Service Bulletin #162

Models: SJ9233/9243/9253 RT
Date: November 30, 2020

ORIFICE REMOVAL AND MOTOR PISTON

REPLACEMENT
SAFETY RELATED

Introduction:

In our continuing effort to provide the best possible product to our customers and yours, Skyjack
requires that this bulletin be completed on all affected models with the listed serial numbers at their
next regularly scheduled service interval.

This bulletin is also available on our website at: www.skyjack.com.

Procedure:

The units listed under “Serial Numbers Affected” must have the Orifice Removal and Motor Piston
Replacement completed at their next regularly scheduled service interval as per the attached
procedure (Skyjack part # 237722). Only qualified and authorized personnel shall be permitted to
service a Mobile Elevating Work Platform.

Contact Skyjack Service (1-800-275-9522 – North America, 44-1691-676-235 – Europe, or +61 (0)
29854 0700– Australia) with any questions regarding the completion of this bulletin.

Serial Numbers Affected:

SJ9233 RT (ANSI/CSA)
A202000095, A202000099, A202000136, A202000137, A202000138

SJ9233 RT (CE)
A202000013, A202000031, A202000033, A202000041, A202000045, A202000047,
A202000053, A202000054, A202000063

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 Service Bulletin #162 Date: November 30, 2020
ORIFICE REMOVAL AND MOTOR PISTON REPLACEMENT
Applies to: SJ9233/9243/9253 RT

SJ9233 RT (AS)
A202000011

SJ9243 RT (ANSI/CSA)
A202000009, A202000010, A202000014, A202000018, A202000020, A202000039,
A202000043, A202000074, A202000087, A202000091, A202000114, A202000115,
A202000117, A202000119, A202000146, A202000147

SJ9243 RT (CE)
A202000005, A202000024, A202000064, A202000069, A202000071, A202000072,
A202000076, A202000078, A202000080, A202000084, A202000085, A202000089,
A202000093, A202000097, A202000109, A202000120, A202000123

SJ9243 RT (AS)
A202000144

SJ9253 RT (ANSI/CSA)
A202000003, A202000008, A202000016, A202000027, A202000028, A202000030,
A202000040, A202000046, A202000049, A202000060, A202000062, A202000086,
A202000088, A202000090, A202000092, A202000094, A202000108, A202000131,
A202000134, A202000135, A202000148, A202000150, A202000152

SJ9253 RT (CE)
A202000001, A202000017, A202000019, A202000023, A202000044, A202000048,
A202000055, A202000056, A202000065, A202000066, A202000068, A202000070,
A202000073, A202000075, A202000077, A202000079, A202000096, A202000098,
A202000104, A202000129, A202000132

SJ9253 RT (AS)
A202000002, A202000034, A202000036, A202000038, A202000121

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 Service Bulletin #162 Date: November 30, 2020
ORIFICE REMOVAL AND MOTOR PISTON REPLACEMENT
Applies to: SJ9233/9243/9253 RT

Parts and Warranty Policy:

Skyjack will reimburse up to 2 hours for labor to complete this bulletin. Skyjack will provide the
necessary parts.

Parts kits (Skyjack part # 238856) must be ordered through our Skyjack Parts Department.

Upon completion of this service bulletin, submit a warranty claim form for each machine stating that
Service Bulletin #162 has been completed. To ensure payment of claim, submit within 30 days of
bulletin completion and no later than one year from bulletin issue date.

Ownership of Machines:

Skyjack requires that you promptly notify us of a new owner’s contact information if you have sold or
transferred any machine. In particular, if you have sold or transferred a machine(s) with the serial
numbers listed above, it is required that you promptly notify Skyjack of the new owner’s contact
information. In addition to notifying Skyjack, this service bulletin must also be forwarded to the new
machine owner.

Contact Information:

We regret any inconvenience and appreciate your cooperation. If you have any questions please call,
Skyjack at 1-800-275-9522 (North America) or 44-1691-676-235 (Europe), or +61 (0) 29854 0700–
(Australia).

You may e-mail any questions to [email protected].

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 Service Bulletin #162 Date: November 30, 2020
ORIFICE REMOVAL AND MOTOR PISTON REPLACEMENT
Applies to: SJ9233/9243/9253 RT

This page intentionally left blank.

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ORIFICE REMOVAL
AND MOTOR PISTON
REPLACEMENT
SJ9233 RT, SJ9243 RT, SJ9253 RT
ANSI/CSA, CE, AS & KC

ROUGH TERRAIN SCISSORS

237722ABA
November 2020
 Please refer to the website (www.skyjack.com) for
contact information, other serial numbers, the most
recent technical manuals, and USB software.

The original instructions are in English.

 THIS SAFETY ALERT SYMBOL MEANS ATTENTION!

BE ALERT! YOUR SAFETY IS INVOLVED.

The Safety Alert Symbol identifies important safety

messages on MEWPs, 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
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 equipment.

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 Notes

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Table of Contents
Section 1 – Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Section 2 – Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Machine Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Tools needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Section 3 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Remove the orifice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Replace the motor piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Section 4 – Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 Prepare the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Set up the test area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Test drive procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Test the low speed drive (turtle) mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5 Test the high speed drive (rabbit) mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Test the elevated drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.8 Function tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Section 5 – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Adjust the low speed drive (turtle) mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Adjust the high speed drive (rabbit) mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3 Elevated drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Section 1 – Kit Components

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 Section 1 – Kit Components

Index Skyjack
Qty. Description
No. Part No.

- 238856 1 FIELD KIT, PISTON ASSEMBLY REPLACEMENT

1 238857 1 • PISTON ASSEMBLY

2 238858 1 • END PLATE
3 238859 1 • GASKET
4 237722 1 • INSTRUCTIONS, ORIFICE AND MOTOR FIX RT

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Section 2 – Before You Start
2.1 Machine Preparation
WARNING
1. Park the MEWP on a firm, level surface.
Only qualified and authorized personnel shall be
permitted to install or service this equipment. 2. Raise the platform and deploy the maintenance
supports. Refer to your machine's operation
manual on how to use the maintenance supports.
WARNING 3. Push in the emergency stop button on the base
control console.
Read all instructions closely before attempting
each step of the procedure. 4. Turn the off/platform/base key switch to the off
position. Remove the key.
IMPORTANT 5. Turn the main power disconnect switch to the off
position.
If you have not received the complete parts
inventory, contact the Skyjack Service Department
to have the missing parts sent to you. Do not
attempt installation without the complete package. 2.2 Tools needed
IMPORTANT ▪ Torque wrench - 110 Nm (81 ft-lbs) capacity
Maintain a clean working space at all times so ▪ Small extendable magnet
you do not contaminate the motor and hydraulic ▪ Brake cleaner or similar
system. ▪ Hydraulic cap - 10JIC
▪ Hydraulic plug- 10JIC
▪ Wash rags
▪ Drip pan
▪ Circlip pliers
▪ Vernier caliper
▪ Torque seal
▪ Stop watch
▪ Two pylons or other indicators
▪ T-handle key - 4.5 mm (3/16"), 4 mm (5/32")
▪ Hex bit - 3 mm (1/8"), 4.5 mm (3/16")

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Section 3 – Procedures
3.1 Remove the orifice
3. Locate the drive manifold.
1. Locate the manifold cover at the rear of the
machine.

Drive Manifold

4. If necessary, remove the hose connected to the

T1 port from the manifold. Use a drip pan and
rag to keep the area clean.
5. Put a cap or plug on the hose and port so the
2. Remove and keep the hardware that secures the hydraulic system does not get contaminated.
manifold cover to the base.

T1

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Section 3 – Procedures Remove the orifice

6. Remove the plug in OR2 using a 3/16" T-handle 9. Use break cleaner to clean the plug and OR2
and set it aside. port.
10. Install the plug.
11. Torque the plug to 19 Nm (14 ft-lbs).
12. Install the hose to the T1 port, if previously
removed.
13. Torque the hose to 77 Nm (57 ft-lbs). Refer to
your machine's service manual on how to torque
fittings correctly.
14. Do not install the manifold cover yet. The drive
manifold will need to be inspected for leaks after
you do the testing procedures in Section 4.
T1
OR2

7. Unscrew the orifice inside the manifold using a

5/32" T-handle.
8. Once it is loose, use a small extendable magnet
to remove and discard the orifice from the
manifold.

T1
OR2

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Replace the motor piston Section 3 – Procedures

3.2 Replace the motor piston

IMPORTANT
4. Loosen the low speed nut using a 3/16" hex bit.
Clean your work area often so contaminants such
as paint debris and dust do not go into the motor.
1. Locate the motor.
2. Remove and set aside the two bolts that secure
the motor to the axle.

5. Remove and set aside the o-ring washer,

bevelled washer and nut. Use a flat head
3. Rotate the motor until the end cap with the word screwdriver to pry off the washers, if necessary.
EATON points up. If necessary, cut zip ties along
the hydraulic hoses to let the motor rotate.

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Section 3 – Procedures Replace the motor piston

6. Remove and set aside the set screw, nut and 9. Hold the end plate with one hand and turn the
washer from the end plate using a 1/8" hex bit. piston screw with the other to loosen it using a
3/16" hex bit. Do not let the end plate rotate.
10. The end plate will start to move upwards as you
turn the piston screw.
11. Remove and discard the end plate and gasket.

7. Gently loosen the four mounting screws holding

the end plate to the motor.
8. Remove and set aside the mounting screws and
washers.
12. Remove and set aside the circlip with circlip pliers.

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Replace the motor piston Section 3 – Procedures

13. Examine the new piston assembly from your kit. 15. Install the circlip with circlip pliers. Push in the
Make sure the piston is clean and free of debris. circlip with a small flat head screw driver.
14. Carefully and quickly remove the old piston
and insert the new one to minimize the loss of
hydraulic oil.

16. Lightly pull on the piston to make sure the circlip is

seated correctly.
17. Install and hand-tighten the set screw, nut and
washer onto the new end plate.

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Section 3 – Procedures Replace the motor piston

18. Put the new gasket and end plate from the kit onto 21. Torque the mounting screws to 10 Nm (7.5 ft-lbs)
the motor. Make sure the word EATON is on top. using the sequence below.
End
plate

1 4
EATON

Gasket
3 2

19. Hold the end plate and gasket with one hand and
turn the piston screw with the other. The end plate 22. Use a calibrated vernier caliper to measure the
should start moving down towards the motor. length of the piston screw from the top of the
screw to the end plate.

20. When the end plate and gasket touches the motor,
loosely install the mounting screws and washers 23. Make sure the length of the screw is 14.27 mm
to help find the correct position of the end plate (9/16"). If not, rotate the screw to adjust the length.
and gasket. Do not proceed if this dimension is not met.

14.27 mm
9/16 "

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Replace the motor piston Section 3 – Procedures

24. Install the o-ring washer, bevelled washer (indent 26. Apply torque seal on the piston screw and the
side facing down) and nut onto the piston screw. mounting screws.

25. Hold the piston screw and torque the nut to 10 Nm 27. Rotate the motor back to the correct position.
(7.5 ft-lbs).
28. Secure the motor using the two bolts and washers
removed earlier.

29. Torque the bolts to 110 Nm (81 ft-lbs).

30. Replace any zip ties that were cut earlier. Make
sure the hydraulic hoses are neatly secured to the
hose bundles.

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Section 4 – Testing

4.1 Prepare the machine

1. Turn the main power disconnect switch to the on position.
2. Pull out the emergency stop button on the base control console.
3. Turn the off/platform/base key switch to the base position.
4. Raise the platform and stow the maintenance supports. Refer to your MEWP’s operation manual on how to
use the maintenance supports.
5. Fully lower the platform.

4.2 Set up the test area

1. Drive your MEWP to a location where you can drive in a flat and straight line for 9 m (30 ft) and raise the
platform to a minimum of 4.3 m (14 ft).
2. Place two pylons, or other indicators, at a distance of 6 m (20 ft) apart.
3. Make sure there is a minimum of 1.5 m (5 ft) before and after the markers. This is to let the MEWP to reach
the correct speed before they pass the pylons and not start from a stopped position.

1.5 m 1.5 m
(5 ft) 6 m (20 ft) (5 ft)

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Test drive procedure Section 4 – Testing

4.3 Test drive procedure 4.5 Test the high speed drive
1. Drive your MEWP 1.5 m (5 ft) before the start (rabbit) mode
marker.
1. Move the inclined/low speed/high speed drive
2. Start the timer when the front tire passes the first switch to the high speed (rabbit) position.
marker.
3. Stop the timer when the front tire passes the
second marker.
4. Do the same process when you drive in reverse.

TM

4.4 Test the low speed drive

(turtle) mode
1. Move the inclined/low speed/high speed drive
switch to the low speed (turtle) position.

2. Drive the MEWP forward and then rearwards.

▪ Result:The MEWP drives 20 feet in 3.9 s - 4.5 s.
TM
3. If your MEWP does not meet the approved drive
times, refer to Section 5 – Troubleshooting.
Otherwise, move on to the next step.

4.6 Test the elevated drive

mode
1. Raise the platform 4.3 m (14 ft) or until it drives
2. Drive the MEWP forward and then rearwards. slower than the lowered travel position.
▪ Result:The MEWP drives 20 feet in 6.0 s - 8.0 s. 2. Drive the MEWP forward and then rearwards.
3. If your MEWP does not meet the approved drive ▪ Result:The MEWP drives 20 feet in 27 s or more.
times, refer to Section 5 – Troubleshooting. 3. If the MEWP’s drive time is lower than 27 s, it is
Otherwise, move on to the next step. too fast and does not meet the approved drive
time. Refer to Section 5 – Troubleshooting.

4.7 Final steps

1. Make sure there are no leaks in the drive manifold
and the reworked motor.
2. Install the manifold cover using the hardware
removed earlier.

4.8 Function tests

1. Perform all the function tests in your MEWP’s
operation manual.

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Section 5 – Troubleshooting
5.1 Adjust the low speed drive 5.3 Elevated drive mode
(turtle) mode 1. Make sure you are testing the elevated drive
mode correctly.
1. Go back to section 3.2 Replace the motor piston
and make sure the piston assembly is installed 2. Contact Skyjack product support if the elevated
correctly and that the piston screw is set to the drive speed still does not meet the approved time.
correct length.

5.2 Adjust the high speed drive

(rabbit) mode
1. Locate the speed adjustment valve on the drive
motor.

2. Loosen the nut on the valve.

3. Use a 1/8" T-handle to turn the valve clockwise or
counterclockwise to get the correct drive speed.
If the drive speed is 1 second slow, turn the valve
counterclockwise for one full turn. If the drive
speed is 1 second fast, turn the valve clockwise
for one full turn.
4. When you get the correct drive speed, hold the
valve and tighten the nut.

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