Skyjack SJ1044 THS Bedienungsanleitung

SERVICE

MANUAL

190130AG

January 2021

ANSI

SJ1044 TH, SJ1044 THS,

SJ1056 TH, SJ1056 THS,

SJ1256 THS

TELEHANDLERS

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Equipment Financing and

Extended Warranties Available

This manual is based on Serial Number(s):

SJ1044 TH/THS: 87 210 001 & Above

SJ1056 TH/THS: 87 310 001 & Above

SJ1256 THS: 87 410 001 & Above

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The Safety Alert Symbol identifies important safety

messages on telehandlers, 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 telehandler.

THIS SAFETY ALERT SYMBOL MEANS ATTENTION!

BECOME ALERT! YOUR SAFETY IS INVOLVED.

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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

Table of Contents

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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

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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

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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 ...................................................149

5.1 General .........................................................................149

5.1-1 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.1-2 Engine and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.2 10 Hour or Daily Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5.2-1 Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5.2-2 Check Coolant Level, Radiator and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5.2-3 Check Transmission Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

5.2-4 Check Air Cleaner Restriction and Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

5.2-5 Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

5.2-6 Drain Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

5.2-7 Fuel Tank ....................................................................153

5.2-8 Check Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

5.2-9 Check Tire Pressure and Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

5.2-10 Check Seat Belt and Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

5.2-11 Check Windshield Washer Fluid Level and Wiper Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

5.3-3 Check Fork Pins ..............................................................156

5.3-4 Grease Frame Level Pivot Bushings and Axle Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

5.3-5 Grease Boom Pivot and Boom Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

5.3-6 Grease Bottom Front & Top Rear Slide Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

5.4 250 Hour or Quarterly Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

5.4-1 Check Lug Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

5.4-2 Check Oil Level in Axle Differential Planetary wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

5.4-3 Check Oil level in Axle differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

5.4-4 Replace Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG

5.4-5 Change Engine Fuel filter and Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

5.4-6 Clean Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

5.4-7 Torque Axle Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

5.4-8 Inspect Boom Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

5.4-9 Check Boom Slide Pad Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

5.4-10 Check Boom Chains Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

5.4-11 Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

5.4-12 E-chain and Hoses Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

5.5 1000 Hour or Annual Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

5.5-1 Change Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

5.5-2 Change Hydraulic Oil and Clean Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

5.5-3 Change Axle Differential Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

5.5-4 Change Axle Planetary Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

5.5-5 Change Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

5.5-6 Change Transmission Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.5-7 Change Continuously Variable Transmission (CVT) Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . 178

5.5-8 Inspect Boom Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.5-9 Inspect RAS System (Rear Axle Stabilization) Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.6 Non-Routine Maintenance ..........................................................182

5.6-1 Boom Hoses and Sheaves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

5.6-2 Boom Chains Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

5.6-3 Slide Pads Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

5.6-4 Hydraulic Pressure Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

5.6-5 Hydraulic Pump Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

5.6-6 T12000 Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

5.7-1 Tilt Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

5.7-2 Reprogramming Existing Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

5.7-3 Test and Verify Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

5.8 Park Brake Release ...............................................................224

5.9 Bearing Installation ...............................................................225

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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG

Section 1 – Scheduled Maintenance

1.1 Read and Heed

SKYJACK is continuously improving and expanding

product features on its equipment, therefore,

specifications and dimensions are subject to change

without notice.

1.1-1 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.

1.1-2 Purpose of Equipment

The SKYJACK telehandlers are designed to lift, handle

and transport agricultural or industrial products by

means of specific attachments.

1.1-3 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.

1.1-4 Manual

Operating Manual: The operating manual is

considered a fundamental part of the telehandler. It

is a very important way to 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.

Service & Maintenance: The purpose of this 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

machine. The updated copy of the manuals are found

on the company’s website: www.skyjack.com.

1.1-5 Service Policy and Warranty

SKYJACK warrants each new product to be free

of defective parts and workmanship for the first 2

years or 3000 hours, whichever occurs first. Any

defective part will be replaced or repaired by your

local SKYJACK dealer at no charge for parts or labor.

In addition, all products have a 5 year structural

warranty. Contact the SKYJACK Service Department

for warranty statement extensions or exclusions.

1.1-6 Operator Safety Reminders,

Warnings and Precautions

Operator safety is SKYJACK’s priority. The operator

should comply with all applicable safety-related

reminders, warnings and precautions found in

the Operating Manual. They should be read and

understood completely before operating the

telehandler.

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Dieses Handbuch passt für folgende Modelle

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