Skyjack SJ1044 TH - Service Manual

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SERVICE

MANUAL

190130AG

January 2021

ANSI

SJ1044 TH, SJ1044 THS,

SJ1056 TH, SJ1056 THS,

SJ1256 THS

TELEHANDLERS

To order go to Discount-Equipment.com

Main Page

Table of Contents5
Section 1 - Scheduled Maintenance10
Read and Heed10
Telehandler Definition10
Purpose of Equipment10
Use of Equipment10
Manual10
Service Policy and Warranty10
Operator Safety Reminders, Warnings and Precautions10
Maintenance and Inspection Schedule11
Owner's Annual Inspection Record11
Replacement Parts11
Maintenance and Service Safety Tips11
Hydraulic System & Component Maintenance and Repair12
Maintenance Hints12
About this Section13
Service Bulletins13
Maintenance and Inspection13
Maintenance Instructions13
Scheduled Maintenance Inspections15
Labels - a15
Electrical15
Mirrors - a15
Hydraulic15
Cylinders - a16
Frame16
Engine Compartment19
Transmission20
Boom - a20
10 Lifting Attachment - a20
11 Grease Fittings - B21
12 Operator's Cab21
Function Tests23
Section 2 - Maintenance Tables24
Standard and Optional Equipment25
Specifications and Features27
Recommended Fluids/Lubrications29
Tire/Wheel Specifications31
Pressure Settings32
Standard Hose Numbering System33
Torque Specifications for Fasteners (US)35
Torque Specifications for Fasteners (Metric)36
Torque Specifications for Hydraulic Couplings & Hoses37
Air Conditioner Temperature/Pressure Chart38
Section 3 - System Component Identification and Schematics39
Electrical Symbol Chart40
Hydraulic Symbol Chart41
Electrical Components Parts List42
Hydraulic Components Parts List45
Hydraulic Pump and Return Filter Ports Identification49
Steering Control Unit Ports Identification50
Service Brake Actuator (Brake Pedal) Ports Identification51
Auxiliary Block Ports Identification52
Joystick Port Identifications53
Premium Joystick Port Identifications54
Premium Joystick Manifold Port Identifications55
Rear Axle Stabilization Manifold Port Identification56
Outrigger Manifold Port Identifications57
Reserve Brake Manifold Port Identifications (Option)58
Anti-Cavitation Relief Valve (SJ1256 THS Only)59
Major Components Identification and Location60
Main Manifold Port Identification61
Enclosed Cab Harness & Wiring Diagram64
Glow Plug Harness & Wiring Diagram65
Road Lights Harness & Wiring Diagram66
Work Lights Harness & Wiring Diagram67
Boom Lights Harness & Wiring Diagram68
Beacon Light Harness & Wiring Diagram69
RAS System Schematic and Wiring70
Elevate Telematics Harness71
A/C Harness72
Heater & A/C Harness73
CVT Vehicle Harness74
CVT Transmission Harness75
Console Harness and Layout 74 HP76
Console Harness Wiring Diagram 74HP77
Console Harness and Layout 107 HP - THS Models78
Console Harness Wiring Diagram 107 HP - THS Models79
Engine Harness 74 HP80
Engine Harness 74 HP Wiring Diagram81
Engine Harness Diagram 107 HP - THS Models82
Engine Harness Wiring Diagram 107 HP83
Chassis Harness84
Chassis Harness Wiring Diagram85
Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH86
Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH89
Electrical Schematic 74 HP Engine with CVT - SJ1044 TH & SJ1056 TH92
Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH96
Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS100
Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH103
Electrical Schematic 107 HP Engine with CVT - SJ1044 TH & SJ1056 TH106
Electrical Schematic - SJ1256 THS110
Electrical Schematic for CVT - SJ1256 THS113
Hydraulic Schematic - SJ1044 TH/THS & SJ1056 TH/THS117
Hydraulic Schematic (Reserve Brake Option) - SJ1044 TH/THS & SJ1056 TH/THS118
Hydraulic Schematic, Premium Joystick - SJ1044 TH/THS & SJ1056 TH/THS119
Ths120
Hydraulic Schematic - SJ1256 THS121
Hydraulic Schematic (Reserve Brake Option) - SJ1256 THS122
Hydraulic Schematic for Premium Joystick- SJ1256 THS123
Section 4 - Troubleshooting Information124
Introduction124
Electrical System125
Engine will Not Crank125
Engine Cranks but will Not Run126
All Electrical Controls Inoperative126
Park Brake will Not Release127
Transmission will Not Engage128
No Forward Drive128
No Reverse Drive128
No 1St Speed Range129
No 2Nd Speed Range129
10 No Boom Up, Front Steer Mode Only130
11 Front Steer Mode Only130
12 No 4W (Round) Steer Mode130
13 No Crab Steer Mode130
14 No Boom up131
15 Frame will Not Tilt over 40° with Boom below 40132
16 No Frame Level133
17 RAS Remains Fully Locked (RAS Indicator Remains Illuminated)136
18 RAS Remains Locked137
19 Function Does Not Switch137
20 Outriggers Inoperative138
Hydraulic System140
All Controls Inoperative140
No Boom Functions140
No Carriage Tilt142
No Frame Level143
No Aux. Functions144
Hard or no Steering144
Park Brake will Not Release144
Park Brake will Not Engage145
Service Brake will Not Engage145
10 Outriggers Inoperative145
Section 5 - Procedures146
General146
Safety and Workmanship146
Engine and Transmission146
Hour or Daily Routine Maintenance147
Check Engine Oil Level147
Check Coolant Level, Radiator and Hoses147
Check Transmission Fluid Level148
Check Air Cleaner Restriction and Filter Elements148
Check Hydraulic Oil Level149
Drain Fuel/Water Separator150
Fuel Tank150
Check Parking Brake150
Check Tire Pressure and Condition150
10 Check Seat Belt and Mounting Hardware151
11 Check Windshield Washer Fluid Level and Wiper Condition151
Hour or Weekly Routine Maintenance152
Grease Axle Pivot Bearings and King Pins152
Grease Drive Shaft U-Joints and Slip Joints152
Check Fork Pins153
Grease Frame Level Pivot Bushings and Axle Lock Cylinder153
Grease Boom Pivot and Boom Cylinders153
Grease Bottom Front & Top Rear Slide Pads154
Hour or Quarterly Routine Maintenance155
Check Lug Nut Torque155
Check Oil Level in Axle Differential Planetary Wheel Ends155
Check Oil Level in Axle Differentials156
Replace Engine Oil and Filter156
Change Engine Fuel Filter and Fuel/Water Separator158
Clean Hydraulic Tank Breather160
Torque Axle Mounting Bolts160
Inspect Boom Chains160
Check Boom Slide Pad Clearances162
10 Check Boom Chains Tension163
11 Chain Tension Adjustment164
12 E-Chain and Hoses Inspection165
1000 Hour or Annual Routine Maintenance166
Change Hydraulic Oil Filter166
Change Hydraulic Oil and Clean Hydraulic Tank166
Change Axle Differential Oil167
Change Axle Planetary Oil168
Change Engine Coolant169
Change Transmission Oil and Filter173
Change Continuously Variable Transmission (CVT) Oil and Filter175
Inspect Boom Chains177
Inspect RAS System (Rear Axle Stabilization) Functionality177
Non-Routine Maintenance179
Boom Hoses and Sheaves Replacement179
Boom Chains Replacement183
Slide Pads Replacement Procedure189
Hydraulic Pressure Test Procedure191
Hydraulic Pump Testing Procedure195
T12000 Modulation195
Deutz Fault Codes199
Starter Replacement Procedure202
Bleeding Hydraulic Circuits204
10 Cable Track Replacement205
11 Carrier Assembly Replacement212
Electronic Tilt Switch Setup Procedure217
Tilt Switch Replacement217
Reprogramming Existing Tilt Switch218
Test and Verify Tilt Circuit219
Park Brake Release221
Bearing Installation222

Skyjack SJ1044 TH - Service Manual

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