1-1/2” x 1/2”) PAD, Slider (Ø 1-1/2” x 3/8”) PAD, Platform slide (3/8 x 1-3/4 x 4”) PIN, Quick release PIN, Locking (3/8”) CABLE, Lanyard (6”) RING KIT, Safety (For components, refer to Figure 1.10) PLATE, Safety label • BOLT, Self tapping (1/4-14 x 3/4”) LABEL, Extension platform (For components, refer to Figure 7.2)

SKYJACK, Page 13

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

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

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL