Skyjack SJ643 TH, SJ843 TH Telehandler Service Manual 190127AD – PDF DOWNLOAD

Description

Skyjack SJ643 TH, SJ843 TH Telehandler Service Manual 190127AD – PDF DOWNLOAD

FILE DETAILS:

Skyjack SJ643 TH SJ843 TH Telehandler Service Manual 190127AD – PDF DOWNLOAD

Language : English
Pages :170
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Skyjack SJ643 TH SJ843 TH Telehandler Service Manual 190127AD – PDF DOWNLOAD

Serial Number(s):
SJ643 TH & SJ843 TH: 87 110 032 & Above

• All information in this manual should be read and understood before any attempt is made to service the machine. The updated copy of the manuals are found on the company’s

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Skyjack SJ643 TH, SJ843 TH Telehandler Service Manual 190127AD – 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 27
2 3 Tire/Wheel Specifications 28
2 4 Recommended Fluids/Lubrication 29
2 5 Pressure Setting 30
2 6 Standard Hose Numbering System 31
2 7 Torque Specifications for Fasteners (US) 33
2 8 Torque Specifications for Fasteners (Metric) 34
2 9 Torque Specifications for Hydraulic Couplings & Hoses 35
2 10 Air Conditioner Temperature/Pressure Chart 36
Section 3 – System Component Identification and Schematics 37
3 1 Electrical Symbol Chart 38
3 2 Hydraulic Symbol Chart 39
3 3 Electrical Schematic Parts List 40
3 4 Hydraulic Schematic Parts List 43
3 5 Hydraulic Pump and Return Filter Ports Identification 45
3 6 Steering Control Unit Ports Identification 46
3 7 Service Brake Actuator (Brake Pedal) Ports Identification 47
3 8 Auxiliary Block Ports Identification 48
3 9 Joystick Port Identifications 49
3 10 Premium Joystick Port Identifications 50
3 11 Premium Joystick Manifold Port Identifications 51
3 12 Optional Reserve Brake Manifold Port Identification 52
3 13 Major Components Identification and Location 53
3 14 Main Control Valve Port Identification 54
3 15 Enclosed Cab Harness & Wiring Diagram 57
3 16 Glow Plug Harness & Wiring Diagram 58
3 17 Road Lights Harness & Wiring Diagram 59
3 18 Work Lights Harness & Wiring Diagram 60
3 19 Boom Lights Harness & Wiring Diagram 61
3 20 Beacon Light Harness & Wiring Diagram 62
3 21 Elevate Telematics Harness 63
3 22 A/C Harness 64
3 23 Heater & A/C Harness 65
3 24 CVT Vehicle Harness 66
3 25 CVT Transmission Harness 67
3 26 Console Harness and Layout 68
3 27 Console Harness Wiring Diagram 69
3 28 Engine Harness 70
3 29 Engine Harness Wiring Diagram 71
3 30 Chassis Harness 72
3 31 Chassis Harness Wiring Diagram 73
3 32 Electrical Schematic 74
3 33 Electrical Schematic – Premium Joystick 77
3 34 Electrical Schematic for CVT 80
3 35 Electrical Schematic for CVT with Premium Joystick 84
3 36 Hydraulic Schematic 88
3 37 Hydraulic Schematic (Reserve Brake Option) 89
3 38 Hydraulic Schematic – Premium Joystick 90
3 39 Hydraulic Schematic (Reserve Brake) – Premium Joystick 91
Section 4 – Troubleshooting Information 93
4 1 Introduction 93
4 2 Electrical System 94
4 2-1 Engine Will Not Crank 94
4 2-2 Engine Cranks But Will Not Run 95
4 2-3 All Electrical Controls Inoperative 95
4 2-4 Park Brake Will Not Release 96
4 2-5 Transmission Will Not Engage 97
4 2-6 No Forward Drive 97
4 2-7 No Reverse Drive 98
4 2-8 No 1st Speed Range 98
4 2-9 No 2nd Speed Range 98
4 2-10 No Boom Up, Front Steer Mode Only 99
4 2-11 Front Steer Mode Only 99
4 2-12 No 4W (Round) Steer Mode 99
4 2-13 No Crab Steer Mode 100
4 2-14 No Boom Up 100
4 2-15 Frame Will Not Tilt Over 40° With Boom Below 40° 101
4 2-16 No Frame Level 102
4 2-17 Function Does Not Switch 104
4 3 Hydraulic System 106
4 3-1 All Controls inoperative 106
4 3-2 No Boom Functions 106
4 3-3 No Carriage Tilt 108
4 3-4 No Frame Level 109
4 3-5 No Aux functions 110
4 3-6 Hard or No Steering 110
4 3-7 Park Brake will not Release 111
4 3-8 Park Brake Will Not Engage 111
4 3-9 Service Brake Will Not Engage 111
Section 5 – Procedures 113
5 1 General 113
5 1-1 Safety and Workmanship 113
5 1-2 Engine and Transmission 113
5 2 10 Hour or Daily Routine Maintenance 114
5 2-1 Check Engine Oil Level 114
5 2-2 Check Coolant Level, Radiator and Hoses 114
5 2-3 Check Transmission Fluid Level 115
5 2-4 Check Air Cleaner Restriction and Filter Elements 115
5 2-5 Check Hydraulic Oil Level 116
5 2-6 Drain Fuel/Water Separator 117
5 2-7 Fuel Tank 117
5 2-8 Check Parking Brake 117
5 2-9 Check Tire Pressure and Condition 117
5 2-10 Check Seat Belt and Mounting Hardware 118
5 2-11 Check Windshield Washer Fluid Level and Wiper Condition 118
5 3 50 Hour or Weekly Routine Maintenance 118
5 3-1 Grease Axle Pivot Bearings and King Pins 118
5 3-2 Grease Drive Shaft U-joints and slip joints 119
5 3-3 Check Fork Pins 120
5 3-4 Grease Frame Level Pivot Bushings 120
5 3-5 Grease Boom Pivot and Boom Cylinders 120
5 3-6 Grease Bottom Front & Top Rear Slide Pads 121
5 4 250 Hour or Quarterly Routine Maintenance 122
5 4-1 Check Lug Nut Torque 122
5 4-2 Check Oil Level in Axle Differential Planetary wheel Ends 122
5 4-3 Check Oil level in Axle differentials 123
5 4-4 Replace Engine Oil and Filter 123
5 4-5 Change Engine Fuel filter and Fuel/Water Separator 125
5 4-6 Clean Hydraulic Tank Breather 127
5 4-7 Torque Axle Mounting Bolts 127
5 4-8 Inspect Boom Chains 127
5 4-9 Check Boom Slide Pad Clearances 128
5 4-10 Check Boom Chains Tension 130
5 4-11 Chain Tension Adjustment 131
5 5 1000 Hour or Annual Routine Maintenance 132
5 5-1 Change Hydraulic Oil Filter 132
5 5-2 Change Hydraulic Oil and Clean Hydraulic Tank 133
5 5-3 Change Axle Differential Oil 134
5 5-4 Change Axle Planetary Oil 134
5 5-5 Change Engine Coolant 135
5 5-6 Change Transmission Oil and Filter 137
5 5-7 Change Continuously Variable Transmission (CVT) Oil and Filter 139
5 5-8 Inspect Boom Chains 141
5 6 Non-Routine Maintenance 141
5 6-1 Boom Hoses and Sheaves Replacement 141
5 6-2 Boom Chains Replacement 145
5 6-3 Slide Pads Replacement Procedure 149
5 6-4 Hydraulic Pressure Test Procedure 151
5 6-5 Hydraulic Pump Testing Procedure 154
5 6-6 T12000 Modulation 154
5 6-7 Deutz Fault Codes 158
5 6-8 Starter Replacement Procedure 161
5 6-9 Bleeding Hydraulic Circuits 163
5 7 Electronic Tilt Switch Setup Procedure 164
5 7-1 Tilt Switch Replacement 164
5 7-2 Reprogramming Existing Tilt Switch 165
5 7-3 Test and Verify Tilt Circuit 166
5 8 Park Brake Release 168

Contact us: [email protected]

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M