Skyjack SJ643 TH SJ843 TH Telehandler Service Manual 190128AB – PDF DOWNLOAD
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Skyjack SJ643 TH SJ843 TH Telehandler Service Manual 190128AB – PDF DOWNLOAD
Description
Skyjack SJ643 TH SJ843 TH Telehandler Service Manual 190128AB – PDF DOWNLOAD
FILE DETAILS:
Skyjack SJ643 TH SJ843 TH Telehandler Service Manual 190128AB – PDF DOWNLOAD
Language : English
Pages : 155
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Skyjack SJ643 TH SJ843 TH Telehandler Service Manual 190128AB – PDF DOWNLOAD
and dimensions are subject to change without notice.
Telehandler Definition
A material handler designed primarily as a fork truck with a pivoting telescopic boom which enables it to pick and
place loads at distances as well as various lift heights.
Purpose of Equipment
The SKYJACK telehandlers are designed to lift, handle and transport agricultural or industrial products by means
of specific attachments.
Use of Equipment
The telehandler is a highly maneuverable, mobile work station. Lifting, handling and driving must be on a flat, level,
compacted surface. It can be driven over uneven terrain only when boom is fully lowered.
Operating
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 telehandler at all times.
The purpose of this manual is to provide the customer with the servicing and maintenance procedures essential
for the promotion of proper machine operation for its intended purpose.
All information in this manual should be read and understood before any attempt is made to service the telehandler.
The updated copy of the manuals are found on the company’s website: www.skyjack.com.
Operator
The operator must read and completely understand both this operating manual and the safety panel label located on
the telehandler and all other warnings in this manual and on the telehandler. Compare the labels on the telehandler
with the labels found within this manual. If any labels are damaged or missing, replace them immediately
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Skyjack SJ643 TH SJ843 TH Telehandler Service Manual 190128AB – PDF DOWNLOAD
Telehandler Definition 7
Purpose of Equipment 7
Use of Equipment 7
Manuals 7
Operator 7
Service Policy and Warranty 7
Optional Accessories 7
Scope of this Manual 8
Operator Safety Reminders 8
Electrocution Hazard 9
Safety Precautions 10
Maintenance and Inspection Schedule 15
Owner’s Annual Inspection Record 15
Replacement Parts 15
Maintenance and Service Safety Tips 16
Jobsite Inspection 16
Hydraulic System & Component Maintenance and Repair 16
Maintenance Hints 17
About this Section 18
Service Bulletins 18
Maintenance and Inspection 18
Maintenance Instructions 18
1 1 Scheduled Maintenance Inspections 21
1 2 Function Tests 29
Tables 37
Table 2 1 Standard & Optional Features 38
Table 2 2 Specifications & Features 39
Table 2 3 Tire/Wheel Specifications 40
Table 2 4 Recommended Fluids/Lubrication 41
Table 2 5 Pressure Settings 42
Charts 43
3 1 Electrical Symbol Chart 44
3 2 Hydraulic Symbol Chart 45
3 3 Electrical Schematic Parts List 46
3 4 Hydraulic Schematic Parts List 48
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 Optional Reserve Brake Manifold Ports Identification 56
3 11 Major Components Identification and Location 57
3 12 Main Control Valve Port Identification 58
3 12 Main Control Valve Port Identification (Continued) 59
3 15 Enclosed Cab Harness & Wiring Diagram 61
3 16 Glow Plug Harness & Wiring Diagram 62
3 17 Road Lights Harness & Wiring Diagram 63
3 18 Work Lights Harness & Wiring Diagram 64
3 19 Boom Lights Harness & Wiring Diagram 65
3 20 Beacon Light Harness & Wiring Diagram 66
3 21 Console Harness and Layout 68
3 22 Console Harness Wiring Diagram 69
3 23 Engine Harness 70
3 24 Engine Harness Wiring Diagram 71
3 25 Chassis Harness 72
3 26 Chassis Harness Wiring Diagram 73
3 27 Electrical Schematic 74
3 27 Electrical Schematic (Continued) 75
3 27 Electrical Schematic (Continued) 76
3 28 Hydraulic Schematic 77
3 27 Hydraulic Schematic (Reserve Brake Option) 78
Introduction 81
4 1 Electrical System 82
4 1-1 Engine Will Not Crank 82
4 1-2 Engine Cranks But Will Not Run 83
4 1-3 All Electrical Controls Inoperative (park brake will not release, all other dash switches and lights inoperative, joystick electrical switches inoperative, etc ) 83
4 1-4 Park Brake Will Not Release (transmission remains in neutral regardless of shift lever position) 83
4 1-5 Park Brake Will Not Release (transmission will engage) 83
4 1-6 Transmission Will Not Engage (park brake will release) 84
4 1-7 No Forward Drive 84
4 1-8 No Reverse Drive 84
4 1-9 No 1st Speed Range 85
4 1-10 No 2nd Speed Range 85
4 1-11 No Boom Up, Front Steer Mode Only 85
4 1-12 Front Steer Mode Only 85
4 1-13 No 4W (Round) Steer Mode 86
4 1-14 No Crab Steer Mode 86
4 1-15 No Boom Up, Frame Level Operates Normally 86
4 1-16 No Boom Up and No Frame Level 87
4 1-17 Frame Will Not Tilt Over 40° With Boom Below 40° 87
4 1-18 No Frame Level 88
4 1-19 No Frame Level With Boom Angle Below 40°, Works Above 40° 88
4 1-20 No Frame Level With Boom Angle Above 40°, Works Below 40° 88
4 1-21 No Frame Level Left 88
4 1-22 No Frame Level Right 89
4 1-23 Function Does Not Switch from Telescope In/Out To Frame Level Left/Right With Frame Level Switch SW5 Depressed or from Boom Raise To Carriage Tilt Up With Carriage Tilt Switch SW6 Depressed 89
4 1-24 Function Does Not Switch from Telescope In/Out To Frame Level Left/Right With Frame Level Switch SW5 Depressed 90
4 1-25 Function Does Not Switch from Boom Raise/Lower To Carriage Tilt Up/Down With Carriage Tilt Switch SW6 Depressed 90
4 2 Hydraulic System 91
4 2-1 All Controls inoperative 91
4 2-2 All Boom Functions Inoperative 91
4 2-3 No Boom Raise 91
4 2-4 No Boom Lower 91
4 2-5 No Telescope Out 92
4 2-6 No Telescope Retract 92
4 2-7 No Carriage Tilt Up 92
4 2-8 No carriage Tilt Down 93
4 2-9 No Frame Level Right 93
4 2-10 No Frame Level Left 93
4 2-11 No Aux functions 94
4 2-12 Hard or No Steering 94
4 2-13 Park Brake will not Release 94
4 2-14 Park Brake Will Not Engage 94
4 2-15 Service Brake Will Not Engage 94
General 99
Safety and Workmanship 99
Engine and Transmission 99
5 1 10 Hour or Daily Routine Maintenance 100
5 1-1 Check Engine Oil Level 100
5 1-2 Check Coolant Level, Radiator and Hoses 100
5 1-3 Check Transmission Fluid Level 101
5 1-4 Check Air Cleaner Restriction and Filter Elements 101
5 1-5 Check Hydraulic Oil Level 102
5 1-6 Drain Fuel/Water Separator 103
5 1-7 Fuel Tank 103
5 1-8 Check Parking Brake 103
5 1-9 Check Tire Pressure and Condition 103
5 1-10 Check Seat Belt and Mounting Hardware 104
5 1-11 Check Windshield Washer Fluid Level and Wiper Condition 104
5 2 50 Hour or Weekly Routine Maintenance 105
5 2-1 Check Lug Nut Torque 105
5 2-2 Check Oil Level in Axle Differential Planetary wheel Ends 105
5 2-4 Check Oil level in Axle differentials 106
5 2-5 Grease Axle Pivot Bearings and King Pins 106
5 2-6 Grease Drive Shaft U-joints and slip joints 107
5 2-7 Check Fork Pins 107
5 2-7 Grease Frame Level Pivot Bushings 108
5 2-8 Grease Boom Pivot and Boom Cylinders 108
5 2-9 Grease Bottom Front & Top Rear Slide Pads 109
5 3 250 Hour or Quarterly Routine Maintenance 110
5 3-1 Replace Engine Oil and Filter 110
5 3-2 Change Engine Fuel filter and Fuel/Water Separator 112
5 3-3 Clean Hydraulic Tank Breather 113
5 3-4 Torque Axle Mounting Bolts 113
5 3-5 Inspect Boom Chains 114
5 3-6 Check Boom Slide Pad Clearances 115
5 3-7 Check Boom Chains Tension 117
5 3-8 Chain Tension Adjustment 118
5 4 1000 Hour or Annual Routine Maintenance 120
5 4-1 Change Hydraulic Oil Filter 120
5 4-2 Change Hydraulic Oil and Clean Hydraulic Tank 120
5 4-3 Change Axle Differential Oil 121
5 4-4 Change Axle Planetary Oil 123
5 4-5 Change Engine Coolant 124
5 4-6 Change Transmission Oil and Filter 125
5 4-7 Inspect Boom Chains 127
5 5 Non-Routine Maintenance 128
5 5-1 Boom Hoses and Sheaves Replacement 128
5 5-1-1 Remove Hose Sheaves 128
5 5-1-2 Remove Boom Hoses 129
5 5-2-2 Inspect Boom Hydraulic Hoses 130
5 5-2-3 Install Hose Sheaves 130
5 5-2-4 Install Boom Hydraulic Hoses 130
5 5-3 Boom Chains Replacement 132
5 5-3-1 Remove Extend Chain 132
5 5-3-2 Install Extend Chain 133
5 5-3-3 Remove Retract Chain 134
5 5-3-4 Install Retract Chain 135
5 5-5 Slide Pads Replacement Procedure 136
5 5-5-1 Remove Slide Pads 136
5 5-5-2 Install Slide Pads 136
5 5-6 Hydraulic Pressure Test Procedure 138
5 5-6-1 System Pressure 138
5 5-6-2 Steering Pressure 138
5 5-6-3 Service Brake Pressure 139
5 5-6-4 Pilot Pressure 139
5 5-7 Hydraulic Pump Testing Procedure 141
5 5-8 Park Brake Release on Rear Axle 141
5 5-12 Deutz Fault Codes 143
5 6 Electronic Tilt Switch Setup Procedure 149
5 6-1 Tilt Switch Replacement 149
5 6-2 Reprogramming Existing Tilt Switch 150
5 6-3 Test and Verify Tilt Circuit 151
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