Skyjack SJ643 TH Manuals

Manuals and User Guides for Skyjack SJ643 TH. We have 2 Skyjack SJ643 TH manuals available for free PDF download: Service Manual, Operating Manual

Skyjack SJ643 TH Service Manual (171 pages)

Brand: Skyjack | Category: Forklifts | Size: 18.71 MB

Table of Contents
4
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
26
Tire/Wheel Specifications
27
Recommended Fluids/Lubrication
28
Pressure Setting
29
Standard Hose Numbering System
30
Torque Specifications for Fasteners (US)
32
Torque Specifications for Fasteners (Metric)
33
Torque Specifications for Hydraulic Couplings & Hoses
34
Air Conditioner Temperature/Pressure Chart
35
Section 3 - System Component Identification and Schematics
36
Electrical Symbol Chart
37
Hydraulic Symbol Chart
38
Electrical Schematic Parts List
39
Hydraulic Schematic Parts List
42
Hydraulic Pump and Return Filter Ports Identification
44
Steering Control Unit Ports Identification
45
Service Brake Actuator (Brake Pedal) Ports Identification
46
Auxiliary Block Ports Identification
47
Joystick Port Identifications
48
Premium Joystick Port Identifications
49
Premium Joystick Manifold Port Identifications
50
Optional Reserve Brake Manifold Port Identification
51
Major Components Identification and Location
52
Main Control Valve Port Identification
53
Enclosed Cab Harness & Wiring Diagram
56
Glow Plug Harness & Wiring Diagram
57
Road Lights Harness & Wiring Diagram
58
Work Lights Harness & Wiring Diagram
59
Boom Lights Harness & Wiring Diagram
60
Beacon Light Harness & Wiring Diagram
61
Elevate Telematics Harness
62
A/C Harness
63
Heater & A/C Harness
64
CVT Vehicle Harness
65
CVT Transmission Harness
66
Console Harness and Layout
67
Console Harness Wiring Diagram
68
Engine Harness
69
Engine Harness Wiring Diagram
70
Chassis Harness
71
Chassis Harness Wiring Diagram
72
Electrical Schematic
73
Electrical Schematic - Premium Joystick
76
Electrical Schematic for CVT
79
Electrical Schematic for CVT with Premium Joystick
83
Hydraulic Schematic
87
Hydraulic Schematic (Reserve Brake Option)
88
Hydraulic Schematic - Premium Joystick
89
Hydraulic Schematic (Reserve Brake) - Premium Joystick
90
Section 4 - Troubleshooting Information
92
Introduction
92
Electrical System
93
Engine will Not Crank
93
Engine Cranks but will Not Run
94
All Electrical Controls Inoperative
94
Park Brake will Not Release
95
Transmission will Not Engage
96
No Forward Drive
96
No Reverse Drive
97
No 1St Speed Range
97
No 2Nd Speed Range
97
10 No Boom Up, Front Steer Mode Only
98
11 Front Steer Mode Only
98
12 No 4W (Round) Steer Mode
98
13 No Crab Steer Mode
99
14 No Boom up
99
15 Frame will Not Tilt over 40° with Boom below 40
100
16 No Frame Level
101
17 Function Does Not Switch
103
Hydraulic System
105
All Controls Inoperative
105
No Boom Functions
105
No Carriage Tilt
107
No Frame Level
108
No Aux. Functions
109
Hard or no Steering
109
Park Brake will Not Release
110
Park Brake will Not Engage
110
Service Brake will Not Engage
110
Section 5 - Procedures
112
General
112
Safety and Workmanship
112
Engine and Transmission
112
Hour or Daily Routine Maintenance
113
Check Engine Oil Level
113
Check Coolant Level, Radiator and Hoses
113
Check Transmission Fluid Level
114
Check Air Cleaner Restriction and Filter Elements
114
Check Hydraulic Oil Level
115
Drain Fuel/Water Separator
116
Fuel Tank
116
Check Parking Brake
116
Check Tire Pressure and Condition
116
10 Check Seat Belt and Mounting Hardware
117
11 Check Windshield Washer Fluid Level and Wiper Condition
117
Hour or Weekly Routine Maintenance
117
Grease Axle Pivot Bearings and King Pins
117
Grease Drive Shaft U-Joints and Slip Joints
118
Check Fork Pins
119
Grease Frame Level Pivot Bushings
119
Grease Boom Pivot and Boom Cylinders
119
Grease Bottom Front & Top Rear Slide Pads
120
Hour or Quarterly Routine Maintenance
121
Check Lug Nut Torque
121
Check Oil Level in Axle Differential Planetary Wheel Ends
121
Check Oil Level in Axle Differentials
122
Replace Engine Oil and Filter
122
Change Engine Fuel Filter and Fuel/Water Separator
124
Clean Hydraulic Tank Breather
126
Torque Axle Mounting Bolts
126
Inspect Boom Chains
126
Check Boom Slide Pad Clearances
127
10 Check Boom Chains Tension
129
11 Chain Tension Adjustment
130
1000 Hour or Annual Routine Maintenance
131
Change Hydraulic Oil Filter
131
Change Hydraulic Oil and Clean Hydraulic Tank
132
Change Axle Differential Oil
133
Change Axle Planetary Oil
133
Change Engine Coolant
134
Change Transmission Oil and Filter
136
Change Continuously Variable Transmission (CVT) Oil and Filter
138
Inspect Boom Chains
140
Non-Routine Maintenance
140
Boom Hoses and Sheaves Replacement
140
Boom Chains Replacement
144
Slide Pads Replacement Procedure
148
Hydraulic Pressure Test Procedure
150
Hydraulic Pump Testing Procedure
153
T12000 Modulation
153
Deutz Fault Codes
157
Starter Replacement Procedure
160
Bleeding Hydraulic Circuits
162
Electronic Tilt Switch Setup Procedure
163
Tilt Switch Replacement
163
Reprogramming Existing Tilt Switch
164
Test and Verify Tilt Circuit
165
Park Brake Release
167
Bearing Installation
168

Skyjack SJ643 TH Operating Manual (108 pages)

TELEHANDLER

Brand: Skyjack | Category: Boom Lifts | Size: 7.76 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

15
- Electrocution Hazard
  15
- Safety Precautions
  16
- Cab Access
  20
- Jobsite Inspection
  20
Section 3 - Familiarization

21
- Component Identification
  22
- Manual Storage Box
  23
- Control Functions
  23
- Safety Features and Devices
  29
  - Reverse Alarm
    29
  - Parking Brake
    29
  - Operator's Cab
    29
  - Operator's Seat
    29
  - Boom Interlock
    30
  - Frame Level
    30
- Optional Equipment
  31
- Optional Attachments
  33
  - Side Tilt Carriage
    33
  - Swing Carriage
    33
  - Block Forks
    34
  - Jib Boom
    34
  - Loader Bucket
    35
  - Truss Boom
    35
  - Fork Positioner
    36
  - Personnel Work Platform
    36
Section 4 - Pre-Operation

37
- Operator's Responsibility
  37
- Visual & Daily Maintenance Inspections
  38
  - Labels
    38
  - Electrical
    38
  - Hydraulic
    38
  - Cylinders
    38
  - Mirrors
    39
  - Frame
    39
  - Engine Compartment
    42
  - Transmission
    42
  - Boom
    43
  - 10 Lifting Attachment
    43
  - 11 Grease Fittings
    43
  - 12 Operator's Cab
    44
  - 13 Operator's Cab Controls
    45
- Function Tests
  46
- Operator's Checklist
  54
Section 5 - Operation

55
- Starting the Engine
  56
- Driving the Telehandler
  56
  - Driving on Level Terrain
    56
  - Driving on Slopes
    56
- Steering the Telehandler
  57
  - Four-Wheel Steering
    57
  - Front Steering (Two-Wheel)
    57
  - Crab Steering
    57
- Operating the Boom
  58
  - Raising or Lowering Boom
    58
  - Extending or Retracting Boom
    58
- Leveling the Telehandler
  58
- Tilting the Attachment
  58
- Handling Loads
  58
- Handling Loads at Ground Level
  59
  - Picking up a Load
    59
  - Transporting a Load
    59
  - Placing a Load
    60
- Handling Loads at Variable Heights
  60
  - Picking up a Load
    60
- Parking and Shutting down the Telehandler
  61
- DEUTZ Engine Data Display Module
  62
  - Function Buttons
    62
  - Contrast & Illumination Settings
    62
  - Engine Main Display
    62
  - Quad Display
    63
  - Graphic Display
    63
  - Error Messages
    63
  - Display Configuration
    64
- Use of the Capacity Charts
  66
  - Examples on Reading the Capacity Chart
    67
- Attachments Installation and Adjustment
  68
- Slinging Loads
  70
- Third-Party Attachments
  70
- Platforms for Elevating Personnel
  71
Section 6 - Additional Procedures

77
- Refueling Procedure
  77
  - Diesel Fuel
    77
- Lifting Skyjack SJ643 TH & SJ843 TH
  78
- Loading, Tie-Downs and Transporting
  79
- Towing the Telehandler
  80
- Using the Telehandler as a Tow Vehicle
  81
  - Towing Pin
    81
  - Pintle Hitch (if Equipped)
    81
Section 7 - Specifications

83
Section 8 - Labels

89
- Models SJ643 TH & SJ843 TH
  90
Section 9 - Unique Skyjack Features

106

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Skyjack SJ643 TH Service Manual (171 pages)

Table of Contents

Skyjack SJ643 TH Operating Manual (108 pages)

Table of Contents

Section 1 - about Your Telehandler

Section 2 - Operator Safety

Section 3 - Familiarization

Section 4 - Pre-Operation

Section 5 - Operation

Section 6 - Additional Procedures

Section 7 - Specifications

Section 8 - Labels

Section 9 - Unique Skyjack Features

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