Skyjack SJ 8841E User manual

Maintenance and Parts Manual
DC Electric Full-Size Rough Terrain
MODELS SJ 8831E SJ 8841E
Part No. 119153AO September 2010

Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, 60174 USA
Phone: [phone]
Toll Free: 1-800-275-9522
Fax: [phone]
Email: [email protected]om
Parts (North America)
Toll Free: 1-800-965-4626
Toll Free Fax: [phone]
Email: [email protected]
Parts & Service (Europe) Unit 1 Maes Y Clawdd, Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Skyjack Asia Pacific Singapore
Phone: [phone]
Fax: [phone]
Email: [email protected]

SKYJACK, Page iSJ800 - E Series
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Section - Paragraph
Section 1 - About Your Aerial Platform
Aerial Platform Definition.................................................................................................................... 1
Purpose of Equipment....................................................................................................................... 1
Use of Equipment .............................................................................................................................. 1
Manual................................................................................................................................................ 1
Operator ............................................................................................................................................. 1
Scope of this Manual ......................................................................................................................... 2
Operator Safety Reminders ............................................................................................................... 3
Electrocution Hazard ......................................................................................................................... 3
Safety Precautions ............................................................................................................................. 4
Section 2 - List of Tables
Table of Contents ............................................................................................................................... 1
Section 3 - System Component Identification and Schematics - Operation
Table of Contents ............................................................................................................................... 1
Section 4 - Troubleshooting Information - Operation
Table of Contents ............................................................................................................................... 1
Section 5 - Maintenance and Service - Operation
Table of Contents ............................................................................................................................... 1
Section 6 - Parts Lists - Operation
Table of Contents ............................................................................................................................... 2
2
1
3
4
5
6
Page No.
Table of Contents
S
E
C
T
I
O
N
I
N
D
E
X

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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 potentionally 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.

Section 1 - About Your Aerial Platform
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SKYJACK INC.is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
AERIAL PLATFORM DEFINITION
A mobile device that has an adjustable position platform supported from ground level by a structure.
PURPOSE OF EQUIPMENT
The SKYJACK Rough Terrain - E Series (Models 8831E & 8841E) aerial platforms are designed to transport and
raise personnel, tools and materials to overhead work areas.
USE OF EQUIPMENT
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving MUST be on a flat, level,
compacted surface.
MANUALS
Operating Manual
The operating manual is considered a fundamental part of the aerial platform. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the aerial platform at all times.
Maintenance & Parts
The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.
All information in this manual should be READ and UNDERSTOOD before any attempt is made to service the
machine. The updated copy of the manuals are found on the company’s website: www.skyjack.com.
OPERATOR
The operator MUST read and completely understand both this operating manual and the safety panel label lo-
cated on the platform and ALL other warnings in this manual and on the aerial platform. Compare the labels on
the aerial platform with the labels found within this manual. If any labels are damaged or missing, replace them
immediately.
OPTIONAL ACCESSORIES
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under “Stan-
dard and Optional Features” in Section 1 of the Operating Manual.
Operating instructions for these options (if equipped) are located in Section 2 of the Operating Manual.
For options not listed under “Standard and Optional Features”, contact the SKYJACK Service Department at
North America:
(: 800 275-9522
7: 630 262-0006
Europe:
(: 44 1691-676-235
7: 44 1691-676-239
Include the model and serial number for each applicable machine.
1

Section 1 - About Your Aerial Platform
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SCOPE OF THIS MANUAL
a. This manual applies to the ANSI/SIA, CSA and CE versions of the E - Series Rough Terrain aerial platform
models listed on Table 2-1a and Table 2-1b.
- Equipment identified with “ANSI” meets the ANSI SIA-A92.6-1999 standard.
- Equipment identified with “CSA” meets the CSA B354.2-01 standard.
- Equipment identified with “CE” meets the requirements for the European countries, i.e., Machinery
Directive 89/392/EEC, 98/37/EC and EMC Directive 89/336/EEC and the corresponding EN standards.
b. CSA (Canada) and CE (Europe)
Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this aerial platform.
c. ANSI/SIA (United States)
Operators are required by the current ANSI/SIA A92.6 standards to read and understand their RESPONSIBILITIES
in the Manual of Responsibilities before they use or operate this aerial platform.

Section 1 - About Your Aerial Platform
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WARNING
Failure to comply with your required responsibilities in the use and operation of the aerial platform
could result in death or serious injury!
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.
ELECTROCUTION HAZARD
This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from ener-
gized power lines and parts as listed below. The operator must allow for the platform to sway, rock or sag. This
aerial platform does not provide protection from contact with or proximity to an electrically charged conduc-
tor.
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
ANSI/SIA A92.6-1999 &
CSA B354.2-01 Requirements
CE Guidance Note
“Avoidance of danger from Overhead Lines”
Voltage Range Minimum Safe Approach Distance
(Phase to Phase) Feet Meters
0 to 300V Avoid Contact
Over 300V to 50KV 10 3.05
Over 50KV to 200KV 15 4.60
Over 200KV to 350KV 20 6.10
Over 350KV to 500KV 25 7.62
Over 500KV to 750KV 35 10.67
Over 750KV to 1000KV 45 13.72
Adhere strictly to the governmental rulings and
regulations applicable in your country.
FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!
60023AC

Section 1 - About Your Aerial Platform
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SAFETY PRECAUTIONS
Know and understand the safety precautions before going on to next section.
WARNING
Failure to heed the following safety pre-
cautions could result in tip over, falling,
crushing, or other hazards leading to
death or serious injury.
• KNOW all national, state/provincial and local
rules which apply to your MACHINE and JOB-
SITE.
• TURN the 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.
• AVOID entanglement with
ropes, cords or hoses.
• AVOID falling. Stay within the
boundaries of the guardrails.
• DO NOT raise the aerial plat-
form in windy or gusty condi-
tions.
• 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 sta-
bility of the aerial platform.
• If operation in areas with
holes or drop-offs is abso-
lutely necessary,elevated
driving shall not be allowed.
Position the machine horizon-
tally only with the platform fully
lowered. After ensuring that
all 4 wheels or outriggers (if
equipped) have contact with
level firm surface, the aerial
platform can be elevated. Af-
ter elevation, the drive function
must not be activated.
• Elevated driving must only
be done on a firm level sur-
face.
• DO NOT ascend or descend
a grade when elevated. When
fully lowered, ascending or de-
scending, only grades up to
rated maximum listed in Table
2-1a and Table 2-1b are permis-
sible.

Section 1 - About Your Aerial Platform
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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 plat-
form that has ladders, scaffold-
ing or other devices mounted
on it to increase its size or work
height. It is prohibited.
• DO NOT exert side forces on
aerial platform while elevated.
• DO NOT use the aerial platform
as a crane. It is prohibited.
• DO NOT sit, stand or climb on
the guardrails. It is prohibited.
• DO NOT climb on scissor arm
assembly. It is prohibited.
• BE AWARE of overhead ob-
structions or other possible
hazards around the aerial plat-
form when driving or lifting.
• DO NOT raise the aerial plat-
form while the machine is on a
truck, fork lift or other device or
vehicle.
• BE AWARE of crushing haz-
ards. Keep all body parts in-
side platform guardrail.
• DO NOT lower the platform
unless the area below is clear
of personnel and obstruc-
tions.
• ENSURE that there are no personnel or obstruc-
tions in the path of travel, including blind spots.
• BE AWARE of blind spots when operating the
aerial platform.
• STUNT driving and horseplay are 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.
• DO NOT use the aerial platform without guard-
rails, locking 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 distrib-
uted on the platform.

Section 1 - About Your Aerial Platform
SKYJACK, Page 6 SJ800 - E Series
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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. (Machines without load
sensing)
• 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 an-
other object to steady the platform.
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appeartobeworkingproperly.
•hasbeendamagedorappearstohave
worn or missing parts.
•hasalterationsormodificationsnotap
proved by the manufacturer.
•hassafetydeviceswhichhavebeen
altered or disabled.
Failure to avoid these hazards could re-
sult in death or serious injury.
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.

Section 2 - List of Tables
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Table of Contents
Table 2-1a. Specifications and Features - ANSI/CSA.................................................................................................2
Table 2-1b. Specifications and Features - CE ............................................................................................................3
Table 2-2. Owner’s Annual Inspection Record .........................................................................................................4
Table 2-3a. Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA ............................................................6
Table 2-3b. Maximum Platform Capacities (Evenly Distributed) - CE ........................................................................7
Table 2-4. Maintenance and Inspection Schedule ...................................................................................................8
2

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Section 2 - List of Tables
Table 2-1a. Specifications and Features - ANSI/CSA
8831E 8841E
10,455 lbs. 11,355 lbs.
Elevated Working 37.0’ 47.0’
Elevated Platform 31.0’ 41’
Stowed Platform 59.0” 69.0”
Drive
Standard 30 x 10-16.5 #6 Air filled 30 x 10-16.5 #6 Air filled
Optional
Normal #6 Air filled Drive (Max)
Elevated Low Drive (Max)
Lift (Rated Load) 46 sec. 71 sec.
Lower (Rated Load) 48 sec. 60 sec.
60125AE-ANSI
Model
Weight*
Width
* Weights are approximate; refer to serial nameplate for specific weight. Values shown are for standard 2WD machines on air
tires with a manual extension platform (Mid Size RT’s) and no extension platforms (Full Size RT’s)
87.0”
137.5”
68” x 133.5”
Length
30%
Full***
Gradeability
Platform Size
.45 mph
2.6 mph
#6 or #7 Foam filled
TiresSpeed Height

Section 2 - List of Tables
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Table 2-1b. Specifications and Features - CE
8831E 8841E
4,898 kg 5,306 kg
Elevated Working 11.28 m 14.3 m
Elevated Platform 9.4 m 12.5 m
Stowed Platform 1.50 m 1.75 m
Drive
Standard 30 x 10-16.5 #6 Air filled 30 x 10-16.5 #6 Air filled
Optional
Normal Drive (Max)
Elevated Low Drive (Max)
Lift (Rated Load) 46 sec. 71 sec.
Lower (Rated Load) 48 sec. 60 sec.
60125AE-CE
#6 or #7 Foam filled
* Weights are approximate; refer to serial nameplate for specific weight. Values shown are for standard 2WD machines on air
tires with a manual extension platform Mid Size RT’s and no extension platforms Full Size RT’s.
Length
Platform Size
30%
7.9 m
4.2 km/h
0.8 km/h
3.5 m
Gradeability
TiresSpeed Height
1.73 x 3.39 m
Model
Weight*
Width 2.21m

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Section 2 - List of Tables
Table 2-2. Owner’s Annual Inspection Record
60141AB
Owner’s Name
Recording Year #
Recording Date
Model Number: ____________________________ Serial Number: ____________________________
9123 85674
As described earlier in this section, this decal is located on the scissor assembly. It must be completed after an annual inspection has
been completed. Do not use the aerial platform if an inspection has not been recorded in the last 13 months.
Inspected By

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Section 2 - List of Tables
Table 2-3a. Maximum Platform Capacities (Evenly Distributed) - ANSI/CSA
MODEL Total First Extension Second Extension
Capacity Number of
Occupants Capacity Number of Occupants Capacity Number of Occupants
8831E
No Extension
Platform 2500 lb. 6 Not Available
One Extension
Platform 2000 lb. 6 500 lb. 2 Not Available
Two Extension
Platforms 1700 lb. 6 500 lb. 2 500 lb. 2
8841E
No Extension
Platform 1700 lb. 5 Not Available
One Extension
Platform 1500 lb. 5 500 lb. 2 Not Available
Two Extension
Platforms 1500 lb. 5 500 lb. 2 500 lb. 2
60279AC-ANSI
NOTE:
Occupants AND materials are not to exceed rated load.
Refer to capacity label at sides of platform for additional information and for models equipped with options.

Section 2 - List of Tables
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Table 2-3b. Maximum Platform Capacities (Evenly Distributed) - CE
MODEL Total First Extension Second Extension
Capacity Number of
Occupants Capacity Number of Occupants Capacity Number of Occupants
8831E
No Extension
Platform 1134 kg 6 Not Available
One Extension
Platform 908 kg 5 227 kg 2 Not Available
Two Extension
Platforms 681 kg 4 227 kg 2 227 kg 2
8841E
No Extension
Platform 681 kg 4 Not Available
One Extension
Platform 681 kg 4 227 kg 2 Not Available
Two Extension
Platforms 681 kg 4 227 kg 2 227 kg 2
60279AC-CE
NOTE:
Occupants AND materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires.
Refer to capacity label at sides of platform for additional information and for models equipped with options.

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Section 2 - List of Tables
General Maintenance
Before attempting any repair work, disconnect the battery by turning the main power disconnect switch to
the “OFF” position. Preventative maintenance is the easiest and least expensive type of maintenance.
Table 2-4. Maintenance and Inspection Schedule
WARNING
Use original or equivalent to the original parts and components for the aerial platform.
Daily Monthly 3 Months 6 Months 12 Months*
Structural damage/welds A A A
Parking brake B &E B &E B & E
Tires/wheels & fasteners A, B & C A, B & C A, B & C
Guides/rollers & slider pads A, B & I A, B & I A, B & I
Railings & railing lock pins A & C A & C A & C
Entry gates B & C B & C B & C
Bolts and fasteners C C C
Maintenance support B B B
Rust AA A
Wheel bearings & king pins A, B & E A, B & E A, B & E
Axle gear oil** FF
Steering cylinder & tie rod A, B & E A, B & E
Battery fluid level A A A
Control switches A & B A & B A & B
Cords & wiring A A A
Battery terminals A & C A & C A & C
Terminals & plugs C C C
Receptacle A & B A & B A & B
Limit switches B B B
Hydraulic oil level H H H
Hydraulic hoses/fittings A & L A, L & C A, L & C
Lift/lowering speeds GG
Cylinders A & B A & B
Emergency lowering B B B
Lift capacity DD D
Hydraulic oil filter FF
Labels and manual A, J & K A, J & K A, J & K
Lanyard attachments A & C A & C A & C
Check for applicable service bulletins AA
60280AE-PM
Weekly
Mechanical
Electrical
Hydraulic
C
A & B
Notes
Miscellaneous
A.Visually inspect.
B. Check operation.
C. Check tightness.
D. Check relief valve setting. Refer to serial number nameplate.
E. Lubricate.
F.Replace.
G. Refer to Table 2-1a and Table 2-1b, “Specifications and
Features.”
H. Check oil level.
I.Ensure there is no metal to metal contact with slider, slider side or running
surface. Check for free movement of surface. Also check for free
movement of the slider pin
J. Replace if missing or illegible.
K. Proper manual must be in box.
L. Check for Leaks.
* Record inspection date and signature.
** Gear Oil Requirements: Axle: ESSO GX 85W-140
Center Drive: ESSO GX 85W-140

SECTION 3, Page 1SJ-800 Series E Battery Powered
119153
Section 3
System Component Identification
And Schematics
Table Of Contents
3
Symbols & Charts
Figure 3.1-1. Relay Function Chart................................................................................................................2
Figure 3.1-2. Tilt Switch Usage Chart............................................................................................................ 3
Figure 3.1-3. Electrical Symbol Chart............................................................................................................4
Figure 3.1-4. Hydraulic Symbol Chart...........................................................................................................5
Hydraulic System
Figure 3.2-1. Hydraulic Schematic Parts List ................................................................................................ 7
Figure 3.2-2. Hydraulic Schematic ...............................................................................................................9
Figure 3.2-3. Hydraulic Manifold Component And Port Identification ........................................................ 10
Figure 3.2-4. Outrigger Manifold And Auto Reset Manifold Port Identification...........................................10
Battery Charger Schematics
Figure 3.3-1. Battery Charger Schematic - MAC BA1001...........................................................................11
Figure 3.3-2. Battery Charger Schematic - Bycan #4825U ........................................................................12
Electrical Diagrams And Schematics
Figure 3.4-1. Electrical Schematic And Diagram Parts List ........................................................................13
Figure 3.4-2. Electrical Inverter Wiring Diagram .........................................................................................18
Figure 3.4-3. Control Box Diagram - ANSI/CSA & CE Equipped with All Options .....................................19
Figure 3.5-1. Electrical Panel Diagram (ANSI/CSA & CE) - All Options .....................................................21
Figure 3.6-1. Electrical Schematic Diagram (ANSI/CSA & CE) - All Options .............................................22
AN

SECTION 3, Page 2 SJ-800 Series E Battery Powered
119153
CONTROL (B+)
NORMALLY
CLOSED
CONTACT
SUPPLY (B+) (Common)
GROUND (B-)
NORMALLY
OPEN
CONTACT
Figure 3.1-1. Relay Function Chart
RELAY NO.RELAY FUNCTION
10ACROutriggerpower
10BCR Brake
12ECR Joystick Enable
17ACR Outrigger lift disable
28CR Tilt
39CRLWS, Limit Switch
41CR LWS Time Delay
42CR LWS Latching
59CCR Speed signal
61CR-1 Drive enable
61CR-2 Lift enable
65CR Lift enable
60066AA

SECTION 3, Page 3SJ-800 Series E Battery Powered
119153
M10281AA
Figure 3.1-2. Tilt Switch Usage Chart
NOTE:Ensure the platform is
parked on a flat level surface
before performing any adjust-
ments or repairs to the tilt
switch assembly.
ANSI, CSA & CE Models
Tilt switch
(X Axis° x Y Axis°)
Model Serial Numbers 117880
(2.5° x 4.5°)
8831E Current production X
8841E Current production X
M600733AA