Skyjack SJ1044 THS User manual

SERVICE
MANUAL
190130AG
January 2021
ANSI
SJ1044 TH, SJ1044 THS,
SJ1056 TH, SJ1056 THS,
SJ1256 THS
TELEHANDLERS
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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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3
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG
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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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG
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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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS190130AG
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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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG
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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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS190130AG
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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11
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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12
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS190130AG
Section 1 – Scheduled Maintenance Maintenance and Inspection Schedule
1.2 Maintenance and
Inspection Schedule
The actual operating environment of the work platform
governs the use of the maintenance schedule. The
inspection points covered in Table 1.2. Maintenance
and lnspection Checklist, indicates the areas of the
telehandler to be maintained or inspected and at what
intervals the maintenance and inspections are to be
performed.
1.2-1 Owner’s Annual Inspection Record
It is the responsibility of the owner to arrange quarterly
and annual inspections of the telehandler. Table 1.1.
Owner’s Annual lnspection Record is to be used for
recording the date of the inspection, owner’s name,
and the person responsible for the inspection of the
work platform.
1.2-2 Replacement Parts
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and
dimensions different from original parts will affect
stability of the Telehandler and must not be used
without manufacturer’s consent.
All replacement tires must be of the same size and
load rating as originally supplied tires; to maintain
safety and stability of Telehandler.
Consult SKYJACK’s Service Department for optional
tires specifications and installation.
WARNING
Any unit that is 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 be performed by
personnel who are trained and qualified to service this
Telehandler.
All maintenance and service procedures should be
performed in a well lighted and well ventilated area.
Anyone operating or servicing this Telehandler
must read and completely understand all operating
instructions and safety hazards in this manual and
operating manual.
All tools, supports and lifting equipment to be used
must be of proper rated load and in good working
order before any service work begins. Work area
should be kept clean and free of debris to avoid
contaminating components while servicing.
Ensure personnel are clear from under unsupported
components/systems that are at risk of movement
during maintenance.
All service personnel must be familiar with employer
and governmental regulations that apply to servicing
this type of equipment.
Keep sparks and flames away from all flammable or
combustible materials.
Properly dispose of all waste material such as
lubricants, rags, and old parts according to the
relative law provisions obtaining in the country.
Before attempting any repair work, disconnect the
main power conenctors.
Keep personnel clear of components, systems or
unsupported loads that may move unexpectedly
during maintenance procedures.
Preventive maintenance is the easiest and least
expensive type of maintenance.
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13
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG
Hydraulic System & Component Maintenance and Repair Section 1 – Scheduled Maintenance
1.3 Hydraulic System &
Component Maintenance
and Repair
The following points should be kept in mind when
working on the hydraulic system or any component:
WARNING
Escaping fluid from a hydraulic pressure leak can
damage your eyes, penetrate the skin and cause
serious injury. Use proper personal preotection at
all times.
1. Any structure has limits of strength and
durability. To prevent failure of structural parts of
hydraulic components, relief valves which limit
pressure to safe operating values are included in
the hydraulic circuits.
2. Tolerance of working parts in the hydraulic
system is very close. Even small amounts of dirt
or foreign materials in the system can cause
wear or damage to components, as well as
general faulty operation of the hydraulic system.
Every precaution must be taken to assure
absolute cleanliness of the hydraulic oil.
3. Whenever there is a hydraulic system failure
which gives reason to believe that there are
metal particles or foreign materials in the system,
drain and flush the entire system and replace the
filter cartridges. A complete change of oil must
be performed under these circumstances.
4. Whenever the hydraulic system is drained,
check the magnets in the hydraulic reservoir for
metal particles. If metal particles are present,
flush the entire system and add a new change
of oil. The presence of metal particles also may
indicate the possibility of imminent component
failure. A very small amount of fine particles is
normal.
5. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a
funnel when necessary 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. When removing any hydraulic component,
be sure to cap and tag all hydraulic lines
involved. Also, plug the ports of the removed
components.
7. All hydraulic components must be disassembled
in spotlessly clean surroundings. During
disassembly, pay particular attention to
the identification of parts to assure proper
reassembly. Clean all metal parts in a clean
mineral oil solvent. Be sure to thoroughly clean
all internal passages. After the parts have been
dried thoroughly, lay them on a clean, lint-free
surface for inspection.
8. Replace all O-rings and seals when overhauling
any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
amounts of petroleum jelly to hold O-rings in
place during assembly.
9. Be sure to replace any lost hydraulic oil when
completing the installation of the repaired
component, and bleed any air from the system
when required.
10. All hydraulic connections must be kept tight. A
loose connection in a pressure line will permit
the oil to leak out or air to be drawn into the
system. Air in the system can cause damage
to the components and noisy or erratic system
operation.
1.3-1 Maintenance Hints
Three simple maintenance procedures have the
greatest effect on the hydraulic system performance,
efficiency and life. Yet, the very simplicity of them may
be the reason they are so often overlooked. They are
simply these:
1. Change filters annually. The filters will need
to be changed more often depending on the
operating conditions. Dirty, dusty, high moisture
environments may cause the hydraulic system
to be contaminated more quickly.
2. Maintain a sufficient quantity of clean hydraulic
oil of the proper type and viscosity in the
hydraulic reservoir.
3. Keep all connections tight.
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14
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS190130AG
Section 1 – Scheduled Maintenance About this Section
1.4 About this Section
This section contains the maintenance and inspection
schedule that is to be performed.
References are made to the procedures in Section
5 that outline detailed step-by-step instructions for
checks and replacements.
1.4-1 Service Bulletins
Before performing any scheduled maintenance
inspection procedure, refer to service bulletins found
in our web site: www.skyjackinc.com for updates
related to service and maintenance of this Telehandler.
1.4-2 Maintenance and Inspection
Death or injury can result if the Telehandler is not kept
in good working order. Inspection and maintenance
should be performed by competent personnel who
are trained and qualified on mantenance of this
Telehandler.
WARNING
Failure to perform each procedure as presented
and scheduled may cause death, serious injury or
substantial damage.
NOTE
Preventive maintenance is the easiest and least
expensive type of maintenance.
▪Unless otherwise specified, perform each
maintenance procedure with the Telehandler 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
components before operating Telehandler.
▪Keep records on all inspections.
1.4-3 Maintenance Instructions
This manual consists of four schedules to be done for
maintaining on an Telehandler. Inspection schedule
frequency is shown below:
Issue or Symptom
PDI/Frequent B
Perform PDI prior to each
delivery, or Frequent
Inspection every 3 months
or 150 hours.
Annual B + C
Perform Scheduled
Maintenance Inspections
every year.
Additional *Perform at time sensitive
maintenance intervals.
▪Make copies of the maintenance and inspection
checklist to be used for each inspection.
▪Check the schedule on the checklist for the type
of inspection to be performed.
▪Place a check in the appropriate box after each
inspection procedure is completed.
▪Use the maintenance and inspection checklist
and step-by-step procedures in Section 1 to
perform these inspections.
▪If any inspection receives a fail, tag and remove
the Telehandler from service.
▪If any Telehandler component(s) has been
repaired, an inspection must be performed again
before removing the tag. Place a check in the
repair column.
Legend
Pass P
Fail F
Repaired R
Not applicable N/A
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15
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG
About this Section Section 1 – Scheduled Maintenance
Serial Number:
Model:
Hourmeter Reading: Operator's Name (Printed):
Date:
Time: Operator's Signature:
INSPECTION FREQUENCY
P- PASS DAILY
F- FAIL WEEKLY or 40 HOURS
R- REPAIRED QUARTERLY OR 250 HOURS
ANNUALLY or 1000 HOURS
P F R P F R
Engine Compartment
256C
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.8 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every week or 40 hrs. Refer to Section 1 of this manual.
C - Perform Scheduled Maintenance Inspection every 3 months or 250 hours. Refer to Section 1 of this manual.
D - Perform Scheduled Maintenance Inspection every year or 1000 hours. Refer to Section 1 of this manual.
Note: Make a copy of this page or visit the Skyjack web site: www.skyjack.com for a printable copy.
A,C
A
A
A
B
A
A
A
Fuel Leaks
A,C
Change Oil Filters
C,DDrain Fuel/Water Separator
A,C
A
A
A
A
A
A,DHydraulic Oil
A
Hydraulic Tank
Operator's Cab
Grease Fittings
Quick Attach apron
Grease Fittings on Boom Assembly
Inner and Outer Shaft Seals
Hub Seals
Function Tests
Operator's Cab Controls
Seat
Pedals
ALifting Attachment(s)
A
A
A
BGrease Fittings on Frame
A
Fork Bars and Locks
AForks
Hub Oil
D
Differential Oil D
Pinion Seal
Test Starter Operation
Test Horn
Test Lights (If Equipped)
Test Boom and Attachment Functions
Test Frame Leveling and Level Indicator
AOperator's Cab Controls
AManual
Foam-filled Tires A
Table 1.1 MAINTENANCE AND INSPECTION CHECKLIST
Each item shall be inspected using the appropriate section of the Skyjack operating manual.
As each item is inspected, write the appropriate grade in the box.
Inspection Schedule
Daily
A
Weekly or 50 Hours A + B
Quarterly or 250 Hours A + B + C
Annually or 1000 Hours A + B + C + D
Schedule Schedule
Schedule Maintenance Inspections
Labels
A
Boom
Electrical
A
Main pins and bushings
C,D
Mirrors A
subcarriage pins and bushings C,D
Hydraulic A
Rollers and Tracks C,D
Cylinders
A,B,C,D
Slide Pads B,C,D
Frame
Chain(s)
A,C
Wheel/Tire Assembly A
Boom Angle Indicator
A
Battery and Cables
A
Proximity Sensors A
Engine Intake Air Filter A,B,C
Air-filled Tires A
Tilt Switch A,B,C,D
Test Frame Leveling and Boom Interlock
Hydraulic Pump A
Belts and Hoses
Change Fuel Filter
Charge Accumulators (if equipped)
Operate and Check Shifting A
Drive Axles
A
A
A
Transmission
King Pins
C,D
Check Drive Shafts and U-Joints C,D
Axle Mounting Pins and Bushings C,D
Axle Housing A
Steer Cylinder Assembly
A
Steer Linkage
A
Fuel Tank
Engine Oil
Engine Coolant Level
Test Accelerator Pedal A
Test Reverse Alarm, Driving & Service Brake A
Test Steering
A
Test Positive Shut-off Valve (if equipped)
A
Test Parking Brake A
Test Outriggers (If Equipped) A
Check for Leaks A
Change Transmission Oil
D
Change Oil Filter
D




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16
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS190130AG
Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections
1.5 Scheduled Maintenance
Inspections
Before performing the visual and daily maintenance
inspections, ensure that the telehandler is parked on a
firm level surface.
Begin the visual and daily maintenance inspections
by checking each item in sequence for the conditions
listed in this section.
WARNING
To avoid injury, do not operate a telehandler until
all malfunctions have been corrected.
WARNING
To avoid possible injury, ensure telehandler power
is off during your visual and daily maintenance
inspections.
NOTE
While performing visual and daily inspections
in different areas, be aware to also inspect all
switches, electrical and hydraulic components.
1.5-1 Labels - A
Refer to the labels section in this manual 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 operation of all gauges.
▪Inspect the following areas for chafed, corroded
and loose wires:
▪boom wiring harnesses - A
▪frame wiring harnesses - A
▪cab wiring harnesses - A
Ensure electrical devices are properly secured with no
signs of visible damage. Ensure there are no loose or
missing parts.
1.5-3 Mirrors - A
Ensure mirrors are properly secured with no signs of
visible damage.
1.5-4 Hydraulic
Maintaining the hydraulic components is essential to
good performance and service life of the telehandler
Perform a visual inspection and check for leaks around
the following areas:
▪hydraulic tank, filter(s), fittings, hoses, pump, and
frame surface
▪all hydraulic cylinders - A
▪all hydraulic manifolds - A
▪underside of the frame - A
▪ground area under the telehandler - A
Boom Assembly
Engine
Compartment Operator’s
Cab
Forks/Lifting
Attachment
Side-View
Mirror Frame
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17
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance
1.5-5 Cylinders - A
Ensure all cylinders are properly secured and there is
no evidence of leakage.
Grease weekly and check pins and bushings to ensure
there is no evidence of damage.
Refer to section 5.3 for greasing procedure.
1.5-6 Frame
▪Wheel/Tire Assembly - A
Tire and/or wheel failure could result in a telehandler
tipover. Component damage may also result if
problems are not discovered and repaired in a timely
fashion.
▪Check all tire treads and sidewalls for cuts or
cracks that expose the cord plies.
▪Check for punctures, holes and unusual wear.
▪Check each wheel rim for damage and cracked
welds.
▪Check each lug nut for proper torque to ensure
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 Tires - A
To safeguard maximum stability, achieve optimum
telehandler handling and minimize tire wear, it is
essential to maintain proper pressure in all air-filled
tires. Refer to tire pressure label.
▪Check each tire with an air pressure gauge and
add air as needed.
WARNING
An improperly inflated tire may cause death or serious
injury.
▪Foam-filled Tires - A
Tire condition can vary significantly depending on
telehandler use, job site environment and preventative
maintenance measures. Inspect tires periodically and
pay extra attention to the following:
▪Check for punctures or holes. Ensure they do not
exceed 1 inch in diameter.
IMPORTANT
Do not intermix foam-filled and air-filled tires.
Frame Level
Cylinder
Rear Axle
Assembly
Wheel/Tire
Assembly
Lug Nut Front & Rear
Drive Shafts
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18
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS190130AG
Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections
▪Drive Axles - A
Ensure drive axles are properly secured, there are
no loose or missing parts, all fittings and hoses are
properly tightened and there is no evidence of oil
leakage.
▪Steer Cylinder - A
Ensure steer cylinders are properly secured, there
are no loose or missing parts, all fittings and hoses
are properly tightened and there is no evidence of
hydraulic oil leakage.
▪Planetary Wheel Ends - C
Check the planetary wheel ends oil level and add as
required. Ensure there is no evidence of oil leakage.
▪Axle Differential - C
Check the axle differential oil level and add as required.
Ensure there is no evidence of oil leakage.
▪Battery - A
Proper battery 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
Explosion hazard. Keep flames and sparks away.
Do not smoke near batteries.
WARNING
Battery acid is extremely corrosive - Wear proper
eye and facial protection as well as appropriate
protective clothing. If contact occurs, immediately
flush with cold water and seek medical attention.
1. Check battery case for damage.
2. Clean battery terminals and cable ends
thoroughly with a terminal cleaning tool or wire
brush.
3. Ensure all battery connections are tight.
4. If applicable, check battery fluid level. If plates are
not covered by at least 1/2” (13 mm) of solution,
add distilled or demineralized water.
5. Replace battery if damaged or incapable of
holding a lasting charge.
WARNING
Use original or manufacturer-approved parts and
components for the telehandler.
Battery
Front Axle
Assembly
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19
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance
▪Engine Intake Air Filter - A
▪Ensure there are no loose or missing parts and
there is no visible damage.
▪Ensure air cleaner vaccuator valve is free from
dirt or dust by squeezing the valve lips.
▪Check air cleaner service indicator and replace
filter element if needed. Refer to section 5.2-4
▪Fuel Tank - A
IMPORTANT
Before using your telehandler ensure there is
enough fuel for expected use.
▪Ensure fuel filler cap is secure.
▪Ensure tank shows no visible damage and no
evidence of fuel leakage.
▪Fuel Leaks - A
Failure 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 fittings
▪fuel pump
▪fuel filter
▪fuel tank
WARNING
Engine fuels are combustible. Inspect the
telehandler in an open, well-ventilated area away
from heaters, sparks and flames. Always have an
approved fire extinguisher within easy reach.
Refer to section 5.4-5 for fuel filter replacement
procedure
▪DEF Tank (if equipped) - A
IMPORTANT
Before using your telehandler ensure there is
enough Diesel Exhaust Fluid for expected use.
▪Ensure tank cap is secure.
▪Ensure DEF tank shows no visible damage
and no evidence of leakage.
▪Hydraulic Oil Tank
▪Ensure hydraulic filler cap is secure.
▪Ensure tank shows no visible damage and no
evidence of hydraulic leakage.
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20
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS190130AG
Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections
Radiator
Fill Cap
Fan Belts
Fuel Filter
Hydraulic
Oil Pump
Transmission
Oil Dipstick
Engine
Oil Dipstick
Engine
Oil Filter
Fuel/Water
Separator
▪Hydraulic Oil - A, D
▪Be sure that the boom is in the lowered and
stowed position, and then visually inspect the
sight gauge located at the rear of the hydraulic
oil tank.
▪Add clean hydraulic oil as required. Refer to
section 5.5-2 for hydraulic oil change.
1.5-7 Engine Compartment
Ensure compartment cover is secure and in proper
working order.
WARNING
Beware of hot engine components.
▪Engine Oil Level on dipstick - A, C
▪Maintaining the engine components is essential
to good performance and service life of the
telehandler.
▪Oil 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
radiator cap when hot. Always open fill cap slowly.
▪Check coolant level on radiator.
▪Add coolant as required.
Refer to section 5.5-5 for engine coolant change
procedure.
▪Belts - A
▪Ensure belts are in good working condition
and have correct tension. Replace if belts are
cracked, frayed, or have chunks of material
missing. Refer to service manual for proper
replacement procedure.
▪Hydraulic Pump - A
▪Ensure there are no loose or missing parts and
there is no visible damage.
▪Ensure all bolts are properly tightened.
▪Ensure all fittings and hoses are properly
tightened and there is no evidence of hydraulic
oil leakage.
▪Fuel/Water Separator “ ” - C, D
Ensure there are no loose or missing parts and
there is no visible damage.
▪Ensure all fittings and hoses are properly
tightened and there is no evidence of fuel leaks.
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21
SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance
▪Drain water by opening water drain plug at
bottom of filter. Close tightly after inspection.
Refer to section 5.4-5 for fuel/water separator
replacement procedure
1.5-8 Transmission
Ensure transmission shifter is working properly and
there is no evidence of damage.
▪Check oil level on dipstick “ ” - D
▪With park brake engaged and transmission
shifter in “N” Nuetral position, start engine.
▪Oil level should be in the ‘safe’ zone. Add oil as
needed. Refer to section 5.5-6 for transmission
oil change procedure.
1.5-9 Boom - A
▪Ensure there are no loose or missing parts and
there is no visible damage.
▪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 no evidence of hydraulic leakage.
▪Boom Angle Switches - A
▪Ensure boom angle switches are properly
secured with no signs of visible damage.
▪Slide Pads - B, C, D
▪Ensure all bolts are tight, there is no visible
damage to the slide pads and that no parts are
missing.
▪Chain - A, C
▪Ensure there are no loose or missing parts and
there is no visible damage
▪Boom Angle Indicator - A
▪Ensure all bolts are tight, and there is no visible
damage and indicator swings freely.
1.5-10 Lifting Attachment - A
▪Ensure there are no loose or missing parts and
there is no visible damage.
▪Ensure attachment is properly positioned and
secured. (refer to Section 2.13 for attachments
installation and operation).
Boom Angle
Switch
Fork Carriage
Attatchment
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