PDF Service Manual Skyjack SJ8831 RT SJ8841 RT Scissor Lift - 2 MB
This is the factory service manual for the Skyjack SJ8831 RT and SJ8841 RT Rough Terrain Scissor Lifts.
It contains all the information needed for qualified technicians to perform complete service and repairs.
The manual includes detailed procedures, hydraulic and electrical schematics, and troubleshooting charts.
This guide is essential for maintaining the safety and functionality of your Skyjack lift.
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.
SERVICE MANUAL (ANSI/CSA)
ROUGH TERRAIN SCISSORS
MODELS SJ8831 RT SJ8841 RT
157945AE March 2018
--- Page 3 ---
Operatorβs Responsibility for Maintenance Service and Maintenance
Safety Precautions (Continued)
Know and understand the safety precautions before going on to next section.
β’ DO NOT use the aerial platform β’ DO NOT attempt to free a snagged platform with
without guardrails, locking pins lower controls until personnel are removed from
and the entry gate(s) in place. the platform.
β’ DO NOT position the aerial platform against
another object to steady the platform.
β’ DO NOT use under influence β’ DO NOT place materials on the guardrails
of alcohol or drugs. or materials that exceed the confines of the
guardrails unless approved by Skyjack.
β’ STUNT driving and horseplay are prohibited.
β’ DO NOT exceed the rated
capacity of the aerial platform.
β’ DO NOT distribute load
unevenly.
β’ DO NOT operate if aerial plat-
form is not working properly
or if any parts are damaged or
worn.
β’ DO NOT leave aerial platform
unattended with key in key
switch.
Mid Size & Full Size SKYJACK, Page 11
Rough Terrain Series
--- Page 4 ---
Section 1 - Scheduled Maintenance Service and Maintenance Inspections
Main Manifold Base Control
Switches
Electrical Panel
Emergency Lowering
Access Rod
Emergency Main
Power Disconnect
Switch
Brake Manifold
Battery
Load/Tilt
Cushion Cylinder Motion Control Manifold
Sensor
β’ Manifolds
- Ensure all fittings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.
- Ensure there are no loose wires or
missing fasteners.
β’ Electrical Panel
- Ensure panel is properly secured and
there is no visible damage.
- Ensure there are no loose wires or
missing fasteners.
β’ Tilt Sensor
- Ensure tilt sensor is properly secured and
there is no visible damage.
Mid Size & Full Size SKYJACK, Page 21
Rough Terrain Series
--- Page 5 ---
Section 1 - Scheduled Maintenance Function Tests
Drive/Steer Enable Rocker Switch
Trigger Switch
Drive/Steer
Torque Switch Controller
Low/High Throttle
Switch
Low/High Speed Range
Switch Operation Light
Horn Raise/Off/Lower
Pushbutton Switch
Glow Plug/Choke
Off/Lift/Drive Key
Pushbutton
Switch
Engine Start
Pushbutton Emergency Stop
Button
Lift Enable
Pushbutton
1.2 Function Tests
Function tests are designed to discover any malfunctions 4. For dual fuel engine, select fuel supply by moving
before aerial platform is put into service. The operator
must understand and follow step-by-step instructions fuel switch to either β β gasoline or β β
to test all aerial platform functions. liquid propane gas position.
WARNING WARNING
Never use a malfunctioning aerial Ensure that you maintain three points of
platform. If malfunctions are discovered, contact when using the ladder to mount/
aerial platform must be tagged and dismount platform.
placed out of service. Repairs to aerial
platform may only be made by a qualified 5. Use the ladder of aerial platform to access
service technician. platform.
After repairs are completed, operator must perform a 6. Close the gate.
pre-operation inspection and a series of function tests
again before putting aerial platform into service. 7. Insert key into off/lift/drive key switch and select β
β lift position.
Prior to performing function tests, be sure to read and
understand Section 3 - Start Operation of the operating
manual. 8. On platform control console, pull out β β
emergency stop button. A beeping sound should
1.2-1 Platform Control Console be audible and light should come on.
1. Turn main power disconnect switch to β β on WARNING
position.
If beeping sound is not audible and light
does not come on, aerial platform must
2. On base control console, pull out β β emergency be tagged and placed out of service.
stop button.
3. On engine control console, select off/on/start 9. Select low/high throttle switch to β β low throttle
switch to β β on position. position.
Mid Size & Full Size SKYJACK, Page 31
Rough Terrain Series
--- Page 6 ---
Section 2
MAINTENANCE TABLES AND DIAGRAMS
Table of Contents
Tables
Table 2.1 Specifications and Features ......................................................................................................................42
Table 2.2a Maximum Platform Capacities (Evenly Distributed) ...............................................................................43
Table 2.2b Maximum Platform Capacities (Evenly Distributed w/ Optional #7 Tires) .............................................44
Table 2.3 Tire Specifications .....................................................................................................................................45
Table 2.4 Floor Loading Pressure .............................................................................................................................47
Table 2.5 Rough Terrain Scissor Fluids ....................................................................................................................48
Table 2.6 Torque Specifications ................................................................................................................................50
2
Mid Size & Full Size SKYJACK, Page 41
Rough Terrain Series
--- Page 7 ---
Section 3
SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Table of Contents
Charts
3.1 Hydraulic Symbol Chart ......................................................................................................................................52
3.2 Electrical Symbol Chart ......................................................................................................................................53
Parts List
3.3 Hydraulic Parts List .............................................................................................................................................54
3.4 Electrical Parts List ..............................................................................................................................................57
Diagrams and Schematics
3.5 Platform Control Console Diagram with All Options (ANSI/CSA) ......................................................................63
3.6 Control Cable Assemblies Diagram ...................................................................................................................64
3.7 Outrigger/Hydraulic Generator Control Console Wiring ....................................................................................65
3.8 Main Manifold Components & Port Identifications .............................................................................................67
3.9 Hydraulic Manifold Components & Port Identifications .....................................................................................68
3.10a Hydraulic Schematic .......................................................................................................................................69
3.10b Hydraulic Schematic .......................................................................................................................................70
3.11 Main Manifold Wiring Diagram (ANSI/CSA) .....................................................................................................71
3.12 Horn, Light, Beeper Wiring Diagram (ANSI/CSA) ............................................................................................72
3.13 Powered Extension Platform - Electrical Connection Diagram ........................................................................73
3
3.14 Electrical Panel Diagram - 12kW Generator Modification (ANSI/CSA) ............................................................74
3.15 12kW Generator Hydraulic and Electric Wiring Schematics (ANSI/CSA)........................................................75
3.16 Electrical Inverter Wiring Diagram ....................................................................................................................76
3.17 Engine Harness Wiring Diagram - Kubota Diesel Engine ................................................................................77
3.18 Engine Harness Wiring Diagram - GM Dual Fuel Engine ................................................................................78
3.19 Engine Harness Wiring Diagram - Kubota Dual Fuel Engine...........................................................................79
3.20 Electrical Panel Diagram (ANSI/CSA)...............................................................................................................80
3.21 Electrical Schematic - Kubota Diesel Engine All Options (ANSI/CSA) ............................................................81
3.22 Electrical Schematic - GM Dual Fuel Engine No Options (ANSI/CSA) ............................................................82
3.23 Electrical Schematic - GM Dual Fuel Engine All Options (ANSI/CSA) .............................................................83
3.24 Electrical Schematic - Kubota Dual Fuel Engine No Options (ANSI/CSA) ......................................................84
3.25 Electrical Schematic - Kubota Dual Fuel Engine All Options (ANSI/CSA) .......................................................85
3.26 Interface & Engine Electrical Schematic - GM Dual Fuel Engine ...................................................................86
3.27 Electrical Panel Diagram - Outrigger Option ....................................................................................................87
3.28 Outrigger Wiring Diagram .................................................................................................................................88
3.29 Electrical Panel Diagram - Oil Cooler Option ...................................................................................................89
3.30 Hydraulic Generator Electrical Panel Diagram - Kubota Engine (ANSI/CSA) .................................................90
Full-Size Rough Terrain Series SKYJACK, Page 51
Models 8831 & 8841
157945
--- Page 8 ---
Service and Maintenance Section 3 - System Component Identification and Schematics
3.4 Electrical Parts List (Continued)
Index Skyjack
Qty. Description
No. Part No.
Parts list continued from the previous page.
LS4 115658 1 LIMIT SWITCH (End-of-stroke)
LS5 119296 1 LIMIT SWITCH (High drive cut-out/tilt-override)
LS61 115658 1 LIMIT SWITCH (Left front outrigger extend)
LS62 115658 1 LIMIT SWITCH (Right front outrigger extend)
LS63 115658 1 LIMIT SWITCH (Right rear outrigger extend)
LS64 115658 1 LIMIT SWITCH (Left rear outrigger extend)
LS65 115658 1 LIMIT SWITCH (Left front outrigger retract)
LS66 115658 1 LIMIT SWITCH (Right front outrigger retract)
LS67 115658 1 LIMIT SWITCH (Right rear outrigger retract)
LS68 115658 1 LIMIT SWITCH (Left rear outrigger retract)
M 142308 1 MOTOR, Engine starter (Dual fuel engine)
147125 1 MOTOR, Engine starter (Diesel fuel engine)
MS1 143518 1 SENSOR, Manifold absolute pressure (GM)
OCM1 132804 1 MODULE, Auto-level control (Outrigger)
OL1 133133 1 LIGHT, Indicator (Outrigger)
OPS1 102838 1 SWITCH, Oil pressure (Diesel fuel engine)
143803 1 SWITCH, Oil pressure (GM)
OXS1 142315 1 SENSOR, Heated exhaust oxygen (GM)
OXS2 142299 1 SENSOR, Oxygen post-cat (GM)
PRV1 142340 1 PROPANE REGULATOR/VAPORIZER (GM)
RA1 -- - ACTUATOR, Throttle body (Dual fuel engine)
RL-22 107098 1 LIGHT, Rotating amber beacon (Option)
RL-29 107098 1 BEACON, Rotating Amber (Option)
S1 119726 1 SWITCH, Main power disconnect
S2 147054 2 N.O. CONTACT (Base - up/off/down switch)
S3 147054 1 N.O. CONTACT (Platform - off/lift/drive select key switch)
147053 2 N.C. CONTACT (Platform - off/lift/drive select key switch)
S4 147053 1 N.C. CONTACT (Platform - emergency stop switch)
S5 147054 2 N.O. CONTACT (Platform - up/down switch)
S6 147053 1 N.C. CONTACT (Base - emergency stop switch)
S7 132537 1 DRIVE/STEER CONTROLLER ASSEMBLY
S7-1 122869 1 β’ SWITCH (2nd speed)
S7-2 122877 1 β’ SWITCH (Right steer)
S7-3 122877 1 β’ SWITCH (Left steer)
S7-4 122869 1 β’ SWITCH (Reverse drive)
S7-5 122869 1 β’ SWITCH (Forward drive)
S7-6 122869 1 β’ SWITCH (3rd speed)
S7-7 122872 1 β’ SWITCH (Enable pushbutton)
S8 147054 1 N.O. CONTACT (Platform - Horn pushbutton)
S9 147054 1 N.O. CONTACT (Platform - Lift enable switch)
S9A 102853 1 SWITCH, Toggle (Outrigger enable)
S9B 127132 1 SWITCH, Toggle (Outrigger enable)
Parts list continued on the following page.
Full-Size Rough Terrain Series SKYJACK, Page 61
Models 8831 & 8841
157945
--- Page 9 ---
3.11 Main Manifold Wiring Diagram (ANSI/CSA)
A B C D E F G H
10E-BLUE/WHITE(1.75")
10E-BLUE/WHITE(4")
10E 10E
INSERT ORIENTATION 10E
BOTTOM VIEW
NC 3 NC 3 NC 3
V
4 4 4
24A 02 23A 02 10A
14 13
LEFT STEER VALVE RIGHT STEER VALVE
GREY HEIRSHMAN BLACK HEIRSHMAN 7A 07
GREY BLACK
NC 1
PIN 1 - 24A BLUE/BLACK PIN 1 - 23A BLACK/WHITE
2
02
PIN 2 - 02 WHITE PIN 2 - 02 WHITE 10A
X2
X1
BASE CONTROLS
CONTACT ORIENTATION
BACK VIEW
QUICK BRAKE VALVE
25 - ORANGE/GREEN
10E 02 - WHITE
10E 10E BASE CONTROL STATION.-6 WIRES
UP/DOWN SWITCH
02
25
N.O. CONTACT 02 - WHITE W
PIN 4 - 13 ORANGE/RED INSERT ORIENTATION 07 - RED
ENABLE SWITCH UP/DOWN SWITCH
N.O. CONTACT NC 3 NC 3 NC 3
PIN 3 - 10E BLUE/WHITE BOTTOM VIEW 7A - RED/WHITE
4 4 4
N.O. CONTACT 10A - BLUE/WHITE
PIN 4 - 10A BLUE/WHITE PIN 4 - 14 BLACK/RED
PIN 3 - 10E BLUE/WHITE(2) 13 - ORANGE/RED
PIN 3 - 10E BLUE/WHITE FORWARD VALVE
7A REVERSE VALVE BLACK HEIRSHMAN 14 - BLACK/RED
02 16B
15B 02
13 GREY HEIRSHMAN PIN 1 - 16B WHITE/BLACK
10A 02 14 PIN 1 - 15B BLUE PIN 2 - 02 WHITE
07 PIN 2 - 02 WHITE BLACK
10A GREY
NC 1
2
X2
X1
LIFT VALVE
E-STOP SWITCH N.C. CONTACT/ LED-2 LIGHT 14B - BLACK
PIN 1 - 07 RED LARGE PUMP DUMP VALVE X
02 - WHITE 17A - BLUE/RED
PIN 2 - 7A RED/WHITE