PDF Operating Manual Skyjack SJ63AJ Articulating Boom - 1 MB
Safety and proper function are paramount when working at height with the Skyjack SJ63AJ Articulating Boom.
This official operating manual provides all the necessary instructions for safe and efficient use of the equipment.
It covers platform controls, ground controls, pre-operation inspections, and emergency procedures.
Ensure all operators are fully trained and have access to this vital information to maintain a safe work environment.
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OPERATING MANUAL (ANSI/CSA)
ARTICULATING BOOMS
MODEL SJ63AJ
159186AD-A August 2014
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Section 1 - About Your Aerial Platform Safety Rules
Safety Precautions
Know and understand the safety precautions before going on to next section.
Fall Protection • Do use three points of contact to enter and exit
All occupants of this aerial platform must wear the platform. Enter and exit the platform from
personal fall protection equipment. the ground only. Face the aerial platform when
entering or exiting the platform.
As per the ANSI A92.5-2006 standard, “Principal
fall protection is provided by the guardrail system. • Three points of contact means that two hands
The user shall direct and monitor the operator to and one foot or one hand and two feet are in
ensure that all components of the guardrail system contact with the aerial platform or the ground at
are in place. The user shall direct and monitor all times during entering and exiting.
the occupants of the work platform to ensure that
they wear a personal fall arrest system to protect WARNING
against the potential effects of ejection or a fall
restraint system to prevent a free fall.” An operator should not use any aerial platform that:
Fall restraint and fall arrest systems are defined • does not appear to be working properly.
within the ANSI A92.5 Manual of Responsibilities • has been damaged or appears to have worn
shipped with this aerial platform. or missing parts.
• has alterations or modifications not approved
Skyjack recommends the use of a fall restraint by the manufacturer.
system to keep an occupant within the confines • has safety devices which have been altered
of the platform, and thus not expose the occupant or disabled.
to any fall hazard requiring a fall arrest. • has been tagged or locked out for non-use or
repair.
CSA B354.4-02 requires the use of a fall arrest
system, therefore Canadian users must use Failure to avoid these hazards could result in death
personal fall arrest protection as opposed to fall or serious injury.
restraint.
Jobsite Inspection
All personal fall protection equipment must comply • Do not use in hazardous locations.
with applicable governmental regulations and must • Perform a thorough jobsite inspection prior to
be inspected and used in accordance with the operating the aerial platform, to identify potential
manufacturer’s recommendations. hazards in your work area.
• Be aware of moving equipment in the area. Take
All personal fall protection equipment must be appropriate actions to avoid collision.
attached only to approved anchorage points within
the platform of the aerial platform.
WARNING
Entering and exiting the aerial platform
should only be done using the three
points of contact.
• Use only equipped access openings.
• Enter and exit only when the aerial
platform is in the fully retracted position.
SJ 63AJ
December 2007 Page 11
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Section 2 - Familiarization Visual & Maintenance Inspection
High Pressure
Filter
Muffler
Battery
Air Filter
Swing Drive
Motor
Main Power
Disconnect
Switch
2.3-5 Engine Compartment
- Ensure all compartment latches are secure 1. Check battery cases for damage.
and in proper working order.
2. Clean battery terminals and cable ends
• Main Power Disconnect Switch thoroughly with a terminal cleaning tool or
- Turn main power disconnect switch to wire brush.
“ ” off position.
- Ensure there are no loose or missing 3. Ensure all battery connections are tight.
parts and there is no visible damage.
4. If applicable, check battery fluid level. If plates
- Ensure all cables are secure and switch are not covered by at least 1/2” (13 mm) of
is in proper working condition. solution, add distilled or demineralized water.
• Battery
5. Replace battery if damaged or incapable of
Proper battery condition is essential to good
holding a lasting charge.
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component WARNING
damage and hazardous conditions. Use original or manufacturer-approved
parts and components for the aerial
WARNING platform.
Explosion hazard. Keep flames
and sparks away. Do not smoke
FAMILIARIZATION
near batteries.
WARNING
Battery acid is extremely corrosive -
Wear proper eye and facial protection as
well as appropriate protective clothing.
If contact occurs, immediately flush with
cold water and seek medical attention.
SJ 63AJ
December
It is the responsibility of the operator to 2007
read, completely understand and follow all instructions and warnings Page 21
contained in this operating manual and on the aerial platform.
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Section 2 - Familiarization Function Tests
Base Control Console
Off/Base/Platform Base/Off/Platform
Key Switch Key Switch
Emergency Emergency
Stop Stop
Start/Function
Enable/
Emergency
Power Switch
NOTE • Test Off/Base/Platform (Base/Off/
To conserve battery power, test each Platform) Switch
function through a partial cycle.
1. Ensure both “ ” emergency stop
3. On base control console, pull out “ ” buttons are pulled out.
emergency stop button. Result: Glow plug light should turn on and
turn off after a slight delay.
4. O n b a s e c o n t r o l c o n s o l e , t u r n
off/base/platform (base/off/platform) key 2. Start engine.
switch to “ ” platform position. 3. O n b a s e c o n t r o l c o n s o l e , t u r n
off/base/platform (base/off/platform) key
5. Select “ ” emergency power position switch to “ ” off position.
from start/function enable/emergency Result: Engine should shut down and
power switch and activate each boom aerial platform functions should not
function. operate.
Result: All selected functions should
operate. 4. O n b a s e c o n t r o l c o n s o l e , t u r n
off/base/platform (base/off/platform) key
6. Turn off/base/platform (base/off/platform)
key switch to “ ” base position. switch to “ ” platform position.
WARNING
7. Select “ ” emergency power position
FAMILIARIZATION
from start/function enable/emergency Ensure that you maintain three points
power switch and activate each boom of contact to mount/dismount platform.
function.
Result: All selected functions should 5. Enter platform and close gate.
operate.
6. On platform control console, select “ ”
NOTE on position from engine enable switch.
The emergency power unit has a
three-minute duty cycle.
SJ 63AJ
December
It is the responsibility of the operator to 2007
read, completely understand and follow all instructions and warnings Page 31
contained in this operating manual and on the aerial platform.
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Section 2 - Familiarization Procedures
2.5 Winching and Towing Procedure a) Ensure aerial platform is on level ground.
This section provides the operator with procedure about Chock or block wheels to keep aerial platform
winching and towing and on how to manually release from rolling.
brakes.
WARNING b) Turn main power disconnect switch to “ ” off
position.
Ensure boom is in stowed position before
winching or towing. Sudden motion could
cause aerial platform to become unstable. CAUTION
Death or serious injury could result. Do not use hydraulic power with brake
disengaged.
WARNING
c) Locate the bypass valve on the inboard side
In emergency situations where aerial of the drive pump. Bypass the drive pump by
platform functions are not available and rotating the valve stem (item 1 - marked with
lowering is impeded by an obstacle, yellow paint) by 90 degrees (clockwise).
utmost care must be taken to move
aerial platform far enough to clear
obstacle. In such cases, operation must
be extremely smooth with no sudden 1
movements and must not exceed a speed
of 2 in./sec (50 mm/sec).
WARNING
When pushing, winching or towing, do
not exceed 2 mph (3.2 km/h).
WARNING Figure 2-7. Drive Bypass Valve
Do not winch or tow aerial platform on
CAUTION
grade steeper than 45%.
Do not release brakes before disengaging
WARNING drive motor!
Do not winch or tow aerial platform onto a d) Push in black brake valve plunger (item 2).
slope, or brake the towing vehicle rapidly.
Do not pull aerial platform down an incline
towards a winch.
3
1. Before winching or towing aerial platform, fully
retract, lower and position boom over rear drive
wheels in line with direction of travel.
2
2. Manually release brakes using the following steps:
NOTE
FAMILIARIZATION
Brakes must be manually disengaged for
winching or towing.
Figure 2-8. Brake Manifold
WARNING e) Actuate red hand pump (item 3) slowly by
Do not manually disengage brakes if moving knob in and out until firm resistance is
aerial platform is on a slope. felt or until 300 psi/21 bar shows on the gauge
(if equipped). Brake is now released.
SJ 63AJ
December
It is the responsibility of the operator to 2007
read, completely understand and follow all instructions and warnings Page 41
contained in this operating manual and on the aerial platform.
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Section 3 - Operation Operator’s Responsibility
3.7 Operator’s Responsibility
It is the responsibility of the operator, prior to each work 3. Cold Weather Hydraulic System Warm Up
shift, to perform the following:
WARNING
1. Visual and Daily Maintenance Inspections
Caution must be exercised when
• are designed to discover any damage of operating aerial platform in cold
components before the aerial platform is put into temperature. Cold temperature can
service. affect the performance of the aerial
platform. Braking response and other
• are done before the operator performs the function functions may delay.
tests.
CAUTION
WARNING Ensure hydraulic oil throughout system
Failure to locate and repair damage, and is warmed before operating aerial
discover loose or missing parts may platform in low temperatures. Failure to
result in an unsafe operating condition. heed this warning can lead to unexpected
movements, product damage, death or
2. Function Tests serious injury.
• are designed to discover any malfunctions before Boom Functions:
the aerial platform is put into service.
WARNING
IMPORTANT Be aware of overhead obstructions or
The operator must understand and follow other possible hazards around the aerial
the step-by-step instructions to test all platform when lifting.
aerial platform functions.
- Run engine at low throttle.
The operator should make a copy of the Operator’s - Raise, lower, extend and retract boom slowly
Checklist (see Table 4.8) and fill out the visual and daily several times until boom functions are at
maintenance inspections and the function tests sections acceptable operating performance.
while performing the items outlined in Section 2.3 and
Section 2.4.
Drive Functions:
IMPORTANT
If aerial platform is damaged or any WARNING
unauthorized variation from factory-
delivered condition is discovered, aerial Ensure that there are no personnel
platform must be tagged and removed or obstructions in the path of travel,
from service. including blind spots.
Repairs to the aerial platform may only be made by a - Run engine (if applicable) in low throttle.
qualified service technician. After repairs are completed, - Drive aerial platform forward and backward
the operator must perform visual and daily maintenance slowly several times until braking response
inspections & function tests again. is in safe operating performance.
Scheduled maintenance inspections shall only
be performed by qualified service technician (see
Table 4.7).
SJ 63AJ
December 2007 Page 51
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Section 3 - Operation Loading/Unloading
3.10-2 Locking the Turret
WARNING
1. Ensure that turret is positioned so that turret Use chains of ample load capacity
transportation lock tube (item 1 - Figure 3-5) is sufficient to withstand aerial platform
aligned into one of two turret locking points in the weight.
turret rotation lock plate.
1. Place boom in stowed position centered
2. Pull out turret lock retaining pin (item 2 - Figure 3-5). between drive wheels. Lock turret using turret
Lower turret lock into locked position and reinsert transportation locking pin (refer to Section 3.10-2)
turret lock retaining pin. into the transport point (refer to Figure 3-5).
3.10-3 Lifting 2. Turn main power disconnect switch to “ ” off
position.
NOTE
When it becomes necessary to lift aerial 3. Remove all loose items from aerial platform.
platform, it is very important that lifting
devices are attached only to designated 4. Properly adjust rigging to prevent damage to aerial
lifting points (refer to Figure 3-6). platform and so aerial platform remains level.
Transport Point
1 2
Figure 3-5. Turret Transportation Lock & Locking Points
Figure 3-6. Lifting Points
NOTE: Center of gravity varies with different options.
SJ 63AJ
December 2007 Page 61
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Section 4 Tables
General Maintenance
Before attempting any repair work, disconnect battery by turning main power disconnect switch to
“ ” off position. Preventive maintenance is the easiest and least expensive type of maintenance.
Table 4.7 Maintenance and Inspection Schedule
3 months or 3 months or
Frequency Daily Yearly Frequency Daily Yearly
150 hours 150 hours
Visual and Daily Maintenance Inspections Cylinders A
Labels A Wear Pads A
Electrical A Hoses A
Limit Switches A Power Track A
B*†
Hydraulic A Special Options
Engine Compartment Battery Warmer/Hydraulic Oil Heater (If Equipped) A
Main Power Disconnect Switch A Work Light (If Equipped) A
Battery A Flashing Amber Light (If Equipped) A
High Pressure Filter A Function Tests
Hydraulic Pumps A Test Main Power Disconnect Switch A
Muffler and Exhaust A Base Control Console
Engine Pivot Tray A Test Base Emergency Stop Light A
Engine Oil Level A Test Base Emergency Stop A
Engine Air Filter A Test Function Enable Switch & All Boom Functions A
Fuel Leaks A Test Platform Self-leveling A
Control Compartment Test Emergency Power A
Base Control Console A Test Base/Off/Platform Switch A
Hydraulic Tank A Platform Control Console
Hydraulic Oil A B*† Test Platform Emergency Stop Light A
Brake and Main Manifolds A Test Platform Emergency Stop A
Emergency Power Unit A Test Footswitch A
Fuel Tank A Test Engine Enable Switch A
Fuel Leaks A Test Steering A B*†
Base Test Driving Function A
Turret Transportation Lock A Test Driving Speed A
Drive Axle A Test Emergency Power A
Oscillating Cylinder Assembly A Test Horn A
Steer Cylinder Assembly A Test Brakes A
Tie Rod A Test Manual Platform Leveling A
Wheel/Tire Assembly A Test Differential Lock Switch A
Manuals A Test Oscillating Axles A
Platform Assembly A Optional Equipment/Attachments
Platform Control Console A Test Work Light (If Equipped) A
Rotary Actuator A Test All Motion Alarm (If Equipped) A
Jib A Test Flashing Amber Light (If Equipped) A
Boom Test Hydraulic Generator (If Equipped) A
1037AA_ANSI
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.3 and Section 2.4 of this manual.
B - Perform Scheduled Maintenance Inspection. Refer to Service & Maintenance manual.
* - Maintenance must be performed only by trained and competent personnel who are familiar with mechanical procedures.
† - Refer to Skyjack's website @ www.skyjack.com for latest service bulletins prior to performing quarterly or yearly inspection.
WARNING
Use original or manufacturer-approved parts and components for aerial platform.
SJ 63AJ
December 2007 Page 71
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Section 5 Labels
Control Compartment
11
2
1
8
9
D 102962AC
ZZ
10
3 3
7 6 5 4 7 6 5 4
No. Label Pictorial Description
Hydraulic Oil Level
Indicates minimum/maximum oil level.
2
Lift and Tie Down Points
Only use these points for lifting or tying down.
3
Tire Pressure*
Indicates rated tire pressure.
*Tire pressure will vary, may not be as shown.
4
Foam-filled Tire (If Equipped)
Indicates foam-filled tire.
Wheel Load*
Indicates rated wheel load.
5 *Wheel load will vary over different aerial platforms.
SJ 63AJ
December 2007 Page 81