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Skyjack SJ1044 TH, Manual

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49

SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS

230790ABA

Hydraulic Components Parts List

 

Section 3 – System Component Identification and Schematics

Index

No.

Skyjack

Part No.

Qty.

Description

MB5

9-169034

1

MANIFOLD, Outrigger

MB5

9-205191

1

MANIFOLD, Outrigger 

- SJ1256 THS

MB6

9-206115

1

MANIFOLD, RV4-1 

- SJ1256 THS

MB7

9-213232

1

MANIFOLD, Premium Joystick (Option)

OR1

9-191807

1

PLUG, Orifice

OR2

9-191808

1

PLUG, Orifice

OR3

9-191809

1

PLUG, Orifice

OR3

9-206178

1

PLUG, Orifice 

- SJ1256 THS

OR4

9-191829

1

PLUG, Orifice

OR4

9-199033

1

PLUG, Orifice 

- SJ1256 THS

OR5

9-199474

1

PLUG, Orifice

OR5

9-191809

1

PLUG, Orifice 

- SJ1256 THS

OR6

9-197300

1

PLUG, Orifice

OR7

9-199032

1

PLUG, Orifice

OR8

9-199475

1

PLUG, Orifice

OR9

9-199475

1

PLUG, Orifice 

- SJ1256 THS

OR10

9-199475

1

PLUG, Orifice 

- SJ1256 THS

OR11

9-206224

1

PLUG, Orifice 

- SJ1256 THS

OR12

9-206224

1

PLUG, Orifice 

- SJ1256 THS

OSM1

9-406450

1

MOTOR, Steering wheel

P1

9-190263

1

PUMP, Hydraulic

P1

9-205221

1

PUMP, Hydraulic 

- SJ1256 THS

PR1

9-191798

1

SWITCH, Pressure reducing/relieving

PR2

9-220518

1

SWITCH, Pressure reducing/relieving  

- SJ1256 THS

PS1

9-191810

1

SWITCH, Pressure 450 PSI

PS2

9-927724

1

SWITCH, Pressure brake light

PS3

9-191800

1

SWITCH, Pressure 350 PSI  

- SJ1256 THS

RV1

9-191802

1

VALVE, Relief

RV2

238579

1

VALVE, Relief

RV3

9-221887

1

VALVE, Relief anti-cavitation

RV4

9-191804

1

VALVE, Relief anti-cavitation

RV4-1

9-206093

1

VALVE, Relief anti-cavitation 

- SJ1256 THS

RV5

9-238580

1

VALVE, Relief

RV6

9-238571

1

VALVE, Relief

RV7

9-238582

1

VALVE, Relief

SV1

9-197301

1

VALVE, Shuttle

SW

9-197304

1

SWITCH, Pressure 1500 PSI

V1

9-191794

1

VALVE, Proportional-pilot operated

V1

9-206190

1

VALVE, Proportional-pilot operated 

- SJ1256 THS

V2

9-191793

1

VALVE, Proportional, pilot operated

V2

9-206191

1

VALVE, Proportional-pilot operated 

- SJ1256 THS

V3

9-191794

1

VALVE, Proportional, pilot operated

V3

9-206190

1

VALVE, Proportional-pilot operated 

- SJ1256 THS

V4

9-191793

1

VALVE, Proportional, pilot operated

V4

9-206191

1

VALVE, Proportional-pilot operated 

- SJ1256 THS

V5

9-191795

1

VALVE, Solenoid 4W3P

V6

9-191796

1

VALVE, Solenoid 4W2P

Summary of Contents for SJ1044 TH

Page 1: ...SERVICE MANUAL 230790ABA August 2021 ANSI SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS TELEHANDLERS...

Page 2: ...nit 1 35 Honeycomb Drive Eastern Creek New South Wales 2766 Australia Tel 61 0 2 9854 0700 Fax 61 0 2 9854 0777 Skyjack Brasil Indaiatuba SP Brasil 13347 653 Tel 55 19 3936 0132 Alameda J piter 710 Lo...

Page 3: ...t 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 po...

Page 4: ...4 SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA Notes...

Page 5: ...2 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 Instruc...

Page 6: ...ium 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...

Page 7: ...tion 104 4 2 Electrical System 106 4 2 1 Engine Will Not Crank 106 4 2 2 Engine Cranks But Will Not Run 107 4 2 3 All Electrical Controls Inoperative 107 4 2 4 Park Brake Will Not Release 108 4 2 5 Tr...

Page 8: ...d Level and Wiper Condition 132 5 3 50 Hour or Weekly Routine Maintenance 133 5 3 1 Check Fork Pins 133 5 4 250 Hour or Quarterly Routine Maintenance 133 5 4 1 Check Lug Nut Torque 133 5 4 2 Check Oil...

Page 9: ...Replacement 159 5 6 2 Boom Chains Replacement 163 5 6 3 Slide Pads Replacement Procedure 169 5 6 4 Hydraulic Pressure Test Procedure 171 5 6 5 Hydraulic Pump Testing Procedure 175 5 6 6 T12000 Modulat...

Page 10: ...10 SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA Notes...

Page 11: ...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...

Page 12: ...damaged or not operating properly must be immediately tagged and removed from service until proper repairs are completed 1 2 3 Maintenance and Service Safety Tips Maintenance and repair should only b...

Page 13: ...ry for filling the hydraulic oil reservoir and fill the reservoir only through the filter opening The use of cloth to strain the oil should be avoided to prevent lint from getting into the system 6 Wh...

Page 14: ...elehandler in the following configuration Telehandler parked on a flat and level surface Disconnect the batteries by disconnecting the main power connectors Repair any damaged or malfunction component...

Page 15: ...l Test Starter Operation Test Horn Test Lights If Equipped Test Boom and Attachment Functions Test Frame Leveling and Level Indicator A Operator s Cab Controls A Manual Foam filled Tires A Table 1 1 M...

Page 16: ...ual and determine that all labels are in place and are legible 1 5 2 Electrical Maintaining the electrical components is essential to good performance and service life of the telehandler Ensure proper...

Page 17: ...e none are loose Refer to section 5 4 1 for torque procedure WARNING If any tire does not meet the criteria outlined above remove telehandler from service and replace wheel tire immediately Air filled...

Page 18: ...condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions WARNING...

Page 19: ...re to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury Perform a visual inspection around the following areas hoses and fitt...

Page 20: ...l level should be between the L low and H high marks Add oil as needed Refer to section 5 4 4 for oil replacement procedure Engine Coolant A WARNING Pressurized fluid present in radiator Never open ra...

Page 21: ...e Ensure all bolts and pins are properly tightened Ensure there are no visible cracks in welds or structure and there are no signs of deformation Ensure all hoses are properly tightened and there is n...

Page 22: ...e points location and service intervals 1 5 12 Operator s Cab Rollover and Falling Object Protective Structure ROPS FOPS B Ensure there is no visible damage WARNING Do not modify drill or alter the op...

Page 23: ...ree points of contact to mount dismount the cab Use the steps of telehandler to access operator s cab Ensure door and windows if equipped are secure and in proper working order Ensure steering wheel i...

Page 24: ...telehandler may only be made by a qualified service technician After repairs are completed operator must perform a pre operation inspection and a series of function tests again before putting telehan...

Page 25: ...25 SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA Section 2 Maintenance Tables...

Page 26: ...erse Backup alarm Engine Block Heater Hydraulic Test Port s Air Filled Tires Rear Axle Stabilization System RAS Frame Leveling System 48 60 72 QA 10K Fork Carriages Lifting Hook Outriggers Optional Eq...

Page 27: ...m Spring applied Hydraulically Released Parking Brake Three Speed Transmisson Three Mode Steering Optional Equipment 1 75 Cu Yd Bucket Loader Attachment 12 ft Truss Boom 15 ft Truss Boom 2 ft Jib Boom...

Page 28: ...e Continuously Variable Transmission Two Range Powershift Speeds forward 2 Speeds reverse 1 Travel Speeds Powershift Range 1 0 4 mph 1 7 km h Range 2 5 8 mph 8 13 km h Range 3 9 15 mph 14 24 km h CVT...

Page 29: ...tive ground 12 Volts Alternator 60 Amps Battery 900 Amps Backup Alarm 107 DBM Dimensions Wheelbase 133 in 337 8 cm Overall width 8 ft 6 in 259 1 cm Overall height 8 ft 7 in 261 6 cm Overall length les...

Page 30: ...n III Capacity 14 2 Quart 13 5 L CVT Oil Type CVT Case VALVOLINE INVARITORC 205 Dropcase ATF DEXRON III Capacity 18 L 0 90 L Axles Differential SAE 80W 90 LS Front Axle Capacity 13 7 Quart 13 L Rear A...

Page 31: ...DEXRON III Capacity 14 2 quart 13 5 L CVT Oil Type CVT Case VALVOLINE INVARITORC 205 Dropcase ATF DEXRON III Capacity 18 L 0 90 L Axles Differential SAE 80W 90 LS Front Axle Capacity 14 8 quart 14 L R...

Page 32: ...tires in good condition can result in death or serious injury Replace tires with the exact Skyjack approved types only IMPORTANT For proper function of each axle differential all four wheels must have...

Page 33: ...I 400 PSI Tilt Comp Carriage Tilt Port Relief 3300 PSI 3900 PSI System Standby Pressure Load Sense GP1 450 PSI 450 PSI Maximum Pressure GP1 3250 PSI 3900 PSI Steering Maximum RV2 2600 PSI 2600 PSI Bra...

Page 34: ...C SWIVEL 100R17 H02 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R13 H03 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R17 H04 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R13 H05 FEMALE 37 JIC S...

Page 35: ...7 JIC SWIVEL 100R16 H43 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R16 H51 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H52 SHORT 45 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H53 MEDIUM 4...

Page 36: ...such as lubrizing oil grease or uncured Loctite 1374AA Size Torque Type SAE2 SAE 5 SAE 8 Dry Lubed Dry Lubed Dry Lubed 9 16 12 ft lb 70 55 110 80 150 110 Nm 95 75 149 108 203 149 9 16 18 ft lb 80 60...

Page 37: ...88 66 126 94 M14 x 2 00 ft lb 104 78 148 111 Nm 141 106 201 150 M16 x 2 00 ft lb 161 121 230 172 Nm 218 164 312 233 M18 x 2 50 ft lb 222 167 318 238 Nm 301 226 431 323 M20 x 2 50 ft lb 314 235 449 33...

Page 38: ...que Chart for JIC Size Steel Brass Dash Frac ft lb Nm ft lb Nm Min Max Min Max Min Max Min Max 4 1 4 10 11 13 15 5 6 6 75 9 6 3 8 17 19 23 26 12 15 17 20 8 1 2 34 38 47 52 20 24 27 66 33 10 5 8 50 56...

Page 39: ...0 psi 1551 1724 kPa 90 F 32 C 45 55 psi 310 379 kPa 250 270 psi 1724 1862 kPa 95 F 35 C 50 55 psi 345 379 kPa 275 300 psi 1896 2068 kPa 100 F 38 C 50 55 psi 345 379 kPa 315 325 psi 2172 2241 kPa 105 F...

Page 40: ...heel Note This is more than 25 of the machine weight due to possible weight distribution over the machine and platform LCP Local Concentrated Pressure is a measure of how hard the MEWP presses on the...

Page 41: ...41 SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA Section 3 System Component Identification and Schematics...

Page 42: ...CTION CIRCUITS CONNECTED BATTERY FUSE GROUND CIRCUIT BREAKER VOLT METER CAPACITOR POTENTIOMETER SINGLE POLE DOUBLE THROW RELAY TRIPLE POLE DOUBLE THROW RELAY RELAY RELAY DOUBLE POLE DOUBLE THROW SINGL...

Page 43: ...TOR MOTION CONTROL VALVE SPRING APPLIED HYDRAULIC RELEASED BRAKE ADJUSTABLE FLOW CONTROL ENGINE FLOW DIVIDER COMBINER BRAKE CYLINDER CYLINDER CHECK VALVE FIXED DISPLACEMENT PUMP COUNTER BALANCE VALVE...

Page 44: ...nable 05CR 9 931298 1 RELAY Park Brake Release 255CR 9 931298 1 RELAY Rear Wiper 258CR 9 931298 1 RELAY Front Wiper 258ACR 9 931298 1 RELAY Top Wiper 250ACR 9 931298 1 RELAY Left Turn Signal 251ACR 9...

Page 45: ...el Joystick SW6 9 405339 1 SWITCH Horn switch button SW7 9 196995 1 SWITCH Carriage Tilt Joystick SW8 9 191680 1 SWITCH Fan SW9 9 191455 1 SWITCH positive shutoff SW10 9 191455 1 SWITCH boom lights SW...

Page 46: ...9 102921 1 DIODE Road light Harness D60 1 9 102921 1 DIODE Console harness D15A 9 102921 1 DIODE Console harness D16 9 102921 1 DIODE Console harness 9 190547 2 SENSOR Inductive proxi mm 9 166700 2 S...

Page 47: ...56 THS C10 9 191123 1 CYLINDER TH Outriggers C10 9 205064 1 CYLINDER TH Outriggers SJ1256 THS C11 9 191123 1 CYLINDER TH Outriggers C11 9 205064 1 CYLINDER TH Outriggers SJ1256 THS C12 9 190025 1 CYLI...

Page 48: ...CV7 9 166066 1 VALVE Check CV7 9 171412 1 VALVE Check SJ1256 THS CV8 9 166066 1 VALVE Check CV8 9 171412 1 VALVE Check SJ1256 THS CV9 9 166066 1 VALVE Check CV9 9 171412 1 VALVE Check SJ1256 THS CV10...

Page 49: ...P1 9 205221 1 PUMP Hydraulic SJ1256 THS PR1 9 191798 1 SWITCH Pressure reducing relieving PR2 9 220518 1 SWITCH Pressure reducing relieving SJ1256 THS PS1 9 191810 1 SWITCH Pressure 450 PSI PS2 9 9277...

Page 50: ...TIONAL AUX 12K SJ1256 THS V15 9 166038 1 VALVE 2 way normally closed spool V15 9 206194 1 VALVE SOLENOID CARTRIDGE 2 WAY SJ1256 THS V16 9 102626 1 VALVE Solenoid cartridge spool V17 9 102626 1 VALVE S...

Page 51: ...3 System Component Identification and Schematics 3 5 Hydraulic Pump and Return Filter Ports Identification Port L To Hyd Tank Load Sense Compesator Adjuster Port S To Hyd Tank Inlet Outlet Return Fil...

Page 52: ...ol Unit Ports Identification Port T to Port STT on Main Manifold Port L to Port L on Front Axle Steering Cylinder Port R to Por ORBR on Main Manifold Port P to Port CF on Main Manifold Port LS to Port...

Page 53: ...fication Section 3 System Component Identification and Schematics 3 7 Service Brake Actuator Brake Pedal Ports Identification Port T to Port DR1 on Main Manifold Port P to Port SB on Main Manifold Por...

Page 54: ...on and Schematics Auxiliary Block Ports Identification Port A to Bulkhead 7 Port B to Bulkhead 7 Port AUX LS to Port AUX LS on Main Manifold Port AUX T to Port AUX T on Main Manifold Port AUX EF1 to P...

Page 55: ...onent Identification and Schematics MACHINE FRONT 4 P 1 2 3 T 3 9 Joystick Port Identifications Port 2 to Port J2 on Main Manifold Port 1 to Port J1 on Main Manifold Port 3 to Port J3 on Main Manifold...

Page 56: ...um Joystick Port Identifications 2 P 4 3 1 T MACHINE FRONT 3 10 Premium Joystick Port Identifications Port 2 to Port J2 on Main Manifold Port 1 to Port J1 on Main Manifold Port 3 to Port J3 on Main Ma...

Page 57: ...ystem Component Identification and Schematics 3 11 Premium Joystick Manifold Port Identifications Port B to Carriage Up Port on Main Manifold Port D to tee fitting GP2 on Main Manifold Port D to tee f...

Page 58: ...Manifold Port Identification 2H 221 1 RAS Unlock 2H 221 2 RAS Unlock 2H 221 3 RAS Unlock RV7 Relief Valve CV15 Check Valve 2H 65 RAS Restrict RV6 Relief Valve 2H 65 RAS Restrict 2H 65 RAS Restrict Por...

Page 59: ...26 4H 225 4H 226 Port R1 to Port R on Right Outrigger Cylinder Port R2 to Port R on Left Outrigger Cylinder Port DR4 to Port DR4 on Main Manifold Port OUTT EF2 to Port OUTT on Main Manifold Port OUTT...

Page 60: ...ection 3 System Component Identification and Schematics Anti Cavitation Relief Valve SJ1256 THS Only 3 14 Anti Cavitation Relief Valve SJ1256 THS Only Port P2 to Port T2 on Main Manifold RV4 1 Anti Ca...

Page 61: ...er Cylinder OSM1 Steering Control Unit MB5 Outrigger Manifold F1 Hydraulic Return Filter P1 Hydraulic Pump F2 Tank Filler Breather C8 Rear Stabilization Cylinder MB4 R A S Manifold MB1 Main Manifold F...

Page 62: ...Port F1 on Return Filter PS2 Switch OR2 OR4 OR3 Port TB to Bulkhead 4 Port BR1 to Port A on Brake Pedal Port TA to Bulkhead 4 Port J1 to Port 1 on Joystick Port FA to Port CB6 on Frame Level Cylinder...

Page 63: ...nal Reserve Brake Manifold CV5 Check Valve OR7 CV2 Check Valve CV1 Check Valve CV9 Check Valve CV8 Check Valve CV12 Check Valve Port LS to Port X on Hydraulic Pump SJ10XX TH THS Port LS to Port X on H...

Page 64: ...Right Solenoid Valve V4 Frame Tilt Solenoid Valve 4H 217 4H 218 Steer Function Solenoid Valve 4H 223 Frame Level Left Solenoid Valve 3H 26 Park Brake Disable Solenoid Valve V3 Telescopic Solenoid Valv...

Page 65: ...E 259A LT YW PE 05L PE J44 05L 16 PE 05N 16 PE 260 16 TN WH 259 16 LT YW PE 259A 16 LT YW PE 1 2 5 4 3 7 6 8 1 4 2 3 1 4 2 3 00 16 WH 260 16 TN WH WASHER MOTOR FOR FRONT TOP WIPER 259 16 LT YW PE 259A...

Page 66: ...M 86 11 BLACK TERM 87 11C RED 11B 11C 11 11A TO 87 TO 30 TO 85 11A 18 BK 11C 8 RD 11B 8 RD TO 86 J5 2 3 11C 18 RD 11A 18 BK 11 18 BK 4 11 18 BK 1 11B 8 RD 2 1 P1 11C 10 RD 11C 10 RD J5 P1 CONNECTOR J5...

Page 67: ...RN SIGNAL HEAD LIGHT 6 3 1 2 5 4 6 3 1 2 5 4 TURN SIGNAL FRONT LEFT HEAD LIGHT TURN SIGNAL HEAD LIGHT FRONT RIGHT TURN SIGNAL RIGHT BRAKE BACKUP RIGHT LIGHT BRAKE TURN SIGNAL LEFT LIGHT BACKUP LEFT 1...

Page 68: ...ONT FRONT GND ON CAB ON CAB 247 14 LT GN WT 00 12 WH 00 14 WH 00 14 WH 246 14 LT GN PK 247 14 LT GN WT 246 14 LT GN PK 1 2 ON FRAME SPL00 SPL00 SPL246 SPL247 1 2 WORKLIGHT ON FRAME RIGHT REAR 00 14 WH...

Page 69: ...SJ1056 THS SJ1256 THS 230790ABA SPL00 GND A B BOOM LIGHTS P26 P26 BOOM LIGHTS A B GROUND TO CHASSIS HARNESS TO CHASSIS HARNESS 256 14 TN BK 256 14 TN BK 256 14 TN BK 00 14 WH 00 14 WH 00 12 WH 256 14...

Page 70: ...70 SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA BEACON OPTION P37 OPT BEACON P37 5D 16 PE 00 16 WH 00 16 WH 5D 16 PE CHASSIS GND ON GROUND 1 2 BEACON LIGHT 3 22 Beacon Light Harness...

Page 71: ...J115 1 2 65 1 16 YW PK 00 16 WH 221 1 16 DK GN TN 00 16 WH RAS RESTRICT J115 J116 1 2 221 2 16 DK GN TN 00 16 WH J117 1 2 221 3 16 DK GN TN 00 16 WH J116 J117 1 4 3 2 SPL65 SPL221 P118 TO CHASSIS HAR...

Page 72: ...26B BLU YEL 16 TEW 221 26B 221 DK GRN TAN 16 TEW 57 BRN GRN 16 TEW 57E BRN GRN 16 TEW 03B GRN PUR 16 TEW 03B 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 D57B 87 30 85 86 J1 BACK VIEW PIN 1 60C WHITE B...

Page 73: ...SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA A C COMPRESSOR PRESS SW HEATER AC TO HARNESS TO ENCL CAB HARNESS COMPRESSOR A C 269 16 DBE RD 268 16 DBE OE 268 16 DBE OE 269 16 DBE RD M...

Page 74: ...G H V Z Y X W 74 SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA P9 Reverse P11 1st Gear P10 Forward P12 2nd Gear 3 26 Transmission Electrical Connections 3 26 Transmission Electrical...

Page 75: ...H 2 3 05S 16 PE 228 16 LT GN BK 1 227 16 LT GN BE 5 2 3 6 05J 16 PE 249 16 LT PE 252 16 PK RED 252A 16 PK RED 4 251A 16 PK BL J108 00 16 WH 254 16 TN 251A 16 PK BL 251B 16 PK BL 30 85 86 87A J100 00 1...

Page 76: ...6 85 J33 1 2 3 4 5 6 7 8 03 16 GN PE 00 16 WH 60B 16 WH BE 60 16 WH BE TELEMATICS 60 16 WH BE 60B 16 WH BE 60 16 WH BE SPL77 77 16 BN GY 246 14 LT GN PK DISPLAY J22 4 8 1 2 3 7 CANH 18 YW BE CANL 18 G...

Page 77: ...BE 5 8 4 1 DEUTSCH J50 05J 16 PE 249 16 LT PE 249 16 LT PE J22 CANH 18 YW BE CANL 18 GN 60 16 WH BE 00 16 WH 12 1 7 6 DEUTSCH J42 271 16 BE YW 15 16 BE 250 16 LT BL BK 261 16 BN YW 12 1 7 6 DEUTSCH 2...

Page 78: ...87A 259A 16 LT YW PE 259A 16 LT YW PE POWER PORT 00 14 WH ENCL CAB OPTION J88 J57 00 49 6 5 10 9 12 11 D60 DIODE SPLD60 1 1 2 5 4 3 7 6 8 TO CHASSIS HARNESS MODULE POSITIVE SHUTOFF OPT 2 6 5 05K 16 PE...

Page 79: ...17 37 57 201 18 WH 77 18 38 58 78 19 39 59 79 20 40 60 80 D2 2 PIN WIRE NO COLOR P8 56A WH BA RD 56B BK 54 BK 87 85 86 30 1 31 2 A02 16 WH 32 A32 16 BK 3 A03 16 WH 33 A33 16 BK 4 A04 16 WH 34 5 A05 16...

Page 80: ...43 BK 18 TXL A44 BK 18 TXL 204 RD 18 TXL 202 WH 18 TXL 203 BK 18 TXL 203 BK 18 TXL 202 WH 18 TXL 204 RD 18 TXL B RD 12 TXL K01 RD 12 TXL K01 RD 14 TXL K01 RD 14 TXL K01 RD 14 TXL 00 WH 14 TXL 00 WH 12...

Page 81: ...BK 10 40 70 A70 18 BK 100 A100 18 WH 11 A11 18 BK 41 A41 18 BK 71 101 A101 18 WH 12 42 72 A72 18 BK 102 A102 18WH 13 A13 18 BK 43 73 A73 18 BK 103 14 44 A44 16 BK 74 A74 18 BK 104 15 A15 18 BK 45 A45...

Page 82: ...50 235 BK 16 TXL 237 WH 18 TXL 239 WH 18 TXL 229 BK 16 TXL 229 BK 18 TXL 00 WH 18 TXL X1 BK 18 TXL 54 2 1 1 2 A48 BK 18 TXL A48 BK 18 TXL 48 A94 BK 18 TXL A95 BK 18 TXL 95 94 A88 BK 18 TXL A63 BK 18...

Page 83: ...K 23 221 DK GN TN 19 49 GN RD 29 28L GN 28 28R GN 24 05R PE 25 212 DK GN OE 26 256 TN BK 30 28B RD WE 31 28A RD BE P31 PIN WIRE NO COLOR P31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23...

Page 84: ...0 16 WH 00 16 WH 00 16 WH 47 16 PE OE 47 16 PE OE 26A 16 BL YW 26A 16 BL YW 19 16 OR GN 5A 16 PE 5D 16 PE 14A 16 BK SPL223 SPL47 SPL00 SPL00 J27 233 16 DK PE OR 234 16 DK PE RD 00 16 WH 00 16 WH 00 16...

Page 85: ...3 120 TO SHEET 2 03 00 ENGINE DETAIL HERE TO ENGINE STARTER POST TO ENGINE GROUND B TO ECU P66 BATTERY DISPLAY MODULE CAN BA TO FUEL PUMP SW 14 WASHER WIPER 1 SWITCH WASHER M2 1 3 2 5 4 6 ENGINE DISPL...

Page 86: ...261 271 271A 271 271A 115 114 261 05D CANL CANH HEATER POT SW17 BLOWER SW WINDSHIELD WASHER BOOM LIGHTS SWITCH FROM SHEET 1 FROM SHEET 1 B A FUEL GAUGE LAMP WORKLIGHT SWITCH HEATER POT A C PRESSURE S...

Page 87: ...48 D2 1 60 PIN 44 43 52 45 53 39 38 54 A19 16 BK A20 16 WH A54 18 BK A39 18 WH A38 18 RD A52 18 BK A37 18 WH A53 18 RD A48 16 BK A18 16 WH A33 16 BK A16 16 WH A05 16 BK A04 16 WH A46 16 BK A03 16 WH...

Page 88: ...A SIGNAL 08 C SIGNAL 02 41 40 10A 00 233 234 10B AUX POWER AUX RETURN GROUND AUX RETURN 5 VDC SENSOR POWER CARRIAGE TILT DUMP SIGNAL CARRIAGE DUMP RETURN CARRIAGE TILT DUMP POWER CARRIAGE TILT UP RETU...

Page 89: ...OM SHEET 1 SW11 WORK LIGHTS SW SW10 BOOM LIGHTS SW SW12 TURN SIGNAL SW 8 SW 13 84 83 82 81 53 77 80 79 78 76 74 75 73 72 71 70 69 68 67 60 66 65 64 63 62 61 59 58 57 56 55 54 51 52 50 49 48 47 45 46 4...

Page 90: ...K 60 16 BK K61 18 BK K61 18 BK A07 18 BK K73 18 BK K28 18 BK 3 32 2 7 46 4 19 5 20 24 23 27 25 26 29 28 16 33 18 35 40 37 48 D2 1 60 PIN 44 43 52 45 53 39 38 54 A19 16 BK A20 16 WH A54 18 BK A39 18 WH...

Page 91: ...OW LINE 243CR RELAY HEATER 3 PRESSURE LINE 240CR RELAY SCR CONTROL STAND STILL SUCTION BACKFLOW PRESSURE HEATER HEATER HEATER DEF PUMP DEF QUALITY LEVEL TEMP SUPPLY MODULE HEATER ENGINE DETAIL HERE M6...

Page 92: ...2 SW19 ROAD LIGHT HEAD LIGHTS HIGH BEAM LOW BEAM HEAD LIGHTS HIGH BEAM LOW BEAM HEAD LIGHTS RIGHT LEFT RIGHT LEFT FROM SHEET 1 SW11 WORK LIGHTS SW SW10 BOOM LIGHTS SW SW12 TURN SIGNAL SW 8 SW 13 SCR...

Page 93: ...8 BK 57 A70 18 BK 70 A70 18 BK A26 18 BK 26 A26 18 BK 47 A47 18 BK A47 18 BK A82 18 BK A05 18 BK A82 18 BK 82 A05 18 BK 05 A98 18 BK A77 18 BK A98 18 BK A77 18 BK X11 18 BK X10 18 BK A98 18 BK A77 18...

Page 94: ...DISCONNECT SWITCH REVERSE SENSOR REV DETECTOR REVERSE WARNING SENSOR OPTION ACC REVERSE CAMERA OPTION REV MONITOR REVERSE REVERSE CAMERA SENSOR 10 A F4 15 4 7 9 10 8 7 3 2 1 11 12 J91 J46A JOYSTICK 1...

Page 95: ...M HEAD LIGHTS RIGHT LEFT RIGHT LEFT FROM SHEET 1 SW11 WORK LIGHTS SW SW10 BOOM LIGHTS SW SW12 TURN SIGNAL SW 8 SW 13 SW6 HORN SW HORN F7 10 A HORN SCR CONTROL 30A 15A AFTER SCR CAT 5A PRIOR SCR CAT 5A...

Page 96: ...BK 70 A70 18 BK A26 18 BK 26 A26 18 BK 47 A47 18 BK A47 18 BK A82 18 BK A05 18 BK A82 18 BK 82 A05 18 BK 05 A98 18 BK A77 18 BK A98 18 BK A77 18 BK X11 18 BK X10 18 BK A98 18 BK A77 18 BK A92 18 BK 92...

Page 97: ...ODULE HEATER 241CR RELAY HEATER 1 SUCTION LINE 242CR RELAY HEATER 2 BACKFLOW LINE 243CR RELAY HEATER 3 PRESSURE LINE 240CR RELAY SCR CONTROL STAND STILL SUCTION BACKFLOW PRESSURE HEATER HEATER HEATER...

Page 98: ...GHTS 4 6 5 1 3 2 SW19 ROAD LIGHT HEAD LIGHTS HIGH BEAM LOW BEAM HEAD LIGHTS HIGH BEAM LOW BEAM HEAD LIGHTS RIGHT LEFT RIGHT LEFT FROM SHEET 1 SW11 WORK LIGHTS SW SW10 BOOM LIGHTS SW SW12 TURN SIGNAL S...

Page 99: ...BK A57 18 BK A57 18 BK 57 A70 18 BK 70 A70 18 BK A26 18 BK 26 A26 18 BK 47 A47 18 BK A47 18 BK A82 18 BK A05 18 BK A82 18 BK 82 A05 18 BK 05 A98 18 BK A77 18 BK A98 18 BK A77 18 BK X11 18 BK X10 18 BK...

Page 100: ...H 65 RESTRICT 2H 65 1 RESTRICT RV5 RV6 RV7 OR8 0 055 CV14 CV15 CV17 CV16 2H 221 3 UNLOCK MB4 MB5 CBCA LHN 4000 3 1 CBCA LHN 4000 3 1 CBCA LHN 4000 3 1 SAE 04 SAE 04 SAE 16 SAE 32 3H V1 PRESSURE COMPEN...

Page 101: ...SATOR 3250 PSI 3H V2 LOAD SENSE COMPENSATOR 450 PSI L L1 X S P S GP P GP 0 015 FRAMELEFT 2H 28A ENABLE FRAMERIGHT 2H 28B ENABLE V17 V16 OR7 0 052 CB1 CB2 1CEL90F30S 230 60 4200 PSI Primary 5 6 1 3350...

Page 102: ...E 08 SAE 08 V23 V24 V22 V20 V21 CV18 CV19 1 3 2 1SE30F20S5 SP3263 psi PR2 1500 PSI 1 3 2 CACL LGN 6000 PSI 2 1 Bore 2 48 in Stroke 10 24 in OR9 0 055 OR10 0 055 CP2 EC1 2 1 RV4 1 4300 PSI C3 Bore 6 3...

Page 103: ...076 PSI PRIMARY 5 6 1 3336 SECONDARY 0 7 1 1740 SAE 12 SAE 12 SAE 08 1SE90F35S4 150 2176 PSI SAE 08 V23 V24 V22 V20 V21 CV18 CV19 1 3 2 1SE30F20S5 SP3263 psi PR2 1500 PSI 1 3 2 CACL LGN 6000 PSI 2 1 B...

Page 104: ...not cover all possible troubles and deficiencies that may occur If a specific trouble is not listed isolate the major component in which the trouble occurs isolate whether the problem is electrical or...

Page 105: ...105 SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA Notes...

Page 106: ...se or broken wire 56B from relay 56ACR to fuel pump Check continuity Replace if defective 9 Defective relay 56ACR Check continuity through contacts of relay Replace if defective 10 Loose or broken gro...

Page 107: ...gine harness connector J1 pin 8 Check continuity Replace if defective 25 Loose or broken 57B wire from engine harness connector P1 pin 8 to 94 pin ECU connector D2 2 pin 35 Check continuity Replace if...

Page 108: ...efective With following conditions Transmission will engage 1 Loose or broken wire 26 from park brake switch SW2 pin 1 to park brake release relay 05CR pin 30 Check continuity Replace if defective 2 L...

Page 109: ...1 Check continuity Replace if defective 4 Loose or broken 00 wire from brake pressure switch PS1 connector P18 pin 2 to ground Check continuity Replace if defective 5 Defective pressure switch PS1 Ch...

Page 110: ...ness P13 pin 2 Check continuity Replace if defective 7 Defective reverse solenoid Replace solenoid 8 Defective transmission shifter Replace shifter 4 2 8 No 1st Speed Range 1 Loose or broken wire 216...

Page 111: ...9CR pin 30 and steer mode select switch SW3 pin 2 Check continuity Replace if defective 4 2 11 Front Steer Mode Only 1 Loose or broken 05A wire from fuse F3 to steer mode select switch SW3 pin 2 Check...

Page 112: ...Replace if defective 4 Boom E O S proximity switch misadjusted or defective Check adjustment set to 70 replace if defective 5 Loose or broken 19 wire from Boom E O S proximity switch connector J23 pi...

Page 113: ...connector J31 pin 24 Check continuity Replace if defective 3 Loose or broken 05R wire from connector P31 pin 24 to frame angle sensor connector J105 pin 2 Check continuity Replace if defective 4 Loos...

Page 114: ...boom angle relay 212CR pin 30 Check continuity Replace if defective 4 Loose or broken wire 65 from chassis harness splice 65 D213B D221 to wire 65 junction to 4 pin connector P113 pin 3 Check continu...

Page 115: ...continuity Replace if defective With following conditions Boom Angle Below 40 Works Above 40 RAS indicator does illuminate above 40 1 Loose or broken wire 223A from 220CR pin 30 to 223ACR pin 86 Chec...

Page 116: ...1connector pin 31 Check continuity Replace if defective 10 Loose or broken wire 28A from P31 connector pin 31 to frame level left enable solenoid J74 pin 1 Check continuity Replace if defective 11 Loo...

Page 117: ...e brake not depressed RAS goes into restrict mode RAS indicator not illuminated above 40 with park brake off transmission in FWD 2 Diode D15a open defective Check for continuity with positive lead on...

Page 118: ...212CR pin 87 to connector J31 pin 23 Check continuity Replace if defective 2 Loose or broke wire 221 from connector P31 pin 23 to connector J118 pin 2 Check continuity Replace if defective 4 2 19 Func...

Page 119: ...use 2 Loose or broken wire 224 from connector J46 pin7 to relay 224CR pin 86 Check continuity Replace if defective 3 Loose or broken wire 00 from 224CR to ground Check continuity Replace if defective...

Page 120: ...efective 4 Right outrigger up solenoid 4H 227 defective Replace if defective With following conditions Left outrigger down inoperative 1 Loose or broken wire 226 from outrigger switch SW21 to connecto...

Page 121: ...required 3 PR1 pressure reducing valve misadjusted or defective Adjust pressure replace if defective With following conditions No Boom Raise 1 Stuck or defective joystick JS1 Clean valve Check operati...

Page 122: ...S1 Clean valve Check operation of valve Repair or replace valve as required 2 PD1 V13 stuck or defective Clean valve Check operation of valve Repair or replace valve as required 3 Stuck or defective l...

Page 123: ...operated check valve CV11 and or CV12 blocked or defective Clean valve Check operation of valve Repair or replace valve as required 6 RV4 misadjusted or defective Adjust pressure replace if defective...

Page 124: ...equired 4 Orifice OR3 and or OR4 plugged Remove and inspect clean or replace as required 5 Stuck or defective frame level valve V4 Clean valve Check operation of valve Repair or replace valve as requi...

Page 125: ...Repair or replace valve as required 3 Defective Auxiliary Optional cylinder s Check seals on cylinder Replace as necessary Replace cylinder if defective 4 LS check valve CV13 blocked or defective Cle...

Page 126: ...Repair or replace valve as required 2 LS check valve CV19 blocked or defective Clean valve Check operation of valve Repair or replace valve as required 3 Stuck or defective counterbalance valves CB10...

Page 127: ...d 5 1 2 Engine and Transmission The engine used on the SJ1044 TH THS SJ1056 TH THS telehandler models is a Deutz TCD 3 6L Tier 4 Final Engine service information can be found in the Deutz Engine Manua...

Page 128: ...he oil level must be between the Full and Low marks 6 If oil level is below the Low mark refer to Section 5 4 4 for engine oil and filter replacement procedure 5 2 2 Check Coolant Level Radiator and H...

Page 129: ...mission Continuously Variable Transmission Transmission Oil Dipstick Figure 03 Transmission Oil Dipstick 4 The oil level should be between the Full and Low marks 5 If transmission oil level is low ref...

Page 130: ...Secondary element in place clean inside the housing and the cover with a damp cloth CAUTION Never use compressed air on an air filter Paper elements should not be washed NOTE Secondary or safety elem...

Page 131: ...ispose of used fuels and other dangerous liquids 5 2 7 Fuel Tank WARNING Do not allow fuel tank to become completely empty If tank is allowed to empty completely the entire fuel system will require bl...

Page 132: ...unting Hardware 1 Check seat belt for wear or damage Check that mounting hardware is tight 2 Inspect the belt hardware and fabric Replace if hardware is damaged frayed or loose stitching is found Seat...

Page 133: ...2 Fork Pin 5 4 250 Hour or Quarterly Routine Maintenance 5 4 1 Check Lug Nut Torque 1 Ensure wheel nuts are tight on all wheels 2 Tighten wheel nuts to a torque of 442 lb ft 599 N m using the cross pa...

Page 134: ...es 3 Wipe the fill plug clean and remove 4 Check oil level at the bottom of the fill hole If required add oil NOTE Refer to Table 2 3 of Section 2 in this manual for oil type and capacity 5 Re install...

Page 135: ...soil rather collect it in a container Dispose of this in accordance with environmental regulations 1 Ensure telehandler is parked on a firm level surface 2 Apply park brake and remove key from igniti...

Page 136: ...during this procedure 7 Refill engine with new oil through the fill area Refer to Table 2 3 for engine oil specifications Engine Oil Fill Cap Figure 19 Engine Oil Fill Cap 8 Start engine and allow it...

Page 137: ...el when removing them 6 Disconnect the water level sensor harness from fuel water separator 7 Unscrew the drain plug assembly from bottom of water separatror 8 Unscrew used fuel filter and separator D...

Page 138: ...will come out of venting plug Retighten venting scerew and primer handle 16 Check area for any leaks 17 Close engine cover back and latch it in place 5 4 6 Clean Hydraulic Tank Breather 1 Clean area...

Page 139: ...k telehandler on a firm level surface 2 Apply parking brake then fully retract and lower the boom 3 Shut down engine and remove key from ignition switch 4 Remove cover on rear of boom structure Rear C...

Page 140: ...learance between the contact surface of the pad and the adjacent sliding surface This clearance ranges between 0 031 0 062 in 0 79 1 58 mm TOTAL for both sides of the boom When clearances exceed this...

Page 141: ...ide of the boom and the upper and lower slide pads Clearance should not exceed 0 08 in 2 mm Repeat procedure for inner boom section s Side Slide Pads Figure 31 Side Slide Pads Clearance 9 Remove boom...

Page 142: ...Check Boom Chains Tension Proper adjustment of the chains at this interval minimizes the risk of chain failure which could cause extensive damage to other boom components and require extensive labor...

Page 143: ...complete the steps outlined in Section 5 3 7 1 Partially extend the boom 2 Using a 1 1 4 wrench loosen jam nut at the chain anchor Chain Anchor Jam Nut Figure 37 Extend Chain Jam Nut SJ1044 TH THS Ch...

Page 144: ...cing windows on the sides of the boom and remove the covers Service Window 4 Examine the e chain and hoses for damage or wear 5 If maintenance is necessary refer to section 5 6 10 Cable Track Replacem...

Page 145: ...are located beside the right boom lift cylinder See figure above 1 Wipe dirt and grease from each remote grease fitting 2 Remove cap and apply 4 shots of grease to each fitting Axle King Pins Each axl...

Page 146: ...linder Grease Points Figure 44 Stabilizer Grease Points Rear Axle Lock Cylinder Grease Points Figure 45 Rear Axle Lock Cylinder Grease Points 5 4 16 Grease Boom Pivot and Boom Cylinders 1 Apply grease...

Page 147: ...cab 5 With boom fully extended smear grease along the path of front bottom slide pads See figures below Front Bottom Slide Pads Grease Points Figure 48 Front Bottom Slide Pads 6 Fully retract the boom...

Page 148: ...ng of clean oil to the gasket on the new filter 6 Install the new filter and turn until the gasket contacts the filter head 7 Tighten an additional 1 2 to 3 4 turn by hand to compress the gasket 5 5 2...

Page 149: ...l the hydraulic tank with new oil from unopened container 12 Check for leakage 13 Install cover plate and tank filler breather 14 Clean up any oil that may have spilled during this procedure 15 Check...

Page 150: ...ry Oil Each axle assembly requires planetary gear lubricant independent of the differential assemblies 1 Ensure that the axle planetary oil is at operating temperature 2 Park the telehandler on a firm...

Page 151: ...pped 1 Open the radiator cap to ensure proper draining Radiator Cap Figure 56 Radiator Cap 2 Place a container capable of holding 5 gallons 17 liters under the radiator drain plug 3 Open the drain plu...

Page 152: ...cool down and open the radiator drain plug and allow radiator and coolant bottle to drain NOTE If heater is equipped remove the plugged hose at the motorized heater valve for proper draining Must be r...

Page 153: ...SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA 1000 Hour or Annual Routine Maintenance Section 5 Procedures Heating Line Cooling Line Solenoid Valve DEF Tank DEF Injector Open Cab Plum...

Page 154: ...THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA Section 5 Procedures 1000 Hour or Annual Routine Maintenance Enclosed Cab Plumbing Cabin Heater Heating Line Cooling Line Solenoid Valve DEF Tank DEF Inje...

Page 155: ...erating temperature when draining Avoid contact with hot oil or components Do not allow oil to drain into the ground 4 Remove drain plugs A and B to drain transmission oil Oil Dipstick Oil Drain Plug...

Page 156: ...on how to dispose of used oil and filter 12 Apply a light coating of oil to the new filter gasket and install it on the transmission 13 Hand tighten the new filter until it touches the base then tight...

Page 157: ...spect RAS System Rear Axle Stabilization Functionality Warning This procedure must be performed by a qualified service personnel only Failure to adhere to the steps outlined below could result in seri...

Page 158: ...0 1 0 0 0 1 0 1 0 0 0 0 0 1 1 0 1 0 0 0 1 0 0 1 0 0 0 0 1 0 1 0 1 0 0 0 1 1 0 1 0 0 0 0 1 1 1 0 1 0 0 1 0 0 0 1 0 0 0 1 0 0 1 0 0 1 0 1 0 1 0 1 0 0 0 1 0 1 1 0 1 0 0 1 1 0 0 1 0 0 0 1 1 0 1 0 0 1 0 1...

Page 159: ...NOTE Right side sheaves are for Fork Tilt hoses Left side sheaves are for Auxiliary Functions hoses 4 Remove the 2 bolts holding each sheave guard bracket to the finger weldment Remove 2 bolts Remove...

Page 160: ...s For SJ1044 TH THS Only 5 Start engine and extend the boom approximately 3 feet to gain acces to side acces hole on fly boom section Figure 72 Boom Side Access Hole 6 Shutdown engine and remove key f...

Page 161: ...ge at the fittings Inspect the pulleys for face and edge damage Replace damaged parts as required 15 Ensure that all wire ties or tags used to mark the long hose during removal are transferred to the...

Page 162: ...oses tank side to bulkhead as shown in figure below 4 Fully loosen off the extend chain anchor jam nut and tension nut Connect hoses at bulkhead Figure 77 Auxilliary Hydraulics Hoses Connection at Bul...

Page 163: ...For SJ1056 TH THS Only 5 Connect hoses at the rear of bulkhead fittings as shown below Connect hoses at bulkhead Figure 81 Fork Tilt hoses Connection 6 Connect the auxiliary hydraulics hoses at the r...

Page 164: ...n 5 4 8 for detailed procedure on how to inspect boom chains Install Extend Chain 1 At the front of the boom link the new extend chain to the end of the old extend chain using a link pin and new cotte...

Page 165: ...e bolts to 80 lb ft using a 3 4 socket NOTE Ensure the chain anchor remains square to the 3rd boom top plate 7 On front of boom apply SKF Antifret grease to threadded end of chain anchor then feed it...

Page 166: ...ract Chain Anchor 4 On front of boom assembly remove 2 bolts from retract anchor weldment 1st Boom Section Retract Chain Cotter Pin Anchor Bolts Figure 91 Front Retract Chain Anchor 5 Pull retract cha...

Page 167: ...hain Removal 1st to 3rd Boom Section 1 With boom on the ground and extended enough to access the anchor plate bolts on 2nd boom section remove rear access cover plate 2 Using snap ring pliers remove t...

Page 168: ...6 Pull retract chain from front of boom and thoroughly inspect NOTE Refer to section 5 4 8 for detailed procedure on how to inspect boom chains Install Retract Chain SJ1056 TH THS 1 Working at the re...

Page 169: ...their location in the boom assembly IMPORTANT Pay attention to high load slide pads Front Lower Rear Upper of boom as most of the weight is exerted on them Figure 98 Slide Pads Locations SJ1056 TH THS...

Page 170: ...r pads 1 Clean installation area to remove any residual grease Ensure threads are free of grease dirt 2 With the carriage lowered to the floor install the top wear pads on the 2nd boom Install the top...

Page 171: ...y Load Sense Compensator Pressure Load Sense Compensator Pressure Check 1 Release residual pressure by moving the joystick several times in each direction 2 Install a 5 000 psi gauge into port GP1 of...

Page 172: ...W to increase the pressure reading and counter clockwise CCW to reduce the pressure reading until desired reading is achieved Steering Pressure Steering Pressure Check 1 Release residual pressure by m...

Page 173: ...minal maximum value IMPORTANT There is no adjustment Replace the brake valve at the service brake pedal Pilot Pressure Pilot Pressure Check 1 Release residual pressure by moving the joystick several t...

Page 174: ...pressure compensator clockwise one full turn 2 With engine running at low idle loosen the lock nut on the maximum steering pressure reducing valve at port RV1 on the main manifold valve Port RV1 Figur...

Page 175: ...nnect Pressure Gauge Figure 111 Pump Pressure Adjustment 5 Start the engine and check the gauge Maximum system pressure should immediately be present 3 250 psi 6 If the pressure reading is different t...

Page 176: ...ponents from Housing Sleeve 5 Install spring spacer in spring retainer as shown in figure below Figure 116 Install Spring Spacer 6 Install spring in spring retainer as shown in figure below Figure 117...

Page 177: ...igure below Figure 121 Install Cross Pin 11 From opposite end position accumulator spool in sleeve as shown in figure below Figure 122 Position Accumulator Coil 12 Install outer accumulator spring as...

Page 178: ...in figure below Figure 127 Install O ring 17 Install O ring on other valve sleeve 18 Install valve or valves in transmission case as shown in figure below Figure 128 Install Valve s 19 Position a new...

Page 179: ...The error list is diplayed by pressing any button The errors already viewed appear in black text on a grey background New messags that have not been read yet appear as emphasized grey text on a black...

Page 180: ...jectors and if necessary replace them check connection cable and if necessary repair or replace it 523354 12 Internal hardware monitoring the ECU detects an error of its injector high current output I...

Page 181: ...ecessary repair or replace it if error is not removable change ECU 168 0 1 2 3 or 4 Battery voltage the voltage measured by ECU is out of the target range either too high too low or eratic Check alter...

Page 182: ...e starter at the left side of the engine between the engine and the frame Figure 134 WARNING A second person to assist will be required to complete this procedure 3 Locate the upper and lower bolts se...

Page 183: ...ses Removal 7 Discard defective existing starter 8 Connect all harnesses to the new starter stud and secure them with the nut and washer do not tighten the nut Engine Cable Harness To Glow Plug Harnes...

Page 184: ...eat above steps and re check Bleed Boom Extend Retract Circuit Fully extend and retract boom several times with boom level Bleed Boom Raise Lower Circuit Fully raise and lower the boom several times E...

Page 185: ...l 0 position 2 Shut down the machine 3 Turn the main power disconnect switch off Lock out the switch Cable Track Removal The right hand cable track carries the fork tilt hydraulic hoses The left hand...

Page 186: ...e middle indicator mark is visible between E and F boom extension letters M62330AA Figure 143 M62303AA Figure 144 6 Turn the main power disconnect switch off Lock out the switch 7 From the side access...

Page 187: ...62288AA Figure 147 14 At the side access hole remove the hex nuts from the four bolt studs that secure the cable track bracket to the mount inside the frame 15 Remove the eyebolt from the cable track...

Page 188: ...ant push the hoses towards the front from the side access hole M62305AA Figure 152 If replacing a hydraulic hose inside the cable track With the cable track removed thread the hose through it before i...

Page 189: ...2299AA Figure 155 Install with Mounting Bracket Down 3 Slide the hose ends into the boom making sure they stay above the cable track mount visible through the side access hole They must be above it be...

Page 190: ...both ends of the sleeve If installing auxiliary hoses install the quick disconnect fittings and hose clamp Do not tighten the clamp M62309AA Figure 159 10 Install both T shaped upper and lower suppor...

Page 191: ...Reach in as far as possible to place it M62329AA 7 in 18 cm Figure 162 View Inside Front Access Hole 2 Pull the hoses tight over the block from the front Before tightening ensure the bolts are 5 16 x...

Page 192: ...ccess hole in the front of the boom See Cable Track Installation on page 189 M62287AA 1 2 3 6 7 5 4 Figure 165 Carrier General Assembly 1 Front Access Hole 2 Upper and Lower Guide Brackets 3 Chain Anc...

Page 193: ...ove the jam nuts then back off the main nuts until slack is observed in the chains anchors are loose If the chain anchors are not loosened the hoses inside the boom at the back of the machine would be...

Page 194: ...n The hoses may be under slight tension when rolled over the sheaves M62294AA Figure 170 Hoses Connected to Bulkhead Plate 6 Remove the 4 bolts securing the carrier bulkhead plate to the inside of the...

Page 195: ...ounts Continue to lift slide the assembly out of the boom Carrier Assembly Installation 1 Using an over head lifting device begin sliding the carrier assembly into the boom Lift slide the assembly inw...

Page 196: ...port the end of it then install both T shaped upper and lower guide brackets M62314AA Figure 176 6 Push the carrier assembly the rest of the way in 7 At the back of the machine attach the hydraulic ho...

Page 197: ...vel indicator is at 0 2 Apply park brake and move transmission shifter to neutral 3 Fully retract and lower the boom just enough to gain access to tilt sensor 4 Chock or block wheels to prevent the te...

Page 198: ...ht Indicators Set up button is located on this face next to harness 1 Ensure telehandler is parked on a firm level surface IMPORTANT Use a digital level to ensure frame is level 2 Apply park brake and...

Page 199: ...een LED 7 Both LEDs will turn on solid for 1 2 seconds Results The new zero position has been learned 8 Turn ignition switch to off position and remove key from ignition switch 9 Remove chocks or whee...

Page 200: ...in 1 Frame Level 4 Left Frame Level 4 Right Frame Level Right Wire 28R Pin 7 Frame Level Left Wire 28L Pin 6 Boom UP Enable Wire 28 Pin 5 0 0 0 1 1 1 0 0 0 1 1 1 1 0 0 1 0 1 0 0 1 0 1 1 1 1 1 0 1 0 0...

Page 201: ...side of the axle housing 4 Tighten the screws on both sides of the axle housing on an alternate sequence by 1 4 turn at a time until the park brake releases CAUTION Tighten maximum by one turn 5 Repea...

Page 202: ...before installing a new bearing Refer to the chart below Bearing PN Maintenance Free Size in Min in Max in 235239 1 375 2 1867 2 1877 920767 1 75 2 8110 2 8120 230943 1 75 2 8110 2 8120 230942 2 3 184...

Page 203: ...203 SJ1044 TH SJ1044 THS SJ1056 TH SJ1056 THS SJ1256 THS 230790ABA Bearing Installation Section 5 Procedures Figure 177 Bearing Orientation...

Page 204: ...1056 THS SJ1256 THS 230790ABA Section 5 Procedures A C Diagram Compressor Drier High Pressure side gas Condenser Expansion Valve Evaporator Blower High Pressure side liquid Low Pressure side liquid Lo...

Page 205: ......

Page 206: ...www skyjack com...

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