Skyjack SJ519 TH Service Manual Download Page 57

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SJ519 TH

216942AC

57-16 BN/GN TEW

SW4

SW6

J53

SW2

J52

SW11

J54

SW10

J50

J51

SW12

J49

SW1

J46

J45

(OPT)

ENCL. CAB

J44

ROAD

LIGHTS

(OPT)

J42

WORKLIGHTS

J41

(OPT)

BEACON

J43

DIAGNOSTIC

ENGINE

P66

THROTTLE

J68

GAUGE

FUEL

SWITCH

HORN

STEER MODE

SELECT SW.

PARK BRAKE SW.

WORK LIGHTS

SW. (OPTION)

GAUGE
LIGHT OPT.

SW (OPT)

BOOM LIGHTS

FLASHER
(OPTION)

TURN SW. (OPT)

IGN. SW.

IGN

ACC

B+

10A

15A

F10

F11

F12

F15

F16

F13

F14

F18

F20

F19

F17

ENCL.
CAB
(OPT)

JOYSTICK

CAP

HOUR

METER

03A-16 GN/PU TEW

05-16 PU TEW

05P-10 PU TEW

16-16 BU TEW

55-16 YL/PU TEW

SPL00-2

SPL246

SPL03-2

SPL105

SPL104

J47

224CR

RELAY

ENABLE

CARRIAGE LEVEL

J39

HARN
(OPT)

J37

CONN.

87A

105-16 GN/BN TEW

217-16 DK BU/BK TEW

218-16 DK BU/GN TEW

FUEL

LEVEL

49-16 GN/RD TEW

256-16 BN/BK TEW

16-16 BU TEW

217-16 DK BU/

BK TEW

218-16 DK BU/

GN TEW

49-16 GN/RD TEW

26-16 BU/YL TEW

05B-16 PU TEW

05T-16 PU TEW

05B-16 PU

05D

-16 PU TEW

05D-16 PU TEW

05K

-16 PU TEW

05K-16 PU TEW

03-16 GN/PU TEW

03B

-16 GN/PU TEW

-ve

+ve

77-16 BN/GY TEW

POSITIVE

SHUTOFF

60A-16 WH/BU TEW

207-18 BN TEW

90-18 RD/GY TEW

105-16 GN/BN TEW

SPL60A

SW9

(OPTION)

POSITIVE SHUTOFF

402-1

6 GN TEW

05B-16 PU TEW

272A-16 DK GN/RD TEW

05C

-16 PU TEW

47-16 PU/OR TEW

245-16 BN/OR TEW

05C-16 PU TEW

SPL05C

05C-16 PU TEW

J69

87A

03A-16 GN/PU TEW

03B

-16 GN/PU TEW

403ACR

RELAY

ENABLE

POSITIVE SHUTOFF

403A-16 RD TEW

SPL403A

224-16 DK GN/

PK TEW

237-16 LT GN/RD TEW

224-16 DK GN/PK TEW

55-16 YL/PU TEW

05-16 PU TEW

10A

05E-14 PU TEW

05E

-14 PU TEW

05F-16 PU TEW

05F

-16 PE TEW

05G-14 PU TEW

246-14 LT GN/PK TEW

246-14 L

T GN/PK TEW

05G-14 PU TEW

05H-16 PU TEW

05G-14 PU TEW

247-14 L

T GN/WH TEW

05J-16 PU TEW

261-16 BN/YL TEW

05J-16 PU TWE

249-16 L

T PU TEW

249-16 L

T PU TEW

249-16 L

T PU TEW

249-16 L

T PU TEW

252-16 PK/RD TEW

250-16 L

T BU/BK TEW

251-16 PK/BU TEW

250-16 L

T BU/BK TEW

251-16 PK/BU TEW

05L-16 PU TEW

05L

-16 PU TEW

05N-16 PU TEW

05P

-10 PU TEW

265-12 DK GN/BK TEW

266-16 BN/YL TEW

BLOWER SWITCH

J55

J58

104-16 GN/OR TEW

60-16 WH/BU TEW

99-18 BK/GY TEW

05R-16 PU TEW

26C

-16 BU/YL TEW

CANH-18 YL/BU TXL

105-1

6 GN/BN TEW

104-1

6 GN/OR TEW

99-18 BK/G

Y TEW

90-18 RD/G

Y TEW

60A-16 WH/BU TEW

54-16 PU/RD TEW

77-16 BN/G

Y TEW

206-18

T GN/YL TEW

TO ENGINE HARNESS

J31

00-10 WH

03-14-FLK

B+

L3-1

3-10 GN/PU T

CANL

-18 GN TXL

05D

-16 PU TEW

CHASSIS

GND ON

03-14-FLK

3-10 GN/PU T

B+

54-16 PU/RD TEW

HAZ SW. (OPT)

SW23

J87

ENGINE

77CR

RUNNING

87A

J33

60-16 WH/BU TEW

60B

-1

6 WH/BU TEW

60-16

WH/BU TEW

SPL77

77-16

BN/G

Y TEW

246-14 L

T GN/PK TEW

DISPLAY

J22

CANH-18 YL/BU TXL

CANL-18 GN TXL

60A-16 WH/BU TEW

00-16 WH TEW

SPL00-4

SPL05F

05F-16 PU TEW

05F

-16 PU TEW

255CR

RELAY REAR WIPER

J28

258CR

RELAY FRONT

WIPER

J32

87A

255-16 L

T YL/BU TEW

255-16 L

T YL/BU TEW

05F

-16 PU TEW

257-16 L

T YL/GN TEW

257A-16 L

T YL/GN TEW

257-16 L

T YL/GN TEW

257A-16 L

T YL/GN TEW

SPL05L

05L

-16 PU TEW

260-16 BN/WH TEW

258-16 L

T YL/PK TEW

SW14

REAR WASHER/WIPER

SW24

WASHER/WIPER 2 (OPT)

05L-16 PU TEW

260-16 BN/WH TEW

05L

-16 PU TEW

05F

-16 PU TEW

258-16 L

T YL/PK TEW

259-16 L

T YL/PU TEW

259-16 L

T YL/PU TEW

87A

259A-16 L

T YL/PU TEW

259A-16 L

T YL/PU TEW

POWER PORT

ENCL. CAB OPTION

J88

J57

6
5

12
11

SPLD60

MODULE

POSITIVE

SHUTOFF (OPT)

05K-16 PU TEW

05K

-16 PU TEW

256-16 BN/BK TEW

05-16 PU TEW

J96

74-16

GN/G

Y TEW

203-16

BK TEW

203-16 BK TEW

74-16 GN/G

Y TEW

RESISTOR

120 Ω

SPLCANH

SPLCANL

CANL-18 GN TXL

CANH-18 YL/BU TXL

403A-16 RD TEW

402-16 GN TEW

57A-16 BN/GN TEW

57-16 BN/GN TEW

57C-16 BN/GN TEW

57B

-16 BN/

GN TEW

26C

-16 BU/YL TEW

PARK BRAKE

05CR

RELEASE

87A

J97

05-16

PU TEW

77-16

BN/G

Y TEW

26B

-16 BU/YL TEW

26B

-16 BU/

YL TEW

26A-16 BU/YL TEW

26E

-16 BU/YW TEW

87A

245ACR

J98

AUX ENABLE

87A

237CR

J80

QUICK COUPLER

ENABLE RELAY

RELAY

245B

-16 BN/OR TEW

SPL255

255-16 L

T YL/BU TEW

SPL258

258-16 L

T YL/PK TEW

REAR WIPER

247-14 L

T GN/WH TEW

246-14 L

T GN/PK TEW

05J-16 PU TEW

SPL05J

252A-16 PK/RD TEW

05J-16 PU TEW

251A-16 PK/BU TEW

250A-16 L

T BU/BK TEW

SPL251A

SPL250A

258A CR

RELAY TOP

WIPER

J100

87A

05L

-16 PU TEW

SPL05L

05L

-16 PU TEW

258-16 L

T YL/PK TEW

208-16 DK PU TEW

208A-16 DK PU TEW

J102

00-16 WH TEW

04-10 RD/YW TEW

03-10 GN/PU TEW

04-10 RD/YW TEW

60-16 WH/BU TEW

J48

RELAY

POWER

60CR

15-16 BU TEW

87A

LEFT TURN

SIGNAL

RIGHT

TURN SIGNAL

87A

254-16 BN TEW

05J-16 PU TEW

250A-16 L

T BU/

BK TEW

SPL 254

254-16 BN TEW

251A-16 PK/BK TEW

251B

-16 PK/BK TEW

250B

-16 L

T BU/BK TEW

SPL05J

BRAKE LAMP

RELAY

26FCR

250ACR

251ACR

250B

-16 L

T BU/BK TEW

251B

-16 PK/BK TEW

J106

J107

J108

J110

SW19

ROAD LIGHTS

SW. (OPTION)

05G-14 PU TEW

05H-16 PU TEW

SPL261

261-16 BN/YL TEW

271-16 BU/YL TEW

271A-16 BU/YL TEW

271-16 BU/YL TEW

245A-16 BN/OR TEW

237-16 L

T GN/RD TEW

237A-16 L

T GN/RD TEW

RESISTOR

1000 Ω

SPL05

16 17

NEUTRAL

57C CR

ENABLE RELAY

87A

J38

57B

-16 BN/

GN TEW

15-16 BU/GN TEW

57C

-16 BN/GN TEW

57A-16 BN/GN TEW

SPL05B

J83

SW25

CONTINUOUS FLOW
FORWARD/REVERSE

SPL05R

05R-16 PU TEW

234-16 DK PU/RD TEW

233-16 DK PU/OR TEW

272-16 DK GN/RD TEW

272CR

DISCONNECT RELAY

QUICK COUPLER/AUX

J104

87A

05T

-16 PU TEW

272-16 DK GN/

RD TEW

272-16 DK GN/RD TEW

SPL272

272A-16 DK GN/RD TEW

SPL272A

J82

SW26

LOCK/UNLOCK

QUICK COUPLER

245 - 16 BN/OR TEW

245A - 16 BN/OR TEW

SPL237A

SPL245B

05-16 PU TEW

15-16 BU/GN TEW

SPL15

265-12 DK GN/

BK TEW

266-16 BN/YL TEW

261-16 BN/YL TEW

03-16 GN/PU TEW

04-10 RD/YL TEW

SPL00

J18

PS1

PRESSURE SWITCH

J19

CRAB

STEER

J20

4-WHEEL

STEER

19 20

22 23

24 25

27 28 29

30 31

HORN

00-16 WH TEW

to Neutral enable relay

REV. to HFX 19

FWD to HFX 15

256-16 BN/BK TEW

BOOM

LIGHTS

(OPT)

00-16 WH TEW

245B-16 BN/OR TEW

15C-16 BK/OR TEW

00-16 WH TEW

BACK-UP

ALARM

87A

86CR

J99

HYD. OIL COOLER

RELAY

05S

-11 PU TEW

86-16 PU/WH TEW

86A-11 PU TEW

00-11 WH TEW

HYDRAULIC

OIL COOLER

J23

TPSW1

OIL TEMPERATURE

SWITCH

05T-16 PU TEW

86-16 PU/WH TEW

05T-16 PU TEW

40A

J24

J26

J34

J13

QUICK COUPLER

(OPT)

STARTER

INTERRUPT

87A

57D CR

26D

-16 BN TEW

26F

-16 BU/YW TEW

26E

-16 BN TEW

SPL26A

P14

05T-16 PU TEW

TPSW3

OIL TEMPERATURE

SWITCH

05TA-16 PU TEW

J124

J56

SPL05T

05-16 PU TEW

05S-11 PU TEW

26D

-16 BN TEW

SPL250

SPL251

J65

F-N-R

J25

47-16 PU/OR TEW

234-16 DK PU/RD TEW

233-16 DK PU/OR TEW

BACK UP ALARM

15B CR

ENABLE RELAY

87A

J119

15C-16 BK/OR TEW

15B-16 BU/GN TEW

05-16 PU TEW

SPL15C

05T

A-16 PU TEW

00-16 WH TEW

00-14 WH TEW

00-16 WH TEW

00-20 WH TEW

00-16 WH TEW

00-20 WH TEW

00-16 WH TEW

61-18 GN/BN TEW

63-18 G

Y/YL TEW

J63

00-20 WH TEW

P63

63-18 G

Y/YL TEW

62-18 GN/RD TEW

61-18 GN/BN TEW

62-18

GN/RD TEW

62-18

GN/RD TEW

26F

-16 BU/YW TEW

GLOW PLUG

PREHEAT

HYDRAULIC

OVER TEMPERATURE

AMB

00-18 WH TEW

206-18 LT GN/YL TEW

207-18

BN TEW

BRAKE RELAY

87A

26D CR

J121

J122

TELEMATICS

DIAGNOSTIC

P66A

CAP

CONN.

00-16 WH TEW

60A-16 WH/BU TEW

104-16 GN/OR TEW

105-16 GN/BN TEW

CANL-18 GN TXL

CANH-18 YL/BU TXL

CANL-18 GN TXL

CANH-18 YL/BU TXL

SPL00

SPL60

D5
7D

26B-16 BU/YW

26B-16 BU/YW TEW

60-16 WH/BU TEW
60B-16 WH/BU TEW

00-16 WH TEW

57-16 BN/

GN TEW

57D

-16 BN/GN TEW

57A-16 BN/GN TEW

03-16 GN/PU TEW

57D-16 GN TEW

00-20 WH TEW

26F

-16 BU/YW TEW

SPLCANL-3

SPLCANH-3

SPLCANH-2

SPLCANL-2

00-20 WH TEW

GROUND

FRAME

00-10 WH

SPL00-3

D252

251-16 PK/BU TEW

D252-1

252-16 PK/RD TEW

250-16 L

T BU/BK TEW

P300

D245B

237A-16 L

T GN/RD TEW

245B

-16 BN/OR TEW

P302

P304

D60-1

P303

D60

P305

60A-16 WH/BU TEW

60-16

WH/BU TEW

D252A-1

D252A-2

252A-16 PK/RD TEW

251A-16 PK/BU TEW

250A-16 L

T BU/BK TEW

P306

D05J

05J-16 PU TEW

P307

P308

74-16 GN/GY TEW

203-16 BK TEW

SPL203

SPL74

RESISTOR

120 Ω

P309

D26B

P312

05-20 PU TEW

SPL05

05-20 PU TEW

00-20 WH TEW

IGN

60-16 WH/BU TEW

60-16 WH/

BU TEW

SPL260

260-16 BN/WH TEW

D00

D00-1

P313

00-16 WH TEW

60-16 WH/BU TEW

26A-16 BU/YL TEW

237A-16 L

T GR/RD TEW

3.18 Console Harness Wiring

M206101AI - S2

Summary of Contents for SJ519 TH

Page 1: ...SERVICE MANUAL 216942AC October 2020 ANSI SJ519 TH TELEHANDLERS...

Page 2: ...tern Creek New South Wales 2766 Australia Tel 61 0 2 9854 0700 Fax 61 0 2 9854 0777 Skyjack Brasil Indaiatuba SP Brasil 13347 653 Tel 55 19 3936 0132 Alameda J piter 710 Loteamento American Park Empre...

Page 3: ...n 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 sit...

Page 4: ...4 SJ519 TH 216942AC Notes...

Page 5: ...nent Maintenance and Repair 11 1 3 1 Maintenance Hints 11 1 4 About this Section 12 1 4 1 Service Bulletins 12 1 4 2 Maintenance and Inspection 12 1 4 3 Maintenance Instructions 12 1 5 Scheduled Maint...

Page 6: ...ts Identification 48 3 11 Major Components Identification and Location 50 3 12 Glow Plug Harness 51 3 13 Road Lights Harness 52 3 14 Boom Lights Harness 53 3 15 Beacon Light Harness 54 3 16 Work Light...

Page 7: ...Reverse Drive 75 Section 5 Procedures 76 5 1 General 76 5 1 1 Safety and Workmanship 76 5 1 2 Engine and Transmission 76 5 2 10 Hour or Daily Routine Maintenance 77 5 2 1 Check Engine Oil Level 77 5...

Page 8: ...olts 87 5 4 8 Check Boom Wear Pad Clearances 88 5 5 1000 Hour or Annual Routine Maintenance 89 5 5 1 Change Hydraulic Oil Filter 89 5 5 2 Change Hydraulic Oil and Clean Hydraulic Tank 90 5 5 3 Change...

Page 9: ...opy 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...

Page 10: ...re completed 1 2 3 Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this telehandler All maintenance and servic...

Page 11: ...raulic oil reservoir and fill the reservoir only through the filter opening The use of cloth to strain the oil should be avoided to prevent lint from getting into the system 6 When removing any hydrau...

Page 12: ...elehandler in the following configuration Telehandler parked on a flat and level surface Engine is turned off Repair any damaged or malfunction components before operating telehandler Keep records on...

Page 13: ...If Equipped Test Boom and Attachment Functions Test Frame Leveling and Level Indicator A Operator s Cab Controls A Manual Foam filled Tires A Table 1 1 MAINTENANCE AND INSPECTION CHECKLIST Each item...

Page 14: ...are legible 1 5 2 Electrical Maintaining the electrical components is essential to good performance and service life of the telehandler Ensure proper operation of all gauges Inspect the following area...

Page 15: ...us injury 5 Foam filled Tires A Tire condition can vary significantly depending on telehandler use job site environment and preventative maintenance measures Inspect tires periodically and pay extra a...

Page 16: ...If contact occurs immediately flush with cold water and seek medical attention 1 Check battery case for damage 2 Clean battery terminals and cable ends thoroughly with a terminal cleaning tool or wire...

Page 17: ...ng areas hoses and fittings fuel pump fuel filter fuel tank Be sure to follow all local provincial territorial state and national regulations related to disposing of fluids and soiled rags cloths etc...

Page 18: ...cial territorial state and national regulations related to disposing of fluids and soiled rags cloths etc 3 Belts A Ensure belts are in good working condition and have correct tension Replace if belts...

Page 19: ...age and indicator swings freely 1 5 9 Lifting Attachment A 3 Ensure attachment is properly positioned and secured Ensure there are no loose or missing parts and there is no visible damage 1 5 10 Greas...

Page 20: ...dals A Ensure brake and accelerator pedals are secure no loose or missing parts no visible damage and movements are not obstructed 4 Manual A Check to be sure manual storage box is present and in good...

Page 21: ...r any malfunctions before the Telehandler is put into service The operator must understand and follow step by step instructions to test all Telehandler functions IMPORTANT Never use a malfunctioning T...

Page 22: ...22 SJ519 TH 216942AC Section 1 Scheduled Maintenance Function Tests...

Page 23: ...23 SJ519 TH 216942AC Section 2 Maintenance Tables...

Page 24: ...nt Tilt Steering 0 38 m3 0 50 Cu Yd 167 64 cm 66 in Bucket Loader Attachment 183 cm 6 ft Truss Boom Attachment Skid Steer Adaptor Attachment 122 cm 48 in Side Tilt Fork Carriage 122 cm 48 in Side Shif...

Page 25: ...BA Dimensions Wheelbase 245 11 cm 8 ft 0 5 in Overall width 182 88 cm 6 ft Overall height stowed 193 04 cm 6 ft 4 in Overall length stowed less forks 408 94 cm 13 ft 5 in Ground clearance 24 13 cm 9 5...

Page 26: ...ch axle differential all four wheels must have same tire size installed at all times Failure to comply with this requirement reduces the life of the differentials and reduce overall mobility of teleha...

Page 27: ...ty 0 7 L 0 74 Quart Front Central House Capacity 4 0 L 4 2 Quart Rear Central House Capacity Front Wheel Hub Capacity 0 9 0 9 L 0 95 0 95 Quart Rear Wheel Hub Capacity 0 9 0 9 L 0 95 0 95 Quart Hydrau...

Page 28: ...GP3 3500 psi System Maximum Pressure GP3 3900 psi Steering Brakes Steering Maximum GP2 2000 psi Brakes Maximum GP2 1000 psi 1721AA NOTE All pressures to be checked with engine running at idle unless...

Page 29: ...MALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R13 H03 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R17 H04 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R13 H05 FEMALE 37 JIC SWIVEL LONG 90 FEMALE 3...

Page 30: ...FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R16 H51 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H52 SHORT 45 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H53 MEDIUM 45 FEMALE 37 JIC SWIVEL...

Page 31: ...grease or uncured Loctite 1374AA Size Torque Type SAE2 SAE 5 SAE 8 Dry Lubed Dry Lubed Dry Lubed 9 16 12 ft lb 70 55 110 80 150 110 Nm 95 75 149 108 203 149 9 16 18 ft lb 80 60 120 90 170 130 Nm 108 8...

Page 32: ...78 148 111 60 45 Nm 141 106 201 150 6 8 5 1 M16 x 2 00 ft lb 161 121 230 172 68 51 Nm 218 164 312 233 7 7 5 8 M18 x 2 50 ft lb 222 167 318 238 12 9 Nm 301 226 431 323 16 12 M20 x 2 50 ft lb 314 235 4...

Page 33: ...Steel Brass Dash Frac ft lb Nm ft lb Nm Min Max Min Max Min Max Min Max 4 1 4 10 11 13 15 5 6 6 75 9 6 3 8 17 19 23 26 12 15 17 20 8 1 2 34 38 47 52 20 24 27 66 33 10 5 8 50 56 69 76 34 40 46 33 55 1...

Page 34: ...34 SJ519 TH 216942AC Notes...

Page 35: ...35 SJ519 TH 216942AC Section 3 System Component Identification and Schematics...

Page 36: ...D BATTERY FUSE GROUND CIRCUIT BREAKER VOLT METER CAPACITOR POTENTIOMETER SINGLE POLE DOUBLE THROW RELAY TRIPLE POLE DOUBLE THROW RELAY RELAY RELAY DOUBLE POLE DOUBLE THROW SINGLE POLE SINGLE THROWN TI...

Page 37: ...L ENGINE BRAKE CYLINDER CYLINDER CHECK VALVE FIXED DISPLACEMENT PUMP COUNTER BALANCE VALVE OIL COOLER VALVE COIL BI DIRECTIONAL HYDRAULIC MOTOR ORBITAL STEERING MOTOR TWO POSITION TWO WAY NORMALLY CLO...

Page 38: ...IL COOLER FAN 26DCR 9 931298 1 RELAY BRAKE 86BCR RELAY DRIVE OIL COOLER FAN 15CR 9 931298 RELAY BACKUP ALARM 57BCR 9 931298 1 RELAY STARTER INTERRUPT F1 9 156203 1 FUSE IGNITION POWER RELAY 10 A F2 9...

Page 39: ...LT SW8 1 SWITCH CAB FAN SW9 9 191455 1 SWITCH POSITIVE AIR SHUTOFF SW10 9 191455 1 SWITCH BOOM LIGHTS SW11 9 191457 1 SWITCH WORK LIGHTS SW12 9 191457 1 SWITCH TURN SIGNALS SW13 1 SWITCH CAB INTERIOR...

Page 40: ...40 SJ519 TH 216942AC Notes...

Page 41: ...JS1 9 190356 1 JOYSTICK M1 9 206918 1 DRIVE MOTOR MB1 9 206311 1 MAIN MANIFOLD MB2 9 206310 1 PILOT MANIFOLD OR1 1 ORIFICE 0 062 OR2 1 ORIFICE 0 035 OR3 1 ORIFICE 0 047 ORB1 9 205277 1 ORBITAL STEERI...

Page 42: ...RELIEF VALVE 2900 psi V12 1 SERVICE BRAKE ACTUATOR V5 1 VALVE SOLENOID 3H 26 9 224051 1 VALVE SOLENOID PARK BRAKE 3H 233 9 224051 1 VALVE SOLENOID CONT AUX FWD 3H 234 9 224051 1 VALVE SOLENOID CONT AU...

Page 43: ...t Identification and Schematics Drive Pump Port B Drive Pump Port E Drive Pump Port A Pressure Sensor Drive Pump Charge M Drive Pump Charge W Drive Pump Port F Charge Relief Port Filter Outlet Filter...

Page 44: ...44 SJ519 TH 216942AC Section 3 System Component Identification and Schematics Steer Manifold Steer Manifold A RCR Steer Manifold T FCR Steer Manifold B RCL Steer Manifold P ORBR 3 6 Steer Manifold...

Page 45: ...A Port TA Port AUX A Port CA Port LA Port LA Lift Cylinder Retract Port T Port LB Lift Cylinder Extend Port LB Port CB Port AUX B Port AUX B Port TB GP2 Port TB Extend cylinder Extend Port P GP3 Stee...

Page 46: ...stick Port JOY S to port P on Joystick Port J1 to port 1 on Joystick Port PB to port P1 on Front Axle Port PB to port P1 on Front Axle Port J4 to port 4 on Joystick Port J4 to port 4 on Joystick Port...

Page 47: ...port Aux A on Main Manifold Port Aux B to port Aux B on Main Manifold Port LA to port LA on Main Manifold Port CA to port CA on Main Manifold Port CB to port CB on Main Manifold Port LB to port LB on...

Page 48: ...m Component Identification and Schematics Pedal Ports Identification 3 9 Pedal Ports Identification Port T to Hyd Tank Port P to port CF on Main Manifold Port A to port LS on Main Manifold Port A to p...

Page 49: ...entification and Schematics P 3 T 2 1 4 Port P to port JOY S on PIlot Manifold Port 4 to port J4 on PIlot Manifold Port 3 to port J3 on PIlot Manifold Port T to Hyd Tank Port 1 to port J1 on PIlot Man...

Page 50: ...harge Filter P1 Drive Pump P1 Drive Pump MB1 Main Manifold C3 Tilt Compensation Cylinder C4 Extension Cylinder C1 Lift Cylinder C2 Fork Tilt Cylinder ORB1 Steering Control Unit V12 Service Brake Actua...

Page 51: ...8GA 11C 11 11A CABLE CONNECTION DETAIL TERM 03 RED 8GA CONNECTOR P1 SOCKET 11C RED 8GA CONNECTOR J5 PIN 1 11C RED PIN 2 11A BLACK PIN 3 11 BLACK PIN 4 PLUGGED J5 1 1 C 8 A W G P1 TO 87 TO 85 11C 8 RD...

Page 52: ...ED BACKUP RIGHT LIGHT WHITE RED HEAD LIGHT TURN SIGNAL HEAD LIGHT 6 3 1 2 5 4 6 3 1 2 5 4 AD AD AD AD 1 2 3 4 5 250 16 LT BU BK TEW 251 16 PK BU TEW 6 00 16 WH TEW 00 16 WH TEW 251B 16 PK BU TEW 250B...

Page 53: ...942AC SPL00 GND A B BOOM LIGHTS P26 A B 256 16 BU YL 256 16 BU YL 256 16 GN GY 00 16 WH 00 16 WH 00 14 WH 256 16 GN GY SPL00 P26 BOOM LIGHTS GROUND TO CONSOLE HARNESS ON CHASSIS TO CONSOLE HARNESS ON...

Page 54: ...A B C D E F G H V Z Y X W 54 SJ519 TH 216942AC BEACON OPT P37 OPT BEACON P37 5D 16 PU TEW 00 16 WH TEW 00 16 WH TEW 5D 16 PU TEW CHASSIS GND ON 1 2 BEACON LIGHT GROUND 3 15 Beacon Light Harness...

Page 55: ...AR WORKLIGHT 1 2 WORKLIGHT LEFT FRONT BACK GND ON CAB ON CAB 247 16 BN WH TEW 00 14 WH TEW 00 16 WH TEW 00 16 WH 246 16 BU YL TEW 247 16 BN WH TEW 246 16 BU YL TEW SPL00 SPL000 WORKLIGHT LEFT FRONT ON...

Page 56: ...W PLUG OVER HEAT LAMP J124 258CR 258ACR 5JCR 250ACR 251ACR BRAKE LAMP LEFT TURN RIGHT TURN TOP WIPER FRONT WIPER FNR J65 J46 J46 JOYSTICK CONNECTOR DEUTSCH DT 8 WAY SOCKET 10 FUEL LEVEL J25 J24 B U AL...

Page 57: ...CR RELAY TOP WIPER J100 87A 05L 16 PU TEW SPL05L 05L 16 PU TEW 258 16 LT YL PK TEW 208 16 DK PU TEW 208 16 DK PU TEW 208A 16 DK PU TEW 208A 16 DK PU TEW J102 00 16 WH TEW 04 10 RD YW TEW 03 10 GN PU T...

Page 58: ...ARK BRAKE RELEASE TOP CARRIAGE TILT DOWN ENABLE BOTTOM AUX CONT FLOW FWD TOP AUX CONT FLOW REV TOP AUX RIGHT ENABLE BOTTOM AUX LEFT ENABLE BOTTOM GROUND ON ENGINE COOLANT SENSOR TO PRE HEAT FUEL PUMP...

Page 59: ...82 K82 20 BK TXL K82 20 BK TXL K44 20 BK TXL K85 20 BK TXL K28 20 BK TXL K73 18 BK TXL 60 20 BK TXL K61 20 BK TXL K61 20 BK TXL A07 20 BK TXL K73 20 BK TXL K28 20 BK TXL 93 52 54 53 80 74 206 20 BK TX...

Page 60: ...PARK BRAKE RELEASE PARK BRAKE RELEASE RELAY 26A 05 D26B DIODE 26 D60 1 DIODE 61 F7 10 A 04 F3 04 5A 60A D60 DIODE 60D 77 57D 60C 60C 77CR ENGINE RUNNING 03 60 CANH CANL M N M N SW1 DISCONNECT SWITCH 2...

Page 61: ...258 259 259A 05L 05L 05L 05L 00 RIGHT REAR WORKLIGHT 247 255CR RELAY REAR WIPER 258CR RELAY FRONT WIPER 6 4 5 2 1 3 D252 1 D252 RIGHT LEFT 3 1 2 2 5JCR BRAKE LAMP RELAY L X FL1 FLASHER F13 5 A 04 05J...

Page 62: ...BK K28 18 BK K73 18 BK 60 16 BK K61 18 BK K61 18 BK A07 18 BK K73 18 BK K28 18 BK 32 2 7 4 19 5 20 24 23 27 25 26 29 28 16 33 18 35 40 37 48 D2 1 60 PIN 44 43 52 45 53 39 38 54 A19 16 BK A20 16 WH A54...

Page 63: ...5 C6 JS1 V12 PC2 STEERING CONTROL UNIT 160 CC 9 76 CIR SAE 06 SAE 04 SAE 08 SAE 08 PO CHECK 3 1 PO CHECK 3 1 PC1 SAE 08 SAE 08 SAE 06 SAE 06 SAE 06 SAE 06 SAE 04 SAE 08 SAE 08 CB3 C2 C3 SAE 08 SAE 08...

Page 64: ...troubles and deficiencies that may occur If a specific trouble is not listed isolate the major component in which the trouble occurs isolate whether the problem is electrical or hydraulic and then iso...

Page 65: ...if defective 9 Loose or broken wire 56B from relay 56ACR to fuel pump Check continuity Replace if defective 10 Defective relay 56ACR Check continuity through contacts of relay Replace if defective 11...

Page 66: ...witch SW2 pin 5 Check continuity Replace if defective 28 Defective park brake switch SW2 Check for voltage at pin 6 of switch SW2 wire 57B while in start position Replace if defective 29 Loose or brok...

Page 67: ...t Release 1 Fuse F2 open Check for defective wiring Replace fuse 2 Loose or broken 05 wire from fuse F2 to park brake switch SW2 pin 2 Check continuity Replace if defective 3 Defective park brake swit...

Page 68: ...Check continuity Replace if defective 6 Defective relay 26DCR Check continuity through contacts of relay pin 30 to 87 with coil energized Replace if defective 7 Loose or broken 26E wire from 26DCR rel...

Page 69: ...shifter pin 4 to shift controller pin 36 Check continuity Replace if defective 2 Loose or broken wire 15 from shift controller pin 36 to 4H 15 reverse solenoid Check continuity Replace if defective 3...

Page 70: ...To Carriage Tilt Up Down With Carriage Tilt Switch SW6 Depressed 5 Fuse F4 open Check for defective wiring Replace fuse 6 Loose or broken wire 05C to joystick connector pin 2 and or frame level enabl...

Page 71: ...ve Check operation of valve Repair or replace valve as required 2 Stuck or defective lift valve V4 Clean valve Check operation of valve Repair or replace valve as required 3 Stuck or defective lift co...

Page 72: ...e as necessary Replace cylinder if defective 4 3 6 No Telescope Retract 1 Stuck or defective joystick JS1 Clean valve Check operation of valve Repair or replace valve as required 2 Stuck or defective...

Page 73: ...e valve as required 6 Defective carriage tilt cylinder C2 Check seals on cylinder Replace as necessary Replace cylinder if defective 7 Defective tilt compensation cylinder C3 Check seals on cylinder R...

Page 74: ...ve park brake C11 Repair or replace as necessary 2 Park brake valve SV3 stuck in shifted position Check valve Replace if defective 4 3 13 Service Brake Will Not Engage 1 Service brake actuator stuck o...

Page 75: ...for drive pump set up procedures Adjust repair or replace as required 3 Worn or defective drive motor M1 Check motor Replace if defective 4 3 16 No Reverse Drive 1 Defective pump displacement control...

Page 76: ...Transmission The engine used on the SJ519 TH telehandler models is a Deutz TCD 2 2L Tier 4 Final Engine service information can be found in the Deutz Engine Manuals It should be noted that engine war...

Page 77: ...e oil level must be between the Full and Low marks 6 If oil level is below the Low mark refer to 5 4 4 Replace Engine Oil and Filter for engine oil and filter replacement procedure 5 2 2 Check Coolant...

Page 78: ...rs are equipped with a two stage air filter system which consists of a primary filter element a secondary safety element Inspect the condition of both the primary and safety elements IMPORTANT The pri...

Page 79: ...r hydraulic oil specifications 5 2 5 Drain Fuel Water Separator WARNING Diesel fuel is flammable and may cause death or serious injury Shut down engine and do not smoke while draining fuel water separ...

Page 80: ...e removing the wheel from the telehandler Wheel Nuts Tire Axle Figure 07 Telehandler Wheel 5 Check tire tread for damage Check for bent or damaged rims and loose or missing hardware 6 Tighten and torq...

Page 81: ...rease fittings are located beside the tilt compensation cylinder See figure above 1 Wipe dirt and grease from each remote grease fitting 2 Remove cap and apply 4 shots of grease to each fitting Axle K...

Page 82: ...gain access to front bottom wear pads 4 Shut down the engine and dismount from cab 5 With boom fully extended smear grease along the path of front wear pads Front Wear Pads Grease Points Figure 14 Fr...

Page 83: ...Axle Differential Planetary wheel Ends WARNING 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...

Page 84: ...ce Engine Oil and 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 e...

Page 85: ...11 Screw on new filter by hand until the gasket is touching then tighten to a torque of 7 9 ft lb 10 12 Nm 12 Clean up any oil that may have spilled during this procedure 13 Refill engine with new oi...

Page 86: ...he drain plug assembly from bottom of water separator 8 Unscrew used fuel filter and separator Discard used filter and separator and any captured spilled fuel Fuel Filter Water Separator Water Level S...

Page 87: ...Close engine cover back and latch it in place 5 4 6 Clean Hydraulic Tank Breather 1 Clean area around hydraulic breather Do not allow dirt to enter the hydraulic tank Hydraulic Tank Breather Figure 2...

Page 88: ...s on a level surface 3 Apply park brake then shutdown the engine and remove key from ignition switch 4 Measure the clearance between the bottom surfaces of the inner boom and the wear pads Bottom Wear...

Page 89: ...he front of the boom 17 If clearances are within 0 08 in 2 mm install the rear boom cover NOTE If any of the clearances are greater than 0 08 in 2 mm shim adjustment or replacement of the slide pads m...

Page 90: ...sition 3 Apply parking brake and shutdown the engine 4 Place a container under the hydraulic oil tank capable of holding approximately 45 gallons 170 Litres 5 Remove hydraulic tank drain plug from und...

Page 91: ...ake shut off the machine and allow it to sit for two minutes 3 Place a container capable of holding approximately 10 quarts 9 5 liters under axle drain plugs 4 Clean the areas around the three 3 drain...

Page 92: ...y Gear Oil 8 Clean the level fill plug and install it in the planetary 9 Repeat procedure for the remaining three planetary ends 5 5 5 Change Engine Coolant WARNING Always shut off the engine and allo...

Page 93: ...ixture as required Refill until coolant is visible 9 Tighten radiator cap start the engine and check for leaks 5 6 Non Routine Maintenance 5 6 1 Wear Pads Replacement Procedure Wear pads are designed...

Page 94: ...e wear pads and the outer boom 7 Remove the screws shims and wear pads For easier installation keep all parts removed together as an assembly Install Wear Pads NOTE To keep the boom section centered m...

Page 95: ...utton 1 Figure 34 Engine Data Display Module If a new error message is received the display will beep and a flashing popup window will open with the latest error messages and details STOP Figure 35 Er...

Page 96: ...y replace them check connection cable and if necessary repair or replace it 523354 12 Internal hardware monitoring the ECU detects an error of its injector high current output If error is not removabl...

Page 97: ...ace it if error is not removable change ECU 168 0 1 2 3 or 4 Battery voltage the voltage measured by ECU is out of the target range either too high too low or eratic Check alternator contact resistanc...

Page 98: ...19 J1939 Network 1 Engine Comm Data Error Loss of communication with engine ecu for greater than 500ms Canbus wiring ecu power 8 741 3 Transmission Forward Solenoid Voltage Above Normal Measured volt...

Page 99: ...Normal Sensor supply voltage greater than expected Wiring problem short to power 23 1709 4 Transmission Controller Power Relay Voltage Below Normal Sensor supply voltage less than expected Wiring prob...

Page 100: ...achine Front 3 With engine running at low idle dead head the boom retract function Indicated system pressure should be 3900 psi 4 If reading is different than what is mentioned above adjustment is req...

Page 101: ...low idle and steering dead headed in either direction read the pressure indicated on the gauge The correct pressure should be 2 000 psi 4 If reading is other than 2 000 psi adjust the orbit motor Stee...

Page 102: ...e nominal maximum value IMPORTANT There is no adjustment Replace the brake valve at the service brake pedal Pilot Pressure Pilot Pressure Check 1 Release residual pressure by moving the joystick sever...

Page 103: ...engine running at low idle turn the adjustment screw clockwise CW to increase the pressure reading and counter clockwise CCW to reduce the pressure reading until desired reading is achieved 3 Tighten...

Page 104: ...ort RV3 on the Main Manifold 2 With engine running at low idle turn the adjustment screw clockwise CW to increase the pressure reading and counter clockwise CCW to reduce the pressure reading until de...

Page 105: ...ly extend and retract boom several times with boom level Bleed Boom Raise Lower Circuit Fully raise and lower the boom several times Ensure carriage remains ahead of the front tires Bleed Frame Level...

Page 106: ...elow 2 Insert a 4 5 mm feeler gauge into the drain port 3 Use the gauge to check the gap between the disks A The minimum distance allowed is 4 5 mm Reinstall the oil level plug A 4 Repeat the inspecti...

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