Skyjack SJ1044 TH Manual
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Skyjack SJ1044 TH Manual

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

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  • Page 1 SERVICE MANUAL SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS TELEHANDLERS 230790ABA August 2021 ANSI...
  • Page 2 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.
  • Page 3 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. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 4 Notes SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 5: Table Of Contents

    Recommended Fluids/Lubrications ........... 30 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 6 Engine Harness Diagram 107 HP - THS Models ......... 81 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 7 Hydraulic Schematic - SJ1044 TH/THS & SJ1056 TH/THS ....... .
  • Page 8 Change Hydraulic Oil Filter ............148 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 9 A/C Diagram ..............204 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 10 Notes SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 11: Section 1 - Scheduled Maintenance

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

  • Page 12: Maintenance And Inspection Schedule

    Any unit that is damaged or not operating properly during maintenance procedures. must be immediately tagged and removed from Preventive maintenance is the easiest and least service until proper repairs are completed. expensive type of maintenance. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 13: Hydraulic System & Component Maintenance And Repair

    6. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also, plug the ports of the removed components. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 14: About This Section

    Disconnect the batteries by disconnecting the ▪ Pass main power connectors. Fail Repair any damaged or malfunction ▪ components before operating Telehandler. Repaired Keep records on all inspections. ▪ Not applicable SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 15 Hourmeter Reading: Operator's Name (Printed): Date: Time: Operator's Signature: 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 FREQUENCY Inspection Schedule ...

  • Page 16: Scheduled Maintenance Inspections

    - ▪ Refer to the labels section in this manual and determine ground area under the telehandler - ▪ that all labels are in place and are legible. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 17: Cylinders - A

    Refer to section 5.4-1 for torque procedure. IMPORTANT Do not intermix foam-filled and air-filled tires. WARNING If any tire does not meet the criteria outlined above, remove telehandler from service and replace wheel/tire immediately. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 18 WARNING Explosion hazard. Keep flames and sparks away. Do not smoke near batteries. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 19 Perform a visual inspection around the following areas: hoses and fittings ▪ fuel pump ▪ fuel filter ▪ fuel tank ▪ SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 20: Engine Compartment

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

  • Page 21: Transmission

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

  • Page 22: 11 Grease Fittings - B

    Structure (ROPS/FOPS) - Ensure manual is legible and in good condition. ▪ Ensure there is no visible damage. Always return manual to the manual storage ▪ ▪ box after use. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 23 Ensure capacity charts are in place and are ▪ legible. WARNING Do not operate the telehandler if capacity charts are missing or not legible. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 24: Function Tests

    NOTE All-function motion alarm should sound while operating any boom and drive function SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 25: Section 2 - Maintenance Tables

    Section 2 – Maintenance Tables SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 26: Standard And Optional Equipment

    48" / 60" / 72" Side-Tilt Fork Carriages 72" Swing Carriage 2 ft. Jib Boom 1.75 Cu. Yd. Bucket Loader Attachment 12 ft. Truss Boom 15 ft. Truss Boom 1340AA SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 27 Enclosed Operator's Cab with A/C Fire Extinguisher Flashing Beacon Foam Filled Tires Four-Wheel Fenders Pintle Hitch Positive Air Shut-off System Premium Multi-function Joystick Reserve Brake System Road/Work/Boom Lights 1230AA SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 28: Specifications And Features

    Carriage forward tilt 92.5° * Engine Idle Speed is measured with 5% droop when in gear. 1341AB ** Add 400 lb (181.437 kg) to the maximum weight for machines with CVT SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 29 2.25 in x 5 in x 48 in (standard tapered forks) Carriage rollback 20° Carriage forward tilt 92.5° * Engine idle speed is measured with 5% droop when in gear. 1231AA SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 30: Recommended Fluids/Lubrications

    Doing so can severely damage hydraulic components. A full hydraulic oil system flush must be performed prior to adding a new type of hydraulic oil. Consult Skyjack service department. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 31 Doing so can severely damage hydraulic components. A full hydraulic oil system flush must be performed prior to adding a new type of hydraulic oil. Consult Skyjack service department. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 32: Tire/Wheel Specifications

    Failure to comply with this requirement will reduce the life of the differentials and reduce overall mobility of telehandler. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 33: Pressure Settings

    NOTE All pressures to be checked with engine running at idle unless specified otherwise. NOTE Service brake pressure is variable. The value provided above is the maximum nominal value. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 34: Standard Hose Numbering System

    REUSABLE, FEMALE, 37° JIC, SWIVEL NO FITTING 300 PSI LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R13 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R4 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 35 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19 LONG 90°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R15 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 36: Torque Specifications For Fasteners (Us)

    1979 4284 3200 1/2-20 ft-lb 2200 1640 3560 2660 1 1/2-12 1329 2983 2224 4827 3606 NOTE: Lubed includes lubricants such as lubrizing, oil, grease, or uncured Loctite. 1374AA SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 37: Torque Specifications For Fasteners (Metric)

    1990 1493 2849 2137 ft-lb 1886 1415 2699 2024 M36 x 4.00 2557 1918 3659 2744 NOTE: Lubed includes lubricants such as lubrizing, oil, grease, 1375AB or uncured Loctite. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 38: Torque Specifications For Hydraulic Couplings & Hoses

    1/4" 6.75 1/4" 3/8" 3/8" 1/2" 27.66 1/2" 5/8" 46.33 5/8" 3/4" 72.33 3/4" 1" 100.5 1" 1 1/4" 101.5 1 1/4" 1 1/2 1 1/2 2" 2" 1276AA SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 39: Air Conditioner Temperature/Pressure Chart

    Need service, possibly blockage of the High expansion valve or orifice tube Need service, possibly faulty High compressor High High System overcharged.* *It is illegal to vent R-134a refrigerant into the atmosphere. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 40: Floor Loading Pressure

    Base Area = Length x Width Wheel Load Weight of MEWP + Capacity LCP = OFL = Foot Print Area Base Area Foot Print Area Base Width Base Length SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 41: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 42: Electrical Symbol Chart

    SINGLE THROWN LEVEL SENSOR SWITCH RELAY DOUBLE POLE TEMPERATURE SINGLE POLE DOUBLE POLE DOUBLE THROW SWITCH DOUBLE THROW SINGLE THROW RELAY RELAY RELAY TRIPLE POLE RHEOSTAT DIODE DOUBLE THROW RELAY SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 43: Hydraulic Symbol Chart

    THREE POSITION TWO POSITION TWO POSITION FOUR WAY TWO WAY THREE WAY VALVE CLOSED CENTER NORMALLY CLOSED PORT OPEN VALVE PRESSURE PILOT LINES Dashed MAIN LINES Solid TRANSDUCER SERVO SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 44: Electrical Components Parts List

    9-156203 FUSE, Work lights (10A) 9-156204 FUSE, Road lights (15A) 9-156202 FUSE, Turn/Hazard/Brake lights (5A) 9-156203 FUSE, Boom lights (10A) 9-156203 FUSE, Front & Top Wiper (10A) Not used. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 45 D26B 9-102921 DIODE, Console harness 9-102921 DIODE, Console harness D252 9-102921 DIODE, Console harness D252-1 9-102921 DIODE, Console harness D252A-1 9-102921 DIODE, Console harness D252A-2 9-102921 DIODE, Console harness SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 46 COIL, #8 4H-223 9-159821 COIL, #8 4H-223-1 9-159821 COIL, #8 4H-47 9-159821 COIL, #8 4H-47-1 9-159821 COIL, #8 3H-26 9-168057 COIL, #10 4H-217 9-168057 COIL, #10 4H-218 9-168057 COIL, #10 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 47: Hydraulic Components Parts List

    VALVE, Counter-balance - 4000PSI 9-206229 VALVE, Counter-balance -225 - SJ1256 THS 9-149366 VALVE, Counter-balance - 4000PSI 9-206181 VALVE, Counter-balance -350 - SJ1256 THS CB10 9-149366 VALVE, Counter-balance - 4000PSI SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 48 JOYSTICK, Hydraulic 9-922265 JOYSTICK, Hydraulic 9-169031 MANIFOLD, Main 9-205190 MANIFOLD, Main - SJ1256 THS 9-169033 MANIFOLD, Auxiliary 9-205202 MANIFOLD, Auxiliary - SJ1256 THS 9-190357 MANIFOLD, Reserve brake 9-198734 MANIFOLD, RAS SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 49 VALVE, Proportional, pilot operated 9-206190 VALVE, Proportional-pilot operated - SJ1256 THS 9-191793 VALVE, Proportional, pilot operated 9-206191 VALVE, Proportional-pilot operated - SJ1256 THS 9-191795 VALVE, Solenoid 4W3P 9-191796 VALVE, Solenoid 4W2P SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 50 VALVE PROPORTIONAL AUX. 12K - SJ1256 THS 9-205813 VALVE PROPORTIONAL AUX. 12K - SJ1256 THS 9-213997 COIL, DROP IN -EHPR98-T33 12VDC (Option) 9-213997 COIL, DROP IN -EHPR98-T33 12VDC (Option)` SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 51: Hydraulic Pump And Return Filter Ports Identification

    Compesator Adjuster Port X to Port LS on Main Manifold Port S Port P to Port P12 To Hyd. Tank on Main Manifold Inlet Outlet Return Filter M190807-1 M191415AA-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 52: Steering Control Unit Ports Identification

    Main Manifold Port P to Port CF on Main Manifold Port LS to Port Steer on Optional Reserve Brake Manifold Port R to Por ORBR on Main Manifold M191585-SM SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 53: Service Brake Actuator (Brake Pedal) Ports Identification

    Port P to Port A1 on optional Reserve Brake Manifold Port P to Port A1 Port P to Port SB on optional Reserve on Main Manifold Brake Manifold M191582-SM SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 54: Auxiliary Block Ports Identification

    Main Manifold to Bulkhead #7 Port AUX T 4H-233 to Port AUX T Solenoid Valve on Main Manifold Port AUX EF1 to Port AUX EF1 on Main Manifold M190791AB-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 55: Joystick Port Identifications

    Port 1 to Port J1 on Main Manifold Port T to Port DR2 on Main Manifold Port 3 to Port J3 on Main Manifold Port 4 to Port J4 on Main Manifold M190356-1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 56: Premium Joystick Port Identifications

    Port 1 to Port J1 on Main Manifold Port T to Port DR2 on Main Manifold Port 3 to Port J3 on Main Manifold Port 4 to Port J4 on Main Manifold M1344040201_JS SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 57: Premium Joystick Manifold Port Identifications

    Carriage Up Port A to Carriage Down Port on Main Manifold Port B to Carriage Up Port Port D to tee fitting GP2 on Main Manifold on Main Manifold 213749AA-SM SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 58: Rear Axle Stabilization Manifold Port Identification

    RAS Restrict Relief Valve Port RAST to Port RAST on Main Manifold 2H-65 RAS Restrict Port RASP to Port RASP Relief Valve on Main Manifold CV15 Check Valve M198734AB-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 59: Outrigger Manifold Port Identifications

    Main Manifold Port R2 to Port R Port E2 to Port E on Left Outrigger on Left Outrigger Cylinder Cylinder Port DR4 to Port DR4 on Main Manifold M191835-S SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 60: Anti-Cavitation Relief Valve (Sj1256 Ths Only)

    Anti-Cavitation Relief Valve (SJ1256 THS Only) 3.14 Anti-Cavitation Relief Valve (SJ1256 THS Only) RV4-1 Anti-Cavitation Relief Valve Port P2 to Port T2 on Main Manifold Port P1 to Port CA on Main Manifold M206115AA SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 61: Major Components Identification And Location

    Steering Control Unit Rear Steer Cylinder Frame Level Cylinder Left Outrigger Cylinder CB6 & CB7 Right Outrigger Counter Balance Cylinder Valves Front Steer Service Brake Cylinder Actuator (Pedal) M190530-Major Components SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 62: Main Manifold Port Identification

    Brake Pedal Solenoid Valve Port FB to Port CB7 Port TA to on Frame Level Bulkhead #4 Pressure Cylinder Port FA to Port CB6 Compensator on Frame Level Cylinder M169032AF-S1-12k SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 63 Reserve Port BR2 Check Valve Brake Manifold to Front Axle Check Valve Port DR3 to Port T on optional Reserve Brake Manifold Pressure Switch Relief Valve M191300AG-S2-12k SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 64 Solenoid Valve Solenoid Valve Telescopic Solenoid Valve 4H-217 & 4H-218 Steer Function Solenoid Valve Boom Function Solenoid Valve Frame Tilt Solenoid Valve 4H-223-1 Frame Level Right Solenoid Valve M169032AF-S3 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 65: Enclosed Cab Harness & Wiring Diagram

    208A-16 DK PE 05L-16 PE 260-16 TN/WH 208-16 DK PE 259-16 LT YW/PE 00-16 WH 259A-16 LT YW/PE 05L-16 PE 05L-16 PE SPL 05N 05N-16 PE SPL 00 LIGHT M191472AC-S SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 66: Glow Plug Harness & Wiring Diagram

    11-18 BK 11-18 BK TO 86 11A-18 BK 11A-18 BK TO 85 11C-18 RD 11C-10 RD 11C-10 RD 11C-8 RD TO 87 11B-8 RD 11B-8 RD TO 30 M191468AB-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 67: Road Lights Harness & Wiring Diagram

    00-16 WH WHITE HARNESS SPL 251B 251B-16 PK/BL 250B-16 LT BL/BK SPL 250B 15-16 BL 15-16 BL 271-16 BE/YW SPL 271 SPL15 271A-16 BE/YW SPL 271A LEFT BACKUP LIGHT M190595AA-S SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 68: Work Lights Harness & Wiring Diagram

    SPL00 SPL246 246-14 LT GN/PK 247-14 LT GN/WT 247-14 LT GN/WT LEFT REAR WORKLIGHT SPL247 00-14 WH ON CAB 00-14 WH REAR GND. RIGHT REAR WORKLIGHT ON FRAME M190231AB-S SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 69: Boom Lights Harness & Wiring Diagram

    3.21 Boom Lights Harness & Wiring Diagram GROUND. TO CHASSIS BOOM LIGHTS HARNESS 00-14 WH 256-14 TN/BK BOOM LIGHTS SPL00 00-14 WH 00-12 WH GND. 256-14 TN/BK 256-14 TN/BK TO CHASSIS HARNESS 256-14 TN/BK M190288AC-S SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 70: Beacon Light Harness & Wiring Diagram

    3.22 Beacon Light Harness & Wiring Diagram GROUND BEACON BEACON LIGHT OPTION GND ON CHASSIS 00-16 WH 5D-16 PE 5D-16 PE BEACON (OPT) M191613AB-S SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 71: Ras System Schematic And Wiring

    SPL00 RAS UNLOCK RAS UNLOCK SPL65 RAS RESTRICT RAS RESTRICT J114 J115 RAS UNLOCK J114 J115 J116 J117 RAS RESTRICT RAS RESTRICT RAS UNLOCK RAS UNLOCK RAS UNLOCK M199375AB-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 72: Elevate Telematics Harness

    PIN 9 - 57D-BROWN/GREEN PIN 10 - PLUGGED 57D-BRN/GRN-16-TEW PIN 11 - 221-DARK GREEN/TAN 57-BRN/GRN-16-TEW 221-DK GRN/TAN-16-TEW PIN 12 - 26B-BLUE/YELLOW D57B 57E-BRN/GRN-16-TEW 26B-BLU/YEL-16-TEW 03B-GRN/PUR-16-TEW 03B-GRN/PUR-16-TEW HARNESS SCHEMATIC M221451AC-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 73: A/C Harness

    3.25 A/C Harness PRESS. SW. TO HARNESS, HEATER & AC COMPRESSOR TO ENCL. CAB 268-16 DBE/OE 269-16 DBE/RD HARNESS COMPRESSOR M191598AB - S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 74: Transmission Electrical Connections

    3.26 Transmission Electrical Connections Reverse Forward 1st Gear 2nd Gear 3.26 Transmission Electrical Connections SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 75: Console Harness And Layout 74 Hp

    220-16 DK GN/WE 57D-18 BN/GR 60-16 WH/BE 00-16 WH 57E-16 BN/GR D57B 05T-16 PE 57-16 BN/GR 65A-16 YW/PK 60-16 WH/BE 65-16 YW/PK 3.27 Console Harness and Layout 74 HP M216785AF-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 76: Console Harness Wiring Diagram 74Hp

    RELAY RELAY (OPT) CHASSIS RUNNING RELEASE SHUTOFF (OPT) RAS RESTRICT MODE 222CR 224CR 403ACR 5JCR 250ACR 251ACR 77CR 05CR ENABLE RELAY 223ACR M216785AF-S1 3.28 Console Harness Wiring Diagram 74HP SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 77: Console Harness And Layout 107 Hp - Ths Models

    05T-16 PE 57E-16 BN/GR D57B 60-16 WH/BE 65A-16 YW/PK 57-16 BN/GR 60B-16 WH/BE 60-16 WH/BE 60-16 WH/BE 65-16 YW/PK M216786AF-S2 3.29 Console Harness and Layout 107 HP - THS Models SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 78: Console Harness Wiring Diagram 107 Hp - Ths Models

    RELEASE SHUTOFF (OPT) 220CR 222CR 224CR 403ACR 5JCR 250ACR 251ACR 77CR 05CR RAS RESTRICT MODE ENABLE RELAY 223ACR 3.30 Console Harness Wiring Diagram 107 HP - THS Models M216786AF-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 79: Engine Harness 74 Hp

    19 - 39 - 59 - 79 - 20- A20-16 WH 40- A40-18 BK 20 - 40 - 60 - 80 - 3.31 Engine Harness 74 HP M232310AB - S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 80: Engine Harness 74 Hp Wiring Diagram

    TO POSI TO CONSOLE HARNESS TO CONSOLE TO PRE-HEAT TO CHASSIS HARNESS FUEL PUMP RELAY TO BATTERY TO WATER HARNESS SENSOR TRANSMISSION 3.32 Engine Harness 74 HP Wiring Diagram M209178AA-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 81: Engine Harness Diagram 107 Hp - Ths Models

    57- 54-18 BK 58- A58-18 BK 88- A88-18 BK 59- A59-18 BK 89- A89-18 BK 29- 206-18 BK 3.33 Engine Harness Diagram 107 HP - THS Models M232311AB - S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 82: Engine Harness Wiring Diagram 107 Hp

    TEMP . TEMP . SENSOR TO UREA PUMP HEATG VALVE LEVEL & AIR INLET SENSOR BEFORE BEFORE VALVE TEMP M232311AB - S2 3.34 Engine Harness Wiring Diagram 107 HP SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 83: Chassis Harness

    213 DK GN/RD 220 DK GN/WE 00-16 WH 28B GN 28A GN DEUTSCH 26A-16 BL/YW 00 WH 00 WH FRAME LEFT FRAME ENABLE RIGHT ENABLE 3.35 Chassis Harness M199477AA-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 84: Chassis Harness Wiring Diagram

    PARK BRAKE SOLS. CHASSIS SOLS. PRESSURE STEER STEER R.A.S. FRAME LEVEL FRAME FRAME DISABLE RESERVE BRAKE SWITCH SPEED RIGHT LEFT SOL. ENABLE ENABLE M199477AA-S2 3.36 Chassis Harness Wiring Diagram SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 85: Electrical Schematic 74 Hp - Sj1044 Th & Sj1056 Th

    3.37 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH M190121AP-S1 3.37 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 86 3.37 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH 3.37 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH M190121AP-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 87 3.37 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH 25 26 SPLK01 SPL00 203-18 BK 202-18 WH 204-18 RD A20-16 WH A19-16 BK K82-18 BK K85-18 BK K44-18 BK A29-18 BK A44-18 BK A43-18 BK A24-18 BK A27-18 BK...

  • Page 88: Electrical Schematic 74 Hp Premium Joystick - Sj1044 Th & Sj1056 Th

    3.38 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH 3.38 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH M213409AG-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 89 3.38 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH 3.38 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH M213409AG-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 90 3.38 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH 25 26 SPLK01 SPL00 203-18 BK 202-18 WH 204-18 RD A20-16 WH A19-16 BK K82-18 BK K85-18 BK K44-18 BK A29-18 BK A44-18 BK A43-18 BK A24-18 BK...

  • Page 91: Electrical Schematic 107 Hp - Sj1044 Ths & Sj1056 Ths

    3.39 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS 9 10 11 12 3.39 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS M190122AJ-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 92 3.39 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS 3.39 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS M190122AJ-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 93 B+ POST B- POST STARTER D56E DIODE 56E (220149AA) STYLE A ALTERNATOR STYLE B 60D-16 BK D60D DIODE 3.39 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS M190122AJ-S3 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 94: Electrical Schematic 107 Hp , Premium Joystick- Sj1044 Th & Sj1056 Th

    3.40 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH 9 10 11 12 3.40 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH M213408AD-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 95 3.40 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH 3.40 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH M213408AD-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 96 3.40 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH A62-18 BK A80-18 BK A04-18 BK A37-18 BK A61-18 BK A41-18 BK A09-18 BK A27-18 BK TO BATTERY TO BATTERY TO BATTERY TO CHASSIS A15-18 BK B+ POST...

  • Page 97: Electrical Schematic - Sj1256 Ths

    3.41 Electrical Schematic - SJ1256 THS 9 10 11 12 3.41 Electrical Schematic - SJ1256 THS M206090AD-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 98 3.41 Electrical Schematic 107 HP - SJ1256 THS 3.41 Electrical Schematic - SJ1256 THS M206090AD-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 99 TO BATTERY TO BATTERY B+ POST B- POST STARTER D56E DIODE STYLE A 56E (220149AA) ALTERNATOR 60D-16 BK STYLE B D60D DIODE 3.41 Electrical Schematic - SJ1256 THS M206090AD-S3 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 100: Hydraulic Schematic - Sj1044 Th/Ths & Sj1056 Th/Ths

    TELESCOPE IN / FRAME LEVEL LEFT BOOM DOWN / CARRIAGE DOWN S-GP SAE 32 RETURN FILTER TANK FILLER FILTER 1 PSI PRESSURE RELIEF M233022AC 3.42 Hydraulic Schematic - SJ1044 TH/THS & SJ1056 TH/THS SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 101: Hydraulic Schematic, Premium Joystick - Sj1044 Th/Ths & Sj1056 Th/Ths

    3.43 Hydraulic Schematic, Premium Joystick - SJ1044 TH/THS & SJ1056 TH/THS 930011 921106 SWING CARRIAGE TILT CARRIAGE 235240 191832 191123 (OPTIONAL) (OPTIONAL) 190044/190045(TH1044) 190038 190043 191831 TILT COMPENSATION/SLAVE PARK BRAKE REAR AXLE STABILIZATION BOOM CYLINDERS CARRIAGE TILT TELESCOPE FRAME LEVEL...

  • Page 102: Hydraulic Schematic - Sj1256 Ths

    TELESCOPE IN / FRAME LEVEL LEFT BOOM DOWN / CARRIAGE DOWN S-GP SAE 32 RETURN FILTER TANK FILLER FILTER 1 PSI PRESSURE RELIEF 3.44 Hydraulic Schematic - SJ1256 THS M233023AC-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 103: Hydraulic Schematic For Premium Joystick- Sj1256 Ths

    BOOM DOWN / CARRIAGE DOWN 213232 MANIFOLD, DUAL S-GP SAE 32 ELEC-HYD RETURN FILTER TANK FILLER FILTER 1 PSI PRESSURE RELIEF 3.45 Hydraulic Schematic for Premium Joystick- SJ1256 THS M233023AC-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 104: Section 4 - Troubleshooting Information

    “probable cause.” The information in the right-hand column, in bold text, represents the “remedy” to the “probable cause” directly beside it. See the example below for clarification. 1. Probable cause Remedy SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 105 Notes SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 106: Electrical System

    Check for defective wiring. Replace/repair if 17. fuse F1 open defective. Replace fuse. 18. Loose or broken 03A wire from fuse F1 to ignition Check continuity. Replace if defective. switch SW1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 107: Engine Cranks But Will Not Run

    29. Loose or broken wire 03 from B+ to power relay Check continuity. Replace if defective 60CR 30. Loose or broken wire 00 from power relay 60CR to Check continuity. Replace if defective ground SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 108: Park Brake Will Not Release

    Check continuity. Replace if defective J31 pin 13. 7. Loose or broken 26A wire from harness connector Check continuity. Replace if defective P31 pin 13 to park brake solenoid 3H-26A. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 109: Transmission Will Not Engage

    4. Loose or broken wire 51 from forward solenoid to Check continuity. Replace if defective. chassis harness P13 pin 2. 5. Defective forward solenoid. Replace solenoid. 6. Defective transmission shifter. Replace shifter 4.2-7 No Reverse Drive SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 110: No 1St Speed Range

    Check continuity. Replace if defective. pin 5 2. Loose or broken wire 215 from 31 pin connector Check continuity. Replace if defective. P31 pin 5 to engine harness connector J13 pin 4. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 111: 10 No Boom Up, Front Steer Mode Only

    Check continuity. Replace if defective. connector J20 pin 2 to ground. 5. Defective 4W solenoid Replace if Defective 4.2-13 No Crab Steer Mode 1. Defective Steer mode switch SW3 Replace if Defective SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 112: 14 No Boom Up

    5 to 4 pin connector P113 pin 2. 13. Loose or broken wire 28 from 4 pin connector J113 Check continuity. Replace if defective pin 2 to boom up enable relay 28CR pin 86 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 113: 15 Frame Will Not Tilt Over 40° With Boom Below 40

    Console harness connector P31 pin 25 5. Loose or broken 212 wire from connector J31 pin Check continuity. Replace if defective 25 to boom angle relay 212CR pin 86. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 114: 16 No Frame Level

    Boom Angle Below 40° ▪ Works Above 40° ▪ Check continuity through contacts of relay (pin 30 1. Defective relay 212CR. to 87 with coil energized). Replace if defective SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 115 RAS indicator illuminates above 40° ▪ 1. Loose or broken wire 223 from 223CR relay pin 87 Check continuity. Replace if defective through splice 223 to 220CR pin 87a SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 116 18. Relay 28RCR defective to 87a with coil de-energized). Replace if defective 19. Loose or broken wire 28B from 28RCR pin 87 to Check continuity. Replace if defective J31connector pin 31 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 117: 17 Ras Remains Fully Locked (Ras Indicator Remains Illuminated)

    Check continuity. Replace if defective 5. Loose or broken wire 220 from connector J31 pin Check continuity. Replace if defective 21 to relay 220CR pin 86 and/or pin 87. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 118: 18 Ras Remains Locked

    2. Loose or broken wire 222 from connector J46 pin8 Check continuity. Replace if defective to relay 222CR pin 86 3. Loose or broken wire 00 from 222CR to ground Check continuity. Replace if defective SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 119: 20 Outriggers Inoperative

    SW21 and SW22 pins 2 With following conditions: Right outrigger down inoperative ▪ 1. Loose or broken wire 228 from outrigger switch Check continuity. Replace if defective SW22 to connector J81 pin F SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 120 C to valve 4H-225 3. Loose or broken wire 00 from valve 4H-225 to Check continuity. Replace if defective ground. 4. Left outrigger up solenoid 4H-225 defective. Replace if defective. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 121: Hydraulic System

    Clean valves. Check O-rings on valve. Repair or CB2-1. replace valve as required. Check seals on cylinder. Replace as necessary. 7. Defective lift cylinder C3 and/or C4. Replace cylinder if defective SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 122 2. Stuck or defective telescope valve V3. replace valve as required. Clean valve. Check operation of valve. Repair or 3. LS check valve CV3 blocked or defective replace valve as required SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 123: No Carriage Tilt

    4. LS check valve CV1 blocked or defective replace valve as required 5. Pilot operated check valve CV11 and or CV12 Clean valve. Check operation of valve. Repair or blocked or defective replace valve as required SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 124: No Frame Level

    3. Frame right enable valve 2H-28A stuck or Clean valve. Check operation of valve. Repair or defective. replace valve as required 4. Orifice OR3 and/or OR4 plugged Remove and inspect, clean or replace as required SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 125: No Aux. Functions

    1. Stuck or defective park brake valve 3H-26 replace valve as required 2. Bypassing or defective parking brake seals in Check seals, replace as necessary. Replace if axle. defective SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 126: Park Brake Will Not Engage

    Clean valves. Check O-rings on valve. Repair or 4. Stuck or defective lift counterbalance valves CB9 replace valve as required. Check seals on cylinder. Replace as necessary. 5. Defective telescope cylinder C10. Replace cylinder if defective SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 127: Section 5 - Procedures

    Water Pump ▪ The air cleaner and exhaust system, cooling system including radiator and hoses are not part of the engine package, and are covered later in this manual. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 128: Hour Or Daily Routine Maintenance

    4. Check coolant level and coolant strenght in the radiator. Adjust mixture as requiered. Refill until coolant is visible. 5. Tighten radiator cap, start the engine, and check for leaks. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 129: Check Transmission Fluid Level

    4. The oil level should be between the “Full” and “Low” marks. 5. If transmission oil level is low, refer to section 5.5- 6 for transmission oil and filter replacement. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 130: Check Hydraulic Oil Level

    Refer to Table 2.3 for hydraulic oil inside the housing and the cover with a damp specifications. cloth. CAUTION Never use compressed air on an air filter. Paper elements should not be “washed”. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 131: Drain Fuel/Water Separator

    2. Remove wheel from telehandler to fill the tire whenever pressure is below 80% of the recommended pressure. 3. Place tire in a cage and inflate using a clip-on chuck and a remote tire pressure gauge. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 132: 10 Check Seat Belt And Mounting Hardware

    2. Inspect the belt hardware and fabric. Replace if hardware is damaged, frayed or loose stitching is found. Seat Seat Belt Figure 10 Seat Assembly SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 133: Hour Or Weekly Routine Maintenance

    (8) hours of operation. 4. Note 5. If nuts are tight after the eight hour check, the interval for checking with a torque wrench can be extended to 250 hours. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 134: Check Oil Level In Axle Differential Planetary Wheel Ends

    Table 2.3 Refer to of Section 2 in this manual for oil type and capacity. 5. Re-install plug and repeat steps above for the three (3) remaining planetary wheel ends. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 135: Replace Engine Oil And Filter

    6. Remove oil drain plug and allow all engine oil to Figure 18 Engine Oil Filter Location drain into container. See figure below. 3. Clean inside the filter head. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 136 11. Close the engine compartment cover then latch to secure in place. NOTE Refer to your local/national regulations on how to dispose of used filter and oil. Figure 19 Engine Oil Fill Cap SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 137: Change Engine Fuel Filter And Fuel/Water Separator

    12. Mount the drain plug on bottom of water separator. Torque to 1 ft.-lb. (1.6 ± 0.3 Nm) 13. Check area around filter and separator for any leaks. 14. Connect water level sensor harness to fuel/water spearator. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 138: Clean Hydraulic Tank Breather

    17. Close engine cover back and latch it in place. Figure 24 Axle Mounting Bolts 1. Torque front axle mounting bolts to 660 lb.ft. (895 N·m). 2. Torque rear axle mounting bolts to 380 lb.ft. (895 N·m). SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 139: Inspect Boom Chains

    Figure 27 Retract Chain SJ1X56 TH/THS 6. If chain appears dry, rusty, or worn, the chains must be removed for a complete inspection and lubrication. Refer to Section 5.6-2 for boom chains replacement procedure. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 140: Check Boom Slide Pad Clearances

    Figure 30 Bottom Slide pads lubrication. Refer to Section 5.6-2 for boom chains replacement procedure. 5. When clearances exceed this amount, add shims or replace the pads. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 141 11. Lower the boom until the forks are resting on the ground and an upward force is being applied to the boom sections. 12. Shut off the engine and remove key. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 142: 10 Check Boom Chains Tension

    3. As you retract the boom slowly, watch for sagging parts or loose links. See figure below.  Figure 34 Extend Chain Slack SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 143: 11 Chain Tension Adjustment

    Chain Anchor Jam Nut Figure 37 Extend Chain Jam Nut (SJ1044 TH/THS) Chain Anchor Jam Nut Figure 40 Chain Anchor Jam Nut Figure 38 Extend Chain Jam Nut (SJ1X56 TH/THS) SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 144: 12 E-Chain And Hoses Inspection

    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 Replacement on page 185 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 145: 14 Grease Drive Shaft U-Joints And Slip Joints

    2. Apply 4 shots of grease to each fitting. See figure below. 2. Remove cap and apply 4 shots of grease to each fitting. Figure 43 Drive Shaft Grease Points SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 146: 15 Grease Frame Level Pivot Bushings

    Left Boom Pivot Cylinder Grease Points Grease Point Grease Points Rear Axle Lock Cylinder Grease Points Figure 45 Rear Axle Lock Cylinder Grease Points Figure 47 Boom Grease Points SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 147: 17 Grease Bottom Front & Top Rear Slide Pads

    7. With boom fully retracted, remove boom rear cover door to gain access to top rear slide pads. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 148: 1000 Hour Or Annual Routine Maintenance

    Figure 50 Hydraulic Oil Filter Location NOTE Figure 51 Hydraulic Tank Drain Plug Refer to your local/national regulations on how to dispose of used hydraulic oil filter. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 149: Change Axle Differential Oil

    NOTE Follow shop practice standards for flushing and cleaning of hydraulic oil tank. 10. Install drain plug back into tank. Replace O-ring seal if needed. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 150: Change Axle Planetary Oil

    2. Park the telehandler on a firm level surface with the level/fill/drain plug at the 6 o’clock position. 3. Shut down the engine, apply parking brake, and allow it to sit for a minimum of two minutes. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 151: Change Engine Coolant

    3. Open the drain plug and allow radiator and Figure 58 Hoses Disconnection coolant bottle to drain. NOTE Refer to your local/national regulations on how to dispose of used coolant fluid. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 152 13. Let the engine cool down and open the radiator 20. Tighten radiator cap, start the engine, and check drain plug and allow radiator and coolant bottle to for leaks. drain. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 153 1000 Hour or Annual Routine Maintenance Section 5 – Procedures Open Cab Plumbing SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 154 Section 5 – Procedures 1000 Hour or Annual Routine Maintenance Enclosed Cab Plumbing SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 155: Change Transmission Oil And Filter

    Figure 62 Transmission Oil Drain Plugs 5. Place a suitable container with enough capacity under drop box to catch drained oil. 6. Remove the drop box drain plug and drain the oil. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 156 Remove Transmission Oil Filter Oil Dipstick Figure 65 Transmission Oil Filter Removal NOTE Refer to local/national environmental regulations on how to dispose of used oil and filter. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 157: Inspect Boom Chains

    10. Install the RAS manifold cover back in place. 11. Perform boom interlock and RAS system test. Refer to Section 1.2 of this manual. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 158 Section 5 – Procedures 1000 Hour or Annual Routine Maintenance RAS System Logic Truth Table Service Axle Park Frame Boom up Brake Fully Driving Brake Leveling >=40 Free Limited Locked Depressed SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 159: Non-Routine Maintenance

    7. Slowly remove hose sheaves (rollers) and keep thrust washers intact in the same order. Thrust Washers Figure 69 Thrust Washers on Hose Sheaves Figure 67 Sheave Guards Removal. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 160 Figure 71 Aux. Hydraulics Hoses Removal at Bulkhead inspect all hoses. Replace hoses if needed. 4. Cap/plug all open lines and fittings. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 161 Ensure to wire tie/tag both ends of the hose. Figure 76 Sheave Guards Removal. 6. Repeat step 5 for the opposite side sheave guard bracket. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 162 Figure 77 Auxilliary Hydraulics Hoses Connection at 6. Shutdown engine and remove key from ignition Bulkhead switch. 7. Connect hoses at the rear of bulkhead as shown below. Connect hoses SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 163: Boom Chains Replacement

    Check hydraulic oil level and top-up as required. Figure 83 Chain Anchor Nut & Washer Removal 5. Slide chain anchor through hole on main boom then lay chain with anchor on top of boom as shown. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 164 4. From the rear of the boom, secure the chain to the anchor by installing the link pin and a new 8. Remove cotter pin and anchor pin then disonncet cotter pin chain from anchor. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 165 6. Torque bolts to 80 lb.-ft. using a 3/4” socket. Chain Anchor Jam Nut NOTE Ensure the chain anchor remains square to the 3rd boom top plate. Figure 89 Chain Anchor Jam Nut SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 166 Discard the cotter pin and old chain. 4. Position the chain anchor to the retract chain and secure by installing the link pin and a new cotter pin. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 167 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. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 168 8. Start the engine and operate extend/retract function through several cycles to assure proper operation. Repair as required. 9. Adjust boom chain tension. Refer to Section 5.4-11 for Chain Tension adjustment procedure. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 169: Slide Pads Replacement Procedure

    5. Remove the screws, shims, and wear pads while holding the bar under the shim. For easier Figure 98 Slide Pads Locations SJ1056 TH/THS and installation, keep all parts removed together as SJ1256 THS an assembly. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 170 2nd boom. 6. Apply loctite 271 red and tighten the screws to 37 ft-lb. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 171: Hydraulic Pressure Test Procedure

    450 psi. 4. If reading is other than 450 psi, adjustment is required. Load Sense Compensator Adjustment: ▪ 1. Loosen the lock nut on the load sense compensator. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 172 (CW) to increase the pressure the pressure reading until a reading of 2,600 psi is reading and counter-clockwise (CCW) to reduce achieved. the pressure reading until desired reading is achieved. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 173 400 psi is achieved. 3. Tighten the lock nut on valve PR1 and re-check the reading to ensure that the correct pressure is maintained. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 174 3900 psi for SJ1256 THS. ▪ 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. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 175: Hydraulic Pump Testing Procedure

    7. If the required pressure cannot be set, the pump must be replaced. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 176 5. Install spring spacer in spring retainer as shown in figure below. Figure 119 Install Component in Sleeve Figure 116 Install Spring Spacer 6. Install spring in spring retainer as shown in figure below. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 177 11. From opposite end, position accumulator spool in sleeve as shown in figure below. Figure 125 Install Inner Spring Figure 122 Position Accumulator Coil 15. Install stop pin in inner spring as shown in figure below. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 178 Figure 130 Install and Torque Housing 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) SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 179: Deutz Fault Codes

    If the list is longer than the screen section, you can browse through the list using buttons 1 and SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 180 Check wiring, sensor defect, check sensor and if necessary replace it, check connection cable and if 0, 1, 3, or 4 ECU is out of the target range; either high or low. necessary repair or replace it 307A-1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 181 Check CAN Bus wiring (Bus scheduling, polarity, short circuit, power interrupt), test protocol of receiver, 524109 Missing CAN message of EGR throttle valve check CAN functional range, check actuator 307A-2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 182: Starter Replacement Procedure

    Lower Bolt Figure 134 Figure 135 Bolts Location. 4. Remove the existing starter from the side of the engine. Front of Front of Machine Machine Figure 136 Starter Removal. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 183 Retaining 13. Perform a full function test as outlined in Section Washer ‘Function Tests’ of the operating manual. To Glow Plug Harness Engine Cable Harness Figure 138 Harnesses Installation. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 184: Bleeding Hydraulic Circuits

    ▪ boom in a low position. Bleed Auxiliary/Optional Circuits Operate function fully in both directions several ▪ times. Bleed Outriggers Circuit Fully lower and raise outriggers several times. ▪ SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 185: 10 Cable Track Replacement

    Preparation: quick-disconnect ends. 1. Place the boom in a horizontal (0°) position. 2. Shut down the machine. 3. Turn the main power disconnect switch off. Lock out the switch. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 186 M62330AA Figure 143 M62304AA Figure 145 10. Once everything is disconnected, fully retract the boom assembly. 11. Turn the main power disconnect switch off. Lock out the switch. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 187 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. Figure 150 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 188 If replacing the cable track itself: Remove the mounting bracket from the old cable ▪ track and install it on the new one. Make sure the bracket is straight before tightening the screws. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 189 6. Install the hex nuts and the eyebolt onto the bracket. Remove any tie-wraps on the hose ends. M62290AA Figure 157 Side Access Hole M62299AA Figure 155 Install with Mounting Bracket Down SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 190 13. Remove any tie-wraps and install the cable track fasteners to secure it to the carrier assembly. M62309AA Figure 159 M62308AA Figure 161 14. Connect the hoses to the tubes as previously marked. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 191 2. Pull the hoses tight over the block from the front. Before tightening, ensure the bolts are 5/16’’ x 1-3/4’’, then tighten the hose clamp inside the front access hole. Remove the wood block. M62311AA   Figure 163 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 192: 11 Carrier Assembly Replacement

    NOTE Place a support stand at the back of the machine so the carrier assembly can be set down to re-sling as required SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 193 Use proper personal protection at all times. Loosen the fitting slowly to relieve pressure. M62310AA Figure 167 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 194 Figure 170 Hoses Connected to Bulkhead Plate Figure 172 6. Remove the 4 bolts securing the carrier bulkhead plate to the inside of the inner boom. M62292AA Figure 171 Carrier Bulkhead Plate SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 195 Figure 173 9. Carefully guide the front end of the carrier assembly when passing the bulkhead plate mounts. Continue to lift/slide the assembly out of the boom. M62296AA Figure 174 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 196 5. Pull the carrier assembly back slightly. Support the end of it, then install both (T-shaped) upper and lower guide brackets. M62317AA M62314AA Figure 176 6. Push the carrier assembly the rest of the way in. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 197: Electronic Tilt Switch Setup Procedure

    1. Ensure telehandler is parked on a firm level LEFT RIGHT surface. SET ZERO IMPORTANT 2. Only the red LED will blink for 4 seconds. Ensure frame level indicator is at 0°. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 198: Reprogramming Existing Tilt Switch

    Green LED Green LED 7. Reprogram the Tilt Switch 1. Press and hold the set zero Red LED button for 3 seconds. Green LED Results: Both LEDs will be OFF. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 199: Test And Verify Tilt Circuit

    Tilt Circuit Test 10. Proceed to Test and Verify Tilt Circuit/Boom Refer to Section 2 - Function Tests of the operating Interlock. manual to Test Frame Leveling and Boom Interlock. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 200 0 = Output Open 0 = Output Open 4° 4° 1 = Switch 1 = output 12V 1 = output 12V 1 = output 12V 1 = output 12V Closed to 12V SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 201: Park Brake Release

    8. To engage the park brake, back out the two set screws on both the left and right sides of the front axle housing and tighten all four locknuts. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 202: Bearing Installation

    3.1846 3.1860 IMPORTANT Do not use grease for bearing or pin installation. Do not use a pin with a grease zerk with a Bearing Driver maintenance free type bearing. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 203 Bearing Installation Section 5 – Procedures Figure 177 Bearing Orientation SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...

  • Page 204: A/C Diagram

    A/C Diagram 5.10 A/C Diagram High Pressure side, gas High Pressure side, liquid Low Pressure side, liquid Low Pressure side, gas Condenser Compressor Evaporator & Drier Blower Expansion Valve SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 230790ABA...
  • Page 206 www.skyjack.com...

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