Skyjack SJ843 TH Service Manual
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Skyjack SJ843 TH Service Manual

Skyjack SJ843 TH Service Manual

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SERVICE
MANUAL
SJ643 TH, SJ843 TH
TELEHANDLERS
190127AE
January 2021
ANSI

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Table of Contents
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Summary of Contents for Skyjack SJ843 TH

  • Page 1 SERVICE MANUAL SJ643 TH, SJ843 TH TELEHANDLERS 190127AE January 2021 ANSI...
  • Page 2 This manual is based on Serial Number(s): SJ643 TH & SJ843 TH: 87 110 032 & Above...
  • Page 3 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.

  • Page 4: Table Of Contents

    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. SJ643 TH, SJ843 TH 190127AE...

  • Page 5: Table Of Contents

    Tire/Wheel Specifications ............28 SJ643 TH, SJ843 TH...
  • Page 6 Electrical Schematic for CVT ............80 190127AE SJ643 TH, SJ843 TH...
  • Page 7 Check Engine Oil Level ............114 SJ643 TH, SJ843 TH...
  • Page 8 Hydraulic Pressure Test Procedure ..........151 190127AE SJ643 TH, SJ843 TH...
  • Page 9 Bearing Installation ............. . . 169 SJ643 TH, SJ843 TH...

  • Page 10: 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 11: 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 12: Hydraulic System & Component Maintenance And Repair

    6. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also, plug the ports of the removed components. SJ643 TH, SJ843 TH 190127AE...

  • Page 13: 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 190127AE SJ643 TH, SJ843 TH...
  • Page 14 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 15: Scheduled Maintenance Inspections

    1.5-1 Labels - underside of the frame - ▪ Refer to the labels section in this manual and determine ground area under the telehandler - ▪ that all labels are in place and are legible. 190127AE SJ643 TH, SJ843 TH...

  • Page 16: Cylinders - A

    Refer to table 2.3 Tire/Wheel Specifications. IMPORTANT Do not intermix foam-filled and air-filled tires. WARNING If any tire does not meet the criteria outlined above, remove telehandler from service and replace wheel/tire immediately. SJ643 TH, SJ843 TH 190127AE...
  • Page 17 Use original or manufacturer-approved parts and levels or damaged cables and connections can result in components for the telehandler. engine component damage and hazardous conditions. WARNING Explosion hazard. Keep flames and sparks away. Do not smoke near batteries. 190127AE SJ643 TH, SJ843 TH...
  • Page 18 Ensure tank shows no visible damage and no ▪ death or serious injury. evidence of hydraulic leakage. Perform a visual inspection around the following areas: hoses and fittings ▪ fuel pump ▪ fuel filter ▪ fuel tank ▪ SJ643 TH, SJ843 TH 190127AE...

  • Page 19: Engine Compartment

    ” - C, D ▪ Ensure there are no loose or missing parts and there is no visible damage. Ensure all fittings and hoses are properly ▪ tightened and there is no evidence of fuel leaks. 190127AE SJ643 TH, SJ843 TH...

  • Page 20: Transmission

    Ensure there are no visible cracks in welds or ▪ structure and there are no signs of deformation. Ensure all hoses are properly tightened and ▪ there is no evidence of hydraulic leakage. SJ643 TH, SJ843 TH 190127AE...

  • Page 21: 11 Grease Fittings - B

    Rollover and Falling Object Protective ▪ Structure (ROPS/FOPS) - Ensure manual is legible and in good condition. ▪ Ensure there is no visible damage. Always return manual to the manual storage ▪ ▪ box after use. 190127AE SJ643 TH, SJ843 TH...
  • Page 22 Ensure all switches and controls are returned ▪ to their neutral position and movements are not obstructed. Ensure capacity charts are in place and are ▪ legible. WARNING Do not operate the telehandler if capacity charts are missing or not legible. SJ643 TH, SJ843 TH 190127AE...

  • Page 23: Function Tests

    Found there will be detailed instructions for which tests to perform, as well as how to properly and successfully perform them. NOTE All-function motion alarm should sound while operating any boom and drive function 190127AE SJ643 TH, SJ843 TH...

  • Page 24: Section 2 - Maintenance Tables

    Section 2 – Maintenance Tables SJ643 TH, SJ843 TH 190127AE...

  • Page 25: Standard And Optional Equipment

    Enclosed Operator's Cab Enclosed Operator's Cab with A/C Fire Extinguisher Flashing Beacon Foam Filled Tires Fork Positioner Four-Wheel Fenders Pintle Hitch Positive Air Shut-off System Premium Multi-function Joystick Reserve Brake System Road/Work/Boom Lights Continuously Variable Transmission 1460AA 190127AE SJ643 TH, SJ843 TH...

  • Page 26: Specifications And Features

    2.25 in x 5 in x 48 in (standard tapered forks) Carriage rollback 20° Carriage forward tilt 92.5° * Engine idle speed is measured with 5% droop when in gear. 1459AA ** Add 400 lb (181.437 kg) to the maximum weight for machines with CVT SJ643 TH, SJ843 TH 190127AE...

  • Page 27: Tire/Wheel Specifications

    Table 2.3 Tire/Wheel Specifications Models SJ643 TH & SJ843 TH Wheel FILL Size Pressure Nuts Rating Torque 87 psi (600 Kpa) 13.00 X 24 TG PRIMEX G3000 FOAM GPX Rough Terrain L3 80 psi (552 Kpa) 13.00 X 24 L3...

  • Page 28: Recommended Fluids/Lubrication

    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. SJ643 TH, SJ843 TH 190127AE...

  • Page 29: Pressure Setting

    Table 2.5 Pressure Setting Model SJ643 TH, SJ843 TH System Component Test Port Pressure Valve Pilot Oil Pressure 400 psi Tilt Comp./ Carriage Tilt Port Relief 3300 psi System Standby Pressure (Load Sense) 450 psi Maximum Pressure 3000 psi Steering...

  • Page 30: Standard Hose Numbering System

    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 SJ643 TH, SJ843 TH 190127AE...
  • Page 31 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 190127AE SJ643 TH, SJ843 TH...

  • Page 32: Torque Specifications For Fasteners (Us)

    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 SJ643 TH, SJ843 TH 190127AE...

  • Page 33: Torque Specifications For Fasteners (Metric)

    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 190127AE SJ643 TH, SJ843 TH...

  • Page 34: Torque Specifications For Hydraulic Couplings & Hoses

    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 SJ643 TH, SJ843 TH 190127AE...

  • Page 35: Air Conditioner Temperature/Pressure Chart

    A/C working properly Add refrigerant Need service, possibly blockage of the High expansion valve or orifice tube Need service, possibly faulty High compressor High High System overcharged.* *It is illegal to vent R-134a refrigerant into the atmosphere. 190127AE SJ643 TH, SJ843 TH...

  • Page 36: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJ643 TH, SJ843 TH 190127AE...

  • Page 37: Electrical Symbol Chart

    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 190127AE SJ643 TH, SJ843 TH...

  • Page 38: Hydraulic Symbol Chart

    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 SJ643 TH, SJ843 TH 190127AE...

  • Page 39: Electrical Schematic Parts List

    9-156202 FUSE, Fan/Interior Light (5A) 9-156164 FUSE, Blower motor (30A) 9-156203 FUSE, Frame Level Interlock (10A) 9-156203 FUSE, Heater Valve & A/C (10A) Not used. Not used. Not used. Not used. 9-156164 FUSE, ECM (30A) 190127AE SJ643 TH, SJ843 TH...
  • Page 40 9-102921 DIODE, Console harness D250 9-102921 DIODE, Road light Harness D251 9-102921 DIODE, Road light Harness 9-190547 SENSOR, Inductive proxi 15 mm 9-166700 SENSOR, Pressure 2H-19A 9-159821 COIL, #8 2H-57 COIL, #8 2H-221 COIL, #8 SJ643 TH, SJ843 TH 190127AE...
  • Page 41 Electrical Schematic Parts List Index Skyjack Qty. Description Part No. 2H-28 COIL, #8 2H-28A COIL, #8 4H-223 COIL, #8 4H-223-1 COIL, #8 4H-47 COIL, #8 4H-47-1 COIL, #8 3H-26 9-168057 COIL, #10 4H-217 COIL, #10 4H-218 COIL, #10 190127AE SJ643 TH, SJ843 TH...

  • Page 42: Hydraulic Schematic Parts List

    9-191807 ORIFICE PLUG 9-191808 ORIFICE PLUG 9-191809 ORIFICE PLUG 9-199033 ORIFICE PLUG 9-199034 ORIFICE PLUG 9-199035 ORIFICE PLUG 9-199032 ORIFICE DISC OSM1 9-406450 MOTOR, Steering wheel 9-190264 PUMP , Hydraulic VR6/843 9-191798 VALVE, Pressure reducing/relieving SJ643 TH, SJ843 TH 190127AE...
  • Page 43 VALVE, Brake (Brake Pedal) 9-191801 VALVE, Piloted 2W N.O. 9-191797 VALVE, Solenoid 5W3P 9-166038 VALVE, Solenoid cartridge 9-102626 VALVE, Solenoid cartridge 9-102626 VALVE, Solenoid cartridge 9-197302 VALVE, Pressure unloading 9-197303 VALVE, Low flow 2 way, normally closed 190127AE SJ643 TH, SJ843 TH...

  • Page 44: Hydraulic Pump And Return Filter Ports Identification

    To Hyd. Tank Pressure Compensator Adjuster Load Sense Compesator Adjuster Port X to Port LS on Main Manifold Port S Port P to Port P12 To Hyd. Tank on Main Manifold Inlet Outlet Return Filter M190807-1, M191415AA-S1 SJ643 TH, SJ843 TH 190127AE...

  • Page 45: Steering Control Unit Ports Identification

    Valve Steering Control Unit OSM1 Port R To Port ORBR on Main Control Port LS Valve To Main Control Valve Port STLS Port LS To Port STEER on Optional Reserve Brake Manifold Steering Control Unit 190127AE SJ643 TH, SJ843 TH...

  • Page 46: Service Brake Actuator (Brake Pedal) Ports Identification

    Port A To Main Control To Main Control Valve Valve Port DR1 Port BR1 Port P To Port SB on Main Control Valve Port P To Port A1 on Optional Reserve Brake Manifold Brake Pedal SJ643 TH, SJ843 TH 190127AE...

  • Page 47: Auxiliary Block Ports Identification

    To Main Control Port B Valve Port AUX. LS to Bulkhead #7 Port AUX. T 4H-233 To Main Control Solenoid Valve Valve Port AUX. EF1 Port AUX. T To Main Control Valve Port AUX. EF1 M190791AB-S1 190127AE SJ643 TH, SJ843 TH...

  • Page 48: Joystick Port Identifications

    To Port J1 on Main Control Valve Port T To Port DR2 Port 3 on Main Control To Port J3 Valve on Main Control Valve Port 4 To Port J4 on Main Control Valve M190356-1 SJ643 TH, SJ843 TH 190127AE...

  • Page 49: Premium Joystick Port Identifications

    Main Manifold Port 1 to Port J1 on Main Manifold Port T to Port DR2 on Main Manifold Port 3 to Port J3 on Main Manifold Port 4 to Port J4 on Main Manifold M1344040201_JS 190127AE SJ643 TH, SJ843 TH...

  • Page 50: Premium Joystick Manifold Port Identifications

    Main Manifold 3H-40 Carriage Down 3H-41 Carriage Up Port A to Carriage Down Port on Main Manifold Port B to Carriage Up Port Port D to tee fitting GP2 on Main Manifold on Main Manifold 213749AA-SM SJ643 TH, SJ843 TH 190127AE...

  • Page 51: Optional Reserve Brake Manifold Port Identification

    To Port P on Brake Pedal Port SW Port T Pressure To Port DR3 Port STLS Switch on Main Control To Port STLS Valve on Main Control Pressure Reducing/ Port SV1 Valve Relief Valve Shuttle Valve M190115AC-S1 190127AE SJ643 TH, SJ843 TH...

  • Page 52: Major Components Identification And Location

    Frame Angle Sensor Joystick Carriage Tilt Cylinder OSM1 Steering Control Unit Rear Steer Cylinder Frame Level Cylinder, CB6 & CB7 Counter Balance Valves Service Brake Actuator (Pedal) Front Steer Cylinder M190529 - HYD. Comp. Location SJ643 TH, SJ843 TH 190127AE...

  • Page 53: Main Control Valve Port Identification

    Port J1 To Port 1 Pressure Reducing Cylinder on Joystick Port CF To Port P on Port TA Valve Steering Control To Bulkhead #4 Port FA To Port CB6 Unit on Frame Level Pressure Cylinder Compensator M169032AF-S1 190127AE SJ643 TH, SJ843 TH...
  • Page 54 To Port STLS Check Valve on Optioanl Reserve Brake Port BR2 Check Valve Manifold Check Valve To Front Axle Check Port DR3 Valve To Port T on Optional Reserve Bake Mainfold Pressure Relief Switch Valve M169032AF-S2 SJ643 TH, SJ843 TH 190127AE...
  • Page 55 Brake Pedal Frame Level Left Solenoid Valve Solenoid Valve Telescopic Solenoid Valve 4H-217 & 4H-218 Steer Function Solenoid Valve Boom Function Solenoid Valve Frame Tilt Solenoid Valve 4H-223-1 Frame Level Right Solenoid Valve M169032AF-S3 190127AE SJ643 TH, SJ843 TH...

  • Page 56: Enclosed Cab Harness & Wiring Diagram

    208-16 DK PE 208A-16 DK PE 208A-16 DK PE 05L-16 PE 260-16 TN/WH 208-16 DK PE 259-16 LT YW/PE 00-16 WH 259A-16 LT YW/PE 05L-16 PE 05L-16 PE SPL 05N 05N-16 PE SPL 00 LIGHT M191472AC-S SJ643 TH, SJ843 TH 190127AE...

  • Page 57: Glow Plug Harness & Wiring Diagram

    SOCKET 2 - 11C RED (10GA) 11-18 BK 11-18 BK TO 86 11A-18 BK 11A-18 BK TO 85 11C-18 RD 11C-10 RD 11C-10 RD 11C-8 RD TO 87 11B-8 RD 11B-8 RD TO 30 M191468AB-S1 190127AE SJ643 TH, SJ843 TH...

  • Page 58: Road Lights Harness & Wiring Diagram

    251-16 PK/BL TO CONSOLE 253-16 RD/GY 00-16 WH WHITE HARNESS SPL 251B 251B-16 PK/BL 250B-16 LT BL/BK SPL 250B 15-16 BL 15-16 BL 271-16 BE/YW SPL 271 SPL15 271A-16 BE/YW SPL 271A LEFT BACKUP LIGHT M190595AA-S SJ643 TH, SJ843 TH 190127AE...

  • Page 59: Work Lights Harness & Wiring Diagram

    ON FRAME HARNESS 00-12 WH FRONT GND. SPL00 SPL246 246-14 LT GN/PK 247-14 LT GN/WT 247-14 LT GN/WT LEFT REAR WORKLIGHT SPL247 00-14 WH ON CAB 00-14 WH REAR GND. RIGHT REAR WORKLIGHT ON FRAME M190231AB-S 190127AE SJ643 TH, SJ843 TH...

  • Page 60: Boom Lights Harness & Wiring Diagram

    3.19 Boom Lights Harness & Wiring Diagram GROUND. TO CHASSIS BOOM LIGHTS HARNESS 00-14 WH 256-14 TN/BK BOOM LIGHTS SPL00 00-14 WH 00-12 WH GND. 256-14 TN/BK 256-14 TN/BK TO CHASSIS HARNESS 256-14 TN/BK M190288AC-S SJ643 TH, SJ843 TH 190127AE...

  • Page 61: Beacon Light Harness & Wiring Diagram

    3.20 Beacon Light Harness & Wiring Diagram GROUND BEACON BEACON LIGHT OPTION GND ON CHASSIS 00-16 WH 5D-16 PE 5D-16 PE BEACON (OPT) M191613AB-S 190127AE SJ643 TH, SJ843 TH...

  • Page 62: Elevate Telematics Harness

    PIN 8 - CANL-GREEN 57D-BRN/GRN-16-TEW PIN 8 - CANL-GREEN PIN 9 - 57D-BROWN/GREEN PIN 10 - PLUGGED 57D-BRN/GRN-16-TEW PIN 11 - 221-DARK GREEN/TAN 57-BRN/GRN-16-TEW 221-DK GRN/TAN-16-TEW PIN 12 - 26B-BLUE/YELLOW D57B 57E-BRN/GRN-16-TEW 26B-BLU/YEL-16-TEW 03B-GRN/PUR-16-TEW 03B-GRN/PUR-16-TEW HARNESS SCHEMATIC SJ643 TH, SJ843 TH 190127AE...

  • Page 63: A/C Harness

    3.22 A/C Harness PRESS. SW. TO HARNESS, HEATER & AC COMPRESSOR TO ENCL. CAB 268-16 DBE/OE 269-16 DBE/RD HARNESS COMPRESSOR M191598AB - S1 190127AE SJ643 TH, SJ843 TH...

  • Page 64: Heater & A/C Harness

    A/C TEMP . SW. MOTOR 1 2 3 4 TO CONSOLE SPL00 HARNESS 266-16 BN/YW SPL266 TO CONSOLE 265-12 DK GN/BK HARNESS TO CONSOLE 05P-10 PE HARNESS (OPT) 268-16 DBE/OE A/C HARN. (OPT) M191490AD - S1 SJ643 TH, SJ843 TH 190127AE...

  • Page 65: Cvt Vehicle Harness

    D26D FU-1410 57CR FUSE IN LINE CR1 POWER RELAY 7.5A 05W-16 PU NEUTRAL PIN87 ENABLE RELAY 219-16 DARK BU/PK TRANSMISSION OIL TEMP 00-16 WH WARNING LAMP J65A VEHICLE SIDE TO CONSOLE HARNESS M220790AB - S1 190127AE SJ643 TH, SJ843 TH...

  • Page 66: Cvt Transmission Harness

    LIMIT SWITCH HIGH P3090 SPL206 SPL90 OUTPUT SPEED SPLCANL P3480 SPLCANH SUMP CVT TEMPERATURE 10 11 12 10 11 12 VEHICLE CONNECTOR VEHICLE CONNECTOR P4000 CLUTCH LOW P4150 OVERDRIVE P4050 P4100 UNDERDRIVE CLUTH REV/HIGH M220793AB - S1 SJ643 TH, SJ843 TH 190127AE...

  • Page 67: Console Harness And Layout

    60-16 WH/BE 05T-16 PE 05F-16 PE 220-16 DK GN/WE 57-16 BN/GR F1 TO F20 60B-16 WH/BE 65A-16 YW/PK 255-16 LT YW/BE 220-16 DK GN/WE 03B-16 GR/PE 60-16 WH/BE 65-16 YW/PK 3.26 Console Harness and Layout M199476AA-S2 SJ643 TH, SJ843 TH 190127AE...

  • Page 68: Console Harness Wiring Diagram

    28L CR 28R CR RELAY RELAY RELAY (OPT) 212CR 220CR CHASSIS 65CR RUNNING RELEASE SHUTOFF (OPT) RAS RESTRICT MODE 222CR 224CR 403ACR 5JCR 250ACR 251ACR 77CR 05CR ENABLE RELAY 223ACR M216785AD-S1 3.27 Console Harness Wiring Diagram SJ643 TH, SJ843 TH 190127AE...

  • Page 69: Engine Harness

    CANL BK 219 DK BL/PK 216 DK BL/GRY 15 BL 215 DK BL/PRL (TOP) 51 BL/GN 51A BL 51 BL/GN 16 WH/BK 00 WH 216 DK BL/GRY 00 WH 215 DK BL/PRL M209177AA-S1 3.28 Engine Harness SJ643 TH, SJ843 TH 190127AE...

  • Page 70: Engine Harness Wiring Diagram

    GROUND TEMP . (TOP) TO POSI FUEL PUMP RELAY TO FUEL PUMP TO BATTERY TO CONSOLE HARNESS TO CONSOLE TO WATER TO PRE-HEAT TO CHASSIS HARNESS HARNESS SENSOR TRANSMISSION M209177AA-S2 3.29 Engine Harness Wiring Diagram SJ643 TH, SJ843 TH 190127AE...

  • Page 71: Chassis Harness

    SWITCH RB. P112 213A DK GN/RD 213 DK GN/RD 220 DK GN/WE 00-16 WH 28B GN 26A-16 BL/YW 28A GN DEUTSCH 00 WH 00 WH FRAME LEFT FRAME ENABLE RIGHT ENABLE M199477AA-S1 3.30 Chassis Harness SJ643 TH, SJ843 TH 190127AE...

  • Page 72: Chassis Harness Wiring Diagram

    FRAME LEVEL CARRIAGE TO ENGINE HARNESS CRAB PARK BRAKE SOLS. PRESSURE CHASSIS R.A.S. FRAME LEVEL FRAME FRAME SOLS. STEER STEER RESERVE BRAKE DISABLE SWITCH SPEED RIGHT LEFT SOL. ENABLE ENABLE M191436AF-S2 3.31 Chassis Harness Wiring Diagram SJ643 TH, SJ843 TH 190127AE...

  • Page 73: Electrical Schematic

    3.32 Electrical Schematic 3.32 Electrical Schematic M190121AL-S1 SJ643 TH, SJ843 TH 190127AE...
  • Page 74 3.32 Electrical Schematic 3.32 Electrical Schematic M190121AL-S2 SJ643 TH, SJ843 TH 190127AE...
  • Page 75 A52-18 BK A37-18 WH A48-16 BK A18-16 WH A33-16 BK A16-16 WH A05-16 BK A04-16 WH A46-16 BK A03-16 WH A32-16 BK A02-16 WH B+-12 RD 00-12 WH 00-12 WH BA+-12 RD M190121AL-S3 3.32 Electrical Schematic SJ643 TH, SJ843 TH 190127AE...

  • Page 76: Electrical Schematic - Premium Joystick

    3.33 Electrical Schematic - Premium Joystick M213409AD-S1 3.33 Electrical Schematic - Premium Joystick SJ643 TH, SJ843 TH 190127AE...
  • Page 77 3.33 Electrical Schematic - Premium Joystick M213409AD-S2 3.33 Electrical Schematic - Premium Joystick SJ643 TH, SJ843 TH 190127AE...
  • Page 78 A48-16 BK A18-16 WH A33-16 BK A16-16 WH A05-16 BK A04-16 WH A46-16 BK A03-16 WH A32-16 BK A02-16 WH B+-12 RD 00-12 WH 00-12 WH BA+-12 RD M213409AD-S3 3.33 Electrical Schematic - Premium Joystick SJ643 TH, SJ843 TH 190127AE...

  • Page 79: Electrical Schematic For Cvt

    3.34 Electrical Schematic for CVT M217976AD-S1 3.34 Electrical Schematic for CVT SJ643 TH, SJ843 TH 190127AE...
  • Page 80 3.34 Electrical Schematic for CVT M217976AD-S2 3.34 Electrical Schematic for CVT SJ643 TH, SJ843 TH 190127AE...
  • Page 81 A37-18 WH A48-16 BK A18-16 WH A33-16 BK A16-16 WH A05-16 BK A04-16 WH A46-16 BK A03-16 WH A32-16 BK A02-16 WH B+-12 RD 00-12 WH 00-12 WH BA+-12 RD M217976AD-S3 3.34 Electrical Schematic for CVT SJ643 TH, SJ843 TH 190127AE...
  • Page 82 3.34 Electrical Schematic for CVT 3.34 Electrical Schematic for CVT M217976AD-S4 SJ643 TH, SJ843 TH 190127AE...

  • Page 83: Electrical Schematic For Cvt With Premium Joystick

    3.35 Electrical Schematic for CVT with Premium Joystick 3.35 Electrical Schematic for CVT with Premium Joystick M217979AD-S1 SJ643 TH, SJ843 TH 190127AE...
  • Page 84 3.35 Electrical Schematic for CVT with Premium Joystick 3.35 Electrical Schematic for CVT with Premium Joystick M217979AD-S2 SJ643 TH, SJ843 TH 190127AE...
  • Page 85 A18-16 WH A33-16 BK A16-16 WH A05-16 BK A04-16 WH A46-16 BK A03-16 WH A32-16 BK A02-16 WH B+-12 RD 00-12 WH 00-12 WH BA+-12 RD 3.35 Electrical Schematic for CVT with Premium Joystick M217979AD-S3 SJ643 TH, SJ843 TH 190127AE...
  • Page 86 3.35 Electrical Schematic for CVT with Premium Joystick 3.35 Electrical Schematic for CVT with Premium Joystick M217979AD-S4 SJ643 TH, SJ843 TH 190127AE...

  • Page 87: Hydraulic Schematic

    52 cc/REV 2600 RPM BOOM UP / CARRIAGE UP TELESCOPE IN / FRAME LEVEL LEFT BOOM DOWN / CARRIAGE DOWN S-GP SAE 32 RETURN FILTER TANK FILLER BREATHER 1 PSI PRESSURE RELIEF 3.36 Hydraulic Schematic M190118AG-S1 SJ643 TH, SJ843 TH 190127AE...

  • Page 88: Hydraulic Schematic (Reserve Brake Option)

    BOOM UP / CARRIAGE UP TELESCOPE IN / FRAME LEVEL LEFT BOOM DOWN / CARRIAGE DOWN S-GP SAE 32 RETURN FILTER TANK FILLER BREATHER 1 PSI PRESSURE RELIEF 3.37 Hydraulic Schematic (Reserve Brake Option) M190118AG-S2 SJ643 TH, SJ843 TH 190127AE...

  • Page 89: Hydraulic Schematic - Premium Joystick

    TELESCOPE OUT / FRAME LEVEL RIGHT S-GP SAE 32 RETURN FILTER 3H-41 3H-40 CARRIAGE UP CARRIAGE DOWN TANK FILLER 213232 BREATHER FORK TILT MANIFOLD 1 PSI PRESSURE SAE 04 RELIEF SAE 04 3.38 Hydraulic Schematic - Premium Joystick 213999AA-S1 SJ643 TH, SJ843 TH 190127AE...

  • Page 90: Hydraulic Schematic (Reserve Brake) - Premium Joystick

    S-GP SAE 32 RETURN FILTER 3H-41 3H-40 CARRIAGE UP CARRIAGE DOWN TANK FILLER 213232 BREATHER FORK TILT MANIFOLD 1 PSI PRESSURE SAE 04 RELIEF SAE 04 3.39 Hydraulic Schematic (Reserve Brake) - Premium Joystick 213999AC-S2 SJ643 TH, SJ843 TH 190127AE...
  • Page 91 Section 3 – System Component Identification and Schematics Hydraulic Schematic (Reserve Brake) - Premium Joystick 190127AE SJ643 TH, SJ843 TH...

  • Page 92: 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 SJ643 TH, SJ843 TH 190127AE...

  • Page 93: Electrical System

    Check continuity. Replace if defective. Check for defective wiring. Replace/repair if 17. fuse F1 open defective. Replace fuse. 18. Loose or broken 03A wire from fuse F1 to ignition Check continuity. Replace if defective. switch SW1 190127AE SJ643 TH, SJ843 TH...

  • Page 94: Engine Cranks But Will Not Run

    60CR 3. Loose or broken wire 03 from B+ to power relay Check continuity. Replace if defective 60CR 4. Loose or broken wire 00 from power relay 60CR to Check continuity. Replace if defective ground SJ643 TH, SJ843 TH 190127AE...

  • Page 95: Park Brake Will Not Release

    05CR pin 87 to chassis harness connector Check continuity. Replace if defective J31 pin 13. 7. Loose or broken 26A wire from harness connector Check continuity. Replace if defective P31 pin 13 to park brake solenoid 3H-26A. 190127AE SJ643 TH, SJ843 TH...

  • Page 96: Transmission Will Not Engage

    4. Loose or broken wire 51 from forward solenoid to Check continuity. Replace if defective. chassis harness P13 pin 2. 5. Defective forward solenoid. Replace solenoid. 6. Defective transmission shifter. Replace shifter SJ643 TH, SJ843 TH 190127AE...

  • Page 97: No Reverse Drive

    6. Defective transmission shifter. Replace shifter 4.2-9 No 2nd Speed Range 1. Loose or broken wire 215 from shifter connector J47 pin 3 to chassis harness 31 pin connector J31 Check continuity. Replace if defective. pin 5 190127AE SJ643 TH, SJ843 TH...

  • Page 98: 10 No Boom Up, Front Steer Mode Only

    12 to 4W solenoid connector J20 pin 1 4. Loose or broken 00 wire from 4W solenoid Check continuity. Replace if defective. connector J20 pin 2 to ground. 5. Defective 4W solenoid Replace if Defective SJ643 TH, SJ843 TH 190127AE...

  • Page 99: 13 No Crab Steer Mode

    Check continuity. Replace if defective. 18 to boom up enable relay 28CR pin 30. With boom below 40° and frame level check for 11. Frame angle sensor defective. voltage on wire 28 (pin 5). Replace if defective 190127AE SJ643 TH, SJ843 TH...

  • Page 100: 15 Frame Will Not Tilt Over 40° With Boom Below 40

    2. Loose or broken 00 wire from boom 40° angle Check continuity. Replace if defective. proximity switch connector J71 pin 3 to ground. 3. Boom 40° angle proximity switch misadjusted or Check adjustment (set to 40°) , replace if defective defective. SJ643 TH, SJ843 TH 190127AE...

  • Page 101: 16 No Frame Level

    7. Defective relay 65CR. to 87 with coil energized). Replace if defective. 8. Loose or defective wire 65A from 65CR relay pin Check continuity. Replace if defective 87 to 28RCR and 28LCR relays pins 30. 190127AE SJ643 TH, SJ843 TH...
  • Page 102 4. Loose or broken wire 28L from connector J31 pin Check continuity. Replace if defective 29 to relay 28LCR pin 86 5. Loose or broken wire 00 from 28LCR pin 85 Check continuity. Replace if defective SJ643 TH, SJ843 TH 190127AE...

  • Page 103: 17 Function Does Not Switch

    2. Loose or broken wire 05B to joystick connector J46 pin 3 & 4 and/or Carriage tilt relay 224CR pin Check for defective wiring. Replace fuse 86 and frame level enable relay 222CR pin 86 190127AE SJ643 TH, SJ843 TH...
  • Page 104 6. Loose or broken wire 00 from carriage tilt enable Check continuity. Replace if defective up and/or down solenoids 4-H-47 and/or 4-H47-1 7. Carriage tilt up enable solenoid 4H-47 and/ or carriage tilt down enable solenoid 4H-47-1 Replace if defective. defective. SJ643 TH, SJ843 TH 190127AE...

  • Page 105: Hydraulic System

    6. Stuck or defective lift counterbalance valves CB2, Clean valves. Check O-rings on valve. Repair or CB2-1. replace valve as required. Check seals on cylinder. Replace as necessary. 7. Defective lift cylinder C3 and/or C4. Replace cylinder if defective 190127AE SJ643 TH, SJ843 TH...
  • Page 106 Clean valve. Check operation of valve. Repair or 2. Stuck or defective telescope valve V3. replace valve as required. Clean valve. Check operation of valve. Repair or 3. LS check valve CV3 blocked or defective replace valve as required SJ643 TH, SJ843 TH 190127AE...

  • Page 107: No Carriage Tilt

    4. LS check valve CV1 blocked or defective replace valve as required 5. Pilot operated check valve CV11 and or CV12 Clean valve. Check operation of valve. Repair or blocked or defective replace valve as required 190127AE SJ643 TH, SJ843 TH...

  • Page 108: No Frame Level

    3. Frame right enable valve 2H-28A stuck or Clean valve. Check operation of valve. Repair or defective. replace valve as required 4. Orifice OR3 and/or OR4 plugged Remove and inspect, clean or replace as required SJ643 TH, SJ843 TH 190127AE...

  • Page 109: No Aux. Functions

    5. Orifice OR1 plugged Remove and inspect, clean or replace as required 6. Relief valve RV2 valve misadjusted or defective Adjust pressure, replace if defective 7. Orifice OR7 plugged Remove and inspect, clean or replace as required 190127AE SJ643 TH, SJ843 TH...

  • Page 110: Park Brake Will Not Release

    Clean valve. Check operation of valve. Repair or 2. Load sense check valve CV6 blocked or defective replace valve as required Check seals, replace as necessary. Replace if 3. Bypassing or defective brake seals in axle. defective SJ643 TH, SJ843 TH 190127AE...
  • Page 111 Notes 190127AE SJ643 TH, SJ843 TH...

  • Page 112: Section 5 - Procedures

    Section 5 – Procedures 5.1 General 5.1-2 Engine and Transmission The engine used on the SJ643 TH & SJ843 TH The following information is provided to assist you in telehandler models is a Deutz TCD 2.9L 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 113: 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 190127AE SJ643 TH, SJ843 TH...

  • Page 114: Check Transmission Fluid Level

    5. The oil level should be between the “Full” and “Low” marks. 6. If transmission oil level is low, refer to 5.5- 6 Change Transmission Oil and Filter Service transmission oil and filter replacement. Indicator Vaccuator Valve Figure 05 Air Cleaner Vaccuator Valve SJ643 TH, SJ843 TH 190127AE...

  • Page 115: Check Hydraulic Oil Level

    Section 4 – Procedures 10 Hour or Daily Routine Maintenance NOTE NOTE SJ643 TH & SJ843 TH telehandlers are equipped Secondary or safety element should not be with a two-stage air filter system; which consists removed unless it is being replaced.

  • Page 116: Drain Fuel/Water Separator

    2. Remove wheel from telehandler to fill the tire whenever pressure is below 80% of the recommended pressure. 3. Place tire in a cage and inflate using a clip-on chuck and a remote tire pressure gauge. SJ643 TH, SJ843 TH 190127AE...

  • Page 117: 10 Check Seat Belt And Mounting Hardware

    5.3-1 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 assemblies requires independent lubrication. Figure 10 Seat Assembly 190127AE SJ643 TH, SJ843 TH...

  • Page 118: Grease Drive Shaft U-Joints And Slip Joints

    1. Wipe dirt and grease from each remote grease fitting. 2. Apply 4 shots of grease to each fitting. See figure below. 2. Remove cap and apply 4 shots of grease to each fitting. Figure 14 Drive Shaft Grease Points SJ643 TH, SJ843 TH 190127AE...

  • Page 119: Check Fork Pins

    Tilt/Comp Cylinder Left Boom Pivot Cylinder Grease Points Grease Point Grease Points Frame Level Cylinder Grease Points Figure 16 Stabilizer Grease Points Figure 17 Rear Axle Lock Cylinder Grease Points Figure 19 Boom Grease Points 190127AE SJ643 TH, SJ843 TH...

  • Page 120: Grease Bottom Front & Top Rear Slide Pads

    6. Fully retract the boom then fully extend it a few times to ensure the path of slide pads is covered with grease for maximum protection. 7. With boom fully retracted, remove boom rear cover door to gain access to top rear slide pads. SJ643 TH, SJ843 TH 190127AE...

  • Page 121: 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/Lubrication this manual for oil type and capacity. 5. Re-install plug and repeat steps above for the three (3) remaining planetary wheel ends. 190127AE SJ643 TH, SJ843 TH...

  • Page 122: Check Oil Level In Axle Differentials

    7 quarts (7.4 litres) under engine oil drain plug. 5. Re-install plug and repeat steps above for the Engine Compartment other axle. Cover Figure 25 Engine Cover SJ643 TH, SJ843 TH 190127AE...
  • Page 123 7. Install oil drain plug with a new seal ring and tighten firmly. 8. Remove oil filter and catch any escaping oil. Engine Oil Filter Figure 28 Engine Oil Fill Cap Figure 27 Engine Oil Filter Location 190127AE SJ643 TH, SJ843 TH...

  • Page 124: Change Engine Fuel Filter And Fuel/Water Separator

    17. Close the engine compartment cover then latch to secure in place. NOTE Refer to your local/national regulations on how to dispose of used filter and oil. SJ643 TH, SJ843 TH 190127AE...
  • Page 125 12. Mount the drain plug on bottom of water separator. Torque to 1 ft.-lb. (1.6 ± 0.3 Nm) 13. Check area around filter and separator for any leaks. 14. Connect water level sensor harness to fuel/water spearator. 190127AE SJ643 TH, SJ843 TH...

  • Page 126: Clean Hydraulic Tank Breather

    See figure below. Figure 34 Boom Cover Removal Figure 33 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.). SJ643 TH, SJ843 TH 190127AE...

  • Page 127: Check Boom Slide Pad Clearances

    5.6-3 Slide Pads Replacement Procedure for slide pads replacement procedure. Lubrication of the pads require application of grease on the boom surfaces which come in contact with the pads. 1. Park telehandler on a firm level surface. 190127AE SJ643 TH, SJ843 TH...
  • Page 128 Measure the clearance between the side of ▪ the boom and the upper and lower slide pads. Clearance should not exceed 0.08 in. (2 mm). Repeat procedure for inner boom section(s). ▪ Figure 39 Rear Upper and Side Slide Pads SJ643 TH, SJ843 TH 190127AE...

  • Page 129: 10 Check Boom Chains Tension

    (2 mm), shim adjustment or replacement of the slide pads may be required. 5.4-10 Check Boom Chains Tension Proper adjustment of the chains at this interval minimizes the risk of chain failure which could cause extensive damage to other boom components and 190127AE SJ643 TH, SJ843 TH...

  • Page 130: 11 Chain Tension Adjustment

    Chain Anchor IMPORTANT Jam Nut If the slack is more than 1.00 in., an adjustment is required. Refer to 5.4-11 Chain Tension Adjustment for chain tension adjustment procedure. Figure 44 Extend Chain Jam Nut SJ643 TH, SJ843 TH 190127AE...

  • Page 131: 1000 Hour Or Annual Routine Maintenance

    80 ft.-lb. Chain Anchor Jam Nut Figure 47 Hydraulic Oil Filter Location Figure 46 Chain Anchor Jam Nut NOTE Refer to your local/national regulations on how to dispose of used hydraulic oil filter. 190127AE SJ643 TH, SJ843 TH...

  • Page 132: Change Hydraulic Oil And Clean Hydraulic Tank

    NOTE Follow shop practice standards for flushing and Figure 48 Hydraulic Tank Drain Plug cleaning of hydraulic oil tank. 10. Install drain plug back into tank. Replace O-ring seal if needed. SJ643 TH, SJ843 TH 190127AE...

  • Page 133: 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. 190127AE SJ643 TH, SJ843 TH...

  • Page 134: Change Engine Coolant

    9. Repeat procedure for the remaining three planetaries. Figure 53 Radiator Cap 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. SJ643 TH, SJ843 TH 190127AE...
  • Page 135 75° to 80° without radiator cap. Check for leaks. Shut down the engine. 12. Place a container capable of holding 5 gallons (17 Motorized Heater Valve liters) under the radiator drain plug. Figure 55 Hoses Disconnection 190127AE SJ643 TH, SJ843 TH...

  • Page 136: Change Transmission Oil And Filter

    Figure 59 Transmission Oil Drain Plugs Figure 58 Surge Tank Location 5. Place a suitable container with enough capacity under drop box to catch drained oil. 6. Remove the drop box drain plug and drain the oil. SJ643 TH, SJ843 TH 190127AE...
  • Page 137 8. Remove drop box fill plug and fill transmission drop box with fresh clean transmission. Figure 62 Transmission Oil Filter Removal NOTE Refer to local/national environmental regulations on how to dispose of used oil and filter. 190127AE SJ643 TH, SJ843 TH...

  • Page 138: Change Continuously Variable Transmission (Cvt) Oil And Filter

    18. Remove the transmission oil dipstick then check the transmission oil level. Add as required. 4. Remove the transmission drain plug to drain transmission oil. Oil Drain Plug Figure 63 Transmission Oil Drain Plugs SJ643 TH, SJ843 TH 190127AE...
  • Page 139 16. Move the Direction Control Lever to ‘Neutral’, and shut down engine. 17. Remove the transmission oil dipstick then check Oil Filling Plug the transmission oil level. Add as required. Figure 65 Transmission Oil Filter Removal 190127AE SJ643 TH, SJ843 TH...

  • Page 140: Inspect Boom Chains

    4. 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. Figure 67 Sheave Guards Removal. SJ643 TH, SJ843 TH 190127AE...
  • Page 141 6. Cap/plug all open lines and fittings. 7. Start the engine and fully retract the boom. 8. Shutdown engine and remove key from ignition switch. 9. Remove end of Fork Tilt hoses at front bulkheads on main boom assembly. 190127AE SJ643 TH, SJ843 TH...
  • Page 142 Figure 73 Aux. Hydraulics Hoses Removal at Bulkhead 12. Cap/plug all open lines and fittings. 13. With rear access cover plate removed, pull the hoses out of boom assembly and thoroughly inspect all hoses. Replace hoses if needed. SJ643 TH, SJ843 TH 190127AE...
  • Page 143 4. Fully loosen off the extend chain anchor jam nut and tension nut. Figure 77 Fork Tilt Hoses Connection at Bulkhead 5. Start engine and extend the boom approximately 3 feet to gain acces to side acces hole on fly boom section. 190127AE SJ643 TH, SJ843 TH...

  • Page 144: Boom Chains Replacement

    13. Check hydraulic oil level and top-up as required. Figure 81 Chain Anchor Nut & Washer Removal 5. Slide chain anchor through hole on main boom then lay chain with anchor on top of boom as shown. SJ643 TH, SJ843 TH 190127AE...
  • Page 145 4. From the rear of the boom, secure the chain to the anchor by installing the link pin and a new 8. Remove cotter pin and anchor pin then disonncet cotter pin chain from anchor. 9. Pull out chain completely from boom and thoroughly inspect. 190127AE SJ643 TH, SJ843 TH...
  • Page 146 SJ1056 TH with 1/2” bolts and washers. ft.-lb. 6. Torque bolts to 80 lb.-ft. using a 3/4” socket. Chain Anchor Jam Nut NOTE Ensure the chain anchor remains square to the 3rd boom top plate. Figure 87 Chain Anchor Jam Nut SJ643 TH, SJ843 TH 190127AE...
  • Page 147 Discard the cotter pin and old chain. 4. Position the chain anchor to the retract chain and secure by installing the link pin and a new cotter pin. 190127AE SJ643 TH, SJ843 TH...

  • Page 148: Slide Pads Replacement Procedure

    The bar prevents the shims from falling when the screws are removed. 5. Remove the screws, shims, and wear pads while holding the bar under the shim. For easier installation, keep all parts removed together as an assembly. SJ643 TH, SJ843 TH 190127AE...
  • Page 149 5. Install the bottom wear pad assemblies consisting of the wear pad, shims and spacer, securing the assemblies by installing screws on the 2nd boom. 6. Apply loctite 271 red and tighten the screws to 37 ft-lb. 190127AE SJ643 TH, SJ843 TH...

  • Page 150: Hydraulic Pressure Test Procedure

    3. With engine running at low idle, dead-head the boom retract function. Indicated system pressure should be 3000 psi. 4. If reading is different than what is mentioned above, adjustment is required. Figure 93 Maximum Steering Pressure SJ643 TH, SJ843 TH 190127AE...
  • Page 151 Service Brake Pressure Check: ▪ 1. Release residual pressure by moving the joystick several times in each direction. 2. Remove plug and install a 1,000 psi gauge into the PS2 port on the main control valve. 190127AE SJ643 TH, SJ843 TH...
  • Page 152 400 psi is achieved. 3. Tighten the lock nut on valve PR1 and re-check the reading to ensure that the correct pressure is maintained. Figure 96 Pilot Pressure Check SJ643 TH, SJ843 TH 190127AE...

  • Page 153: Hydraulic Pump Testing Procedure

    6. If the pressure reading is different than the required pressure, use the pressure adjustment screw on the pump to adjust the pressure to the proper level. 7. If the required pressure cannot be set, the pump must be replaced. 190127AE SJ643 TH, SJ843 TH...
  • Page 154 7. Check orifice in regulator spool to be free and clear of any foreign material as shown in figure below. Figure 102 Remove Components from Housing Sleeve Figure 105 Verify Orifice is Clear of Debris SJ643 TH, SJ843 TH 190127AE...
  • Page 155 13. Install middle spring as shown in figure below. 10. Install cross pin as show in figure below. Figure 111 Install Middle Spring Figure 108 Install Cross Pin 14. Install inner spring as shown in figure below. 190127AE SJ643 TH, SJ843 TH...
  • Page 156 Figure 114 Install O-ring 17. Install O-ring on other valve sleeve. 18. Install valve or valves in transmission case as shown in figure below. SJ643 TH, SJ843 TH 190127AE...

  • Page 157: Deutz Fault Codes

    The alarm last received is automatically displayed the first time the error list is called up. If the list is longer than the screen section, you can browse through the list using buttons 1 and 2. 190127AE SJ643 TH, SJ843 TH...
  • Page 158 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 SJ643 TH, SJ843 TH 190127AE...
  • Page 159 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 190127AE SJ643 TH, SJ843 TH...

  • Page 160: Starter Replacement Procedure

    Rear View Upper Bolt Lower Bolt Figure 120 Figure 121 Bolts Location. 4. Remove the existing starter from the side of the engine. Front of Front of Machine Machine Figure 122 Starter Removal. SJ643 TH, SJ843 TH 190127AE...
  • Page 161 11. Tighten nut securing the harnesses. Nut and 12. Connect battery. Retaining 13. Perform a full function test as outlined in Section Washer ‘Function Tests’ of the operating manual. To Glow Plug Harness Engine Cable Harness Figure 124 Harnesses Installation. 190127AE SJ643 TH, SJ843 TH...

  • Page 162: 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. ▪ SJ643 TH, SJ843 TH 190127AE...

  • Page 163: Electronic Tilt Switch Setup Procedure

    Observe LED flash codes as shown below. 1. Ensure telehandler is parked on a firm level LEFT RIGHT surface. SET ZERO IMPORTANT 2. Only the red LED will blink for 4 seconds. Ensure frame level indicator is at 0°. 190127AE SJ643 TH, SJ843 TH...

  • Page 164: Reprogramming Existing Tilt Switch

    Red LED Red LED Green LED Green LED 7. Reprogram the Tilt Switch 1. Press and hold the set zero Red LED button for 3 seconds. Green LED Results: Both LEDs will be OFF. SJ643 TH, SJ843 TH 190127AE...

  • Page 165: Test And Verify Tilt Circuit

    9. Remove chocks or wheel blocks. Tilt Circuit Test 10. Proceed to Test and Verify Tilt Circuit/Boom Refer to Section 2 - Function Tests of the operating Interlock. manual to Test Frame Leveling and Boom Interlock. 190127AE SJ643 TH, SJ843 TH...
  • Page 166 0 = Output Open 0 = Output Open 0 = Output Open 4° 4° 1 = Switch 1 = output 12V 1 = output 12V 1 = output 12V 1 = output 12V Closed to 12V SJ643 TH, SJ843 TH 190127AE...

  • Page 167: Park Brake Release

    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. 190127AE SJ643 TH, SJ843 TH...

  • Page 168: Bearing Installation

    4. To install the bearings, use a bearing driver or a press that fully contacts the outer race of the bearing. 5. If applicable, apply grease to the inner ring of the bearing. Bearing Driver SJ643 TH, SJ843 TH 190127AE...
  • Page 169 Section 4 – Procedures Bearing Installation Figure 126 Bearing Orientation 190127AE SJ643 TH, SJ843 TH...
  • Page 170 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.

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