Skyjack SJ1044 THS Service Manual
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Skyjack SJ1044 THS Service Manual

Skyjack SJ1044 THS Service Manual

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SERVICE
MANUAL
SJ1044 TH, SJ1044 THS,
SJ1056 TH, SJ1056 THS,
SJ1256 THS
TELEHANDLERS
190130AG
January 2021
ANSI

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Summary of Contents for Skyjack SJ1044 THS

  • Page 1 SERVICE MANUAL SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS TELEHANDLERS 190130AG January 2021 ANSI...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.
  • Page 3 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...
  • Page 4 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 190130AG...

  • Page 5: Table Of Contents

    Recommended Fluids/Lubrications ........... 30 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 6 Engine Harness 74 HP ............. 82 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 7 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS .......
  • Page 8 Replace Engine Oil and Filter ........... . 159 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 9 Bearing Installation ............. . . 225 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 10: 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 190130AG...

  • Page 11: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 12: 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 190130AG...

  • Page 13: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 14 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 15: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 16: 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 190130AG...
  • Page 17 WARNING Explosion hazard. Keep flames and sparks away. Do not smoke near batteries. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 18 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 190130AG...

  • Page 19: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 20: 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 190130AG...

  • Page 21: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 22 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 190130AG...

  • Page 23: Function Tests

    NOTE All-function motion alarm should sound while operating any boom and drive function 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 24: Section 2 - Maintenance Tables

    Section 2 – Maintenance Tables SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 25: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 26 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 190130AG...

  • Page 27: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 28 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 190130AG...

  • Page 29: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 30 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 190130AG...

  • Page 31: Tire/Wheel Specifications

    Failure to comply with this requirement will reduce the life of the differentials and reduce overall mobility of telehandler. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 32: 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 190130AG...

  • Page 33: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 34 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 190130AG...

  • Page 35: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 36: 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, or uncured Loctite. 1375AA SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 37: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 38: 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 190130AG...

  • Page 39: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 40: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 41: 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 190130AG...

  • Page 42: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 43 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 190130AG...
  • Page 44 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 45: 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 190130AG...
  • Page 46 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 47 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 190130AG...
  • Page 48 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)` 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 49: 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 190130AG...

  • Page 50: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 51: 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 190130AG...

  • Page 52: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 53: 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 190130AG...

  • Page 54: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 55: 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 190130AG...

  • Page 56: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 57: 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 190130AG...

  • Page 58: Reserve Brake Manifold Port Identifications (Option)

    Port T to Port DR3 Port SW on Main Manifold Pressure Switch Port STLS to Port STLS on Main Manifold Pressure Reducing/ Port SV1 Relief Valve Shuttle Valve M190115AC-S1 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 59: Anti-Cavitation Relief Valve (Sj1256 Ths Only)

    Section 3 – System Component Identification and Schematics 3.15 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 190130AG...

  • Page 60: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 61: 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 190130AG...
  • Page 62 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 63 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 190130AG...

  • Page 64: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 65: 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 190130AG...

  • Page 66: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 67: 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 190130AG...

  • Page 68: Boom Lights Harness & Wiring Diagram

    3.22 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 69: Beacon Light Harness & Wiring Diagram

    3.23 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 190130AG...

  • Page 70: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 71: 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 190130AG...

  • Page 72: A/C Harness

    3.26 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 73: Heater & A/C Harness

    1 2 3 4 TO CONSOLE SPL00 HARNESS 266-16 BN/YW SPL266 TO CONSOLE 265-12 DK GN/BK HARNESS TO CONSOLE 05P-10 PE HARNESS (OPT) 268-16 DBE/OE A/C HARN. (OPT) M191490AD - S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 74: Cvt Vehicle Harness

    CR1 POWER RELAY 7.5A 05W-16 PU NEUTRAL PIN87 ENABLE RELAY 219-16 DARK BU/PK TRANSMISSION OIL TEMP 00-16 WH WARNING LAMP J65A VEHICLE SIDE TO CONSOLE HARNESS M220790AB - S1 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 75: Cvt Transmission Harness

    OUTPUT SPEED SPLCANL P3480 SPLCANH SUMP CVT TEMPERATURE 10 11 12 10 11 12 VEHICLE CONNECTOR VEHICLE CONNECTOR P4000 CLUTCH LOW P4150 OVERDRIVE P4100 P4050 CLUTH REV/HIGH M220793AB - S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 76: 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 3.30 Console Harness and Layout 74 HP M216785AF-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 77: 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 3.31 Console Harness Wiring Diagram 74HP SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 78: 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 3.32 Console Harness and Layout 107 HP - THS Models SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 79: 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 3.33 Console Harness Wiring Diagram 107 HP - THS Models M216786AF-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 80: Engine Harness 74 Hp

    19 - 39 - 59 - 79 - 51 BL/GN 51A BL 51 BL/GN 16 WH/BK 20 - 40 - 60 - 80 - 3.34 Engine Harness 74 HP M209178AA-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 81: Engine Harness 74 Hp Wiring Diagram

    TO CHASSIS HARNESS TO CONSOLE TO CHASSIS HARNESS FUEL PUMP RELAY TO FUEL PUMP TO BATTERY TO WATER TO PRE-HEAT HARNESS SENSOR TRANSMISSION 3.35 Engine Harness 74 HP Wiring Diagram M209178AA-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 82: Engine Harness Diagram 107 Hp - Ths Models

    A89-18 BK A19-18 BK 20- A25-16 BK 41- A24-16 WH 62- A85-16 BK 21- A101-18 BK 42- A87-16 BK M209179AA-S1 3.36 Engine Harness Diagram 107 HP - THS Models SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 83: Engine Harness Wiring Diagram 107 Hp

    CAT WHITE SENSOR TO UREA PUMP HEATG TEMP. TEMP. VALVE CAT BLACK LEVEL & AIR INLET SENSOR VALVE BEFORE BEFORE TEMP M209179AA-S2 3.37 Engine Harness Wiring Diagram 107 HP SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 84: 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 3.38 Chassis Harness M199477AA-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 85: 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 3.39 Chassis Harness Wiring Diagram SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 86: Electrical Schematic 74 Hp - Sj1044 Th & Sj1056 Th

    3.40 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH 3.40 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH M190121AL-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 87 3.40 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH 3.40 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH M190121AL-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 88 A04-16 WH A46-16 BK A03-16 WH A32-16 BK A02-16 WH B+-12 RD 00-12 WH 00-12 WH BA+-12 RD 3.40 Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH M190121AL-S3 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 89: Electrical Schematic 74 Hp Premium Joystick - Sj1044 Th & Sj1056 Th

    3.41 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH 3.41 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH M213409AD-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 90 3.41 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH 3.41 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH M213409AD-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 91 A46-16 BK A03-16 WH A32-16 BK A02-16 WH B+-12 RD 00-12 WH 00-12 WH BA+-12 RD 3.41 Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH M213409AD-S3 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 92: Electrical Schematic 74 Hp Engine With Cvt - Sj1044 Th & Sj1056 Th

    3.42 Electrical Schematic 74 HP Engine with CVT - SJ1044 TH & SJ1056 TH 3.42 Electrical Schematic 74 HP Engine with CVT - SJ1044 TH & SJ1056 TH M217976AD-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 93 3.42 Electrical Schematic 74 HP Engine with CVT - SJ1044 TH & SJ1056 TH M217976AD-S2.ai 3.42 Electrical Schematic 74 HP Engine with CVT - SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 94 A03-16 WH A32-16 BK A02-16 WH B+-12 RD 00-12 WH 00-12 WH BA+-12 RD M217976AD-S3.ai 3.42 Electrical Schematic 74 HP Engine with CVT - SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 95 3.42 Electrical Schematic 74 HP Engine with CVT - SJ1044 TH & SJ1056 TH M217976AD-S4.ai 3.42 Electrical Schematic 74 HP Engine with CVT - SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 96: Electrical Schematic 74 Hp Engine With Cvt And Premium Joystick- Sj1044 Th & Sj1056 Th

    3.43 Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH M217979AD-S1.ai 3.43 Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 97 3.43 Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH M217979AD-S2.ai 3.43 Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 98 A32-16 BK A02-16 WH B+-12 RD 00-12 WH 00-12 WH BA+-12 RD M217979AD-S3.ai 3.43 Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 99 3.43 Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH M217979AD-S4.ai 3.43 Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 100: Electrical Schematic 107 Hp - Sj1044 Ths & Sj1056 Ths

    3.44 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS 9 10 11 12 3.44 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS M190122AJ-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 101 3.44 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS 3.44 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS M190122AJ-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 102 3.44 Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS 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 B+ POST...

  • Page 103: Electrical Schematic 107 Hp , Premium Joystick- Sj1044 Th & Sj1056 Th

    3.45 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH 9 10 11 12 3.45 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH M213408AD-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 104 3.45 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH 3.45 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH M213408AD-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 105 B- POST STARTER D56E DIODE 56E (220149AA) STYLE A ALTERNATOR 60D-16 BK STYLE B D60D 3.45 Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH M213408AD-S3 DIODE SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 106: Electrical Schematic 107 Hp Engine With Cvt - Sj1044 Th & Sj1056 Th

    3.46 Electrical Schematic 107 HP Engine with CVT - SJ1044 TH & SJ1056 TH 9 10 11 12 M217969AD-S1 3.46 Electrical Schematic 107 HP Engine with CVT - SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 107 3.46 Electrical Schematic 107 HP Engine with CVT - SJ1044 TH & SJ1056 TH M217969AD-S2 3.46 Electrical Schematic 107 HP Engine with CVT - SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 108 STARTER ALTERNATOR D56E DIODE 56E (220149AA) STYLE A 60D-16 BK STYLE B D60D DIODE M217969AD-S3 3.46 Electrical Schematic 107 HP Engine with CVT - SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 109 3.46 Electrical Schematic 107 HP Engine with CVT - SJ1044 TH & SJ1056 TH M217969AD-S4 3.46 Electrical Schematic 107 HP Engine with CVT - SJ1044 TH & SJ1056 TH SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 110: Electrical Schematic - Sj1256 Ths

    3.47 Electrical Schematic - SJ1256 THS 9 10 11 12 3.47 Electrical Schematic - SJ1256 THS M206090AD-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 111 3.47 Electrical Schematic 107 HP - SJ1256 THS 3.47 Electrical Schematic - SJ1256 THS M206090AD-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 112 TO BATTERY TO BATTERY B+ POST B- POST STARTER D56E DIODE STYLE A 56E (220149AA) ALTERNATOR 60D-16 BK STYLE B D60D DIODE 3.47 Electrical Schematic - SJ1256 THS M206090AD-S3 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 113: Electrical Schematic For Cvt - Sj1256 Ths

    3.48 Electrical Schematic for CVT - SJ1256 THS 9 10 11 12 3.48 Electrical Schematic for CVT - SJ1256 THS M220493AD-S1 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 114 3.48 Electrical Schematic for CVT - SJ1256 THS 3.48 Electrical Schematic for CVT - SJ1256 THS M220493AD-S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 115 TO BATTERY B+ POST B- POST STARTER D56E DIODE 56E (220149AA) STYLE A ALTERNATOR 60D-16 BK STYLE B D60D DIODE 3.48 Electrical Schematic for CVT - SJ1256 THS M220493AD-S3 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 116 3.48 Electrical Schematic for CVT - SJ1256 THS 3.48 Electrical Schematic for CVT - SJ1256 THS M220493AD-S4 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 117: 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 M190120AE-S1 3.49 Hydraulic Schematic - SJ1044 TH/THS & SJ1056 TH/THS SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 118: Hydraulic Schematic (Reserve Brake Option) - Sj1044 Th/Ths & Sj1056 Th/Ths

    BOOM DOWN / CARRIAGE DOWN S-GP SAE 32 RETURN FILTER TANK FILLER FILTER 1 PSI PRESSURE RELIEF M190120AE-S2 3.50 Hydraulic Schematic (Reserve Brake Option) - SJ1044 TH/THS & SJ1056 TH/THS SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 119: Hydraulic Schematic, Premium Joystick - Sj1044 Th/Ths & Sj1056 Th/Ths

    TANK 213232 FILLER FORK TILT FILTER MANIFOLD 1 PSI PRESSURE SAE 04 RELIEF SAE 04 213999AB - S1 3.51 Hydraulic Schematic, Premium Joystick - SJ1044 TH/THS & SJ1056 TH/THS SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 120: Ths

    FORK TILT FILTER MANIFOLD 1 PSI PRESSURE SAE 04 RELIEF SAE 04 3.52 Hydraulic Schematic Premium Joystick (Reserve Brake Option) - SJ1044 TH/THS & SJ1056 TH/THS 213999AB - S2 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 121: 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 M205157AC-S1 3.53 Hydraulic Schematic - SJ1256 THS SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 122: Hydraulic Schematic (Reserve Brake Option) - Sj1256 Ths

    TELESCOPE IN / FRAME LEVEL LEFT BOOM DOWN / CARRIAGE DOWN S-GP SAE 32 RETURN FILTER TANK FILLER FILTER 1 PSI PRESSURE RELIEF M205157AC-S2 3.54 Hydraulic Schematic (Reserve Brake Option) - SJ1256 THS SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 123: 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 3.55 Hydraulic Schematic for Premium Joystick- SJ1256 THS M205157AC-S3 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 124: 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 190130AG...

  • Page 125: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 126: 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 190130AG...

  • Page 127: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 128: 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 190130AG...

  • Page 129: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 130: 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 190130AG...

  • Page 131: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 132: 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 190130AG...

  • Page 133: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 134 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 190130AG...
  • Page 135 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 136: 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 190130AG...

  • Page 137: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 138: 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 190130AG...
  • Page 139 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 140: 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 190130AG...
  • Page 141 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 142: 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 190130AG...

  • Page 143: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 144: 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 190130AG...

  • Page 145: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 146: 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 190130AG...

  • Page 147: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 148: 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 190130AG...

  • Page 149: 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”. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 150: 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 190130AG...

  • Page 151: 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 152: Hour Or Weekly Routine Maintenance

    2. Apply 4 shots of grease to each fitting. See figure the right boom lift cylinder. See figure below. below. 1. Wipe dirt and grease from each remote grease fitting. Figure 14 Drive Shaft Grease Points SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 153: Check Fork Pins

    Right Extend Boom Pivot Cylinder Grease Points Grease Points Frame Level Cylinder Grease Points Figure 18 Boom Grease Points Figure 16 Stabilizer Grease Points 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 154: Grease Bottom Front & Top Rear Slide Pads

    5. With boom fully extended, smear grease along the path of front bottom slide pads. See figures Boom Rear below. Cover Figure 21 Front Bottom Slide Pads 9. Shut down the engine and remove key. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 155: Hour Or Quarterly Routine Maintenance

    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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 156: Check Oil Level In Axle Differentials

    10. Re-install plug and repeat steps above for the Engine Compartment other axle. Cover Figure 25 Engine Cover 6. Remove oil drain plug and allow all engine oil to drain into container. See figure below. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 157 2. Remove oil filter and catch any escaping oil. Engine Oil Filter Figure 28 Engine Oil Fill Cap Figure 27 Engine Oil Filter Location 3. Clean inside the filter head. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 158: Change Engine Fuel Filter And Fuel/Water Separator

    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. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 159 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 160: Clean Hydraulic Tank Breather

    Figure 34 Boom Cover Removal Figure 33 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 190130AG...
  • Page 161 6. If chain appears dry, rusty, or worn, the chains lubrication. Refer to Section 5.6-2 for boom chains must be removed for a complete inspection and replacement procedure. lubrication. Refer to Section 5.6-2 for boom chains replacement procedure. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 162: Check Boom Slide Pad Clearances

    See figure below. Figure 39 Bottom Slide pads 5. When clearances exceed this amount, add shims or replace the pads. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 163: 10 Check Boom Chains Tension

    11. Lower the boom until the forks are resting on the ground and an upward force is being applied to the boom sections. Figure 43 Extend Chain Slack 12. Shut off the engine and remove key. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 164: 11 Chain Tension Adjustment

    Refer to Section 5.3-8 for chain tension adjustment procedure. Figure 46 Extend Chain Jam Nut (SJ1044 TH/THS) Chain Anchor Jam Nut Figure 47 Extend Chain Jam Nut (SJ1X56 TH/THS) SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 165: 12 E-Chain And Hoses Inspection

    80 ft.-lb. 5. If maintenance is necessary, refer to section 5.6- 10 Cable Track Replacement on page 208 Chain Anchor Jam Nut Figure 49 Chain Anchor Jam Nut 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 166: 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 190130AG...

  • Page 167: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 168: 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 190130AG...

  • Page 169: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 170 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 190130AG...
  • Page 171 Section 5 – Procedures 1000 Hour or Annual Routine Maintenance Open Cab Plumbing 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 172 1000 Hour or Annual Routine Maintenance Section 5 – Procedures Enclosed Cab Plumbing SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 173: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 174 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 190130AG...

  • Page 175: Change Continuously Variable Transmission (Cvt) Oil And Filter

    Oil Drain Plug Figure 66 Transmission Oil Drain Plugs Oil Filling Plug Figure 68 Transmission Oil Filter Removal 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 176 17. Remove the transmission oil dipstick then check the transmission oil level. Add as required. Figure 69 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 190130AG...

  • Page 177: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 178 1000 Hour or Annual Routine Maintenance Section 5 – Procedures 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 190130AG...

  • Page 179: Non-Routine Maintenance

    7. Slowly remove hose sheaves (rollers) and keep thrust washers intact in the same order. Thrust Washers Figure 73 Thrust Washers on Hose Sheaves Figure 71 Sheave Guards Removal. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 180 Figure 75 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 190130AG...
  • Page 181 Ensure to wire tie/tag both ends of the hose. Figure 80 Sheave Guards Removal. 6. Repeat step 5 for the opposite side sheave guard bracket. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 182 6. Shutdown engine and remove key from ignition Bulkhead switch. 7. Connect hoses at the rear of bulkhead as shown below. Connect hoses Figure 84 Fork Tilt Hoses Connection SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 183: Boom Chains Replacement

    Check hydraulic oil level and top-up as required. Figure 87 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 184 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 190130AG...
  • Page 185 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 93 Chain Anchor Jam Nut 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 186 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 190130AG...
  • Page 187 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 188 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 190130AG...

  • Page 189: Slide Pads Replacement Procedure

    5. Remove the screws, shims, and wear pads while holding the bar under the shim. For easier Figure 102 Slide Pads Locations SJ1056 TH/THS and installation, keep all parts removed together as SJ1256 THS an assembly. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 190 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 190130AG...

  • Page 191: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 192 (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 190130AG...
  • Page 193 400 psi is achieved. 3. Tighten the lock nut on valve PR1 and re-check the reading to ensure that the correct pressure is maintained. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 194 2. With engine running at low idle, loosen the lock nut on the maximum steering pressure reducing valve at port RV1 on the main manifold valve. Port RV1 Figure 114 Maximum Steering Pressure Adjustment SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 195: Hydraulic Pump Testing Procedure

    7. If the required pressure cannot be set, the pump must be replaced. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 196 5. Install spring spacer in spring retainer as shown in sleeve against inner cross pin as shown in in figure below. figure below. Figure 120 Install Spring Spacer Figure 123 Install Component in Sleeve SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 197 11. From opposite end, position accumulator spool in sleeve as shown in figure below. Figure 129 Install Inner Spring Figure 126 Position Accumulator Coil 15. Install stop pin in inner spring as shown in figure below. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 198 Figure 134 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 132 Install Valve(s) SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 199: Deutz Fault Codes

    If the list is longer than the screen section, you can browse through the list using buttons 1 and 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 200 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 190130AG...
  • Page 201 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 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 202: Starter Replacement Procedure

    Lower Bolt Figure 138 Figure 139 Bolts Location. 4. Remove the existing starter from the side of the engine. Front of Front of Machine Machine Figure 140 Starter Removal. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 203 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 142 Harnesses Installation. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 204: 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 190130AG...

  • Page 205: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 206 M62330AA Figure 147 M62304AA Figure 149 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 190130AG...
  • Page 207 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 154 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 208 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 190130AG...
  • Page 209 6. Install the hex nuts and the eyebolt onto the bracket. Remove any tie-wraps on the hose ends. M62290AA Figure 161 Side Access Hole M62299AA Figure 159 Install with Mounting Bracket Down 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 210 13. Remove any tie-wraps and install the cable track fasteners to secure it to the carrier assembly. M62309AA Figure 163 M62308AA Figure 165 14. Connect the hoses to the tubes as previously marked. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 211 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 167 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 212: 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 190130AG...
  • Page 213 M62293AA Figure 173 Sheave Guards M62310AA Figure 171 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 214 Carefully maneuver it when pulling outward. Set the carrier assembly down on the support stand to re-sling as required. M62294AA Figure 174 Hoses Connected to Bulkhead Plate M62284AA Figure 176 SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 215 Figure 177 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 178 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 216 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 180 6. Push the carrier assembly the rest of the way in. SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...

  • Page 217: 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°. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 218: 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 190130AG...

  • Page 219: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 220 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 190130AG...

  • Page 221: 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. 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...

  • Page 222: Bearing Installation

    4. To install the bearings, use a bearing driver or a press that fully contacts the outer race of the bearing. 5. If applicable, apply grease to the inner ring of the bearing. Bearing Driver SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS 190130AG...
  • Page 223 Section 5 – Procedures Bearing Installation Figure 181 Bearing Orientation 190130AG SJ1044 TH, SJ1044 THS, SJ1056 TH, SJ1056 THS, SJ1256 THS...
  • Page 224 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.

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