Skyjack SJ1044 TH

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Table of Contents5
Section 1 - Scheduled Maintenance11
Read and Heed11
Telehandler Definition11
Purpose of Equipment11
Use of Equipment11
Manual11
Service Policy and Warranty11
Operator Safety Reminders, Warnings and Precautions11
Maintenance and Inspection Schedule12
Owner's Annual Inspection Record12
Replacement Parts12
Maintenance and Service Safety Tips12
Hydraulic System & Component Maintenance and Repair13
Maintenance Hints13
About this Section14
Service Bulletins14
Maintenance and Inspection14
Maintenance Instructions14
Scheduled Maintenance Inspections16
Labels - a16
Electrical16
Mirrors - a16
Hydraulic16
Cylinders - a17
Frame17
Engine Compartment20
Transmission21
Boom - a21
10 Lifting Attachment - a21
11 Grease Fittings - B22
12 Operator's Cab22
Function Tests24
Section 2 - Maintenance Tables25
Standard and Optional Equipment26
Specifications and Features28
Recommended Fluids/Lubrications30
Tire/Wheel Specifications32
Pressure Settings33
Standard Hose Numbering System34
Torque Specifications for Fasteners (US)36
Torque Specifications for Fasteners (Metric)37
Torque Specifications for Hydraulic Couplings & Hoses38
Air Conditioner Temperature/Pressure Chart39
Floor Loading Pressure40
Section 3 - System Component Identification and Schematics41
Electrical Symbol Chart42
Hydraulic Symbol Chart43
Electrical Components Parts List44
Hydraulic Components Parts List47
Hydraulic Pump and Return Filter Ports Identification51
Steering Control Unit Ports Identification52
Service Brake Actuator (Brake Pedal) Ports Identification53
Auxiliary Block Ports Identification54
Joystick Port Identifications55
Premium Joystick Port Identifications56
Premium Joystick Manifold Port Identifications57
Rear Axle Stabilization Manifold Port Identification58
Outrigger Manifold Port Identifications59
Anti-Cavitation Relief Valve (SJ1256 THS Only)60
Major Components Identification and Location61
Main Manifold Port Identification62
Enclosed Cab Harness & Wiring Diagram65
Glow Plug Harness & Wiring Diagram66
Road Lights Harness & Wiring Diagram67
Work Lights Harness & Wiring Diagram68
Boom Lights Harness & Wiring Diagram69
Beacon Light Harness & Wiring Diagram70
RAS System Schematic and Wiring71
Elevate Telematics Harness72
A/C Harness73
Transmission Electrical Connections74
Console Harness and Layout 74 HP75
Console Harness Wiring Diagram 74HP76
Console Harness and Layout 107 HP - THS Models77
Console Harness Wiring Diagram 107 HP - THS Models78
Engine Harness 74 HP79
Engine Harness 74 HP Wiring Diagram80
Engine Harness Diagram 107 HP - THS Models81
Engine Harness Wiring Diagram 107 HP82
Chassis Harness83
Chassis Harness Wiring Diagram84
Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH85
Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH88
Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS91
Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH94
Electrical Schematic - SJ1256 THS97
Hydraulic Schematic - SJ1044 TH/THS & SJ1056 TH/THS100
Hydraulic Schematic, Premium Joystick - SJ1044 TH/THS & SJ1056 TH/THS101
Hydraulic Schematic - SJ1256 THS102
Hydraulic Schematic for Premium Joystick- SJ1256 THS103
Section 4 - Troubleshooting Information104
Introduction104
Electrical System106
Engine will Not Crank106
Engine Cranks but will Not Run107
All Electrical Controls Inoperative107
Park Brake will Not Release108
Transmission will Not Engage109
No Forward Drive109
No Reverse Drive109
No 1St Speed Range110
No 2Nd Speed Range110
10 No Boom Up, Front Steer Mode Only111
11 Front Steer Mode Only111
12 No 4W (Round) Steer Mode111
13 No Crab Steer Mode111
14 No Boom up112
15 Frame will Not Tilt over 40° with Boom below 40113
16 No Frame Level114
17 RAS Remains Fully Locked (RAS Indicator Remains Illuminated)117
18 RAS Remains Locked118
19 Function Does Not Switch118
20 Outriggers Inoperative119
Hydraulic System121
All Controls Inoperative121
No Boom Functions121
No Carriage Tilt123
No Frame Level124
No Aux. Functions125
Hard or no Steering125
Park Brake will Not Release125
Park Brake will Not Engage126
Service Brake will Not Engage126
10 Outriggers Inoperative126
Section 5 - Procedures127
General127
Safety and Workmanship127
Engine and Transmission127
Hour or Daily Routine Maintenance128
Check Engine Oil Level128
Check Coolant Level, Radiator and Hoses128
Check Transmission Fluid Level129
Check Air Cleaner Restriction and Filter Elements129
Check Hydraulic Oil Level130
Drain Fuel/Water Separator131
Fuel Tank131
Check Parking Brake131
Check Tire Pressure and Condition131
10 Check Seat Belt and Mounting Hardware132
11 Check Windshield Washer Fluid Level and Wiper Condition132
Hour or Weekly Routine Maintenance133
Check Fork Pins133
Hour or Quarterly Routine Maintenance133
Check Lug Nut Torque133
Check Oil Level in Axle Differential Planetary Wheel Ends134
Check Oil Level in Axle Differentials134
Replace Engine Oil and Filter135
Change Engine Fuel Filter and Fuel/Water Separator137
Clean Hydraulic Tank Breather138
Torque Axle Mounting Bolts138
Inspect Boom Chains139
Check Boom Slide Pad Clearances140
10 Check Boom Chains Tension142
11 Chain Tension Adjustment143
12 E-Chain and Hoses Inspection144
13 Grease Axle Pivot Bearings and King Pins144
14 Grease Drive Shaft U-Joints and Slip Joints145
15 Grease Frame Level Pivot Bushings146
16 Grease Boom Pivot and Boom Cylinders146
17 Grease Bottom Front & Top Rear Slide Pads147
1000 Hour or Annual Routine Maintenance148
Change Hydraulic Oil Filter148
Change Hydraulic Oil and Clean Hydraulic Tank148
Change Axle Differential Oil149
Change Axle Planetary Oil150
Change Engine Coolant151
Change Transmission Oil and Filter155
Inspect Boom Chains157
Inspect RAS System (Rear Axle Stabilization) Functionality157
Non-Routine Maintenance159
Boom Hoses and Sheaves Replacement159
Boom Chains Replacement163
Slide Pads Replacement Procedure169
Hydraulic Pressure Test Procedure171
Hydraulic Pump Testing Procedure175
T12000 Modulation175
Deutz Fault Codes179
Starter Replacement Procedure182
Bleeding Hydraulic Circuits184
10 Cable Track Replacement185
11 Carrier Assembly Replacement192
Electronic Tilt Switch Setup Procedure197
Tilt Switch Replacement197
Reprogramming Existing Tilt Switch198
Test and Verify Tilt Circuit199
Park Brake Release201
Bearing Installation202
A/C Diagram204

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