Skyjack SJ519 TH Service Manual
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Skyjack SJ519 TH Service Manual

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SERVICE
MANUAL
SJ519 TH
TELEHANDLERS
216942AC
October 2020
ANSI

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Summary of Contents for Skyjack SJ519 TH

  • Page 1 SERVICE MANUAL SJ519 TH TELEHANDLERS 216942AC October 2020 ANSI...
  • Page 2 This manual is based on Serial Number(s): SJ519 TH: 87 500 000 to 87 599 999 Please refer to the website (www.skyjack.com) for other Serial Numbers, most recent Technical Manuals and USB software. Skyjack Service Center Parts & Service (Europe) 3451 Swenson Ave.
  • Page 3 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. SJ519 TH 216942AC...
  • Page 4 Notes 216942AC SJ519 TH...

  • Page 5: Table Of Contents

    Tire/Wheel Specifications ............26 SJ519 TH...
  • Page 6 4.2-10 No Crab Steer Mode ............70 216942AC SJ519 TH...
  • Page 7 Check Lug Nut Torque ............83 SJ519 TH...
  • Page 8 Brake Inspection ............. . 106 216942AC SJ519 TH...

  • Page 9: Section 1 - Scheduled Maintenance

    SKYJACK dealer at no charge for parts or labor. In addition, all products have a 5 year structural 1.1-1 Telehandler Definition warranty.

  • Page 10: Maintenance And Inspection Schedule

    Before attempting any repair work, disconnect the approved capacity charts. main power conenctors. Consult SKYJACK’s Service Department for optional Keep personnel clear of components, systems or tires specifications and installation. unsupported loads that may move unexpectedly during maintenance procedures.

  • Page 11: Hydraulic System & Component Maintenance And Repair

    The use of cloth to strain the oil should be avoided to prevent lint from getting into the system. 6. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also, plug the ports of the removed components. SJ519 TH 216942AC...

  • Page 12: About This Section

    Telehandler parked on a flat and level surface ▪ Legend Engine is turned off. ▪ Pass Repair any damaged or malfunction ▪ Fail components before operating telehandler. Keep records on all inspections. ▪ Repaired Not applicable 216942AC SJ519 TH...
  • Page 13 Hourmeter Reading: Operator's Name (Printed): Date: Time: Operator's Signature: Each item shall be inspected using the appropriate section of the Skyjack operating manual. As each item is inspected, write the appropriate grade in the box. INSPECTION FREQUENCY Inspection Schedule ...

  • Page 14: Scheduled Maintenance Inspections

    Ensure all cylinders are properly secured and there is legible. no evidence of leakage. Grease weekly and check pins and bushings to ensure there is no evidence of damage. 216942AC SJ519 TH...

  • Page 15: Mirrors - A

    Failure to operate with matched, approved Air-filled Tires - tires in good condition can result in death or serious injury. Replace tires with exact, Skyjack- To safeguard maximum stability, achieve optimum approved types only. telehandler handling and minimize tire wear, it...
  • Page 16 13 mm (1/2 in) of solution, add distilled or demineralized water. 5. Replace battery if damaged or incapable of holding a lasting charge. WARNING Use original or manufacturer-approved parts and components for the telehandler. 216942AC SJ519 TH...
  • Page 17 ▪ 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. SJ519 TH 216942AC...

  • Page 18: Engine Compartment

    Belts - Ensure belts are in good working condition ▪ and have correct tension. Replace if belts are cracked, frayed, or have chunks of material missing. Refer to service manual for proper replacement procedure. 216942AC SJ519 TH...

  • Page 19: Boom - A

    Refer to the Daily & Weekly Maintenance Chart located inside operator’s cab for grease points 1.5-9 Lifting Attachment location and service intervals. Ensure attachment is properly positioned and secured. Ensure there are no loose or missing parts and ▪ there is no visible damage. SJ519 TH 216942AC...

  • Page 20: 11 Operator's Cab

    Ensure a copy of operating manual, and other ▪ important documentation are enclosed in manual storage box. Ensure manual is legible and in good ▪ condition. Always return manual to the manual storage ▪ box after use. 216942AC SJ519 TH...

  • Page 21: 12 Operator's Cab Controls

    Do not operate the telehandler if capacity charts which tests to perform, as well as how to are missing or not legible. properly and successfully perform them. NOTE All-function motion alarm should sound while operating any boom and drive function SJ519 TH 216942AC...
  • Page 22 Section 1 – Scheduled Maintenance Function Tests 216942AC SJ519 TH...

  • Page 23: Section 2 - Maintenance Tables

    Section 2 – Maintenance Tables SJ519 TH 216942AC...

  • Page 24: Standard And Optional Equipment

    Section 2 – Maintenance Tables Standard and Optional Equipment Table 2.1 Standard and Optional Equipment MODEL SJ519 TH Standerd Equipment 122 cm (48 in) Standard Carriage Air Filled Tires Diesel Engine Four-wheel drive Lifting Hook Open Operator's Cab Operator horn...

  • Page 25: Specifications And Features

    Table 2.2 Specifications and Features MODEL SJ519 TH Standard Engine Type Deutz TCD 2.2 L T4 Cylinders Horsepower @ 2600 RPM 74 HP Capacity 2.2 L Torque @ 1600 RPM 280 N•m (206.5 lbf•ft) Idle Speed* 1200 rpm Fuel type...

  • Page 26: Tire/Wheel Specifications

    Table 2.3 Tire/Wheel Specifications Model SJ519 TH "Wheel "Ply FILL Size Pressure Nuts Rating" Torque" 552 Kpa (80 psi) FOAM NON MARKING BLACKSTONE OTR 552 Kpa (80 psi) 26.7 cm x 44.5 cm (12.00 in x 16.5 in) NON MARKIING "...

  • Page 27: Recommended Fluids/Lubrications

    Doing so can severely damage hydraulic components. A full hydraulic oil system flush must be performed prior to adding a new type of hydraulic oil. Consult Skyjack service department. SJ519 TH 216942AC...

  • Page 28: Pressure Setting

    Table 2.5 Pressure Setting Model SJ519 TH System Component Test Port Pressure Valve Pilot Oil Pressure Item Tilt Comp./ Carriage Tilt Port Relief 3500 psi System Maximum Pressure 3900 psi Steering & Brakes Steering Maximum 2000 psi Brakes Maximum 1000 psi...

  • Page 29: Standard Hose Numbering System

    NO FITTING NO FITTING 300 PSI REUSABLE, FEMALE, 37° JIC, SWIVEL NO FITTING 300 PSI LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R13 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R4 SJ519 TH 216942AC...
  • Page 30 FEMALE, 37° JIC, SWIVEL 100R19 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19 LONG 90°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R15 216942AC SJ519 TH...

  • Page 31: Torque Specifications For Fasteners (Us)

    1460 3160 2360 1 1/2-6 ft-lb 1180 2630 1979 4284 3200 1/2-20 ft-lb 2200 1640 3560 2660 1 1/2-12 1329 2983 2224 4827 3606 NOTE: Lubed includes lubricants such as lubrizing, oil, grease, or uncured Loctite. 1374AA SJ519 TH 216942AC...

  • Page 32: Torque Specifications For Fasteners (Metric)

    1468 1101 2101 1576 M33 x 3.50 1990 1493 2849 2137 ft-lb 1886 1415 2699 2024 M36 x 4.00 2557 1918 3659 2744 NOTE: Lubed includes lubricants such as lubrizing, oil, grease, or uncured Loctite. 1375AA 216942AC SJ519 TH...

  • Page 33: Torque Specifications For Hydraulic Couplings & Hoses

    Min. Max. Min. Max. Min. Max. Min. Max. 1/4" 6.75 1/4" 3/8" 3/8" 1/2" 27.66 1/2" 5/8" 46.33 5/8" 3/4" 72.33 3/4" 1" 100.5 1" 1 1/4" 101.5 1 1/4" 1 1/2 1 1/2 2" 2" 1276AA SJ519 TH 216942AC...
  • Page 34 Notes 216942AC SJ519 TH...

  • Page 35: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJ519 TH 216942AC...

  • Page 36: Electrical Symbol Chart

    TILT SWITCH TRANSISTOR SINGLE POLE VACUUM POTENTIOMETER SINGLE THROWN LEVEL SENSOR SWITCH RELAY DOUBLE POLE TEMPERATURE SINGLE POLE DOUBLE POLE DOUBLE THROW SWITCH DOUBLE THROW SINGLE THROW RELAY RELAY RELAY TRIPLE POLE RHEOSTAT DIODE DOUBLE THROW RELAY 216942AC SJ519 TH...

  • Page 37: Hydraulic Symbol Chart

    TWO WAY DISPLACEMENT CLOSED CENTER NORMALLY HYDRAULIC MOTOR OPEN PORT CLOSED VALVE THREE POSITION BI DIRECTIONAL FOUR WAY DYNAMIC SIGNAL HYDRAULIC CLOSED CENTER PRIORITY VALVE MOTOR CLOSED PORT ORBITAL STATIC SIGNAL STEERING PRESSURE TRANSDUCER PRIORITY VALVE MOTOR SJ519 TH 216942AC...

  • Page 38: Electrical Schematic Parts List

    FUSE, BLOWER - 30 A 9-156202 FUSE, FAN/INT. LIGHT 5 A 9-156203 FUSE, HEATER VALVE, A/C - 10 A 9-156164 FUSE, ECM - 30 A 9-121504 FUSE,FUEL PUMP 9-165031 FUSE, GLOW PLUG 9-206096 FUSE, HFX12M 9-121504 LOAD PWR + 216942AC SJ519 TH...
  • Page 39 SW17 9-191491 SWITCH, BLOWER SW18 9-191491 SWITCH, AIR CONDITIONING SW19 9-191457 SWITCH, ROAD LIGHTS SW20 SW21 SW22 SW23 9-191455 SWITCH, HAZARD LIGHTS SW24 SWITCH, WASHER/WIPER SW25 9-191457 SWITCH, CONTINUOUS FLOW FORWARD/REVERSE SW26 9-206757 SWITCH, LOCK/UNLOCK QUICK COUPLER SJ519 TH 216942AC...
  • Page 40 Notes 216942AC SJ519 TH...

  • Page 41: Hydraulic Schematic Parts List

    RELIEF VALVE 3500 psi RELIEF VALVE 348 psi RELIEF VALVE 6500 psi RELIEF VALVE 6500 psi RELIEF VALVE 7000 psi RV10 RELIEF VALVE 7000 psi RV11 RELIEF VALVE 600 psi RV12 RELIEF VALVE 600 psi RV14 RELIEF VALVE 2000 psi SJ519 TH 216942AC...
  • Page 42 VALVE, SOLENOID - CONT AUX FWD 3H-234 9-224051 VALVE, SOLENOID - CONT AUX REV 4H-47 9-224052 VALVE, SOLENOID - CARRIAGE UP 4H-47-1 9-224052 VALVE, SOLENOID - CARRIAGE DOWN 4H-237A 9-224052 VALVE, SOLENOID - AUX LEFT 4H-237A-1 9-224052 VALVE, SOLENOID - AUX RIGHT 216942AC SJ519 TH...

  • Page 43: Hydraulic Pump And Return Filter Ports Identification

    Port B Drive Pump Hydrostat (H) Drive Pump Port A Drive Pump Port E Filter Outlet Charge Relief Port Pressure Drive Pump Sensor Port F Filter Inlet Return Filter Drive Pump Drive Pump Charge (W) Charge (M) SJ519 TH 216942AC...

  • Page 44: Steer Manifold

    Section 3 – System Component Identification and Schematics Steer Manifold 3.6 Steer Manifold Steer Manifold A (RCR) Steer Manifold P (ORBR) Steer Manifold T (FCR) Steer Manifold B (RCL) 216942AC SJ519 TH...

  • Page 45: Main Manifold

    Port CA Port CB Port LB Fork Tilt Cylinder Fork Tilt Cylinder Port CA Retract Extend Tilt Comp Cylinder Retract Port LA Port CB Lift Cylinder Port LB Tilt Comp Cylinder Retract Lift Cylinder Extend Extend Port T SJ519 TH 216942AC...

  • Page 46: Pilot Manifold

    Port JOY-S to port P on Joystick Port MOTOR to port E Port CON-F to port P Port CHARGE to port on Drive MOTOR on Aux Valve M on Drive pump Port RRP to port RRP on Aux Valve 216942AC SJ519 TH...
  • Page 47 Aux B on Main Manifold Port CB to port CB on Main Manifold Port LB to port LB on Main Manifold Port LA to port LA Port CA to port CA on Main Manifold on Main Manifold SJ519 TH 216942AC...

  • Page 48: Pedal Ports Identification

    Pedal Ports Identification 3.9 Pedal Ports Identification Pressure Sensor Port P to port CF on Port A to port LS on Port A to port P2 on Port T to Hyd Tank Main Manifold Main Manifold Front Axle 216942AC SJ519 TH...
  • Page 49 Port P to port JOY-S Port 1 to port J1 on on PIlot Manifold PIlot Manifold Port 4 to port J4 on Port 3 to port J3 on Port T to Hyd Tank PIlot Manifold PIlot Manifold SJ519 TH 216942AC...

  • Page 50: Major Components Identification And Location

    Extension Cylinder Return Filter Lift Cylinder Drive Pump Fork Tilt Cylinder ORB1 Steering Hydraulic Control Unit Motor Pilot Manifold Front Steer Service Brake Drive Pump Charge Pump Charge Filter Cylinder Actuator (Pedal) Joystick TH-065 Major components 519 TH 216942AC SJ519 TH...

  • Page 51: Glow Plug Harness

    TERM 87 - 11C (8GA) CONNECTOR P1 SOCKET - 11C RED (8GA) 11-18 BK 11-18 BK TO 86 11A-18 BK 11A-18 BK TO 85 11C-18 RD 11C-8 RD 11C-8 RD TO 87 11B-8 RD 11B-8 RD TO 30 SJ519 TH 216942AC...

  • Page 52: Road Lights Harness

    BRAKE SPL 261 250B-16-LT BU/BK-TEW SPL 250 250-16-LT BU/BK-TEW SPL 251 251-16-PK/BU-TEW TO CONSOLE 00-16-WH-TEW WHITE SPL 251B HARNESS 251B-16-PK/BU-TEW LEFT SPL 250B 250B-16-LT BU/BK -TEW BACKUP LIGHT 15-16-BU-TEW 15-16-BU-TEW SPL 271 271-16-BU/YL-TEW SPL15 271A-16-BU/YL-TEW SPL 271A 216942AC SJ519 TH...

  • Page 53: Boom Lights Harness

    3.14 Boom Lights Harness GROUND. SPL00 TO CONSOLE HARNESS ON BOOM LIGHTS CHASSIS 00-16 WH 256-16 GN/GY BOOM LIGHTS SPL00 00-14 WH 00-16 WH GND. 256-16 BU/YL 256-16 BU/YL 256-16 GN/GY TO CONSOLE HARNESS ON CHASSIS SJ519 TH 216942AC...

  • Page 54: Beacon Light Harness

    3.15 Beacon Light Harness GROUND BEACON BEACON LIGHT OPT. GND ON CHASSIS 00-16 WH-TEW 5D-16 PU-TEW 5D-16 PU-TEW BEACON (OPT) 216942AC SJ519 TH...

  • Page 55: Work Lights Harness

    ON CAB TO CONSOLE HARNESS LEFT REAR SPL000 WORKLIGHT ON CAB LEFT FRONT WORKLIGHT ON CAB TO CONSOLE HARNESS 00-14 WH-TEW BACK GND. SPL00 246-16 BU/YL-TEW 247-16 BN/WH-TEW 247-16 BN/WH-TEW LEFT REAR WORKLIGHT 00-16 WH ON CAB SJ519 TH 216942AC...

  • Page 56: Console Harness

    259-16 LT YW/PE 271A-16 BE/YW 253-16 RD/GY P305 251B-16 PK/BL 271-16 BE/YW 15-16 BE 250B-16 LT BL/BK 218-16 DK BU/GN P306 00-16 WH 51-16 BU/GN HORN 00-16 WH PS1 PRESSURE SWITCH 3.17 Console Harness M206101AH - S1 SJ519 TH 216942AC...

  • Page 57: Console Harness Wiring

    PARK BRAKE POSITIVE ENGINE 86CR 245ACR 237CR 272CR 57D CR ENABLE RELAY RELEASE SHUTOFF (OPT) RUNNING CHASSIS D245B D60-1 224CR 403ACR 26FCR 250ACR 251ACR 57C CR 05CR 77CR D252 D252-1 3.18 Console Harness Wiring M206101AI - S2 SJ519 TH 216942AC...

  • Page 58: Engine Harness

    P311 PARK BRAKE CARRIAGE TILT RELEASE DOWN ENABLE (TOP) (BOTTOM) PUMP SENSOR N P310 J199 DRIVE MOTOR TO HYDRAULIC PUMP SENSOR CARRIAGE TILT UP ENABLE (BOTTOM) P128 P129 FUEL PUMP RELAY P198 DRC26-40SA HFX12M 3.19 Engine Harness SJ519 TH 216942AC...

  • Page 59: Engine Harness Wiring

    TO PUMP TO WATER TO PUMP TO PRE-HEAT DEUTSCH Inc. -DRC26 - 40 SA P/N : 460-010-20141 for 16-18 AWG FUEL PUMP RELAY PRESSURE PRESSURE SENSOR SENSOR SENSOR N SENSOR P P198 TO HFX12m 3.20 Engine Harness Wiring SJ519 TH 216942AC...

  • Page 60: Electrical Schematic

    3.21 Electrical Schematic 3.21 Electrical Schematic M205230AC - S1 SJ519 TH 216942AC...
  • Page 61 3.21 Electrical Schematic 3.21 Electrical Schematic M205230AC - S2 SJ519 TH 216942AC...
  • Page 62 A38-18 RD A53-18 RD A52-18 BK A37-18 WH A48-16 BK A18-16 WH A33-16 BK A16-16 WH A05-16 BK A04-16 WH A32-16 BK A02-16 WH B+-12 RD 00-12 WH 00-12 WH BA+-12 RD 3.21 Electrical Schematic M205230AC - S3 SJ519 TH 216942AC...

  • Page 63: Hydraulic Schematic

    (20.6 GPM @ 2600 RPM) SAE 04 PRESSURE DRIVE PUMP CHARGE PUMP RELIEF (64 CC/ 3.88 CIR) (17.4 CC/1.06 CIR) (42 GPM@2600 RPM) (12 GPM@2600 RPM) SAE 06 SERVICE BRAKE ACTUATOR 0-900 psi TANK ASM, HYDRAULIC 3.22 Hydraulic Schematic M205220AB SJ519 TH 216942AC...

  • Page 64: Section 4 - Troubleshooting Information

    “probable cause.” The information in the right-hand column, in bold text, represents the “remedy” to the “probable cause” directly beside it. See the example below for clarification. 1. Probable cause Remedy SJ519 TH 216942AC...

  • Page 65: Electrical System

    17. Loose or broken 03 wire from B+ to fuse F1 Check continuity. Replace if defective Check for defective wiring. Replace/repair if 18. Fuse F1 open defective. Replace fuse 19. Loose or broken 03A wire from fuse F1 to ignition Check continuity. Replace if defective switch SW1 SJ519 TH 216942AC...
  • Page 66 37. Loose or broken 05 wire from fuse F2 to shifter pin Check continuity. Replace if defective 38. Loose or broken 57B wire from park brake switch Check continuity. Replace if defective SW2, pin 6 to transmission shift lever pin 5 216942AC SJ519 TH...

  • Page 67: Engine Cranks But Will Not Run

    8. Defective relay 05CR to 87 with coil energized). Replace if defective 9. Loose or broken 26A wire from park brake release relay 05CR pin 87 to chassis harness connector Check continuity. Replace if defective J31 pin 13 SJ519 TH 216942AC...

  • Page 68: Forward Or Reverse Will Not Engage

    Check continuity. Replace if defective controller pins 9, 10, and/or 19 16. Loose or broken 00 wire from drive controller pins Check continuity. Replace if defective 7, 18, 28, and/or 29 17. Defective drive controller Replace if defective 216942AC SJ519 TH...

  • Page 69: No Forward Drive

    2 4.2-8 Front Steer Mode Only 1. Loose or broken 05B wire from fuse F3 to steer Check continuity. Replace if defective mode select switch SW4 pin 2 2. Defective Steer mode switch SW4 Replace if Defective SJ519 TH 216942AC...

  • Page 70: No 4W (Round) Steer Mode

    11. Loose or broken wire 00 from carriage tilt enable Check continuity. Replace if defective up and/or down solenoids 4H-47 and/or 4H-47-1 12. Carriage tilt up enable solenoid 4H-47 and/ or carriage tilt down enable solenoid 4H-47-1 Replace if defective defective 216942AC SJ519 TH...

  • Page 71: Hydraulic System

    Clean valve. Check operation of valve. Repair or 2. Stuck or defective lift valve V4 replace valve as required Clean valve. Check O-rings on valve. Repair or 3. Stuck or defective lift counterbalance valves CB2 replace valve as required SJ519 TH 216942AC...

  • Page 72: No Telescope Extend

    2. 4H-47 stuck or defective replace valve as required Clean valve. Check operation of valve. Repair or 3. Stuck or defective carriage tilt valve V3 replace valve as required 4. RV5 misadjusted or defective Adjust pressure, replace if defective 216942AC SJ519 TH...

  • Page 73: No Carriage Tilt Down

    2. Stuck or defective shuttle valve SV1 Clean valve. Repair or replace valve as required Check O-rings and clean valve. Repair or replace 3. Stuck or defective steering motor OSM1 orbit motor as required SJ519 TH 216942AC...

  • Page 74: 11 Park Brake Will Not Release

    Check motor. Replace if defective Check brake pedal is returning to up (off) position. 4. Service brake V12 not releasing Clean, repair or replace valve as required 5. Park brake not releasing See “park brake will not release” in this section 216942AC SJ519 TH...

  • Page 75: 15 No Forward Drive

    2. Defective or misadjusted drive relief valves RV12, See section 5 for drive pump set up procedures. RV8, or RV10 Adjust, repair, or replace as required 3. Worn or defective drive motor M1 Check motor. Replace if defective SJ519 TH 216942AC...

  • Page 76: Section 5 - Procedures

    Section 5 – Procedures 5.1 General 5.1-2 Engine and Transmission The engine used on the SJ519 TH telehandler models The following information is provided to assist you in is a Deutz TCD 2.2L Tier 4 Final. the use and application of servicing and maintenance Engine service information can be found in the procedures contained in this chapter.

  • Page 77: Hour Or Daily Routine Maintenance

    3. Run the engine for 25 minutes without radiator cap to achieve operating temperature. Shut down the engine. 4. Check coolant level in the radiator. Refill untilcoolant is visible. nstallInstall radiator cap. 5. I SJ519 TH 216942AC...

  • Page 78: Check Air Cleaner Restriction And Filter Elements

    10 Hour or Daily Routine Maintenance 5.2-3 Check Air Cleaner Restriction and NOTE Filter Elements SJ519 TH telehandlers 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.

  • Page 79: Check Hydraulic Oil Level

    5.2-7 Check Parking Brake 2. Add clean hydraulic oil through the tank filler 1. Check the park brake operation daily or every 10 as required. Refer to 2.4 Recommended Fluids/ hours of service. Lubrications for hydraulic oil specifications. SJ519 TH 216942AC...

  • Page 80: Check Tire Pressure And Condition

    6. Tighten and torque wheel nuts. 5.2-9 Check Seat Belt and Mounting Hardware 1. Check seat belt for wear or damage. Check that mounting hardware is tight. Figure 09 Windshield Washer Fluid. 216942AC SJ519 TH...

  • Page 81: Hour Or Weekly Routine Maintenance

    2. Apply 4 shots of grease to each fitting. See figure the tilt compensation cylinder. See figure above. below. 1. Wipe dirt and grease from each remote grease fitting. 2. Remove cap and apply 4 shots of grease to each fitting. Figure 12 Drive Shaft Grease Points SJ519 TH 216942AC...

  • Page 82: Check Fork Pins

    3. Fully extend the boom to 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 Front Wear Pads 216942AC SJ519 TH...

  • Page 83: Hour Or Quarterly Routine Maintenance

    4. Check oil level at the bottom of the fill hole. If required, add oil. NOTE Refer to 2.4 Recommended Fluids/Lubrications this manual for oil type and capacity. 5. Re-install plug and repeat steps above for the three (3) remaining planetary wheel ends. SJ519 TH 216942AC...

  • Page 84: Check Oil Level In Axle Differentials

    2.4 Recommended Fluids/Lubrications 5. Place a container capable of holding this manual for oil type and capacity. approximately 7 quarts (7.4 litres) under engine oil drain plug. 5. Re-install plug and repeat steps above for the other axle. 216942AC SJ519 TH...
  • Page 85 7-9 ft.-lb. (10- secure in place. 12 Nm). 12. Clean up any oil that may have spilled during this NOTE procedure. Refer to your local/national regulations on how to dispose of used filter and oil. SJ519 TH 216942AC...

  • Page 86: Change Engine Fuel Filter And Fuel/Water Separator

    8. Unscrew used fuel filter and separator. Discard used filter and separator and any captured spilled fuel. Fuel Filter/ Water Separator Figure 22 Priming the Fuel System Water Level Sensor Fuel Filter Water Harness Drain Plug Figure 21 Fuel Filter & Water Separator 216942AC SJ519 TH...

  • Page 87: Clean Hydraulic Tank Breather

    See figure below. Figure 24 Axle Mounting Bolts 1. Torque front axle mounting bolts to 320 ft·lb. (434 N·m.). 2. Torque rear axle mounting bolts to 320 ft·lb (434 N·m.). SJ519 TH 216942AC...

  • Page 88: Check Boom Wear Pad Clearances

    6. Start the engine and raise the boom off the level surface ensuring there is no upward force applied to the boom. 7. With park brake applied, shut down engine and remove key from ignition switch. Figure 27 Rear Upper and Side Slide Pads 216942AC SJ519 TH...

  • Page 89: 1000 Hour Or Annual Routine Maintenance

    If any of the clearances are greater than 0.08 in. (2 mm), shim adjustment or replacement of the slide pads may be required. Figure 28 Hydraulic Oil Filter Location NOTE Refer to your local/national regulations on how to dispose of used hydraulic oil filter. SJ519 TH 216942AC...

  • Page 90: Change Hydraulic Oil And Clean Hydraulic Tank

    NOTE Follow shop practice standards for flushing and cleaning of hydraulic oil tank. Drain Plug 10. Install drain plug back into tank. Replace O-ring seal if needed. Figure 29 Hydraulic Tank Drain Plug 216942AC SJ519 TH...

  • Page 91: Change Axle Differential Oil

    2. Park the telehandler on a firm level surface with the level/fill/drain plug at the 6 o’clock position. 3. Shut down the engine, apply parking brake, and allow it to sit for a minimum of two minutes. SJ519 TH 216942AC...

  • Page 92: Change Engine Coolant

    2. Place a container capable of holding 5 gallons (17 liters) under the radiator drain plug. 3. Open the drain plug and allow radiator and coolant bottle to drain. NOTE Refer to your local/national regulations on how to dispose of used coolant fluid. 216942AC SJ519 TH...

  • Page 93: Non-Routine Maintenance

    85° to 90° without radiator cap. Shut down the engine. 8. Check coolant level and coolant strength in the radiator. Adjust mixture as required. Refill until coolant is visible. 9. Tighten radiator cap, start the engine, and check for leaks. SJ519 TH 216942AC...
  • Page 94 4. Start the engine and raise the carriage from the For easier installation, keep all parts removed floor. together as an assembly. 5. Install the bottom wear pad assemblies. 6. Apply blue loctite red and tighten the screws to 37 ft-lb. 216942AC SJ519 TH...

  • Page 95: Display Fault Codes

    Button 1 recommended action to take. 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. SJ519 TH 216942AC...
  • Page 96 Check wiring, sensor defect, check sensor and if necessary replace it, check connection cable and if 0, 1, 3, or 4 ECU is out of the target range; either high or low. necessary repair or replace it 307A-1 216942AC SJ519 TH...
  • Page 97 Missing CAN message of EGR throttle valve check CAN functional range, check actuator Check CAN Bus wiring (Bus scheduling, polarity, short circuit, power interrupt), test protocol of receiver, 524109 Missing CAN message of EGR throttle valve check CAN functional range, check actuator 307A-2 SJ519 TH 216942AC...
  • Page 98 Above Normal Transmission Reverse Wiring problem, Pressure Sensor Voltage Measured voltage is less than expected faulty sensor Below Normal Transmission Hydraulic System Feedback Er- Contamination, me- Pump swash traveling the wrong direction ractic, Intermittent, Or chanical failure Incorrect 216942AC SJ519 TH...
  • Page 99 Normal Accelerator Pedal Position Measured voltage is greater than ex- Wiring problem, faulty 1 Voltage Above Normal pected sensor Accelerator Pedal Position Wiring problem, faulty Measured voltage is less than expected 1 Voltage Below Normal sensor SJ519 TH 216942AC...

  • Page 100: Hydraulic Pressure Test Procedure

    GP3 Test Port 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 required. 216942AC SJ519 TH...
  • Page 101 3. With engine running at low idle and steering pressure is maintained. 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. SJ519 TH 216942AC...
  • Page 102 If damaged NOTE then the complete valve must be replaced The pressure setting value is the nominal maximum value. IMPORTANT There is no adjustment. Replace the brake valve at the service brake pedal. 216942AC SJ519 TH...
  • Page 103 2. With engine running at low idle, dead-head in pressure is maintained. both directions the fork tilt function. Indicated system pressure should be 3,500 psi for both directions. Port RV4 3. If reading is different than 3,500 psi, adjustment is required. Port RV5 SJ519 TH 216942AC...
  • Page 104 2. With engine running at low idle, dead-head in both directions the auxiliary hydraulics functions. Port RV2 Indicated system pressure should be 3000 psi for both directions. 3. If reading is different than 3,000 psi, adjustment is required. Port RV3 216942AC SJ519 TH...

  • Page 105: Bleeding Hydraulic Circuits

    Tilt telehandler fully side to side several times ▪ with boom in a low position. Bleed Auxiliary/Optional Circuits Operate function fully in both directions several ▪ times. Bleed Outriggers Circuit Fully lower and raise outriggers several times. ▪ SJ519 TH 216942AC...

  • Page 106: Brake Inspection

    4. Repeat the inspection on the other axle arm. If the gap is smaller than 4.5 mm between the disks of either arm (i.e. the gauge doesn’t fit), the brake disks must be replaced on both arms. 216942AC SJ519 TH...
  • Page 108 www.skyjack.com...

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