VR1056D Ingersoll Rand Manual

SERVICE MANUAL
TELEHANDLERS
MODEL VR-1056D
155167AD March 2014

This manual is based on Serial Number(s):
VR 1056D 87 300 001 to 87 300 303
Please refer to the website (www.skyjack.com) for older Serial Numbers.
Skyjack Service Center Parts & Service (Europe)

3451 Swenson Ave. St. Charles, Unit 1 Maes Y Clawdd
Illinois, 60174 USA Maesbury Road Industrial Estate
Phone: 630-262-0005 Oswestry, Shropshire SY10 8NN UK
Toll Free: 1-800-275-9522 Phone: +44-1691-676-235
Fax: 630-262-0006 Fax: +44-1691-676-238
Email: service@skyjack.com E-mail: info@skyjackeurope.co.uk
Parts (North America) Skyjack Brasil

Toll Free: 1-800-965-4626 Alameda Júpiter, 710
Toll Free Fax: 1-888-782-4825 Loteamento American Park Empresarial
E-mail: parts@skyjack.com Indaiatuba, SP, Brasil 13347-653
Tel: +55 19 3936 0132
Skyjack Australia Pty Ltd.
4 Coates Place
Wetherill Park
New South Wales 2164
Australia
Tel: +61 (0) 28786 3200
Fax: +61(0) 28786 3222
SERVICE AND MAINTENANCE
Table of Contents
Section 1 - Scheduled Maintenance

Table of Contents
Section 2 - Maintenance Tables

List of Tables
Section 3 - Schematics
List of Contents
Section 4 - Troubleshooting
Troubleshooting
Section 5 - Procedures
List of Procedures
VR Telehandler Series
Model VR-1056D December 2007 Page 3
155167
The Safety Alert Symbol identifies important
safety messages on telehandlers, safety signs This Safety Alert Symbol means attention!
in manuals or elsewhere. When you see this
symbol, be alert to the possibility of personal Become alert! Your safety is involved.
injury or death. Follow the instructions in the
safety message.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.
IMPORTANT
IMPORTANT indicates a procedure essential for safe operation and which,
if not followed, may result in a malfunction or damage to the telehandler.
Page 4 December 2007 Model VR-1056D
155167
Section 1
SCHEDULED MAINTENANCE
Table of Contents
1
Operator’s Responsibility for Maintenance
Telehandler Definition .................................................................................................................................... 7
Purpose of Equipment .................................................................................................................................. 7
Use of Equipment .......................................................................................................................................... 7
Manuals ......................................................................................................................................................... 7
Operator ........................................................................................................................................................ 7
Service Policy and Warranty ......................................................................................................................... 7
Optional Accessories .................................................................................................................................... 7
Scope of this Manual..................................................................................................................................... 8
Operator Safety Reminders........................................................................................................................... 8
Electrocution Hazard ..................................................................................................................................... 9
Safety Precautions ...................................................................................................................................... 10
Maintenance and Inspection Schedule ...................................................................................................... 15
Owner’s Annual Inspection Record ............................................................................................................ 15
Replacement Parts ...................................................................................................................................... 15
Maintenance and Service Safety Tips ......................................................................................................... 15
Jobsite Inspection ....................................................................................................................................... 15
Hydraulic System & Component Maintenance and Repair ........................................................................ 16
Maintenance Hints....................................................................................................................................... 16
Service and Maintenance

About this Section ....................................................................................................................................... 17
Service Bulletins .......................................................................................................................................... 17
Maintenance and Inspection ....................................................................................................................... 17
Maintenance Instructions ............................................................................................................................ 17
Scheduled Maintenance Inspections

1.1 Scheduled Maintenance Inspections................................................................................................... 19
1.2 Coolant Level Maintenance .................................................................................................................. 27
1.3 Function Tests ...................................................................................................................................... 28
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Notes
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Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
1
Telehandler Definition
A material handler designed primarily as a fork truck with a pivoting telescopic boom which enables it to pick and
place loads at distances as well as various lift heights.
Purpose of Equipment
The SKYJACK telehandlers are designed to lift, handle and transport agricultural or industrial products by means
of specific attachments.
Use of Equipment
The telehandler is a highly maneuverable, mobile work station. Lifting, handling and driving must be on a flat, level,
compacted surface. It can be driven over uneven terrain only when boom is fully lowered.
Manuals
Operating
The operating manual is considered a fundamental part of the telehandler. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the telehandler at all times.
Service & Maintenance

The purpose of this manual is to provide the customer with the servicing and maintenance procedures essential
for the promotion of proper machine operation for its intended purpose.
All information in this manual should be read and understood before any attempt is made to service the telehandler.
The updated copy of the manuals are found on the company’s website: www.skyjack.com.
Operator
The operator must read and completely understand both this operating manual and the safety panel label located on
the telehandler and all other warnings in this manual and on the telehandler. Compare the labels on the telehandler
with the labels found within this manual. If any labels are damaged or missing, replace them immediately.
Service Policy and Warranty

SKYJACK warrants each new VR series telehandler to be free of defective parts and workmanship for the first 12
months or 2000 hours, whichever occurs first. Any defective part will be replaced or repaired by your local SKYJACK
dealer at no charge for parts or labor. Contact SKYJACK Service Department for warranty statement extensions or
exclusions.
Optional Accessories
The SKYJACK telehandler is designed to accept a variety of optional accessories. Operating instructions for these
options (if equipped) are listed under “Attachments Installation and Operation” in Section 2 of the operating manual.
For non-standard components or systems, contact the SKYJACK Service Department at

( : 800 275-9522
7 : 630 262-0006
Include the model and serial number for each applicable telehandler.
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Operator’s Responsibility for Maintenance Section 1 - Scheduled Maintenance
Scope of this Manual

a. This manual applies to the ANSI/ASME/ITSDF and CSA versions of the VR-1056D telehandlers.
- Equipment identified with “ANSI” meets the ASME/ANSI B56.6 standard.

- Equipment identified with “CSA” meets the CSA B335-04 standard.
b. CSA (Canada)
Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this telehandler.
c. ANSI (United States)

Operators are required by the current ANSI standards to conform to national, territorial/provincial and local
health and safety regulations applicable to the operation of this telehandler.
WARNING
Failure to comply with your required responsibilities in the use and operation of the telehandler
could result in death or serious injury!
Operator Safety Reminders

A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to
follow simple and fundamental safety rules and precautions.
You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this telehandler
is mandatory. The following pages of this manual should be read and understood completely before operating the
telehandler.
Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety
devices to protect your eyes, ears, hands, feet and body.
Some attachments may not be approved for use with certain telehandler models. Use only approved attachments.
Any modifications from the original design are strictly forbidden without written permission from Skyjack.
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Electrocution Hazard
This telehandler is not electrically insulated. Use extreme caution around high-voltage overhead power lines and
maintain a Minimum Safe Approach Distance (MSAD) of 10 feet from source of power. Adhere to all federal/na-
tional, state/provincial, or local safety regulations for your own protection.
No part of telehandler or payload should be brought closer to any energized overhead electrical conductor with
nominal phase voltage rating as specified below:
Voltage Distance
750 to 150,000 10 feet
150,000 to 250,000 15 feet
250,000 20 feet
DANGER
Never approach any power line with any part of telehandler. Use extreme caution; serious injury
or death can result with contact from any power line.
IMPORTANT
Always assume electrical power sources and overhead lines are energized.
DO NOT USE TELEHANDLER AS A GROUND FOR WELDING.

DO NOT OPERATE TELEHANDLER DURING LIGHTNING OR STORMS.
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AC
Safety Precautions
Know and understand all safety precautions before going on to the next section.
WARNING
DO NOT operate this telehandler without
proper authorization and training. Failure
• DO NOT use
telehandler as a man lift
to avoid this hazard could result in death
or equip this telehandler
or serious injury.
with a personnel work
platform.
WARNING
Failure to heed the following safety
precautions could result in tip over,
falling, crushing, or other hazards leading
to death or serious injury. • DO NOT use carriage or
any other portion of the
• MAKE SURE all DANGER, WARNING, boom for slinging loads
CAUTION and INSTRUCTIONAL DECALS are in
place and can be read. Clean or replace decals
as required.
• KNOW all national, state/provincial and local

rules which apply to your telehandler and jobsite.
• DO NOT elevate the
• WEAR all the protective clothing and personal boom in windy or gusty
safety devices issued to you or called for by job conditions.
conditions.
• DO NOT wear loose

clothing, dangling neck-
ties, scarves, rings, wrist-
watches or other jewelry • DO NOT drive with boom
while operating this tele- elevated.
handler.
• DO NOT operate on
• DO NOT climb on this surfaces not capable of
vehicle for any reason. holding the weight of the
telehandler; including the
rated load (e.g., covers,
drains, and trenches).
• DO NOT stand on forks.

Use of forks to lift person-
nel is strictly prohibited. • DO NOT maneuver a load
while moving. This greatly
increases the chance of
spills and injury.
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Safety Precautions (Continued)

• DO NOT exceed the maximum safe operating
slope.
• DO NOT lower the boom
unless the area below is
clear of personnel and
obstructions.
• DO NOT elevate the

boom while the telehan-
dler is on a truck, forklift
or other device or vehicle.
• ENSURE that there are

• DO NOT use frame leveling no personnel or obstruc-
when boom is elevated. It tions in the path of travel,
is recommended that fram including blind spots.
leveling be used only when
boom is retracted and in
the lowered position.
• BE AWARE of crush-
ing hazards. Keep head,
• DO NOT use the frame arms, hands, legs and all
leveling mechanism to other body parts inside
compensate for swinging the operator’s cab at all
loads. times.
• AVOID jerks and sudden

• DO NOT enter the danger area under or around stops.
the boom when forks are off the ground or while
engine is running.
• AVOID entanglement
with ropes, cords or hos-
es.
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AC

• BE AWARE of all obstructions while traveling.
Check for clearance before traveling between ob-
stacles. • ALWAYS wear your seat
belt when operating this
vehicle.
• KNOW the weight of the

load you are transport-
ing. Never lift more than
the lifting capacity at any
given extension or eleva-
tion of the boom as listed
• USE CAUTION when on the load charts.
boom is fully extended.
The further out the boom
is extended, the less load
telehandler can support. • CHECK for cracks and
signs of stress.
• USE CAUTION when

placing loads at high el-
evations and on downhill • TRAVEL SLOWLY over
slopes. rough terrain.
• If operation in
areas with holes or
• WALK AROUND the drop-offs is absolute-
telehandler before ly necessary, ensure
operation and check that all 4 wheels or stabi-
for any visible signs of lizers (if equipped) have
damage or malfunction. contact with firm surface.
Then level the frame.
Once frame is level the
boom can be elevated. After elevation, the drive
function must not be activated.
• DRIVE DOWNHILL
• ALWAYS maintain three UNLOADED. Without a
points of contact when load, the back end is the
entering vehicle. Use heaviest part of the tele-
provided hand-holds and handler. Driving downhill
steps only. decreases potential for
tipover.
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AC

• DRIVE UPHILL LOAD- • TETHER LOADS that

ED. When holding a load, may swing, keeping them
driving uphill decreases close to the ground. Pro-
potential for load to slip vide ample clearance for
out. personnel to guide the
load safely.
• SLINGING LOADS is
• LEVEL FRAME ON acceptable only when the
2
SLOPES before elevating load is appropriately at-
boom tached to a jib boom or
1 the throat of a tilted fork,
and the precautions out-
lined in Section 1.1 are
followed.
• WHEN
TRANSPORTING
LOADS fully retract the • BE AWARE of the tele-
boom, keep the load low handler’s travel envelope,
to the ground and forks especially when turning.
tilted back slightly. This is Keep sufficient clearance
the most stable position at all times between the
possible for the vehicle. telehandler and any ob-
stacles or people.
• KEEP forks close to the
ground when in motion
to increase telehandler
stability and decrease po-
tential for injury to others. • KEEP OTHERS AWAY at
When fully stopped, lower all times during operation.
forks completely to the
ground.
• TILT forks backward

slightly when traveling to
decrease potential of load
slipping off. • CHECK lights for proper
function before operating.
• SECURE loose loads with

chains or straps to de-
crease potential of spills • ENSURE ALL tires are in
or injury to others. good condition and lug
nuts are properly tight-
ened.
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• DO NOT alter or disable safety devices. • DO NOT change steering mode while the
telehandler is traveling. Change the steering
• DO NOT burn or drill holes in forks. Modifying mode only when telehandler is stopped.
any part of telehandler or attachment affects its
capacity and/or stability. • ALWAYS look in the direction of travel. Reduce
speed and be especially careful when traveling
• DO NOT try to start the telehandler by pushing or in reverse and/or turning. Bring the telehandler
towing. Such operation may cause severe dam- to a complete stop before changing the direction
age to the transmission. of travel.
• IF DRIVING ON ROADS OPEN TO PUBLIC • STAY CLEAR of pinch points and rotating
TRAFFIC respect the local regulations. parts on the material handler. Getting caught
in a pinch point or a moving part can cause
serious injury or death. Before performing any
• THE OPERATOR’S CAB provides a falling maintenance on telehandler, follow the shutdown
object protection structure (FOPS) and a rollover procedure on Section 2.9-9 of the operating
protection structure (ROPS). Do not make manual.
any modification to this structure. If
damaged, the cab cannot be repaired. It must be • DO NOT position the telehandler against an-
replaced. other object to steady the load.
• STUNT driving and horseplay are prohibited. • SHUT DOWN by positioning the telehandler in
a safe location. Lower boom to ground, apply
• ALWAYS USE FRONT steering when traveling the parking brake, move all controls to ‘neutral’
on highways and public roads. and allow engine to idle for 3 to 5 minutes. Stop
engine and remove ignition key to prevent unau-
thorized use. Block wheels.
WARNING
Always engage park brake and shut off
engine before leaving the operator’s cab.
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Consult SKYJACK’s Service Department for optional
WARNING
tires specifications and installation.
Operator should not use any telehandler
that:
WARNING
• does not appear to be working properly.
• has been damaged or appears to have worn or Any unit that is damaged or not operating
missing parts. properly must be tagged and removed
• has alterations or modifications not approved by immediately from service until proper
the manufacturer. repairs are completed.
• has safety devices which have been altered or
disabled.
• has been tagged or locked out for non-use or Maintenance and Service Safety Tips
repair. Maintenance and repair should only be performed by
• bears an unapproved attachment. personnel who are trained and qualified to service this
telehandler.
Failure to avoid these hazards could
result in death or serious injury. All maintenance and service procedures should be
performed in a well lighted and well ventilated area.
Maintenance and Inspection Schedule Anyone operating or servicing this telehandler must read
The actual operating environment of the telehandler and completely understand all operating instructions
governs the use of the maintenance schedule. The and safety hazards in this manual and operating manual.
inspection points covered in Table 1.1. Maintenance
and lnspection Checklist, indicates the areas of the All tools, supports and lifting equipment to be used
telehandler to be maintained or inspected and at what must be of proper rated load and in good working order
intervals the maintenance and inspections are to be before any service work begins. Work area should be
performed. kept clean and free of debris to avoid contaminating
components while servicing.
Owner’s Annual Inspection Record
All service personnel must be familiar with employer
It is the responsibility of the owner to arrange quarterly
and governmental regulations that apply to servicing
and annual inspections of the telehandler. Table 1.1.
this type of equipment.
Owner’s Annual lnspection Record is to be used for
recording the date of the inspection, owner’s name,
Keep sparks and flames away from all flammable or
and the person responsible for the inspection of the
combustible materials.
telehandler.
Properly dispose of all waste material such as lubricants,
Replacement Parts rags, and old parts according to the relative law
Use only original replacement parts. Parts such as provisions obtaining in the country.
wheels, etc. with weight and dimensions different from
original parts will affect stability of the telehandler and Preventive maintenance is the easiest and least
must not be used without manufacturer’s consent. expensive type of maintenance.
All replacement tires must be of the same size and load Jobsite Inspection
rating as originally supplied tires; to maintain safety and • Do not use in hazardous locations.
stability of telehandler. • Perform a thorough jobsite inspection prior to
operating the telehandler, to identify potential
Replacement attachments must be equivalent to the hazards in your work area.
originals and be associated with manufacturer approved • Be aware of moving equipment in the area. Take
capacity charts. appropriate actions to avoid possible collision.
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Hydraulic System & Component Maintenance 6. All hydraulic components must be disassembled
and Repair in spotlessly clean surroundings. During
The following points should be kept in mind when disassembly, pay particular attention to the
working on the hydraulic system or any component: identification of parts to assure proper reassembly.
Clean all metal parts in a clean mineral oil solvent.
Be sure to thoroughly clean all internal passages.
WARNING
After the parts have been dried thoroughly, lay
Escaping fluid from a hydraulic pressure them on a clean, lint-free surface for inspection.
leak can damage your eyes, penetrate
the skin and cause serioud injury. Use 7. Replace all O-rings and seals when overhauling
proper personal preotection at all times. any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
amounts of petroleum jelly to hold O-rings in
1. Any structure has limits of strength and durability. place during assembly.
To prevent failure of structural parts of hydraulic
components, relief valves which limit pressure 8. Be sure to replace any lost hydraulic oil when
to safe operating values are included in the completing the installation of the repaired
hydraulic circuits. component, and bleed any air from the system
when required.
2. Tolerance of working parts in the hydraulic system
is very close. Even small amounts of dirt or 9. All hydraulic connections must be kept tight. A
foreign materials in the system can cause wear loose connection in a pressure line will permit
or damage to components, as well as general the oil to leak out or air to be drawn into the
faulty operation of the hydraulic system. Every system. Air in the system can cause damage
precaution must be taken to assure absolute to the components and noisy or erratic system
cleanliness of the hydraulic oil. operation.
3. Whenever there is a hydraulic system failure Maintenance Hints

which gives reason to believe that there are metal Three simple maintenance procedures have the
particles or foreign materials in the system, drain greatest effect on the hydraulic system performance,
and flush the entire system and replace the filter efficiency and life. Yet, the very simplicity of them may
cartridges. A complete change of oil must be be the reason they are so often overlooked. What are
performed under these circumstances. they? Simply these:
4. All containers and funnels used in handling 1. Change filters annually. The filters will need
hydraulic oil must be absolutely clean. Use a to be changed more often depending on the
funnel when necessary for filling the hydraulic operating conditions. Dirty, dusty, high moisture
oil reservoir, and fill the reservoir only through environments may cause the hydraulic system
the filter opening. The use of cloth to strain the to be contaminated more quickly.
oil should be avoided to prevent lint from getting
into the system. 2. Maintain a sufficient quantity of clean hydraulic oil
of the proper type and viscosity in the hydraulic
5. When removing any hydraulic component, be reservoir.
sure to cap and tag all hydraulic lines involved.
Also, plug the ports of the removed components. 3. Keep all connections tight.
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Section 1 - Scheduled Maintenance Service and Maintenance
About this Section Maintenance Instructions

This section contains the maintenance and inspection This manual consists of four maintainance schedules
schedule that is to be performed. to be done on a telehandler. Inspection schedule
frequency is shown below:
References are made to the procedures in Section 5
that outline detailed step-by-step instructions for checks Inspection Schedule
and replacements. Daily A
Weekly or 40 hours A+B
Service Bulletins Quarterly or 250 hours A+B+C
Before performing any scheduled maintenance Annually or 1000 hours A+B+C+D
inspection procedure, refer to service bulletins found
in our web site: www.skyjack.com for updates related • Make copies of the maintenance and inspection
to service and maintenance of this telehandler. checklist to be used for each inspection.
• Check the schedule on the checklist for the type

Maintenance and Inspection of inspection to be performed.
Death or injury can result if the telehandler is not kept
in good working order. Inspection and maintenance • Place a check in the appropriate box after each
should be performed by competent personnel who inspection procedure is completed.
are trained and qualified on maintenance of this
telehandler. • Use the maintenance and inspection checklist and
step-by-step procedures in Section 5 to perform
WARNING these inspections.
Failure to perform each procedure as
presented and scheduled may cause • If any inspection receives a fail, tag and remove
death, serious injury or substantial the telehandler from service.
damage.
• If any telehandler component(s) has been repaired,
NOTE an inspection must be performed again before
Preventive maintenance is the easiest and removing the tag. Place a check in the repair
least expensive type of maintenance. column.
• Unless otherwise specified, perform each Legend

maintenance procedure with the telehandler in the P = Pass
following configuration: F = Fail
R = Repaired
- Telehandler parked on a flat and level surface
- Engine is turned off.
• Repair any damaged or malfunction components

before operating telehandler.
• Keep records of all inspections.
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AC
Service and Maintenance Section 1 - Scheduled Maintenance
Table 1.1 MAINTENANCE AND INSPECTION CHECKLIST
Serial Number:
Model:
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
P - PASS  DAILY Daily A
F - FAIL  WEEKLY or 40 HOURS Weekly or 40 Hours A+B
R - REPAIRED  QUARTERLY OR 250 HOURS Quarterly or 250 Hours A+B+C
 ANNUALLY or 1000 HOURS Annually or 1000 Hours A+B+C+D
Schedule P F R Schedule P F R
Schedule Maintenance Inspections Change Transmission Filter D
Labels A Boom
Electrical A Main pins and bushings C,D
Mirrors A subcarriage pins and bushings C,D
Hydraulic A Rollers and Tracks C,D
Cylinders A,B,C,D Slide Pads B,C,D
Frame Chain(s) A,C
Wheel/Tire Assembly A Boom Angle Indicator A
Batteries and Cables A Proximity Sensor A
Engine Air Filter A,B,C Lifting Attachment A
Engine Coolant A Forks A
Muffler and Exhaust A Fork Bars and Locks A
Drive Axles Quick Attach apron A
Hub Oil C Grease Fittings
Change Differential Oil D Grease Fittings on Frame B
Pinion Seal A Grease Fittings on Boom Assembly B
Inner and Outer Shaft Seals A Operator's Cab
Hub Seals A Seat A
King Pins C,D Pedals A
Check Drive Shafts and U-Joints C,D Manual A
Axle Mounting Pins and Bushings C,D Operator's Cab Controls A
Axle Housing A Function Tests
Steer Cylinder Assembly A Operator's Cab Controls
Steer Linkage A Test Starter Operation A
Engine Compartment Test Horn A
Engine Oil A,C Test Reverse Alarm A
Engine Coolant Level A
Fuel Leaks A Test Gauges A
Hydraulic Pump A Test Lights A
Belts and Hoses A Test Switches A
Fuel Tank A Test Steering Wheel and Column A
Change Fuel Filter A,C Test Boom and Attachment Functions A
Drain Water from Fuel Filter C,D Test Frame Leveling and Level Indicator A
Hydraulic Tank A Test Frame Level Lock A
Hydraulic Oil A,D Test Accelerator Pedal A
Hydraulic Return Filter A,C Test Driving and Service Brake Functions A
Change Oil Filters A,C Test Steering A
Charging System A Test Parking Brake A
Transmission Test Stabilizers (if equipped) A
Operate and Check Shifting A 256B
Check for Leaks A
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.7 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every week or 40 hrs. Refer to Section 1 of this manual.
C - Perform Scheduled Maintenance Inspection every 3 months or 250 hours. Refer to Section 1.0 of this manual.
D - Perform Scheduled Maintenance Inspection every year or 1000 hours. Refer to Section 1 of this manual.
Note: Make a copy of this page or visit the Skyjack web site: www.skyjack.com for a printable copy.
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Section 1 - Scheduled Maintenance Scheduled Maintenance Inspections
Lifting
Attachment
Boom Safety
Stop
Operator’s
Cab
1.1 Scheduled Maintenance Inspections 1.1-2 Electrical

Before performing the scheduled maintenance Maintaining the electrical components is essential to
inspections, ensure that the telehandler is parked on a good performance and service life of the telehandler.
firm level surface.
• Ensure proper operation of all gauges
Begin the scheduled maintenance inspections by • Check charging system Ammeter/Voltmeter
checking each item in sequence for the conditions listed • Inspect the following areas for chafed, corroded
in this section. and loose wires:
• boom wiring harnesses
WARNING • frame wiring harnesses
• cab wiring harnesses
To avoid injury, do not operate a
telehandler until all malfunctions have Ensure electrical devices are properly secured with no
been corrected. signs of visible damage. Ensure there are no loose or
missing parts.
WARNING
1.1-3 Mirrors
To a v o i d p o s s i b l e i n j u r y, e n s u r e
Ensure mirrors are properly secured with no signs of
telehandler power is off during your visual
visible damage.
and daily maintenance inspections.
1.1-4 Hydraulic
NOTE
Maintaining the hydraulic components is essential to
While performing visual and daily
good performance and service life of the telehandler
inspections in different areas, be aware
Perform a visual inspection and check for leaks around
to also inspect all switches, electrical and
the following areas:
hydraulic components.
• hydraulic tank, filter(s), fittings, hoses, pump,
1.1-1 Labels
and frame surface
Refer to the labels section in this manual and determine
• all hydraulic cylinders
that all labels are in place and are legible.
• all hydraulic manifolds
• underside of the frame
• ground area under the telehandler
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Scheduled Maintenance Inspections Section 1 - Scheduled Maintenance
Bottom View
Rear Drive
Shaft
Front Axle
Rear Axle
Front Drive
Shaft
1.1-5 Cylinders - Check each lug nut for proper torque to

- Ensure all cylinders are properly secured ensure none are loose.
and there is no evidence of leakage.
To safeguard maximum stability, achieve optimum
- Grease weekly and check pins and telehandler handling and minimize tire wear, it is
bushings to ensure there is no evidence essential to maintain proper pressure in all air-
of damage. filled tires.
1.1-6 Frame - Check each tire with an air pressure gauge
and add air as needed.
• Wheel/Tire Assembly
The telehandler is either equipped with air • Drive Axle
tires or foam-filled tires. Tire and/or wheel - Ensure drive axle is properly secured,
failure could result in a telehandler tipover. there are no loose or missing parts, all
Component damage may also result if fittings and hoses are properly tightened
problems are not discovered and repaired in and there is no evidence of oil leakage.
a timely fashion.
• Steer Cylinder Assembly
- Ensure steer cylinder assembly is
WARNING properly secured, there are no loose
An over-inflated tire can explode and or missing parts, all fittings and hoses
may cause death or serious injury. are properly tightened and there is no
evidence of hydraulic oil leakage.
- Check all tire treads and sidewalls for cuts,
• Steer Linkage
cracks, punctures and unusual wear.
- Ensure there are no loose or missing
- Check each wheel for damage and cracked parts, steer linkage studs are locked and
welds. there is no visible damage.
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AC
Horn
Battery
• Batteries 5. Replace battery if damaged or incapable of

Proper battery condition is essential to good holding a lasting charge.
engine performance and operational safety.
Improper fluid levels or damaged cables and WARNING
connections can result in engine component
damage and hazardous conditions. Use original or manufacturer-approved
parts and components for the
telehandler.
WARNING
Explosion hazard. Keep flames
and sparks away. Do not smoke • Engine Air Filter
near batteries. - Ensure there are no loose or missing
parts and there is no visible damage.
WARNING - Ensure air cleaner vaccuator valve (if

applicable) is free from dirt or dust by
Battery acid is extremely corrosive -
squeezing the valve lips.
Wear proper eye and facial protection as
well as appropriate protective clothing. • Engine Coolant
If contact occurs, immediately flush with - Check coolant level by checking the
cold water and seek medical attention. recovery bottle. Level should be between
cold and hot fill (See figure at the top of
1. Check battery case for damage. the next page). Refer to Section 1.2 for
coolant level maintenance.
2. Clean battery terminals and cable ends
thoroughly with a terminal cleaning tool or • Muffler and Exhaust
wire brush. - Ensure muffler and exhaust systems are
properly secured, with no evidence of
3. Ensure all battery connections are tight. damage.
4. If applicable, check battery fluid level. If plates

are not covered by at least 1/2” (13 mm) of
solution, add distilled or demineralized water.
155167
Engine Air
Filter
Engine
Coolant
1.1-7 Engine Compartment Perform a visual inspection around the following

- Ensure compartment cover is secure and in areas:
proper working order. • hoses and fittings
• fuel pump
• fuel filter
• Engine Oil Level • fuel tank
- Maintaining the engine components
is essential to good performance and • Hydraulic Pump
service life of the telehandler. - Ensure there are no loose or missing
parts and there is no visible damage.
WARNING
Beware of hot engine components. - Ensure all bolts are properly tightened.
- Ensure all fittings and hoses are properly
• Check oil level on dipstick tightened and there is no evidence of
- Oil level should be between the “L” low hydraulic oil leakage.
and “H” high marks. Add oil as needed.
Refer to Table 2.4 for recommended oil • Belts
type. - Ensure belts are in good working
condition and have correct tension.
• Fuel Leaks Replace if belts are cracked, frayed, or
Failure to detect and correct fuel leaks will have chunks of material missing. Refer
result in an unsafe condition. An explosion or to service manual for proper replacement
fuel fire may cause death or serious injury. procedure.
• Fuel Tank
DANGER
Engine fuels are combustible. Inspect IMPORTANT
the telehandler in an open, well- Before using your telehandler ensure
ventilated area away from heaters, there is enough fuel for expected use.
sparks and flames. Always have an
approved fire extinguisher within easy - Ensure fuel filler cap is secure.
reach.
- Ensure tank shows no visible damage
and no evidence of fuel leakage.
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Engine Compartment -
Tank Side
Fuel Tank
Sight Gauge
Hydraulic
Oil Tank
• Hydraulic Tank 1.1-9 Boom

- Ensure hydraulic filler cap is secure. - Ensure there are no loose or missing parts
and there is no visible damage.
- Ensure tank shows no visible damage
and no evidence of hydraulic leakage. - Ensure all bolts and pins are properly
tightened.
• Hydraulic Oil
- Be sure that the boom is in the stowed - Ensure there are no visible cracks in welds
position, and then visually inspect the or structure and there are no signs of
sight gauge located at front of hydraulic deformation.
oil tank.
- Ensure all hoses are properly tightened and
- Add fresh clean hydraulic oil as required. there is no evidence of hydraulic leakage.
Refer to Table 2.4 for recommended oil
type. • Boom Angle Sensor
- Ensure boom angle sensor is properly
• Hydraulic Suction Filter secured with no signs of visible damage.
- Ensure filter element is secure.
- Ensure there are no signs of leakage or • Slide Pads
visible damage. - Ensure all bolts are tight, there is no
visible damage to the slide pads and that
no parts are missing.
1.1-8 Transmission
- Ensure transmission shifter is working • Chain
properly and there is no evidence of damage. - Ensure there are no loose or missing
parts and there is no visible damage
• Check oil level on dipstick
- Oil level should be in the “safe” zone. • Boom Angle Indicator
Add oil as needed. Refer to Table 2.4 for - Ensure all bolts are tight, and there is no
recommended oil type. visible damage.
155167
Boom Assembly
Lifting
Attachment
1.1-10 Lifting Attachment Grease Points on Frame

- Ensure there are no loose or missing parts 1. Ensure telehandler is on a firm level surface
and there is no visible damage. and is in stowed position.
- Ensure attachment is properly positioned and 2. Locate grease fittings (refer to label on
secured. engine compartment cover) and pump
grease in the following:
1.1-11Grease Points
Maintaining properly greased components is essential - axle pivot bearings (front and rear)
for good performance and service life of the telehandler. - axle lock cylinder (top and bottom)
If components are improperly greased, it could result
in component damage. - lift cylinder (top and bottom, both sides)
- frame level cylinders (top and bottom)
WARNING - stabilizer pins (if equipped)
Ensure that there are no personnel or
obstructions in maintenance area. - slave cylinders (top and bottom)
3. Using a creeper, slide under the frame to
Greasing intervals are based on telehandler usage
locate grease fittings and pump grease in
of 40 hours. Use of telehandler may vary significantly
the following:
and greasing frequency must be adjusted to obtain
maximum service life.
- drive shaft U-joint (front and rear)
- slip joint on drive shaft (front and rear)
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Frame and Boom

Grease Points
Grease Points on Boom Assembly 1.1-12 Operator’s Cab

1. Ensure telehandler is on a firm level surface
and is in stowed position. • Rollover and Falling Object Protective
2. Locate grease fittings (refer to label on Structure (ROPS/FOPS)
engine compartment cover) and pump - Ensure there is no visible damage.
grease in the following:
WARNING
Do not modify, drill or alter the operator’s
- main boom pivot bearing pins cab in any way.
- retract chain rollers
• Seat
- hose rollers - Ensure seat is properly secured with no
- extension chains and rollers sign of visible damage.
- slide pads - Ensure seat belt is working properly with

no sign of visible damage.
- attachment tilt cylinders (top and bottom)
• Pedals
- attachment pivot bearings - Ensure brake and accelerator pedals are
secure, no loose or missing parts, no sign
of visible damage and movements are
not obstructed.
• Manual
- Check to be sure manual storage box is
present and in good condition.
- Ensure a copy of operating manual,
and other important documentation are
enclosed in manual storage box.
- Ensure manual is legible and in good
condition.
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AC
Operator’s Cab
Steering Capacity
Wheel Charts
Transmission
Shifter
Single Joystick
Control
Brake Pedal
- Always return manual to the manual - Ensure capacity charts are in place and
storage box after use. are legible.
• Operator’s Cab Controls DANGER
Do not operate the telehandler if capacity
WARNING charts are missing or not legible.
Ensure that you maintain three points
of contact to mount/dismount the cab. 1.1-13 Slinging Loads
Use the steps of telehandler to access operator’s CAUTION

cab.
Sling loads from appropriate attachment
- Ensure door and windows (if equipped) to the jib boom or a tilted fork ONLY.
are secure and in proper working order.
1. Slinging of loads must only be performed following
- Ensure steering wheel is secured with no a complete risk assessment by a qualified person
sign of visible damage. regarding the rigging and guiding of any such load.
- Ensure all switches and controls are 2. The rated capacity of the unit and attachment
properly secured with no sign of visible at the sling position must not be exceeded. The
damage. sling must be in good repair and restrained from
- Ensure all switches and controls are movement at all times.
returned to their neutral positions and
movements are not obstructed.
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AC
1.2 Coolant Level Maintenance 5. Fill recovery bottle to full cold. See Figure 1-2.
Refer to this section for instructions on maintaining

correct coolant levels.
Recovery Bottle
1.2-1 Radiator Fill Maintenance

Figure 1-2 Recovery Bottle Location
WARNING 6. Run the engine for 25 minutes without radiator

Pressurized fluid present in radiator. cap to achieve operating temperature. Shut down
Never open radiator cap when hot. the engine.
7. Check coolant in the radiator. Refill to top if

1. Open engine vent. Leave vent open during radiator
necessary. Refill recovery bottle to full hot if
fill. Refer to Figure 1-1.
necessary.
8. Install radiator cap.
NOTE
Additional coolant may be required in the
top tank and recovery bottle after a few
operational cycles.
9. Refer to Section 5.5-8 for Radiator Draining

Procedure.
Engine Vent
Figure 1-1 Engine Vent Location
2. Remove radiator cap.
3. Fill radiator through the radiator neck until a solid,

airless stream of coolant flows out of the engine
vent, then close the engine vent.
NOTE
When filling the radiator, do not exceed
3GPM fill rate.
4. Fill radiator completely through the radiator neck.
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Function Tests Section 1 - Scheduled Maintenance
Single Joystick
Control
Steering
Wheel
Ignition
Switch
1.3 Function Tests 1.3-1 Operator’s Cab Controls

Function tests are designed to discover any malfunctions
before telehandler is put into service. The operator must WARNING
understand and follow step-by-step instructions to test
all telehandler functions. Ensure that you maintain three points of
contact to mount/dismount the cab.
IMPORTANT
Never use a malfunctioning telehandler. If • Test Starter Operation
malfunctions are discovered, telehandler
must be tagged and placed out of service. 1. Enter cab and close door (if equipped).
Repairs to telehandler may only be made
by a qualified service technician. WARNING
The seat belt must be worn at all times.
After repairs are completed, operator must perform a
pre-operation inspection and a series of function tests 2. Sit in the driver’s seat and fasten seat belt.
again before putting telehandler into service.
3. Using a spotter, adjust the mirrors.
Prior to performing function tests, be sure to read
and understand Section 2.9 - Start Operation of the 4. Ensure parking brake is engaged.
Operating manual.
WARNING
Ensure that there are no personnel or
obstructions in test area and that there
is sufficient room to test all telehandler
functions.
155167
Section 1 - Scheduled Maintenance Function Tests
Single Joystick
Control
Horn
Ignition
Switch
6. Insert key into ignition switch and select “ ” • Test Boom and Attachment Functions
on position. Turn the key to start position.
WARNING
7. Allow engine to idle for 30 seconds. Ensure there are no personnel or
obstructions in test area and there is
• Test Horn sufficient room to test all telehandler
functions.
1. Push “ ” horn on steering wheel.
Result: Horn should sound. 1. Ensure the parking brake indicator light is
on.
WARNING
2. Raise the boom by moving the joystick
If the warning indicator lights illuminate
backward.
when engine is running, immediately
Result: Boom should raise and boom
shut down the telehandler and have it
angle indicator should be functioning.
serviced.
3. Extend the boom by moving the joystick
• Test Reverse Alarm
to the right.
Result: Boom should extend and boom
1. Start engine and release park brake
extension indicators are visible.
switch.
4. Tilt attachment forward by pressing and
2. Depress service brake pedal and move
holding the left switch up .
the transmission lever to “REV” reverse
Result: Attachment should tilt forward.
position.
Result: The reverse alarm should sound.
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Attachment
Tilt Switch
Transmission
Shifter
Single Joystick
Controller
5. Tilt attachment backward by pressing and • Test Frame Leveling and Level Indicator
holding the left switch down.
Result: Attachment should tilt backward. 1. Ensure parking brake switch is on.
6. Retract the boom by moving the joystick 2. Tilt frame to the right by pressing and
to the left. holding button at back of joystick and
Result: Boom should retract. moving the joystick to the right.
Result: Frame should tilt to the right.
7. Lower the boom by moving the joystick
forward. 3. Tilt frame to the left by pressing and
Result: Boom should lower. holding button at back of joystick and
moving the joystick to the left.
8. Lower the boom until attachment is 2 feet Result: Frame should tilt to the left.
above the ground.
4. Use the frame level indicator to ensure
NOTE frame is level.
Ensure to test all attachment functions
if telehandler is equipped with optional
attachments.
155167
RAS (Rear Axle Stabilization) • Test RAS (Rear Axle Stabilization)

The RAS system automatically locks the rear axle
to the frame through a hydraulic cylinder. This 1. Drive telehandler so that one of the
system which is independent of the telehandler’s rear wheels is up on the block. The
hydraulic system, contains a bracket and trunnion telehandler’s front and rear axles will not
mounted cylinder that is attached between the be on the same plane.
frame and the axle lug and a proximity sensor
mounted to the frame. 2. Raise boom up in the air more than 40°.
With either the parking brake or service brake 3. Apply the service brake sufficiently to
applied, this system locks the rear axle to the frame engage the RAS system (the amber RAS
if the boom is raised 40° (or more) relative to the indicator will light).
frame on level ground.
4. Applying pressure to the service brake (so
NOTE the RAS is still engaged), slowly back off
While the system is engaged, an amber of the block.
indicator light illuminates. Result: The rear axle’s position should be
held as long as the RAS is engaged.
WARNING
5. Engage the parking brake and release the
Failure to recognize and identify RAS service brake.
(Rear Axle Stabilization) failure or Result: The rear axle’s position should be
operational problems will compromise held as long as the RAS is engaged.
machine stability. Serious injury or death
may result. 6. Release the parking brake.
Result: Both of the rear wheels should
NOTE touch the ground.
Testing the RAS (rear axle stabilization)
system requires use of a solid wooden
block (10 cm x 10 cm [4 in x 4 in] or similar
structure) that is capable of being driven on
and support one wheel of the rear axle.
155167
Steering Capacity
Wheel Charts
Transmission Steering
Shifter Selector Switch
Ignition Switch
Brake Pedal
Throttle Pedal
• Test Accelerator Pedal 6. Depress service brake pedal slowly.

Result: Telehandler should stop.
1. Ensure parking brake switch is on.
7. Move transmission lever to “REV” reverse
2. Depress accelerator pedal slowly. position and release the service brake
Result: The engine RPM should increase. pedal slowly.
Result: Telehandler should move
3. Release the accelerator pedal. backward.
Result: The engine RPM should decrease.
8. Depress service brake pedal slowly.
Result: Telehandler should stop.
• Test Driving & Service Brake Functions
9. Return transmission lever to neutral
1. Ensure path of intended motion is clear. position and engage parking brake.
2. Ensure all four wheels are aligned straight

ahead. • Test Steering
3. Depress service brake pedal. CAUTION
4. Release parking brake. Before changing steering modes, bring

Result: Parking brake indicator light all four wheels into alignment (i.e., in the
should turn off. straight-ahead position).
5. Lift transmission lever up from lock WARNING

position and move to “FWD” forward
Before driving on public roads and
position then release the service brake
highways check the alignment of the
pedal slowly.
wheels and drive with FRONT steering
Result: Telehandler should move forward.
only.
155167
Steering Capacity
Wheel Charts
Ignition Switch
Brake Pedal
Throttle Pedal
4. Press the upper portion of the steering

WARNING
mode selector switch “ ” for 4 wheel
Do not change steer mode while steering.
telehandler is traveling.
5. Turn the steering wheel left or right and
NOTE drive forward.
Avoid steering the wheels while telehandler Result: Telehandler should move in the
is stationary. chosen direction, producing a turning
circle, with front wheels pointing in the
opposite direction to the rear wheels.
Coordinated (4 wheel)
6. Steer telehandler straight ahead until all
four wheels are aligned.
7. Depress service brake pedal until

telehandler stops.
Front Steer (2 wheel)
Figure 2-4. 4 Wheel Steering
1. Ensure path of intended motion is clear.
2. Ensure all four wheels are aligned straight

ahead.
3. Release parking brake switch and depress Figure 2-5. Front Steering
service brake pedal.
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Steering Capacity
Wheel Charts
Ignition Switch
Brake Pedal
Throttle Pedal
8. Select steering mode selector switch to 12. Press the lower portion of the steering
middle “ ” position for front steering. mode selector switch to backward “ ”
for crab steering.
9. Turn steering wheel to left or right and
drive forward. 13. Turn steering wheel left or right and drive
Result: Only front wheels of telehandler forward.
should turn in chosen direction. Result: Telehandler should move in
chosen direction with both front and rear
10. Steer telehandler straight ahead until all wheels in the same direction.
four wheels are aligned.
14. Steer telehandler straight ahead until all
11. Depress service brake pedal until four wheels are aligned.
telehandler stops.
Crab Steer 15. Depress service brake pedal until

telehandler stops.
• Test Parking Brake
CAUTION
Refer to Section 2.9-3 of Operating
manual for instructions on how to drive
on a slope.
1. Ensure path of intended motion is clear.

Figure 2-6. Crab Steering
155167
Steering Capacity
Wheel Charts
Transmission
Shifter
Park Brake
Left and Right Switch
Stabilizer Switches
2. Move park brake switch to “ON” position. Always raise the stabilizers completely
Result: Red indicator light on park brake before driving the telehandler. Failure to
switch illuminates. have the stabilizers in the upright position
may result in damage to the telehandler.
3. Depress service brake pedal then press
park brake test switch. NOTE
To enhance telehandler stability,
4. Rotate transmission range selector to ‘2’ stabilizers are best used in combination
(2nd gear) position, then lift and move with the automatic Rear Axle Stabilization
the direction lever to the “FWD” forward (RAS) system.
position.
1. Ensure parking brake switch is on.
5. Depress throttle pedal completely to the
floor and slowly remove pressure from 2. Lower stabilizers by pressing down and
service brake pedal. holding rocker switch “ ”.
Result: Telehandler should not move Result: Stabilizers s h o u l d
forward.
lower down.
• Test Stabilizers (if equipped) 3. Raise stabilizers by pressing up “ ”

and holding rocker switch until
stabilizers are fully raised.
WARNING Result: Stabilizers should raise up.
Stabilizers stabilize the telehandler when

lifting and placing a load only. They are
not outriggers and are not designed to lift
the telehandler.
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Notes
155167
Section 2
MAINTENANCE TABLES AND DIAGRAMS
Table of Contents
Tables
Table 2.1 Standard & Optional Features ................................................................................................... 38
Table 2.2 Specifications and Features ...................................................................................................... 39
Table 2.3 Tire/Wheel Specifications .......................................................................................................... 40
Table 2.4 Recommended Fluids/Lubrication ............................................................................................ 41
Table 2.5 Pressure Settings....................................................................................................................... 42
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Tables Section 2 - Maintenance Tables and Diagrams
Table 2.1 Standard & Optional Features
MODEL VR-1044D VR-1056D
Diesel Engine � �
Four-wheel drive � �
Three-Speed Transmisson � �
Three-Mode Steering � �
Open/Enclosed Operator's Cab � �
Spring-applied Hydraulically Released
� �
Parking Brake
Operator horn � �
Reverse/Backup alarm � �
Rotating Beacon � �
Four-Wheel Fenders � �
Engine Block Heater � �
Hydraulic Test Port � �
Air Filled Tires � �
Foam Filled Tires � �
Road/Work/Boom Lights � �
Boom Safety Stop � �
Stabilizers � �
Rear Axle Stabilization System (RAS) � �
Frame Leveling System � �
48" QA 10K Fork Carriages � �
60" / 72" QA Fork Carriages � �
72" Swing Carriage � �
1.75 Cu. Yd. Bucket Loader Attachment � �
60S QA Fork Positioning Carriage � N/A
12 ft. Truss Boom � �
15 ft. Truss Boom � �
Drywall Handler Attachment � �
Scrap Grapple Bucket Attachment � �
241B
Legend
� = Standard
� = Optional
N/A = Not Available
155167
Section 2 - Maintenance Tables and Diagrams Tables
Table 2.2 Specifications and Features
MO D EL V R -1044D V R -1056D
Engine
Standard Cummins Tier 3 QSB3.3 Turbocharged
Cylinders 4
Horsepower @ 2400 RPM 110 HP
Capacity 199 cu.in. (3261 cm3)
Torque @ 1500 RPM 302 lb. ft (409 N-m)
Fuel type Diesel
Transmission
Type Powershift with soft shift
Speeds forward 3
Speeds reverse 3
Travel Speeds
Range 1 0-4 mph (1-7 km/h)
Range 2 5-8 mph (8-13 km/h)
Range 3 9-20 mph (14-32 km/h)
Electrical
Negative ground 12 Volts
Alternator 62 Amps
Battery 900 Amps
Backup Alarm 107 DBM
Dimensions
Wheelbase 128 in (325 cm) 133 in (337 cm)
Overall width 102 in (259 cm)
Overall height 97 in (247 cm) 98 in (248 cm)
Overall length (less forks) 254 in (644 cm) 270 in (686 cm)
Ground clearance 16 in (41 cm)
Maximum weight without attachment 29,980 lb (13,598 kg) 34,500 lb (15,649 kg)
Turn radius (inside) 71 in (181 cm) 86 in (218 cm)
Turn radius (outside) 147 in (373 cm) 153 in (389 cm)
Boom
Number of sections 3 4
Maximum lift height 44 ft. 5 in (1354 cm) 56 ft. 3 in (1714 cm)
Maximum forward reach 26 ft 4 in (803 cm) 41 ft 5 in (1262 cm)
2¼ x 5 x 48 in
Standard Forks
(5.72 x 12.70 x 121.92 cm)
Carriage rollback 23°
Carriage forward tilt 90°
244B
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Table 2.3 Tire/Wheel Specifications
VR-1044D VR-1056D
Tire Size 13.00 x 24TG G2 14.00 x 24TG G2
Tire Ply Rating 14 12
Pressure 75 psi (517.2 kPa)
Wheel Nuts Torque 442 ft-lb (600 Nm)
231A
WARNING
Intermixing tires of different types or using tires of types other than those originally supplied with
this equipment can adversely affect stability. Therefore, replace tires only with the exact original
Skyjack-approved type. Failure to operate with matched approved tires in good condition may
result in death or serious injury.
IMPORTANT
For proper function of each axle differential, all four wheels must have same tire size installed at
all times. Failure to comply with this requirement will reduce the life of the differentials and reduce
overall mobility of telehandler.
155167
Section 2 - Maintenance Tables and Diagrams Tables
Table 2.4 Recommended Fluids/Lubrication
VR-1044D VR-1056D
Fuel Type Diesel (#2 ASTMD-975-60T)
Fuel Tank Capacity 35 gal (132 L)
Recommended Oil Type SAE 15W40
ne
gi
Capacity 7.4 Quart (7.0 L)

En
Coolant Type 50% Water/50% Glycol

Capacity 4 gal (15.2 L)
on
Oil Type Multipurpose ATF

si
is
ms
an
Capacity 13.6 Quart (12.9 L)

Tr
Differential Mobilube HD
Front Axle Capacity 15.6 Quart (14.76 L)
s
18 Quart (17.03 L)
le
Rear Axle Capacity

Ax
Planetary Wheel Ends SAE 80W-90EP

Capacity 2 Quart (1.89 L)
il
Type Multipurpose ATF

O
lic
au
dr
Tank Capacity 40 gal (151 L)

Hy
243B
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Table 2.5 Pressure Settings
Model VR-1056D
Pilot Pressure 500 psi
Fork Tilt Port Relief 3625 psi
Stabilizers Pilot Pressure 500 psi
System
Standby Pressure 550 psi
Maximum Pressure 3480 psi
Steering
Neutral 400 psi
Maximum 2600 psi
Brakes
Service Brakes 850-900 psi
258A
Note: All pressure settings to be completed with engine running at idle
155167
Section 3
SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Table of Contents
Charts
3.1 Electrical Symbol Chart ........................................................................................................................ 44
3.2 Hydraulic Symbol Chart ....................................................................................................................... 45
Diagrams and Schematics

3.3 Electrical Schematic Parts List ............................................................................................................. 46
3.4 Hydraulic Schematic Parts List ............................................................................................................ 49
3.5 Hydraulic Pump and Filter Port Identifications .................................................................................... 51
3.6 Steer Select Valve and Steering Orbitrol Port Identifications .............................................................. 52
3.7 Brake Valve (Pedal) Port Identifications ............................................................................................... 53
3.8 Stabilizer Valve Port Identifications ...................................................................................................... 54
3.9 Single Joystick Port Identifications ...................................................................................................... 55
3.10 Major Components Identification and Location ................................................................................. 57
3.11 Rear Manifold (Boom Function) Port Identification............................................................................ 58
3.12 Main Manifold Port Identification ........................................................................................................ 59
3.13 Open Cab Harness & Wiring Diagram ............................................................................................... 62
3.14 Enclosed Cab Harness & Wiring Diagram......................................................................................... 63
3.15a Stabilizer Harness & Wiring Diagram ............................................................................................... 64
3.15b Stabilizer Harness & Wiring Diagram .............................................................................................. 65
3.16 Boom Lights Harness & Wiring Diagram ........................................................................................... 66
3.17 Front Worklight, A/C, Turn Signal and Brake Harnesses & Wiring Diagrams ................................... 67
3
3.18 Console Harness and Layout............................................................................................................. 68
3.19 Console Harness Wiring Diagram...................................................................................................... 69
3.20a Chassis Harness............................................................................................................................... 70
3.20b Chassis Harness .............................................................................................................................. 71
3.21 Chassis Harness Wiring Diagram ...................................................................................................... 72
3.22 Electrical Schematic (No Options) ..................................................................................................... 73
3.23 Electrical Schematic (Optional Features) .......................................................................................... 74
3.24 Hydraulic Schematic .......................................................................................................................... 75
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System Component Identification and Schematics Section 3
3.1 Electrical Symbol Chart

ACC
CIRCUITS CROSSING B+ LIMIT SWITCH

NO CONNECTION HOURMETER IGN
KEY SWITCH
ST
N.O.
LIMIT SWITCH
CIRCUITS LIGHT FOOT SWITCH N.O. HELD
CONNECTED CLOSED
LIMIT SWITCH
HYDRAULIC
BATTERY TOGGLE SWITCH N.C.
VALVE COIL
PROPORTIONAL LIMIT SWITCH

GROUND HYDRAULIC PUSH BUTTON
N.C HELD OPEN
VALVE COIL
SILICON
ELECTRIC CONTROLLED
FUSE ROTARY SWITCH
MOTOR RECTIFIER
CIRCUIT PROXIMITY
HORN LIMIT SWITCH
BREAKER SWITCH
EMERGENCY CAM OPERATED PNP

VOLT METER STOP BUTTON LIMIT SWITCH TRANSISTOR
CAPACITOR RESISTOR NPN

TILT SWITCH
TRANSISTOR
SINGLE POLE PRESSURE

POTENTIOMETER LEVEL SENSOR SINGLE THROWN VACUUM
RELAY SWITCH
SINGLE POLE DOUBLE POLE DOUBLE POLE TEMPERATURE

DOUBLE THROW SINGLE THROW DOUBLE THROW SWITCH
RELAY RELAY RELAY
TRIPLE POLE
DOUBLE THROW DIODE RHEOSTAT
RELAY
155167
Section 3 System Component Identification and Schematics
3.2 Hydraulic Symbol Chart
ACCUMULATOR, SINGLE ACTING

LINE CROSSING HAND PUMP GAS CHARGED CYLINDER
RELIEF VALVE PRESSURE DOUBLE ACTING

LINE JOINED
SWITCH CYLINDER
DOUBLE ACTING
PRESSURE
HYDRAULIC DOUBLE
REDUCING
TANK SHUTTLE VALVE RODDED
VALVE
CYLINDER
A1 A2
HYDRAULIC SPRING APPLIED

SW
CHARGE VALVE HYDRAULIC
FILTER WITH FIXED ORIFICE
LS
DUAL RELEASED
BYPASS
P T
BRAKE
A
SW
LS
ELECTRIC ADJUSTABLE CHARGE VALVE BRAKE

MOTOR FLOW CONTROL SINGLE CYLINDER
P T
THREE POSITION TWO POSITION

CHECK VALVE SIX WAY TWO WAY
ENGINE
OPEN CENTER NORMALLY
CLOSED PORT OPEN VALVE
FIXED
DISPLACEMENT OIL COOLER COUNTER
MAIN LINES Solid
PUMP BALANCE VALVE
VARIABLE
TWO POSITION
DISPLACEMENT VALVE COIL PILOT LINES Dashed
THREE WAY VALVE
PUMP
TWO POSITION THREE POSITION

VARIABLE FOUR WAY
DISPLACEMENT TWO WAY
NORMALLY CLOSED CENTER
HYDRAULIC MOTOR OPEN PORT
CLOSED VALVE
BI DIRECTIONAL THREE POSITION

HYDRAULIC FOUR WAY DYNAMIC SIGNAL
MOTOR CLOSED CENTER PRIORITY VALVE
CLOSED PORT
L R
ORBITAL CF EF LS
STEERING PRESSURE STATIC SIGNAL

MOTOR TRANSDUCER PRIORITY VALVE
LS
P T P T
155167
3.3 Electrical Schematic Parts List

Index Skyjack
Qty. Description
No. Part No.
CR1 931298 1 RELAY, Power

CR2 931298 1 RELAY, Brake test (ALT DROOP)
CR3 931298 1 RELAY, Brake test (NEUTRAL)
CR4 931298 1 RELAY, Brake test (LATCHING)
CR5 931298 1 RELAY, Brake test (REVERSE LOCKOUT)
CR7 931298 1 RELAY, Brake test (PRESSURE SWITCH)
CR8 931298 1 RELAY, Frame level enable
CR9 931298 1 RELAY, Frame level latching
CR10 931298 1 RELAY, Starter
CR11 931298 1 RELAY, Grid heater
CR28 931298 1 RELAY, Brake lamp
F1 930807 1 FUSE, Ignition/power relay
F2 930807 1 FUSE, Transmission/backup alarm/park brake
F3 930807 1 FUSE, Steer select/gauges/indicator lamps
F4 930807 1 FUSE, Horn/beacon option
F5 931961 1 FUSE, ECM power switch
F6 930807 1 FUSE, Rear axle stabilization (RAS)
F7 932325 1 FUSE, Power port
F8 930807 1 FUSE, Rear wiper
F9 930807 1 FUSE, Frame level/fork tilt/aux hydraulic option
F10 930807 1 FUSE, Stabilizers
F11 932325 1 FUSE, Work lights
F12 932325 1 FUSE, Work lights
F13 930807 1 FUSE, Turn signals/haz./brake lights
F14 932325 1 FUSE, Boom lights
F15 930807 1 FUSE, Front wiper
F16 930807 1 FUSE, Top wiper
F17 930807 1 FUSE, Heater valve, A/C
F18 932325 1 FUSE, Washer/fan/interior light
F19 925192 1 FUSE, Blower
F20 - - FUSE, Open
F21 925192 1 FUSE, Engine ECM (BATT +)
F22 923502 1 FUSE, Grid heater
SW1 926721 1 SWITCH, Ignition
SW2 923507 1 SWITCH, Park brake
SW3 926343 1 SWITCH, Front ballast
SW4 921219 1 SWITCH, Steer select
SW5 - 1 SWITCH, Seat belt
SW6 927813 1 BUTTON, Horn
SW7 923958 1 SWITCH, Park brake test
SW8 923967 1 SWITCH, Beacon
SW9 921217 1 SWITCH, Left stabilizer
SW10 921218 1 SWITCH, Right stabilizer
SW11 920591 1 SWITCH, Work lights
SW12 927422 1 SWITCH, Turn signal/haz.
SW13 921845 1 SWITCH, Boom lights
SW14 921221 1 SWITCH, Washer
Parts list continued on following page.
155167
3.3 Electrical Schematic Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.
Parts list continued from previous page.
SW15 922753 1 SWITCH, Blower

SW16 920078 1 SWITCH, A/C
SW17 923159 1 SWITCH, A/C Temperature
TPS1 923159 1 SWITCH, Transmission temperature
TPS2 932731 1 SWITCH, Coolant temperature
PS1 927724 1 PRESSURE SWITCH, Brake (RAS)
PS2 927724 1 PRESSURE SWITCH, RAS
PUMP-PS 922964 1 PRESSURE SWITCH, Pump
PB-PS2 922963 1 PRESSURE SWITCH, Park brake (PRESSURE FROM PUMP)
JPS 920659 1 PRESSURE SWITCH, Frame level
PB-PS 922964 1 PRESSURE SWITCH, Park brake (LIGHT ON DASH)
FE1 927724 1 PRESSURE SWITCH, Left stabilizer
FR1 927724 1 PRESSURE SWITCH, Right stabilizer
PSFR1 927724 1 PRESSURE SWITCH, Stabilizer (RIGHT)
PSFE1 927724 1 PRESSURE SWITCH, Stabilizer (LEFT)
PSRJ3 927724 1 PRESSURE SWITCH, Frame level left
PSRJ1 927724 1 PRESSURE SWITCH, Frame level right
OPS1 933104 1 PRESSURE SWITCH, Oil
SPST-NO 922964 1 PRESSURE SWITCH
D1 927423 1 DIODE ASSEMBLY, Neutral switch
D2 927423 1 DIODE ASSEMBLY, Neutral switch
D6 927423 1 DIODE, Frame level latching
D7 927423 1 DIODE, Frame level isolation
D8 927423 1 DIODE ASSEMBLY, 2ND Gear
D9 927423 1 DIODE ASSEMBLY, Reverse
D10 927423 1 DIODE ASSEMBLY, Reverse
R1 - 1 COIL, Stabilizer (RETRACT RIGHT)
R2 - 1 COIL, Stabilizer (RETRACT LEFT)
E1 - 1 COIL, Stabilizer (EXTEND RIGHT)
E2 - 1 COIL, Stabilizer (EXTEND LEFT)
SV1 - 1 COIL, Frame level
SV2 922825 1 COIL, Frame level (12 VDC)
SV3 922825 1 COIL, Park brake (12 VDC)
SV4 922825 1 COIL, CRE (12 VDC)
SV5 922825 1 COIL, CRR (12 VDC)
SV6 922825 1 COIL, Slow frame level (12 VDC)
SV15 924003 1 COIL, Stabilizer lockout (12 VDC)
SV16 928747 1 COIL, Stabilizer (LEFT)
SV17 928747 1 COIL, Stabilizer (RIGHT)
SOL A 922618 1 COIL, Aux. Hyd.
SOL B 922618 1 COIL, Aux. Hyd.
155167
3.3 Electrical Schematic Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.
RH-
FORK- 922618 1 COIL, Fork Dump
DUMP
LH-
FORK- 922618 1 COIL, Fork tilt
TILT
F - 1 COIL, RAS Lock (inside rear manifold)

E - 1 COIL, RAS Restrictor (inside rear manifold)
A - 1 COIL, RAS Level right (inside rear manifold)
C - 1 COIL, RAS Level left (inside rear manifold)
155167
3.4 Hydraulic Schematic Parts List

Index Skyjack
Qty. Description
No. Part No.
C1 924004 1 CYLINDER, Front steer

C2 924004 1 CYLINDER, Rear steer
C3 929274 1 CYLINDER, Boom
C4 929274 1 CYLINDER, Boom
C5 930493 1 CYLINDER, Telescope
C6 929268 1 CYLINDER, Carriage tilt
C7 929274 1 CYLINDER, Tilt compensation/slave
C8 929274 1 CYLINDER, Tilt compensation/slave
C9 929270 1 CYLINDERS, Stabilizers
C10 929270 1 CYLINDERS, Stabilizers
C11 - 1 CYLINDER, Park brake
C12 920686 1 CYLINDER, Frame level
C13 920368 1 CYLINDER, Rear axle stabilization
CB1 928716 1 VALVE, Counterbalance (BOOM CYLINDER)
CB2 928716 1 VALVE, Counterbalance (BOOM CYLINDER)
CB3 923955 1 VALVE, Counterbalance (TELESCOPE CYLINDER)
CB4 921271 1 VALVE, Counterbalance (TELESCOPE CYLINDER)
CB5 921256 1 VALVE, Counterbalance (CARRIAGE TILT CYLINDER)
CB6 928748 1 VALVE, Counterbalance (STABILIZER CYLINDER)
- 927293 1 • VALVE, Check
CB7 928748 1 VALVE, Counterbalance (STABILIZER CYLINDER)
- 927293 1 • VALVE, Check
JS1 922265 1 JOYSTICK, Boom/telescope/tilt/frame level
OSM1 921147 1 MOTOR, Orbitrol steering
P1 923854 1 PUMP
F1 928395 1 FILTER, Tank filler
F2 926645 1 FILTER, Return
F3 928304 1 STRAINER, Suction
F4 922602 1 FILTER, Pilot oil
ACC1 923801 1 ACCUMULATOR
MB1 921702 1 MANIFOLD, Lift/telescope/tilt (REAR)
MB2 922744 1 MANIFOLD, Main (FRONT)
MB3 923997 1 MANIFOLD, Stabilizers
MB4 923865 1 MANIFOLD, Rear axle stabilization valve (RAS)
SH1 924002 1 VALVE, Shuttle (MAIN MANIFOLD)
SH7 924002 1 VALVE, Shuttle (STABILIZER MANIFOLD)
SV1 920939 1 VALVE, Solenoid (FRAME LEVEL)
SV2 922310 1 VALVE, Solenoid (MAIN MANIFOLD)
SV3 920939 1 VALVE, Solenoid (PARK BRAKE)
SV4 921159 1 VALVE, Solenoid (FRAME LEVEL CRE INTERLOCK)
SV5 921159 1 VALVE, Solenoid (FRAME LEVEL CRR INTERLOCK)
155167
3.4 Hydraulic Schematic Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.
SV6 922825 1 VALVE, Solenoid (MAIN MANIFOLD)

V7 922823 1 VALVE, Solenoid frame level (MAIN MANIFOLD)
V12 920245 1 VALVE, Solenoid (STEER SELECTOR)
MB1 921027 1 VALVE, Single joystick lift/crowd

V7 - 1 • VALVE, Frame level
V8 - 1 • VALVE, Boom lift
V9 - 1 • VALVE, Telescope
V10 - 1 • VALVE, Tilt
V11 - 1 • VALVE, Aux./Opt.
PRV3 - 1 • VALVE, Pressure reducing
SV13 923998 1 VALVE, Solenoid (C9 - STABILIZER CYLINDER)

SV14 923998 1 VALVE, Solenoid (C10 - STABILIZER CYLINDER)
SV15 924000 1 VALVE, Solenoid (STABILIZERS)
SV16 928746 1 VALVE, Solenoid (CB6)
SV17 928746 1 VALVE, Solenoid (CB7)
V18 926370 1 VALVE, Service brake actuator
CV1 927293 1 VALVE, Check (FRAME LEVEL)
LE1 922506 1 CARTRIDGE, Neutral steering pressure adjustment.
LE2 922824 1 LOGIC ELEMENT
PR1 923999 1 CARTRIDGE, Pressure reducer
OR1 921169 1 ORIFICE
RV1 925800 1 CARTRIDGE, Maximum pressure relief
PRV4 923999 1 VALVE, Pressure reducing
155167
3.5 Hydraulic Pump and Filter Port Identifications

Port X
To Port LS-PUMP
on
Main Manifold
Port TP
To Port P on
Brake Valve
(Pedal)
Port L2
To Tank Drains
Port DRN1
Port S
To Hyd. Oil Tank
Suction
Inlet Port B
To PUMP port on
Main Manifold
Outlet
Filter
Hyd. Pump Hyd. Filter
155167
3.6 Steer Select Valve and Steering Orbitrol Port Identifications
Steer Select
Valve
Port B
To Rear Right
Steer Cylinder
Port T
To Front Right
Steer Cylinder
Port T
Port L
To Main Manifold
Port P Port T3 To Front Axle
To port R STRL
on
Steering Orbitrol
Port A
To Rear Left
Steer Cylinder
Steering
Orbitrol
Port P
To port CF on Main
Manifold
Port R Port LS
To Steer Select To Main Manifold
Valve port P Port STLS
Steering Orbitrol & Steer Valve
155167
3.7 Brake Valve (Pedal) Port Identifications
Port T
Port A
To Main Manifold
To Main Manifold
Port DR1
Port BR1
Port P
To Port TP
on Hyd. Pump
Brake Pedal
155167
3.8 Stabilizer Valve Port Identifications
Port LS
to Port STAB-LS on
Main Manifold
Port E1
To Barrel End Port E Pressure Reducing
at Right Stabilizer Valve
Cylinder
Port A
To Rod End
at Left Stabilizer
Port DR
Cylinder
To Main Manifold
Port DR3
Port B
To Rod End Port T
at Right Stabilizer To Main Manifold
Cylinder Port T2
Port P
Port R1 To Main Manifold
To Rod End Port R Port EF2
at Right Stabilizer
Cylinder
Port E2
Shuttle Valve To Barrel End Port E
Port R2
at Left Stabilizer
To Rod End Port R
Cylinder
at Left Stabilizer
Cylinder
M13173331_S3
155167
3.9 Single Joystick Port Identifications
MACHINE
FRONT
"3"
"2" "P" "4"
"1" "T"
Port 2
Port P
To Port J3 on
To Port PP1
Main Manifold
on Main Manifold
Port 1
To (LIFT) Pilot Port
vb on Lift/Tele/Tilt
Manifold
Port T
To Port DR2
Port 3
on Main Manifold
To (LIFT) Pilot Port
va on Lift/Tele/Tilt
Manifold Port 4
To Port J1 on main
Manifold
M1344040201_JS
155167
Notes
3.10 Major Components Identification and Location
A B C D E F G H
CB3 & CB4
Counter Balance
MB4 Valves
MB1 Rear Axle Stabilization
Rear Manifold Manifold V
C13 C5
Rear Axle Stabilization Telescope
Cylinder Cylinder
P1
Pump
C7 & C8 CB5
Tilt Compensation/ Counter Balance
Valve W
Slave Cylinders
Level
Sensor CB1 & CB2
Counter Balance C3 & C4
Valves Boom Lift
Cylinders
X
MB2
Main
Manifold JS1
C2 Joystick C6
Rear Steer
Carriage Tilt
Cylinder
Cylinder
OSM1
Orbitrol Steering
Motor
Y
CB6
Counter Balance C9
F2 Valve Right Stabilizer
Hyd. Return Cylinder
Filter
V12
Steering Selector C12
Valve Z
Frame Level Cylinder V18
& Service Brake
CV1 C1 MB3
Actuator (Pedal)
Check Valve Front Steer Stabilizers
Cylinder Manifold Components Location
VR Telehandler Series SKYJACK, Page 57

Model VR-1056D
155167
3.11 Rear Manifold (Boom Function) Port Identification
A B C D E F G H
To Rod End of Port B (TELESCOPE)

Port A (TILT) Rear Tilt To Base End of
To Rod End of Cylinder(s) Telescope Cylinder
Fork Tilt Cylinder
V
Port A (TELESCOPE)
Port B (TILT)
To Rod End of
To Base End of
Telescope Cylinder Port T2
Fork Tilt Cylinder
To Hydraulic Oil
To Base End of Return Filter on
Rear Tilt Hydraulic Tank
Cylinder(s) Port A (LIFT)
To Port (RET) of
Port A (AUX) Right-hand Boom
Lift Cylinder W
To Rod End of
Aux. Cylinder Port a (TELESCOPE)
To Port CRR
Port B (AUX) Port A (LIFT) on Main Manifold
To Base End of To Port (RET) of
Aux. Cylinder Left-hand Boom
Port TP Lift Cylinder
Port a (LIFT)
To Port DR4 To Port 4
on Main Manifold on Joystick
REAR OF X
Port PS MACHINE
To Port PS
on Main Manifold
Port B (LIFT)
To (EXT) of Left-hand "A"
Boom Lift Cylinder TP "B" "A"
Port B (LIFT) "B"
To (EXT) of Right-hand T2
Port P1
Boom Lift Cylinder P1 To Port EF1 Y
Port b (TELESCOPE) on Main Manifold
To Port CRE P2
on Main Manifold AUX
FUNCTION
FORK
TILT
Port P2
BOOM
TELESCOPE To Port F130-P2
Port b (LIFT) BOOM on Main Manifold
To Port 1 LIFT Z
on Joystick
M13334438_0101
SKYJACK, Page 58 VR Telehandler Series

Model VR-1056D
155167
3.12 Main Manifold Port Identification
A B C D E F G H
Port DR2
To Port T
on Joystick V
Port “PUMP”
To Port B of
Hyd. Pump
Port A
To Port FLR
REAR OF W
MACHINE
Port GP2
To Hyd. Pressure Port EF2
X
Accumulator To Port P on
Stabilizers Manifold
Port PB
To Fron Axle
Park Brake Port EF1
To Port P1 on
Lift/Tele/Tilt Valve
Port PS
Port B
To Port PS on Y
To Port FLE
Port DR4
To Port TP on
Port F130-P2
To Port P2 on “STAB-LS”
Lift/Tele/Tilt Valve To Port LS of
Stabilizers Maniofld Port T2 Z
To Port T of
Port T3
To Port T on Port BR2 Port BR3 Port OR6 Port OR5
Steering Orbitrol To Front Axle To Rear Axle To Rear End of To Base End of
Port BRK-R Port BRK-R Frame Level Cylinder Frame Level Cylinder
M13443353_0201

Model VR-1056D
155167
3.12 Main Manifold Port Identification (Continued)
A B C D E F G H
SH2
Shuttle Valve
PR1 Port STLS

Pressure Reducing To Port LS on
Cartridge Steering Orbitrol
LE2 SH2 W
Logic Element Shuttle Valve
J1
Frame Level/Tele
Port PP1
Pressure Switch
To Port P on
Joystick
RV1 Port LS-PUMP

J3 Port CF To Port X on
Maximum Steering
Frame Level/Tele To Port P on Hydraulic Pump
Pressure Cartridge
Pressure Switch Steering Orbitrol
Port DR1 Port EF2
To Port T on To Port P on
MB2 Service Brake Valve Stabilizers Manifold Y
Main Manifold
Bottom View
Port CRR
To Port a (TELESCOPE)
on Lift/Tele/Tilt Valve Port T4
To Port T on
“J3”
Frame Level/Tele
From port 4 on Joystick Port T1
Port BR1
To Hyd. Tank Z
To Port A on
Service Brake Valve Return
“J1” Port CRE
Frame Level/Tele To Port b (Telescope)
From port 2 on Joystick on Lift/Tele/Tilt Valve
M13443353_0201

Model VR-1056D
155167
3.12 Main Manifold Port Identification (Continued)
A B C D E F G H
SV3 LE1 FE1 JPS

Neutral Steering SV2
Park Brake Left Stabilizer Frame Level
Pressure Adjustment Frame Level
Solenoid Valve Pressure Switch Pressure Switch
Cartridge Solenoid Valve
V
FR1
Right Stabilizer
Pressure Switch
PUMP-PS
Pump Pressure
W
Switch
PS2
PB-PS2 RAS Pressure
Park Brake Switch
Pressure Switch
PS1
Service Brake X
Pressure Switch
SH6
Shuttle Valve
RJ1
Slow Frame Level
Pressure Switch (R)
RJ3
Slow Frame Level
Pressure Switch (L) V7
Frame Level
Valve Assembly
SV5
Frame Level CRR (Crowd Retract) SH5
Solenoid Valve Shuttle Valve
SH1 SH4 Z
SV1 Shuttle Valve Shuttle Valve
Frame Level SH3
Solenoid Valve SV4
Shuttle Valve
Frame Level CRE (Crowd Extend)
Solenoid Valve
M13443353_0201-3

Model VR-1056D
155167
3.13 Open Cab Harness & Wiring Diagram
A B C D E F G H
POWER PORT
BEACON BEACON
B A V
58 DPE/RD
G207 BK
REAR WORKLIGHTS L.F. WORKLIGHTS
WASHER B A B A
REAR
WORKLIGHTS
25 DBE/GN
G201 BK
G201 BK
24 PK
WASHER W
SWITCH
LEFT FRONT
WORKLIGHTS
WASHER SWITCH
REAR WIPER
38 YW/BN 2
67 LBE/GY 3
P18 P14 P12 36 RD/WE G207 BK
X
Open Cab Harness Wiring Diagram
TO CONSOLE
HARNESS REAR WIPER
WASHER BEACON REAR LEFT FRONT

SWITCH WORKLIGHTS REAR WIPER WORKLIGHTS
POWER PORT
2 3 AB AB AB
25-2.0 DBE/GN
58-1.0 DPE/RD
67-2.0 LBE/GY
90-2.0 OE/GN
38-2.0 YW/BN
36-1.0 RD/WE
G207-2.0 BK
G207-1.0 BK
G201-2.0 BK
G207-2.0 BK
G201-2.0 BK
24-2.0 PK
GROUND
P18 P14 P18

36-1.0 RD/WE
A
A F B
Y
A C
38-2.0 YW/BN
TO C
CONSOLE D
HARNESS E
90-2.0 OE/GN
F
25 DBE/GN
36 RD/WE
90 OE/GN
38 YW/BN
G201 BK
P14
24 PK
25-2.0 DBE/GN
B
24-2.0 PK
A
G201-3.0 BK
C
S702
P12
58-1.0 DPE/RD
S706
S701 Z
67-2.0 LBE/GY
G207-2.0 BK
G207-2.0 BK
G207-2.0 BK
WASHER GND
M922795AB

Model VR-1056D
155167
3.14 Enclosed Cab Harness & Wiring Diagram
A B C D E F G H
BEACON
HEATER POT FAN B A
A
G201 BK
V
58 DPE/RD
57 TN POWER
G207 BK
55B DGN/OE
PORT TOP WIPER
C
BLOWER MOTOR G207 BK 54 BN

HEATER
1 2
POT 89 YW 62 RD/WE
G207 BK DEUTSCH
86 OE A/C TEMP SW BEACON REAR WORKLIGHTS
4 3 B A
TOP WIPER
B A
OUT
A/C SW.
56 LGN/OE
85 BK/PK
BLOWER
25 DBE/GN
(OPT.) GND
G201 BK
(+)
MOTOR
C
WASHER
BLOWER
L
A/C TEMP REAR W
SWITCH H WORKLIGHT FRONT WIPER
SW. (OPT.)
B+
G207 BK 35 WE/OE
M
B
53 LPE
55 DGN/OE FRONT
WIPER
A
P89
TO CONSOLE
HARNESS HEATER VALVE
57 TN
D C
G207 BK
L.F. WORKLIGHTS
55 DGN/OE B
REAR WIPER INT. LIGHT G201 BK
P18 P14 P12 P90 F A LEFT FRONT 24 PK X
G207 BK 36 RD/WE
WORKLIGHT A
WASHER P18 TO A/C

SWITCH P14 HARNESS
36 RD/WE HEATER REAR WIPER
(OPT.)
A
24 PK VALVE
A
38 YW/BN
25 DBE/GN
35 WE/OE A/C
WASHER SWITCH 54 BN
G201 BK
C
TEMP. SW.
90 OE/GN BLOWER (OPT.) BEACON
POWER
F
FAN MOTOR WASHER

38 YW/BN PORT TOP WIPER
67 LBE/GY
2
G207-1.0 BK REAR
3 HEATER A
57-1.0 TN
1 2 3 4 A B A B A B
B WORKLIGHT
POT. 55B-1.0 DGN/OE
38-2.0 YW/BN
25-2.0 DBE/GN
56-1.0 LGN/OE
C
58-1.0 DPE/RD
67-2.0 LBE/GY
90-2.0 OE/GN
62-5.0 RD/WE
G207-5.0 BK
G207-1.0 BK
G207-2.0 BK
G207-1.0 BK
85-1.0 BK/PK
G201-2.0 BK
G207-2.0 BK
89-5.0 YW
54-1.0 BN
86-5.0 OE
56-1.0 LGN/OE
A/C SW. OUT
55A-1.0 DGN/OE S707
(+)
(OPT.) GND
G207-1.0 BK
S706
55-1.0 DGN/OE
GROUND TO CONS. P89 A
53-3.0 LPE S700
HARNESS
Y
B
C
53-3.0 LPE
89-5.0 YW
BLOWER L
62-5.0 RD/WE
M
SWITCH H
86-5.0 OE
B+
37-5.0 DGN
WASHER 2
38-2.0 YW/BN
3
67-2.0 LBE/GY
SWITCH
S704
37-5.0 DGN
P90
S701
36-1.0 RD/WE
P18 A
B
C
38-2.0 YW/BN S703
35-1.0 WE/OE 35-1.0 WE/OE
D
54-1.0 BN
E
TO CONSOLE F
90-2.0 OE/GN
HARNESS G207-1.0 BK
S705
25-2.0 DBE/GN FRONT

P14 B
24-2.0 PK
A
G201-3.0 BK
WIPER
C
S702
P12
58-1.0 DPE/RD
Z
55-1.0 DGN/OE
36-1.0 RD/WE
G207-1.0 BK
G207-1.0 BK
38-2.0 YW/BN
G201-2.0 BK
G207-2.0 BK
24-2.0 PK
57-1.0 TN
G207-3.0 BK
G207-2.0 BK
G207-1.0 BK
G207-5.0 BK
85-1.0 BK/PK
Enclosed Cab TO A/C HARN.

(OPT) LEFT FRONT
Harness Wiring A B C D E F
HEATER
A B A B
WORKLIGHT
INT. LIGHT
Diagram GND VALVE REARWIPER
M922721AB

Model VR-1056D
155167
AC 3.15a Stabilizer Harness & Wiring Diagram
A B C D E F G H
Serial Breakdown
Reference Chart
Figure Serial Number
3.15a 87,300,226 & above
V
3.15b 87,300,225 & below
Stabilizer
Harness Wiring
Diagram
M164805AA

Model VR-1056D
155167
3.15b Stabilizer Harness & Wiring Diagram AC
A B C D E F G H
Serial Breakdown
Reference Chart STAB. LEFT
PRESS. SWITCHES STAB. SOL'S LOCKOUT SOL
Figure Serial Number B A
G202 BK 43 PK/RD
52 TN/RD
45 BN/RD
44 BK/WE
30 LBE/RD
59 DBE/BK
33 WE/GY
33 WE/GY
3.15a 87,300,226 & above
STAB. LEFT V
3.15b 87,300,225 & below
G2
A
A
A
B
B
B
42 YW/WE
ROD LOCKOUT
G202 BK
43 PK/RD
G202 BK
G202 BK
G202 BK
G202 BK
DIODE ASSY.
P16
D E
33 WE/GY
45 BN/RD 30 LBE/RD
PRESS. SWITCHES STAB. SOL'S
ROD LOCKOUT
44 BK/WE 52 TN/RD
FR1 FE1 LEFT RIGHT
W
LOCKOUT SOL.
A H A C E2 R2 E1 R1
GND
59 DBE/BK
42 YW/WE
43 PK/RD
TO CONSOLE
HARNESS STAB. RIGHT
STAB. RIGHT
P16 B A
G202 BK 42 YW/WE
G1
ROD LOCKOUT
DIODE ASSY.
STABLIZER VALVE SOL"S.
PRESS. SW'S LOCKOUT

LEFT RIGHT STAB. CYL.
SOL.
FR1 FE1 GND E2 R2 E1 R1 (L)
A B A B A B A B A B A B B A A B C
A B
42-1.0 YW/WE
59-1.0 DBE/BK
59-1.0 DBE/BK
33-1.0 WE/GY
33-1.0 WE/GY
30-1.0 LBE/RD
43-1.0 PK/RD
42-1.0 YW/WE
G202-2.0 BK
G202-1.0 BK
44-1.0 BK/WE
45-1.0 BN/RD
43-1.0 PK/RD
52-1.0 TN/RD
G202-1.0 BK
G202-1.0 BK
G202-1.0 BK
G202-1.0 BK
G202-1.0 BK
43-1.0 PK/RD
G202-1.0 BK
P16 33-1.0 WE/GY S606 Stabilizer
E
B 44-1.0 BK/WE Harness Wiring
TO CONSOLE 45-1.0 BN/RD
C Diagram
HARNESS F
30-1.0 LBE/RD
52-1.0 TN/RD
G
S603
S604
Z
42-1.0 YW/WE
A STAB. CYL.
S605 G202-1.0 BK
B (R)
S602
M923539AB

Model VR-1056D
155167
3.16 Boom Lights Harness & Wiring Diagram
A B C D E F G H
BOOM LIGHTS
B V
G600 BK
121 DBE/YW
A
GND.
P56
BOOM TO CHASSIS
W
LIGHTS HARNESS
Boom Lights Harness

G600-2.0 BK
A Wiring Diagram
BOOM LIGHTS
121-2.0 DBE/YW
B Y
S601
G600-2.0 BK G600-3.0 BK
A GND.
121-2.0 DBE/YW 121-2.0 DBE/YW TO CHASSIS
B Z
HARNESS
S600
P56
M922151AB

Model VR-1056D
155167
3.17 Front Worklight, A/C, Turn Signal and Brake Harnesses & Wiring Diagrams
A B C D E F G H
GND.
PS2
BRAKE PRESSURE V
RIGHT FRONT SWITCH
WORKLIGHT
BRAKE PRESS. SW.
B
P13 G205 BK
100 PK/RD
A
TO CONSOLE
HARNESS
B
G206 BK GND
24 PK
BRAKE LAMP RELAY
A
GND.
RF WORKLIGHT Front Worklight Harness 100 PK/RD
41 LBE
85 30 28 LPE
28 LPE
RIGHT
TURN SIGNAL/ W
& Wiring Diagram 87 86
G206-2.0 BK
BRAKE
BRAKE LAMP RELAY

RIGHT TURN SIGNAL LEFT TURN SIGNAL
C
C
G206-2.0 BK G205 BK G205 BK
A P13 41 LBE 41 LBE
40 LGN 39 YW
24-2.0 PK 24-2.0 PK TO CONSOLE
B
A
A
HARNESS
P15
RIGHT FRONT
WORKLIGHT TO CONSOLE
HARNESS
X
LEFT
P15 TURN SIGNAL/
BRAKE
28 LPE
Road Light Harness
PRESS. SW.
A
39 YW
40 LGN
& Wiring Diagram
C
PS2 RIGHT
TO ENCL. CAB A/C BRAKE PRESSURE TURN SIGNAL/
HARNESS COMPRESSOR SWITCH BRAKE Y
GND
A B A B C
41-1.0 LBE
A/C Harness
G205-2.0 BK
G205-2.0 BK
G205-1.0 BK
G205-1.0 BK
40-1.0 LGN
41-1.0 LBE
87 100-1.0 PK/RD
87A 85 LEFT
& Wiring Diagram BRAKE LAMP RELAY 28-1.0 LPE
28-1.0 LPE
TURN SIGNAL/
30
86
BRAKE
S607
G205-2.0 BK
P15 C
S609
28-1.0 LPE 41-1.0 LBE
85-1.0 BK/PK
A
88-1.0 BN
B
S608
TO CONSOLE 39-1.0 YW 39-1.0 YW Z
B A
HARNESS
40-1.0 LGN
C
TO ENCL. CAB 85-1.0 BK/PK 88-1.0 BN A/C
HARNESS COMPRESSOR
M921639AB_M921573AB_M921570AB

Model VR-1056D
155167
3.18 Console Harness and Layout
A B C D E F G H I J K L M N O
R
FUSE AMPERE J5/CR2
NO. RATING
CIRCUIT J28 J37 J35 J36 BRAKE TEST (ALT DROOP)
F4 F8 F12 F16 F20
F1 10A IGNITION/POWER RELAY
6 WE
BEACON (OPT.) BOOM LIGHTS (OPT.) WORK LIGHTS (OPT.) J30 J29 105 GY/RD
87 TN/WE 87
85
F2 10A TRANS/B-U ALARM/PARK BRAKE LEFT STABILIZER RIGHT STABILIZER 104 LGN/RD 30
6 WE
6 WE B G200 BK G200 BK G200 BK G200 BK 86
F3 10A STEER SELECT/GAUGES/INDIC LAMPS 53 LPE
9 9 9
36 RD/WE 133 DBE 54 BN 25 DBE/GN 1 4
24 PK
F4 10A HORN/BEACON OPT.
2x 9 PK/WE
55 DGN/OE 9 PK/WE
58 DPE/RD
2 124 GY/BK 2
133 DBE
24 PK
2 5
10 DGN/RD 45 BN/RD 1
52 TN/RD 1 J6/CR3
F5 5A ECM SW PWR A 3 3 33B WE/GY 2
33C WE/GY 2
BRAKE TEST (NEUTRAL)
90 OE/GN 10 DGN/RD 35 WE/OE 37 DGN 3 G200 BK
8 44 BK/WE 30 LBE/RD 23 BN/YW 85
F6 10A REAR AXLE STABIL (RAS) 3 3
F7 15A POWER PORT

2x 7 PK/BE
J32 105 GY/RD
23 BN/YW
87
30
6 WE 2x 83 DPE 2x 33 WE/GY 124 GY/BK 38 YW/BN 107 BK/OE 86
F8 10A WIPER, REAR
F9 10A FRAME LEVEL/FORK TILT/AUX HYD OPT.
8 TN 6 WE 6 WE
ENCL. CAB J26 S
F10
1 RD 123 DBE/WE 65 DPE/WE 2x 28 LPE 55 DGN/OE
OPTION
CR1 40 LGN
C J7/CR4
10A STABILIZERS
26 DGN/YW FUEL BRAKE TEST (LATCHING)
F11 15A WORK LIGHTS
2x 32 DBE/RD J28 87 30 POWER 5 OE G200 BK 39 YW GAUGE HOUR 85
23C BN/YW
F12 15A WORK LIGHTS 5 OE 53 LPE
J26
RELAY A METER 107 BK/OE 87 107 BK/OE
86 85 G200 BK 30
15A
F13 10A TURN/HAZ./BRAKE LIGHTS F17 F20
F1 F5 F9 F13 F17 85
107 BK/OE
OPTIONS
86
F14 15A BOOM LIGHTS

G (-) 87
30 J5/CR2
FUSEBLOCK - WIRE ENTRY VIEW J37 J35 J36 86
F15 10A WIPER, FRONT F13 F16

J33 J47 J34 S I (+)
87
85
J6/CR3 J8/CR5
F16 10A WIPER, TOP
ENCLOSED
F1 TO F20 J41 J85 9 9 9
"+" "-" 30
86
85
BRAKE TEST (REVERSE LOCKOUT)
SEAT BELT INDICATOR TRANS TEMP/RAS LAMPS 1 4 "S" "+"
F17 10A HEATER VALVE, A/C CAB F9
87
J7/CR4 13 LBE/WE 85
10A
F12 2 2 2 5 30
OPTION 3 3 86 119 OE/BE 87

F18 15A WASHER/FAN/INT. LIGHT G200 BK 34 OR/RD 19 GY/OE 7 PK/BE 8 6 1 8 1 85
12 WE/YW 30
9 7 9 7
101 YW/BE 11 GY 27 GY/GN
87
30 J8/CR5 G200 BK 86
F19 30A BLOWER F8 40 LGN 27 GY/GN
DEUTSCH
10A
F5
15A
28 LPE 27 GY/GN
10A
86
DEUTSCH
5A
12 WE/YW 14 YW/RD 86
27 GY/GN
F20 OPEN
39 YW 26 DGN/YW G200 BK 15 WE/BE J30 J29 30
J89/CR10 J89/CR10
F21 30A ENGINE ECM (BATT +) 84 RD G200 BK F1 F4
J39 J38 J40 4 DBE/BK 87A 87
85
STARTER T
10A
10A
10A
10A
10 8
4 3 85
F22 300A GRID HEATER 9 7 5 4 1 1 87

30 J80/CR7 17 LGN/BK
P20 P21 1 1
2
3
2
3
86
85
60 LGN/WE
86
J1 SOCKET # - WIRE NO. & COLOR B B J83 J82 J41 J85 J83 J82 J81
2 5 2 5 2 87
30 J87/CR8 31 LBE/RD
137 BK/LBE
30
1-11 GY 16-31 LBE/RD 71 GY/BK 74 TN/BK

CHECK ENGINE/STOP ALTERNATOR/WAIT
3 6 3 6 3
J52 86
85 19 GY/OE 87A 87
85
J1 2-12 WE/YW 17-109 BE/BK 66 YW/BK 66 YW/BK ENGINE LAMPS TO START LAMPS 9 7 9 7 9 7 9 7 9 7 "-"
87
30 J88/CR9
31 20
3-108 OE/WE
4-14 YW/RD
18-110 LGN/BE
19-111 RD/BK A A 110 LGN/BE 9 7
7 PK/BE 60 LGN/WE 9 7
7 PK/BE TURN/HAZ SEAT
86
J80/CR7
30 21
BRAKE TEST (PRESS SW)
B A
BELT
8
19 9
5-15 WE/BE 20-112 DBE
18 2 10
352 GN 351 YW
J33 DIODE ASSY
J34
29 22
7 3 10 8 10 8 10 8 10 8
21-113 RD
DEUTSCH
17 11
6-16 WE/RD 85
ALARM 106 BN/BK
1
28 6 4 23
FRAME LEVEL OPTIONAL

16 12
5
22-114 TN "+"
15 13
7-17 LGN/BK 13 LBE/WE 87
27
26
14
25
24
23-104 LGN/RD
TURN/HAZ. FLASHER 132 PK/RD 30
8-18 YW/GN 7 PK/BE 109 BE/BK 7 PK/BE 111 RD/BK C
9-19 GY/OE 24-115 DPE/OE PRESS SW'S 10 8 10 8 OPTIONAL J47 OPTIONAL G200 BK 86
TERM.
25-116 OE/BK FNR
10-20 RD/BE
26-103 DGN/WE RJ3 RJ1 RESISTOR
HORN GUAGE
J87/CR8
11-21 BK/PK
12-22 BN/WE 27-123 DBE/WE J81 J39 J38 J40 J32 LIGHT
13-61 LBE/BK 28-351 YW FRAME LEVEL ENABLE
14-9 PK/WE 29-352 GN
ENG TEMP/OIL PRESS LAMPS PARK BRAKE PARK BRAKE TEST STEER SELECT J52 OPTIONAL
97 OE/WE 85
U
15-7 PK/BE 30,31-N/U
P20 P21 17 LGN/BK 9 7
7 PK/BE G200 BK 9 7
106 BN/BK 65 DPE/WE 87
J2 13 LBE/WE
8 TN
1
2 5
3 LBE 105 GY/RD 2 5
87 TN/WE
21 BK/PK
7 PK/BE
1
66 YW/BK
G200 BK
30
86
2
8 1 23 BN/YW 3 6
61 LBE/BK 102 RD/GN 3 6
103 DGN/WE 22 BN/WE 3
121 DBE/YW 75 LGN/OE 7 PK/BE 18 YW/GN
J88/CR9
DEUTSCH
10 8
119 OE/BE 76 YW/WE
J25 J25
{
83 DPE 79 WE/BK FRAME LEVEL LATCHING
82 DGN 81 TN/GN
TO CHASSIS J1 FRAME ANGLE G200 BK 85
5 4 3 4 49 LBE/BK 87
HARNESS SENSOR 70 WE 73 DBE/RD

ALTERNATOR D 129 GY 30
J2 G201 BK DEUTSCH
83 DPE
RESISTOR J45 P44,P46 C E 129 GY 86
J4 2 1
B
J
A
G
F
126 BK/LBE
3 4
126 BK/LBE J4 J86 DIODE ASSYS.
H
48 TN/BN DEUTSCH
46 GY/WE TO RT. FRT. LIGHT ENGINE LED GRAY BLK 1
2 1
OPT HARN.
J13 RESISTORS C1 C2 354 YW
P51 355 LGN

356 BK
V
J27
GROUND
{
P3 P3 "GR" IGNITION P51 3
A 1 RD
G200 BK
TO CHASSIS J86 TERM SWITCH ENGINE J99 J99
JOYSTICK RAS
1 RD HARNESS J84 D DIAGNOSTIC
C 110 LGN/BE
SERVICE
J96 B 109 BE/BK PLUG
98 WE/BN 111 RD/BK TOOL
FRAME LEVEL 66 YW/BK J96 TOC-2 7 PK/BE
J84 LATCHING DIODE A
P51 PIN # - WIRE NO. & COLOR
A
A-G200 BK
50 GY/RD
B A
51 RD/GN J45 P44 P46 B-32 DBE/RD
DEUTSCH
96 BK/OE
B
J27 B A C A C A C-351 YW C1 C2
C
SV3 J9 FRAME LEVEL 129 GY
J91 D-352 GN
1
PARK BLOCKING DIODE 66 YW/BK J97 J19
32 DBE/RD
E-N/U 12 1 12 1
W
13 LBE/WE J97 A
BAT 3 LBE
F-N/U 70 WE G200 BK 73 DBE/RD
68 DBE/GN BRAKE SOL 74 TN/BK 83 DPE 83 DPE 75 LGN/OE
DEUTSCH
STRTR
DEUTSCH
108 OE/WE
102 RD/GN
IGN
137 BK/LBE G-N/U
102 RD/GN
107 BK/OE
101 YW/BE
132 PK/RD
15 WE/BE
136 WE/GY 77 RD/GY
4 DBE/BK
PR
71 GY/BK 354 YW
1
H-N/U 76 YW/WE 80 DBE
2
J91 J19 5 OE 355 LGN
IGN 2
ACC
J-N/U 356 BK 79 WE/BK 81 TN/GN
5 OE 84 RD 82 DGN
72 DGN/RD 106 BN/BK
8 1 7 6
16
7 6
8
1 92 RD/BK
DEUTSCH
130 DBE/GN 93 YW/BE
98 WE/BN 93 YW/BE
PBPS-2 80 DBE 94 BK/WE 92 RD/BK 97 OE/WE 94 BK/WE
PARK BRK INDIC P11 G201 BK P24 130 DBE/GN 92 RD/BK SEAT BELT
RAS BRK. GRAY BLACK
B PRESS SW P24 2 5 4 SWITCH
106 BN/BLK PRESS SW. PS1 126 BK/LBE 96 BK/OE
9 PK/WE
46 GY/WE 50 GY/RD J98 J98
A 48 TN/BN 51 RD/GN
C 1 X
J95 JPS 98 WE/BN
65 DPE/WE
J95
G201 BK 65 DPE/WE
13 LBE/WE
9
49 LBE/BK 34 OE/RD
SV2 A
2
B PBPS J92 FRAME LEVEL
G201 BK
68 DBE/GN PARK BRK P10 SOL. 1
136 WE/GY
A PRESS SW G201 BK J92
SV6 2 J50
J22 SLOW FRAME J14 J16 J18 J15 J12 J90
B
LEVEL SOL. 72 DGN/RD THROTTLE

83 DPE J22 WORK OPEN/ ROAD BEACON ENCL.
STAB. RAS Y
A
J50 LIGHTS ENCL. LIGHTS CAB
CAB
}
CONTROLLER
6 1
FRAME 116 OE/BK 104 LGN/RD
DEUTSCH
CRE SOL 113 RD 115 DPE/OE

J23 LEVEL SOL 112 DBE 114 TN
SV4 J93 OPTIONS
SV1 4 3
J94
1
J14 J18
CRR SOL 77 RD/GY J16 F
J15
G201 BK 90 OE/GN
1 SV5 G201 BK
C A H 54 BN
40 LGN
C
2 35 WE/OE
129 GY
G201 BK 1
25 DBE/GN
24 PK
44 BK/WE
45 BN/RD
52 TN/RD
30 LBE/RD 38 YW/BN
39 YW Z
28 LPE
33 WE/GY
129 GY A 36 RD/WE A
2
G201 BK D E A
M923496AC_XL
SKYJACK, Page 68 NOTE: To determine the correct hydraulic/electrical schematic that resembles your telehandler, VR Telehandler Series
refer to the “Table Of Contents” found at the beginning of this section. Model VR-1056D
155167
3.19 Console Harness Wiring Diagram
ENG LED RESISTORS

R
LAMP
5100 OHM 1 WATT
ALTERNATOR ALT. CHECK
DIODE DIODES TRANS. SW4 SW2 SW7 SW11
RESISTOR STABILIZER
ENGINE CHECK HIGH SW8 SW5
56 OHM 5 WATT STEER MODE PARK BRAKE SW. PARK BRAKE TEST SW. WORK LIGHTS SW13 SW9 SW'S (OPTION) SW10 CR1
CR6 STOP ENGINE TEMP. RAS SW12
SELECT SW. SEAT BELT BEACON SW. SW. (OPTION) SEAT BELT SEAT BELT SW1
SW6 BOOM LIGHTS FLASHER TURN/HAZ L.H. R.H. POWER RELAY
INDICATOR (OPTION) SWITCH TURN/HAZ SWITCH (OPT) ALARM IGN. SW.
S379 S380 SW (OPT) (OPTION) DIODE ASSY (OPT) 33B S305 33C
RD YW YW YW HORN
SWITCH
2 2 5 2 5
- +
2 2 GR
30 87
9 2 5 5 PR ST ACC IGN IGN B+
8 10 7 9 9 7 10 8 7 9 9 9
A B C D 87 30 86 87A 85 3 2 9 8 1 2 1 4 6 3 2 C B A
3 2 3 1 3 1
J83 J85 1 3 7
3 1 4 J33 86
3 1 6 3 6 J34 J32 J27
J86 J89 J37 J35 J30 J29
J40 J36
26-1.0 DGN/YW
27-1.0 GY/GN
27-1.0 GY/GN
85
26-1.0 DGN/YW
J39
60-1.0 LGN/WE
J38
27-1.0 GY/GN
28-1.0 LPE
27-1.0 GY/GN
110-0.8 LGN/BE
G200-1.0 BK
40-1.0 LGN
19-1.0 GY/OE
34-1.0 OE/RD
34-1.0 OE/RD
34-1.0 OE/RD
13-1.0 LBE/WE
20-1.0 RD/BE
109-0.8 BE/BK
137-1.0 BK/LBE
G200-1.0 BK
39-1.0 YW
32-1.0 DBE/RD
G200-1.0 BK
60-1.0 LGN/WE
137-1.0 BK/LBE
40-1.0 LGN
G200-1.0 BK
30-1.0 LBE/RD
J26
39-1.0 YW
G200-1.0 BK
121-2.0 DBE/YW
7-1.0 PK/BE
110-0.8 LGN/BE
7-1.0 PK/BE
31-1.0 LBE/RD
17-1.0 LGN/BK
33-1.0 WE/GY
44-1.0 BK/WE
45-1.0 BN/RD
10-2.0 DGN/RD
52-1.0 TN/RD
84-1.0 RD
6-5.0 WE
7-1.0 PK/BE
7-1.0 PK/BE
58-1.0 DPE/RD
133-2.0 DBE
6-5.0 WE
22-1.0 BN/WE
19-1.0 GY/OE
G200-1.0 BK
111-0.8 RD/BK
3-1.0 LBE
109-0.8 BE/BK
124-2.0 GY/BK
21-1.0 BK/PK
106-1.0 BN/BK
5-1.0 OE
G200-1.0 BK
7-1.0 PK/BE
9-1.0 PK/WE
G200-1.0 BK
5-1.0 OE
G200-1.0 BK
G200-2.0 BK
7-1.0 PK/BE
103-1.0 DGN/WE
25-2.0 DBE/GN
24-2.0 PK
24-2.0 PK
13-1.0 LBE/WE
G200-1.0 BK
61-1.0 LBE/BK
23-1.0 BN/YW
3-1.0 LBE
105-1.0 GY/RD
102-1.0 RD/GN
1-5.0 RD
87-1.0 TN/WE
8-1.0 TN
5-1.0 OE
1-5.0 RD
S377 24-1.0 PK
S300
S376
S351
GAUGE
LIGHT OPT. S306
S307 S
J81
S400
9 17-1.0 LGN/BK
ENGINE RD
HIGH
7-1.0 PK/BE S350
TEMP.
7
10 7-1.0 PK/BE
RD
ENGINE
LOW OIL 18-1.0 YW/GN
PRESS. 8
J82 1-5.0 RD
8 111-0.8 RD/BK S378 S304
WAIT RD
S303
TO 7-1.0 PK/BE
START
10
7
32-1.0 DBE/RD
RD 7-1.0 PK/BE 10A F1
ALT. 32-1.0 DBE/RD
CHARGE 60-1.0 LGN/WE
9 8-1.0 TN 10A F2
S360
S372 7-1.0 PK/BE
10A F3
5-1.0 OE
7-1.0 PK/BE
HOUR
60-1.0 LGN/WE S364 9-1.0 PK/WE
10A F4
T
METER G200-1.0 BK 9-1.0 PK/WE
123-0.8 DBE/WE 5A F5
7-1.0 PK/BE 83-1.0 DPE

+
10A F6
G200-1.0 BK 83-1.0 DPE
FUEL
- G200-1.0 BK
GAUGE 90-2.0 OE/GN 15A F7
6-5.0 WE
16-1.0 WE/RD
S
6-5.0 WE
36-1.0 RD/WE 10A F8
P44
132-1.0 PK/RD 65-1.0 DPE/WE 10A F9
D10 A
REVERSE 101-1.0 YW/BE
B 33-1.0 WE/GY
DIODE ASSY. 102-1.0 RD/GN F10
D9 C 33-1.0 WE/GY
6-5.0 WE
S356
6-5.0 WE
J45 10-2.0 DGN/RD F11
D8 15-1.0 WE/BE
2ND GEAR A
102-1.0 RD/GN
DIODE ASSY. B 133-2.0 DBE F12
U
P46 28-1.0 LPE
107-1.0 BK/OE F13
D2 A 28-1.0 LPE
NEUTRAL SW. 4-1.0 DBE/BK
B
DIODE ASSY. 108-1.0 OE/WE 124-2.0 GY/BK F14
D1 C
35-1.0 WE/OE F15

S362
J47 15-1.0 WE/BE

3 54-1.0 BN F16
14-1.0 YW/RD
2
4-1.0 DBE/BK
5
G200-1.0 BK 55-1.0 DGN/OE F17
6
F-N-R 8
101-1.0 YW/BE
12-1.0 WE/YW 38-2.0 YW/BN F18
7
53-3.0 LPE
6-5.0 WE
11-1.0 GY
1
37-5.0 DGN F19
4
F20
J25 83-1.0 DPE
1 ENCL.
FRAME 2
G201-1.0 BK CAB
A
B
53-3.0 LPE V
ANGLE 70-1.0 WE (OPT)
SENSOR 3
73-1.0 DBE/RD S375
4
BRAKE PRESS. P24 83-1.0 DPE

A
SW. (RAS) 72-1.0 DGN/RD 66-1.0 YW/BK P21 FRAME LVL (R)
B A
PS1 S301 74-1.0 TN/BK PRESS SW.
B
RJ1
SLOW J22 80-1.0 DBE
1 S366 66-1.0 YW/BK P20
FRAME LEVEL A
FRAME LVL (L)
G201-1.0 BK
2 71-1.0 GY/BK PRESS SW.
SOL. SV6 B
RJ3
J23 77-1.0 RD/GY J96

FRAME 1
LEVEL 66-1.0 YW/BK FRAME LEVEL
G201-1.0 BK A
SOL. SV1 2 S365 98-1.0 WE/BN D6 LATCHING
B
DIODE
J92 136-1.0 WE/GY J97

FRAME 1 66-1.0 YW/BK
LEVEL A FRAME LEVEL
G201-1.0 BK
SOL. SV2 2 129-1.0 GY D7 ISOLATION
B
SERVICE
DIODE
W
TOOL S367
129-1.0 GY J93
1 CRE
G201-1.0 BK
2 SOL. SV4
1 2 3 129-1.0 GY J94
1 CRR
G201-1.0 BK
2 SOL. SV5
C1 G200-1.0 BK
1
83-1.0 DPE 49-1.0 LBE/BK J95
2 A
FRAME LEVEL
354-1.0 YW 65-1.0 DPE/WE
S374
3 B PRESS. SW.
355-1.0 LGN S368 98-1.0 WE/BN JPS
4 S354 C
356-1.0 BK S369
5
106-1.0 BN/BK
GRAY 6
72-1.0 DGN/RD 92-1.0 RD/BK J19
7 1
8 93-1.0 YW/BE
2
9 94-1.0 BK/WE
71-1.0 GY/BK 3
10 92-1.0 RD/BK
S370
74-1.0 TN/BK 4
11 JOYSTICK
70-1.0 WE 130-1.0 DBE/GN
12 5
RAS
CONTROLLER
97-1.0 OE/WE
6 X
S359
73-1.0 DBE/RD 98-1.0 WE/BN

C2 7
1
75-1.0 LGN/OE S302 8
2
77-1.0 RD/GY
3
80-1.0 DBE
4 S352 65-1.0 DPE/WE J91
81-1.0 TN/GN 1
5 51-1.0 RD/GN
82-1.0 DGN 2
BLACK 6 50-1.0 GY/RD
84-1.0 RD 3
7 96-1.0 BK/OE
79-1.0 WE/BK 4
8 92-1.0 RD/BK
76-1.0 YW/WE 7
9 93-1.0 YW/BE
136-1.0 WE/GY 8 FRAME LEVEL/
10 G201-1.0 BK
83-1.0 DPE 9 AUX HYD.
11
48-1.0 TN/BN CONTROLLER
12 10
46-1.0 GY/WE TOC-2
11
S353 126-1.0 BK/LBE
12
J50 116-0.8 OE/BK 94-1.0 BK/WE
6 15
30-1.0 LBE/RD
35-1.0 WE/OE
90-2.0 OE/GN
36-1.0 RD/WE
33-1.0 WE/GY
38-2.0 YW/BN
44-1.0 BK/WE
45-1.0 BN/RD
115-0.8 DPE/OE 130-1.0 DBE/GN
52-1.0 TN/RD
37-5.0 DGN
2 16
40-1.0 LGN
28-1.0 LPE
39-1.0 YW
54-1.0 BN
104-0.8 LGN/RD S357
1 5
THROTTLE 114-0.8 TN
3 6
5
113-0.8 RD
112-0.8 DBE
S299
S358 J15 J16
13 Y
G201-3.0 BK
G201-5.0 BK
4 14
J18
J90
S363 B C A B C E F G F A D E C B
S373
S371
P51 G200-1.0 BK
A
32-1.0 DBE/RD
B
351-0.5 YW S381 ROAD STABILIZERS OPEN/ENCL. CAB ENCL. CAB
C
23C-1.0 BN/YW
LIGHTS
104-1.0 LGN/RD
65-1.0 DPE/WE
119-1.0 OE/BE
(OPT)
13-1.0 LBE/WE
12-1.0 WE/YW (OPT) (OPT)
13-1.0 LBE/WE
106-1.0 BN/BK
49-1.0 LBE/BK
107-1.0 BK/OE
107-1.0 BK/OE
107-1.0 BK/OE
132-1.0 PK/RD
87-1.0 TN/WE
23-1.0 BN/YW
105-1.0 GY/RD
105-1.0 GY/RD
107-1.0 BK/OE
S382
23-1.0 BN/YW
97-1.0 OE/WE
352-0.5 GN
66-1.0 YW/BK
G200-1.0 BK
25-2.0 DBE/GN
G200-1.0 BK
(OPT)
G200-1.0 BK
G200-1.0 BK
G200-1.0 BK
G200-1.0 BK
D
58-1.0 DPE/RD
ENGINE
68-1.0 DBE/GN
68-1.0 DBE/GN
13-1.0 LBE/WE
106-1.0 BN/BK
129-1.0 GY
9A-1.0 PK/WE
G201-3.0 BK
S383
129-1.0 GY
DIAGNOSTIC CAP GND
126-1.0 BK/LBE
126-1.0 BK/LBE
G201-1.0 BK
E
51-1.0 RD/GN
46-1.0 GY/WE
CONN.
96-1.0 BK/OE
24-2.0 PK
50-1.0 GY/RD
48-1.0 TN/BN
G200-5.0 BK
24-2.0 PK
F
1-5.0 RD
1-5.0 RD
G
H
J80 J5 J6 J7 J8 J87 J88
121-2.0 DBE/YW
J14
75-1.0 LGN/OE
J
119-1.0 OE/BE
J12
76-1.0 YW/WE
79-1.0 WE/BK
81-1.0 TN/GN
J9 P10 P11
82-1.0 DGN
83-1.0 DPE
A B C
85 86 85 86 85 86 85 86 85 86 85 86 85 86 1 2 A B B A
A B C 1 2 3 4 A B C
RESISTOR
103-1.0 DGN/WE
351-0.5 YW 87A
123-0.8 DBE/WE
87A 87A 87A 87A 87A 87A

104-0.8 LGN/RD
115-0.8 DPE/OE
110-0.8 LGN/BE
A
108-1.0 OE/WE
31-1.0 LBE/RD
30
17-1.0 LGN/BK
116-0.8 OE/BK
61-1.0 LBE/BK
30 30
111-0.8 RD/BK
30 30 30 30
109-0.8 BE/BK
22-1.0 BN/WE
120
12-1.0 WE/YW
18-1.0 YW/GN
16-1.0 WE/RD
14-1.0 YW/RD
20-1.0 RD/BE
87
15-1.0 WE/BE
19-1.0 GY/OE
J13
21-1.0 BK/PK
87 87 87 87 87 87
9-1.0 PK/WE
J84 J4 P3 PARK
112-0.8 DBE
352-0.5 GN PARK
7-1.0 PK/BE
OHM
351-0.5 YW
352-0.5 GN
PARK BRK.
113-0.8 RD
114-0.8 TN
B BRAKE BRAKE BEACON

11-1.0 GY
PRESS SW. WORKLIGHTS

SOL. INDIC.
C
1 2 3 4 5 6 7 8
TO CHASSIS HARNESS R.F.
BRAKE TEST BRAKE TEST BRAKE TEST BRAKE TEST REVERSE FRAME LEVEL FRAME LEVEL PBPS PRESS SW.
(OPT) (OPT)
Z
WORKLIGHT LATCHING RELAY SV3
(PRESS SW) (ALT DROOP) (NEUTRAL) RELAY RELAY ENABLE LATCHING
J52 HARN PBPS-2
(OPT) RELAY RELAY RELAY RELAY
J2 CR3 CR4 CR5
CR7 CR2 CR8 CR9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 TO CHASSIS HARNESS
J1
TO CHASSIS HARNESS
M923496AB_XL-SH-2
VR Telehandler Series NOTE: To determine the correct hydraulic/electrical schematic that resembles your telehandler, SKYJACK, Page 69
Model VR-1056D refer to the “Table Of Contents” found at the beginning of this section.
155167
AC
3.20a Chassis Harness
Serial Breakdown
Reference Chart
3.20a 87,300,217 & above
3.20b 87,300,216 & below
R
HORN
2515
2440 S
J55
FRONT BALLAST
1855
SAFETY SWITCH
280
355
COOLANT
TEMP. ALTERNATOR
B+ GND
1065 1065
1040 T
ECM
990 PWR
J98 J73 ECM (LH) (RH)
760
FORK FORK
1015 J72 ECM TILT DUMP
915 660 GND 545
685 STUD
J85 J86
510
U
785 510
GND ON 455
200 255 ENG BLOCK
OIL PRESS.
735 430
SWITCH 265
J74
STARTER
405 B+ ST
GND (BOTTOM) ECM FUSE 190
J68 BOOM
CRAB 100 F21 30A 330 330
330 330 AUX. LIGHTS V
STEER
B/U HYD. (OPT.)
315 J70
(TOP) TERM. ALARM (OPT.)
255 BOOM
4W RESISTOR
J69 STEER ANGLE
180
180 125 J58 SENSOR
240 150
100
P1 100
125 100 J53 J56
115 J57 J80
TO CONS. 150
HARNESS 200 1065 1220 100 1550 RAS
CYL. W
P2
J79 SOLS.
585 1295 1370 1725 4040 4115 4445 5790 5890
TO CONS. J3 5995
HARNESS J64
P4 255 J59 100
TO CONS.
HARNESS J65 X
P84 305
TO POS. J66
BATT. P83 380 STARTER
90
CABLE RELAY
0 75 405
430
455 J67 Y
J61 445
455
510
510
535
TRANS. FUEL
TEMP. LEVEL GRID
HEATER
RELAY
M164804AA
155167
AC
3.20b Chassis Harness
Serial Breakdown
Reference Chart
3.20a 87,300,217 & above
3.20b 87,300,216 & below
HORN
R
J98
1
J55
31 LBE/RD
7 PK/BE FRONT BALLAST
A
SAFETY SWITCH
B
3
S
BOOT
COOLANT J85 J86
TEMP. ALTERNATOR 2 1 2 1
GND 96 BK/OE 51 RD/GN 96 BK/OE 50 GY/RD
B+
J98 ECM
PWR
J72
J73 J72 SOCKET # - WIRE NO. & COLOR (LH) (RH)
J73 ECM
1-351 YW 43-110 LGN/BE FORK FORK
G103 BK
1 2
J72 1 10
15-115 DPE/OE
21-352 GN
44-138 WE/BN
45-123 DBE/WE TILT DUMP T
69 RD/WE DEUTSCH
24-116 OE/BK 47-109 BE/BK

4 3 51 60 27-113 RD 49-103 DGN/WE ECM
28-112 DBE
35-114 TN
53-111 RD/BK
54-137 LGN/YW
GND
41-104 LGN/RD STUD J85 J86
J74
A
P1 PIN # - WIRE NO. & COLOR
J68 1 RD
69 RD/WE
GND ON
1-11 GY 17-109 BE/BK
P1 2-12 WE/YW 18-110 LGN/BE B ENG BLOCK
3-108 OE/WE 19-111 RD/BK B A
G101 BK 21 BK/PK
4-14 YW/RD
5-15 WE/BE
20-112 DBE OIL PRESS.
21-113 RD
21
20 31
30 6-16 WE/RD SWITCH U
J58 J57 J53
8
22-114 TN
J74
9 19
10 2 18 7-17 LGN/BK
22 3 7 29
23-104 LGN/RD
11 1 17
8-18 YW/GN
23
12
4
5
6
16
28
9-19 GY/OE
24-115 DPE/OE STARTER 2 1 2 3
ECM FUSE
13 15
24 14 27
25-116 OE/BK G104 BK 46 GY/WE 48 TN/BN G104 BK
25 26 10-20 RD/BE 75 LGN/OE
26-103 DGN/WE DEUTSCH
12 WE/YW 127 DGN/BK DEUTSCH
126 BK/LBE 83 DPE
11-21 BK/PK
J68 F21 30A B+ ST
12-1.0 BN/WE
13-61 LBE/BK
27-123 DBE/WE
28-351 YW GND (BOTTOM) 1 4 3 1
14-9 PK/WE 29-352 GN
15-7 PK/BE 30-N/U CRAB
31-N/U
16-31 LBE/RD STEER
J70 J80
TERM. BACKUP
RESISTOR ALARM G100 BK
B
(TOP) AUX. BOOM BOOM 76 YW/WE
4W HYD. ANGLE LIGHTS A
P2 STEER
J58
J69 (OPT.) SENSOR (OPT.) V
J70
{
1 8
75 LGN/OE 121 DBE/YW P1 J80
DEUTSCH
76 YW/WE 119 OE/BE B A

351 YW
J69
DEUTSCH
79 WE/BK
81 TN/GN
83 DPE
82 DGN
J57 J53 J56
B A C
G101 BK 22 BN/WE
4 5 RAS
P2 CYL.
SOLS.
J3 TO CONS.
A 1 RD
HARNESS
G200 BK
1 RD
J3
C J79
J64 W
{
2
G101 BK
J64 DEUTSCH
11 GY
REV 64 DGN/YW 85 30 1 RD F
P4 (TOP)
G100 BK
P4 1
2 DBE 108 OE/WE
79 WE/BK
G100 BK
2 1 J59 87 86 82 DGN
48 TN/BN
126 BK/LBE
46 GY/WE
127 DGN/BK
J65 G100 BK
P84 2
DEUTSCH
G101 BK 81 TN/GN
3 4 J65 DEUTSCH
119 OE/BE FWD STARTER J59 A
TRANS. RELAY
1
SOLS.
2
J66
P84 J66 DEUTSCH
G101 BK
14 YW/RD 1ST
51 RD/GN A B 50 GY/RD 1
DEUTSCH
C
96 BK/OE X
2 J67
G101 BK
J67 DEUTSCH
15 WE/BE 2ND
1
TO POS.
BATT. P83
CABLE
J61
TRANS. FUEL
LEVEL GRID Y
TEMP.
HEATER
B A RELAY
16 WE/RD
G105 BK
M923497AB-SH-1
155167
AC
3.21 Chassis Harness Wiring Diagram
TO POS.
TO CONSOLE HARNESS BATT.
TO CONSOLE HARNESS CABLE R
P1 P2 J3 P4 P84 P83
A B C 1 2 3 4 A B C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8
127-1.0 DGN/BK
126-1.0 BK/LBE
51-1.0 RD/GN
103-0.8 DGN/WE
50-1.0 GY/RD
96-1.0 BK/OE
123-0.8 DBE/WE
46-1.0 GY/WE
121-2.0 DBE/YW
104-0.8 LGN/RD
48-1.0 TN/BN
110-0.8 LGN/BE
115-0.8 DPE/OE
1-8.0 RD
108-1.0 OE/WE
17-1.0 LGN/BK
111-0.8 RD/BK
31-1.0 LBE/RD
75-1.0 LGN/OE
22-1.0 BN/WE
18-1.0 YW/GN
12-1.0 WE/YW
116-0.8 OE/BK
61-1.0 LBE/BK
109-0.8 BE/BK
76-1.0 YW/WE
G200-5.0 BK
119-1.0 OE/BE
16-1.0 WE/RD
20-1.0 RD/BE
19-1.0 GY/OE
14-1.0 YW/RD
21-1.0 BK/PK
81-1.0 TN/GN
79-1.0 WE/BK
15-1.0 WE/BE
9-1.0 PK/WE
112-0.8 DBE
351-0.5 YW
7-1.0 PK/BE
352-0.5 GN
82-1.0 DGN
1-5.0 RD
1-5.0 RD
113-0.8 RD
83-1.0 DPE
114-0.8 TN
11-1.0 GY
S
J85
51-1.0 RD/GN (LH)
1
96-1.0 BK/OE FORK
2
S113
TILT
J86
50-1.0 GY/RD (RH)
1
96-1.0 BK/OE FORK
2
DUMP
J57
46-1.0 GY/WE J80
1
48-1.0 TN/BN 76-1.0 YW/WE T
AUX HYD 2 A RAS LOCK SOLENOID
126-1.0 BK/LBE G100-1.0 BK (TOP FRONT)
HARN (OPT) 3 B
127-1.0 DGN/BK
4
J79
79-1.0 WE/BK
J53 E RAS RESTRICT SOLENOID
G100-1.0 BK (BOTTOM FRONT)
F
75-1.0 LGN/OE
2
BOOM ANGLE 83-1.0 DPE
1
SENSOR G104-1.0 BK S100
3 81-1.0 TN/GN
A
FRAME LEVEL LEFT SOL.
G100-1.0 BK
B (BOTTOM REAR)
U
J55
82-1.0 DGN
C
SW3
A
61-1.0 LBE/BK FRAME LEVEL RIGHT SOL.
FRONT G100-1.0 BK
D (TOP REAR)
BALLAST
SWITCH 64-1.0 DGN/YW
B
20-1.0 RD/BE
HORN 9-1.0 PK/WE
V
J56
BOOM
121-2.0 DBE/YW
LIGHTS
(OPT)
J58
12-1.0 WE/YW
1
BACKUP
ALARM G104-1.0 BK
2
S112 W
S108
S109
S110
1-8.0 RD
X
S102
S101
S106
S105
103-0.8 DGN/WE
137-0.8 LGN/YW
S107
123-0.8 DBE/WE
104-0.8 LGN/RD
S104
115-0.8 DPE/OE
110-0.8 LGN/BE
138-0.8 WE/BN
116-0.8 OE/BK
111-0.8 RD/BK
69-5.0 RD/WE
109-0.8 BE/BK
69-5.0 RD/WE
137-0.8 LGN/YW
138-0.8 WE/BN
G103-5.0 BK
112-0.8 DBE
351-0.5 YW
352-0.5 GN
113-0.8 RD
114-0.8 TN
G103-5.0 BK
351-0.5 YW
352-0.5 GN
1-5.0 RD
22-1.0 BN/WE
21-1.0 BK/PK
G101-1.0 BK
119-1.0 OE/BE
G101-1.0 BK
14-1.0 YW/RD
15-1.0 WE/BE
G101-1.0 BK
G101-1.0 BK
G101-1.0 BK
G101-1.0 BK
11-1.0 GY
64-1.0 DGN/YW
108-1.0 OE/WE
17-1.0 LGN/BK
2-3.0 DBE
16-1.0 WE/RD
18-1.0 YW/GN
G202-13.0 BK
G202-13.0 BK
G105-1.0 BK
31-1.0 LBE/RD
19-1.0 GY/OE
1-3.0 RD
7-1.0 PK/BE
G104-1.0 BK
G101-2.0 BK
G100-2.0 BK
G105-1.0 BK
G106-1.0 BK
G200-5.0 BK
J74 J72
2-3.0 DBE
J73 J70
1-13.0 RD
1-5.0 FLK
1-1.0 FLK
1-2.0 FLK
1-2.0 FLK
B A 1 21 47 43 53 28 27 35 41 15 24 49 45 54 44
J64 J65 J66 J67 J68 J69 A B C
1 2 3 4
J59 J61 2 1 2 1 2 1 2 1 B A B A Y
GRID
A B ECM 30A HEATER
85 86 3 2 1 ECM PWR ECM
J98 (TOP) GND 120 OHM RELAY
B+ ST FWD 1ST 2ND (BOTTOM) (TOP)
REV STUD F21
87A
B+ GND CRAB 4W
30 STEER STEER ECM TERM.
87 GND ON FUEL COOLANT OIL TRANS.
STARTER FUSE RESISTOR
ENGINE LEVEL TEMP. PRESS. TEMP.
GND ON
CR10 BLOCK
ALTERNATOR ENGINE TRANSMISSION
STARTER
RELAY BLOCK SOLENOIDS
M923497AB-SH-2
155167
155167
CR11
GRID HEATER
A
RELAY
137 LGN/YW 138 WE/BN GRID HEATER RELAY
TO ECM A B TO ECM 1
Model VR-1056D
LINE 82 LINE 81
2 GRID HEATER
RD RD
GRID HEATER
SW3
FRONT BALAST SW. CR6 3
FUSE AMPERE STARTER RELAY
61 LBE/BK 64 DGN/YW 108 OE/WE BALAST SWITCH
NO. RATING CIRCUIT 4
N.O. HELD
CLOSED F22 5 STARTER RELAY
300 A 1 RD 2 DBE BK
6 STARTER
ALTERNATOR
F2 10A TRANS/B-U ALARM/PARK BRAKE B+
1 RD 1 RD 1 RD ALTERNATOR
M 7
F3 10A STEER SELECT/GAUGES/INDIC LAMPS IGN
+
7 PK/BE
B1 BATTERY 8 BATTERY
F4 10A HORN/BEACON OPT. 31 LBE/RD G STARTER
LAMP G202 BK BK
-
F5 5A ECM SW PWR 9
GND
F6 10A REAR AXLE STABIL (RAS) 10
B
F7 15A POWER PORT 11
F8 10A WIPER, REAR SW 5 SEAT BELT IND. 12

SEAT BELT SW. RD
F9 10A FRAME LEVEL/FORK TILT/AUX HYD OPT. 13 LBE/WE 34 OE/RD G200 BK 13 SEAT BELT SWITCH
F10 10A STABILIZERS SEAT BELT INDICATOR
1 RD 1 RD 6 WE 14
SEAT BELT ALARM
F11 15A WORK LIGHTS 34 OE/RD + - G200 BK
SW1 - IGNITION SWITCH 15 SEAT BELT ALARM
F12 15A WORK LIGHTS
OFF 16 PARKING BRAKE SOL. - SV3
F13 10A TURN/HAZ./BRAKE LIGHTS 13 LBE/WE 68 DBE/GN G201 BK
ON PARKING BRAKE PRESSURE
F1 SV3
10 A
17 SWITCH - PBPS
F14 15A BOOM LIGHTS START PARK BRAKE
OPTIONS
PBPS 18 IGNITION SWITCH
WIPER, FRONT 5 OE G200 BK G200 BK
F15 10A
B+ CR5
32 DBE/RD IGN 5 OE REVERSE RELAY 19 POWER RELAY
F16 10A WIPER, TOP
ENCLOSED CR1 SW2 - PARK 13 LBE/WE G200 BK
POWER BRAKE SW. 20 PARKING BRAKE SWITCH
F17 10A HEATER VALVE, A/C CAB RELAY
3 REVERSE RELAY
OPTION 6 WE 8 TN 2 D10 REV. DIODE
C
F18 15A WASHER/FAN/INT. LIGHT 1 13 LBE/WE 132 PK/RD 101 YW/BE 12 WE/YW 119 OE/BE G101 BK 21 REVERSE SOL.
F2
10 A 6 REVERSE
30A BLOWER ST 3 LBE 3 LBE 5 22
F19 4
F20 OPEN 23
106 BN/BK
137 BK/LBE PR 9 PK/WE 7 9 G200 BK G200 BK
F21 30A ENGINE ECM (BATT +) CR3
PARKING BRAKE INDICATOR
B- G200 BK 24 PRESSURE SWITCH
BRAKE TEST RELAY
F22 300A GRID HEATER PBPS-2 (NEUTRAL) BRAKE TEST (NEUTRAL) RELAY
23 BN/YW 23 BN/YW 107 BK/OE 25
105 GY/RD 107 BK/OE D1 26 NEUTRAL SWITCH DIODES

NEUTRAL SW.
CR4 DIODES
BRAKE TEST LATCH D2 BRAKE TEST LATCHING RELAY
23 BN/YW 107 BK/OE 4 DBE/BK 27
107 BK/OE 28
G200 BK G200 BK
29
106 BN/BK G200 BK G200 BK BRAKE TEST (PRESS SW.) RELAY
30
HORN CR7 SW6 - HORN SW.
BRAKE TEST RELAY 31
D
RELAY CHART 6 WE 9 PK/WE 20 RD/BE (PRESS SW.) G200 BK HORN AND SWITCH
F4 CR2 32
RELAY 10 A BRAKE TEST RELAY
FUNCTION (ALT DROOP)
NO. 105 GY/RD G200 BK G200 BK 33 BRAKE TEST (ALT DROOP) RELAY
CR1 POWER RELAY 87 TN/WE 104 LGN/RD 34
SW7 - PARK BRAKE
CR2 BRAKE TEST (ALT DROOP) RELAY TEST SW. 35 REVERSE AND 2ND GEAR DIODES
D8 2ND GEAR DIODE
15 WE/BE 15 WE/BE G101 BK
1 2ND GEAR SOL.
CR3 BRAKE TEST (NEUTRAL) RELAY 105 2 D9 REV. DIODE 2ND GEAR 36
3 102 RD/GN 101 YW/BE
CR4 BRAKE TEST (LATCHING) RELAY 4 37 PARK BRAKE TEST SWITCH

87 TN/WE 5
6 103 DGN/WE
CR5 BRAKE TEST (REVERSE LOCKOUT) RELAY F-N-R J47

38
9 PK/WE F - N - R SHIFTER
8 101 YW/BE 39
CR6 ALTERNATOR & LAMP CHECK DIODES C 3RD
2ND
1 11 GY 11 GY G101 BK
1ST 40 FORWARD SOL.
CR7 BRAKE TEST (PRESS SW) RELAY TO 155964 OPTIONS
SCHEMATIC 3 15 WE/BE FORWARD
41
CR8
E
FRAME LEVEL ENABLE RELAY

2 14 YW/RD 14 YW/RD G101 BK 42 1ST GEAR SOL.
CR9 FRAME LEVEL LATCHING RELAY
1ST GEAR
5 4 DBE/BK 43
CR10 STARTER RELAY R
N
F 44
6 G200 BK G200 BK
CR11 GRID HEATER RELAY
BACKUP ALARM 45
7 12 WE/YW 12 WE/YW G104 BK BACKUP ALARM
46
SW4 - STEER
MODE SW. STEERING MODE SWITCH
47
1 21 BK/PK G101 BK
6 WE 7 PK/BE 7 PK/BE 2 CRAB STEER SOL.
3
CRAB STEER 48
F3
10 A 22 BN/WE G101 BK
WAIT ENGINE ENGINE TRANS. 49 4 WHEEL STEER SOL.
CHECK ENGINE ALT. ALT.
TO LOW OIL HIGH HIGH 4W STEER
R1 R2 R3 ENGINE STOP R4 CHARGE DIODE
START PRESS. TEMP. TEMP.
56 Ω 50 WARNING INDICATOR LAMPS
5100 Ω TYP. D3
51 ALTERNATOR DIODE AND

RD YW RD RD RD RD YW
111 RD/BK RESISTOR
F
110 LGN/BE 52
109 BE/BK 60 LGN/WE 53

TRANS.
TEMP.
LAMP CHECK DIODES 54
TPS1
137 BK/LBE D4 19 GY/OE FRAME
TRANSMISSION TEMP. SWITCH TPS1
COOLANT 55
TEMP LAMP CHECK DIODES
TPS2
D5 17 LGN/BK FRAME 56
COOLANT TEMP SWITCH TPS2
OIL
PRESSURE 57
18 TW/GN OPS1 FRAME
FUEL GAUGE HOURMETER OIL PRESSURE SWITCH OPS1
+ 58
16 WE/RD
S TT 59 FUEL GAUGE
-
G200 BK G200 BK 60 HOURMETER
61
FUEL LEVEL
16 WE/RD FUEL LEVEL SENDER
G
62
G105 BK 63
G200 BK 64 ECM A
G103 BK
65
ECM 66
J73
1 BATT (-) 67
1 RD 69 RD/WE 69 RD/WE
4 BATT (+)
F21
68
30 A
J72 69
5 OE 123 DBE/WE 123 DBE/WE
45 KEY SWITCH (+)
F5 70
5A 103 DGN/WE
49 ALT. DROOP SELECT
ENGINE DIAGNOSTIC 109 BE/BK
71
CONNECTION P51 47 STOP LAMP
72 ENGINE CONTROL MODULE
G200 BK 110 LGN/BE
H
A 43 WARNING LAMP
32 DBE/RD 111 RD/BK 73
B 53 WAIT TO START LAMP
351 YW 351 YW 74
C 1 J1939 (+)
352 GN 352 GN
D 21 J1939 (-) 75
P50 J50
113 RD 113 RD
THROTTLE VREF +5 V 5 5 27 THROTTLE (+) 76 THROTTLE PEDAL
114 TN 114 TN
THROTTLE SIGNAL 3 3 35 THROTTLE (SIG) 77
112 DBE 112 DBE
THROTTLE GROUND 4 4 28 THROTTLE(-)
78
116 OE/BK 116 OE/BK
IDLE ON 6 6 24 ON IDLE
79
104 LGN/RD 104 LGN/RD
IDLE GROUND 1 1 41 IDLE RETURN
80
115 DPE/OE 115 DPE/OE
3.22 Electrical Schematic (No Options)
IDLE OFF 2 2 15 OFF IDLE
138 WE/BN 81
THROTTLE LINE 1 B 44 GRID HEATER RELAY (-)
TO GRID HEATER RELAY 82
PEDAL 137 LGN/YW
LINE 1 A 54 GRID HEATER RELAY (SIG)
I
83
R5 J52 R6 J70
351 YW 351 YW
A A 84 TERMINATION RESISTORS
120 Ω 120 Ω
352 GN 352 GN
B B 85
C C G106 BK
86
G200 BK G200 BK
refer to the “Table Of Contents” found at the beginning of this section.

87
FRAME ANGLE
88
SENSOR
89
R
90
RT
6 WE 83 DPE 83 DPE G201 BK
91 FRAME ANGLE SENSOR
F6 LT
R
10 A
BOOM ANGLE 92
NOTE: To determine the correct hydraulic/electrical schematic that resembles your telehandler,
SERVICE TOOL SENSOR
J
93
1 2 3 1 4 75 LGN/OE
BOOM ANGLE SENSOR
94
3 G104 BK
95
RAS CONTROLLER C1 - GRAY
G200 BK G200 BK REAR AXLE STABILIZATION
GROUND 1 96
CONTROLLER
83 DPE
12VDC POWER IN 2
97
354 YW
CAN + 3
98
355 LGN
CAN - 4
99
356 BK
CAN SHIELD 5
106 BN/BK
100
PARKING BRAKE INPUT (PB) 6
72 DGN/RD PS1 83 DPE 101
SERVICE BRAKE INPUT (SB) 7 BRAKE PRESSURE SWITCH (RAS) - PS1
71 GY/BK 102
FRAME LEVEL LEFT PRESS. SW. INPUT (IL) 10
74 TN/BK 103
K
FRAME LEVEL RIGHT PRESS. SW. INPUT (IR) 11

70 WE 104
FRAME ANGLE SENSOR LEFT INPUT (AL) 12
C2 - BLACK
105
73 DBE/RD
FRAME ANGLE SENSOR RIGHT INPUT (AR) 1
106
75 LGN/OE
BOOM ANGLE SENSOR INPUT (S) 2
107
77 RD/GY 77 RD/GY FRAME LVL G201 BK
FRAME LEVEL ENABLE OUTPUT (OE) 3 FRAME LEVEL SOL - SV1
SV1
80 DBE 80 DBE G201 BK
108
SLOW FRAME LVL
SLOW FRAME LEVEL SOLENOID OUTPUT (OS) 4 SLOW FRAME LEVEL SOL - SV6
SV6
81 TN/GN 81 TN/GN RAS LVL LEFT G100 BK 109
RAS LEVEL LEFT SOLENOID OUTPUT (OL) 5 RAS LEVEL LEFT SOL "C"
82 DGN 82 DGN RAS LVL RIGHT G100 BK 110
RAS LEVEL RIGHT SOLENOID OUTPUT (OR) 6 RAS LEVEL RIGHT SOL "A"
RAS
84 RD 84 RD YW G200 BK 111
INDICATOR LIGHT OUTPUT (L) 7 RAS INDICATOR LAMP
79 WE/BK 79 WE/BK RAS RESTRICT G100 BK
RESTRICT SOLENOID OUTPUT (R) 8 112 RAS RESTRICT SOL "E"
76 YW/WE 76 YW/WE RAS LOCK G100 BK
LOCK SOLENOID OUTPUT (L) 9 113 RAS LOCK SOL "F"
L
136 WE/GN 136 WE/GN FRAME LVL G201 BK

FRAME LEVEL ENABLE OUTPUT (OE) 10 114 FRAME LEVEL SOL - SV2
SV2
83 DPE
12VDC POWER IN 11
115
CR8
FRAME LEVEL ENABLE 116
RELAY
CONTROL 97 OE/WE G200 BK
HANDLE 117 FRAME LEVEL ENABLE RELAY
4.3V
FORK DUMP
4.3V
AUX (-) 6 WE 65 DPE/WE 66 YW/BK PSRJ1 74 TN/BK 118 FRAME LEVEL (R)
PRESSURE SWITCH - PSRJ1
2.5V 2.5V
F9
10 A
119
0.7V FORK TILT (UP) 0.7V AUX (+)
120
SGL SGL PSRJ3
-
71 GY/BK
+
FRAME LEVEL (L)

JOYSTICK 121 PRESSURE SWITCH - PSRJ3
J19
130 DBE/GN JPS 122 FRAME LEVEL
5 B A
94 BK/WE
C PRESSURE SWITCH - JPS
3 LATCH DIODE J96 123
D6 98 WE/BN FRAME LEVEL DIODES
92 RD/BK CR9
M
4 FRAME LEVEL 124

93 TW/BE ISOLATION DIODE J97 LATCHING RELAY
2 D7 129 GY G200 BK 125
92 RD/BK
1
126
97 OE/WE 49 LBE/BK 129 GY 129 GY CRE G201 BK
6 CRE SOL - SV4
FRAME LEVEL SV4 127
SWITCH 98 WE/BN 129 GY CRR G201 BK
7 CRR SOL - SV5
SV5 128
FRAME LVL/ 129

AUX HYD.
CONTROLLER TOC-2 J91 130
65 DPE/WE
12VDC POWER IN 1
131 FORK TILT SOL
51 RD/DGN 51 RD/DGN FORK TILT
FORK TILT UP RETURN 2
50 GY/RD 50 GY/RD
132 FORK DUMP SOL
FORK DUMP
FORK DUMP RETURN 3
96 BK/OE 96 BK/OE 133
FORK TILT/DUMP POWER 4
92 RD/BK 134
N
+5 VDC SENSOR POWER 7

93 TW/BE 135
FORK TILT/DUMP SIGNAL 8
G201 BK G201 BK 136
GROUND 9
G Y/R
48 TN/BN 48 TN/BN AUX. HYD. (OPTION)
AUX (-) RETURN 10 137 AUX. HYD. SOL (OPTION)
POWER STATUS
ON LED LED 46 GY/WE 46 GY/WE AUX. HYD. (OPTION)
AUX (+) RETURN 11 AUX. HYD. SOL (OPTION)
138
126 BK/LBE 126 BK/LBE
AUX (+/-) POWER 12
139
94 BK/WE
INPUT SENSOR GROUND 15
130 DBE/GN
AUX (+/-) SIGNAL 16
6 WE GROUND
D E
TO 155964 OPTIONS TO 155964 OPTIONS

SCHEMATIC SCHEMATIC
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FROM 155963 NO OPTIONS FROM 155963 NO OPTIONS FROM 155963 NO OPTIONS
SCHEMATIC SCHEMATIC SCHEMATIC
D C E 1
6 WE 9 PK/WE GROUND
SW8 2
B
BEACON SW.
4 3 BEACON SWITCH
9 PK/WE 2
3 58 DPE/RD 58 DPE/RD G207 BK
4 BEACON
GN
BEACON 5
7 9 G200 BK
6 WE 90 OE/GN 90 OE/GN G207 BK 8 POWER PORT

F7
C
15 A POWER PORT 9
10
6 WE 36 RD/WE 36 RD/WE G207 BK 11

M REAR WIPER
F8
10 A 12
SW9
STABILIZER SW. REAR WIPER
LEFT 13
1 45 BN/RD 45 BN/RD G202 BK RETRACT LEFT
6 WE 33 WE/GY 2 14
3 R2 STABILIZER SOL - R2
F10 RETRACT LEFT RIGHT STABILIZER SW.
10 A SW10 44 BK/WE 44 BK/WE G202 BK 15 EXTEND LEFT
STABILIZER SW. STABILIZER SOL - E2
D
E2
RIGHT EXTEND LEFT 16
1 52 TN/RD 52 TN/RD G202 BK RETRACT RIGHT
33 WE/GY 2
3 R1 17 STABILIZER SOL - R1
RETRACT RIGHT LEFT STABILIZER SW.
30 LBE/RD 30 LBE/RD G202 BK EXTEND RIGHT
18
E1 STABILIZER SOL - E1
EXTEND RIGHT
19
PSFR1 STABILIZER (R) PRESSURE SW. - PSFR1
33 WE/GY 42 YW/WE 42 YW/WE SV17 G202 BK
20 STABILIZER (R) SOL - SV17
G1
STABILIZER (R)
D11
21
ROD LOCKOUT 59 DBE/BK 59 DBE/BK SV15 G202 BK
22 STABILIZER LOCKOUT SOL - SV15
E
DIODES
---
D12 LOCKOUT
23
PSFE1 STABILIZER (L) PRESSURE SW. - PSFE1
33 WE/GY 43 PK/RD 43 PK/RD SV16 G202 BK 24
STABILIZER (L) SOL - SV16
G2
STABILIZER (L)
25
SW11 - WORK
LIGHTS SW. 26
WORKLIGHT SWITCH
4 24 PK 24 PK G201 BK
6 WE 10 DGN/RD 5 27 LEFT FRONT WORKLIGHT
6
F11
15 A LEFT FRONT WORKLIGHT
24 PK 28
GAUGE LIGHT OPTION
F
29
1 25 DBE/GN 25 DBE/GN G201 BK
6 WE 133 DBE 2 REAR WORKLIGHT
3 30
F12
15 A REAR WORKLIGHT
31
24 PK 24 PK G206 BK
RIGHT FRONT WORKLIGHT
7 10 32
RIGHT FRONT WORKLIGHT
33
9 GN 8 GN
G200 BK G200 BK
34
35
G
SW12 - TURN / HAZ.

FLASHER SW.
36 FLASHER
4 LEFT 39 YW 39 YW G205 BK
6 WE 28 LPE X L 27 GY/GN 1 LEFT TURN SIGNAL
6 RIGHT
F13
37 TURN/HAZARD SWITCH
10 A 40 LGN 40 LGN G205 BK
38 RIGHT TURN SIGNAL
2 3 HAZ. 26 DGN/YW D13
TURN SIGNALS
TURN/HAZ 39
D14 DIODES
CR 28
BRAKE LAMP RELAY PS2 40
28 LPE 100 PK/RD G205 BK G205 BK
BRAKE LAMP RELAY
41 BRAKE PRESSURE SWITCH
H
28 LPE 41 LBE 41 LBE G205 BK 42

BRAKE LIGHT
43
SW13 41 LBE G205 BK
BOOM LIGHTS BRAKE LIGHT
SW. 44
BRAKE LIGHTS
6 WE 124 GY/BK 2
3 121 DBE/YW 121 DBE/YW G600 BK 45
F14 BOOM LIGHT
15 A GN BOOM LIGHTS SWITCH
46
7 9 121 DBE/YW G600 BK
BOOM LIGHT
47
BOOM LIGHTS
3.23 Electrical Schematic (Optional Features)
G200 BK G200 BK 48
I
49
50
6 WE 35 WE/OE 35 WE/OE G207 BK
M FRONT WIPER
F15 51
10 A
refer to the “Table Of Contents” found at the beginning of this section.

FRONT WIPER 52
53
54
6 WE 54 BN 54 BN G207 BK
TOP WIPER
J
NOTE: To determine the correct hydraulic/electrical schematic that resembles your telehandler,
F16 55
10 A
TOP WIPER 56
57
58
6 WE 38 YW/BN 38 YW/BN FRAME
M FAN
F18 59
15 A
FAN 60
61
K
G207 BK 62 INTERIOR LIGHT
SW14 INT. LIGHT 63

WASHER
SW.
64
2 3 67 LBE/GY 67 LBE/GY G207 BK
M 65 WINDSHIELD WASHER SWITCH
WINDSHIELD WASHER
66
WASHER
SW15
BLOWER 67
SW.
86 OE 86 OE
L
H
68
M 62 RD/WE 62 RD/WE G207 BK
M BLOWER MOTOR
6 WE 37 DGN B+ L 89 YW 89 YW
69
F19 70
30 A 0 BLOWER
C
SW16 71
A/C SW. SW17 PS3
A/C TEMP. SW. A/C PRESS. SW.
72
53 LPE 55 DGN/OE +
OUT 56 LGN/OE 85 BK/PK 88 BN 88 BN FRAME
F17 A/C PRESSURE SWITCH
73 A/C COMPRESSOR SOL
10 A A/C COMPRESSOR
FUSE AMPERE
CIRCUIT 74
NO. RATING
GN
M

GND G207 BK 75
F2 10A TRANS/B-U ALARM/PARK BRAKE
F3 10A STEER SELECT/GAUGES/INDIC LAMPS 76
F4 10A HORN/BEACON OPT. HEATER POT.
55 DGN/OE G207 BK 77
F5 5A ECM SW PWR B70 REAR
F6 10A REAR AXLE STABIL (RAS) WIPER MOTOR
57 TN 57 TN D 78
F7 15A POWER PORT 55 DGN/OE 55 DGN/OE A C G207 BK
F8 10A WIPER, REAR
M 79 HEATER POT.
F9 10A FRAME LEVEL/FORK TILT/AUX HYD OPT.
80
F10 STABILIZERS
MOTORIZED
10A
HEATER VALVE MOTORIZED
81 HEATER VALVE
N
F11 15A WORK LIGHTS
F12 15A WORK LIGHTS

82
F13 10A TURN/HAZ./BRAKE LIGHTS
F14 15A BOOM LIGHTS OPTIONS 83

F15 10A WIPER, FRONT
84
F16 10A WIPER, TOP
ENCLOSED
F17 10A HEATER VALVE, A/C CAB 85
OPTION
F18 15A WASHER/FAN/INT. LIGHT
F19 30A BLOWER
F20 OPEN
F21 30A ENGINE ECM (BATT +)

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F22 300A GRID HEATER

M923495AC-SH-2
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155167
Model VR-1056D
3.24 Hydraulic Schematic
FRONT STABILIZER
CYLINDERS
LEFT C9 C10 RIGHT
BORE: Ø4.5" FRAME LEVEL

ROD: Ø2.25" PARK BRAKE SERVICE BRAKES R
BOOM CYLINDERS STROKE: 17.6" CYLINDER
REAR AXLE STABILIZATION
(NO CUSHIONS TILT SV16 SV17 CYLINDER/VALVE MANIFOLD ASS'Y
TELESCOPE CARRIAGE TILT C11
ON LOWER) COMPENSATION/SLAVE C12 C13
CYLINDER CYLINDER
LEFT RIGHT
C6
CYLINDERS RIGHT RIGHT BORE: Ø4.0"
ROD: Ø1.5"
C3 C4 C5 BORE: Ø4.5" STROKE: 10.38"
LEFT RIGHT 6
ROD: Ø2.25"
STROKE: 21.0" C7 C8
FRONT AXLE REAR AXLE A
6 6
BORE: Ø5.75" BORE: Ø5" B
ROD: Ø3.25" ROD: Ø3.72"
STROKE: 38.5" STROKE: 141.25"
LEFT LEFT
CB6 8 8 4 4 8 8 CB7
6 C D
6 6
6
CV1 S
CB5
E2 R2 E1 R1 A B
F E
SH7 SH9 G
SH8
BORE: Ø3.0"
ROD: Ø1.5"
E2 R2 E1 R1
6
STROKE: 18.25" H
8 8 8 8 10 10
CB1 CB2 CB3 CB4 6
T SV13 SV14 SV15
MB4
DR
PRV4
500 psi
P T
RAS VALVE CHART
~
12 SEE DWG. 156306
OPTIONAL HYDRAULICS VALVE
MB3 REF.
FUNCTION
~
12 A RAS LEVEL RIGHT
LS
B RELIEF - RAS LEVEL RIGHT
C RAS LEVEL LEFT
D RELIEF - RAS LEVEL LEFT
E RAS RESTRICT
F RAS LOCK
G RESERVOIR CHECK
ACC1 H MAIN RELIEF 4500 psi
250
PSI PS1 PS2
LS GAGE
LS PUMP
STAB. LS
F130 P2
REAR FRONT
BR1
BR2
BR3
PS1
PS2
PB- U
PS
MANIFOLD MANIFOLD
vb b a vb b a b a b a JPS DR5 DR3 PS2 PB PP1 GP2 EF2 B A
X X X
OR5 OR6
Ø0.063" SH5 Ø0.063"
SH4
P1 SV3
SH6
Ø0.031" SH3
P2 SH2
X T1
RV4
RV3 3625 PRV3 LE1
OR1 400
3625 psi psi 500 Ø0.025"
SV1
PSI SV6
psi PR1
SV4 3000 V
F4 RV1 PSI V7
2610 FRAME
T2 PSI LEVEL
OR4 OR2
OR3 LE2 Ø0.032" Ø0.109"
LH FORK RH FORK SOL B SOL A Ø0.040" 200
TILT DUMP PSI
SH1
X
MB1 X
SV2
va va PS TP
V8 V9 V10 V11 SV5
BOOM TELESCOPE TILT OPTIONAL
MB2
CRE CRR FR1 FLE FE1 RJ3 J3 J1 RJ1 DR4 DR2 DR1 T1 CF T2 T3 PUMP PUMP-PS EF1 b T4 a
STLS
FLR
W
PB-
PS PS PS PS
FR1 RJ3 RJ1
JS1 PS
BOOM/TELESCOPE FE1
TILT/FRAME LEVEL
JOYSTICK
3
2
P
X
T
PORT FUNCTION FRONT STEER REAR STEER

CYLINDER CYLINDER
1 BOOM UP C1 C2
2 TELESCOPE IN / FRAME LEVEL RIGHT L R L R
3 BOOM DOWN TP B X (LS)
4 TELESCOPE OUT / FRAME LEVEL LEFT BORE: Ø90mm 8 8 8 8 P1
PUMP COMP: 3480 PSI Ø0.7mm A T P
ROD: Ø45mm DIFFERENTIAL: 550 PSID PUMP
STROKE: 200.4mm 57 cc/REV Y
4-WHEEL CRAB
2425 RPM
A B V12 M2 X
STEERING
P T SELECTOR
X
VALVE
E
L 8 8 R
STEERING M4
X
UNIT & COL. OSM1 Ø0.8mm
315 cc/REV ORBITROL
STEERING L2 S V18
MOTOR F2
SERVICE BRAKE
RETURN ACTUATOR
F3 F1 FILTER
Z
T P LS
TANK SUCTION
8 8 FILLER STRAINER
FILTER
M922769AC-2
155167
Notes
155167
Section 4
TROUBLESHOOTING INFORMATION
Table of Contents
Introduction ................................................................................................................................................. 79
4.1 Electrical System

4.1-1 All Controls Inoperative (No Crank) ................................................................................................ 80
4.1-2 Engine Cranks But Will Not Start .................................................................................................... 81
4.1-3 No Throttle ...................................................................................................................................... 81
4.1-4 No Drive (Park Brake Does Not Release) ....................................................................................... 82
4.1-5 No Drive (Park Brake Releases) ..................................................................................................... 82
4.1-6 No Forward Drive ............................................................................................................................ 83
4.1-7 No Reverse Drive ............................................................................................................................ 83
4.1-8 No 1st Speed Range....................................................................................................................... 83
4.1-9 No 2nd Speed Range ..................................................................................................................... 84
4.1-10 Front Steer Mode Only ................................................................................................................... 84
4.1-11 No Round (4 wheel) Steer Mode .................................................................................................... 84
4.1-12 No Crab Steer Mode ....................................................................................................................... 84
4.1-13 No Carriage Tilt, Aux. Hyd. or Frame Level Functions ................................................................... 85
4.1-14 No Carriage Tilt or Aux. Hyd. Functions ......................................................................................... 85
4.1-15 No Carriage Tilt Function ................................................................................................................ 85
4.1-16 No Carriage Tilt Up ......................................................................................................................... 85
4.1-17 No Carriage Tilt Down ..................................................................................................................... 85
4.1-18 No Frame Level Function ................................................................................................................ 86
4.1-19 No Frame Level Left ........................................................................................................................ 86
4
4.1-20 No Frame Level Right ..................................................................................................................... 86
4.1-21 No Stabilizer Function ..................................................................................................................... 87
4.1-22 No Right Stabilizer Lower Function ................................................................................................ 87
4.1-23 No Right Stabilizer Raise Function ................................................................................................. 87
4.1-24 No Left Stabilizer Lower Function ................................................................................................... 87
4.1-25 No Left Stabilizer Raise Function .................................................................................................... 88
4.2 Hydraulic System

4.2-1 All Controls Inoperative ................................................................................................................... 89
4.2-2 All Boom Functions Inoperative...................................................................................................... 89
4.2-3 No Boom Raise ............................................................................................................................... 89
4.2-4 No Boom Lower .............................................................................................................................. 89
4.2-5 No Boom Extend............................................................................................................................. 89
4.2-6 No Boom Retract ............................................................................................................................ 90
4.2-7 No Carriage Tilt Back ...................................................................................................................... 90
4.2-8 No Carriage Tilt Forward................................................................................................................. 90
4.2-9 No Auxiliary/Optional Hydraulic Control ......................................................................................... 91
4.2-10 No Frame Level or Stabilizer Functions ......................................................................................... 91
4.2-11 No Frame Level Right ..................................................................................................................... 91
4.2-12 No Frame Level Left ........................................................................................................................ 91
4.2-13 No Stabilizer Function ..................................................................................................................... 91
4.2-14 No Right Stabilizer Lower ............................................................................................................... 92
4.2-15 No Right Stabilizer Raise ................................................................................................................ 92
4.2-16 No Left Stabilizer Lower .................................................................................................................. 92
155167
Service and Maintenance Section 4 - Troubleshooting Information
Table of Contents (Continued)

4.2-17 No Left Stabilizer Raise ................................................................................................................... 92
4.2-18 Both Stabilizers Lower When Right Lower is Selected .................................................................. 92
4.2-19 Both Stabilizers Lower When Left Lower is Selected ..................................................................... 92
4.2-20 Both Stabilizers Raise When Either Right or Left Raise are Selected Independently.................... 93
4.2-21 Hard or No Steering ........................................................................................................................ 93
4.2-22 Wheels Go Out of Synch. When in 4 Wheel Steer Mode ............................................................... 93
4.2-23 Park Brake Will Not Release ........................................................................................................... 93
4.2-24 Park Brake Will Not Engage ........................................................................................................... 93
155167
Section 4 - Troubleshooting Information Service and Maintenance
Introduction
The following pages contain the necessary troubleshooting information for locating and correcting electrical and
hydraulic malfunctions that may arise. Careful and accurate analysis of the systems listed, will localize the problem
more quickly than any other method.
Prior to performing any troubleshooting procedure, observe the following recommendations:
1. Isolate the major component in which the trouble occurs

2. Isolate whether the problem is electrical or hydraulic
3. Isolate and correct the specific problem
NOTE
If a specific problem is not listed, or after performing all necessary steps a
problem can not be resolved; consult SKYJACK’s service department.
The content of this section is divided into “probable cause” and “remedy.” The information preceded by a number
represents the “probable cause.” The following line, noted by a dash represents the “remedy” to the “probable
cause” directly above it. See example below for clarification.
1. Probable Cause
- Remedy
155167
4.1 Electrical System
4.1-1 All Controls Inoperative (No Crank)

1. Battery cable(s) loose or disconnected.
- Tighten or connect battery cable(s).
2. Battery discharged.
- Charge battery.
3. Loose or broken wire from starter to alternator B+ post.
- Check continuity. Replace if defective.
4. Loose or broken red wire(s) from Alternator B+ post to 3 pin connector J3 (pin A and/or pin C).
- Check continuity. Replace if defective
5. Loose or broken red wire(s) from 3 pin connector P3 (pin A and/or pin C) to fuse F1.
6. Defective fuse F1.
- Check for defective wiring, Replace Fuse.
7. Loose or broken dark blue/red wire from fuse F1 to ignition switch SW1 (B+).
8. Defective ignition switch SW1.
- Replace if defective.
9. Loose or broken light blue wire from ignition switch SW1 (ST) to park brake switch SW2 (pin 5).
10. Defective park brake switch SW2.
11. Loose or broken light blue/black wire from park brake switch SW2 (pin 6) to 30 pin connector J1 (pin 13).
12. Loose or broken light blue/black wire from 30 pin connector P1 (pin 13) to front ballast switch SW3
connector J55 (pin A).
13. Defective front ballast switch.
14. Loose or broken dark green/yellow wire from front ballast switch SW3 connector J55 (pin B) to starter
relay CR10 (pin 85).
15. Loose or broken red wire from starter (B+) to starter relay CR10 (pin30).
16. Loose or broken orange/white wire from starter relay CR10 (pin 86) to 30 pin connector P1 (pin 3).
17. Loose or broken orange/white wire from 30 pin connector J1 to neutral switch diode assembly 3 pin
connector P46 (pin C).
18. Defective neutral switch diode D1.
19. Loose or broken dark blue/black wire from neutral diode assembly 3 pin connector P46 (pin B) to
transmission shifter 8 pin connector J47 (pin 5).
20. Defective transmission shifter.
21. Loose or broken black wire from transmission shifter 8 pin connector P46 (pin 6) to 3 pin connector
P3 (pin B).
155167
22. Loose or broken black wire from 3 pin connector J3 (Pin B) to engine block ground.
- Replace fuse.
23. Loose or broken dark blue wire from starter relay CR10 (pin 87) to starter (ST).
24. Defective starter relay CR10.
25. Defective starter.
4.1-2 Engine Cranks But Will Not Start

1. Loose or broken ECM red battery cable from to fuse F21.
- Check for defective wiring, Replace Fuse.
3. Lose or broken red/white wire from fuse F21 to ECM Connector J73 (pin 4).
4. Loose or broken ECM black ground cable from ECM connector J73 (pin 1) to ground.
5. Loose or broken orange wire from ignition switch SW1 to fuse F5.
- Check for defective wiring, Replace fuse.
7. Loose or broken dark blue/white wire from fuse F5 to 31 pin connector J1 (pin 27).
8. Loose or broken dark blue/white wire from 31 pin connector P1 (pin 27) to ECM connector J72 (Pin 45).
NOTE
For other engine related problems, consult engine manufacturers’ manual.
4.1-3 No Throttle
1. Loose or broken red wire 113 from throttle pedal connector J50 (pin 5) to 31 pin connector J1 (pin 21).
2. Loose or broken red wire 113 from 31 pin connector P1 (pin 21) to ECM connector J72 (pin 27).
3. Loose or broken dark blue wire 112 from throttle pedal connector J50 (pin 4) to 31 pin connector J1 (pin 20).
4. Loose or broken dark blue wire 112 from 31 pin connector P1 (pin 20) to ECM connector J72 (pin 28).
5. Loose or broken tan wire 114 from throttle pedal connector J50 (pin 3) to 31 pin connector J1 (pin 22).
6. Loose or broken tan wire 114 from 31 pin connector P1 (pin 22) to ECM connector J72 (pin 35).
7. Loose or broken light green/red wire 104 from throttle pedal connector J50 (pin 1) to 31 pin connector J1 (23).
8. Loose or broken light green/red wire 104 from 31 pin connector P1 (pin 23) to ECM connecter J72 (pin 41)
9. Loose or broken orange/black wire 116 from throttle pedal connector J50 (pin 6) to 31 pin connector J1 (pin 25).
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10. Loose or broken orange/black wire 116 from 31 pin connector P1 (pin 25) to ECM connecter J72 (pin 24).
11. Loose or broken dark purple/orange wire 115 from throttle pedal connector J50 (pin 2) to 31 pin
connector J1 (pin 24).
12. Loose or broken dark purple/orange wire 115 from 31 pin connector P1 (pin 24) to ECM connecter
J72 (pin 15).
13. Defective throttle pedal
- Replace throttle pedal.
NOTE
For other engine related problems, consult engine manufacturer’s
manual.
4.1-4 No Drive (Park Brake Does Not Release)

1. Loose or broken red wire(s) from P3 (pins A and/or C) to power relay CR1 (pin 30).
2. Loose or broken orange wire from ignition switch SW1 (IGN) to power relay CR1 (pin 86).
3. Loose or broken black wire from power relay CR1 (pin 85) to 3 pin connector P3 (pin B)
4. Loose or broken white wire(s) from power relay CR1 (pin 87) to fuse block assy.
5. Defective power relay CR1.
7. Loose or defective tan wire from fuse F2 to park brake switch SW2 (pin 2).
8. Defective park brake switch SW2.
9. Loose or broken light blue/white wire from park brake switch SW2 (pin 1) to park brake solenoid SV3
(J9 pin 1) and brake test relay CR7 (pin 30) through splice S353.
10. Defective Park brake valve SV3.
11. Loose or broken dark blue/green wire from park brake valve SV3 (J9 pin 2) to park brake pressure
switch PBPS (P10 pin A).
12. Defective park brake pressure switch PBPS.
13. Loose or broken black wire from park brake pressure switch PBPS (P10 pin B) to ground (G201).
4.1-5 No Drive (Park Brake Releases)

1. Normally closed park brake pressure switch PBPS-2 stuck in the closed position.
2. Defective brake test relay CR7. Normally closed (pin 30 to 87A) is open.
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3. Loose or broken pink/red wire from brake test relay CR7 (pin 87) to reverse diode assembly connector P44 (pin A)
4. Defective Reverse Diode D10.
5. Loose or broken yellow/blue wire from reverse diode assembly connector P44 (pin B) to transmission shifter
connector J47 (pin 8).
4.1-6 No Forward Drive

1. Loose or broken grey wire from shifter connector J47 (pin 1) to 31 pin connector J1 (pin 1)
2. Loose or broken black wire from solenoid connector P1 (pin 1) to forward solenoid connector J64 (pin 1).
3. Loose or broken black wire from forward solenoid connector J64 (pin 2) to ground.
4. Defective forward solenoid.
- Replace solenoid.
- Replace shifter
4.1-7 No Reverse Drive

1. Loose or broken white/yellow wire from shifter connector J47 (pin 7) to 31 pin connector J1 (pin 2).
2. Loose or broken white/yellow wire from 31 pin connector P1 (pin 2) to reverse relay CR5 (pin 87).
3. Loose or broken black ground wire from reverse relay CR5 (pin 86) to connector P3 (pin B).
4. Loose or broken light blue/white wire from park brake switch SW2 (pin 1) to reverse relay CR5 (pin 85) through
splice S353.
5. Loose or defective orange/blue wire from reverse relay CR5 (pin 30) to 8 pin connector J2 (pin7).
6. Defective reverse relay CR5.
7. Loose or broken orange/blue wire from connector P2 (pin 7) to reverse solenoid connector J65 (pin 1).
8. Loose or broken black wire from reverse solenoid connector J65 (pin 2) to ground.
9. Defective reverse solenoid.
- Replace solenoid.
10. Defective shifter.
- Replace shifter.
4.1-8 No 1st Speed Range

1. Loose or broken yellow/red wire from shifter connector J47 (pin 2) to 31 pin connector J1 (pin 4)
2. Loose or broken yellow/red wire from 31 pin connector P1 (pin 4) to 1st solenoid connector J66 (pin 1).
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3. Loose or broken black wire from solenoid connector J66 (pin 2) to ground.
4. Defective 1st solenoid.
- Replace solenoid.
- Replace shifter.
4.1-9 No 2nd Speed Range

1. Loose or broken white/blue wire from shifter connector J47 (pin 3) to 31 pin connector J1 (pin 5)
2. Loose or broken white/blue wire from 31 pin connector P1 (pin 5) to 2nd solenoid connector J67 (pin 1).
3. Loose or broken black wire from solenoid connector J67 (pin 2) to ground.
4. Defective 2nd solenoid.
- Replace solenoid.
- Replace shifter.
4.1-10 Front Steer Mode Only

- Check for defective wiring, Replace fuse
2. Loose or broken pink/blue wire from fuse F3 to steer mode select switch SW4 connector J40 (pin 2).
3. Defective steer mode select switch SW4.
- Replace switch.
4.1-11 No Round (4 wheel) Steer Mode

- Replace switch.
2. Loose or broken brown/white wire from steer switch SW4 connecter J40 (pin 3) to connector J1 (pin 12).
3. Loose or broken brown/white wire from connecter P1 (pin 12) to round (4 wheel) steering mode solenoid
top coil connector J69 (pin A).
4. Loose or broken black wire from round (4 wheel) steering mode solenoid connector J69 (pin B) to ground.
5. Defective round (4 wheel) steering solenoid.
- Replace solenoid.
4.1-12 No Crab Steer Mode

- Replace switch.
2. Loose or broken brown/pink wire from steer switch SW4 connecter J40 (pin 1) to connector J1 (pin 11).
3. Loose or broken brown/pink wire from connecter P1 (pin 11) to crab steering mode solenoid bottom
coil connector J68 (pin A).
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4. Loose or broken black wire from crab steering mode solenoid connector J68 (pin B) to ground.
5. Defective crab steering solenoid.
- Replace solenoid.
4.1-13 No Carriage Tilt, Aux. Hyd. or Frame Level Functions

1. Blown or defective fuse F9.
2. Loose or broken dark purple/white wire from fuse F9 to connectors J91 (pin 1), pressure switch JPS (J95 pin
B) and frame level enable relay (CR8 pin 30).
4.1-14 No Carriage Tilt or Aux. Hyd. Functions

1. Loose or broken black wire from connector J91 (pin 9) to ground G201.
2. Loose or broken red/black wire from connector J91 (pin7) to Joystick (J19 pins 1 & 4).
3. Defective Joystick.
4. Loose or broken black/white wire from Joystick (J19 pins 3) to connector J91 (pin15).
5. Defective frame level/aux. hyd. Controller TOC-2.
4.1-15 No Carriage Tilt Function

1. Loose or broken yellow/blue wire from Joystick (J19 pin 2) to connector J91 (pin 8).
2. Loose or broken black/orange wire from connector J91 (pin 4) to connector J84 (pin C)
3. Loose or broken black/orange wire from connector P84 (pin C) to fork tilt/dump solenoids (pin 2 of J85 and J86)
4.1-16 No Carriage Tilt Up

1. Defective solenoid fork tilt (LH).
2. Loose or broken red/green wire from J85 (pin 1) to P84 (pin A).
3. Loose or broken red/green wire from J84 (pin A) to J91 (pin 2).
4.1-17 No Carriage Tilt Down

1. Defective solenoid fork dump (RH).
2. Loose or broken grey/red wire from J86 (pin 1) to P84 (pin B).
3. Loose or broken grey/red wire from J84 (pin B) to J91 (pin 3).
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4.1-18 No Frame Level Function

1. Stuck or defective pressure switch JPS.
2. Loose or broken white/brown wire from JPS connector J95 (pin C) to Joystick connector J19 (pin 7).
3. Defective control handle frame level switch.
4. 4Loose or broken orange/white wire from J19 (pin 6) to frame level enable relay (CR8 pin 85).
5. Loose or broken black wire from CR8 (pin 86 to ground (G200).
6. Defective relay CR8.
7. Loose or broken yellow/black wire from CR8 (pin 87) to frame level left pressure switch PSRJ3 connector
P20 (pin A) and frame level right pressure switch PSRJ1 connector J21 (pin A).
- Check for defective wiring. Replace fuse.
9. Loose or defective dark purple wire from fuse F6 to frame angle sensor connector J25 (pin 1), RAS
controller grey connector C1 (pin 2) and black connector C2 (pin 11)
10. Loose or defective black wire from RAS controller grey connector C1 (pin 1) to ground (G200).
4.1-19 No Frame Level Left

1. Stuck or defective pressure switch PSRJ3.
2. Loose or broken grey/black wire from PSRJ3 connector P20 (pin B) to RAS controller grey connector
C1 (pin 10).
3. Loose or broken red/grey wire from RAS controller black connector C2 (pin 3) to SV1 connector J23
(pin1).
4. Loose or broken black wire from SV1 connector J23 (pin 2) to ground G201.
5. Defective frame level solenoid SV1.
6. Defective RAS controller.
4.1-20 No Frame Level Right

1. Stuck or defective pressure switch PSRJ1.
2. Loose or broken tan/black wire from PSRJ1 connector P21(pin B) to RAS controller grey connector C1
(pin 11).
3. Loose or broken white/grey wire from RAS controller black connector C2 (pin 10) to SV2 connector
J92 (pin1).
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4. Loose or broken black wire from SV2 connector J92 (pin 2) to ground G201.
5. Defective frame level solenoid SV2
6. Defective RAS controller.
4.1-21 No Stabilizer Function

2. Loose or broken white/grey wire from fuse F10 to stabilizer switches connector J30 (pin 2) and J29 (pin2).
4.1-22 No Right Stabilizer Lower Function

1. Defective right outrigger switch SW9.
- Replace switch.
2. Loose or broken light blue/red wire from right outrigger switch SW9,m connector J29 (pin 3) to connector J16
(pin F).
3. Loose or broken light blue/red wire from connector P16 (pin F) to right lower solenoid connector E1 (pin A)
4. Defective right lower solenoid E1.
- Replace solenoid.
5. Loose or broken black wire from right lower solenoid connector E1 (pin B) to ground G202.
4.1-23 No Right Stabilizer Raise Function

1. Defective right outrigger switch SW9.
- Replace switch.
2. Loose or broken tan/red wire from right stabilizer switch SW9 connector J29 (pin 1) to connector J16 (pin G).
3. Loose or broken tan/red wire from connector P16 (pin G) to right raise solenoid connector R1 (pin A)
4. Defective right raise solenoid R1.
- Replace solenoid.
5. Loose or broken black wire from right raise solenoid connector R1 (pin B) to ground G202.
4.1-24 No Left Stabilizer Lower Function

1. Defective left stabilizer switch SW10.
- Replace switch.
2. Loose or broken black/white wire from left stabilizer switch SW10 connector J30 (pin 3) to connector J16 (pin B).
3. Loose or broken black/white wire from connector P16 (pin B) to left lower solenoid connector E2 (pin A)
4. Defective left lower solenoid E2.
- Replace solenoid.
5. Loose or broken black wire from left lower solenoid connector E2 (pin B) to ground G202.
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4.1-25 No Left Stabilizer Raise Function

1. Defective left stabilizer switch SW10.
- Replace switch.
2. Loose or broken brown/red wire from left stabilizer switch SW10 connector J30 (pin1) to connector
J16 (pin C).
3. Loose or broken brown/red wire from connector P16 (pin C) to left raise solenoid connector R2 (pin A)
4. Defective left raise solenoid R2.
- Replace solenoid.
5. Loose or broken black wire from left raise solenoid connector R2 (pin B) to ground G202.
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4.2 Hydraulic System
4.2-1 All Controls Inoperative

1. Worn or defective pump shaft or coupling.
- Check pump shaft and coupling. Replace if defective.
2. No PTO rotation.
- Repair transmission, or flex plate.
3. Hydraulic oil level low.
- Check oil level. Fill to proper level.
4. Shuttle valve SH2 blocked or defective.
- Clean valve. Check operation of valve. Repair or replace valve as required.
5. System pump P1 is out of adjustment or is defective.
- Refer to section 5 for pump set up/test procedure. Repair or replace if defective.
4.2-2 All Boom Functions Inoperative

1. Stuck or defective valve LE2.
- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
2. Stuck or defective pressure reducing valve PRV3.
- Clean valve. Check operation of valve. Repair or replace valve as required
4.2-3 No Boom Raise

1. Stuck or defective joystick JS1.
2. Stuck or defective lift valve section V8.
3. Stuck or defective lift counterbalance valves CB1, CB2.
- Clean valve. Check o-rings on valve. Repair or replace valve as required.
4. Defective lift cylinder C3 and/or C4.
- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-4 No Boom Lower

2. Stuck or defective lift valve sections V8.
3. Stuck or defective lift counterbalance valves CB1, CB2.
4. Defective lift cylinder C3 and/or C4.
4.2-5 No Boom Extend

2. Stuck or defective SV4.
3. Stuck or defective divert valve SV1.
- Clean valve. Check operation of valve. Repair or replace valve as required
4. Stuck or defective extension valve sections V9.
5. Stuck or defective extension counterbalance valve CB3.
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6. Defective extension cylinder C5.

4.2-6 No Boom Retract

2. Stuck or defective SV5.
4. Stuck or defective extension valve section V9.
5. Stuck or defective extension counterbalance valve CB4.
6. Defective extension cylinder C5.
4.2-7 No Carriage Tilt Back

1. Stuck or defective LH Fork tilt Valve.
2. Stuck or defective carriage tilt valve section V10
3. Stuck or defective port relief valve RV3.
4. Stuck or defective carriage tilt counterbalance valve CB5.
5. Defective carriage slave cylinder C7and/or C8.
6. Defective carriage tilt cylinder C6.
4.2-8 No Carriage Tilt Forward

1. Stuck or defective RH Fork Dump valve.
2. Stuck or defective carriage tilt valve section V10.
3. Stuck or defective port relief valve RV4.
4. Stuck or defective carriage tilt counterbalance valve CB5.
5. Defective carriage slave cylinder C7 and/or C8.
6. Defective carriage tilt cylinder C6.
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4.2-9 No Auxiliary/Optional Hydraulic Control

1. Stuck or defective SOL A and/or Sol B valves.
2. Stuck or defective Auxiliary/Optional valve section V11.
3. Stuck or defective Auxiliary/Optional counterbalance valve (if equipped).
4. Defective Auxiliary/Optional cylinder(s).
4.2-10 No Frame Level or Stabilizer Functions

1. Stuck or defective pressure reducing valve PR1.
- Clean valve. Check operation of valve. Adjust, repair or replace valve as required.
4.2-11 No Frame Level Right

3. Stuck or defective frame level valve V7.
4. Stuck or defective frame level pilot check valve CV1.
5. Defective frame level cylinder C12.
6. Shuttle valve SH5, SH4, SH6, SH3, or SH2 blocked or defective.
- Clean valves. Check operation of valves. Repair or replace valves as required.
4.2-12 No Frame Level Left

3. Stuck or defective frame level valve V7.
4. Stuck or defective frame level pilot check valve CV1.
5. Defective frame level cylinder C12.
6. Shuttle valve SH5, SH4, SH6, SH3, or SH2 blocked or defective.
- Clean valves. Check operation of valves. Repair or replace valves as required.
4.2-13 No Stabilizer Function

1. Stuck or defective pressure reducing valve PRV4.
- Clean valve. Check operation of valve. Adjust, repair or replace valve as required.
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4.2-14 No Right Stabilizer Lower

1. Stuck or defective right stabilizer valve SV14.
2. Stuck or defective right outrigger counterbalance valve CB7.
3. Defective right outrigger cylinderC10.
4. Shuttle valve SH9, SH8, SH4,SH6, SH3, or SH2 blocked or defective.
- Clean valves. Check operation of valves. Repair or replace valves as required
4.2-15 No Right Stabilizer Raise

1. Stuck or defective right stabilizer valve SV14.
4.2-16 No Left Stabilizer Lower

1. Stuck or defective left stabilizer valve SV13.
4.2-17 No Left Stabilizer Raise

1. Stuck or defective left stabilizer valve SV13.
4. Shuttle valve SH7, SH8, SH4, SH6, SH3, or SH2 blocked or defective.
4.2-18 Both Stabilizers Lower When Right Lower is Selected

1. Stuck or defective SV17
4.2-19 Both Stabilizers Lower When Left Lower is Selected

- lean valve. Check operation of valve. Repair or replace valve as required.
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4.2-20 Both Stabilizers Raise When Either Right or Left Raise are Selected Independently
4.2-21 Hard or No Steering

1. Stuck or defective priority Logic element LE1 or relief valve RV1.
- Set valves to specifications. Check o-rings and clean valve. Repair or replace valve as required.
2. Stuck or defective steering motor OSM1.
- Check o-rings and clean valve. Repair or replace valve as required.
3. Defective steer cylinder C1 and/or C2.
4. Shuttle valve SH3, or SH2 blocked or defective.
4.2-22 Wheels Go Out of Synch. When in 4 Wheel Steer Mode

1. Stuck or defective steer function valve V12
2. Defective steer cylinder C1 and/or C2.
4.2-23 Park Brake Will Not Release

1. Stuck or defective park brake valve SV3.
2. Bypassing or defective parking brake C11.
- Check seals, replace as necessary. Replace if defective.
4.2-24 Park Brake Will Not Engage

1. Defective park brake C11.
- Repair or replace as necessary.
2. Park brake valve SV3 stuck in shifted position.
- Check valve. Replace if defective.
3. Park brake out of adjustment.
- Adjust park brake.
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Notes
Section 5
PROCEDURES
List of Procedures
General ........................................................................................................................................................ 97
Safety and Workmanship ............................................................................................................................ 97
Engine and Transmission ............................................................................................................................ 97
5.1 10 Hour or Daily Routine Maintenance

5.1-1 Check Engine Oil Level................................................................................................................... 98
5.1-2 Check Coolant Level, Radiator and Hoses .................................................................................... 98
5.1-3 Check Transmission Fluid Level ..................................................................................................... 99
5.1-4 Check Air Cleaner Restriction and Filter Elements ........................................................................ 99
5.1-5 Check Hydraulic Oil Level............................................................................................................. 101
5.1-6 Drain Fuel/Water Separator .......................................................................................................... 101
5.1-7 Fuel Tank ....................................................................................................................................... 102
5.1-8 Check Parking Brake .................................................................................................................... 102
5.1-9 Check Tire Pressure and Condition.............................................................................................. 102
5.1-10 Check Seat Belt and Mounting Hardware .................................................................................... 103
5.2 50 Hour or Weekly Routine Maintenance

5.2-1 Grease Chain Sheave Bearings.................................................................................................... 104
5.2-2 Check Lug Nut Torque .................................................................................................................. 105
5.2-3 Check Oil Level in Axle Differential Planetary wheel Ends ........................................................... 105
5.2-4 Check Oil level in Axle differentials ............................................................................................... 106
5.2-5 Grease Axle Pivot Bearings and King Pins ................................................................................... 106
5.2-6 Check Fork Pins ............................................................................................................................ 107
5.2-7 Grease Frame Level Pivot Bushings and Stabilizer Pivot Bushings ............................................ 107
5.2-8 Grease Boom Pivot and Boom Cylinders..................................................................................... 107
5.3 250 Hour or Quarterly Routine Maintenance

5.3-1 Replace Engine Oil and Filter ....................................................................................................... 108
5.3-2 Change Engine Fuel filter and Fuel/Water Separator................................................................... 109
5.3-3 Clean Hydraulic Tank Breather ..................................................................................................... 110
5.3-4 Torque Axle Mounting Bolts .......................................................................................................... 111
5.3-5 Inspect Boom Chains ................................................................................................................... 111
5.3-6 Check Boom Slide Pad Clearances ............................................................................................. 113
5.3-7 Check Boom Chains Tension ....................................................................................................... 115
5.3-8 Retract Chain Tension Adjustment ............................................................................................... 115
5.3-9 Extend Chain Tension Adjustment................................................................................................ 116
5.3-10 Check Boom Hose Tension .......................................................................................................... 118
5
5.3-11 Adjust Boom Hose Tension .......................................................................................................... 118
5.4 1000 Hour or Annual Routine Maintenance

5.4-1 Change Hydraulic Oil Filter ........................................................................................................... 120
5.4-2 Change Hydraulic Oil and Clean Suction Strainer ....................................................................... 120
5.4-3 Change Axle Differential Oil .......................................................................................................... 121
5.4-4 Change Axle Planetary Oil ............................................................................................................ 122
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Service and Maintenance Section 5 - Procedures
List of Procedures (Continued)
5.4-5 Change Engine Coolant ............................................................................................................... 123

5.4-6 Change Transmission Oil .............................................................................................................. 124
5.4-7 Change Transmission Oil Filter ..................................................................................................... 125
5.4-8 Inspect Boom Chains ................................................................................................................... 125
5.4-9 Inspect RAS Cylinder Oil Level ..................................................................................................... 126
5.5 Non-Routine Maintenance

5.5-1 Boom Hoses Replacement Procedure ......................................................................................... 127
5.5-1-1 Remove Boom Hydraulic Hoses............................................................................................... 127
5.5-1-2 Inspect Boom Hydraulic Hoses ................................................................................................ 130
5.5-1-3 Install Boom Hydraulic Hoses................................................................................................... 130
5.5-2 Boom Chains Replacement Procedure ........................................................................................ 133
5.5-2-1 Remove Retract Chain #1: ....................................................................................................... 133
5.5-2-2 Inspect Retract Chain #1: ......................................................................................................... 134
5.5-2-3 Install Retract Chain #1: ........................................................................................................... 134
5.5-2-4 Remove Retract Chain #2: ....................................................................................................... 135
5.5-2-5 Inspect Retract Chain #2: ......................................................................................................... 139
5.5-2-6 Install Retract Chain #2: ........................................................................................................... 139
5.5-2-7 Remove Extend Chain #2: ....................................................................................................... 143
5.5-2-8 Inspect Extend Chain #2: ......................................................................................................... 144
5.5-2-9 Install Extend Chain #2: ........................................................................................................... 144
5.5-2-10 Remove Extend Chain #1: ..................................................................................................... 145
5.5-2-11 Inspect Extend Chain #1: ....................................................................................................... 145
5.5-2-12 Install Extend Chain #1: ......................................................................................................... 145
5.5-3 Slide Pads Replacement Procedure ............................................................................................. 146
5.5-3-1 Front Lower Slide Pads ............................................................................................................. 146
5.5-3-2 Front Side Slide Pads ............................................................................................................... 146
5.5-3-3 Front Upper Slide Pads ............................................................................................................. 147
5.5-3-4 Rear Upper Slide Pads.............................................................................................................. 147
5.5-3-5 Rear Lower Slide Pads .............................................................................................................. 148
5.5-3-6 Rear Side Slide Pads ................................................................................................................ 148
5.5-4 Hydraulic Pressure Test Procedure .............................................................................................. 149
5.5-4-1 System Standby Pressure ........................................................................................................ 149
5.5-4-2 System Maximum Pressure ...................................................................................................... 150
5.5-4-3 Neutral Steering Pressure ......................................................................................................... 150
5.5-4-4 Maximum Steering Pressure ..................................................................................................... 151
5.5-4-5 Service Brake Pressure ............................................................................................................. 151
5.5-4-6 Pilot Pressure ............................................................................................................................ 152
5.5-5 Hydraulic Pump Testing Procedure .............................................................................................. 153
5.5-6 Park Brake Release on Front Axle ................................................................................................ 153
5.5-7 Crowd Cylinder Replacement Procedure ..................................................................................... 154
5.5-7-1 Preparation Procedure .............................................................................................................. 154
5.5-7-2 Crowd Cylinder Removal Procedure ........................................................................................ 155
5.5-7-3 Crowd Cylinder Replacement Procedure ................................................................................. 158
5.5-8 Coolant Draining Procedure ......................................................................................................... 165
5.5-8-1 Radiator Fill Maintenance ......................................................................................................... 165
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Section 5 - Procedures Service and Maintenance
General
The following information is provided to assist you in the use and application of servicing and maintenance procedures
contained in this chapter.
Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support
is provided.
Engine and Transmission

The engine used on the VR-1056D Variable Reach model is a Cummins QSB3.3T3.
Engine service information can be found in the Cummins Engine Manuals. It should be noted that engine warranty
service work is to be directed to and administered by your nearest authorized Cummins dealer/distributor.
Skyjack cannot enter into any warranty service work requirements.
The basic Cummins engine warranty covers the entire engine from the fan to the fly wheel including all internal parts
as well as the following list of parts supplied with the engine as original:
1. Starter
2. Alternator
3. Injectors
4. Fuel Pump
5. Fuel Solenoid
6. 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.
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5.1 10 Hour or Daily Routine Maintenance 5.1-2 Check Coolant Level, Radiator and
Perform maintenance inspections for the items Hoses
described in this section on a daily basis or at the start
of each work shift. 1. Check coolant level at the overflow bottle. If
coolant level is low, add coolant to the correct
level.
5.1-1 Check Engine Oil Level
Coolant Overflow
1. Park telehandler on a firm level surface with boom Bottle
fully retracted and lowered.
2. Shut off engine then release latch and slide

engine cover to open.
3. Wait approximately 15 minutes after engine has

been shut off.
4. Pull out dipstick and wipe it off with a clean, dry,

lint-free cloth; then place it back in the hole until
it stops.
Engine Oil
Dipstick Figure 5-2. Overflow Bottle Location
2. Check radiator fins and clean as necessary using

compressed air or water.
3. Check radiator hoses for leaks or damage.
Figure 5-1. Engine Oil Dipstick
5. Pull the dipstick out again and check the oil level
on the dipstick. The oil level must be between the
“Full” and “Low” marks.
6. If oil level is below the “Low” mark, refer to

section 5.3-1 for engine oil and filter replacement
procedure.
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5.1-3 Check Transmission Fluid Level 5.1-4 Check Air Cleaner Restriction and
Filter Elements
1. Park telehandler on a firm level surface, move
transmission gear selector to Neutral and apply 1. Service the air cleaner when a red band appears
park brakes. on the restriction indicator. After servicing, press
the indicator to reset it. See Figure 5-4.
2. Release latch and slide engine cover to access
engine compartment. Restriction
Indicator
3. Start engine and allow the transmission to
reach normal operating temperature between
180° - 240° F (82° - 93° C).
4. Pull out dipstick and wipe with a clean, dry,

lint-free cloth. Fully insert dipstick back into the
tube and then pull it out and check the oil level.
Transmission Oil
Dipstick
Figure 5-4. Restriction Indicator Location
2. Check the air cleaner vaccuator valve to see that

it is clean and that the rubber is not cracked.
Squeeze the valve lips and remove any dirt or
dust. It should expel dust and dirt continuously
when the engine is running. See Figure 5-5.
Vaccuator
Figure 5-3. T12000 Transmission Valve
5. The oil level should be between the “Full” and

“Low” marks.
6. If transmission oil level is low, refer to section 5.4-5 Figure 5-5. Air Cleaner Vaccuator Valve
for transmission oil and filter replacement.
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• VR-1056D telehandler is equipped with a 3. Clean the safety element (item 1 on Figure 5-8)
two-stage air filter system; which consists of and clean the inside of the housing and dust
a primary filter element & a secondary safety cover with a damp cloth.
element. Inspect the condition of both the primary
and safety elements.
IMPORTANT
The primary element can be replaced
or cleaned. The safety element cannot
be cleaned and must be replaced only.
NOTE
For maximum engine protection, replace
the safety element after every third cleaning
of the primary element or annually. Figure 5-8. Air Cleaner Safety Element
CAUTION
1. Pull out latch, then rotate dust cover counter
Never use compressed air on an air
clockwise (CCW) and pull outward to remove.
filter. Paper elements should not be
Air Cleaner “washed”.
Latch
IMPORTANT
Secondary or safety element should
not be removed unless it is being
replaced.
Replace the safety element if:
• Examination reveals tears or perforations in the

safety element.
• The primary element has been replaced three
times or the element has been in service one
year.
Figure 5-6. Engine Air Cleaner
2. Remove and clean the primary air cleaner

element (item 1 on Figure 5-7).
Figure 5-7. Air Cleaner Primary Element
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5.1-5 Check Hydraulic Oil Level 5.1-6 Drain Fuel/Water Separator
Maintaining the hydraulic components and hydraulic oil DANGER

at the proper level are essential to good performance
and service life of the telehandler. Diesel fuel is flammable and may
cause serious injury or death. Shut
The telehandler must be on level ground and all down engine and do not smoke while
cylinders retracted when checking oil level. draining fuel/water separator.
Refer to oil sight gauge on side of tank to check that 1. Ensure engine is shut down & telehandler is
the hydraulic fluid is within 4 inches below the top of parked on a firm level surface.
the tank.
2. Prepare a container for draining the fuel/water
separator and place it under the separator.
Hydraulic Tank
Sight Gauge 3. Open drain reservoir and allow approximately
one cup of fuel and any collected sediment to
drain into the container. Refer to Figure 5-11.
TELEHANDLER 57 57
14 9
VR - 1044D / 1056D 16 16
18 18
8
SERVICE FUNCTIONS :
S - CHECK A - ADD 20
G - GREASE T - TORQUE
AR - AS REQUIRED
15 15
C - CHANGE D - DRAIN
52 18 18
F - FILL CL - CLEAN 5 51 52
7 14
FTLH - FILL TO LEVEL HOLE
14 34
SERVICE REMARKS COMMENTS

S, A MULTI-PURP PREMIUM ENG OIL FULL ON DIPSTICK
S, A WATER / ANTI-FREEZE AR
S, A PREMIUM MULTI-PURPOSE ATF FULL ON DIPSTICK
S AR 1 PLACE
S, A PREMIUM MULTI-PURPOSE ATF FILL TO SIGHT GAGE
D COLLECTED WATER AR 1 PLACE
S, A #2 DIESEL FUEL AR
S (3)
S, A PRESSURE / CONDITION (3)
G EP2 GREASE 2 FITTINGS

S, T 442 FT-LBS / 619 N-M 40 PLACES
S, A PREMIUM LTD-SLIP COMP LUBE 2 PLUGS
S, A PREMIUM LTD-SLIP COMP LUBE 4 PLUGS
G EP2 GREASE AR
D, F MULTI-PURP PREMIUM ENG OIL 7.4 QTS. / 7.0 L.
C (5) 1 REQ'D
C (4) 2 REQ'D
CL (4) 1 REQ'D
S CHAIN LUBRICANT AR
G EP2 GREASE 30 PADS
G EP2 GREASE 53 PADS
T (3) ADJUST
C 1 REQ'D
D, F PREMIUM LTD-SLIP COMP LUBE 33.6 QTS. / 31.8 L.
S CHAIN LUBRICANT AR
CL (3)
FILL TO SIGHT GAGE
19 QTS. / 17.9 L
8 QTS. / 7.6 L.
13.6 QTS. / 12.9 L.
1 REQ'D
923124AB
Drain
Reservoir
Figure 5-10. Hydraulic Oil Tank Sight Gauge

Figure 5-11. Fuel/Water Separator
1. Check hydraulic tank sight gauge. 4. Close the drain then dispose of the collected
liquid in an environmentally safe manner.
2. Add clean hydraulic oil through the tank filler
as required. Refer to Table 2.4 for hydraulic oil NOTE
specifications. Refer to your local/national environmental
regulations on how to dispose of used fuels
and other dangerous liquids.
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5.1-7 Fuel Tank 5.1-9 Check Tire Pressure and Condition
WARNING 1. Check the tire pressure when cold and inflate to

the recommended pressure. Refer to Operating
Do not allow fuel tank to become Manual for tires and tire pressure specifications.
completely empty. If tank is allowed
to empty completely, the entire fuel
DANGER
system will require bleeding.
Do not over-inflate. Tire may explode
1. Check fuel gauge inside operator’s cab. causing severe injury or death.
2. Ensure fuel is at an appropriate level before the 2. Remove wheel from telehandler to fill the
start of each work shift. tire whenever pressure is below 80% of the
recommended pressure.
3. Add diesel fuel as required.
3. Place tire in a cage and inflate using a clip-on
NOTE chuck and a remote tire pressure gauge.
Refer to Operating Manual for refueling
procedure. 4. If tire must be removed for repairs, remove the air
pressure from the tire before removing the wheel
5.1-8 Check Parking Brake from the telescopic material handler.
1. Check the park brake operation daily or every 10 Tire

hours of service.
NOTE
Refer to “Park Brake Test Procedure” in
Section 2 of Operating Manual.
Wheel
Nut
Figure 5-12. Telehandler Wheel
5. Check tire tread for damage. Check for bent or

damaged rims and loose or missing hardware.
6. Tighten and torque wheel nuts.
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5.1-10 Check Seat Belt and Mounting

Hardware
1. Check seat belt for wear or damage. Check that

mounting hardware is tight.
2. Inspect the belt hardware and fabric. Replace if

hardware is damaged, frayed or loose stitching
is found.
Seat Belt Seat
Figure 5-13. Seat Assembly
3. Check the operation of the seat belt warning

system. This includes the seat belt indicator light
on the right-hand control panel and the audible
alarm.
NOTE
Replace seat belt assemblies every three
(3) years, regardless of appearance. Seat
belt strength degrades over time and use
due to exposure to weather conditions.
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5.2 50 Hour or Weekly Routine 5. Apply four shots of grease to the retract chain
Maintenance sheave grease fittings. See Figure 5-15.
Grease Fittings
5.2-1 Grease Chain Sheave Bearings
NOTE
Refer to Table 2.4 in Section 2 of this manual
for recommended grease type.
1. Ensure telehandler is on a firm level surface.
2. Fully lower and retract the boom and apply

parking brake.
3. Shut down engine and remove key from ignition

switch.
4. Remove boom cowl at the back of boom structure Figure 5-15. Retract Chain Sheave Fittings
to access retract chain bearing sheave grease
fittings. See Figure 5-14. 6. Replace boom cowl.
Boom Cowl CAUTION

Always maintain three points of contact
when entering vehicle. Use provided
hand-holds and steps only.
7. Enter cab and start engine.
8. Fully extend the boom exposing the extend chain

sheaves on tanks side of telescopic boom. See
Figure 5-16.
Boom Access
Holes
Figure 5-14. Boom Cowl Removal
WARNING
Never place fingers or hands in boom
access holes while telehandler is
operating. Always replace covers
after maintenance or service work is
completed.
Figure 5-16. Extend Chain Sheaves Location
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9. Apply a few shots of grease to each of the grease 5.2-3 Check Oil Level in Axle Differential
fittings. See Figure 5-17. Planetary wheel Ends
Grease Fittings
Through Access WARNING
Holes Hot oil or components can burn. Oil
must be at normal operating temperature
when draining. Avoid contact with hot oil
or components.
NOTE
Each axle has two independent planetary
assemblies that require gear oil lubricant.
1. Park telehandler on a firm level surface with

the fill plug in the vertical position as shown in
Figure 5-19.
Figure 5-17. Grease Fittings on Side of Boom
Fill plug
5.2-2 Check Lug Nut Torque
1. Ensure wheel nuts are tight on all wheels.
2. Tighten wheel nuts to a torque of 442 lb. ft. (599

N.m) using the cross pattern shown in Figure
5-18.
7 1
6
3
10
9 Figure 5-19. Planetary Wheel Plug
4
5 2. Apply park brake and shut off engine and allow
2 8
telehandler to sit for a minimum of two minutes.
3. Wipe the fill plug clean and remove.
Figure 5-18. Wheel Nuts Torque Procedure 4. Check oil level at the bottom of the fill hole. If
required, add oil.
3. When the wheels are removed and reinstalled,
check the nuts after eight (8) hours of operation. NOTE
Refer to Table 2.4 of Section 2 in this manual
4. If nuts are tight after the eight hour check, the for oil type and capacity.
interval for checking with a torque wrench can
be extended to 250 hours. 5. Replace plug and repeat steps above for the
three (3) remaining planetary wheel ends.
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5.2-4 Check Oil level in Axle differentials Axle Pivot Bearings
NOTE There are remote grease fittings for pivot bearing

Each axle assembly requires gear lubricant lubrication. The front axle grease fittings are located on
independent of the planetary assemblies. the right front frame rail next to the frame level cylinder.
See Figure 5-21.
1. Ensure telehandler is parked on a firm level
surface. Frame Level
Grease Fittings
Cylinder
2. Apply park brake and turn off engine, then allow
it to sit for a minimum of two minutes.
3. Wipe check plug clean and remove. See Figure

5-20.
Oil Drain Level/Fill Figure 5-21. Front Axle Pivot

Plug Plug Bearing Grease Fittings
The rear axle grease fittings are located to the rear of

Figure 5-20. Axle Plugs the radiator. See Figure 5-22.
4. Check oil level at the bottom of the fill hole. Add Grease Fittings Radiator
oil as needed.
NOTE
Refer to Table 2.4 of Section 2 in this manual
for oil type and capacity.
5. Replace plug and repeat steps above for the

other axle.
5.2-5 Grease Axle Pivot Bearings and King

Pins
Each axle has two integral pivot assemblies which

attach the axle to the frame. Each of the four pivot Figure 5-22. Rear Axle Pivot
assemblies requires independent lubrication. Bearing Grease Fittings
1. Wipe dirt and grease from each remote grease

fitting.
2. Apply 4 shots of grease to each fitting (one on

top and one on bottom).
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Axle King Pins 5.2-7 Grease Frame Level Pivot Bushings

and Stabilizer Pivot Bushings
Each axle has two king pins. Each king pin has an
upper and a lower grease fitting (total of 4 king pins
1. Apply grease to the grease fittings at each end
on each axle). Follow the steps below to lubricate the
of the frame level cylinder.
king pins.
2. Apply grease to the stabilizers assembly. There
1. Wipe each fitting clean.
are 5 grease points in each stabilizer (2 on
cylinder, 1 on support arm, and 2 on stabilizer
2. Apply 4 shots of grease to each fitting. See
arm). See Figure 5-25.
Figure 5-23.
Top King Pin

Stabilizer Cylinder
Grease Points
Bottom
King Pin
Figure 5-23. Axle King Pins

Stabilizer Arms
Grease Points
5.2-6 Check Fork Pins
Figure 5-25. Stabilizer Grease Points
1. Check the condition of the fork pins.
2. Inspect for cracks and other deformations. 5.2-8 Grease Boom Pivot and Boom
Cylinders
3. Replace if required.
Fork Pins 1. Apply grease to the following grease points on

boom pivot and boom cylinders: Refer to Figure
5-26.
Figure 5-24. Fork Pins

Figure 5-26. Boom Grease Points
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5.3 250 Hour or Quarterly Routine 7. Install oil drain plug with a new seal ring and
Maintenance tighten firmly.
8. Remove oil filter and catch any escaping oil.

5.3-1 Replace Engine Oil and Filter
Oil Filter
Maintaining the engine components is essential to
good performance and service life of the telehandler.
Periodic replacement of the engine oil and filter is
essential to good engine performance.
NOTE
Shut off engine and allow it to cool down
prior to performing this procedure.
CAUTION
Beware of hot engine components.
Contact with hot engine components
may cause severe burns.
Figure 5-28. Engine Oil Filter Location
CAUTION
9. Clean inside the filter head.
When draining hot oil, there is a risk of
scalding. Do not let used oil run into
10. Add clean engine oil to the new oil filter.
the soil, rather collect it in a container.
Dispose of this in accordance with 11. Apply a thin layer of engine oil to the new oil
environmental regulations. filter gasket.
1. Ensure telehandler is parked on a firm level 12. Install new filter as per manufacturer’s
surface. recommendations. Be careful, mechanical
overtightening may distort threads or damage
2. Apply park brake and remove key from ignition the gasket.
switch.
13. Clean up any oil that may have spilled during
3. Allow engine to cool down. this procedure.
4. Unlatch engine cover locks & slide cover forward. 14. Refill engine with new oil through the fill area.
Refer to Table 2.4 for engine oil specifications.
5. Place a container capable of holding
approximately 7 quarts (7.4 litres) under engine Engine Oil
oil drain plug. Fill Cap
6. Remove oil drain plug and allow all engine oil to

drain into container. See Figure 5-27.
Figure 5-27. Engine Oil Draining Figure 5-29. Engine Oil Fill Cap
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15. Start engine and allow it to run for 30 seconds 5.3-2 Change Engine Fuel filter and Fuel/
then stop the engine. Water Separator
16. Check for oil leakage.
The engine has both a fuel filter and a fuel/water
17. Check engine oil level on dipstick and add oil if separator to filter water, rust particles, dust and other
needed. particles from the fuel. See Figure 5-31.
Engine Oil WARNING

Dipstick
The fuel pump high-pressure fuel lines
and fuel rail contain very high pressure
fuel. Never loosen any fittings while the
engine is running. Personal injury and
property damage can result.
1. Ensure telehandler is on firm level surface.
2. Apply parking brake, shut down the engine and

remove key from ignition switch.
3. Unlatch engine cover locks & slide cover forward

so that engine components are accessible.
4. Clean area around fuel filter and fuel/water

Figure 5-30. Engine Oil Dipstick Location
separator.
18. Slide the engine cover back then latch and secure 5. Place a container under filter and separator to
it in place. collect any escaping fuel when removing them.
NOTE
Refer to your local/national regulations on
how to dispose of used filter and oil.
Fuel/Water
Separator
Engine Fuel
Filter
Oil Dipstick
Figure 5-31. Engine Fuel Filter and

Fuel/Water Separator Location
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6. Unscrew used fuel filter and separator using 75 - 11. Prime fuel system after fuel filters have been
80 mm and 90 - 95 mm wrenches. Discard used reinstalled as follows: Refer to Figure 5-33.
filter and separator and any captured spilled fuel.
• Turn the primer pump handle counter clockwise
Fuel Filter Water Separator (CCW) to release the handle.
• Pump the handle in and out until pressure
builds in the fuel system (handle will gradually
become firm).
• Retighten the handle.
Primer Pump Handle
Figure 5-32. Fuel Filter & Water Separator
NOTE
how to dispose of used filter and separator.
7. Clean the sealing surface of the dual filter head. If

necessary, replace O-ring on the dual filter head.
8. Fill replacement filter and separator with clean

Figure 5-33. Priming the Fuel System
fuel and lubricate O-ring seal with clean oil.
9. Install replacement filter and separator as 12. Slide engine cover back and latch it in place.
specified by manufacturer. Most filters have
instructions printed on the side.
5.3-3 Clean Hydraulic Tank Breather
IMPORTANT
No manual bleeding of fuel lines is 1. Clean area around hydraulic breather. Do not
required if fuel filters are changed allow dirt to enter the hydraulic tank.
according to these instructions. Refer
to engine manufacturer’s manual for Hydraulic Tank
information on bleeding the fuel system. Breather
10. Check machine for any leaks.
Figure 5-34. Hydraulic Tank Breather
2. Remove the breather and clean with solvent.

Blow dry with compressed air.
3. Place the cleaned breather on the tank.
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5.3-4 Torque Axle Mounting Bolts 5.3-5 Inspect Boom Chains
The axles are secured to the frame by an axle WARNING

pivot assembly on each side of the axle. The pivot
assemblies are bolted to the machine frame with axle Do not enter the danger area under or
mounting bolts. See Figure 5-35. around the boom when forks are off the
ground or while engine is running.
Front Axle
Front Mounting CAUTION
Bolts
Before making any repairs, use blocks
and chains on the boom sections and
forks to ensure that they cannot move.
Make sure the moveable parts are
attached to non-moveable parts.
1. Park telehandler on a firm level surface.
2. Apply parking brake then fully retract and lower

the boom.

switch.
4. Remove boom cowl on rear of boom structure.
Boom Cowl
Figure 5-35. Axle Mounting Bolts
1. Torque front axle mounting bolts to 660 lb.ft.

(895 N.m.).
2. Repeat procedure for rear axle.
Figure 5-36. Boom Cowl Removal
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5. Inspect the retract chain inside the rear of the 10. Inspect the extend chains through inspection
boom. ports. See Figure 5-38.
NOTE Boom Inspection

The chains should appear well lubricated, Ports
with no signs of wear or rust.
Retract Chain
Figure 5-38. Boom Inspection Ports
NOTE
The chains should appear well lubricated,
with no signs of wear or rust.
Figure 5-37. Retract Chain 11. If chain appears dry, rusty, or worn, the chains
must be removed for a complete inspection
6. If chain appears dry, rusty, or worn, the chains and lubrication. Refer to Section 5.5-2 for boom
must be removed for a complete inspection chains replacement procedure.
and lubrication. Refer to Section 5.5-2 for boom
chains replacement procedure.
7. When the chains are well lubricated, reinstall

the cowl.
8. Start the engine and fully extend the boom.

switch.
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5.3-6 Check Boom Slide Pad Clearances 7. With park brake applied, shut down engine and
remove key from ignition switch.
Slide pads support the boom components as the boom
is extended and retracted. The slide pads must maintain 8. Measure the clearance between each side slide
clearance between the contact surface of the pad and pad & the boom at each section as follows:
the adjacent sliding surface. This clearance ranges
Side Slide Pads
between 0.031 – 0.062 in. (0.79 – 1.58 mm) TOTAL for
both sides of the boom. When clearances exceed this
amount, shims need to be added or the pads replaced.
The slide pads are chamfered on the corner of the

wear surface. This serves as a wear indicator. When
the chamfer is no longer visible, replace the pads.
Additional wear will allow interference with inserts in the
pads. Refer to Section 5.5-3 for slide pads replacement
procedure.
Lubrication of the pads require application of grease on

the boom surfaces which come in contact with the pads.
2. Extend the boom and rest the forks on a level

surface. Figure 5-40. Side Slide Pads Clearance
3. Apply park brake then shutdown the engine and • Place a bar against the side of the boom section
remove key from ignition switch. and pry the section sideways as far as possible.
4. Measure the clearance between the bottom • Measure the clearance between the side of
surfaces of the boom and slide pads at each the boom and the upper and lower slide pads.
section. Clearance should not exceed 0.08 in. Clearance should not exceed 0.08 in. (2 mm).
(2 mm). • Repeat procedure for inner boom section.
Bottom Slide Pads Clearance
Figure 5-39. Bottom Slide pads
5. When clearances exceed this amount, add shims

or replace the pads.
6. Start the engine and raise the boom off the level
surface ensuring there is no upward force applied
to the boom.
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9. Remove boom cowl so that rear of the boom 17. If clearances are within 0.08 in. (2 mm), install
sections are visible. the boom cowl.
10. Start the engine and fully retract the boom so that NOTE
upper and side slide pads on each boom section If any of the clearances are greater than
are visible. Refer to Figure 5-41. 0.08 in. (2 mm), shim adjustment or
replacement of the slide pads may be
Side Slide Pad Upper Slide Pads Side Slide Pad required. Refer to Section 5.5-3.
Figure 5-41. Upper and Side Slide Pads
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.
13. Measure the slide shoe clearance at the top of

each boom section. Clearance should range not
exceed 0.025 in. (0.63 mm).
14. Start the machine and raise the boom high

enough to lift the forks off of the ground.
15. Shut off the engine.
16. Measure the side slide pads clearance using the

same procedure as outlined in step 8 for the side
slide pads at the front of the boom.
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5.3-7 Check Boom Chains Tension

IMPORTANT
If nesting dimensions are GREATER
Check and adjust the extend and retract boom chains,
THAN the MAXIMUM shown, the retract
if necessary, at the 250 hour maintenance interval.
chains require adjustment as described
in Section 5.3-8.
Proper adjustment of the chains at this interval
minimizes the risk of chain failure which could cause
extensive damage to other boom components and
IMPORTANT
require extensive labor hours to repair.
If nesting dimensions are LESS THAN
the MINIMUM shown, the extend chains
NOTE
require adjustment as described in
If the chains make noise such as banging on
Section 5.3-9.
the interior boom parts, or the gap identified
below is less than the minimum acceptable
amount, adjustment is necessary.
5.3-8 Retract Chain Tension Adjustment
1. Park telehandler on firm level ground and apply
parking brake. NOTE
To adjust the boom chains, torque the
2. Fully lower and retract the boom then shut off retract chains.
engine.
1. Extend the boom several inches to minimize the
3. Measure the gaps shown in Figure 5-42. effort required to torque the chain. Torque the
retract chain #1 anchor nut to 110 lb.ft. (149
ACCEPTABLE GAPS: N.m.). See Figure 5-43.
A = 0.75 to 1.75 in. (19 to 45 mm)
B = 3.25 to 4.25 in. (80 to 105 mm) Retract Chain #2 Retract Chain #1
Anchor Nut Anchor Nut
Boom Section 1 2 3 4
A
A = 19 to 45 mm (0.75 to 1.75 inch)

Figure 5-43. Retract Chain Anchor Nuts
B = 80 to 105 mm (3.25 to 4.25 inch)
Figure 5-42. Nested Boom Section 2. Fully retract the boom and check dimension “B”
Clearance Measurements on Figure 5-42, if measurement is within the range
shown, retract chain #1 is correctly adjusted.
NOTE
If measurement is LESS THAN the MINIMUM,
extend chain #1 requires adjustment (See
Section 5.3-9).
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3. Extend the boom several inches to minimize the 3. Extend chain #1 is adjusted by turning the deep
effort required to torque the chain. Torque the nut on the end of the extend chain rod
retract chain #2 anchor nut to 55 lb.ft. (75 N.m).
Hex Lock
Retract Chain #2 Retract Chain #1
Collar
Anchor Nut Anchor Nut
Extend Chain
Rod
Deep Nut
Figure 5-44. Retract Chain Anchor Nuts
4. Fully retract the boom and check dimension “A”

on Figure 5-42, if measurement is within the range
shown, retract chain #2 is correctly adjusted.
NOTE
If measurement is LESS THAN the MINIMUM,
Figure 5-45. Extend Chain Adjustment
extend chain #2 requires adjustment (See
Section 5.3-9).
4. Remove the hex lock collar from the deep nut.
5. Use a 1-13/16 inch shallow well socket to tighten

5.3-9 Extend Chain Tension Adjustment the rod nut and tighten the chain. Tightening
extend chain number 1 pulls boom section
If nesting dimensions are LESS THAN the MINIMUM number 3 from boom section number 2, thus
required, the extend chains require adjustment. Loosen extending the gap between boom sections
the retract chain anchor nuts (see Figure 5-? above) to number 2 and number 3.
provide slack in the retract chains and to reduce the
effort required to turn the extend chain adjustment nuts. CAUTION
Do not torque the rod nut at this time.
NOTE
Carefully read the steps outlined.
ALWAYS leave slack in the retract anchors
when tightening the extend chains.
6. Fully retract the boom and check the nesting
Adjust Extend Chain #1: measurements as shown in Figure 5-42.
7. Repeat steps 5 & 6 until the gap between boom

1. Ensure telehandler is parked on a firm level sections number 2 & number 3 EXCEEDS the
surface and park brake applied. acceptable required measurement.
2. Remove boom cowl from rear of boom to gain NOTE

access to extend chain torque nut. Using a scale, measure the depth from the
end of the adjustment nut to the anchor
rod inside the nut. The nut is 90mm long.
Minimum acceptable engagement into the
nut is 25 mm (65 mm showing on the scale).
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8. Once the required gap becomes greater than the 3. Loosen jam nut. See Figure 5-46.
maximum acceptable measurement, use a ruler to
check the thread engagement of the adjustment 4. Tighten (do not torque) the adjusting nut to
nut on the chain anchor rod. The MINIMUM tighten extend chain number 2.
acceptable thread engagement is 1 in. (25 mm.)
NOTE
9. When the gap between sections number 2 Tightening extend chain number 2 pulls
and number 3 EXCEEDS the MAXIMUM, and boom section number 4 from boom section
the MINIMUM thread engagement has been number 3, thus extending the gap between
achieved, tighten the hex lock collar. Refer to boom sections number 3 and number 4.
Figures 5-42 & 5-45.
5. Fully retract the boom and check the nesting
10. Extend the boom slightly to gain easy access measurements as shown in Figure 5-42.
to the retract chain number 1 anchor nut on the
bottom front of boom section number 1. Refer 6. Repeat steps 3–5 until the gap between boom
to Figure 5-44. Extending the boom slightly also sections number 3 and number 4 EXCEEDS the
reduces the effort required to turn the retract chain MAXIMUM acceptable measurement.
anchor nut.
7. When the gap between sections number 3 and
11. Tighten retract chain number 1 anchor nut. number 4 EXCEEDS the MAXIMUM, tighten the
jam nut to lock the adjustment.
12. Fully retract the boom and check dimension “B”
shown in Figure 5-42. 8. Extend the boom slightly to gain easy access
to the retract chain number 2 anchor nut on the
13. If the MAXIMUM measurement, shown in Figure bottom front of boom section number 2. Refer
5-42, has NOT been achieved, repeat steps 10 to Figure 5-?. Extending the boom slightly also
through 12. reduces the effort required to turn the retract chain
anchor nut.
14. When the MAXIMUM measurement, shown in
Figure 5-49, HAS BEEN achieved, torque the 9. Tighten retract chain number 2 anchor nut.
chain anchor nut to 110 lb.ft. (149 N.m.).
10. Fully retract the boom and check dimension “A”
shown on Figure 5-42.
Adjust Extend Chain #2:
NOTE
Access to the chain anchor is gained through the
If the MAXIMUM measurement, shown in
inspection hole located on boom section number 2.
Figure 5-42, HAS NOT been achieved,
Refer to Figure 5-46.
repeat procedure. When the MAXIMUM
measurement HAS BEEN achieved, torque
1. Fully extend boom so that inspection access
the chain anchor nut to 55 lb.ft. (75 N.m.).
holes are visible and clear of obstructions.
2. Rest attachment on the ground, apply park brake Adjusting

then shut off engine. Nut
Jam Nut
Figure 5-46. Extend Chain #2 Adjustment
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5.3-10 Check Boom Hose Tension 4. Working from the rear most inspection hole
in boom section number 2, place hand inside
Telehandlers equipped with auxiliary hydraulics have inspection hole and feel for the two hoses along
two sets of boom hoses inside the boom assembly. the inside wall of the boom.
The hoses on the right (tanks-side) of the boom are for Boom Section #2
fork tilt functions. The hoses on the left (cab-side) of the Inspection Hole
boom assembly are for the auxiliary hydraulic functions.
Fork Tilt Auxiliary

Hoses Hydraulics Hoses
Figure 5-48. Boom Inspection Hole
5. When properly tensioned, position the lower hose

19 mm to ¾ in. to 1 in. (25 mm) from the bottom
of the boom section:
• If the lower hose is higher than 1 ¼ in. (32 mm),

the tension must be reduced. Refer to Section
Figure 5-47. Hoses Inside Boom 5.3-11.
Tension check and adjustment procedures are the • If the lower hose is closer than ¾ in. (19 mm)
same for either set of hoses. from the bottom of the boom, the tension must
be increased. Refer to Section 5.3-11.
1. Remove any load from forks/auxiliary attachments.
2. With parking brake applied, fully extend the 5.3-11 Adjust Boom Hose Tension
boom and partially extend the fork tilt/ auxiliary
hydraulics cylinder. 1. Remove the cover plate from the boom tip.
IMPORTANT Boom
DO NOT fully extend the cylinder. Lower Cover Plate
the boom close to, but NOT touching the
ground.
3. Shutdown the engine and remove key from

ignition switch.
NOTE
The two hoses are transitioning from
an over-and-under configuration to a
side-to-side configuration as they reach the
Inspection hole in boom section number 2.
Figure 5-49. Boom Cover Plate Removal
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2. To increase tension, tighten nut on the end of the

twin hose tension adjuster. Refer to Figure 5-50.
3. To decrease tension, loosen the nut.
Auxiliary
Fork Tilt Hoses Hydraulics Hoses
Tension Adjuster Tension Adjuster
Nut Nut
Figure 5-50. Tension Adjuster Nuts Location
NOTE
No more than 4.5 in. (114 mm) of threads
should be exposed when tension is
decreased (i.e. Nut is loosened).
4. After adjustment has been made, recheck the

hose tension as described in step 4 of Section
5.3-10.
5. When hoses are tensioned correctly, re-install the

cover plate on the boom tip.
6. Enter cab and start engine then operate the

boom/telescope functions through several cycles
to ensure satisfactory operation.
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5.4 1000 Hour or Annual Routine 6. Install the new filter and turn until the gasket
Maintenance contacts the filter head.
7. Tighten an additional 1/2 to 3/4 turn by hand to

5.4-1 Change Hydraulic Oil Filter compress the gasket.
1. Ensure telehandler is on a firm level surface, apply
the park brake and shut off the engine.
5.4-2 Change Hydraulic Oil and Clean
2. Place suitable container under filter. Suction Strainer
3. Remove deck plate. NOTE

Dirt in the hydraulic system will lead to
Deck Plate premature component failure. A clean,
contaminant-free system is extremely
important to the telehandler’s proper
function. Take extra care when working
around or on the hydraulic system to ensure
its complete cleanliness.
2. Fully retract and lower the boom to the stowed

position.
3. Apply parking brake and shutdown the engine.
Figure 5-51. Deck Plate 4. Place a container under the hydraulic oil tank
capable of holding approximately 50 gallons
(190 Litres).
4. Remove and discard the old hydraulic oil filter. Be
sure all traces of the old filter gasket are removed
5. Remove hydraulic tank drain plug from under
from the filter head.
hydraulic oil tank and allow all hydraulic oil to
drain into container.
Remove Drain
Figure 5-52. Hydraulic Oil Filter Location Plug
NOTE
how to dispose of used hydraulic oil filter.
5. Apply a light coating of clean oil to the gasket on

the new filter. Figure 5-53. Hydraulic Tank Drain Plug
NOTE
how to dispose of used hydraulic oil.
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6. Disconnect hydraulic hose routed from hydraulic 11. Apply pipe sealant to the new or cleaned strainer
pump port “S” to tank as shown in Figure 5-54 and screw it back into the manifold pipe inside
below. the tank.
12. Remove the breather (Figure 5-55) and fill the

tank with clean hydraulic oil from unopened
containers. When adding oil, be sure to filter it
through a 10 micron filter.
Disconnect
Hose NOTE
Refer to Table 2.4 for hydraulic oil
secifications and tank capacity.
13. Install the breather.
14. Start engine and work hydraulic functions.
15. Check hydraulic oil level through the sight gauge.

Figure 5-54. Tank Hose Removal Add additional oil as required.
7. Remove hydraulic suction strainer by un-

threading it from the tank.
5.4-3 Change Axle Differential Oil
Suction Each axle assembly requires gear lubricant

Strainer independent of the planetary assemblies.
WARNING
Hot oil or components can burn. Oil must
be at normal operating temperature when
draining. Avoid contact with hot oil or
components. Do not allow oil to drain
into the ground.
1. Ensure that the axle differential oil is at normal

operating temperature.
Figure 5-55. Hydraulic Tank
Suction Strainer 2. Park the machine on a firm level surface, apply
parking brake, shut off the machine, and allow it
to sit for two minutes.
8. Clean the strainer in a solvent, using a stiff, fiber
brush. If impurities cannot be removed, replace 3. Place a container capable of holding approximately
with a new strainer. 10 quarts (9.5 litres) under axle drain plugs.
NOTE
A partially plugged strainer will lead to
cavitation, and or a sluggish operating
machine. Ensure the strainer is cleaned or
replaced annually.
9. Air-dry the suction strainer from the inside out.
10. Install drain plug back into tank.
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4. Clean the areas around the three (3) drain plugs 4. Clean the area around the plug and remove it,
and level/fill plug, and remove the level/fill plug. then drain the axle oil into a container.
Oil Drain Level/Fill

Plug Plug
Figure 5-57 Draining Planetary Gear Oil
Figure 5-56. Axle Plugs
NOTE
5. Remove all three (3) drain plugs and drain the
how to dispose of used oil.
oil from the differential. Dispose of used oil in
accordance with local regulations.
5. Wipe off the magnetic drain plug with a clean rag
NOTE and install it in the planetary.
how to dispose of used oil. 6. Reposition the plug to the 3 o’clock or 9 o’clock
position then remove plug again.
6. Wipe off the magnetic drain plugs with a clean 7. Slowly fill the planetary with 1 quart (0.95 liters) of
rag and install them in the axle. gear oil until oil begins to overflow from the level/
fill hole. Refer to Table 2.4 for oil specifications.
7. Slowly fill the axle with 7 quarts (6.6 liters) of gear
oil until oil begins to overflow from the level/fill
hole. Refer to Table 2.4 for axle differential oil
specifications.
8. Clean and replace the level fill plug.
9. Repeat procedure for the second axle
Figure 5-58. Filling Planetary Gear Oil
5.4-4 Change Axle Planetary Oil 8. Clean the level/fill plug and install it in the
planetary.
Each axle assembly requires planetary gear lubricant
independent of the differential assemblies. 9. Repeat procedure for the remaining three
planetaries.
1. Ensure that the axle planetary oil is at operating
temperature.
2. Park the machine 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.
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5.4-5 Change Engine Coolant Open the

Drain Plug
Drain and flush the coolant system at least once a year,
preferably twice a year. Use any effective, commercial
flushing agent. Unless the coolant has a corrosion
preventive in it, rust and scale will eventually clog up
the system.
WARNING
Always shut off the engine and allow
it to cool down before removing the
radiator cap. Steam or fluid escaping
from the radiator may cause severe
injury. Remove cap slowly to relieve
pressure. Avoid contact with steam or
escaping fluid.
Figure 5-60. Radiator Draining
NOTE
Remove the radiator cap when draining the
4. Place a container under the engine block coolant
system to ensure proper draining.
drain plug located on the bottom of the engine
water inlet hose connection point.
1. Open the radiator cap to ensure proper draining.
Disconnect Hose
Radiator Cap at Water Pump
Figure 5-59. Radiator Cap
2. Place a container capable of holding 25 quarts

(24 liters) under the radiator drain plug. Figure 5-61. Coolant Hose Disconnection
5. Disconnect hose and remove plug then drain

3. Open the drain plug and allow radiator and coolant from the engine.
coolant bottle to drain.
6. Check for damaged hoses and loose or damaged
hose clamps. Replace as required. Check radiator
for leaks, damage and buildup of dirt. Clean and
repair as required.
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7. Following the manufacturer’s instructions, flush the 4. Remove drain plug and drain transmission oil.
system using a good grade commercial radiator
cleaning agent. Refer to engine manufacturer’s
manual.
8. After cleaning and flushing operations are

completed, close the drain plug (Figure 5-60). Re-
install hose then replace and tighten the engine
block drain plug (Figure 5-61).
9. Refill the radiator using a mixture of ethylene

glycol antifreeze and water (Table 2.4). Refer to
engine manufacturer’s manual. Remove
Drain
NOTE
Plug
how to dispose of used coolant fluid.
10. Replace the radiator cap, start the engine, and

check for leaks.
Figure 5-62. Transmission Oil Drain Plug
5. Remove the deck cover plate from telehandler

5.4-6 Change Transmission Oil frame to gain access to transmission.
6. Remove the dipstick and fill the transmission with

1. Allow engine to run until the transmission oil
14 quarts (13 liters) of fresh clean transmission
temperature reaches operating temperature.
oil through the dipstick tube. Refer to Table 2.4
2. Park telehandler on a firm level surface, apply for transmission oil specifications.
park brake and shut down the engine. Transmission Oil
Dipstick
3. Place a container with a capacity of at least 14
quarts (13 liters) under the transmission drain
point.
WARNING
Hot oil or components can burn. Oil must
be at normal operating temperature when
draining. Avoid contact with hot oil or
components. Do not allow oil to drain
into the ground.
Figure 5-63. Transmission Oil Fill
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7. Replace the dipstick. 3. Apply a light coating of oil to the filter gasket and
install it on the transmission.
8. Start engine and allow it to run until the transmission
oil is at normal operating temperature. 4. Hand tighten the filter until it touches the base
then tighten an additional 1/2 to 3/4 turn.
9. Move the Direction Control Lever to ‘Neutral’, and
shut down engine. 5. Install deck plate.
10. Remove the transmission oil dipstick then check

the transmission oil level. Add as required.
5.4-8 Inspect Boom Chains
NOTE
5.4-7 Change Transmission Oil Filter Refer to Section 5.5-2 for a comprehensive
chain inspection and replacement
1. Clean the area around the transmission filter. procedure.
2. Remove the used filter and discard in accordance
with local guidelines. 1. Inspect the chains annually for the following items,
replace the chains as necessary:
Remove Transmission
Oil Filter • worn, cracked or broken plates
• wear of plate and pin head
• stiff links or enlarged plate holes
• worn or rusted connecting pins
L+ 3%
Broken (MAXIMUM)
Stiff Links
Cracked
Worn
Chain Plate Deformations
2. Measure chain elongation. Measurement should

be MAXIMUM of new chain length plus 3%.
3. If chain replacement is NOT necessary; clean

Figure 5-64. Transmission Oil
the chain in solvent, and dry using low pressure
Filter Removal
compressed air.
NOTE 4. Prior to installation, soak the chain in a pan of

Refer to local/national environmental SAE 40 engine oil or chain and cable lubricant
regulations on how to dispose of used oil for a MINIMUM of 8 hours to ensure correct
and filter. lubrication of the pins and links.
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5.4-9 Inspect RAS Cylinder Oil Level
1. Inspect oil level on cylinder sight gauge.
Sight
Gauge
RAS Cylinder Sight Gauge
2. Perform a function test of the RAS (Rear Axle

Stabilization) system. Refer to Section 1.2
Function Tests.
3. If oil level is below the “low” mark, replace

cylinder.
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5.5 Non-Routine Maintenance Boom Tip

Cover Plate
Boom Cowl
5.5-1 Boom Hoses Replacement Procedure
This procedure describes the removal and replacement

of the fork tilt hydraulic hoses in the right side (tanks-
side) of the boom assembly. Auxiliary hydraulics hoses
(if equipped) are located on the left side (cab-side) of
the boom.
The procedures shown in this section are valid for BOTH

the fork tilt hoses and the auxiliary hydraulics hoses.
NOTE
Always replace boom hoses in pairs.
Either both fork tilt hoses or both auxiliary
hydraulics hoses. Never replace a single Figure 5-66. Boom Cover Plates Removal
hose to a boom tip function.
4. Remove the screw that secures the hose guide
5.5-1-1 Remove Boom Hydraulic Hoses clamp to the crowd cylinder inside of boom
section #3. Remove the clamp from inside the
1. Park telehandler on a firm level surface, apply boom.
park brake and fully extend the boom to expose
the inspection hole located at the rear right side Remove
of boom section #3. Clamp
Boom Section #3
Inspection Hole
Figure 5-65. Boom Inspection Hole Figure 5-67. Boom Hose Guide Clamp
2. Shutdown engine and remove key from ignition 5. Enter cab and start engine, then fully retract and
switch. lower the boom to access the boom tip inspection
hole. Shut off engine.
3. Remove boom cowl and front cover from boom
tip. 6. Loosen the fork tilt hose tension adjuster until the
square section of the tension adjuster is even with
the rear part of its bracket.
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Fork Tilt Tension Adjuster Install Caps/Plugs Disconnect

Hoses of Fork Tilt Hoses Fork Tilt Hoses
Figure 5-70. Tubes & Fittings

at Front of Boom
10. Loosen the tube clamps at three places along

Figure 5-68. Hoses Inside Boom the bottom right side of boom section #1 and
slide the compensation tubes rearward to provide
7. Start engine and raise the boom enough to better access to the two hose fittings.
access compensation tubes on under side of
boom. See Figure 5-69. 11. Fasten a wire tie/tag to the hose end closest to
the outside of the boom. This is the longest hose
Remove Tubes and the tag will help in assembly.
from Fittings
12. Disconnect the tilt cylinder two hoses from the
fittings at the bottom front of boom section #1.
Cap/plug all open hydraulic lines and fittings to
prevent contamination. See Figure 5-70.
13. Tie a length of cord/wire to the ends of the two

hoses to help in re-assembly.
14. From the inspection hole in the right side of the

boom, remove the screw that secures the dead
anchor lock and dead anchor to the crowd box.
Dead Anchor Remove

Lock Screw
Figure 5-69. Compensation Tubes Location
8. Place a suitable container under work area to Dead

capture all hydraulic oil that may spill and dispose Anchor
of in accordance with local/national regulations.
9. Disconnect the compensation tubes from the Dead

fittings at the bottom front right of boom section Anchor
#1. Cap or plug all open hydraulic lines and Removed
fittings to prevent contamination. See Figure 5-70.
Figure 5-71. Dead Anchor Removal
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15. Pull the dead anchor through the boom tip to 19. Place a tie wrap or tag on the end of the longest
the outside. hose to help in re-assembly.
Dead Anchor 20. Enter cab and start engine then extend the boom
fully to expose the hose/tube fittings on the right
side of boom section #3. See Figure 5-74.
21. Prior to disconnecting the hoses, fasten a wire

tie/tag to the end of the longest hose.
NOTE
The longest hose is attached to the tube with
the tightest bend . The shorter hose is fitted
Figure 5-72. Dead Anchor Out of Boom with a “spacer clamp” installed contacting
the crimped hose sleeve end. The tie/tag
and the “spacer clamp” will be important
16. Working through the boom tip inspection hole,
help in assembly.
remove the hose tension adjuster from its bracket
in the boom and attach the loose end of the dead
anchor cable to the tension adjuster. 22. Place a suitable container to capture all hydraulic
oil that may spill and dispose of in accordance
17. Pull the cable (attached to the hose tension with local/national environmental regulations.
adjuster) from the boom tip until the hose/cable
sheave assembly is exposed. Check the length of 23. Disconnect the twin hoses from the fittings. Cap/
cord/wire (Installed in step #11) attached to the plug all open hydraulic lines and fittings to prevent
ends of the two hoses. Be sure cord does not get contamination. Remove the clamp bolt and hose
pulled completely into the boom when the cable clamp from the inspection port at the two hose/
is removed from the boom. See Figure 5-73. tube fittings. See Figure 5-74.
Cable Hose Longest Hose Clamp

Hose Fittings Bolt
5-74. Twin Hoses Removal
Figure 5-73. Fork Tilt Hose Cable Removal 24. Working from the boom tip, pull the remaining
lengths of the two hoses from the boom tip. Be
18. Pull the hose/cable sheave assembly from the sure cord/wire (installed in step #11) does not get
boom tip, followed by the two hoses. Be sure pulled completely into the boom when the hoses
cord does not get pulled completely into the are removed from the boom.
boom when hoses are removed. Be sure hose
fittings clear under the hose sheave at the rear
right of boom section #1. If fittings will not clear
the sheave, the sheave must be removed.
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5.5-1-2 Inspect Boom Hydraulic Hoses 2. Attach the end of the cord/wire that is hanging
from right side of the inspection hole in boom
1. Lay the two hoses and sheave assembly on the section #4 to one end of BOTH hoses.
floor and note the long hose passes over the
largest pulley and the short hose passes over the 3. With the boom fully extended, feed the end
intermediate sized pulley. (without the cord/wire attached) of the new hoses
into the opening at the boom tip. Slide the hoses
Longest Hose Short Hose along the right inside of boom section #4 until
they reach the tube fittings that are visible through
the cut-out on the right side of boom section #3.
4. Working from outside the right side of boom

section #3, install the hoses into the hose clamp
to secure the hose ends near the tube fittings. Do
not tighten the clamp at this point. Be sure the
long hose (identified by the wire tie/tag installed
at disassembly) is located in the upper position
of the clamp. Refer to Figure 5-76.
Longest Hose Clamp

Hose Fittings Bolt
Figure 5-75. Boom Hoses Inspection
2. Inspect hoses for damage such as cuts, blisters

and/or soft spots along their length. Inspect hoses
for damage at the fittings. Inspect the cables for
fraying and kinks. Inspect the pulleys for face
and edge damage. Replace damaged parts as
required.
3. Ensure that all wire ties or tags used to mark the

long hose during removal is transferred to the 5-76. Twin Hoses Installation
new long hose prior to beginning the assembly
process. Ensure to wire tie/tag BOTH ends of the
NOTE
long hose.
Capture all spilled hydraulic oil and dispose
in accordance with local regulations.
5.5-1-3 Install Boom Hydraulic Hoses 5. Remove the caps/plugs from the tubing fittings
and the two hoses. Be sure to connect the longest
hose (identified by the tag, wire tie, etc.) to the
NOTE
upper tube fitting, and the shorter hose to the
Always replace boom hoses in pairs.
lower fitting. Refer to Figure 5-76.
Replace both fork tilt hoses or both auxiliary
hydraulics hoses. Never replace a single 6. Tighten the screw to secure the hose clamp,
hose to a boom tip function. installed in step 4, with the end of the hose crimp
against the “spacer clamp”.
1. Lay the replacement hose out on the floor and 7. Enter cab and start engine then fully retract the
install them on the hose sheave assembly. Be boom and shut down engine.
sure the longest hose passes over the largest
sheave and the shorter hose passes over the
intermediate sheave (see Figure 5-75).
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8. Pass the double sheave assembly through the 12. From the right side inspection hole in boom
boom tip and along the two hoses, keeping the section #1, attach the end of the hose tension
hoses that are now attached to the fittings, on the cable (the end with one crimped barrel) to the
top of the sheaves. The long hose oriented on top dead anchor plate. Position the dead anchor plate
of the short hose. to its mounting location in the slot of the crowd
box. Be sure the plate is positioned so the curve of
9. While a helper is holding both ends of the hose the plate is pointing upward. Refer to Figure 5-78.
tension cable from in the front of the boom, pull
the cord/wire from the rear of the boom. This will Dead Anchor Crowd Box
feed the other end of the two hoses through the
boom to the hose sheave at the rear. Note that
when the hoses passed over the hose/cable
sheave assembly in the boom, the long hose is
now on the bottom as they run toward the rear
of the boom assembly. While positioning the
hoses, make sure they do not twist and the long
hose remains on the bottom of the short hose.
The crowd box will help keep the double sheave
Figure 5-78. Dead Anchor Installation
assembly vertical.
10. The helper should now pass the hose tension NOTE
adjuster, with cables attached, through the If new hoses are installed, ALWAYS use the
opening in the boom tip. crimped barrel position nearest the end on
the hose tension cable.
11. Working from the rear of the boom, pass the two
hoses over the hose sheaves. Pass the fittings 13. Working from the boom tip, pull the tension
of the two hoses under the sheaves. Install the adjuster end (with three crimped barrels) of the
shorter hose to the inside sheave (see Figure hose tension cable through the inspection hole
5-77). in the front of boom section #4. Attach the hose
tension adjuster to the cable using the crimped
Shorter Hose Hose Sheaves barrel position that was noted at disassembly (If
new hoses are installed, ALWAYS use the first
crimped barrel position [nearest the end] on the
hose tension cable). Refer to Figure 5-79.
Hose Tension
Cable
Figure 5-77. Hoses Rear Sheaves Figure 5-79. Tension Adjuster Installation
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14. While the helper is holding the hose tension 18. Connect the longer of the two hoses to the
adjuster at the front of the boom, pull the cord/wire bulkhead fitting CLOSEST to the side of the
attached to the two hose ends through the bottom boom. Connect the shorter of the two hoses to
of boom section #1 until the tension adjuster is the bulkhead fitting toward the inside of the boom.
pulled to the inspection hole of boom section #4.
19. Slide the compensation tubes to the bulkhead
NOTE fittings on the right underside of boom section #1.
DO NOT position the tension adjuster to its Connect the tubes to the corresponding fittings.
mounting bracket at this time.
20. Tighten the three clamps that secure the fork tilt
15. Place the hose tension adjuster with cable tubes to the bottom of boom section #1.
attached inside of boom section #4. Check to
make sure the cable makes a simple loop around NOTE
the cable sheave and is not twisted. Be sure the hose tension cable is NOT
twisted between the cable sheave and the
16. Working from the inspection hole in the right side tension adjuster. If the cable is twisted, the
of the boom, install dead anchor lock to secure cable will fray and eventually break during
the dead anchor to the crowd box. Secure the lock the extend/retract cycle.
by installing the screw. Apply blue thread locking
compound to the screw prior to installation. 21. Working through the inspection hole in the front
of boom section #4, position the fork tilt hose
Dead Anchor Remove tension adjuster into the mounting brackets on the
Lock Screw inside right of the boom section. Be sure the hose
tension cable is NOT twisted between the cable
sheave and the tension adjuster. If the cable is
twisted, the cable and hoses will beak eventually
as the boom is extended/retracted.
Dead
Anchor 22. Tighten the nut on the threaded rod of the adjuster
until 4” of unengaged threads are exposed
between the adjuster bracket and the end of the
Figure 5-80. Dead Anchor Installation square length of the adjuster rod. Refer to Figure
5-82.
17. Working from the right underside of boom section
Tighten Tension
#1, Identify the longest of the two hoses by the
Adjuster Nut
wire tie/tag installed in the disassembly process.
Remove the caps/plugs from the bulkhead fittings
and the two hoses. Remove the cord/wire from
the hoses.
Remove Caps/Plugs Connect

Fork Tilt Hoses
Figure 5-82. Tightening Tension Adjuster

Figure 5-81. Tubes and Hoses Connections
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23. Start engine and extend the boom to expose the 5.5-2 Boom Chains Replacement Procedure
mounting location for the hose guide clamp on
the right side of boom section #3. Turn off engine. 5.5-2-1 Remove Retract Chain #1:
Install
Clamp This procedure shows the removal of the retract chain
#1 on a machine that is not equipped with auxiliary
hydraulics.
If the machine being repaired is equipped with auxiliary

hydraulics, the auxiliary hydraulics hose tension must
be slackened from the front of the machine, and the
auxiliary hydraulics hose sheave must be removed from
the rear of the boom assembly.
1. Park telehandler on a firm level surface and apply

park brake.
2. Extend boom enough to access chain tension

Figure 5-83. Hose Guide Clamp Installation adjuster nut located on underside front end of
boom section#1. Refer to Figure 5-84.
NOTE
The hose guide clamp is NOT to grip the 3. Shutdown engine and remove key from ignition
hoses but to guide them vertically. switch then remove front and rear boom cover
plates.
24. Position the hose guide to the inside of boom
section #2. Insert the mounting screw to just 4. From the underside of boom section #1, remove
barely engage the inside half of the guide. Turn the adjuster nut and washer that secures retract
the inside half of the guide to horizontal to allow chain #1 anchor to the flange of the boom
the hoses to be positioned on the outside half of section.
the guide. Using a hook to assist in positioning
the hoses, raise the top hose into the guide first. Remove Nut
Then lift the bottom hose to the guide. Twist the
inner half of the guide to the vertical position to
secure the hoses. Secure the guide by tightening
the screw from the outside of boom section #3.
25. Start engine and cycle the extend and retract

functions several times to purge air from the
hydraulic system.
26. Check for leaks and repair as necessary.
27. Inspect the hose/cable sheave assembly to Figure 5-84. Retract Chain #1 Tension Adjuster Nut
assure it is vertical inside the boom after the hoses
have been pressurized. The hoses can be turned NOTE
at the boom tube fittings to remove twist. Ensure the cord/wire installed below is long
enough to reach through the entire length
28. Check hydraulic oil level and top-off as necessary.
of boom section #1 and still extend from
Refer to Section 2 of this manual for hydraulic oil
the front and rear of the boom section. This
specifications.
cord/wire will help in assembly.
29. Install the covers.
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5. Fasten a length of cord/wire to the chain anchor 9. Remove retract chain #1, by pulling it from rear
and push the chain anchor through the flange on of the machine being careful not to pull the cord/
the bottom of the boom section. wire installed in step 5 completely through the
flange at the front of boom section #1.
6. From the rear of the boom assembly, pull slack
in retract chain #1 .
5.5-2-2 Inspect Retract Chain #1:
7. Remove the bolt, anchor and locating pin that
secures the retract chain #1 sheave to the finger
bracket. Remove the sheave. 1. Inspect the chain for cracks, worn and/or broken
links, and worn pivot pin holes. Replace the chain
Locating Bolt & Retract as necessary.
Pin Anchor Chain
2. Clean the chain in solvent, and dry using low
pressure compressed air.
3. Prior to installation, soak the chain in a pan of SAE

40 engine oil or chain and cable lubricant for a
MINIMUM of 8 hours to ensure correct lubrication
of the pins and links.
4. Dispose of used solvent, oil and/or chain lubricant

in accordance with local/national environmental
regulations.
5.5-2-3 Install Retract Chain #1:

Figure 5-85. Retract Chain Rear Sheave Removal
1. Fasten the end of the cord/wire installed during
removal to the male anchor end of the new chain.
8. Remove the cotter pin and locating pin that
Be careful not to pull the cord/wire completely
secures the retract chain #1 to the double chain
through the boom section.
anchor attached to boom section #3 by the wing
bracket. Disconnect the retract chain. 2. As the new retract chain (Figure 5-86) is fed into
Double Chain Wing the rear of the boom assembly, under the finger
Anchor Bracket bracket, have a helper pull on the cord/wire that
extends through the cutout in the front bottom of
boom section #1. When the anchor on the chain
is visible in the cut-out, stop feeding the chain.
3. Position the female end of the chain to its

Finger mounting location in the double chain anchor at
Bracket the rear of boom section #3 (see Figure 5-86).
Secure the chain to the anchor by installing the
locating pin and a new cotter pin.
Retract 4. Position the retract chain #1 sheave to its

Chain mounting location on the finger bracket. Secure
the sheave to the bracket by installing the locating
pin, anchor and bolt.
5. Grease the sheave locating pin. Refer to Section

Figure 5-86. Retract Chain at Rear of Boom
2 of this manual for grease & lubricating oil
specifications.
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6. Working from the front of the machine, using 4. Remove the screws that secure the hose guide
the cord/wire, pull the chain anchor through the clamps to the crowd cylinder inside of boom
flange in the bottom of boom section #1. Remove section #3. Remove the clamps from inside the
and discard the cord/wire. Secure the anchor to boom.
the flange by installing the washer and adjusting
nut. See Figure 5-87. Remove
Clamp
Install &
Tighten
Nut
Figure 5-88. Hose Guide Clamp Installation

Figure 5-87. Retract Chain #1 Tension Adjuster Nut
5. Enter cab and start engine then retract the boom
7. Set the tension on retract chain #1. Refer to fully and lower the boom to provide access to the
Section 5.3-8. Confirm the tension on retract inspection hole in the boom tip.
chain #2.
6. Working through the front of the boom tip on the
8. Install boom cover plates. right side, loosen the fork tilt hose tension adjustor
until the square section of the tension adjustor is
even with the rear part of its bracket.
5.5-2-4 Remove Retract Chain #2: Loosen Tension
Adjuster Nuts
NOTE
This procedure requires the release of
tension on the fork tilt hoses, as well as
significant disassembly of the rear of the
boom assembly.
1. Remove the cover plates from the rear, tip and

both sides of the boom.
2. Lower the boom to gain access to the inspection

hole in the boom tip.
3. Fully extend the boom to expose the inspection

hole that allow access to the hose guide clamps
and attachment screws at the rear on each side
of boom section #3.
Figure 5-89. Tension Adjuster Nuts
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7. Working through the front of the boom tip on 12. From the inspection hole in the left side of the
the left side, loosen the auxiliary hydraulic hose boom, remove the screw that secures the dead
tension adjustor until the square section of the anchor lock to the crowd box. Remove the dead
tension adjustor is even with the rear part of its anchor for the auxiliary hydraulics hoses from its
bracket. Refer to Figure 5-89. mounting location on the crowd box and lay it on
the inside of boom section #4.
8. Enter cab and start engine, then raise the boom
to a level position. Shutdown engine. Dead Anchor Remove
Lock Screw
9. Release the tension on the adjustment nut for
retract chain #2 at the underside flange of boom
section #2 until it is finger tight.
Retract Chain #2 Retract Chain #1 Dead

Adjustment Nut Adjustment Nut Anchor
Figure 5-92. Dead Anchor Installation
13. From the inspection hole in the right side of the

boom, remove the screw that secures the dead
anchor lock to the crowd box. Remove the dead
anchor for the fork tilt hoses from its mounting
location on the crowd box and lay it on the inside
of boom section #4.
Figure 5-90. Retract Chain Anchor Nuts 14. From the inspection hole in the right side of the
boom, remove the cotter pin and locating pin
that secures extend chain #2 to its anchor on
10. Release the tension on the adjustment nut for
the crowd cylinder barrel. Disconnect the chain
retract chain #1 at the underside flange of boom
from the anchor and allow the chain to lay on the
section #1 until it is finger tight
inside of boom section #4.
11. Release the tension on the extend chain Cotter Pin
adjustment nut at the rear of boom section #1 Chain Anchor & Locating Pin
until it is finger tight
Extend Chain
Adjustment Nut
Figure 5-93. Extend Chain Removal
15. Prepare a container under the rear part of the

boom to capture all hydraulic that may spill.
Figure 5-91. Extend Chain Nut
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16. From the rear of the boom, disconnect the two Crowd Loosen
crowd cylinder hoses. Cap/plug all open hydraulic Remove Lock
Cylinder “T” Bracket
lines and fittings to prevent contamination. Bolt, Nut
Dispose of hydraulic oil in accordance with local/ Anchor
national environmental regulations. & Locating
Pin
17. Remove the adjustment nut from extend chain
#1 rod.
Remove Disconnect
Disconnect
Adjustment Nut Hose
Hose
Figure 5-96. T-Bracket Removal
22. Slacken the fork tilt hoses. Remove the bolt,

keeper and pin that secures the fork tilt hose
sheave from the right side of the finger bracket.
Remove the sheave. See Figure 5-97.
23. Slacken the auxiliary hydraulics hoses . Remove

the bolt, keeper and pin that secures the auxiliary
Figure 5-94. Extend Chain Nut
hydraulics hose sheave from the left side of the
finger bracket. Remove the sheave. See Figure
18. Remove the four screws (two on each side of
5-97.
boom) that secure the “T” bracket to boom
section #1. Remove
Auxiliary Hoses
Sheaves
Remove
Bolts
Figure 5-95. T-Bracket Bolts
19. Remove the bolt, anchor and locator pin that

secures the crowd cylinder to the “T” bracket.
Figure 5-97. Hose Sheaves Removal
20. Using a 1 ½” crow’s foot wrench, loosen the lock
nut on extend chain #1 rod to allow the rod to 24. Secure the two sets of hoses, one to each side
be pushed through the “T” bracket. Push the rod of the boom assembly and away from the boom
through the bracket until free. opening.
21. Remove the “T” bracket from boom section #1
being careful to disengage the vertical legs of
the “T” bracket from the slots in the bottom of
boom section.
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25. Working from the front of the boom, remove the 28. Remove the cotter pin and locator pin that secures
adjuster nut from the retract chain #1 anchor at retract chain #1 to the double chain anchor on
the flange in the underside of boom section #1. the wing bracket at the rear of boom section #3.
Tie a cord/ wire to the chain anchor to help in re- remove the chain from the anchor and allow the
assembly. Push the retract chain anchor through chain to hang from the opening in the rear of the
the flange. Refer to Figure 5-90. boom.
26. Remove the adjuster nut from the retract chain Double Chain Wing
#2 anchor at the flange in the underside of boom Anchor Bracket
section #2. Tie a cord/wire to the chain anchor to
help in re-assembly. Push the retract chain anchor
through the flange. Refer to Figure 5-90.
27. Working at the rear of the boom, pull slack in

retract chain #1. Remove the bolt, anchor and
locator pin that secures retract chain #1 sheave to Finger
the center position of the finger bracket. Remove Bracket
the sheave. Allow retract chain #1 to hang from Bolts
the opening in the rear of the boom.
Retract
Pull Slack Remove Pin Chain
in Chain From Sheave
Figure 5-99. Retract Chain at Rear of Boom
29. Remove the two bolts that secure the finger

bracket to the bottom of boom section #2.
Remove the finger bracket from the machine.
30. Pull slack in retract chain #2. Remove the cotter

pin and locating pin that secures retract chain #2
Figure 5-98. Pin Removal sheave to the rear of boom section #3. Remove
the sheave.
Retract Retract Retract Chain

Chain #1 Chain #2 Sheave
Figure 5-100. Retract Chain Removal
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31. Remove the cotter pin and locating pin that Retract Retract Wing Bracket &
secures the retract chain #2 to boom section #4. Chain #1 Chain #2 Bolts
Allow retract chain #2 to hang from the opening
in the rear of the boom.
Remove
Locating Pin
Figure 5-102. Retract Chain Installation
2. Grease the locator pin for retract chain #2 sheave.

Figure 5-101. Locating Pin Removal
(Figure 5-101).
NOTE NOTE
Remove the chain from the boom assembly When attaching chains, slight movement in
by pulling it out from the rear of the boom. or out of the boom section may be required
Take particular care NOT to pull the cord/ to allow correct alignment of mounting
wire fastened to the chain anchor all the holes. Movement can be accomplished by
way through the boom assembly as it is to use of a large pry bar.
remain in the boom to help in installation.
3. Working through the inspection hole in the side
of boom section #1, Position extend chain #2
5.5-2-5 Inspect Retract Chain #2: to its mounting location on the chain anchor on
the front of the crowd cylinder. Secure the chain
1. Inspect the chain for cracks, worn and/or broken by installing the locator pin and a new cotter pin.
links, and worn pivot pin holes. Replace the chain Refer to Figure 5-93.
as necessary.
4. Working from the front of the boom, pull the cord/
2. Clean the chain in solvent, and dry using low wire attached to the chain anchor on the front of
pressure compressed air. retract chain #2. Guide the anchor through the
flange on the bottom of boom section #2. Secure
3. Prior to installation, soak the chain in a pan of SAE the anchor to boom section #2 by installing the
40 engine oil or chain and cable lubricant for a washer and adjusting nut. DO NOT tighten the
MINIMUM of 8 hours to ensure correct lubrication nut at this time.
of the pins and links.
5. Working from the rear of the boom, position the
4. Dispose of used solvent, oil and/or chain lubricant finger bracket to its mounting location on the
in accordance with local/national environmental inside bottom of boom section #2. Secure the
regulations. bracket to the boom section #2 by installing two
bolts. Apply blue thread locking compound to the
bolts prior to assembly. See Figure 5-102.
5.5-2-6 Install Retract Chain #2:
6. Position the end of retract chain #1 (the large
chain), which is hanging from the rear of the boom
1. Install 4 bolts (two on each side) (Figure 5-102) assembly, to the chain anchor on the wing bracket
that attach the wing bracket on the crowd box which is bolted to the rear of boom section #3.
to boom section #3. Apply red thread locking Secure the chain to the anchor by installing the
compound to the bolts prior to assembly and locator pin and a new cotter pin.
torque the bolts to 80 lb.ft. (108 N.m.).
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7. Loop retract chain #1 over the large metal chain 11. Position the fork tilt hose sheave to its mounting
sheave. Position the chain sheave to its mounting location on the right side of the finger bracket.
location in the center of the finger bracket. Secure Secure the sheave to the bracket by installing the
the sheave to the bracket by installing the locator locator pin, keeper and bolt.
pin, anchor and bolt.
12. Remove the ties that secure the boom hoses on
Loop Retract Install Pin each side of the boom assembly. Position the
Chain #1 On Sheave hoses loosely over the hose sheaves.
13. Connect the two crowd cylinder hoses to the

fittings on the inside bottom of boom section #1.
Install Hoses Lock Nut
Figure 5-103. Pin Installation
8. Grease the locator pin for retract chain #1 sheave.
9. Working from the front of the boom, pull the cord/

wire attached to the chain anchor on the front of
retract chain #1. Guide the anchor through the
flange on the bottom of boom section #1. Secure
the anchor to boom section #1 by installing the
washer and adjusting nut. DO NOT tighten the
nut at this time. Figure 5-105. Crowd Cylinder Hoses Installation
10. Working from the rear of the boom, position the

14. Using a 1 ½” crow’s foot wrench, back the lock
auxiliary hydraulic hose sheave to its mounting
nut (2) on the end of the extend chain rod toward
location on the left side of the finger bracket.
the front of the machine to allow the rod to be
Secure the sheave to the bracket by installing the
inserted into the “T” bracket.
locator pin, keeper and bolt.
Install 15. Position the “T” bracket to its mounting location

Auxiliary Hoses inside the rear of boom section #1. The lower part
Sheaves
of the bracket should protrude through the slots in
the bottom of boom section #1. The extend chain
rod should pass through the block on the top of
the “T” bracket. The sides of the top plate of the
bracket should engage the mounting blocks on
the inside plates of boom section #1.
16. Align the holes in the crowd cylinder rod clevis

with the holes in the vertical sections of the “T”
bracket. Secure the rod to the bracket by installing
the locator pin, anchor and bolt. Apply red thread
locking compound to the bolt prior to assembly.
Torque the bolt to 65 lb.ft. (80 N.m.).
Figure 5-104. Hose Sheaves Installation
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Crowd Install 19. From the LEFT side inspection hole in boom
Install Lock section #1, attach the end of the twin hose
Cylinder “T” Bracket
Bolt, Nut tension cable with one lock block to the dead
Anchor anchor plate. Position the dead anchor plate
& Locating to its mounting location in the slot of the crowd
Pin box. Be sure the plate is positioned so the curve
of the plate is pointing DOWNWARD. Refer to
Figure 5-108.
Dead Anchor Crowd Box
Figure 5-106. T-Bracket Installation
17. Install the extend chain adjusting nut on the

extend chain rod and tighten until 25mm of rod
is engaged in the nut. The lock nut may need to
be backed off to allow the correct engagement. Figure 5-108. Dead Anchor Installation
A rule inserted into the rear of the adjusting nut
can measure the engagement. The nut is 90mm 20. Install dead anchor lock to secure the dead
deep. When a rule inserted into the rear of the nut anchor to the crowd box. Secure the lock by
shows 65 mm of open nut remaining, then 25 mm installing the screw. Apply blue thread locking
of rod has engaged the nut. compound to the screw prior to installation.
18. Secure the “T” bracket to boom section #1 by Dead Anchor Install
installing the mounting plates to the inside of Lock Screw
the boom section and two screws through the
outside of the boom section on each side of boom
section #1.
Dead
Install
Anchor
Bolts
Figure 5-109. Dead Anchor Lock
21. From the RIGHT side inspection hole in boom

section #1, attach the end of the twin hose tension
cable with one lock block to the dead anchor
plate (Refer to Figure 5-109). Position the dead
anchor plate to its mounting location in the slot
Figure 5-107. T-Bracket Bolts of the crowd box. Be sure the plate is positioned
so the curve of the plate is pointing UPWARD.
22. Install dead anchor lock to secure the dead

anchor to the crowd box. Secure the lock by
installing the screw. Apply blue thread locking
compound to the screw prior to installation.
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Remove Caps/Plugs Connect 32. Connect the LONGER of the auxiliary hydraulics
Fork Tilt Hoses hoses to the bulkhead fitting CLOSEST to the side
of the boom. Connect the SHORTER of the twin
hoses to the bulkhead fitting toward the INSIDE
of the boom.
33. Slide the auxiliary hydraulics tubes to the

bulkhead fittings on the left underside of boom
section #1. Remove the plugs from the tubes and
connect the tubes to the corresponding fittings.
34. Tighten the three clamps that secure the auxiliary

hydraulic tubes to the bottom of boom section
Figure 5-110. Tubes and Hoses Connections #1.
NOTE
23. Working from the right underside of boom section Be sure the boom hose tension cable is NOT
#1, pull the cord/wire that is attached to the fork twisted between the cable sheave and the
tilt hoses to position the hoses at the cutout on tension adjustor. If the cable is twisted, the
the underside of the boom. cable will fray and eventually beak during
the extend/retract cycle.
24. Identify the longest of the fork tilt hoses by the
wire tie/tag installed in the disassembly process.
35. Working through the inspection hole in the front of
25. Remove the caps/plugs from the bulkhead fittings boom section #4, position the auxiliary hydraulic
and fork tilt hoses. Remove the cord/wire from hose tension adjustor into the mounting brackets
the hoses. on the inside right of the boom section. Refer to
Figure 5-111.
26. Connect the LONGEST of the hoses to the
bulkhead fitting CLOSEST to the side of the 36. Tighten the nut on the threaded rod of the adjustor
boom. Connect the SHORTER of the hoses to the until 4 inches of unengaged threads are exposed
bulkhead fitting toward the INSIDE of the boom. between the adjustor bracket and the end of the
square length of the adjustor rod.
27. Slide the fork tilt tubes to the bulkhead fittings on
the right underside of boom section #1. Remove 37. Position the fork tilt hose tension adjustor into the
the plugs from the tubes and connect the tubes mounting bracket on the inside left of the boom
to the corresponding fittings. section. Refer to Figure 5-112.
28. Tighten the three clamps that secure the fork tilt 38. Tighten the nut on the threaded rod of the adjustor
tubes to the bottom of boom section #1. until 4 inches of unengaged threads are exposed
between the adjuster bracket and the end of the
29. Working from the left underside of boom section square length of the adjuster rod.
#1, pull the cord/wire that is attached to the
auxiliary hydraulics hoses to position the hoses Fork Tilt Hoses Auxiliary
at the cutout on the underside of the boom. Tension Adjuster Hydraulics
Nut Hoses
30. Identify the longest of the auxiliary hydraulics Tension
hoses by the wire tie/tag installed in the Adjuster
disassembly process. Nut
31. Remove the caps/plugs from the bulkhead fittings

and the auxiliary hydraulics hoses. Remove the
cord/wire from the hoses.
Figure 5-111. Tension Adjuster Nuts Location
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39. Extend the boom to expose the mounting location 6. From the outside of both sides of boom section
for the hose guide clamps, one on each side of #1, remove the retaining ring that secures the
boom section #2. locating pins to boom section #2. See Figure
5-112.
40. Position the hose guide clamp with the boom
hoses attached to each side of the inside of boom
section #2. Have helper assist in positioning
hoses to the clamps by moving hose through the
inspection hole in boom section #2. Secure the
clamps by installing the screws from the outside
of boom section #3.
41. Adjust the extend chains as described in Section

5.3-9.
42. Adjust retract chains as described in Section

5.3-8. Figure 5-112. Retaining Ring Removal
43. Adjust the tension on both sets of boom hoses 7. Install a bolt into each of the locating pins and
as described in Section 5.3-11. pry the pins from their mounting locations. This
frees the crowd cylinder from boom section #2.
5.5-2-7 Remove Extend Chain #2:
1. Ensure telehandler is parked on a firm level

surface and park brake applied.
2. Fully extend boom horizontally and shutdown

engine then remove key from ignition switch.
3. Remove the rear, side and boom tip cover plates.

Figure 5-113. Trunnion Pin Removal
4. Remove the crowd box/crowd cylinder from inside
the boom. 8. Attach a chain/sling to the rear of the crowd
cylinder/crowd box assembly and attach the
NOTE
sling/chain to a suitable lifting device capable of
To remove crowd box/crowd cylinder
holding the weight of the cylinder/box.
assembly, the hydraulic hoses and
retract chains must be removed prior to
disassembling the crowd assembly. Refer
to Section 5.5-2-4 then follow the procedure
outlined blow.
5. Once all chains and hydraulic hoses have been

disconnected inside the boom assembly, remove
the four bolts that secure the crowd box wing
bracket to the rear of boom section #3. Figure 5-114. Crowd Box/Crowd Cylinder
Removal
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9. Using the lifting device, lift and pull the crowd 3. Prior to installation, soak the chain in a pan of SAE
cylinder/crowd box assembly part way from the 40 engine oil or chain and cable lubricant for a
rear of the boom assembly. Make sure the weight MINIMUM of 8 hours to ensure correct lubrication
is evenly distributed by reposition the sling/chain of the pins and links.
as necessary.
10. Slowly pull the crowd box/crowd cylinder in accordance with local/national environmental
assembly from the boom assembly and place it regulations.
on the floor.
11. Working from the side of the boom assembly,

fasten a cord/wire to the anchor on the forward
5.5-2-9 Install Extend Chain #2:
end of extend chain #2 that was disconnected in
the crowd cylinder/crowd box removal procedure.
Be sure this cord/wire is long enough to run 1. Fasten the end of the cord/wire installed during
the length of the boom assembly to aide in removal to the anchor end of the new chain.
installation. Be careful not to pull the cord/wire completely
through the boom section.
NOTE
When fastening the cord/wire to the chain 2. As the new chain is fed into the rear of the boom
anchor, be sure the cord/wire is significantly assembly, have a helper pull on the cord/wire
longer than the boom assembly as it is to that extends through the cut-out in the side of
remain in the boom to help in installation. boom section #1. When the anchor on the chain
is visible in the cut-out, stop feeding the chain.
12. From the rear of the boom assembly, remove the 3. Still working in the rear of the boom assembly,
cotter pin and locating pin that secures extend position the other end of the chain to its mounting
chain #2 to its anchor on the rear of boom section location in the double chain anchor at the rear of
#4. Discard the cotter pin. Disconnect the chain boom section #4. Secure the chain to the anchor
from the anchor. by installing the locating pin and a new cotter pin.
NOTE 4. Install crowd cylinder/crowd box and connect all
Take extra care NOT to pull the cord/wire hydraulic hoses.
fastened to the chain anchor all the way
through the boom assembly as it is to
remain in the boom to aide in installation.
13. Pull extend chain #2 from the rear of the boom

and out of the machine.
14. Remove the cord/wire from the chain and leave

it inside the boom assembly.
5.5-2-8 Inspect Extend Chain #2:
1. Inspect the chain for cracks, worn and/or broken

links, and worn pivot pin holes. Replace the chain
as necessary.
2. Clean the chain in solvent, and dry using low

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5.5-2-10 Remove Extend Chain #1: 5.5-2-11 Inspect Extend Chain #1:
1. Ensure telehandler is parked on a firm level 1. Inspect the chain for cracks, worn and/or broken
surface and park brake applied. links, and worn pivot pin holes. Replace the chain
as necessary.
2. Remove crowd box/crowd cylinder assembly.
Refer to Sections 5.5-2-4 & 5.5-2-7. 2. Clean the chain in solvent, and dry using low
3. Disassemble crowd box/crowd cylinder.
3. Prior to installation, soak the chain in a pan of SAE
4. From the underside of the crowd cylinder, remove 40 engine oil or chain and cable lubricant for a
the cotter pin and locating pin that secures extend MINIMUM of 8 hours to ensure correct lubrication
chain #1 to the wing bracket anchor. Discard the of the pins and links.
cotter pin. Disconnect the chain.
Wing Bracket in accordance with local/national environmental
Anchor regulations.
Extend
Chain #1
5.5-2-12 Install Extend Chain #1:
1. Position one end of extend chain #1 to its

mounting position on the anchor at the extend
chain rod. Secure the chain to the rod by installing
the locating pin and a new cotter pin. Refer to
Figure 5-115. Chain Anchor at Wing Bracket Figure 5-116.
5. From the topside of the crowd cylinder, remove 2. Position one end of extend chain #1 to its
the cotter pin and locating pin that secures extend mounting position on the anchor at the wing
chain #1 to the extend chain rod. Discard the bracket. Secure the chain to the bracket by
cotter pin. Disconnect the chain. installing the locating pin and a new cotter pin.
Refer to Figure 5-116.
Extend Chain Extend Chain
Rod #1 3. Assemble the crowd cylinder/crowd box then
install it back in place inside the boom assembly.
Figure 5-116. Chain Anchor at Extend Chain Rod
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5.5-3 Slide Pads Replacement Procedure 6. Install new slide pad and enough shims to allow
a 0.5 mm clearance between the slide pad and
Slide pads are designed to protect the structural the bottom section of the boom.
integrity of the boom sections. In addition, slide pads
partially carry the weight of the boom sections and 7. Secure the slide pad and shim(s) by installing two
will wear out over time and based on daily operation. screws. Apply red thread locking compound to
Ensure to check slide pads quarterly. Refer to Section screws prior to installation. Torque screws to 65
5.3-6 for slide pads inspection procedure. lb.ft. (88 N.m.).
8. Repeat steps 4 through 7 for the slide pad on the

IMPORTANT
opposite bottom side of the boom section being
Pay attention to high-load slide pads
repaired.
(Front-Lower & Rear-Upper of boom) as
most of the weight is exerted on them.
5.5-3-2 Front Side Slide Pads
5.5-3-1 Front Lower Slide Pads

NOTE
There are two sets of slide pads on each side
1. With park brake applied and telehandler is parked of the front of each boom section. Always
on a firm level surface, extend boom horizontally replace all four as a set. All four must be
to allow access to front lower slide pads. removed before any are replaced to assure
the boom is centered when completed.
2. Lower the boom until boom tip contacts the
ground and places weight against the upper slide
1. With park brake applied and telehandler is parked
pads. Ensure lower slide pads are NOT in contact
on a firm level surface, extend boom horizontally
with boom section(s).
to allow access to front side slide pads. Do not
3. Shut off engine and remove key from ignition allow boom tip to contact the floor.
switch.
2. Remove the two screws that secure each slide
4. Remove two screws that secure the slide pad and pad to the side of the boom. Use a pry bar to
shims to the lower area of the boom section. See relieve the tension on the slide pad if necessary.
Figure 5-117. Remove Shims Remove Screws
Remove 2 Screws Shims
Figure 5-117. Front Lower Slide Pads

Figure 5-118. Front Side Slide Pads
5. Remove the slide pad and any shims from the
boom
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3. Remove the slide pad and any shims from the 3. Install the new slide pad and one shim to the
boom. boom and secure by installing two screws (1).
Apply red thread locking compound to screws
4. Repeat steps 2-3 for the remaining three slide prior to installation. Torque the screws to 65 lb.ft.
pads on the sides of the boom section being (88 N.m.).
serviced.
4. Repeat steps 1-3 for the opposite side top of the
5. Use a pry bar to center the inner boom section boom section being repaired.
on the lower slide pads.
NOTE
An equal number of shims is to be used on
all side mounted slide pads to assure the 5.5-3-4 Rear Upper Slide Pads
inner boom section remains centered on
the lower slide pads after assembly has IMPORTANT
been completed. Pay attention to high-load slide pads
(Front-Lower & Rear-Upper of boom) as
6. Install the new slide pad and the required number most of the weight is exerted on them.
of shims (Figure 5-118) to one of the four side
pad locations. 1. Ensure telehandler is parked on a firm level
surface, park brake applied and boom fully
7. Secure the slide pad and shims by installing two retracted.
screws. Apply red thread locking compound to
screws prior to installation. Torque the screws to 2. Shut off engine and remove key from ignition
65 lbs.ft. (88 N.m.). switch then remove boom rear cowl to allow
access to the rear slide pads.
8. Repeat steps 6-7 for the other three slide pad
positions on the sides of the boom. NOTE
There are two slide pads on the top rear
of each boom section as shown in Figure
5-120. Remove and replace procedures are
the same for all upper slide pads.
5.5-3-3 Front Upper Slide Pads
3. Remove two screws that secure the slide pad to
1. Remove two screws that secure the slide pad and the upper area of the boom section.
shim(s) to the upper area of the boom section.
2. Remove the slide pad and any shims from the boom.
boom.
Upper Slide
Remove Shims Remove Screws Pads
Figure 5-120. Rear Upper Slide Pads
5. Lubricate and install new slide pad and enough

shims to allow a 0.5 mm clearance between the
slide pad and the bottom section of the boom.
Refer to Table 2.4 for lubricant specifications.
Figure 5-119. Front Upper Slide Pads
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6. Secure the slide pad and shim(s) by installing 3. Lubricate and install new slide pad and enough
two screws. Apply red thread locking compound shims to allow a 0.5 mm clearance between the
to screws prior to installation. Torque the screws slide pad and the bottom section of the boom.
to 65 lb.ft. (88 N.m.).
4. Secure the slide pad and shim(s) by installing two
7. Repeat steps 3-6 for the opposite side top of the screws. Apply red thread locking compound to
boom section being repaired. screws prior to installation. Torque the screws to
65 lb.ft. (88 N.m.).
8. Install the crowd box/crowd cylinder.
5. Repeat steps 1-4 for the slide pad on the opposite
9. Replace the rear boom cover. bottom side of the boom section being repaired.
6. Assemble crowd box/crowd cylinder into the rear

5.5-3-5 Rear Lower Slide Pads of the boom. Refer to Section 5.5-2-6.
NOTE
There are two slide pads on the bottom rear 5.5-3-6 Rear Side Slide Pads
of each boom section. Remove and replace
procedures are the same for all lower slide NOTE
pads. There are two sets of slide pads on each
side of boom sections 2 & 3. All four pads
NOTE for each section must be removed before
To gain access to all rear lower slide pads, any are replaced to assure that boom
the crowd box/crowd cylinder assembly section is centered when completed.
must be removed. Perform the procedure
outlined in Section 5.5-2-4 to disassemble 1. Extend boom to access the side slide pads that
the crowd box/crowd cylinder. require replacement, but do not allow the boom
tip to contact the floor.
1. Upon completion of the disassembly process up
to the point where the finger bracket is removed 2. Shut down engine and remove key from ignition
from the machine, ALL rear lower slide pads will switch then remove rear boom cover to allow
be accessible as shown in Figure 5-121. access to rear side slide pads.
Remove 2 Remove Shims 3. Remove the two screws that secures the slide pad
Screws & Slide Pads to the side of the boom. Use a pry bar to relive the
tension on the slide pad if necessary.

boom.
Rear Side
Slide Pad
Figure 5-121. Rear Lower Slide Pads
Figure 5-122. Rear Side Slide Pads

2. Remove two screws that secure each slide pad to
the lower area of the boom section, then remove
5. Repeat steps 1-4 for the remaining three slide
the slide pad and any shims from the boom
pads on the sides of the boom section being
section being repaired.
serviced.
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6. Use a pry bar to center the inner boom section

CAUTION
on the lower slide pads.
The addition of a hydraulic accumulator
NOTE on this system causes residual pressure
An equal number of shims is to be used on to be present AFTER the engine has
all side mounted slide pads to assure the been turned OFF. Prior to opening any
inner boom section remains centered on hydraulic fitting in this system, move the
the lower slide pads after assembly has joystick several times in each direction
been completed. to relieve this residual pressure. Failure
to do so may result in personal injury.
7. Install the new slide pad and the required number
of shims to one of the four side pad locations.
5.5-4-1 System Standby Pressure
8. Secure the slide pad and shims by installing two
screws. Apply red thread locking compound to
System standby and maximum system pressure
screws prior to installation. Torque the screws to
checks/adjustments are made at the hydraulic pump,
65 lb.ft. (88 N.m.).
located at the forward end of the transmission.
9. Repeat steps 7-8 for the other three slide pad
positions on the sides of the boom and replace Standby/Differential Pressure Check:
the rear boom cover.
1. Release residual pressure by moving the joystick
several times in each direction.
5.5-4 Hydraulic Pressure Test Procedure
2. Remove hose LS from port X at hydraulic pump
and cap the plug. See Figure 5-123.
IMPORTANT
All checks and adjustments are to be 3. Install a 1,000 psi gauge in the M2 port of
made with the engine running at low idle, hydraulic pump. See Figure 5-123.
the transmission shifter in Neutral and
the parking brake applied.
Transmission Install
Port X
Oil Filter Cap
Remove
Hose
Connect
Pressure
Gauge
Remove
Plug
Port
M2
Figure 5-123. System Standby and Maximum

Pressure Check
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4. With engine running at low idle and no hydraulic Maximum System Pressure Adjustment:
functions engaged, the gage should read 550psi.
If some reading other than 550 psi is present, 1. Loosen the lock nut on the maximum system
adjustment is required. pressure control adjustment screw (Figure 5-124)
on the inlet side of the hydraulic pump.
Standby/Differential Pressure Adjustment: 2. With engine running at low idle, dead-head

the fork tilt function in either direction. Turn the
1. Loosen the lock nut on the standby pressure pressure control adjustment screw to adjust
control adjustment screw on engine side of the pressure reading on the gage. Turn the
hydraulic pump. See Figure 5-124. adjustment screw clockwise (CW) to increase the
pressure reading and counter-clockwise (CCW)
System Maximum to reduce the pressure reading.
Stanby Pressure
pressure adjustment
Adjustment
3. When the correct pressure reading (3,480 psi) is
reached, tighten the lock nut. Re-check pressure
to ensure reading did not change when lock nut
was tightened.
Front of Rear of
Machine Machine
Figure 5-124. Pump Pressure Adjustment 5.5-4-3 Neutral Steering Pressure
2. Turn the pressure control adjustment screw to Neutral Steering Pressure Check:
adjust the pressure reading on the gauge. Turn
the adjustment screw clockwise (CW) to increase
the pressure reading and counter-clockwise
(CCW) to reduce the pressure reading.
2. Remove hose from port CF on the main hydraulic
3. When the correct pressure reading (550psi) is
function manifold.
reached, tighten the lock nut. Re-check pressure
reading to ensure it did not change when lock nut 3. Install a 1,000 psi gauge into the CF port on the
was tightened. underside of the hydraulic function manifold.
4. Connect hose LS back to port X. Loosen
Lock Nut
to Adjust
5.5-4-2 System Maximum Pressure
Maximum System Pressure Check:

Port CF
2. Install a 5,000 psi gage in the M2 port of hydraulic
pump (Figure 5-123).
Figure 5-125. Neutral Steering Pressure
3. With engine running at low idle, dead-head the
boom retract function. Indicated standby pressure
should be 3,480 psi.
4. With engine running at low idle and NO STEERING
4. If some reading other than 3,480 psi is present, EFFORT made, pressure should be 400 psi.
adjustment is required.
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Neutral Steering Pressure Adjustment: Maximum Steering Pressure Adjustment:
1. Loosen the lock nut on the neutral steering 1. Loosen the lock nut on the maximum steering
pressure reducing valve at port LE1 (Figure 5-125) pressure reducing valve at port RV1 (Figure
on the top face of the hydraulic function manifold. 5-127) on the bottom face of the hydraulic function
manifold.
2. With engine running at low idle and NO STEERING
EFFORT made, turn the adjustment screw RV1
clockwise (CW) to increase the pressure reading
and counter-clockwise (CCW) to reduce the
CF
pressure reading until a reading of 400 psi is
made.
3. Tighten the lock nut on the neutral steering

pressure-reducing valve and re-check the reading
to assure that 400 psi is maintained. Figure 5-127. Maximum Steering Pressure
Adjustment (Bottom View of Main Manifold)
2. With engine running at low idle and the steering

5.5-4-4 Maximum Steering Pressure dead-headed to on side, turn the adjustment
screw clockwise (CW) to increase the pressure
Maximum Steering Pressure Check: reading and counter-clockwise (CCW) to reduce
the pressure reading until a reading of 2,600 psi.
1. Release residual pressure by moving the joystick 3. Tighten the lock nut on the maximum steering
several times in each direction pressure-reducing valve RV1 and re-check the
reading to assure that the correct pressure is
2. Install a 5,000 psi gauge into the CF port on the
maintained.
underside of the hydraulic function manifold. See
Figure 5-126.
5.5-4-5 Service Brake Pressure
Service Brake Pressure Check:

Port CF 2. Remove plug and install a 1,000 psi gauge into
the PS1 port on the hydraulic function manifold.
See Figure 5-128.
Figure 5-126. Maximum Steering Pressure
PS1
3. With engine running at low idle and steering

dead-headed in either direction, read the pressure
indicated on the gauge. The correct pressure
should be 2,600 psi.
4. If reading is other than 2,600 psi, adjustment is

required.
Figure 5-128. Service Brake Pressure
(Top View of Main Manifold)
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3. With engine running at low idle, depress brake 2. With the engine OFF, move the joystick from side-
pedal fully. Pressure should read 850-900 psi. to-side to relieve residual hydraulic pressure from
the pilot circuit.
4. If maximum pressure is less than 850 psi, brake
valve must be replaced.
NOTE Remove
There is no adjustment. Replace the brake Plug
valve at the service brake pedal.
5.5-4-6 Pilot Pressure
Pilot Pressure Check:

Figure 5-130. Boom Function manifold Plug

several times in each direction. CAUTION
The pressure reducing valve of the
2. Install a 1,000 psi gauge into the tee fitting at port Boom Function manifold is under spring
GP2 of the hydraulic function manifold. tension. Remove the plug carefully to
avoid possible injury.
3. With engine running at low idle and NO hydraulic
function engaged, pressure should be 550 psi.
3. Carefully loosen the large hex plug of the pressure
GP2 reducing valve from the end plate of the Boom
Function manifold. The plug is under strong
spring tension.
Remove
Filter
Remove
Plug
Figure 5-131. Boom Function manifold

Plugs Removal
Figure 5-129. Pilot Pressure Check
4. Remove the pressure reducing valve (PRV3) from
NOTE the end plate bore. A magnet may be required to
Pilot pressure is NOT adjustable. Low pilot remove some of the components.
pressure can be restored to normal from the
rear of the machine on the Boom Function 5. Clean the parts removed in step 4 and the end
manifold. plate bore.
1. Remove the cover plates from the rear of the 6. Inspect the parts for obvious damage. If pressure
machine to expose the Boom Function manifold. reducing valve parts are damaged, replace the
valve assembly. If damage is found in the bore,
replace the end plate.
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7. Remove the pilot oil filter from the end plate bore. 5. Start the engine and check the gauge. Maximum
A magnet may be required to remove some of system pressure should immediately be present
the components. (3,480 psi).
8. Clean the parts removed in step 7 and the end 6. If the pressure reading is different than the
plate bore. required pressure, use the pressure adjustment
screw on the pump to adjust the pressure to the
9. Inspect the parts for obvious damage. If pilot proper level.
oil filter parts are damaged, replace the filter
assembly. If damage is found in the bore, replace Loosen
the end plate. Lock Nut
CAUTION
Considerable force is required to
overcome spring tension when installing
the pressure reducing valve into the Rear of Front of
Boom Function manifold. Use caution to Machine Machine
avoid slippage and possible injury from
Figure 5-133. Pump Pressure Adjustment
flying parts.
10. Install the pressure reducing valve into the end 7. If the required pressure cannot be set, the pump
plate of the Boom Function manifold. Use caution must be rebuilt or replaced.
to avoid possible injury when overcoming the
spring tension.
11. Install the pilot oil filter into the end plate of the 5.5-6 Park Brake Release on Front Axle
Boom Function manifold.
12. Start engine and re-check pilot pressure. If pilot CAUTION

pressure is still below 550 psi, replace the entire Always chock the wheels of the disabled
end plate assembly. Refer to Parts Manual. machine to prevent accidental movement
when the park brake is released. This is
especially important if machine failure
occurs on an incline.
5.5-5 Hydraulic Pump Testing Procedure
1. Ensure engine is turned off.
If the hydraulic pump is suspected to be bad, the
2. Chock or block telehandler wheels to prevent it
following test will quickly determine if the hydraulic
from accidnetal movement.
pump requires replacement.

several times in each direction
2. Remove and cap the hose from the “X” port of

the hydraulic pump.
3. Check the orifice at the “X” port. Be sure it is tight

and free of debris.
4. Install a hose and 5,000 psi gauge between the

“M2” port and the “X” port of the hydraulic pump.
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Axle Housing 5.5-7 Crowd Cylinder Replacement Procedure
5.5-7-1 Preparation Procedure
Lock 1. Ensure telehandler is parked on a firm and level

Nuts surface.
IMPORTANT
Ensure there is sufficient overhead
clearance for lifting and extending.
WARNING
Set Screws
Be aware of overhead obstructions
or other possible hazards around the
machine when lifting.
Figure 5-134. Park Brake Release on Front Axle
2. Lower the boom to allow access to the working
3. Loosen the lock nuts on each side of the axle area. Set the parking brake, then shut down the
housing. See Figure 5-134. engine and remove the key from the ignition.
4. Turn the screws on each side of the axle housing 3. Remove the cover plates from the rear, tip and
until the park brake releases. See Figure 5-134. both sides of the boom.
5. Repeat steps 3 and 4 on right side of front axle. 4. Extend the boom to expose the inspection hole
that allows access to the hose guide clamps and
6. Remove the chocks from the wheels to move the attachment screws (see Figure 5-135). These are
machine. located at the rear of the machine, on each side
of boom section #3.
7. Ensure to engage the park brake after the
machine has been moved to the desired location.
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.
Figure 5-135. Inspection holes
5. Set the parking brake, then shut down the engine

and remove the key from the ignition.
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6. Through the inspection hole, remove the hose 2. Release the tension on the adjustment nut for
guide clamps from within the boom, on either retract chain #1 (Figure 5-138, point 3), located at
side. See Figure 5-136. the underside flange of boom section #1 (Figure
5-138, point 4) until it is finger tight.
3. Release the tension and remove the adjustment

nut for retract chain #2 (Figure 5-138, point 1),
located at the underside flange of boom section
#2 (Figure 5-138, point 2). Tie a cord/wire to the
chain anchor to aid in re-assembly. Push the
retract chain anchor through the flange.
Figure 5-136. Hose guide clamp.
7. Retract the boom fully, then lower the boom

to provide access to the inspection hole in the
boom tip.
8. Set the parking brake, then shut down the engine

and remove the key from the ignition.
9. Chock or block the front wheels to prevent motion

of the VR telehandler during this replacement
Figure 5-138. Retract Chain Tension Release
procedure.
5.5-7-2 Crowd Cylinder Removal Procedure 4. Remove the chain extension adjustment nut
lock and nut (Figure 5-139) at the rear of boom
section #1.
1. Working through the front of the boom tip, loosen
the tension adjuster (Figure 3, point #1) on both
sides until the square section of the tension
adjuster is even with the rear part of its bracket
(Figure 5-137, point #2).
Figure 5-139. Extend Chain Tension Release
. 5. Using a pry bar, shift boom section #4 slightly out

of the boom assmebly to release chain tension.
Figure 5-137. Hose Tension Adjuster Push the rod through the bracket until free.
6. Ensure the crowd cylinder is fully retracted.
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7. Remove the bolt and locator pin (Figure 5-140, 11. Pull the securing pins that hold the dead anchor
point 1) that secures the crowd cylinder (Figure brackets to the crowd box through the boom
5-140, point 2) to the “T” bracket (Figure 5-140, inspection hole (See Figure 5-142). Remove
point 3). the dead anchor brackets from their mounting
location on the crowd box, and lay them on the
outside of boom section #1.
Figure 5-140. “T” Bracket Removal Figure 5-142. Dead Anchor Securing Pins
8. Remove the set bars and four screws, two on 12. Remove the cotter and locating pins that secure
each side of the boom (Figure 5-141, point 1), the extension chaine #2 to its anchor on the
that secure the “T” bracket to boom section #1. crowd cylinder barrel (Figure 5-143, point 1).
Disconnect the chain from the anchor and allow
the chain to lay on the inside of boom section #4.
Figure 5-143. Extend Chain #2 Anchor

Figure 5-141. “T” Bracket securing bolts
9. Remove the “T” bracket from boom section #1.

Carefully disengage the vertical legs of the “T”
bracket from the slots in the bottom of the boom.
CAUTION
To prevent hydraulic system
contamination, cap all hydraulic hoses
and fittings after removal.
10. Remove the two crowd cylinder hydraulic hoses

at the rear end of the boom.
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13. Remove the bolt and hose sheave bracket, then

slacken the hydraulic hoses (see Figure 5-144).
Remove the pin hose sheaves from the finger
bracket.
Figure 5-146. Retract Chain #1 & Finger Plate

Removal
18. Remove the four bolts (two on each side) that

secure the wing bracket to the rear of boom
Figure 5-144. Boom Hydraulic Hose Sheaves (Single)
section #3. See Figure 5-147.
14. Secure the two sets of hoses with tie wraps, one
to each side of the boom wall. Remove
15. Slacken the retract chain #1 (Figure 5-145, point
1). Remove the bolt and locator pin (Figure 5-145,
point 2) that secures the chain sheave (Figure
5-145, point 3) to the center position of the finger
bracket. Remove the sheave.
Figure 5-147. Wing Plate Removal
19. From the outside of both sides of boom section

#1, remove the retaining ring (Figure 5-148,
point 1) that secures the locating pins to boom
section #2.
Figure 5-145. Retract Chain #1 Sheave
16. Remove the cotter and locator pins that secure

retract chain #1 to the wing plate (Figure 5-146,
point 1). Remove the chain from the anchor and
allow the chain to hang from the opening in the
rear of the boom.
17. Remove the two bolts (Figure 5-146, point 2) that Figure 5-148. Locating Pin Removal
secure the finger bracket (Figure 5-146, point 3)
to the bottom of boom section #2. Remove the
finger bracket from the machine.
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20. Remove the locating pins from the boom to free 6. Carefully remove the crowd cylinder from the
the crowd clyinder from boom section #2. crowd box with suitable lifting equipment.
21. Using straps and a suitable lifting device, lift and 7. Remove the wear pads at the front extension
pull the crowd cylinder/crowd box assembly from chain #1 anchor. See Figure 5-151.
the boom assembly and place it on a secure
stand. See Figure 5-149.
Remove
Figure 5-151. Extension chain #1 anchor wear pads
8. Remove the extension chain #1 connecting pin at

the front of the cylinder. See Figure 5-152.
Figure 5-149. Crowd Cylinder/Crowd Box Assembly

Removal
5.5-7-3 Crowd Cylinder Replacement Procedure

Remove
1. Attach a chain to the barrel end of the crowd box
and fasten it to a stationary point.
2. Remove the bolts (Figure 5-150, point 1) that

secure the wear pads to each side of the front and Figure 5-152. Extension Chain #1 Connecting Pin
rear end of the crowd box assembly. The wear
pads will be removed when the crowd cylinder 9. Remove the securing bolts at the rod anchor of
and crowd box are separated. extension chain #1. See Figure 5-153.
Securing
Bolts
1
Figure 5-150. Crowd Assembly Wear Pads Figure 5-153. Extension Chain #1 Rod Anchor
3. Fasten crowd cylinder rod end with a chain to the 10. Remove extension chain #1 rod from the old
lifting equipment in use. cylinder and install it on the replacement cylinder
in the same way shown in Figure 5-153.
4. Unmount the wing bracket by removing the four
bolts that secure wing bracket to the crowd box.
5. Remove the wing bracket from extension chain

#1 by removing the connecting pin.
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11. Grease the barrel of the crowd cylinder as 14. Remove the cylinder barrel end wear pad from
required. See the Operator’s/Maintenance Manual the old cylinder, and install it on the replacement
or the machine Lubrication Chart for the correct cylinder. See Figure 5-156. Apply red Loctite or
lubricant. equivalent to the bolts prior to installation.
12. Remove the front sheave of extension chain

#1 from the old cylinder, and install it on the
replacement cylinder (See Figure 5-154). Ensure
to install the retainer ring.
Figure 5-156. Cylinder Barrel End Wear Pad
15. Install the extension chain #1 on the replacement

cylinder. Ensure the chain is seated on the sheave
properly. Install wear pads at the front of extension
Figure 5-154. Extension Chain #1 Front Sheave chain #1. See Figure 5-157.
13. At the front of the cylinder, remove the extension

chain #2 anchor from the old cylinder, and install Wear Pads
it on the replacement cylinder. There should be
1-3/8 to 1-1/2 inch of anchor rod protruding from
the front of the bracket to the back of the anchor.
See Figure 5-155.
Connecting Pin
Figure 5-157. Extension Chain #1 Installation
(Barrel end)
16. Carefully lift the replacement cylinder assembly

and install it to the crowd box from the crowd box
end. The barrel end of the cylinder should be even
with the forward most cut-out of the crowd box.
Figure 5-155. Extension Chain #2 Anchor
Ensure the crowd cylinder box is secured from
moving and extension chain #1 is in position.
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17. Install the wear pads to both ends of the crowd 21. Carefully lift and install the crowd cylinder/crowd
box, and shim the wear pads until they center the box assembly to main boom assembly. Ensure
cylinder in the box, but do not bind. Secure each to align the mounting holes on the sides of
wear pad by installing two bolts (Figure 5-158, boom section #1 and #2 with the crowd cylinder
point 1). Apply red Loctite or equivalent to the trunnion. See Figure 5-160. Ensure hydraulic
bolts prior to installation. Torque the front rear hoses and chains are cleared and in place.
wear pad bolts to 65lbs/ft (88Nm) and the front
wear pad bolts to 45lbs/ft (61Nm). CAUTION
Slight movement of the boom section
may be required to allow correct
alignment of mounting holes. This may
be achieved with a large pry bar. USE
CAUTION.
Figure 5-158. Crowd Box Wear Pads Installation
18. Install the wing bracket to the extension chain #1

at the end of the cylinder rod.
19. Position the wing bracket into the slots on the

crowd box and secure by installing the 4 bolts Figure 5-160. Boom Section Mounting Holes
(two each side). Apply red Loctite or equivalent Alignment
to the bolts prior to installation. Torque the bolts
to 80lbs/ft (108Nm). 22. Remove the chain and 4X4 that are attached to
the boom sections.
20. Prior to installing the crowd cylinder/crowd box
assembly into the boom sections, secure boom 23. Install the trunnion pins through the mounting
sections #2, #3 & #4 to section #1 by wrapping holes on the boom assembly from both sides.
a chain around the front of the boom tip, secured Secure the pins by installing the retaining rings.
to the inspectin ports on each side. (Figure 5-159,
point 1). Position a 4X4 piece of wood between 24. Install the 4 bolts (two on each side) that secure
the boom tip and the chain (Figure 5-159, point 2). the wing bracket to the rear of boom section #3.
This will ensure the inner boom sections will not See Figure 5-161. Apply red Loctite or equivalent
extend while installing the crowd cylinder/crowd to the bolts prior to assembly and torque the bolts
box to the rear of the boom assembly. to 80lbs/ft (108Nm).
Install
Figure 5-159. Boom Section Securing Procedure
Figure 5-161. Wing Plate installation
155167
25. From the boom side inspection hole, install the

cotter pin and connecting pin that secures the
extension chain #2 (Figure 5-162, point 1) to its
anchor on the crowd cylinder box.
1
1
2
Figure 5-164. Retract Chain #1 & Sheave Installation

Figure 5-162. Extend Chain #2 Front Anchor
28. Grease the locator pin for theretract chain #1
sheave.
26. At the boom end, install the two bolts (Figure
5-163, point 1) that secure the finger bracket 29. Position the hydraulic sheaves to the mount
(Figure 5-163, point 3) to the bottom of boom locations on the finger bracket and secure with
section #2. Apply blue Loctite or equivalent to the locator pin, keeper pin and bolt. Ensure to
the bolts prior to assembly. Torque the bolt to install a washer between the two sheaves. See
38lbs/ft (52Nm). Figure 5-165.
Install
Figure 5-165. Boom Hydraulic Hose Sheaves
Figure 5-163. Retract Chain #1 & Finger Plate

30. Install the hydraulic hose keeper bracket on each
Removal
side.
27. Loop the retract chain #1 over its sheave (Figure

5-164, point 1) and position the chain sheave to
its mounting location in the center of the finger
bracket. Secure the sheave to the bracket by
installing the locator pin, keeper pin and bolt
(Figure 5-164, point 2).
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31. Remove the ties that secure the boom hoses 33. Working through the inspection hole in the front
on each side of the boom assembly. Position of boom section #4, position the hydraulic hose
the hoses loosely over the hose sheaves. See tension adjusters (Figure 5-168, point 1) into the
Figure 5-166. mounting brackets (Figure 5-168, point 3) on
both sides of the boom section. Be sure the hose
tension cable is not twisted between the cable
sheave and the tension adjuster. If the cable is
twisted, the cable will fray and eventually beak
during the extend/retract cycle.
Figure 5-166. Boom Hydraulic Hose Sheaves Bracket
32. From the inspection hole of the boom, adjust the

tension on the dead anchor cables on both sides .
until the hydraulic hoses are seated correctly on
each sheave. Install the securing pins that secures Figure 5-168. Hydraulic Hose Tension Adjuster
the dead anchor plates to the crowd box, ensuring
correct orientation (see Figure 5-167). 34. Tighten the nut on the threaded rod until 4” of
unengaged threads are exposed between the
adjuster bracket (Figure 5-168, point 1) and
the end of the square length of the adjuster rod
(Figure 5-168, point 2).
35. At the boom end, push the lock nut on the end
of the extend chain rod toward the front of the
machine to allow the rod to be inserted into the
“T” bracket.
Figure 5-167. Dead Anchor
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36. Position the “T” bracket (Figure 5-169, point 1) 40. Install the adjustment nut (Figure 5-170, point
to its mounting location inside the rear of boom 1) for retract chain #2 at the underside flange of
section #1. The lower part of the bracket should boom section #2 (Figure 5-170, point 4). Adjust
protrude through the slots (Figure 5-169, point 2) the position of the boom section 4 if required.
in the bottom of boom section #1. The extend
chain rod should pass through the block on the
top of the “T” bracket. The sides of the top plate
of the bracket should engage the mounting blocks
(Figure 5-169, point 3) on the inside plates of
boom section #1.
1 5 3
4
Figure 5-170. Retract Chain Front Anchor
41. Connect the two crowd cylinder hoses to the

fittings on the bottom inside of boom section #1.
2 42. Start the engine and extend the boom to expose

. the mounting location for the hose guide clamps,
one on each side of boom section #2 (see Figure
Figure 5-169. Hose Tension Adjuster 5-171).
37. Align the holes in the crowd cylinder rod clevis

(Figure 5-169, point 4) with the holes in the vertical
sections of the “T” bracket. Secure the rod to the
bracket by installing the locator pin, keeper pin
and bolt. Apply red Loctite or equivalent to the
bolt prior to assembly. Torque the bolt to 65lbs/
ft (88Nm).
38. Install the extend chain adjusting nut (Figure Figure 5-171. Hose guide clamp.
5-169, point 5) on the extend chain rod and
tighten until 25mm of rod is engaged in the nut. 43. From one side of the boom, position the hose
The jam nut may need to be backed off to allow guide to the inside of boom section #2. Insert the
the correct engagement. In order to measure mounting screw to just barely engage the inside
the engagement, insert a rule into the rear of the half of the guide. Turn the inside half of the guide
adjusting nut; when the rule shows 65mm of open to horizontal to allow the hoses to be positioned
nut remaining, then 25mm of rod is engaged (nut on the outside half of the guide. Using a hook to
is 90mm in total). assist in positioning the hoses, raise the top hose
into the guide first. Then lift the bottom hose to
39. Secure the “T” bracket to boom section #1 by the guide. Twist the inner half of the guide to the
installing the mounting plates to the inside of vertical position to secure the hoses. Secure the
the boom section (Figure 5-169, point 3), using guide by tightening the screw from the outside of
two screws through the outside of the boom on boom section #3. Repeat the procedure for the
each side. hoses and guide on the other side of the boom.
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44. Adjust all boom chains. Refer to Section 5.3-

7 to Section 5.3-10 for the chain adjustment
procedure.
45. Install the extend chain adjustment nut lock and

nut (see Figure 5-172). Tighten the jam nut with
1-1/4 inch crows foot wrench.
Figure 5-172. Extend Chain Lock Nut
46. Adjust the tension on both sets of boom hoses.

Refer to Section 5.3-11 for the hose adjustment
procedure.
47. Start engine and operate the boom through

several extend, retract, tilt and tip cycles to purge
air from the system and to ensure satisfactory
operation.
48. Check for leaks and repair as necessary.
49. Install the cover plates from the rear, tip and both
sides of the boom.
50. Perform visual inspections and function tests as

described in the Operating manual.
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AC
5.5-8 Coolant Draining Procedure

NOTE
Refer to this section for instructions on maintaining When filling the radiator, do not exceed
correct coolant levels. 3GPM fill rate.
5. Fill radiator completely through the radiator neck.
6. Fill recovery bottle to full cold. See Figure 5-173.
5.5-8-1 Radiator Fill Maintenance
WARNING
Pressurized fluid present in radiator. Recovery Bottle
Never open radiator cap when hot.
1. Ensure to make use of an appropriate container Figure 5-173 Recovery Bottle Location
when collecting used coolant. Open the radiator
drain, and drain engine coolant completely. 7. Run the engine for 25 minutes without radiator
cap to achieve operating temperature. Shut down
2. Open engine vent. Leave vent open during
the engine.
radiator fill. Refer to Figure 5-172.
8. Check coolant in the radiator. Refill to top if
necessary. Refill recovery bottle to full hot if
necessary.
9. Install radiator cap.
NOTE
Additional coolant may be required in the
top tank and recovery bottle after a few
operational cycles.
Engine Vent
Figure 5-172 Engine Vent Location
3. Remove radiator cap.
4. Fill radiator through the radiator neck until a solid,

airless stream of coolant flows out of the engine
vent, then close the engine vent.
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Notes
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SERVICE MANUAL

155167AD March 2014

VR 1056D 87 300 001 to 87 300 303

Please refer to the website (www.skyjack.com) for older Serial Numbers.

Skyjack Service Center Parts & Service (Europe)

Parts (North America) Skyjack Brasil

Section 1 - Scheduled Maintenance

Section 2 - Maintenance Tables

Service and Maintenance

Scheduled Maintenance Inspections

Service & Maintenance

Service Policy and Warranty

For non-standard components or systems, contact the SKYJACK Service Department at

Scope of this Manual

- Equipment identified with “ANSI” meets the ASME/ANSI B56.6 standard.

c. ANSI (United States)

Operator Safety Reminders

DO NOT USE TELEHANDLER AS A GROUND FOR WELDING.

• KNOW all national, state/provincial and local

• DO NOT wear loose

• DO NOT stand on forks.

Safety Precautions (Continued)

• DO NOT elevate the

• ENSURE that there are

• AVOID jerks and sudden

Safety Precautions (Continued)

• KNOW the weight of the

• USE CAUTION when

Safety Precautions (Continued)

• DRIVE UPHILL LOAD- • TETHER LOADS that

• TILT forks backward

• SECURE loose loads with

Safety Precautions (Continued)

Safety Precautions (Continued)

3. Whenever there is a hydraulic system failure Maintenance Hints

About this Section Maintenance Instructions

• Check the schedule on the checklist for the type

• Unless otherwise specified, perform each Legend

• Repair any damaged or malfunction components

Table 1.1 MAINTENANCE AND INSPECTION CHECKLIST

Check for Leaks A

1.1 Scheduled Maintenance Inspections 1.1-2 Electrical

1.1-5 Cylinders - Check each lug nut for proper torque to

• Batteries 5. Replace battery if damaged or incapable of

WARNING - Ensure air cleaner vaccuator valve (if

4. If applicable, check battery fluid level. If plates

1.1-7 Engine Compartment Perform a visual inspection around the following

• Hydraulic Tank 1.1-9 Boom

1.1-10 Lifting Attachment Grease Points on Frame

Frame and Boom

Grease Points on Boom Assembly 1.1-12 Operator’s Cab

- slide pads - Ensure seat belt is working properly with

Use the steps of telehandler to access operator’s CAUTION

Refer to this section for instructions on maintaining

1.2-1 Radiator Fill Maintenance

WARNING 6. Run the engine for 25 minutes without radiator

7. Check coolant in the radiator. Refill to top if

8. Install radiator cap.

9. Refer to Section 5.5-8 for Radiator Draining

Figure 1-1 Engine Vent Location

2. Remove radiator cap.

3. Fill radiator through the radiator neck until a solid,

4. Fill radiator completely through the radiator neck.