Skyjack SJ1044 TH User manual

SERVICE
MANUAL
230790ABA
August 2021
ANSI
SJ1044 TH, SJ1044 THS,
SJ1056 TH, SJ1056 THS,
SJ1256 THS
TELEHANDLERS

This manual is based on Serial Number(s):
SJ1044 TH/THS: 87 210 168 & Above
SJ1056 TH/THS: 87 312 009 & Above
SJ1256 THS: 87 410 638 & Above
Please refer to the website (www.skyjack.com) for
other Serial Numbers, most recent Technical Manuals
and USB software.
Parts (North America)
Toll Free: 1-800-965-4626
Toll Free Fax: [phone]
E-mail: [email protected]
Skyjack Australia Pty Ltd.
Unit 1, 35 Honeycomb Drive
Eastern Creek
New South Wales 2766
Australia
Tel: [phone]
Fax: [phone]
Skyjack Brasil
Indaiatuba, SP, Brasil 13347-653
Tel: [phone]
Alameda Júpiter, 710
Loteamento American Park Empresarial
Skyjack Service Center
3451 Swenson Ave. St. Charles,
Phone: [phone]
Toll Free: 1-800-275-9522
Fax: [phone]
Email: [email protected]om
Illinois, 60174 USA
Parts & Service (Europe)
Unit 1 Maes Y Clawdd
Oswestry, Shropshire SY10 8NN UK
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Maesbury Road Industrial Estate

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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA
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
230790ABA
Notes

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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA
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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230790ABA
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
2.11 Floor loading pressure .............................................................40
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 Anti-Cavitation Relief Valve (SJ1256 THS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3.15 Major Components Identification and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3.16 Main Manifold Port Identification .....................................................62
3.17 Enclosed Cab Harness & Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
3.18 Glow Plug Harness & Wiring Diagram .................................................66
3.19 Road Lights Harness & Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.20 Work Lights Harness & Wiring Diagram ................................................68
3.21 Boom Lights Harness & Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
3.22 Beacon Light Harness & Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
3.23 RAS System Schematic and Wiring ...................................................71
3.24 Elevate Telematics Harness .........................................................72
3.25 A/C Harness ......................................................................73
3.26 Transmission Electrical Connections ..................................................74
3.27 Console Harness and Layout 74 HP ...................................................75
3.28 Console Harness Wiring Diagram 74HP ...............................................76
3.29 Console Harness and Layout 107 HP - THS Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
3.30 Console Harness Wiring Diagram 107 HP - THS Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
3.31 Engine Harness 74 HP .............................................................79
3.32 Engine Harness 74 HP Wiring Diagram ................................................80
3.33 Engine Harness Diagram 107 HP - THS Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA
3.34 Engine Harness Wiring Diagram 107 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.35 Chassis Harness ..................................................................83
3.36 Chassis Harness Wiring Diagram .....................................................84
3.37 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
3.38 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH. . . . . . . . . . . . . . . . . . . . .88
3.39 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.40 Electrical Schematic 107 HP, Premium Joystick- SJ1044 TH & SJ1056 TH . . . . . . . . . . . . . . . . . . . . 94
3.41 Electrical Schematic - SJ1256 THS ...................................................97
3.42 Hydraulic Schematic - SJ1044 TH/THS & SJ1056 TH/THS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
3.43 Hydraulic Schematic, Premium Joystick - SJ1044 TH/THS & SJ1056 TH/THS . . . . . . . . . . . . . . . .101
3.44 Hydraulic Schematic - SJ1256 THS ..................................................102
3.45 Hydraulic Schematic for Premium Joystick- SJ1256 THS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.1 Introduction .....................................................................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 Transmission Will Not Engage ...................................................109
4.2-6 No Forward Drive. .............................................................109
4.2-7 No Reverse Drive .............................................................109
4.2-8 No 1st Speed Range ...........................................................110
4.2-9 No 2nd Speed Range ..........................................................110
4.2-10 No Boom Up, Front Steer Mode Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2-11 Front Steer Mode Only .........................................................111
4.2-12 No 4W (Round) Steer Mode .....................................................111
4.2-13 No Crab Steer Mode ...........................................................111
4.2-14 No Boom Up .................................................................112
4.2-15 Frame Will Not Tilt Over 40° With Boom Below 40° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.2-16 No Frame Level ...............................................................114
4.2-17 RAS remains fully locked (RAS indicator remains illuminated) . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.2-18 RAS remains locked ...........................................................118
4.2-19 Function Does Not Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.2-20 Outriggers inoperative .........................................................119
4.3 Hydraulic System .................................................................121
4.3-1 All Controls inoperative .........................................................121
4.3-2 No Boom Functions ...........................................................121
4.3-3 No Carriage Tilt ...............................................................123
4.3-4 No Frame Level ...............................................................124
4.3-5 No Aux. functions .............................................................125
4.3-6 Hard or No Steering ...........................................................125

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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS
230790ABA
4.3-7 Park Brake will not Release .....................................................125
4.3-8 Park Brake Will Not Engage .....................................................126
4.3-9 Service Brake Will Not Engage ...................................................126
4.3-10 Outriggers Inoperative .........................................................126
Section 5 – Procedures ...................................................127
5.1 General .........................................................................127
5.1-1 Safety and Workmanship .......................................................127
5.1-2 Engine and Transmission .......................................................127
5.2 10 Hour or Daily Routine Maintenance ................................................128
5.2-1 Check Engine Oil Level ........................................................128
5.2-2 Check Coolant Level, Radiator and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2-3 Check Transmission Fluid Level ..................................................129
5.2-4 Check Air Cleaner Restriction and Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2-5 Check Hydraulic Oil Level ......................................................130
5.2-6 Drain Fuel/Water Separator ......................................................131
5.2-7 Fuel Tank ....................................................................131
5.2-8 Check Parking Brake ..........................................................131
5.2-9 Check Tire Pressure and Condition ...............................................131
5.2-10 Check Seat Belt and Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.2-11 Check Windshield Washer Fluid 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 Level in Axle Differential Planetary wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.4-3 Check Oil level in Axle differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.4-4 Replace Engine Oil and Filter ....................................................135
5.4-5 Change Engine Fuel filter and Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.4-6 Clean Hydraulic Tank Breather ...................................................138
5.4-7 Torque Axle Mounting Bolts .....................................................138
5.4-8 Inspect Boom Chains ..........................................................139
5.4-9 Check Boom Slide Pad Clearances ...............................................140
5.4-10 Check Boom Chains Tension ....................................................142
5.4-11 Chain Tension Adjustment ......................................................143
5.4-12 E-chain and Hoses Inspection ...................................................144
5.4-13 Grease Axle Pivot Bearings and King Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.4-14 Grease Drive Shaft U-joints and slip joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.4-15 Grease Frame Level Pivot Bushings ...............................................146
5.4-16 Grease Boom Pivot and Boom Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.4-17 Grease Bottom Front & Top Rear Slide Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.5 1000 Hour or Annual Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
5.5-1 Change Hydraulic Oil Filter ......................................................148

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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA
5.5-2 Change Hydraulic Oil and Clean Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.5-3 Change Axle Differential Oil .....................................................149
5.5-4 Change Axle Planetary Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.5-5 Change Engine Coolant ........................................................151
5.5-6 Change Transmission Oil and Filter ...............................................155
5.5-7 Inspect Boom Chains ..........................................................157
5.5-8 Inspect RAS System (Rear Axle Stabilization) Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.6 Non-Routine Maintenance ..........................................................159
5.6-1 Boom Hoses and Sheaves 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 Modulation ............................................................175
5.6-7 Deutz Fault Codes .............................................................179
5.6-8 Starter Replacement Procedure ..................................................182
5.6-9 Bleeding Hydraulic Circuits .....................................................184
5.6-10 Cable Track Replacement .......................................................185
5.6-11 Carrier Assembly Replacement ..................................................192
5.7 Electronic Tilt Switch Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
5.7-1 Tilt Switch Replacement ........................................................197
5.7-2 Reprogramming Existing Tilt Switch ...............................................198
5.7-3 Test and Verify Tilt Circuit .......................................................199
5.8 Park Brake Release ...............................................................201
5.9 Bearing Installation ...............................................................202
5.10 A/C Diagram .....................................................................204

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SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS
230790ABA
Notes