Skyjack SJ1256 THS Telehandler Manuals

Manuals and User Guides for Skyjack SJ1256 THS Telehandler. We have 3 Skyjack SJ1256 THS Telehandler manuals available for free PDF download: Service Manual, Manual, Operating Manual

Skyjack SJ1256 THS Service Manual (225 pages)

Brand: Skyjack | Category: Forklifts | Size: 33.02 MB

Table of Contents
5
Section 1 - Scheduled Maintenance
10
Read and Heed
10
Telehandler Definition
10
Purpose of Equipment
10
Use of Equipment
10
Manual
10
Service Policy and Warranty
10
Operator Safety Reminders, Warnings and Precautions
10
Maintenance and Inspection Schedule
11
Owner's Annual Inspection Record
11
Replacement Parts
11
Maintenance and Service Safety Tips
11
Hydraulic System & Component Maintenance and Repair
12
Maintenance Hints
12
About this Section
13
Service Bulletins
13
Maintenance and Inspection
13
Maintenance Instructions
13
Scheduled Maintenance Inspections
15
Labels - a
15
Electrical
15
Mirrors - a
15
Hydraulic
15
Cylinders - a
16
Frame
16
Engine Compartment
19
Transmission
20
Boom - a
20
10 Lifting Attachment - a
20
11 Grease Fittings - B
21
12 Operator's Cab
21
Function Tests
23
Section 2 - Maintenance Tables
24
Standard and Optional Equipment
25
Specifications and Features
27
Recommended Fluids/Lubrications
29
Tire/Wheel Specifications
31
Pressure Settings
32
Standard Hose Numbering System
33
Torque Specifications for Fasteners (US)
35
Torque Specifications for Fasteners (Metric)
36
Torque Specifications for Hydraulic Couplings & Hoses
37
Air Conditioner Temperature/Pressure Chart
38
Section 3 - System Component Identification and Schematics
39
Electrical Symbol Chart
40
Hydraulic Symbol Chart
41
Electrical Components Parts List
42
Hydraulic Components Parts List
45
Hydraulic Pump and Return Filter Ports Identification
49
Steering Control Unit Ports Identification
50
Service Brake Actuator (Brake Pedal) Ports Identification
51
Auxiliary Block Ports Identification
52
Joystick Port Identifications
53
Premium Joystick Port Identifications
54
Premium Joystick Manifold Port Identifications
55
Rear Axle Stabilization Manifold Port Identification
56
Outrigger Manifold Port Identifications
57
Reserve Brake Manifold Port Identifications (Option)
58
Anti-Cavitation Relief Valve (SJ1256 THS Only)
59
Major Components Identification and Location
60
Main Manifold Port Identification
61
Enclosed Cab Harness & Wiring Diagram
64
Glow Plug Harness & Wiring Diagram
65
Road Lights Harness & Wiring Diagram
66
Work Lights Harness & Wiring Diagram
67
Boom Lights Harness & Wiring Diagram
68
Beacon Light Harness & Wiring Diagram
69
RAS System Schematic and Wiring
70
Elevate Telematics Harness
71
A/C Harness
72
Heater & A/C Harness
73
CVT Vehicle Harness
74
CVT Transmission Harness
75
Console Harness and Layout 74 HP
76
Console Harness Wiring Diagram 74HP
77
Console Harness and Layout 107 HP - THS Models
78
Console Harness Wiring Diagram 107 HP - THS Models
79
Engine Harness 74 HP
80
Engine Harness 74 HP Wiring Diagram
81
Engine Harness Diagram 107 HP - THS Models
82
Engine Harness Wiring Diagram 107 HP
83
Chassis Harness
84
Chassis Harness Wiring Diagram
85
Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH
86
Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH
89
Electrical Schematic 74 HP Engine with CVT - SJ1044 TH & SJ1056 TH
92
Electrical Schematic 74 HP Engine with CVT and Premium Joystick- SJ1044 TH & SJ1056 TH
96
Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS
100
Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH
103
Electrical Schematic 107 HP Engine with CVT - SJ1044 TH & SJ1056 TH
106
Electrical Schematic - SJ1256 THS
110
Electrical Schematic for CVT - SJ1256 THS
113
Hydraulic Schematic - SJ1044 TH/THS & SJ1056 TH/THS
117
Hydraulic Schematic (Reserve Brake Option) - SJ1044 TH/THS & SJ1056 TH/THS
118
Hydraulic Schematic, Premium Joystick - SJ1044 TH/THS & SJ1056 TH/THS
119
Ths
120
Hydraulic Schematic - SJ1256 THS
121
Hydraulic Schematic (Reserve Brake Option) - SJ1256 THS
122
Hydraulic Schematic for Premium Joystick- SJ1256 THS
123
Section 4 - Troubleshooting Information
124
Introduction
124
Electrical System
125
Engine will Not Crank
125
Engine Cranks but will Not Run
126
All Electrical Controls Inoperative
126
Park Brake will Not Release
127
Transmission will Not Engage
128
No Forward Drive
128
No Reverse Drive
128
No 1St Speed Range
129
No 2Nd Speed Range
129
10 No Boom Up, Front Steer Mode Only
130
11 Front Steer Mode Only
130
12 No 4W (Round) Steer Mode
130
13 No Crab Steer Mode
130
14 No Boom up
131
15 Frame will Not Tilt over 40° with Boom below 40
132
16 No Frame Level
133
17 RAS Remains Fully Locked (RAS Indicator Remains Illuminated)
136
18 RAS Remains Locked
137
19 Function Does Not Switch
137
20 Outriggers Inoperative
138
Hydraulic System
140
All Controls Inoperative
140
No Boom Functions
140
No Carriage Tilt
142
No Frame Level
143
No Aux. Functions
144
Hard or no Steering
144
Park Brake will Not Release
144
Park Brake will Not Engage
145
Service Brake will Not Engage
145
10 Outriggers Inoperative
145
Section 5 - Procedures
146
General
146
Safety and Workmanship
146
Engine and Transmission
146
Hour or Daily Routine Maintenance
147
Check Engine Oil Level
147
Check Coolant Level, Radiator and Hoses
147
Check Transmission Fluid Level
148
Check Air Cleaner Restriction and Filter Elements
148
Check Hydraulic Oil Level
149
Drain Fuel/Water Separator
150
Fuel Tank
150
Check Parking Brake
150
Check Tire Pressure and Condition
150
10 Check Seat Belt and Mounting Hardware
151
11 Check Windshield Washer Fluid Level and Wiper Condition
151
Hour or Weekly Routine Maintenance
152
Grease Axle Pivot Bearings and King Pins
152
Grease Drive Shaft U-Joints and Slip Joints
152
Check Fork Pins
153
Grease Frame Level Pivot Bushings and Axle Lock Cylinder
153
Grease Boom Pivot and Boom Cylinders
153
Grease Bottom Front & Top Rear Slide Pads
154
Hour or Quarterly Routine Maintenance
155
Check Lug Nut Torque
155
Check Oil Level in Axle Differential Planetary Wheel Ends
155
Check Oil Level in Axle Differentials
156
Replace Engine Oil and Filter
156
Change Engine Fuel Filter and Fuel/Water Separator
158
Clean Hydraulic Tank Breather
160
Torque Axle Mounting Bolts
160
Inspect Boom Chains
160
Check Boom Slide Pad Clearances
162
10 Check Boom Chains Tension
163
11 Chain Tension Adjustment
164
12 E-Chain and Hoses Inspection
165
1000 Hour or Annual Routine Maintenance
166
Change Hydraulic Oil Filter
166
Change Hydraulic Oil and Clean Hydraulic Tank
166
Change Axle Differential Oil
167
Change Axle Planetary Oil
168
Change Engine Coolant
169
Change Transmission Oil and Filter
173
Change Continuously Variable Transmission (CVT) Oil and Filter
175
Inspect Boom Chains
177
Inspect RAS System (Rear Axle Stabilization) Functionality
177
Non-Routine Maintenance
179
Boom Hoses and Sheaves Replacement
179
Boom Chains Replacement
183
Slide Pads Replacement Procedure
189
Hydraulic Pressure Test Procedure
191
Hydraulic Pump Testing Procedure
195
T12000 Modulation
195
Deutz Fault Codes
199
Starter Replacement Procedure
202
Bleeding Hydraulic Circuits
204
10 Cable Track Replacement
205
11 Carrier Assembly Replacement
212
Electronic Tilt Switch Setup Procedure
217
Tilt Switch Replacement
217
Reprogramming Existing Tilt Switch
218
Test and Verify Tilt Circuit
219
Park Brake Release
221
Bearing Installation
222

Skyjack SJ1256 THS Manual (206 pages)

TELEHANDLERS

Brand: Skyjack | Category: Lifting Systems | Size: 26.74 MB

Table of Contents
5
Section 1 - Scheduled Maintenance
11
Read and Heed
11
Telehandler Definition
11
Purpose of Equipment
11
Use of Equipment
11
Manual
11
Service Policy and Warranty
11
Operator Safety Reminders, Warnings and Precautions
11
Maintenance and Inspection Schedule
12
Owner's Annual Inspection Record
12
Replacement Parts
12
Maintenance and Service Safety Tips
12
Hydraulic System & Component Maintenance and Repair
13
Maintenance Hints
13
About this Section
14
Service Bulletins
14
Maintenance and Inspection
14
Maintenance Instructions
14
Scheduled Maintenance Inspections
16
Labels - a
16
Electrical
16
Mirrors - a
16
Hydraulic
16
Cylinders - a
17
Frame
17
Engine Compartment
20
Transmission
21
Boom - a
21
10 Lifting Attachment - a
21
11 Grease Fittings - B
22
12 Operator's Cab
22
Function Tests
24
Section 2 - Maintenance Tables
25
Standard and Optional Equipment
26
Specifications and Features
28
Recommended Fluids/Lubrications
30
Tire/Wheel Specifications
32
Pressure Settings
33
Standard Hose Numbering System
34
Torque Specifications for Fasteners (US)
36
Torque Specifications for Fasteners (Metric)
37
Torque Specifications for Hydraulic Couplings & Hoses
38
Air Conditioner Temperature/Pressure Chart
39
Floor Loading Pressure
40
Section 3 - System Component Identification and Schematics
41
Electrical Symbol Chart
42
Hydraulic Symbol Chart
43
Electrical Components Parts List
44
Hydraulic Components Parts List
47
Hydraulic Pump and Return Filter Ports Identification
51
Steering Control Unit Ports Identification
52
Service Brake Actuator (Brake Pedal) Ports Identification
53
Auxiliary Block Ports Identification
54
Joystick Port Identifications
55
Premium Joystick Port Identifications
56
Premium Joystick Manifold Port Identifications
57
Rear Axle Stabilization Manifold Port Identification
58
Outrigger Manifold Port Identifications
59
Anti-Cavitation Relief Valve (SJ1256 THS Only)
60
Major Components Identification and Location
61
Main Manifold Port Identification
62
Enclosed Cab Harness & Wiring Diagram
65
Glow Plug Harness & Wiring Diagram
66
Road Lights Harness & Wiring Diagram
67
Work Lights Harness & Wiring Diagram
68
Boom Lights Harness & Wiring Diagram
69
Beacon Light Harness & Wiring Diagram
70
RAS System Schematic and Wiring
71
Elevate Telematics Harness
72
A/C Harness
73
Transmission Electrical Connections
74
Console Harness and Layout 74 HP
75
Console Harness Wiring Diagram 74HP
76
Console Harness and Layout 107 HP - THS Models
77
Console Harness Wiring Diagram 107 HP - THS Models
78
Engine Harness 74 HP
79
Engine Harness 74 HP Wiring Diagram
80
Engine Harness Diagram 107 HP - THS Models
81
Engine Harness Wiring Diagram 107 HP
82
Chassis Harness
83
Chassis Harness Wiring Diagram
84
Electrical Schematic 74 HP - SJ1044 TH & SJ1056 TH
85
Electrical Schematic 74 HP Premium Joystick - SJ1044 TH & SJ1056 TH
88
Electrical Schematic 107 HP - SJ1044 THS & SJ1056 THS
91
Electrical Schematic 107 HP , Premium Joystick- SJ1044 TH & SJ1056 TH
94
Electrical Schematic - SJ1256 THS
97
Hydraulic Schematic - SJ1044 TH/THS & SJ1056 TH/THS
100
Hydraulic Schematic, Premium Joystick - SJ1044 TH/THS & SJ1056 TH/THS
101
Hydraulic Schematic - SJ1256 THS
102
Hydraulic Schematic for Premium Joystick- SJ1256 THS
103
Section 4 - Troubleshooting Information
104
Introduction
104
Electrical System
106
Engine will Not Crank
106
Engine Cranks but will Not Run
107
All Electrical Controls Inoperative
107
Park Brake will Not Release
108
Transmission will Not Engage
109
No Forward Drive
109
No Reverse Drive
109
No 1St Speed Range
110
No 2Nd Speed Range
110
10 No Boom Up, Front Steer Mode Only
111
11 Front Steer Mode Only
111
12 No 4W (Round) Steer Mode
111
13 No Crab Steer Mode
111
14 No Boom up
112
15 Frame will Not Tilt over 40° with Boom below 40
113
16 No Frame Level
114
17 RAS Remains Fully Locked (RAS Indicator Remains Illuminated)
117
18 RAS Remains Locked
118
19 Function Does Not Switch
118
20 Outriggers Inoperative
119
Hydraulic System
121
All Controls Inoperative
121
No Boom Functions
121
No Carriage Tilt
123
No Frame Level
124
No Aux. Functions
125
Hard or no Steering
125
Park Brake will Not Release
125
Park Brake will Not Engage
126
Service Brake will Not Engage
126
10 Outriggers Inoperative
126
Section 5 - Procedures
127
General
127
Safety and Workmanship
127
Engine and Transmission
127
Hour or Daily Routine Maintenance
128
Check Engine Oil Level
128
Check Coolant Level, Radiator and Hoses
128
Check Transmission Fluid Level
129
Check Air Cleaner Restriction and Filter Elements
129
Check Hydraulic Oil Level
130
Drain Fuel/Water Separator
131
Fuel Tank
131
Check Parking Brake
131
Check Tire Pressure and Condition
131
10 Check Seat Belt and Mounting Hardware
132
11 Check Windshield Washer Fluid Level and Wiper Condition
132
Hour or Weekly Routine Maintenance
133
Check Fork Pins
133
Hour or Quarterly Routine Maintenance
133
Check Lug Nut Torque
133
Check Oil Level in Axle Differential Planetary Wheel Ends
134
Check Oil Level in Axle Differentials
134
Replace Engine Oil and Filter
135
Change Engine Fuel Filter and Fuel/Water Separator
137
Clean Hydraulic Tank Breather
138
Torque Axle Mounting Bolts
138
Inspect Boom Chains
139
Check Boom Slide Pad Clearances
140
10 Check Boom Chains Tension
142
11 Chain Tension Adjustment
143
12 E-Chain and Hoses Inspection
144
13 Grease Axle Pivot Bearings and King Pins
144
14 Grease Drive Shaft U-Joints and Slip Joints
145
15 Grease Frame Level Pivot Bushings
146
16 Grease Boom Pivot and Boom Cylinders
146
17 Grease Bottom Front & Top Rear Slide Pads
147
1000 Hour or Annual Routine Maintenance
148
Change Hydraulic Oil Filter
148
Change Hydraulic Oil and Clean Hydraulic Tank
148
Change Axle Differential Oil
149
Change Axle Planetary Oil
150
Change Engine Coolant
151
Change Transmission Oil and Filter
155
Inspect Boom Chains
157
Inspect RAS System (Rear Axle Stabilization) Functionality
157
Non-Routine Maintenance
159
Boom Hoses and Sheaves Replacement
159
Boom Chains Replacement
163
Slide Pads Replacement Procedure
169
Hydraulic Pressure Test Procedure
171
Hydraulic Pump Testing Procedure
175
T12000 Modulation
175
Deutz Fault Codes
179
Starter Replacement Procedure
182
Bleeding Hydraulic Circuits
184
10 Cable Track Replacement
185
11 Carrier Assembly Replacement
192
Electronic Tilt Switch Setup Procedure
197
Tilt Switch Replacement
197
Reprogramming Existing Tilt Switch
198
Test and Verify Tilt Circuit
199
Park Brake Release
201
Bearing Installation
202
A/C Diagram
204

Skyjack SJ1256 THS Operating Manual (106 pages)

Brand: Skyjack | Category: Boom Lifts | Size: 9.29 MB

Table of Contents
5
Section 1 - about Your Telehandler
9
Read and Heed
9
Telehandler Definition
9
Purpose of Equipment
9
Use of Equipment
9
Manual
9
Operator
9
Service Policy and Warranty
9
Ownership of Machine
9
Optional Accessories
9
Scope of this Manual
10
Symbols & Nomenclature
11
Forklift Hand Signals
11
Major Assemblies
12
Serial Number Nameplate
12
Operator's Responsibility for Maintenance
13
Maintenance and Inspection Schedule
13
Owner's Inspections
13
Section 2 - Operator Safety
14
Electrocution Hazard
14
Safety Precautions
15
Cab Access
19
Jobsite Inspection
19
Section 3 - Familiarization
20
Component Identification
21
Manual Storage Box
22
Control Functions
22
Operator's Cab Controls
22
Standard Multi-Functional Joystick
23
Premium Multi-Functional Joystick (if Equipped)
24
Operator's Cab Dash Controls
25
Safety Features and Devices
28
Reverse Alarm
28
Parking Brake
28
Operator's Cab
28
Operator's Seat
28
RAS (Rear Axle Stabilization) System
29
Boom Interlock
29
Frame Level
29
General Components
29
Outriggers (if Equipped)
29
Optional Equipment
30
Positive Air Shutoff Switch (if Equipped)
30
Reserve Braking System (if Equipped)
30
Flashing Beacon (if Equipped)
30
Road Lights, Boom Lights & Work Lights (if Equipped)
30
Fire Extinguisher (if Equipped)
30
Back-Up Sensor with Display Buzzer (if Equipped)
30
Back-Up Sensor/Camera with Monitor (if Equipped)
31
Optional Attachments
32
Side Tilt Carriage
32
Swing Carriage
32
Block Forks
33
Jib Boom
33
Loader Bucket
34
Truss Boom
34
Fork Positioner
35
Section 4 - Pre-Operation
36
Operator's Responsibility
36
Visual & Daily Maintenance Inspections
37
Labels
37
Electrical
37
Hydraulic
37
Cylinders
37
Mirrors
38
Frame
38
Engine Compartment
41
Transmission
41
Boom
42
10 Lifting Attachment
42
11 Grease Fittings
42
12 Operator's Cab
43
13 Operator's Cab Controls
44
Function Tests
45
Test Starter Operation
45
Test Horn
46
Test Lights (if Equipped)
46
Test Boom Functions
47
Test Attachment Functions
47
Test Frame Leveling and Level Indicator
48
Test Boom Interlock & Rear Axle Stabilization (RAS) System
48
Test Accelerator Pedal
49
Test Reverse Alarm, Driving, and Service Brake
49
10 Test Parking Brake
50
11 Test Steering
50
12 Test Outriggers (if Equipped)
52
13 Test Back-Up Sensor with Display Buzzer (if Equipped)
52
14 Test Back-Up Sensor/Camera with Monitor (if Equipped)
52
Operator's Checklist
53
Section 5 - Operation
54
Starting the Engine
55
Driving the Telehandler
55
Driving on Level Terrain
55
Driving on Slopes
55
Steering the Telehandler
56
Four-Wheel Steering
56
Front Steering (Two-Wheel)
56
Operating the Boom
57
Raising or Lowering Boom
57
Extending or Retracting Boom
57
Leveling the Telehandler
57
Tilting the Attachment
57
Handling Loads
57
Handling Loads at Ground Level
58
Picking up a Load
58
Transporting a Load
58
Placing a Load
59
Handling Loads at Variable Heights
59
Picking up a Load
59
Parking and Shutting down the Telehandler
60
DEUTZ Engine Data Display Module
61
Function Buttons
61
Contrast & Illumination Settings
61
Engine Main Display
61
Quad Display
62
Graphic Display
62
Error Messages
62
Display Configuration
63
Use of the Capacity Charts
64
Examples on Reading the Capacity Chart
65
Attachments Installation and Adjustment
66
Installing Attachments Using the Quick Attach Feature
66
Removing Attachments Using the Quick Attach Feature
66
Adjusting Forks
67
Changing Forks
67
Slinging Loads
68
Third-Party Attachments
68
Section 6 - Additional Procedures
69
Refueling Procedure
69
Diesel Fuel
69
Diesel Exhaust Fluid (DEF) (if Equipped)
69
Selective Catalytic Reduction (SCR) and Standstill
70
Standstill
70
Lifting SJ1044 TH/THS, SJ1056 TH/THS, & SJ1256 THS
72
Loading, Tie-Downs and Transporting
74
Towing the Telehandler
75
Using the Telehandler as a Tow Vehicle
76
Towing Pin
76
Pintle Hitch (if Equipped)
76
Section 7 - Specifications
77
Standard and Optional Equipment
77
Specifications and Features
79
Tire/Wheel Specifications
81
Recommended Fluids/Lubrications
82
Section 8 - Labels
84
Model SJ1044 TH/THS, SJ1056 TH/THS, SJ1256 THS
85
Section 9 - Unique Skyjack Features
103

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