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

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

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