Skyjack SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS Telehandlers Service Manual 190130AF – PDF DOWNLOAD

Description

Skyjack SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS Telehandlers Service Manual 190130AF – PDF DOWNLOAD

FILE DETAILS:

Skyjack SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS Telehandlers Service Manual 190130AF – PDF DOWNLOAD

Language : English
Pages : 227
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Skyjack SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS Telehandlers Service Manual 190130AF – PDF DOWNLOAD

Serial Number:
SJ1044 TH/THS: 87 210 001 & Above
SJ1056 TH/THS: 87 310 001 & Above
SJ1256 THS: 87 410 001 & Above

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Skyjack SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS Telehandlers Service Manual 190130AF – PDF DOWNLOAD

Table of Contents 5
Section 1 – Scheduled Maintenance 11
1 1 Read and Heed 11
1 1-1 Telehandler Definition 11
1 1-2 Purpose of Equipment 11
1 1-3 Use of Equipment 11
1 1-4 Manual 11
1 1-5 Service Policy and Warranty 11
1 1-6 Operator Safety Reminders, Warnings and Precautions 11
1 2 Maintenance and Inspection Schedule 12
1 2-1 Owner’s Annual Inspection Record 12
1 2-2 Replacement Parts 12
1 2-3 Maintenance and Service Safety Tips 12
1 3 Hydraulic System & Component Maintenance and Repair 13
1 3-1 Maintenance Hints 13
1 4 About this Section 14
1 4-1 Service Bulletins 14
1 4-2 Maintenance and Inspection 14
1 4-3 Maintenance Instructions 14
1 5 Scheduled Maintenance Inspections 16
1 5-1 Labels – A 16
1 5-2 Electrical 16
1 5-3 Mirrors – A 16
1 5-4 Hydraulic 16
1 5-5 Cylinders – A 17
1 5-6 Frame 17
1 5-7 Engine Compartment 20
1 5-8 Transmission 21
1 5-9 Boom – A 21
1 5-10 Lifting Attachment – A 21
1 5-11 Grease Fittings – B 22
1 5-12 Operator’s Cab 22
1 6 Function Tests 24
Section 2 – Maintenance Tables 25
2 1 Standard and Optional Equipment 26
2 2 Specifications and Features 28
2 3 Recommended Fluids/Lubrications 30
2 4 Tire/Wheel Specifications 32
2 5 Pressure Settings 33
2 6 Standard Hose Numbering System 34
2 7 Torque Specifications for Fasteners (US) 36
2 8 Torque Specifications for Fasteners (Metric) 37
2 9 Torque Specifications for Hydraulic Couplings & Hoses 38
2 10 Air Conditioner Temperature/Pressure Chart 39
Section 3 – System Component Identification and Schematics 41
3 1 Electrical Symbol Chart 42
3 2 Hydraulic Symbol Chart 43
3 3 Electrical Components Parts List 44
3 4 Hydraulic Components Parts List 47
3 5 Hydraulic Pump and Return Filter Ports Identification 51
3 6 Steering Control Unit Ports Identification 52
3 7 Service Brake Actuator (Brake Pedal) Ports Identification 53
3 8 Auxiliary Block Ports Identification 54
3 9 Joystick Port Identifications 55
3 10 Premium Joystick Port Identifications 56
3 11 Premium Joystick Manifold Port Identifications 57
3 12 Rear Axle Stabilization Manifold Port Identification 58
3 13 Outrigger Manifold Port Identifications 59
3 14 Reserve Brake Manifold Port Identifications (Option) 60
3 15 Anti-Cavitation Relief Valve (SJ1256 THS Only) 61
3 16 Major Components Identification and Location 62
3 17 Main Manifold Port Identification 63
3 18 Enclosed Cab Harness & Wiring Diagram 66
3 19 Glow Plug Harness & Wiring Diagram 67
3 20 Road Lights Harness & Wiring Diagram 68
3 21 Work Lights Harness & Wiring Diagram 69
3 22 Boom Lights Harness & Wiring Diagram 70
3 23 Beacon Light Harness & Wiring Diagram 71
3 24 RAS System Schematic and Wiring 72
3 25 Elevate Telematics Harness 73
3 26 A/C Harness 74
3 27 Heater & A/C Harness 75
3 28 CVT Vehicle Harness 76
3 29 CVT Transmission Harness 77
3 30 Console Harness and Layout 74 HP 78
3 31 Console Harness Wiring Diagram 74HP 79
3 32 Console Harness and Layout 107 HP – THS Models 80
3 33 Console Harness Wiring Diagram 107 HP – THS Models 81
3 34 Engine Harness 74 HP 82
3 35 Engine Harness 74 HP Wiring Diagram 83
3 36 Engine Harness Diagram 107 HP – THS Models 84
3 37 Engine Harness Wiring Diagram 107 HP 85
3 38 Chassis Harness 86
3 39 Chassis Harness Wiring Diagram 87
3 40 Electrical Schematic 74 HP – SJ1044 TH & SJ1056 TH 88
3 41 Electrical Schematic 74 HP Premium Joystick – SJ1044 TH & SJ1056 TH 91
3 42 Electrical Schematic 74 HP Engine with CVT – SJ1044 TH & SJ1056 TH 94
3 43 Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH 98
3 44 Electrical Schematic 107 HP – SJ1044 THS & SJ1056 THS 102
3 45 Electrical Schematic 107 HP, Premium Joystick- SJ1044 TH & SJ1056 TH 105
3 46 Electrical Schematic 107 HP Engine with CVT – SJ1044 TH & SJ1056 TH 108
3 47 Electrical Schematic – SJ1256 THS 112
3 48 Electrical Schematic for CVT – SJ1256 THS 115
3 49 Hydraulic Schematic – SJ1044 TH/THS & SJ1056 TH/THS 119
3 50 Hydraulic Schematic (Reserve Brake Option) – SJ1044 TH/THS & SJ1056 TH/THS 120
3 51 Hydraulic Schematic, Premium Joystick – SJ1044 TH/THS & SJ1056 TH/THS 121
3 52 Hydraulic Schematic Premium Joystick (Reserve Brake Option) – SJ1044 TH/THS & SJ1056 TH/THS 122
3 53 Hydraulic Schematic – SJ1256 THS 123
3 54 Hydraulic Schematic (Reserve Brake Option) – SJ1256 THS 124
3 55 Hydraulic Schematic for Premium Joystick- SJ1256 THS 125
Section 4 – Troubleshooting Information 126
4 1 Introduction 126
4 2 Electrical System 128
4 2-1 Engine Will Not Crank 128
4 2-2 Engine Cranks But Will Not Run 129
4 2-3 All Electrical Controls Inoperative 129
4 2-4 Park Brake Will Not Release 130
4 2-5 Transmission Will Not Engage 131
4 2-6 No Forward Drive 131
4 2-7 No Reverse Drive 131
4 2-8 No 1st Speed Range 132
4 2-9 No 2nd Speed Range 132
4 2-10 No Boom Up, Front Steer Mode Only 133
4 2-11 Front Steer Mode Only 133
4 2-12 No 4W (Round) Steer Mode 133
4 2-13 No Crab Steer Mode 133
4 2-14 No Boom Up 134
4 2-15 Frame Will Not Tilt Over 40° With Boom Below 40° 135
4 2-16 No Frame Level 136
4 2-17 RAS remains fully locked (RAS indicator remains illuminated) 139
4 2-18 RAS remains locked 140
4 2-19 Function Does Not Switch 140
4 2-20 Outriggers inoperative 141
4 3 Hydraulic System 143
4 3-1 All Controls inoperative 143
4 3-2 No Boom Functions 143
4 3-3 No Carriage Tilt 145
4 3-4 No Frame Level 146
4 3-5 No Aux functions 147
4 3-6 Hard or No Steering 147
4 3-7 Park Brake will not Release 147
4 3-8 Park Brake Will Not Engage 148
4 3-9 Service Brake Will Not Engage 148
4 3-10 Outriggers Inoperative 148
Section 5 – Procedures 150
5 1 General 150
5 1-1 Safety and Workmanship 150
5 1-2 Engine and Transmission 150
5 2 10 Hour or Daily Routine Maintenance 151
5 2-1 Check Engine Oil Level 151
5 2-2 Check Coolant Level, Radiator and Hoses 151
5 2-3 Check Transmission Fluid Level 152
5 2-4 Check Air Cleaner Restriction and Filter Elements 152
5 2-5 Check Hydraulic Oil Level 153
5 2-6 Drain Fuel/Water Separator 154
5 2-7 Fuel Tank 154
5 2-8 Check Parking Brake 154
5 2-9 Check Tire Pressure and Condition 154
5 2-10 Check Seat Belt and Mounting Hardware 155
5 2-11 Check Windshield Washer Fluid Level and Wiper Condition 155
5 3 50 Hour or Weekly Routine Maintenance 155
5 3-1 Grease Axle Pivot Bearings and King Pins 155
5 3-2 Grease Drive Shaft U-joints and slip joints 156
5 3-3 Check Fork Pins 157
5 3-4 Grease Frame Level Pivot Bushings and Axle Lock Cylinder 157
5 3-5 Grease Boom Pivot and Boom Cylinders 157
5 3-6 Grease Bottom Front & Top Rear Slide Pads 158
5 4 250 Hour or Quarterly Routine Maintenance 159
5 4-1 Check Lug Nut Torque 159
5 4-2 Check Oil Level in Axle Differential Planetary wheel Ends 159
5 4-3 Check Oil level in Axle differentials 160
5 4-4 Replace Engine Oil and Filter 160
5 4-5 Change Engine Fuel filter and Fuel/Water Separator 162
5 4-6 Clean Hydraulic Tank Breather 164
5 4-7 Torque Axle Mounting Bolts 164
5 4-8 Inspect Boom Chains 164
5 4-9 Check Boom Slide Pad Clearances 166
5 4-10 Check Boom Chains Tension 167
5 4-11 Chain Tension Adjustment 168
5 4-12 E-chain and Hoses Inspection 169
5 5 1000 Hour or Annual Routine Maintenance 170
5 5-1 Change Hydraulic Oil Filter 170
5 5-2 Change Hydraulic Oil and Clean Hydraulic Tank 170
5 5-3 Change Axle Differential Oil 171
5 5-4 Change Axle Planetary Oil 172
5 5-5 Change Engine Coolant 173
5 5-6 Change Transmission Oil and Filter 177
5 5-7 Change Continuously Variable Transmission (CVT) Oil and Filter 179
5 5-8 Inspect Boom Chains 181
5 5-9 Inspect RAS System (Rear Axle Stabilization) Functionality 181
5 6 Non-Routine Maintenance 183
5 6-1 Boom Hoses and Sheaves Replacement 183
5 6-2 Boom Chains Replacement 187
5 6-3 Slide Pads Replacement Procedure 193
5 6-4 Hydraulic Pressure Test Procedure 195
5 6-5 Hydraulic Pump Testing Procedure 198
5 6-6 T12000 Modulation 199
5 6-7 Deutz Fault Codes 202
5 6-8 Starter Replacement Procedure 205
5 6-9 Bleeding Hydraulic Circuits 207
5 6-10 Cable Track Replacement 208
5 6-11 Carrier Assembly Replacement 215
5 7 Electronic Tilt Switch Setup Procedure 222
5 7-1 Tilt Switch Replacement 222
5 7-2 Reprogramming Existing Tilt Switch 223
5 7-3 Test and Verify Tilt Circuit 224
5 8 Park Brake Release 226

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