Skyjack 6826El, 6832E Operating Manual

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OPERATING MANUAL

ANSI & CSA

This manual MUST be kept and stored with the aerial platform at all times.

SJIII Series E

For Service please call ....................................................................... 800 275-9522

Skyjack Inc. Service Center 3451 Swenson Ave., St. Charles, IL. 60174 ........ FAX 630 262-0006

For Parts in North America and Asia please call ...................................... 800 965-4626

Skyjack Inc. Parts Center 3451 Swenson Ave., St. Charles, IL. 60174 .................. FAX 888 782-4825

For Parts & Service in Europe please call .................................................. 44-1691-676-235

Skyjack Europe, Glovers Meadow, Maesbury Rd., Oswestry, Shropshire, U.K.......FAX 44-1691- 676-239

129924AB Printed in Canada April 2006

Models 6826E and 6832E

The Conventionals

OPERATING MANUAL

ANSI/CSA

This manual MUST be kept and stored with the aerial platform at all times.

USE THE SERIAL NUMBER OF YOUR MACHINE TO DETERMINE THE

CORRECT OPERATING MANUAL TO USE

Manual Part #

Release Date May 2002 April 2006 April 2006

118931AI

129924AB

(ANSI/CSA)

129923AB

(CE)

M O

D E L S

6826 E

6832 E

75643 & Below 75644 & Above 75644 & Above

83154 & Below 83155 & Above 83155 & Above

60304AF

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SJIII Series E - CONVENTIONALS

April 2006

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.

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death

WARNING indicates a potentially hazardous

situation which, if not avoided, could result in

death or serious injury.

This Safety Alert Symbol means attention!

Become alert! Your safety is involved.

DANGER

or serious injury.

WARNING

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.

SJIII Series E - CONVENTIONALS

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April 2006

Read and Heed

Aerial Platform Definition .............................................................................................................................................6

Purpose of Equipment .................................................................................................................................................6

Use of Equipment ........................................................................................................................................................6

Manual ......................................................................................................................................................................... 6

Operator ......................................................................................................................................................................6

Optional Accessories ................................................................................................................................................... 6

Scope of this Manual...................................................................................................................................................6

Section 1 - About Your Aerial Platform

1.1 Major Assemblies ...............................................................................................................................................7

1.2 Platform ..............................................................................................................................................................7

1.3 Operator’s Control Box ......................................................................................................................................7

1.4 Manual Storage Box...........................................................................................................................................7

1.5 Lifting Mechanism ..............................................................................................................................................7

1.6 Maintenance Support ......................................................................................................................................... 7

1.7 Base ...................................................................................................................................................................7

1.8 Tilt Sensing System ............................................................................................................................................ 8

1.9 Serial Number Nameplate ..................................................................................................................................8

1.10 Major Components ............................................................................................................................................. 9

1.11 Standard and Optional Features ......................................................................................................................10

1.12 Operator Safety Reminders .............................................................................................................................. 11

1.13 Electrocution Hazard ........................................................................................................................................ 11

1.14 Safety Precautions ............................................................................................................................................12

Section 2 - Operation

2.1 General ............................................................................................................................................................. 15

2.1-1 Operator Qualifications ..................................................................................................................... 15

2.1-2 Operator’s Responsibility for Maintenance .......................................................................................15

2.1-3 Maintenance and Inspection Schedule ............................................................................................. 15

2.1-4 Owner’s Inspections .......................................................................................................................... 15

2.2 Component Identification ................................................................................................................................. 16

2.2-1 Emergency Main Power Disconnect Switch ......................................................................................16

2.2-2 Motion Alarm .................................................................................................................................... 16

2.2-3 Tilt Alarm ........................................................................................................................................... 16

2.2-4 Base Controls ...................................................................................................................................16

2.2-5 Parking Brake System ......................................................................................................................17

2.2-6 Battery Charger ................................................................................................................................ 17

2.2-7 Emergency Lowering System ........................................................................................................... 17

2.2-8 Maintenance Support ....................................................................................................................... 18

2.2-9 AC Outlet on Platform .......................................................................................................................18

2.2-10 Operator’s Control Box ..................................................................................................................... 19

2.2-11 Outrigger Controls ............................................................................................................................ 19

2.2-12 Folding Guardrail System .................................................................................................................20

2.2-13 Lanyard Attachment Ring ................................................................................................................. 20

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Table of Contents

Section 2 - Continued

2.3 Component Identification (Special Options) .................................................................................................... 21

2.3-1 1500W AC Inverter (If Equipped) ....................................................................................................... 21

2.3-2 Powered Extension Deck Control Box (If Equipped) ........................................................................ 21

2.4 Setup Procedure ..............................................................................................................................................22

2.5 Start Operation .................................................................................................................................................24

2.5-1 Pre-Start Inspection .......................................................................................................................... 24

2.5-2 Operator’s Checklist ......................................................................................................................... 24

2.5-3 To Raise the Platform using the Base Controls ................................................................................. 25

2.5-4 To Lower the Platform using the Base Controls ................................................................................25

2.5-5 To Raise the Platform using the Operator’s Control Box ...................................................................25

2.5-6 To Lower the Platform using the Operator’s Control Box ..................................................................26

2.5-7 To Drive Forward or Backward..........................................................................................................27

2.5-8 To Steer .............................................................................................................................................27

2.5-9 To Extend/Retract Manual Extension Deck ....................................................................................... 27

2.5-10 To Extend/Retract Powered Extension Deck (If Equipped) ............................................................... 28

2.5-11 Hydraulic Outriggers (If Equipped) ................................................................................................... 28

2.5-11a Before Operation ........................................................................................................ 28

2.5-11b Extending the Outriggers ............................................................................................28

2.5-11c Retracting the Outriggers ...........................................................................................29

2.5-12 Electrical Inverter (If Equipped) ......................................................................................................... 29

2.5-13 Shutdown Procedure ........................................................................................................................29

2.6 Loading/Unloading ........................................................................................................................................... 30

2.6-1 Lifting ................................................................................................................................................30

2.6-2 Driving ............................................................................................................................................... 31

2.7 Winching and Towing ....................................................................................................................................... 32

2.7-1 To Release the Parking Brake Manually............................................................................................32

2.8 Emergency Lowering Procedure ...................................................................................................................... 33

2.9 Battery Maintenance ........................................................................................................................................ 34

2.9-1 Battery Service Procedures .............................................................................................................. 34

2.9-2 Battery Charging Operation ..............................................................................................................34

2.10 Tables ...............................................................................................................................................................3

2.11 Labels ...............................................................................................................................................................43

List of Tables

Table 2-1. Specifications and Features ...................................................................................................................... 38

Table 2-2. Owner’s Annual Inspection Record ........................................................................................................... 39

Table 2-3. Floor Loading Pressure .............................................................................................................................40

Table 2-4. Maximum Platform Capacities (Evenly Distributed) ...................................................................................42

Table 2-5. Maintenance and Inspection Schedule ..................................................................................................... 43

SJIII Series E - CONVENTIONALS

April 2006

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Read and Heed

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 SJIII series 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.

The aerial platform can be driven over uneven terrain only when the platform is fully lowered.

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.

Operator

The operator MUST read and completely understand both this operating manual and the safety panel label located 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 “Standard and Optional Features” in Section 1.11.

Operating instructions for these options (if equipped) are located in Section 2 of this manual.

For options not listed under “Standard and Optional F

 : :

 :

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 : 800 275-9522

 : 630 262-0006

Include the model and serial number for each applicable machine.

Scope of this Manual

a. This manual applies to the ANSI/SIA, CSA and CE versions of the SJIII Series aerial platform models listed

on Table 2-1.

- Equipment identified with “ANSI” meets the ANSI SIA-A92.6-1999 standard.

- Equipment identified with “CSA” meets the CSA B354.2-01 standards.

b. CSA (Canada) and CE (Europe)

Operators are required to conform to national, state/province 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 His/Her RESPONSIBILITIES in the Manual of Responsibilities before they use or operate this aerial platform.

eatures”, contact the SKYJACK Service Department at

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SJIII Series E - CONVENTIONALS

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Section 1 - About Your Aerial Platform

1. About Your Aerial Platform

This section provides general information about your aerial platform. It describes the major components, standard and optional features, safety reminders and precautions.

1.1 Major Assemblies

The aerial platform consists of three major assemblies: the platform, the lifting mechanism and the base. An operator’s control box is mounted on one of the platform guardrails. Auxiliary and emergency controls are located at the base.

1.2 Platform

The platform is constructed of a tubular support frame, a skid-resistant “diamond plate” deck surface and 40” to 43-1/2" (1016 - 1100mm) hinged guardrails with 6" (152mm) toe boards and mid-rails. The platform can be entered from the rear through an entry chain or optional

spring-returned gate with latch. The platform is also equipped with an extension platform.

1.3 Operator’s Control Box

1.5 Lifting Mechanism

The lifting mechanism is constructed of formed steel or tube sections making up a scissor-type assembly. The scissor assembly is raised and lowered by single-acting hydraulic lift cylinders with holding valves. A two-section pump, driven by an electric motor, provides hydraulic power to the lift cylinders.

1.6 Maintenance Support

A maintenance support is located inside the lifting mechanism. When properly positioned, it can support the scissor assembly and empty platform. The maintenance support MUST be used during inspection and maintenance or when repairs are being performed within the lifting mechanism.

1.7 Base

The base is a rigid, one-piece weldment which supports two side cabinets or two swing out trays.

• One tray contains the hydraulic and electrical components. The other tray contains battery charger and eight (8) 6 volt batteries.

A removable control box, mounted at the front right of the platform, contains controls for aerial platform motion and emergency stopping.

1.4 Manual Storage Box

This weather-resistant box is mounted to the inside of the hydraulic cabinet door at the base or at the front of the platform. It contains the

Operating Manual, the Operating/ Maintenance and Parts Manual and other important documentation. The Operating Manual for this make and model of aerial platform MUST remain with the aerial platform and should be stored in this box.

• The front axle has two non-driven wheels, steerable by a hydraulic cylinder.

• The rear axle is a rigid axle with a self-locking differential and an integral gearbox.

• A variable speed 48 V DC electric motor and holding brake is flange mounted to the gearbox.

SJIII Series E - CONVENTIONALS

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April 2006

Section 1 - About Your Aerial Platform

1.8 Tilt Sensing System

The tilt sensing system located on the base of the aerial platform is designed to prevent lifting or driving when the machine is on a slope greater than a predetermined limit. If in this situation the platform must be fully lowered immediately.

1.9 Serial Number Nameplate

The serial number nameplate, located at the rear of the machine, lists the following:

• Model number

• Serial number

• Machine weight

• Maximum drivable height

• Maximum capacities

• Maximum number of persons permissible on the platform

• Voltage

• System pressure

• Lift pressure

• Maximum platform height

• Maximum wheel load

• Maximum wind speed

• Maximum manual force

• Maximum incline

Use this information for proper operation and maintenance and when ordering service parts.

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1.10 Major Components

Operator’s

Control Box

Extension

Platform

Section 1 - About Your Aerial Platform

Main Platform

Base

Lifting Mechanism

Hydraulic/ Electric Tray

SJIII Series E - CONVENTIONALS

SKYJACK SJIII Series Aerial Platform

(Model 6832E

shown)

April 2006

SKYJACK, Page 9

Section 1 - About Your Aerial Platform

1.11 Standard and Optional Features

SJIII 68xxE Series – Conventionals – SPECIFICATIONS – ANSI/CSA

Descent alarm Motion alarm Joystick controller with proportional lift & drive functions * Swing-out side trays Spring-applied, electronically-released parking brakes Manual lowering system with electric holding valves on lift cylinders Operator horn 3-foot manual extension platform AC outlet on platform Lanyard attachment rings Urethane foam-filled tires

Spring-loaded full-height gate Spring-loaded half-height gate Flashing amber light 800W AC generator Hydraulically-powered extension platform Shop air hose to platform Propane/gasoline or diesel engine package Scissor guards Lowering warning system Light duty pipe rack Outriggers and outriggers alarm 1500W electrical inverter

* Platform lowering and steering are not proportional.

Standard Equipment

Optional Equipment

60425AA-ANSI

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Section 1 - About Your Aerial Platform

Warning

Failure to comply with your required responsibilities in the use and operation of the aerial platform

could result in death or serious injury!

1.12 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.

1.13 Electrocution Hazard

This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from energized

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 conductor.

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 &

Voltage Range Minimum Safe Approach Distance

(Phase to Phase) Feet

0 To 300V Avoid Contact

Over 300V to 50KV 10

Over 50KV to 200KV 15 Over 200KV to 350KV 20 Over 350KV to 500KV 25 Over 500KV to 750KV 35

Over 750KV to 1000KV 45

FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!

CSA B354.2-01 Requirements

60023AC-ANSI

SJIII Series E - CONVENTIONALS

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April 2006

Section 1 - About Your Aerial Platform

Know and understand the safety precautions before going on to next section.

1.14 Safety Precautions

Warning

Failure to heed the following safety precautions could

result in tip over, falling, crushing, or other hazards

leading to death or serious injury

• KNOW all national, state or territorial/provincial and local rules which apply to your MACHINE and JOBSITE.

• TURN the emergency 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.

• 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 stability of the aerial platform.

• If operation in areas with holes

or drop-offs is absolutely necessary, elevated driving shall not

be allowed. Position the aerial platform horizontally 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. After elevation, the drive function must not be activated.

• Elevated driving must only be

• AVOID entanglement with

ropes, cords or hoses.

• AVOID falling. Stay within the boundaries of the guardrails.

• DO NOT raise the aerial platform in windy or gusty conditions.

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April 2006

done on a firm level surface.

• DO NOT ascend or descend a grade when elevated. When fully lowered, ascending or descending, only grades up to the rated maximum listed in Table 2-1 are permissible.

1.14 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 platform that has ladders, scaffolding 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.

Section 1 - About Your Aerial Platform

• DO NOT raise the aerial platform

while the machine is on a truck, fork lift or other device or vehicle.

• BE AWARE of crushing hazards.

Keep all body parts inside platform guardrails.

• DO NOT lower the platform un-

less the area below is clear of personnel and obstructions.

• 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 as-

sembly. It is prohibited.

• BE AWARE of overhead obstructions or other possible hazards around the aerial platform when driving or lifting.

• ENSURE that there are no personnel or obstructions 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 guardrails, locki

ng pins and the entry gate/chain/bar in place.

• DO NOT exceed the rated capacity of the aerial plat-

form. Do make sure the load is evenly distributed on the platform.

SJIII Series E - CONVENTIONALS

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April 2006

Section 1 - About Your Aerial Platform

1.14 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.

• 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 another object to steady the platform.

• DO NOT place materials on the guardrails or ma-

terials that exceed the confines of the guardrails unless approved by Skyjack.

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 approved by the manufacturer.

• has safety devices which have been altered or disabled.

Failure to avoid these hazards could result in

death or serious injury.

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.

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.

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April 2006

General

Section 2 - Operation

2. Operation

This section provides the necessary information needed to operate the aerial platform. It covers the basic and optional components of the machine, operation and start procedures, winching and towing procedures, loading/unloading, tires specifications, labels, platform capacities and tables related to the proper maintenance of this aerial platform. It is important that the user reads and understands this section before operating the aerial platform.

2.1 General

In order for this aerial platform to be in good working condition, it is important that the operator follows the maintenance and inspection schedule referred to in this section.

2.1-1 Operator Qualifications

• ONLY trained and authorized personnel SHALL be permitted to operate an aerial platform.

• Safe use of this aerial platform requires the operator to understand the limitations and warnings, operating procedures and operator’s responsibility for maintenance. Accordingly, the operator MUST understand and be familiar with this operating manual, its warnings and instructions, manual of responsibilities and ALL warnings and instructions on the aerial platform.

2.1-2 Operator’s Responsibility for Maintenance

Warning

Maintenance MUST be performed by competent

personnel who are familiar with mechanical

procedures.

Death or serious injury could result from the use of

an aerial platform that is not properly maintained or

kept in good working condition.

• The operator must be sure that the aerial platform has been properly maintained and inspected before using it.

• The operator must perform ALL the daily inspections found in Table 2-5, even if the operator is not directly responsible for the maintenance of this aerial platform.

2.1-3 Maintenance and Inspection Schedule

• The inspection points covered in Table 2-5 indicate the areas of the aerial platform to be maintained or inspected and at what intervals the maintenance and inspections are to be performed.

• The actual operating environment of the aerial platform may affect the maintenance schedule.

Warning

• The operator MUST be familiar with employer’s work rules and related government regulations and be able to demonstrate the ability to understand and operate THIS make and model of aerial platform in the presence of a qualified person.

SJIII Series E - CONVENTIONALS

Use original or equivalent to the original parts and

components for the aerial platform.

2.1-4 Owner’s Inspections

It is the responsibility of the owner to arrange daily, weekly, monthly and annual inspections of the aerial platform. Refer to Table 2-5 for recommended maintenance and inspec- tion areas and intervals. A record of annual inspection is kept on a label located on the scissor assembly. Refer to

Table 2-3 in this manual.

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April 2006

Section 2 - Operation Component Identification

2.2 Component Identification

The following descriptions are for identification, explanation and locating purposes only.

2.2-1 Emergency Main Power Disconnect Switch

Emergency Main Power Disconnect Switch - This

switch is located at the rear of the base.

Figure 2-1. Emergency Main Power

Disconnect Switch

1. Emergency Main Power Disconnect Switch -

This switch, when in “OFF” position, disconnects power to all circuits. Switch MUST be in “ON” position to operate any circuit.

2.2-2 Motion Alarm

The aerial platform is equipped with a motion alarm. The alarm produces an audible sound accompanied by the amber light (if equipped) when any control function is selected.

2.2-3 Tilt Alarm

The aerial platform is equipped with a device which senses when the machine is out of level in any direction. When activated, it disables drive and lift functions of the aerial platform and an alarm produces an audible sound accompanied by the amber light (if equipped). This alarm activates once every 1.5 seconds. Lower platform completely, then reposition machine so that it is level before raising platform.

2.2-4 Base Controls

This control station is located in the hydraulic/electric tray. It contains the following controls:

Figure 2-2. Electrical Panel

1. Buzzer Alarm - This audible pulse alarm sounds when platform is being electrically lowered. On machines with certain options, this alarm sound when any control function is selected.

2. Hourmeter - This gauge records the accumulated time of operation of the aerial platform.

3. Circuit Breaker Resets - In the event of a power overload or positive circuit grounding, the circuit breaker will pop out. Push the breaker back in to reset.

4. Platform UP/DOWN Toggle Switch - This toggle type switch raises or lowers the platform to a desired height.

5. Enable Switch -This switch, when activated, brings power to the UP/DOWN toggle switch.

Note

If the tilt alarm sounds and the platform does not,

or only partially raises, immediately lower the

platform and ensure that the machine is on a firm

LEVEL surface.

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April 2006

Component Identification Section 2 - Operation

2.2-5 Parking Brake System

The parking brake system is located at the rear axle on the back of the machine.

Figure 2-3. Parking Brakes

Parking Brakes - The parking brakes are devices that are always mechanically engaged until hydraulically or manually released. Before towing or winching, the brakes have to be released manually. Refer to Section

2.7-1.

2.2-6 Battery Charger

This machine is battery-powered and is equipped with a battery charger.

Battery Charger - The charger is located inside the battery tray. Refer to Section 2.9-2 for details on charging operation.

2.2-7 Emergency Lowering System

The emergency lowering system allows platform lowering in the event of an emergency or an electrical system failure. Refer to Section 2.8 for the emergency lowering procedure. The system contains the following controls:

Figure 2-5. Emergency Lowering System

1. Holding Valve Manual Override Knob - Located on the holding valve at the bottom of each lift cylinder.

Figure 2-4. Battery Charger

SJIII Series E - CONVENTIONALS

2. Access Rod - Located at the left side of the

base.

3. Emergency Lowering Valve - Located at the rear of the hydraulic/electric tray.

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April 2006

Section 2 - Operation Component Identification

2.2-8 Maintenance Support

Figure 2-6. Maintenance Support

1. Maintenance Support - The maintenance support is a safety mechanism designed to support the scissor assembly. When properly positioned it can support the scissor assembly and empty platform. The maintenance support MUST be used when inspection and/or maintenance is to be performed within the lifting mechanism.

Warning

To Store the Maintenance Support

• Turn on emergency main power disconnect switch.

• Raise platform until there is adequate clearance to swing up the maintenance support.

• Swing bar up into storage bracket.

• Lower platform.

Warning

Do not reach through the scissor assembly when

the platform is raised without the maintenance

support properly positioned.

Failure to avoid this hazard could result in death

or serious injury.

2.2-9 AC Outlet on Platform

AC Outlet on Platform - This outlet is a source of

110V/220V power on the platform.

The maintenance support must be used when

inspection and/or maintenance or repairs are to be

performed within the lifting mechanism.

Failure to use this safety mechanism could result

in death or serious injury.

Proper Use of Maintenance Support

• Remove all material from platform.

• Raise platform until there is adequate clearance

to swing down the maintenance support. Refer to Section 2.5-3 on how to raise the platform using the base controls.

• Swing maintenance support down from storage bracket into a vertical position.

• Remove hands and arms from scissor assembly area.

• Lower platform until bottom end of maintenance support contacts the labeled cross bar and scissor assembly are supported by maintenance support. Refer to Section 2.5-4 on how to lower the platform using the base controls.

Figure 2-7. AC Outlet on Platform

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April 2006

Component Identification Section 2 - Operation

2.2-10 Operator’s Control Box

Operator’s Control Box - This metal control station is

mounted at the right front of the platform. It contains the following controls:

Figure 2-8. Operator’s Control Box

6. LIFT/OFF/DRIVE Select Toggle Switch Selecting “OFF” position disconnects power from both lift and drive circuits. Selecting “LIFT” position energizes the lift circuit. Selecting “DRIVE” position energizes the drive circuit.

7. Horn Push-Button - Located on the side of the

operator’s control box, this push-button switch, when depressed, sounds an automotive-type horn.

2.2-11 Outrigger Controls

Outrigger Controls - Located on the operator’s

control box, these switches control each outrigger’s extension and retraction.

1. LIFT/DRIVE/STEER Controller - This one-hand toggle-type lever controls lift/drive and steer motions. Internal springs return it to neutral when stick is released.

2. LIFT/DRIVE Enable Switch - This momentary switch energizes the proportional controller. It must be held depressed continuously while engaging either the lift/drive functions.

3. Warning Alarm Indicator Light - This light glows and an alarm sounds when an unsafe condition occurs.

4. BASE/OFF/PLATFORM Select Key Switch This three-way selector switch allows the operator to turn off the power to the aerial platform or to activate either the base or platform controls.

5. Emergency Stop Button - When depressed, this red “mushroom-head” push-button switch disconnects power to the control circuit.

Figure 2-9. Outrigger Controls on

Operator’s Control Box

1. Outrigger UP/DOWN Control Toggle Switches

- These switches control the extension and retraction of each individual outrigger.

2. Enable Push-Button - When depressed and held, this push-button switch brings power to the outrigger circuit.

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April 2006

Section 2 - Operation Component Identification

2.2-12 Folding Guardrail System

Folding Guardrail System - When folded down, the

folding guardrail system reduces the height of the retracted aerial platform for transporting only.

DETENT BALL

CLEAR OF SIDE

OF PIVOT BRACKET

Correct Position of Locking Pin

Figure 2-10. Folding Guardrail System

2.2-13 Lanyard Attachment Ring

Lanyard Attachment Ring - Use this ring as an at-

tachment point for safety belt/harness tethers. DO NOT attach belts/harnesses to any other point on the platform. DO NOT use this ring to lift, anchor, secure or support the platform or any other apparatus or material.

Figure 2-11. Lanyard Attachment Ring

Warning

The lanyard attachment ring is used for travel

restraint, within the limits of the platform only.

It is not a fall arresting device!

Use as such could result in death or serious injury.

Warning

The scissor assembly must be fully lowered

before raising or lowering the guardrails.

Guardrail Locking Pin with Lanyard - To fold

the guardrail system down, remove the locking pin at each pivot point and lower each guardrail. To raise the guardrail system, swing up each guardrail and lock in place with the locking pins ensuring that the detent ball of each pin is all the way through and clear of the side of the pivot brackets (Figure 2-10).

Warning

Before operating this aerial platform

check the guardrail system for loose or missing

locking pins. The guardrail system must be upright

and all pins must be locked in place.

Death or serious injury could result if the guardrail

system is not upright or properly locked.

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Section 2 - OperationComponent Identification (Special Options)

2.3 Component Identification (Special Options)

This following descriptions are for identification, explanation and locating purposes only of optional equipment.

2.3-1 1500W AC Inverter (If Equipped)

Inverter - The inverter is located on the base of the

machine. It has the following controls:

Figure 2-12. 1500W AC Inverter

Note

The inverter operation is automatic. These

controls do not need to be manipulated

for normal operation.

ON/OFF Switch - This diagnostic slide switch

activates or terminates inverter operation. It should remain in the “ON” position.

2.3-2 Powered Extension Deck Control Box

(If Equipped)

This metal control box is mounted on one of the extension platform guardrails. It contains the following controls:

Figure 2-13. Powered Extension

Deck Control Box

1. Enable Switch - This switch, when activated and held, allows the extension deck extend/retract switch functions to operate.

2. EXTEND/RETRACT Switch - This switch, when activated, extends or retracts the powered extension deck. Refer to Section 2.5-10 on how to extend/retract a powered extension deck.

2. Status LEDs - These LEDs indicate the operating or fault status of the inverter .

3. 15 Amp Circuit Breaker - In the event of a power overload or circuit grounding, the circuit breaker will pop out. Push the breaker back in to reset.

4. GFCI Outlet - During inverter operation, this outlet provides AC power.

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April 2006

Section 2 - Operation Setup Procedure

2.4 Setup Procedure

The following are descriptions of normal operating procedures. A qualified operator MUST read and com- pletely understand these descriptions before operating this aerial platform.

1. Before a new aerial platform is put into operation it must be carefully inspected for any evidence of damage resulting from shipment and inspected periodically thereafter. Refer to Table 2-5, Maintenance and Inspection Schedule.

Remove all packing materials and inspect for damage incurred during transport. Report any damage to delivery carrier immediately.

3. Inspect aerial platform thoroughly and remove any foreign objects.

4. Raise all guardrails to their upright position and lock in place with locking pins. Refer to

Section 2.2-12.

Warning

Before operating this aerial platform

check the guardrail system for loose or missing

locking pins. The guardrail system must be upright

and all pins must be locked in place.

Death or serious injury could result if the guardrail

system is not upright or properly locked.

8. Move the aerial platform to a firm, level test area where the platform can be later vertically extended to its maximum working height. If the aerial platform is to be pushed, towed or winched, refer to Section 2.7 for winching and towing procedures.

9. Unlock and swing out the hydraulic/electric tray.

10. Check the tank’s hydraulic oil level (scissor assembly must be fully lowered). Level should be at or slightly above the top mark on the sight glass.

Note

If required, add a quality grade hydraulic oil such as

ATF Dexron III (ESSO). Never mix hydraulic oils.

. Close the hydraulic/electric tray.

12. Unlock and swing out the battery tray.

13. Check the battery fluid level. If fluid level is not at FULL mark on the battery, add distilled or demineralized water only.

Warning

Explosion Hazard

Keep flames and sparks away. Do not

smoke near batteries.

5. Ensure the emergency main power disconnect switch is switched to the “OFF” position.

6. Remove the operator’s control box from its shipping container and secure it to the guardrail at the right front of the platform.

7. Attach the control cable and power extension deck cable (if equipped) to the machine’s control cable.

14. Connect the AC battery charger cord to the proper

15. Close the battery tray.

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April 2006

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.

AC voltage source and charge the batteries. Refer to Section 2.9-2 for battery charging procedures. When charger cycle is complete, disconnect battery charger AC cord.

Warning

16. From the base controls, carefully raise the platform. Refer to Section 2.5-3 for procedure on how to raise the platform.

17. Unlatch and carefully swing down the maintenance support. Refer to Section 2.2-8 for procedure to properly position the maintenance support.

Warning

The maintenance support must be used during

inspection and maintenance or repairs are to be

performed within the lifting mechanism.

Failure to avoid this hazard could result

in death or serious injury.

18. From the base controls, carefully lower the platform until the scissor assembly is firmly resting on the maintenance support. For procedure on how to lower the platform refer to Section 2.5-4 .

Section 2 - OperationSetup Procedure

. Inspect all hoses, fittings, wires, cables, valves,

etc. for leaks, loose or missing parts, hidden damage and foreign material.

20. Raise the platform until there is an adequate clearance to swing up maintenance support and lock in position.

21. Raise the platform to the maximum extension height.

Warning

Be aware of overhead obstructions or other possible

hazards around the machine when lifting.

22. Fully lower the platform.

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April 2006

Section 2 - Operation Start Operation

2.5 Start Operation

Carefully read and completely understand ALL of this Operating Manual and ALL warnings and instruction labels on the aerial platform.

Before operating this aerial platform, perform the prestart inspection and the tasks on the operator’s checklist as described in this section.

Do not operate this aerial platform without proper

authorization and training.

Failure to avoid this hazard could result in death or

Warning

serious injury.

2.5-1 Pre-Start Inspection

It is the responsibility of the operator to perform a prestart inspection.

The pre-start inspection is a visual inspection performed by the operator prior to each work shift.

1. Ensure that there are no obstacles around the aerial platform and in the path of travel such as holes, drop offs, debris, ditches and soft fill.

2. Ensure that there are no electrical cords and hoses in the path of travel.

3. Ensure that the batteries are fully charged. Disconnect the AC charger cord from the external power source.

4. Ensure that both battery and hydraulic/electric trays are closed and locked.

5. Ensure that the free-wheeling valve is fully closed.

6. Make sure all guardrails and lock pins are in place and locked in position.

6. Make sure you do not climb or descend a grade steeper than rated maximum listed in Table 2-1 Elevated driving must only be done on firm level surfaces.

2.5-2 Operator’s Checklist

It is the user’s responsibility to inspect the machine operation before the start of each shift:

. Operating and emergency controls.

2. Safety devices and limit switches.

3. Personal protective devices.

4. Tires and wheels.

5. Outriggers (if equipped) and other structures.

6. Air, hydraulic and fuel system(s) for leaks.

7. Loose or missing parts.

8. Cables and wiring harnesses.

9. Placards, warnings, control markings and operating manuals.

10. Guardrail system including locking pins.

11. Battery fluid level.

12. Hydraulic reservoir level.

13. Coolant level (if equipped).

8. Check overhead clearances.

Warning

Do not use or operate the aerial platform if any

component appears to be altered, damaged or if it

is tagged or locked out for non-use or repair.

Operation of aerial platform while in any of the

above states may result in death or serious injury.

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April 2006

14. Parking brakes (check operation).

Start OperationSection 2 - Operation

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 approved by the manufacturer.

• has safety devices which have been altered or disabled.

Failure to avoid these hazards could result in

death or serious injury.

2.5-3 To Raise the Platform using the Base Controls

Warning

Be aware of overhead obstructions or other possible

hazards around the machine when lifting.

7. Raise the platform by selecting “ platform UP/DOWN toggle switch from the base controls.

2.5-4 To Lower the Platform using the Base

Controls

1. On the base controls, press and hold the enable switch.

2. Lower the platform by selecting “Ø” (DOWN) with platform UP/DOWN toggle switch from the base controls.

2.5-5 To Raise the Platform using the Operator’s

Control Box

1. Turn the emergency main power disconnect switch to “ON” position.

Warning

Ensure that you maintain three points of contact

when using the ladder to mount/dismount

the platform.

××

×” (UP) with

××

Warning

Ensure that you maintain three points of contact

when using the ladder to mount/dismount

the platform.

1. Use the ladder of the aerial platform to access the aerial platform deck.

2. Close the gate/chain.

3. Select “BASE” position with BASE/OFF/ PLATFORM select key switch.

4. Ensure the emergency stop button is pulled out.

5. Dismount the platform using the ladder.

6. Turn the emergency main power disconnect switch to “ON” position.

7. On the base controls, press and hold the enable switch.

2. Use the ladder of the aerial platform to access the aerial platform deck.

3. Close the gate/chain.

Warning

Be aware of overhead obstructions or other possible

hazards around the machine when lifting.

4. Ensure the emergency stop button is pulled out.

5. Select “PLATFORM” position with BASE/OFF/ PLATFORM select key switch.

6. Select “LIFT” position with LIFT/OFF/DRIVE select toggle switch.

7. Activate and hold the enable trigger switch by squeezing it towards the proportional controller.

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Section 2 - Operation Start Operation

8. Push the proportional controller handle forward until desired height is reached.

9. Return the proportional controller to the neutral center position to stop. Release the enable trigger switch.

Warning

To protect against unintended movement of the

aerial platform, push in the emergency stop

button after you have arrived at your desired

location and/or elevation.

Note

If the tilt alarm sounds and the platform does not,

or only partially raises, immediately lower the

platform and ensure that the machine is on a firm

LEVEL surface.

2.5-6 To Lower the Platform using the Operator’s Control Box

Warning

Do not lower the platform unless the area below is

clear of personnel and obstructions.

1. Ensure the emergency stop button is pulled out.

2. Select “PLATFORM” position with BASE/OFF/

PLATFORM select key switch.

3. Select “LIFT” position with LIFT/OFF/DRIVE

select toggle switch.

4. Activate and hold the enable trigger switch by

squeezing it towards the proportional controller.

5. Pull the proportional controller handle backward

until desired height is reached.

Note

Lowering is not proportional.

6. Return the proportional controller to the neutral center position to stop. Release the enable trigger switch.

Warning

To protect against unintended movement of the

aerial platform, push in the emergency stop button

after you have arrived at your desired location or

elevation.

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April 2006

2.5-7 To Drive Forward or Backward

Warning

Be aware of blind spots when operating the aerial

platform.

Start OperationSection 2 - Operation

Warning

Steering is not proportional. It is not self-centering

and will remain in the selected orientation.

Driving and steering may be active at the same time.

Warning

Ensure that there are no personnel or obstructions

in the path of travel, including blind spots.

1. Ensure the emergency stop button is pulled out.

2. Select “PLATFORM” position with BASE/OFF/ PLATFORM select key switch.

3. Select “DRIVE” position with the LIFT/OFF/DRIVE select toggle switch.

4. Activate and hold the enable trigger switch by squeezing it towards the proportional controller.

5. Push or pull the controller handle forward or

backward to the desired speed and direction of platform travel.

6. Return the proportional controller to the neutral center position to stop. Release the enable trigger switch.

2.5-9 To Extend/Retract a Manual Extension Deck

1. To extend/retract the manual extension deck, remove the retaining locking pins and push/pull the extension deck using the push bar or sliding handrails to one of four or five desired locking positions.

2. Upon extension or retraction, reinsert the locking pins. Insert the pin on one side of the machine in front of the upright bar and the pin on the other side of the machine behind the upright bar to prevent accidental movement, in either direction, of the manual extension platform during travel or transport. Refer to Figure 2-14 for a configuration example.

Upright Bar

Warning

To protect against unintended movement of the

aerial platform, push in the emergency stop

button after you have arrived at your desired

location or elevation.

2.5-8 To Steer

1. Select “DRIVE” position with LIFT/OFF/DRIVE select toggle switch.

2. Press the rocker on top of the controller handle in the direction you wish to steer.

SJIII Series E - CONVENTIONALS

Upright Bar

Figure 2-14.Variable Position Manual Extension Deck

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April 2006

Section 2 - Operation Start Operation

2.5-10 To Extend/Retract Powered Extension Deck

(If Equipped)

1. To extend the powered extension deck, ensure the emergency stop button is pulled out.

2. On the operator’s control box, select “LIFT” position with LIFT/OFF/DRIVE select toggle switch.

3. On the powered extension deck control box, press and hold the enable switch, then push the EXTEND/RETRACT switch to the “×” (EXTEND) position until desired extension is reached. Release switch to stop.

4. To retract the platform, ensure the emergency stop button is pulled out and select “LIFT” position using the LIFT/OFF/DRIVE select toggle switch.

5. On the powered extension deck control box, press and hold the enable switch, then push the EXTEND/RETRACT switch to the “Ø” (RETRACT) position until desired extension is reached. Release switch to stop.

Warning

To protect against unintended movement of the

aerial platform, push in the emergency stop

button after you have arrived at your desired

location or elevation.

2.5-11 Hydraulic Outriggers (If Equipped)

3. Check that the supporting surface under the tires and outrigger pads is level, firm and capable of supporting aerial platform and rated load. DO NOT place outrigger pad on a street drain, manhole cover or other unsupported surface.

2.5-11b Extending the Outriggers

1. Ensure the emergency stop button is pulled out.

2. Select “PLATFORM” position with BASE/OFF/

PLATFORM select key switch.

3. Select the “LIFT” position with LIFT/OFF/DRIVE

select key switch.

Note

Check that the platform is fully lowered.

The outrigger controls are not functional when the

platform is raised.

4. While holding the outrigger enable switch, extend

each outrigger using the individual outrigger UP/ DOWN control toggle switches until the platform is fully supported by the outriggers and is level. The tilt alarm produces an audible sound while the platform is being leveled and remains until the platform is level.

5. Check that each outrigger pad is in firm

contact with a suitable supporting surface!

Make adjustments if necessary using the independent outrigger controls.

These devices are mounted to the four corners of the base. When properly positioned, they increase the stability of the aerial platform.

2.5-11a Before Operation

1. Check overhead clearances and ground obstructions. This will require the operator to move around the aerial platform.

2. Check that the platform is fully lowered. (The outrigger controls are not functional when the platform is raised.)

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Each outrigger pad must be in firm contact with the

ground for most aerial platform functions to work.

Drive functions are disabled if the outriggers are

in any position other than fully retracted.

Note

Start OperationSection 2 - Operation

Warning

If alarm sounds during operation, the aerial platform

is not level or an outrigger does not have firm

ground contact. Lower the platform immediately!

Make the necessary adjustments to level the aerial

platform.

2.5-11c Retracting the Outriggers

1. Ensure the emergency stop button is pulled out.

2. Select “PLATFORM” position with BASE/OFF/ PLATFORM select key switch.

3. Select the “LIFT” position with LIFT/OFF/DRIVE select key switch.

4. Lower the aerial platform.

5. Select and hold the outrigger enable toggle switch in either the “UP” or “DOWN” position, then push and hold pairs (front or rear) of outrigger UP/DOWN toggle switches to “UP” position until the outriggers are fully retracted.

2.5-12 Electrical Inverter (If Equipped)

1. Turn the emergency main power disconnect switch to the “ON” position.

2. Make sure the ON/OFF switch of the inverter is “ON.”

3. Inverter activation is indicated by a glowing green LED on the front of the inverter.

Caution

The emergency main power disconnect switch

MUST be turned OFF at the end of the shift or

the batteries will drain.

2.5-13 Shutdown Procedure

1. Completely lower the platform.

2. Push in emergency stop button located on operator’s control box.

3. Turn BASE/OFF/PLATFORM select key switch to “OFF” position and remove the key from the control box.

Note

Limit switches are used to protect the outriggers

from being damaged. If aerial platform will not drive,

visually check to see that ALL outriggers are fully

retracted.

Warning

Ensure that you maintain three points of contact

when using the ladder to mount/dismount

the platform.

4. Dismount the platform using the ladder.

5. Turn emergency main power disconnect switch to “OFF” position.

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April 2006

Section 2 - Operation Loading/Unloading

2.6 Loading/Unloading

KNOW all national, state or territorial/provincial and local rules which apply to your loading/unloading of aerial platforms.

Only qualified personnel shall operate machinery during loading/unloading.

Be sure vehicle capacity and loading equipment hoists, chains, straps, etc. are sufficient to withstand maximum aerial platform weight.

The transport vehicle must be parked on a level surface and must be secured to prevent rolling while the aerial platform is being loaded or unloaded.

2.6-1 Lifting

When it is necessary to lift the Skyjack aerial platform the following conditions must be met:

• The platform must be fully lowered.

• The emergency main power disconnect switch must be in the “OFF” position.

• The hydraulic/electric and battery trays must be closed and securely latched.

• The extension deck must be retracted and secured.

• The control box must be secured to the railings or removed.

• The platform must be cleared of all personnel, tools, and materials.

• The lifting/rigging may be attached to all four lifting points as illustrated in Figure 2-17.

Tie down/ lifting points

Figure 2-15. Tie Downs/Lifting Points

Note

The mass of the aerial platform is as per Table 2-1. The center of gravity is approximately located in the middle of the aerial platform, front to back and side to side, as illustrated in Figure 2-16. Vertically, the center of gravity is approximately just above the base chassis.

Center of

Gravity

Tie down/ lifting points

Center of

Gravity

Figure 2-16. Center of Gravity

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April 2006

Section 2 - OperationLoading/Unloading

Note

The aerial platform can be lifted with a forklift from the sides but Skyjack does not recommend this use. Lift with forks

in designated pockets as illustrated in Figure 2-17.

Forklift Pocket Forklift Pocket

2.6-2 Driving

When driving the aerial platform:

• Ramp or dock capacity should be sufficient to withstand maximum machine weight.

• Ramp should be equipped with side guards to prevent inadvertent fall from the ramp.

• Incline should not exceed machine gradeability (refer to Table 2-1).

• Aerial platform brakes should be checked for proper operation.

• Aerial platform speed should be on high torque setting (if equipped) and batteries fully charged (electric machines).

Rear of the Aerial Platform

Figure 2-17. Forklift Pockets

Warning

When transporting, the aerial platform must be secured to the truck or trailer deck. Tie downs are available as

illustrated in Figure 2-15.

SJIII Series E - CONVENTIONALS

April 2006

SKYJACK, Page 31

Section 2 - Operation Winching and Towing Procedures

2.7 Winching and Towing Procedures

This section provides the operator with procedures about towing and winching and on how to manually release the parking brake.

Warning

Ensure platform is fully lowered before winching or

towing. Sudden motion could cause the aerial

platform to become unstable.

Death or serious injury could result.

Warning

In emergency situations where machine functions

are not available and lowering is impeded by an

obstacle, the utmost care must be taken to move

the machine far enough to clear the obstacle. In

such cases operation must be extremely smooth

with no sudden movements and must not exceed

a speed of 2”/sec.

2.7-1 To Release the Parking Brake Manually

Figure 2-18. Parking Brake

Parking Brake - The brake MUST be manually disengaged for pushing, towing or winching.

Warning

Do not manually disengage the parking brakes

if the aerial platform is on a slope.

1. Make sure that the aerial platform is on level ground. Chock or block the wheels to keep aerial platform from rolling.

Warning

When pushing, towing or winching,

do not exceed 2 mph (3.2 km/h).

Warning

Do not push, tow or winch vehicle on to

a slope, or brake the towing

vehicle rapidly. Do not pull the aerial platform

down an incline towards a winch.

2. Turn emergency main power disconnect switch to “OFF” position.

3. Pull handle (item 1) firmly outwards then rotate handle up to OFF position. A safety switch on the brake disconnects power from the control system when brake is manually disconnected.

4. Remove the wheel chocks or blocks, then push, tow or winch the aerial platform to the desired location.

5. Position aerial platform on a firm level surface. Chock or block the wheels to prevent the aerial platform from rolling.

6. To restore brake and normal functions, rotate handle downwards to ON position and release handle.

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Section 2 - OperationEmergency Lowering Procedure

2.8 Emergency Lowering Procedure

This section guides the operator on how to use the emergency lowering system. This system allows platform lowering in the event of an emergency or an electrical system failure.

Warning

Keep clear of scissors mechanism when using

emergency lowering valve.

1. Remove any obstructions from a descending platform.

2. The extension platform(s) may need to be retracted or the platform may need to be moved to clear the obstruction. Refer to Section 2.7, Winching and Towing Procedures, for proper instructions.

4. On the hydraulic tray, pull out and hold the emergency lowering valve (item 3) to lower the platform.

5. To restore normal operation, depress and turn the holding valve manual override knobs clockwise.

Figure 2-19. Emergency Lowering System

3. Locate the holding valve manual override knobs (item 1) at the base of each lift cylinder. Depress and turn counterclockwise. If necessary, use the access rod (item 2) that is located on the base of the machine.

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Section 2 - Operation Battery Maintenance

2.9 Battery Maintenance

This section provides the operator with procedures on how to service and charge the battery. This also provides charger operation instructions.

2.9-1 Battery Service Procedures

Warning

Explosion Hazard

Keep flames and sparks away

Do not smoke 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.

2.9-2 Battery Charging Operation

Figure 2-20. Battery Charger

Operation of Charger

Danger

Risk of electric shock. Do not immerse the charger

in water. Though the charger is highly resistant to

water, it is not designed for immersion and an

electric shock can occur.

1. Turn emergency main power disconnect switch to “OFF” position.

2. Check battery case for damage.

3. Check battery fluid level in each battery. If plates are not covered by at least 1/2” (13mm) of solution, add distilled or demineralized water.

4. Clean battery terminals and cable ends thoroughly with a terminal cleaning tool or wire brush.

5. Make sure all battery connections are tight.

6. Replace any battery that is damaged or incapable of holding a lasting charge.

7. Do not use any batteries other than flooded leadacid batteries of the proper AH rating.

Warning

Use original or equivalent to the original parts and

components for the aerial platform.

1. Provide adequate ventilation for the batteries and charger. The convection cooled design requires access to cooling air for proper operation. Do not allow blankets or other materials to cover the charger. Although the charger protects itself against overheating, the charger cooling fins should be cleaned if clogged with debris for best performance.

Warning

There could be a spark during charging. Be careful

when using fuels, solvents or other flammables near

the charger or batteries.

2. Connect the power supply cord to a properly grounded 100V/50 or 60Hz, 115V/ 60Hz, or 230V/ 50 or 60Hz socket. This charger automatically senses and adjusts to the AC input voltage range.

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April 2006

Caution

When changing the input voltage wait until all the

LEDs are OFF or wait a minimum of 20 seconds

before switching on the new voltage.

3. The charging time is affected by numerous factors including battery Amp-Hour capacity, depth of discharge, battery temperature, and battery condition (new, old or defective). Batteries larger than 240 Ah can be recharged but will take longer.

Danger

Do not disconnect the DC output wires near the

batteries when the charger is ON. The resulting

arcing could cause the batteries to explode.

If the charger must be disconnected, first disconnect

the AC power supply cord

from its outlet, then disconnect the

charger DC connections.

Danger

Risk of an electric shock. Do not touch un-insulated

parts of the charger output wires, battery connector,

or battery terminals.

Danger

Section 2 - OperationBattery Maintenance

Charging State LED

State of charge 1ST LED 2ND LED 3RD LED

0 to 50% Blinking Off Off

50% to 75% On Blinking Off

75% to 100% On On Blinking

100% On On On

60133AA

The charger goes into an equalizing charge mode after the batteries are charged and all 3 LEDs are “ON”. The charger will continue to charge at a low current then shut-off automatically when complete. If all 3 LEDs blink together, there is a problem.

ake proper action according to the following

T instructions:

3 LEDs blink once simultaneously: Output connection error. Check the battery and charger connection. The output may not be connected to the batteries or the connections to the batteries may have corroded or loosened. The output may be shorted due to improper connection to the batteries or pinched wires. The output may be connected in reverse polarity to the batteries. The charger is not damaged by any of these problems.

3 LEDs blink twice simultaneously: The charger is indicating that the AC voltage is too low or too high. Check the AC input voltage.

3 LEDs blink three times simultaneously: Charger is overheated. No action required. When the charger cools, charging will re-start automatically. Check and correct for dirt or other debris on charger that may be reducing cooling.

Visually and manually inspect to verify the DC output

wires and terminals are in good working condition

before each use.

4. The charger will start automatically within four to six seconds. The charger will start even with severely discharged batteries (down to 1V terminal voltage). Once charging starts, the LEDs indicate the charging progress.

SJIII Series E - CONVENTIONALS

3 LEDs blink four times simultaneously:

Input or output over current. No action required, charger will correct and re-start automatically.

100% LED lamp blinks:

Charger 18 hour timer has timed out due to battery problem.

SKYJACK, Page 35

April 2006

Section 2 - Operation Battery Maintenance

Batteries do not fully charge.

If the batteries are charged overnight, make sure the AC supply is not being switched off at night with other building items. Check battery condition and for dead cells or reduced capacity. Replace charger only if other problems are not found.

The AC line circuit breaker or fuse is blown.

A defective circuit breaker or fuse, an overloaded circuit, or a charger problem can cause this condition. Try connecting the charger to a different AC outlet (on a different circuit) in the building. If the AC supply checks good, the charger should be replaced.

EE-Rated Machines

Warning

Do not charge batteries in hazardous area !

The EE-rating of a machine does not include the

charging of batteries.

1. Move the aerial platform to an area designated

for battery charging. Refer to NFPA 505 for charging set-up. NFPA 505 is a publication of the National Fire Protection Association, Inc., Batterymarch Park, Quincy, MA 02269 (USA).

2. Connect battery charger DC plug into the battery

plug at the rear of the base.

3. Charge batteries. Refer to Section 2.9-2 for

battery charging operation. When charge cycle is completed, disconnect charger plug from battery tray.

SKYJACK, Page 36 SJIII Series E - CONVENTIONALS

April 2006

Section 2 - Operation

MODEL 6826E 6832E

Tables

Table 2-1. Specifications and Features

Weight

Width 68.0” 68.0”

Length 99.25” 99.25”

Platform Size 60” x 81” 60” x 81”

Elevated Working 32.0’ 38.0’

Elevated Platform 26.0’ 32.0’

Stowed Fixed Railing 93.6” 99.0”

Height

Stowed Platform 50.0” 55.3”

Drive FULL

Normal Drive (Max) 2 mph 2 mph

Elevated Low Drive (Max) .67 mph .67 mph

5860 lb. 6160 lb.

Speed

Gradeability 25% 25%

Tire Contact

Pressure (Max)

* Weight with standard 3’ extension platform. (Refer to nameplate for machines with 5’ extension platform, CE models and other options.) ** Fill Hardness: 55 Durometer *** Refer to Serial Nameplate

Lift

(Rated Load)

Lower

(Rated Load)

Tires

59 sec. 59 sec.

57 sec. 50 sec.

23 x 10.5 x 12

Foam Filled

*** ***

23 x 10.5 x 12

Foam Filled

60346AF-ANSI

SKYJACK, Page 38 SJIII Series E - CONVENTIONALS

April 2006

Tables

Section 2 - Operation

Table 2-2. Owner’s Annual Inspection Record

Model Number____________________________ Serial Number_________________

Recording

Date

Recording

Year #

Owner’s

Name

Inspected

60141AA 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.

1 2 3 4 5 6 7 8

SJIII Series E - CONVENTIONALS

SKYJACK, Page 39

April 2006

Section 2 - Operation

Tables

Table 2-3. Floor Loading Pressure

TOTAL MACHINE

MODEL

6826E

Outrigger Pads

6832E

Outrigger Pads

* min - Total machine weight with no options

max - Machine weight + all options + full capacity

** LCP - Locally Concentrated Pressure is a measure of how hard the machine presses on the areas

in direct contact with the floor. The floor covering (tile, carpet, etc.) must be able to withstand more

that the indicated values above. OUP - Overall Uniform Pressure is a measure of the average load the machine imparts on the whole surface directly underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values above.

NOTE:

The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or architect for that particular structure.

min* 5860 2344 152.70 125.40

max* 7110 2844 155.30 152.15

min* 6280 88.65 115.02

max* 7530

min* 6160 2464 154.90 131.82

max* 7260 2904 157.40 155.36

min* 6580 92.89 120.51

max* 7680

WEIGHT

lb. lb. psi psf

Wheel LCP** OUP**

N/A

TOTAL MACHINE LOAD

106.30 137.91

108.41 140.66

60344AB-ANSI

SKYJACK, Page 40 SJIII Series E - CONVENTIONALS

April 2006

Tables

Section 2 - Operation

Floor Loading Pressure

Local Concentrated Pressure (LCP):

Foot Print Area = Length x Width

Weight of Machine + Capacity (lb.)

LCP=

Foot Print Area x 4 (Tires)

Length

Overall Uniform Pressure (OUP):

Base Area = Length x Width

Weight of Machine + Capacity (lb.)

OUP=

Base Area

Width

Length

Warning

Intermixing tires of different types or using tires of types other than those originally supplied with this

equipment can adversely affect stability. Therefore, replace tires only with the exact original Skyjack

approved type. Failure to operate with matched approved tires in good condition may result in death or

serious injury.

SJIII Series E - CONVENTIONALS

SKYJACK, Page 41

April 2006

Section 2 - Operation

Tables

Table 2-4. Maximum Platform Capacities (Evenly Distributed)

MODEL

6826 900 lb.

6832 700 lb.

NOTE: Overall capacity - Occupants and materials not to exceed rated load.

With 3’ Extension Platform With 5’ Powered Extension Platform

Main Platform Extension Platform Main Platform Extension Platform

Persons

300 lb.

Person

700 lb.

Persons

300 lb.

Warning

Use only original replacement parts. Parts such as batteries, chargers, wheels, railings, etc. with weight and

dimensions different from original parts will affect the stability of the aerial platform and must not be used

without the manufacturer’s consent.

Person

60084AF-ANSI

SKYJACK, Page 42 SJIII Series E - CONVENTIONALS

April 2006

Tables

Section 2 - Operation

General Maintenance

Before attempting any repair work, disconnect the battery by turning the battery disconnect switches to the OFF

position. Preventative maintenance is the easiest and least expensive type of maintenance.

Table 2-5. Maintenance and Inspection Schedule

Daily Weekly Monthly 3 Months 6 Months 12 Months*

Mechanical

Structural damage/welds A A A

Parking brakes B B B

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/entry chains/gates A, B, C A, B, C A, B, C

Bolts and fasteners C C C

Maintenance support B B B

Rust A A A

Wheel bearings and king pins A, B, E A, B, E A, B, E

Pothole protection device A, B A, B A, B

Steering cylinder & tie rod A, B, E A, B, E

Electrical

Battery fluid level A A A

Control switches/indicator lights** A, B A, B A, B

Cords & wiring A A A

Battery terminals A, C A, C A, C A, C

Inverter/AC receptacle A, B A, B A, B

Terminal and plugs C C C

Limit switches B B B

Hydraulic

Hydraulic oil H H H

Hydraulic hoses/fittings A, L C A, L, C A, C, L

Lift/lowering drive times G G

Cylinders A, B A, B A, B

Emergency lowering system B B B

Lift capacity D D D

Hydraulic oil filter F F

Miscellaneous

Labels & manual A, J, K A, J, K A, J, K

Check for applicable service bulletins A A

Notes

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 2-1, “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 through the slider and pad.

J. Replace if missing or illegible. K. Proper manual must be in box. L. Check for leaks. * Record inspection date and signature.

** Since the enable switch works in conjunction with lift/drive or steer

function, to inspect operation of the joystick enable switch activate the steer controller once with activating the enable switch and once without activating the enable switch.

60028AG-68E

SJIII Series E - CONVENTIONALS

SKYJACK, Page 43

April 2006

Section 2 - Operation

Tables

Labels and Nameplates

6 7 8

1 LABEL, Warning, Falling Hazard 2 LABEL, E 3 LABEL, Model Designation SJIII 6832 4 LABEL, Tape Assembly 5 LABEL, CE 6 LABEL, Tape Assembly 7 LABEL, Skyjack Logo 8 LABEL, Caution Lift 9 LABEL, Annual Inspection

11 12 13

10 LABEL, Side Force/Outdoor 11 LABEL, Caution Brake 12 LABEL, Keep 13 LABEL, Clear 14 LABEL, Battery Charger Connnection In Tray 15 LABEL, Tape Assembly 16 LABEL, No Step 17 LABEL, Safety Belt harness

15 16

* ANSI/SIA & CSA Standards Only

SKYJACK, Page 44 SJIII Series E - CONVENTIONALS

April 2006

10817AA

Tables

Section 2 - Operation

Labels and Nameplates

SJIII Series E - CONVENTIONALS

1 LABEL, Manual Box 2 LABEL, Safety Bar 3 LABEL, Skyjack Logo 4 LABEL, Platform Capacities 5 LABEL, Checklist 6 LABEL, Do Not Wear Jewellery 7 LABEL, Danger, Foam Filled Tires 8 LABEL, Manual Enclosed 9 LABEL, Danger/Warning 10 LABEL, Tape Assembly 11 LABEL, Side Force/Outdoor 12 LABEL, ON/OFF Slab 13 LABEL, Tie down/Lift lugs pictorial 14 LABEL, Forklift Boot 13 LABEL, Safety Bar

10818AA

SKYJACK, Page 45

April 2006

Section 2 - Operation Labels

Labels and Nameplates

1 LABEL, Rail Height 2 LABEL, Emergency Stop 3 LABEL, Power BASE/OFF/PLATFORM 4 LABEL, Operator Warning 5 LABEL, Enable Joystick 6 LABEL, Operation 7 LABEL, Controller, LIFT/DRIVE 8 LABEL, LIFT/OFF/DRIVE Switch 9 LABEL, Horn 10 LABEL, Hydraulic Proportional

SKYJACK, Page 46 SJIII Series E - CONVENTIONALS

April 2006

11 LABEL, Orifice 12 LABEL, Enable (w/ powered extensions) 13 LABEL, Attention, Power Deck 14 LABEL, Platform EXTEND/RETRACT (If

Equipped) 15 LABEL, Emergency Lowering 16 LABEL, Enable 17 LABEL, Outrigger

10819AA

Labels and Nameplates

Section 2 - OperationLabels

891011

345

1 LABEL, Battery Disconnect Switch Location 2 LABEL, Power OFF/ON 3 NAMEPLATE, Serial Number 4 LABEL, Connect AC Supply Here 5 LABEL, UP/DOWN Or EXTEND/RETRACT 6 LABEL, Emergency Stop 7 LABEL, UP/DOWN 8 LABEL, Enable 9 LABEL, Power Reset 10 LABEL, 24V 11 LABEL, 48V 12 LABEL, Emergency Lowering 13 LABEL, Warning Replacement Parts 14 LABEL, Push To Down 15 LABEL, Hydraulic System 16 LABEL, Danger! Hand/foot pinch 17 LABEL, Do Not Alter

SJIII Series E - CONVENTIONALS

10820AB

SKYJACK, Page 47

April 2006

MOBILE ELEVATING PLATFORMS

www.skyjackinc.com

Skyjack 6826El, 6832E Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents