Skyjack SJ7127 RT User manual

.
ROUGH TERRAIN SCISSORS
MODELS SJ7127 RT SJ7135 RT
163761AE November 2015
SERVICE MANUAL (ANSI/CSA)

Parts (North America)
Toll Free: 1-800-965-4626
Toll Free Fax: [phone]
E-mail: [email protected]
Skyjack Australia Pty Ltd.
4 Coates Place
Wetherill Park
New South Wales 2164
Australia
Tel: [phone]
Fax: [phone]
Skyjack Brasil
Indaiatuba, SP, Brasil 13347-653
Tel: [phone]
Alameda Júpiter, 710
Loteamento American Park Empresarial
Skyjack Service Center
3451 Swenson Ave. St. Charles,
Phone: [phone]
Toll Free: 1-800-275-9522
Fax: [phone]
Email: [email protected]om
Illinois, 60174 USA
Parts & Service (Europe)
Unit 1 Maes Y Clawdd
Oswestry, Shropshire SY10 8NN UK
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Maesbury Road Industrial Estate
This manual is based on Serial Number(s):
SJRT 71XX 34 002 584 & Above
Please refer to the website (www.skyjack.com) for older Serial Numbers.

Mid-Size Rough Terrain
Models 7127 & 7135
163761
SKYJACK, Page 3
SERVICE AND MAINTENANCE
Table of Contents
Section 1 - Scheduled Maintenance
Table of Contents
Section 2 - Maintenance Tables
Table of Contents
Section 3 - Schematics
Table of Contents
Section 4 - Troubleshooting
Table of Contents
Section 5 - Procedures
Table of Contents

SKYJACK, Page 4 Mid-Size Rough Terrain
Models 7127 & 7135
163761
Operator’s Responsibility for MaintenanceService and Maintenance
The Safety Alert Symbol identies important
safety messages on aerial platforms, 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) essential for safe operation and which,
if not followed, may result in a malfunction or damage to the aerial platform.

Mid-Size Rough Terrain
Models 7127 & 7135
163761
SKYJACK, Page 5
1
Section 1
SCHEDULED MAINTENANCE
Table of Contents
Operator’s Responsibility for Maintenance
Aerial Platform and Mobile Elevating Work Platform Denition ..................................................................................6
Purpose of Equipment .................................................................................................................................................6
Use of Equipment ........................................................................................................................................................6
Manuals........................................................................................................................................................................6
Service Policy and Warranty........................................................................................................................................6
Operator Safety Reminders, Warnings, and Precautions ...........................................................................................6
Maintenance and Inspection Schedule .......................................................................................................................7
Owner’s Annual Inspection Record.............................................................................................................................7
Replacement Parts.......................................................................................................................................................7
Maintenance and Service Safety Tips .........................................................................................................................7
Hydraulic System & Component Maintenance and Repair ........................................................................................8
Maintenance Hints .......................................................................................................................................................8
Service and Maintenance
About this Section........................................................................................................................................................9
Service Bulletins...........................................................................................................................................................9
Maintenance and Inspection .......................................................................................................................................9
Maintenance Instructions.............................................................................................................................................9
Tables
Table 1.1 Owner’s Annual Inspection Record ..........................................................................................................10
Table 1.2 Pre-Delivery/Maintenance Inspection Checklist .......................................................................................11
Scheduled Maintenance
1.1 Scheduled Maintenance Inspections ...........................................................................................................12
1.2 Function Tests...............................................................................................................................................24

SKYJACK, Page 6 Mid-Size Rough Terrain
Models 7127 & 7135
163761
Operator’s Responsibility for MaintenanceService and Maintenance
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specications
and dimensions are subject to change without notice.
Aerial Platform and Mobile Elevating Work Platform Definition
A mobile device that has a positionable platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK Rough Terrain’s mid and full size 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. Work platform elevation and elevated driving
must only be done on a rm level surface. It can be driven over uneven terrain only when the platform is fully low-
ered.
Manuals
Operating
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.
Service & Maintenance
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.
Service Policy and Warranty
SKYJACK warrants each new SJRT series work platform to be free of defective parts and workmanship for the rst
24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or
labor. Contact the SKYJACK Service Department for warranty statement extensions or exclusions.
Operator Safety Reminders, Warnings, and Precautions
Operator safety is SKYJACK’s priority. The operator should comply with all applicable safety-related reminders,
warnings and precautions found in the Operating Manual. They should be read and understood completely before
operating the aerial platform.
Operator’s Responsibility for
Maintenance

Mid-Size Rough Terrain
Models 7127 & 7135
163761
SKYJACK, Page 7
Operator’s Responsibility for Maintenance Service and Maintenance
Maintenance and Inspection Schedule
The actual operating environment of the work platform
governs the use of the maintenance schedule. The
inspection points covered in Table 1.2. Maintenance
and lnspection Checklist, indicates the areas of the
aerial platform to be maintained or inspected and at
what intervals the maintenance and inspections are to
be performed.
Owner’s Annual Inspection Record
It is the responsibility of the owner to arrange quarterly
and annual inspections of the aerial platform. Table 1.1.
Owner’s Annual lnspection Record is to be used for
recording the date of the inspection, owner’s name,
and the person responsible for the inspection of the
work platform.
Replacement Parts
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and
dimensions different from original parts will affect
stability of the aerial platform and must not be used
without manufacturer’s consent.
All replacement tires must be of the same size and load
rating as originally supplied tires; to maintain safety and
stability of aerial platform.
Consult SKYJACK’s Service Department for optional
tires specications and installation.
WARNING
Any unit that is damaged or not operat-
ing properly must be immediately tagged
and removed from service until proper
repairs are completed.
Maintenance and Service Safety Tips
Maintenance and repair should only be performed by
personnel who are trained and qualied to service this
aerial platform.
All maintenance and service procedures should be
performed in a well lighted and well ventilated area.
Anyone operating or servicing this aerial platform
must read and completely understand all operating
instructions and safety hazards in this manual and
operating manual.
All tools, supports and lifting equipment to be used
must be of proper rated load and in good working order
before any service work begins. Work area should be
kept clean and free of debris to avoid contaminating
components while servicing.
All service personnel must be familiar with employer
and governmental regulations that apply to servicing
this type of equipment.
Keep sparks and ames away from all ammable or
combustible materials.
Properly dispose of all waste material such as
lubricants, rags, and old parts according to the relative
law provisions obtaining in the country.
Before attempting any repair work, turn Battery
Disconnect Switch to the “OFF” position.
Preventive maintenance is the easiest and least
expensive type of maintenance.

SKYJACK, Page 8 Mid-Size Rough Terrain
Models 7127 & 7135
163761
Operator’s Responsibility for MaintenanceService and Maintenance
Hydraulic System & Component
Maintenance and Repair
The following points should be kept in mind when
working on the hydraulic system or any component:
WARNING
Escaping uid from a hydraulic pressure
leak can damage your eyes, penetrate the
skin and cause serious injury. Use proper
personal protection at all times.
1. Any structure has limits of strength and durability.
To prevent failure of structural parts of hydraulic
components, relief valves which limit pressure to
safe operating values are included in the hydraulic
circuits.
2. Tolerance of working parts in the hydraulic system
is very close. Even small amounts of dirt or foreign
materials in the system can cause wear or damage
to components, as well as general faulty operation
of the hydraulic system. Every precaution must
be taken to assure absolute cleanliness of the
hydraulic oil.
3. Whenever there is a hydraulic system failure which
gives reason to believe that there are metal particles
or foreign materials in the system, drain and ush
the entire system and replace the lter cartridges. A
complete change of oil must be made under these
circumstances.
4. Whenever the hydraulic system is drained, check
the magnets in the hydraulic reservoir for metal
particles. If metal particles are present, ush the
entire system and add a new change of oil. The
presence of metal particles also may indicate the
possibility of imminent component failure. A very
small amount of ne particles is normal.
5. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a funnel
when necessary for lling the hydraulic oil reservoir,
and ll the reservoir only through the lter opening.
The use of cloth to strain the oil should be avoided
to prevent lint from getting into the system.
6. When removing any hydraulic component, be sure
to cap and tag all hydraulic lines involved. Also,
plug the ports of the removed components.
NOTE
Samples of hydraulic oil should be drawn
from the reservoir and tested annually.
These samples should be taken when the
oil is warmed through normal operation of
the system. The sample should be analyzed
by a qualied lubrication specialist to
determine if it is suitable for continued use.
Oil change intervals will depend on the
care used in keeping the oil clean, and the
operating conditions. Dirt and/or moisture
cotamination will dictate that the oil should
be changed more often. Under normal use
and operating conditions, the hydraulic oil
should be changed every two years. Refer
to Table 1.2 of this manual.
7. All hydraulic components must be disassembled in
spotlessly clean surroundings. During disassembly,
pay particular attention to the identication of parts
to assure proper reassembly. Clean all metal parts
in a clean mineral oil solvent. Be sure to thoroughly
clean all internal passages. After the parts have
been dried thoroughly, lay them on a clean, lint-free
surface for inspection.
8. Replace all O-rings and seals when overhauling
any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small amounts
of petroleum jelly to hold O-rings in place during
assembly.
9. Be sure to replace any lost hydraulic oil when
completing the installation of the repaired
component, and bleed any air from the system
when required.
10. All hydraulic connections must be kept tight. A
loose connection in a pressure line will permit the
oil to leak out or air to be drawn into the system.
Air in the system can cause damage to the
components and noisy or erratic system operation.
Maintenance Hints
Three simple maintenance procedures have the greatest
effect on the hydraulic system performance, efciency
and life. Yet, the very simplicity of them may be the
reason they are so often overlooked. What are they?
Simply these:
1. Change lters annually. The lters will need
to be changed more often depending on the
operating conditions. Dirty, dusty, high moisture
environments may cause the hydraulic system
to be contaminated more quickly.
2. Maintain a sufcient quantity of clean hydraulic
oil of the proper type and viscosity in the
hydraulic reservoir.
3. Keep all connections tight.

Mid-Size Rough Terrain
Models 7127 & 7135
163761
SKYJACK, Page 9
Section 1 - Scheduled Maintenance Service and Maintenance Inspections
About this Section
This section contains the maintenance and inspection
schedule that is to be performed.
References are made to the procedures in section 5
that outline detailed step-by-step instructions for checks
and replacements.
Service Bulletins
Before performing any scheduled maintenance
inspection procedure, refer to service bulletins found
in our web site: www.skyjack.com for updates related
to service and maintenance of this aerial platform.
Maintenance and Inspection
Death or injury can result if the aerial platform is not kept
in good working order. Inspection and maintenance
should be performed by competent personnel who
are trained and qualied on mantenance of this aerial
platform.
WARNING
Failure to perform each procedure as pre-
sented and scheduled may cause death,
serious injury or substantial damage.
NOTE
Preventive maintenance is the easiest and
least expensive type of maintenance.
• Unless otherwise specified, perform each
maintenance procedure with the aerial platform in
the following conguration:
- Aerial platform parked on a flat and level
surface
- Disconnect the battery by turning the main
power disconnect switch to the “OFF” position.
• Repair any damaged or malfunction components
before operating aerial platform.
• Keep records on all inspections.
Maintenance Instructions
This manual consists of four schedules to be done for
maintaining on an aerial platform. Inspection schedule
frequency is shown below:
Inspection Schedule
PDI / Frequent B
PDI / Frequent B
Annual B + C
Additional *
B - Perform PDI prior to each delivery, or Frequent
Inspection every 3 months or 150 hours.
C - Perform Scheduled Maintenance Inspections
every year.
* - Perform at time sensitive maintenance intervals.
• Make copies of the maintenance and inspection
checklist to be used for each inspection.
• Check the schedule on the checklist for the type of
inspection to be performed.
• Place a check in the appropriate box after each
inspection procedure is completed.
• Use the maintenance and inspection checklist and
step-by-step procedures in section 5 to perform
these inspections.
• If any inspection receives a fail, tag and remove the
aerial platform from service.
• If any aerial platform component(s) has been
repaired, an inspection must be performed again
before removing the tag. Place a check in the repair
column.
Legend
P = Pass
F = Fail
R = Repaired
N/A = Not applicable
Service and Maintenance

SKYJACK, Page 10 Mid-Size Rough Terrain
Models 7127 & 7135
163761
Section 1 - Scheduled MaintenanceService and Maintenance Inspections
Table 1.1 Owner’s Annual Inspection Record
1000AB
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.
20__ 20__ 20__
**
Model Number: _________________ Serial Number:__________________
* 20__ 20__ 20__ 20__ 20__ 20__
Pictorial Description
*
Inspection Date
**
Inspector Signature
Tables

Mid-Size Rough Terrain
Models 7127 & 7135
163761
SKYJACK, Page 11
Section 1 - Scheduled Maintenance Service and Maintenance Inspections
Table 1.2 Pre-Delivery/Maintenance Inspection Checklist
Note: Visit skyjack.com for a printable copy of this form.
167830AA
Serial Number: Product Owner:
Model:
Hourmeter Reading: Product User:
Date/Time:
P- Pass

PDI BF- Fail

Frequent BR- Repaired

Annual B + C
Items for Inspection P F R
N/A
Items for Inspection P F R
N/A
B B
B, C
B
B B
B
B
B
B
B B
B, C
B
B B
B
B
B
B, C
B
B
B B
BB, C


B
Owner: ________________________________________________ / _____________________________________________ / ______________________________________________________
Print Name Signature Date (DD/MM/YY)
User: _________________________________________________ / _____________________________________________ / ______________________________________________________
Print Name Signature Date (DD/MM/YY)
Comments:
Motor Controller. Secure & no damage. No loose
connections. B
Steer Cylinder Assembly. Secure & no damage, leaks or
missing parts. B
Ladder. Secure & no damage.
Brakes. Secure & no damage or leaks.
AC Power to Platform (Plug Cord Receptacle). No
obstructions, dirt or damage.
B
Emergency Lowering Access Rod. Secure & no
damage. B
Base Control Switches. Switches to neutral position &
no damage. B
Axles. Secure & no missing parts. Tight fittings and hoses
& no leaks.
Pothole Protection Device. Check both sides for
obstructions, dirt, or damage.
PASS
FAIL
Platform Control Console. Switches to neutral position
& secure. No missing parts.
Raillings and Gate/Chain. Secure & no damage or
missing parts.
Lanyard Attachment Anchorage. Attachment rings
secure & no damage.
Scissor Guards. Secure & no damage.
Greasing Points. No obstructions, dirt, or damage.
Function Tests
(Refer to your corresponding Serial #'s Operating
Manual for information on running these tests.)
Engine Tray. No damage or missing parts.
Engine Control Console. Secure & no damage.
Engine Air Filter. No damage or missing parts.
Electrical Panel. Secure & no damage. Tight wire
connections and fasteners.
Engine Oil. Level between "L" and "H". Ensure oil change
interval has not been exceeded.
B
Refer to skyjack.com for the latest service bulletins.
Radiator. Secure & no damage or missing parts. Check
coolant level.
Main Power Disconnect Switch. Cables secure & in
working order.
B
AC Outlet. No obstructions, dirt, or damage.
Outriggers. No damage or missing parts.
Tilt (Load) Sensor. Secure & no damage.
B
B
Ensure Annual Inspection has been completed within the
last 13 months.
Wheel/Tire Assembly. Check all tires for damage, wear
& proper alignment. Lug nuts torqued as recommended. B
Propane Tank. Straps fastened to brackets & coupler
tight. B
Tie Rod. End studs locked & no damage.
Battery Charger. Secure, & no damage.
Hydraulic Tank. Filler cap secure & no damage or leaks.
Use this form for Pre-Delivery Inspections (PDI) prior to each rental, lease or sale, or as a guide for all Frequent Inspections and Annual Inspections. Refer to the
applicable Operating and Service Manuals for inspection details (eg. Visual Inspection and Function Tests, Torque Specs., Engine Oil, Chain Inspection Intervals, etc.).
Pre-Delivery/Maintenance Inspection Checklist
Mast Assembly. No damage or deformation.
Rollers. Secure & no obstructions, dirt, or damage/wear.
Sliders. Secure & no obstructions, dirt, or damage/wear.
Maintenance Support. Secure & no damage.
Lift Cylinder(s). No damage or missing parts. Tight
fittings and hoses & no leaks.
Fuel Tank. Filler cap is secure & no damage.
B - Perform PDI prior to each delivery or Frequent Inspections every 3 months or 150 hrs. For further details refer to Service & Operating
Manuals.
Mast Chains & Control Cables. No damage or missing
parts. B
Free-wheeling Valve Knob. Secure & no damage or
missing parts.
Base Weldment. No deformation or cracks.
Manifolds. Tight fittings and hoses & no damage or leaks.
Tight wire connections & no missing parts.
Manuals & Required Documents. In storage box, in
good condition & legible. B
Vertical Mast, SJIII, & Rough Terrain
C - Perform Scheduled Maintenance Inspections every year. For further details refer to Service & Operating Manuals.
B
Battery. No damage, tight connections, fluid levels
correct. Clean terminals and cable ends.
Muffler and Exhaust. Secure & no damage.
Fuel Shut-off Valve. No damage or missing parts.
Scissor Assembly. No deformation/damage. Pins secure.
Cables & wires routed with no damage.
Battery/ Hydraulic Tray. Latch is secure, & no missing
parts. B
B
B
Check the appropriate box as each item is inspected. If an item is found to be not acceptable, please describe the issue in the comments box provided.
Labels. In place, secure & legible.
Inspection Type Schedule
B
B
B
B, C
Scissor Bumpers. Secure & no damage.
Limit Switches. Secured & no obstructions or damage.
Hydraulic Components & Hoses. Secure & no damage
or leaks.
Hydraulic Oil. Level at, or slightly above top mark.
B
N/A - Not Applicable
B
Powered Extension Control Console. Switches to
neutral position & secure. No missing parts.
B
B
B
B, C
Fuel Leaks. Tight fittings and hoses & no damage or
leaks. B
The undersigned confirms that all areas listed have been inspected, and any and all discrepancies have been brought to the attention of the owner. Furthermore, the
undersigned confirms that all discrepancies have been corrected prior to using this machine.
Propane Tank Leaks. No leaks (refer to service manual
for procedure). B
Scissor Pins. No damage/wear or missing parts.
Wear Pads. No damage/wear or missing parts. Fasteners
tightened. B
B
Extension Deck. Secure & no damage or missing parts.
Check fluid level (if applicable).

SKYJACK, Page 12 Mid-Size Rough Terrain
Models 7127 & 7135
163761
Section 1 - Scheduled MaintenanceService and Maintenance Inspections
1.1 Scheduled Maintenance Inspections
Begin the scheduled maintenance inspections by
checking each item in sequence for the conditions listed
in this section.
WARNING
To avoid injury, do not operate an aerial
platform until all malfunctions have been
corrected.
WARNING
To avoid possible injury, ensure aerial
platform power is off during your visual
and daily maintenance inspections.
Electrical
Maintaining the electrical components is essential to
good performance and service life of the aerial platform.
Inspect the following areas for chafed, corroded
and loose wires:
• base to platform cables and wiring harness
• engine compartment electrical panel
• engine wiring harness
• hydraulic/electrical wiring harnesses
Hydraulic
Maintaining the hydraulic components is essential to
good performance and service life of the aerial platform.
Perform a visual inspection around the following
areas:
• hydraulic tank lter, ttings, hoses, emergency
power unit (if equipped) and base surfaces
• engine compartment ttings, hoses, main
pump, and lter
• all hydraulic cylinders
• all hydraulic manifolds
• the underside of the base
• ground area under the aerial platform
• outriggers
1.1-1 Manuals (B)
Ensure a copy of the operating manual and any other
important documents are enclosed in the manual
storage box.
- Check to be sure manual storage box is
present and in good condition.
- Ensure manuals are legible and in good
condition.
- Always return manuals to the manual storage
box after use.
1.1-2 Labels (B)
Refer to the labels section in the operating manual and
determine that all labels are in place and are legible.
Platform
Assembly
Limit Switch
Platform Control
Console
Base
Scissor
Assembly
Electrical/Hydraulic
Compartment
Ladder
Scheduled Maintenance

Mid-Size Rough Terrain
Models 7127 & 7135
163761
SKYJACK, Page 13
Section 1 - Scheduled Maintenance Service and Maintenance Inspections
1.1-3 Limit Switches (B)
Detecting limit switch malfunction is essential to safe
aerial platform operation. Ensure limit switches are
properly secured with no signs of visible damage and
movement is not obstructed.
Visually inspect all limit switch located inside the
scissor arms and the outrigger assemblies for the
following:
• broken or missing actuator arm
• missing fasteners
• loose wiring
1.1-4 Emergency Lowering Access Rod (B)
- Ensure rod is properly secured and there is
no visible damage.
1.1-5 Electrical and Control Components
- Ensure all compartment latches are secure
and in proper working order.
• Main Power Disconnect Switch (B)
- Turn main power disconnect switch to
“ ” off position.
- Ensure all cables are secure and switch
is in proper working condition.
• Base Control Switches (B)
- Ensure there are no signs of visible
damage and all switches are in their
neutral positions.
• Battery (B)
Proper battery condition is essential to
good performance and operational safety.
Improper uid levels or damaged cables and
connections can result in component damage
and hazardous conditions.
WARNING
Explosion hazard. Keep ames
and sparks away. Do not smoke
near batteries.
WARNING
Battery acid is extremely corrosive
- Wear proper eye and facial protec-
tion as well as appropriate protective
clothing. If contact occurs, immediately
ush with cold water and seek medical
attention.
1. Check battery case for damage.
2. B - Frequent Inspection
Clean battery terminals and cable ends
thoroughly with a terminal cleaning tool or
wire brush.
3. Ensure all battery connections are tight.
(Emergency) Main
Power Disconnect
Switch
Electrical Panel
Motion Control Manifold
Base Control
Switches
Load/Tilt
Sensor
Cushion Cylinder
Main Manifold
Brake Manifold
Emergency Lowering
Access Rod

SKYJACK, Page 14 Mid-Size Rough Terrain
Models 7127 & 7135
163761
Section 1 - Scheduled MaintenanceService and Maintenance Inspections
Emergency Main
Power Disconnect
Switch
Electrical Panel
Motion Control Manifold
Base Control
Switches
Load/Tilt
Sensor
Cushion Cylinder
Main Manifold
Brake Manifold
Emergency Lowering
Access Rod
4. If applicable, check battery uid level.
B - Frequent Inspection
If plates are not covered by at least 1/2
in. (13 mm) of solution, add distilled or
demineralized water.
5. B - Frequent Inspection
Replace battery if damaged or incapable of
holding a lasting charge.
WARNING
Use original or manufacturer-approved
parts and components for the aerial
platform.
• Manifolds (B,C)
- Ensure all ttings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.
- Ensure there are no loose wire
connections or missing fasteners.
• Electrical Panel (B)
- Ensure panel is properly secured and
there is no visible damage.
- Ensure there are no loose wire
connections or missing fasteners.
• Tilt Sensor (B)
- Ensure tilt sensor is properly secured and
there is no visible damage.

Mid-Size Rough Terrain
Models 7127 & 7135
163761
SKYJACK, Page 15
Section 1 - Scheduled Maintenance Service and Maintenance Inspections






1.1-6 Fuel and Hydraulic Compartment
- Ensure all compartment latches are secure
and in proper working order.
• Hydraulic Tank (B)
- Ensure hydraulic ller cap is secure.
- Ensure tank shows no visible damage
and no evidence of hydraulic leakage.
• Hydraulic Oil (B,C)
- Ensure platform is fully lowered, and
outriggers retracted, and then visually
inspect the sight gauge located on the
side of the hydraulic oil tank. Check oil
level against label that indicates minimum
and maximum oil levels.
C - Annual Inspection
- Refer to Section 1 - Hydraulic System
& Component Maintenance and Repair.
• Fuel Tank (B)
IMPORTANT
Before using your aerial platform ensure
there is enough fuel for expected use.
- Ensure fuel ller cap is secure.
- Ensure tank shows no visible damage
and no evidence of fuel leakage.
• Fuel Leaks (B)
- Ensure there are no fuel leaks.
DANGER
Engine fuels are combustible. Inspect
the aerial platform in an open, well-ven-
tilated area away from heaters, sparks
and ames. Always have an approved
re extinguisher within easy reach.
- Ensure fuel pump, fuel lter, hoses and
ttings show no visible damage and no
evidence of fuel leakage.
• Propane Tank (If Equipped) (B)
- Ensure metal peg on compartment
oor is inserted into propane tank rim.
- Ensure propane tank straps are
fastened tightly to brackets.
- Ensure coupler to propane tank is tight.
• Propane Tank Leaks (If Equipped) (B)
- Ensure there are no fuel leaks.
- To check for leaks, close valve (turn
clockwise) and apply soap water or
neutral detergent to pipe connection
and propane tank.
- Open valve fully and check for any
bubbles, indicating gas leaks.
- Wipe off soap water or detergent after
inspection is completed.
Fuel Tank Hydraulic Tank
Propane Tank

SKYJACK, Page 16 Mid-Size Rough Terrain
Models 7127 & 7135
163761
Section 1 - Scheduled MaintenanceService and Maintenance Inspections
1.1-7 Engine Compartment
WARNING
Beware of hot engine components.
1. Pull on the two latches to pull out engine
compartment.
• Engine Control Console (B)
- Ensure all switches are returned to
neutral and are properly secured
- Ensure there are no loose or missing
parts and there is no visible damage.
WARNING
Beware of hot liquids and radiator com-
ponents.
• Radiator (B,C)
- Ensure radiator is secure.
- Ensure there are no loose or missing
parts and there is no visible damage.
- Check coolant level and add as needed.
C - Annual Inspection
- For recommended coolant change, refer
to engine manual.
• Muffler and Exhaust (B)
- Ensure mufer and exhaust system are
properly secured, with no evidence of
damage.
• Engine Tray (B)
- Ensure there are no loose or missing
parts and no visible damage to the engine
tray. Ensure that both tray-securing bolts
are in place.
• Hydraulic Pump (B)
- Ensure there are no loose or missing
parts and there is no visible damage.
- Ensure all bolts are properly tightened.
- Ensure all ttings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.
Radiator
Mufer and Exhaust Engine
Battery
Engine Air Filter
Hydraulic Pump
Engine Tray
Engine Control
Console

Mid-Size Rough Terrain
Models 7127 & 7135
163761
SKYJACK, Page 17
Section 1 - Scheduled Maintenance Service and Maintenance Inspections
• Engine Air Filter (B,C)
- Ensure there are no loose or missing
parts and there is no visible damage.
B - Frequent Inspection
- For engine air filter maintenance
procedure, refer to engine manual.
C - Annual Inspection
- For engine air filter replacement
procedure, refer to engine manual.
• Engine Oil (B)
- Maintaining the engine components
is essential to good performance and
service life of the aerial platform.
Check oil level on dipstick
- Oil level should be between the “L” and
“H” marks.
B - Frequent Inspection
- For recommended oil change, refer to
engine manual
• Fuel Leaks (B,C)
- Ensure there are no fuel leaks.
DANGER
Engine fuels are combustible. Inspect
the aerial platform in an open, well-ven-
tilated area away from heaters, sparks
and ames. Always have an approved
re extinguisher within easy reach.
- Ensure fuel pump, fuel lter, hoses and
ttings show no visible damage and no
evidence of fuel leakage.
C - Annual Inspection
- For engine fuel filter replacement
procedure, refer to engine manual.
2. Push in engine compartment until the two
latches lock to base.
Radiator
Mufer and Exhaust Engine
Battery
Engine Air Filter
Hydraulic Pump
Engine Tray
Engine Control
Console

SKYJACK, Page 18 Mid-Size Rough Terrain
Models 7127 & 7135
163761
Section 1 - Scheduled MaintenanceService and Maintenance Inspections
1.1-8 Platform Assembly
WARNING
Ensure that you maintain three points
of contact to mount/dismount platform.
1. Use the ladder of aerial platform to access
platform.
2. Close the gate.
- Ensure there are no loose or missing
parts and there is no visible damage.
- Ensure all fasteners are securely in place.
- Ensure all railings are properly positioned
and secured.
- Ensure gate is in good working order.
• Fall Protection Anchorage (B)
- Ensure attachment rings are secure and
have no visible damage.
• AC Outlet on Platform (B)
- Ensure outlet has no visible damage and
free from dirt or obstructions.
• Platform Control Console (B)
- Ensure all switches and controller are
returned to neutral and are properly
secured.
- Ensure there are no loose or missing
parts and there is no visible damage.
• Powered Extension Control Console
(If Equipped) (B)
- Ensure all switches are returned to
neutral and are properly secured.
- Ensure there are no loose or missing
parts and there is no visible damage.
WARNING
Ensure that you maintain three points
of contact to mount/dismount platform.
3. Use the ladder to dismount from platform.
• Extension Deck (If Equipped) (B)
- Ensure assembly is securely attached to
the bottom of the platform.
- Ensure there are no loose or missing
parts and there is no visible damage or
leaks.
Extension
Deck
Platform Control
Console
Platform
Railing
AC Outlet
Platform Assembly Powered Extension
Control Con\sole
Fall Protection
Anchorage
AE

Mid-Size Rough Terrain
Models 7127 & 7135
163761
SKYJACK, Page 19
Section 1 - Scheduled Maintenance Service and Maintenance Inspections
1.1-9 Lifting Mechanism
• Sliders (B)
- Ensure sliders are secure and there is no
visible damage.
- Ensure sliders’ path of travel are free from
dirt and obstructions.
1. Raise the platform until there is adequate
clearance to swing down the maintenance
support.
• Maintenance Support (B)
- Ensure maintenance support is properly
secured and shows no visible damage.
• Scissor Assembly (B)
- Ensure scissor assembly shows no visible
damage and no signs of deformation in
weldments.
- Ensure all pins are properly secured.
- Ensure cables and wires are properly
routed and shows no signs of wear and/
or physical damage.
• Scissor Bumpers (B)
- Ensure bumpers are secure and shows
no sign of visible damage.
• Scissor Pin Inspection (B)
- Complete a structural inspection of
the scissor pin connections, looking
for indicators of pin and/or scissor arm
damage. These indicators include, but
are not limited to:
- Noise coming from binding/seized pins
- Rust forming near pin joint
- Cracks in welds or in surrounding metal
- Evidence of metal dust or shavings from
wearing components
- Broken/missing pin retainer bolts
- Broken/missing pin retainers
- Rotated pin
- Elongation/enlargement of pin hole
Scissor Assembly
Maintenance
Support
Lift Cylinder
Scissor Bumper
Slider
Limit Switch

SKYJACK, Page 20 Mid-Size Rough Terrain
Models 7127 & 7135
163761
Section 1 - Scheduled MaintenanceService and Maintenance Inspections
Examples of pivot pin connections with no
damage:
- No rust
- Pin has not rotated
- Area is clear of dust/metal shavings
- Pin retainer/retainer bolts are in place
Pin retainer in place
No rust. Pin has not
rotated. Area
is clean of
dust/metal
shavings
Center pin pivot - Inner
Center pin pivot - Middle
Center pin pivot - Outer
Pin retainer bolts
in place
Scissor Assembly
Maintenance
Support
Lift Cylinder
Scissor Bumper
Slider
Limit Switch