Mustang Telehandler 519 Service Manual (913302) - PDF DOWNLOAD

519 TELEHANDLER SERVICE MANUAL PART # 913302 Revision A - 04/08

Mustang Manufacturing Company, Inc.

INTRODUCTION With correct maintenance and proper use, this Mustang Telehandler will give years of dependable service. This service manual is intended to be a guide in the assembly and disassembly, installation and removal, adjustment and testing, troubleshooting and replacement of components that together make up the Mustang 519 Telehandler.

The Table of Contents can be used to make the procedure you need to find an easier process. Many photographs, schematics and line art drawings are used to help perform the necessary repairs, tests, or adjustments that this Telehandler needs to keep it in good running condition.

If you have any additional questions, please contact your authorized Mustang dealer or call the Mustang Service Department for assistance.

Table of Contents GENERAL SECTION Safety Information and Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 ENGINE Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201 ELECTRICAL Electrical Schematic, Troubleshooting, Testing and Adjustment Procedures . . . . . . . . .301 Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302 STEERING Steering Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401 POWER TRAIN Hydrostatic Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501 Rear Axle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502 Front Axle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503 Brake Bleeding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .504 HYDRAULIC SYSTEM Hydraulic Schematic, Troubleshooting, Testing and Adjustment Procedures . . . . . . . . .601 Hydraulic Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602 Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603 Hydraulic Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .604 Slave Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .605 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .606 Boom Extend Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .607 TELESCOPING BOOM Boom Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701 Inner Boom Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .702 CHASSIS Hood and Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800

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913302

Section 100 PERSONAL SAFETY INFORMATION AND DECAL LOCATIONS 519 Telehandler

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GENERAL TABLE OF CONTENTS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MANDATORY SAFETY SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SAFETY RULES AND REMINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MODIFICATIONS, NAMEPLATES, MARKINGS AND LOAD CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ROLL OVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DECAL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 NEW DECAL APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DECAL LOCATIONS - FRAME AND BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DECAL LOCATIONS - OPERATOR STATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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519 Telehandler

PERSONAL SAFETY SAFETY

The above Safety Alert Symbol means ATTENTION! ALWAYS BE ALERT! YOUR SAFETY IS INVOLVED! It stresses an attitude of safety awareness.

Before attempting to operate this equipment, read and study the following safety information. In addition, be sure that everyone who operates or works with this equipment, whether family member or employee, is familiar with these safety precautions.

Mustang Manufacturing Company ALWAYS takes the operator’s safety into consideration when designing its machinery, and guards exposed moving parts for his/ her protection. However, some areas cannot be guarded in order to assure proper operation. Further, the Operator’s Manual and decals on the machine warn of additional hazards and should be read and observed closely.

REMEMBER! It is the owner’s responsibility for communicating information on the safe use and proper maintenance of this machine! This includes providing understandable interpretations of these instructions for operators who are not fluent in reading English.

It is the responsibility of the operator to read and understand the Operator’s Manual and use the correct operating procedures. Machine should be operated only by qualified operators.

MANDATORY SAFETY SHUTDOWN PROCEDURE Before cleaning, adjusting, lubricating or servicing the unit: 1. Stop the machine on a level surface. (AVOID parking on a slope, but if necessary, park across the slope and block the tires.)

2. Fully retract the boom and lower the attachment tool to the ground. Idle the engine for gradual cooling.

DANGER

3. Place controls in NEUTRAL and apply the parking brake.

“DANGER” indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

4. Shut off the engine and remove the key.

ONLY when you have taken these precautions can you be sure its safe to proceed. Failure to follow the above procedure could lead to death or serious bodily injury.

‘WARNING” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION ‘CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also alert to unsafe practices.

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519 Telehandler

PERSONAL SAFETY Additional Safety Reminders

WARNING U.S. OSHA regulations require employers in g e n e r a l i n d u s t ry a n d t h e c o n s t r u c t i o n , shipyard and cargo-handling industries (excepting agricultural operations) to ensure that forklift operators are competent, as demonstrated by successful completion of a training course.

The training course must consist of a combination of formal instruction and practical training, including both forkliftrelated and workplace-related topics, and evaluation of the operator’s performance in the workplace.

•

Operator/user safety practices, as established by industry standards, are included in the Operator’s Manual and intended to promote safe operation of the machine. These guidelines do not preclude the use of good judgment, care and common sense as may be indicated by the particular jobsite work conditions.

•

It is essential that operators be physically and mentally fit and free of mind-altering drugs and chemicals, and thoroughly trained in the safe operation of the machine. Such training should be presented completely to all new operators and not condensed for those claiming previous experience.

Information on operator training is available from several sources, including the manufacturer.

•

Some illustrations used in this manual may show doors, guards and shields open or removed for illustration purposes ONLY. BE SURE that all doors, guards and shields are in their proper operating positions before starting the engine.

All operator training and evaluation is to be conducted by persons who have the knowledge, training and experience to train and evaluate operators.

Before Operation Safety Reminders •

Check brakes, steering, and hydraulic system prior to starting operation. Operate all controls to ensure proper operation. Observe all gauges and indicators for proper operation. If any malfunctions are found, correct the cause prior to using the machine.

•

ALWAYS wear appropriate personal protective equipment for the job and working conditions. Hard hats, goggles, protective shoes, gloves, reflectortype vests, respirators and ear protection are exampes of types of equipment that may be required. DO NOT wear loose fitting clothing, long hair, jewelry or loose personal items while operating or servicing the machine.

•

ALWAYS check the job site for terrain hazards, obstructions and people. Remove all objects that do not belong in or on the machine and its equipment.

•

Walk around the machine and warn all personnel who may be servicing the machine or who are in the machine path prior to starting. DO NOT start until all personnel are clearly away from the machine.

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WARNING ALWAYS mainta in a safe d istance from electric power lines and avoid contact with any electrically charged conductor or gas line.

It is not necessary to make direct contact with a power line for power to ground through the structure of the machine. Keep the boom at least 10 ft. (3 m) from all power lines.

Accidental contact or rupture can result in electrocution or an explosion. Contact the north American One-Call Referral System at (888) 258-0808 for the local “Digger’s Hotline” number or proper local authorities for utility line locations before strating to dig!

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519 Telehandler

PERSONAL SAFETY •

DO NOT leave the operator’s station with the boom and attachment tool raised. ALWAYS lower the boom and attachment tool to the ground, shut off the engine and engage the parking brake BEFORE leaving the operator’s station.

•

DO NOT drive too close to an excavation or ditch.

BE SURE that the surrounding ground has adequate strength to support the weight of the machine and the load it is carrying.

•

DO NOT turn quickly while traveling on a slope or operate the machine beyond the grade and slope limits noted in the Operation and Adjustments chapter of the Operator’s Manual.

•

NEVER allow any riders on this machine or use as a lift for personnel. This is strictly a single-seat, NO passenger machine!

•

When road travel is required, know and use the signaling devices on the machine. Provide an escort and Slow-Moving Vehicle (SMV) emblem when required.

•

If necessary to park on a slope, park across the slope and block the tires.

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Operation Safety Reminders •

•

Any or all of the following elements may affect the stability of the machine: terrain, engine speed, type of load being carried and placed, improper tire inflation, weight of the attachment tool, and abrupt movement of any control lever. IF YOU ARE NOT CAREFUL WHILE OPERATING THIS MACHINE, ANY OF THE ABOVE FACTORS COULD CAUSE THE MACHINE TO TIP AND THROW YOU OUT OF THE OPERATOR’S STATION, WHICH MAY CAUSE SERIOUS BODILY INJURY OR DEATH! ALWAYS wear the seat belt provided to prevent being thrown from the machine. If you are in an overturn: - DO NOT jump!

- Hold on tight and stay with the machine!

- Lean away from the fall!

•

ALWAYS keep hands, feet and arms inside of the operator’s station when operating the machine!

•

Always look in the direction of travel. Look to the rear before backing.

•

ALWAYS use the recommended hand holds and steps with at least three points of support when getting on and off the machine. Keep steps and platform clean. Face the machine when climbing up and down.

•

DO NOT raise or drop a loaded fork or bucket suddenly. Abrupt movements under load can cause serious instability.

•

Study the load chart carefully. It shows maximum capacity to be lifted and placed at specific outward and upward distances. ALWAYS be aware of load weights prior to attempting lift and placement with this machine.

•

DO NOT exceed the machine’s rated operating capacity for the type of attachment tool being used.

•

DO NOT allow minors or any unqualified personnel to operate or be near the machine unless properly supervised.

•

DO NOT start the engine or operate any controls unless properly seated in the operator’s seat!

•

DO NOT run the engine in an enclosed area without providing proper ventilation for the exhaust.

Exhaust gases contain carbon monoxide, an odorless and deadly gas. Internal combustion engines deplete the oxygen supply within enclosed spaces and may create a serious hazard unless the oxygen is replaced. This includes the atmosphere within the cab when equipped.

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519 Telehandler

PERSONAL SAFETY

Servicing Safety Reminders •

ALWAYS be aware of and avoid pinch-point areas on the machine, such as wheels-to-frame, cylinders-to-frame, boom- and attachment-tool-toframe.

•

NEVER attempt to by-pass the keyswitch to start the engine. ONLY use the jump-starting procedure detailed in the Service and Storage chapter of the Operator’s Manual.

•

•

NEVER use your hands to search for hydraulic fluid leaks. Instead use a piece of paper or cardboard.

Escaping fluid under pressure can be invisible and can penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

ALWAYS wear safety glasses with side shields when striking metal against metal. In addition, it is also recommended that a softer (chip-resistant) material be used to cushion the blow. Failure to heed could lead to serious injury to the eyes or other parts of the body.

•

DO NOT refill the fuel tank when the engine is hot.

Allow engine to cool before refilling to prevent hot engine parts from igniting the fuel if it should spill or splash.

•

DO NOT smoke while filling the fuel tank, working on the fuel or hydraulic systems, or working around the battery.

•

DO NOT fill the fuel tank completely. Allow room for expansion. Maintain control of the fuel filler nozzle when filling the tank. Use the correct fuel grade for the operating season.

• •

NEVER use fuel for cleaning purposes.

•

•

Avoid lubrication or mechanical adjustments with the machine in motion or the engine running. If the engine must be running to make certain adjustments, place the equipment in a safe position, place the transmission in neutral, apply the parking brake, securely block the tires and use extreme caution.

•

To ensure continued safe operation, replace damaged or worn-out parts with genuine Mustang service parts before using this equipment.

Modifications, Nameplates, Markings and Capacities •

Modifications and additions that affect capacity or safe operation must never be performed without the manufacturer’s prior written approval. Where such authorization is granted, any applicable markings are to be changed accordingly.

•

All attachment tools MUST be marked to identify the attachment tool and the total capacity with the attachment tool at maximum elevation with the load laterally centered.

•

ALWAYS be sure all nameplates, warnings and instruction markings are in place and legible. Local government regulations may require specific decals, which are the responsibility of the owner to provide.

Safety Guards and Warning Devices •

This machine is fitted with a Roll-Over Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) in accordance with industry standards. The structure is intended to offer protection to the operator in case of an overturn and from falling objects, but it cannot protect against every possible hazard. Therefore it should not be considered a substitute for good judgment and safe practices in operating the machine. If the ROPS ⁄ FOPS structure is damaged, it must be replaced to restore the protection it provides.

•

This machine is equipped with a horn and backup alarm. The user must determine if operating conditions require the machine to be equipped with additional devices (mirrors, rotating beacon, etc.) and be responsible for providing and maintaining such devices.

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DO NOT remove the radiator cap after the engine has reached operating temperature or if it is overheated. At operating temperatures, the engine coolant will be extremely hot and under pressure.

ALWAYS wait for the engine to cool before attempting to relieve pressure and remove the radiator cap. Failure to heed this warning could result in severe burns.

DO NOT loosen or disconnect any hydraulic lines, hoses or fittings without first relieving hydraulic circuit pressure. Also, be careful not to touch any hydraulic components that have been in recent operation because they can be extremely hot and can burn you!

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519 Telehandler

DECALS DECAL LOCATIONS NEW DECAL APPLICATION

GENERAL INFORMATION

Before applying the new decals, surfaces must be free from dirt, dust, grease and other foreign material. To apply a solid-formed decal, remove the smaller portion of the decal backing paper and apply this part of the exposed adhesive backing to the clean surface while maintaining proper position and alignment. Slowly peel off the other portion of the backing paper while applying hand pressure to smooth out decal surface. To apply a die-cut decal, first remove the backing paper. Then, properly orient and position the decal onto the clean mounting surface. After the decal is firmly applied and smoothly pressed down, remove any front covering paper.

CAUTION ALWAYS read and follow the safety precautions and information shown on decals.

If any decals are damaged or unreadable, or if the unit is repainted, the decals must be replaced. If repainting, BE SURE that all decals that apply to your machine are affixed in their proper locations.

When a decal is applied on a part that is to be replaced, make sure that the replacement part has the decal applied or apply a new decal.

PAINT

Decal location information is provided to assist in the proper selection and application of new decals, in the event the original decals become damaged or the machine is repainted.

Use this list to order paint for refinishing: 167763 167765 167754 167753

For correct replacement of decals, compare the location photographs to the macine before starting to refinish the unit. Check off each required decal using the illustration reference number to find the part number, description and quantity in the list. Refer to the appropriate illustration for replacement locations.

Decal Kits

NOTE: Refer to the Safety chapter of the Operator’s Manual for specific information provided on the safety decals.

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One Gallon Yellow 6 (12-oz. spray Cans) Yellow One Gallon Gun-Metal Gray 6 (12-oz. Spray Cans) Gun-Metal Gray

104886

519 Telehandler

NOTE: Decals may be purchased in kits or individually.

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DECALS

9 2

7 10 8

7

4

3

6

2

5 1

DECAL LOCATIONS REF. NO.

DESCRIPTION

PART NO.

01 02 03 04 05

DANGER - HANDS OUT WARNING - PINCH POINT WARNING - JUMP START ANTI-FREEZE COOLANT UNDER PRESSURE

L70305 L65927 L65933 056859 072798

06 07 08 09 10

HYDRAULIC OIL MUSTANG, 4” X 21.19” HORSE, RH MUSTANG, RH BOOM SIDE 519

137632 104893 104888 104890 104891

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DECALS

5 10 1

8

9

3 4 1

6

7 2

DECAL LOCATIONS REF. NO.

DESCRIPTION

PART NO.

01 02 03 04 05

WARNING - PINCH POINT QUICKATTACH DIAGRAM DANGER-PERSONAL INJURY BRAKE FLUID MUSTANG, LH BOOM SIDE

L65927 L65937 L65928 L63474 104889

06 07 08 09 10

QUICKATTACH-UNLOCKED DIESEL FUEL HORSE, LH 519 MUSTANG, 4” X 21.19”

L66613 137634 104887 104891 104893

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DECALS 3

13

2 6

12

10 14

1

11

5

16

17 8

4

16

7

15 9

16

17

DECAL LOCATIONS REF. NO.

DESCRIPTION

PART NO.

01 02 03 04 05

WARNING-TILT HAZARD/GENERAL OPERATOR WARNING - CARRY LOAD LOW F-N-R SHIFT MADE IN USA WARNING - PARK BRAKE/SEAT BELT

L70306 L65926 L68295 140516 101506

06 07

DANGER-HI VOLT/MOVING PARTS STANDARD CARRIAGE LOAD CHART ROTATING CARRIAGE LOAD CHART BUCKET LOAD CHART TRUSS BOOM LOAD CHART

L70307 104881 104882 104883 104884

08 09 10 11 12

ATTACHMENT TILT/AUXILIARY BOOM CONTROL IGNITION/START/HORN WARNING-FALL HAZARD OPERATOR MANUAL WARNING

100400 L63631 104405 L65928 100359

13 14 15 16 17

LUBE CHART NO RIDERS WARNING-PINCH POINT TIEDOWN LIFT POINT

104398 L65932 L65927 104945 104946

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Section 101 GENERAL INFORMATION AND SPECIFICATIONS 519 Telehandler

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GENERAL TABLE OF CONTENTS SAE FASTENER TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 METRIC FASTENER (ISO) TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INDICATOR AND CONTROL SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FLUID CAPACITIES AND TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GENERAL DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 519 LOAD ZONE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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GENERAL SAE FASTENER TORQUE CHART

NOTE: Use these torques, unless special torques are specified. Values are for UNC and UNF thread fasteners, plated or unplated, as received from supplier. Fasteners can be dry or lubricated with normal engine oil. Values do not apply if graphite, moly-disulphide or other extreme pressure lubricant is used.

SAE Grade No.

2

5

8*

Bolt head identification (See Note 1) LB-FT Bolt Size

Min

Nm Max

Min

LB-FT Max

Min

Nm Max

Min

LB-FT Max

Min

Nm Max

Min

Max

1/4

5

6

7

8

9

11

12

15

12

15

16

20

5/16

10

12

14

16

17

20.5

23

28

24

29

33

39

3/8

20

23

27

31

35

42

48

57

45

54

61

73

7/16

30

35

41

47

54

64

73

87

70

84

95

114

1/2

45

52

61

70

80

96

109

130

110

132

149

179

9/16

65

75

88

102

110

132

149

179

160

192

217

260

5/8

95

105

129

142

150

180

203

244

220

264

298

358

3/4

150

185

203

251

270

324

366

439

380

456

515

618

7/8

160

200

217

271

400

480

542

651

600

720

814

975

1

250

300

339

406

580

696

787

944

900

1080

1220

1464

1-1/8

800

880

1085

1193

1280

1440

1736

1953

1-1/4

1120

1240

1519

1681

1820

2000

2468

2712

1-3/8

1460

1680

1980

2278

2380

2720

3227

3688

1-1/2

1940

2200

2631

2983

3160

3560

4285

4827

NOTE 1: Bolt head identification marks as per grade. Manufacturing marks will vary. *Thick nuts must be used with Grade 8 bolts.

METRIC FASTENER (ISO) TORQUE CHART NOTE: Use these torques, unless special torques are specified. Values are for UNC and UNF thread fasteners, plated or unplated, as received from supplier. Fasteners can be dry or lubricated with normal engine oil. Values do not apply if graphite, moly-disulphide or other extreme pressure lubricant is used.

ISO Grade No.

8.8

10.9

12.9

Bolt head identification (See Note 1) LB-FT

Nm

LB-FT

Nm

LB-FT

Bolt Size

Min

Max

Min

Max

Min

Max

Min

Max

M4

3

4

2

3

4

5

3

4

M5

6.5

8

5

6

9.5

11

7

8

M6

10.5

12

8

9

15

17.5

11

13

M8

26

31

19

23

37

43

27

32

M10

52

61

38

45

73

87

54

64

M12

90

107

66

79

125

150

93

112

*M14

144

172

106

127

200

245

149

179

M16

217

271

160

200

310

380

230

280

M20

434

515

320

380

610

730

450

540

M24

675

815

500

600

1050

1275

780

940

M30

1250

1500

920

1100

2000

2400

1470

1770

M36

2175

2600

1600

1950

3500

4200

2580

3090

Min

Nm Max

Min

Max

Because of the low ductility of these fasteners, the torque range is to be determined individually for each application. As a general rule, the torque ranges specified for grade 10.9 fasteners can be used satisfactorily. *M14 is not a preferred size

NOTE 1: Bolt head identification marks as per grade. Manufacturing marks will vary.

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GENERAL

STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS TUBE NUTS FOR 37° FLARED FITTINGS TUBING O.D. SIZE

O-RING BOSS PLUGS, ADJUSTABLE FITTING LOCK NUTS, SWIVEL JIC - 37° SEATS

LB-FT

Nm

LB-FT

Nm

Inches

mm

THREAD SIZE

4

1/4

6.4

7/16-20

9

12

12

5

5/16

7.9

1/2-20

12

15

16

6

3/8

9.5

9/16-18

21

24

29

33

15

20

20

27

8

1/2

12.7

3/4-18

35

40

47

54

25

30

34

41

Min

Max

Min

Max

Min

Max

Min

Max

16

6

10

8

14

20

10

15

14

20

10

5/8

15.9

7/8-14

53

58

72

79

35

40

47

54

12

3/4

19/1

1-1/16-12

77

82

104

111

60

70

81

95

14

7/8

22.2

1-3/16-12

90

100

122

136

70

80

95

109

16

1

25.4

1-51/6-12

110

120

149

163

80

90

108

122

20

1-1/4

31.8

1-5/18-12

140

150

190

204

95

115

129

156

24

1-1/2

38.1

1-7/8-12

160

175

217

237

120

140

163

190

32

2

50.8

2-1/2-12

225

240

305

325

250

300

339

407

Above torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations and swivel nuts, either swaged or brazed. These torques are not recommended for tubes 1/2 inch (12.7 mm) O.D. and larger with wall thickness of 0.035 inch (0.889 mm) or less. The torque is specified for 0.035 inch (0.889 mm) wall tubes on each application individually.

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GENERAL Indicator and Operation Symbols

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GENERAL FLUID CAPACITIES AND TYPES

All fluid capacitites listed are a guide to the quantities required, always use dipsticks or level plugs to ensure that the units are filled to the correct level.

Engine Crankcase Capacity (with filter) Turbocharged Deutz T02009L04....................................................................................................7 qts. (6.5 L) Oil Type ............................................................................................. API Service Classificiation CH-4/CG-4/CI-4 (See Engine Manual) Cooling System Capacity ................................................................................................................ 12 Qts.(11.3 L) Coolant Type..................................................................................... 45/55 Mixture of Ethylene Glycol and Water

Axle (Each) Differentials (each) ...........................................................................................................................4.4 qts. (4.2 L) Planetary Hubs (each)....................................................................................................................: 15 oz. (0.45 L) Gear Case (Front Axle) .................................................................................................................... 0.8 qt (0.75 L) Oil Type........................................................ MobilFluid® 422/423 or 85W90 Oil Meeting API-GL-5 Classification

Brake System Oil Type............................................................................................................... SUNCO Multi-ATF or Equivalent

Hydraulic System Reservoir Capacity ..........................................................................................................................18.0 gal. (68 L) Oil Type........................................................................................... Mobil DTE 15M or Equivalent Oil Conforming to ISO VG 46 Specifications

Fuel System Fuel Tank Capacity..........................................................................................................................17.0 gal. (64 L) Fuel Type ............................................................................... No. 2D or Winter Blend in Cold Weather Operation

Grease Fittings (all) .......................................................................................No. 2 Lithium-Based Gun Grease

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GENERAL GENERAL SPECIFICATIONS

POWER TRAIN Hydrostatic Transmission Type .................................................................... Rexroth A4VG560A/32, 2 Speeds Forward, 2 Speeds Reverse Travel Speeds Low speed: ............................................................................................................... Fwd/Rev 4 mph (6.4 km/h) High speed: ............................................................................................................. Fwd/Rev 15 mph (24 km/h)

Axles (Front and Rear) Make .............................................................................................................................................................. Dana Type ............................................................ Full-time four-wheel drive, Steerable, Front: Limited Slip Differential, Rear: Open Differential, Double-Reduction Planetaries Ratio (overall) ..............................................................................................................................................29.21:1

Engine Make ............................................................................................................................................................. Deutz Model ............................................................................................................................Turbocharged TD2009L04 Type ........................................................................................................................................Diesel, In-line 4 Cyl. Displacement ......................................................................................................................... 140 cu. in. (2290 cc) Aspiration ....................................................................................................................................... Turbo-Charged High Idle Speed (no load) ......................................................................................................................2750 RPM Rated Speed (governed) ........................................................................................................................2600 RPM Low Idle Speed (approx.) .......................................................................................................................1100 RPM Power Rating (at 2600 RPM) .......................................................................................................... 64 HP (48 kW) NOTE: Also refer to engine manual.

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GENERAL

HYDRAULIC SYSTEM Type ................................................................................................................................................... Open-Center Pump............................................................................................................................. Single-Section Gear-Type Pump Displacement (revolution) ............................................................................................... 1.95 cu. in. (32 cc) Pump Flow (at 2750 RPM)....................................................................................................... 22 GPM (83 L/min) Main Relief Pressure ................................................................................................................ 3350 PSI (230 bar) Steering Relief Pressure .......................................................................................................... 2400 PSI (165 bar) Main Control Valve ................................................................................................. Parallel, 4-Section Spool Type Hydraulic Filter Type ........................................................................................... Return-type, 16-Micron, Replaceable Element Rated Flow......................................................................................................................... 35 GPM (132 L/min) Rated Pressure ...................................................................................................................... 1000 PSI (70 bar) By-Pass Pressure (Full Flow) ................................................................................................. 50 PSI (345 kPa)

STEERING SYSTEM Type ........................................................................................................................... Fixed-Displacement, Rotary Displacement/Rev. .................................................................................................................... 7.3 cu. in. (120 cc) System Pressure ...................................................................................................................... 2400 PSI (165 bar) Steering Cylinders........................................................................................................................... One Each Axle Steering Mode Valve .................................................................................... 3-Position, 4-Way Solenoid Actuated Dash-Mounted Switch Steering Modes ............................................................................................................. 2-Wheel, 4-Wheel or Crab

BRAKE SYSTEM Service Brakes Type ........................................................................................ Oil-Immersed Inboard Hydraulic Wet-Disc Type Location ............................................................................................................................................. Front Axle Actuation ..............................................................................................................................Manual, Foot Pedal Park Brake Type ............................................................................................Spring-Applied, Hydraulic-Release Disc-Type Location ............................................................................................................................................. Front Axle Actuation ................................................................................................... Electric Switch with Engine Running Automatic Apply with Engine Shutdown

INSTRUMENTATION Monitoring Lights.................................................. Engine Oil Pressure, Alternator, Engine Coolant Temperature, Hydrostatic Drive Oil Temperature Gauges............................................................................................ Coolant Temperature, Fuel Level, Hourmeter Visual Indicators............................................................................................................Boom Angle, Frame Angle

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GENERAL

ELECTRICAL SYSTEM Type ............................................................................................................................... 12-Volt, Negative Ground Battery ...................................................................................... One - 950 minimum CCA Low-Maintenance Type Alternator.................................................................................................................................................... 50 Amp Circuit Protection ...................................................................................................................................Fuse Panel Backup Alarm .........................................................................................................................................107 dB (A) Horn .......................................................................................................................................................111 dB (A) Neutral Start Switch ................................................................................................................................. Standard Headlights ................................................................................................................................................. Optional Brake/Tail Lights ....................................................................................................................................... Optional

LIFTING PERFORMANCE Maximum Lift Capacity: ......................................................................................................... 5500 lbs. (2495 kg) Maximum Lift Height:...................................................................................................................... 19’ 1” (5.8 m) Capacity at Maximum Lift Height:......................................................................................... 3000 lbs. (1360 kg) Maximum Forward Reach to Load Center: ......................................................................................11’ (3.35 m) Capacity at Maximum Forward Reach: .................................................................................. 1850 lbs. (839 kg) Maximum Reach Below Grade:............................................................................................................ 0” (0 mm)

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GENERAL GENERAL DIMENSIONS

Based on standard machine equipped with listed tires, 48” (1.2 m) masonry carriage and 48” (1.2 m) pallet forks.

Recommended Tire Type:......................................................................................................... 12-16.5 NHS 10-ply Overall Length (less forks): ................................................................................................................ 148” (3.76 m) Overall Width: ........................................................................................................................................ 71” (1.80 m) Overall Height: ....................................................................................................................................... 76” (1.93 m) Ground Clearance: .............................................................................................................................. 14” (356 mm) Wheel base:............................................................................................................................................ 90” (2.29 m) Turning Radius (outside):................................................................................................................... 132” (3.35 m) Machine Weight: ...................................................................................................................... 10,000 lbs. (4536 kg)

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GENERAL 519 Load Zone Charts

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GENERAL 519 Load Zone Charts

Decal 210021 Fork Shift

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Decal 210022 Side Shift

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Section 201 ENGINE REMOVAL AND INSTALLATION 519 Telehandler

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GENERAL TABLE OF CONTENTS ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SPECIAL TORQUE VALUES U.S. Value Metric Value Engine Mount Bolts ................................................................ 150 to 180 lb.-ft.......................... 203 to 244 Nm Ground Wire Bolts ............................................................................37.5 lb.-ft.......................................51 Nm Exhaust Bolts ......................................................................................53 lb.-ft.......................................72 Nm Fan Shroud Bolts ......................................................................... 9 to 10 lb.-ft.............................. 12 to 14 Nm Fan Guard Bolts ........................................................................... 9 to 10 lb.-ft.............................. 12 to 14 Nm Hydraulic Cooler Mounting Bolts ................................................ 30 to 35 lb.-ft.............................. 41 to 47 Nm Air Cleaner Mounting Bolts.........................................................30 to 35 lb.-ft. ............................ 41 to 47 Nm Radiator Mounting Bolts .............................................................30 to 35 lb.-ft. ............................ 41 to 47 Nm Front Wheel-well Mounting Bolts ................................................30 to 35 lb.-ft. ............................ 41 to 47 Nm Rear Wheel-well Mounting Bolts.................................................30 to 35 lb.-ft. ............................ 41 to 47 Nm Muffler Mounting Bolts .................................................................9 to 10 lb.-ft. ............................ 12 to 14 Nm High Pressure Hydraulic Hose Flange Bolts ...............................45 to 50 lb.-ft. ............................ 61 to 68 Nm Hydrostatic Pump Mounting Bolts........................................... 220 to 240 lb.-ft. .........................298 to 325 Nm

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ENGINE

ENGINE REMOVAL

STEP 3

BEFORE cleaning, lubricating or servicing this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information and Decal Locations).

STEP 1

G0607001

Remove the battery. Complete Steps 1 through 5 of Section 302 for the correct procedure.

STEP 4

G0607021

Remove the engine cover. Complete Steps 1 through 3 of Section 800 for the correct procedure.

STEP 2

G0707007

Open the radiator drain valve and drain the coolant into an approved container.

NOTE: Attaching a hose to the drain valve will help direct the coolant flow to the container.

STEP 5 G0707005

Remove the radiator cover. Complete Steps 8 through 10 of Section 800 for the correct procedures.

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After all the coolant is drained, close the drain valve.

Recycle or dispose of the coolant in an environmentally safe manner.

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ENGINE

STEP 6

STEP 9 2

1

G1107042

G0707048

Remove the two bottom wheel-well mounting bolts.

Remove the hose clamp (1) and the over-flow hose (2).

STEP 7

STEP 10

G1107043

Remove the two side wheel-well mounting bolts.

G0707046

Remove the inner fan guard mounting bolt.

STEP 8

STEP 11 2 1

1 G1107046

Remove the top wheel-well mounting bolt and remove the wheel-well.

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G0707009

Remove the two outer fan guard mounting bolts (1) and the fan guard (2).

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ENGINE

STEP 12

STEP 15 1 2 1

2

1

1

3 G0707017

G1107044

Loosen the hose clamps (1) and remove the upper radiator hose (2).

Remove the two exhaust pipe mounting bolts (1), exhaust pipe (2) and gasket (3).

STEP 13

STEP 16

1 2

3 G0707026

G1107045

Loosen the two clamp nuts and the exhaust clamp.

Loosen the hose clamp (1) and remove the lower radiator hose (2) from the water pump (3).

STEP 14

STEP 17

G1107060

Remove the four nuts and bolts from the muffler mounting brackets and remove the muffler.

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G1107041

Remove the lower radiator bracket bolt.

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ENGINE

STEP 18

STEP 21

G1107079

G1107052

With the help of an assistant, remove the three side mounting bolts from the radiator bracket and remove the radiator.

Remove the two air filter bracket mounting bolts an remove the air filter assembly.

STEP 22

STEP 19

1

2

2

1

G0208007

Loosen the hose clamp (1) and remove the upper air intake hose (2).

Loosen the hydraulic oil fill cap (1) to relieve residual pressure in the system. Remove the hydraulic hose (2) from the oil cooler. Install a cap and plug on the fittings.

STEP 20

STEP 23

G1107049

1

1

2 1

G1107051

G020809

Loosen the hose clamp (1) and remove the lower intake hose (2).

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Disconnect the tube (1) from the oil filter. Cap and plug the fittings. Disconnect the hydraulic tank breather line (2).

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ENGINE

STEP 24

STEP 27

1

1

1

G0208013

G0707014

Disconnect the hydraulic reservoir fill hose.

Remove the three front hydraulic cooler mounting bolts (1).

STEP 25

STEP 28

2

1

G1107058

Loosen the hose clamp (1) and remove the drain hose from the air box weldment (2).

Remove the oil cooler mounting bolts.

STEP 26

STEP 29

G0208008

1 2

2 1

1

G1107088

G0208018

Remove the two hoses (1) from the coolant recovery tank and remove the P-clamp mounting bolt (2).

Remove the hydraulic filter (1). Remove the cooler mounting bolt (2). With the help of an assistant, remove the hydraulic cooler. Install a cap on the hydraulic reservoir fill fitting and a plug in the line from Step 24.

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ENGINE

STEP 30

STEP 32 2

1

G1107048

G0707022

If equipped, label and loosen the two heater hose clamps. Disconnect the heater hoses.

Remove the throttle linkage (1) from the fuel injector pump. Remove the throttle cable from the throttle cable mounting bracket (2).

NOTE: Place a container under the hoses prior to disconnecting.

STEP 33

STEP 31

G1107062

Label and disconnect the three electrical connectors.

G0707044

If equipped, pull the two heater hoses through the Pclamp and install plugs in the lines.

STEP 34

G1107061

Remove the two ground wire mounting bolts.

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ENGINE

STEP 35

STEP 38

G1107063

G1107066

Disconnect the hydraulic hose from the hydraulic test port on the battery tray. Cap and plug the fittings.

Remove the two front wheel-well side mounting bolts. Remove the front wheel-well.

STEP 36

STEP 39

G1107065

G1107069

Remove the front wheel-well outer mounting bolt.

STEP 37

G1107074

Loosen the top and bottom high pressure hose flange mounting bolts.

G1107067

Remove the two front wheel-well lower mounting bolts.

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ENGINE

STEP 40

STEP 42

G1107070

G1107073

Using lifting straps and a chain hoist, support the hydrostatic pump and the gear pump.

Move the hydrostatic pump assembly forward until it is clear of the engine.

STEP 41

STEP 43

G1107064

G1107076

Lower the hydrostatic pump assembly onto the blocking. Tape the pump spline to protect it during engine removal and installation.

STEP 44

G1107068

Remove the two hydrostatic pump mounting bolts.

G0707019

Disconnect the two fuel lines. Install plugs into the fuel lines.

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ENGINE

STEP 45

STEP 47 1

2

G0707035

2

G1107078

Remove the two left side engine mounting bolts.

Attach a 2000 lb. (920 kg) or larger capacity load rotor (1) to the lifting brackets (2). Attach the load rotor to the hoist. Raise the hoist enough to support the weight of the engine.

STEP 46

STEP 48 3 2 1 3 G0707033

Remove the two latch bracket bolts (1) and engine cover latch bracket (2). Remove the two right side engine mounting bolts (3).

G1107077

Lift the engine until the oil pan and engine mounts clear the frame rail; then remove the engine from the machine.

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ENGINE

ENGINE INSTALLATION

STEP 3

STEP 1

1 1 2 1 3 2

2 G0707033

G0707038

Install a 2000 lb. (920 kg) or larger capacity load rotor (1) to the lifting brackets (2). Attach the load rotor to a heavy-duty portable hoist.

Install the right side engine mount bolts, washers and lock nuts (1) onto the engine mounts. Install the engine cover latch bracket (2) with the two mounting bolts (3).

STEP 4

STEP 2

G0707035

G1107077

Move the engine over the engine mount holes and lower into place.

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Install the left side engine mount bolts, washers and lock nuts onto the engine mounts. Torque the engine mount bolts to 150 - 180 lb.-ft. (200 - 240 Nm).

Remove the load rotor and hoist.

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ENGINE

STEP 5

STEP 7

G0707019

G1107068

Install the fuel supply and return line.

STEP 6

G1107064

G1107070

Remove protective tape from the pump spline. Using lifting straps and a chain hoist, move the hydrostatic pump assembly into the engine.

913302

Install the two hydrostatic pump mounting bolts and tighten to a torque of 220 - 240 lb.-ft. (300 - 325 Nm).

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ENGINE

STEP 8

STEP 10

G1107069

G1107067

Install the two lower wheel-well mounting bolts.

STEP 11

G1107074

Tighten the top and bottom high pressure hose flange mounting bolts to a torque of 45 - 50 lb.-ft. (60 - 70 Nm).

STEP 9

G1107065

Install the front wheel-well outer mounting bolt.

Tighten all of the wheel-well mounting bolts to a torque of 30-35 lb.-ft. (40 - 50 Nm).

STEP 12

G1107066

Install the two front wheel-well mounting bolts.

G1107063

Install the hydraulic hose to the battery tray test port and tighten.

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ENGINE

STEP 13

STEP 16 2 1

1 2

1

G1107061

G0707044

Install the three ground wires (1) and the two mounting bolts (2). Tighten the mounting bolts to a torque of 38 lb.-ft. (50 Nm).

If equipped, remove the plugs in the heater hoses and slide them through the P-clamp.

STEP 17

STEP 14

G1107048

Connect the three wiring harness connectors.

If equipped, install the heater lines and tighten the two hose clamps.

STEP 15

STEP 18

G1107062

2

2

1 3

1

G0707022

G0208018

Install the throttle linkage (1) to the fuel injector pump. Install the throttle cable onto the throttle cable mount bracket (2).

With the help of an assistant, install the hydraulic cooler (1), and cooler mounting bolt (2). Install the hydraulic filter (3).

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ENGINE

STEP 19

STEP 22

1

1

G0707014

Install the three hydraulic cooler mounting bolts.

G0208009

Remove the caps and plugs. Connect the hydraulic tank breather line (1) and the tube (2) to the oil filter.

STEP 20

STEP 23

2 1

G0208008

Install the two mounting bolts and tighten all of the hydraulic cooler mounting bolts to a torque of 30 - 35 lb.-ft. (40 - 50 Nm).

Install the drain hose (1) and tighten the hose clamp (2).

STEP 21

STEP 24

G1107058

G0208013

Tighten the hydraulic reservoir fill line.

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G0208010

Remove the cap and plug, then install the hydraulic cooler hose.

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ENGINE STEP 28

STEP 25 1

2

2

1

1

G1107088

G1107051

Install the two coolant recovery tank hoses (1) and the P-clamp mounting bolt (2).

Install the lower air intake hose (1) and tighten the hose clamp (2).

STEP 26

STEP 29 2

1

2

2 G1107052

G1107079

Install the air cleaner assembly and tighten the bracket bolts to a torque of 30 - 35 lb.-ft. (40 - 50 Nm).

With the help of an assistant, install the radiator (1) and the three side mounting bolts (2).

STEP 30

STEP 27

1 2

G1107041 G1107049

Install the upper air intake hose (1) and tighten the hose clamp (2).

913302

Install the lower radiator mounting bracket bolts.

Tighten all of the radiator mounting bolts to a torque of 30 - 35 lb.-ft. (40 - 50 Nm).

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ENGINE STEP 34

STEP 31

3 1

2 G1107045

Install the lower radiator hose (1) onto the water pump (2) and tighten the hose clamp (3).

G0707026

Tighten the exhaust clamp.

STEP 35

STEP 32

2

3

1

2

3

2 1 G0707017 G1107044

Install the exhaust pipe gasket (1), exhaust pipe (2) and the two exhaust pipe mounting bolts (3). Tighten the two bolts to a torque of 35 lb.-ft. (50 Nm).

Install the upper radiator hose (1) and tighten the two hose clamps (2).

STEP 36

STEP 33 2 1

2

2

1

2

2 2 G0707009

G1107060

Install the fan guard (1) and the two outer mounting bolts (2).

Install the muffler (1) and tighten the muffler mounting bolts and nuts (2).

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ENGINE

STEP 37

STEP 40

G0707046

Install the inner fan guard mounting bolt. Tighten all of the mounting bolts to a torque of 9 - 10 lb.-ft. (12 14 Nm).

G1107042

Install the two bottom wheel-well mounting bolts.

STEP 41

STEP 38 1

2

G1107046

G0707048

Install the coolant over-flow hose (1) and fasten to the fan guard with a zip-tie (2).

Install the top wheel-well mounting bolt. Tighten all of the wheel-well mounting bolts to a torque of 30 - 35 lb.-ft. (40 - 50 Nm).

STEP 42

STEP 39

G0607001 G1107043

With the help of an assistant, install the rear wheelwell side mounting bolts.

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Install the battery. Complete Steps 6 through 9 of Section 302 for the correct procedure.

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ENGINE

STEP 43

STEP 45 See the Operator’s Manual for the specified hydraulic fluid, engine coolant and correct levels.

Fill the hydraulic reservoir with the specified oil.

Fill the radiator and engine block with the specified coolant.

Bleed the fuel system by following the procedures in the Service / As Required section of the Engine Operation and Maintenance Manual.

G0707005

Install the radiator cover. Complete Steps 11 and 12 of Section 800 for the correct procedure.

STEP 44

STEP 46 Start the engine and run until the coolant has reached operating temperature. Adjust the throttle cable linkage until the engine speed is 1100 RPM at low idle and 2700 to 2800 RPM at high idle.

STEP 47 Check the hydraulic functions for proper operation.

Shut off the engine and check for leaks and correct fluid levels.

G0607021

Install the engine cover. Complete Steps 4 through 6 of Section 800 for the correct procedure.

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Section 301 ELECTRICAL SCHEMATICS, TROUBLESHOOTING TESTING AND ADJUSTMENT PROCEDURES 519 Telehandler

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TABLE OF CONTENTS TROUBLESHOOTING................................................................................................................................... 2 STARTER CIRCUIT TROUBLESHOOTING .................................................................................................... 2 PARK BRAKE CIRCUIT TROUBLESHOOTING .............................................................................................. 4 STEERING MODE CIRCUIT TROUBLESHOOTING ....................................................................................... 6 INSTRUMENT PANEL OR PANEL BULB REPLACEMENT ................................................................................ 7 ELECTRICAL SCHEMATICS ................................................................................................................................ 8 ELECTRICAL SYSTEM TESTS .......................................................................................................................... 10 BATTERY TEST .............................................................................................................................................. 10 FUSE POWER TESTS ................................................................................................................................... 11 IGNITION RELAY TESTS .............................................................................................................................. 12 STARTER TESTS ............................................................................................................................................ 12 KEY SWITCH AND STARTER SWITCH TESTS .......................................................................................... 13 FUEL SHUT-OFF SOLENOID TEST ............................................................................................................. 16 PARK BRAKE CIRCUIT TESTS .................................................................................................................... 17 STEERING MODE CIRCUIT TESTS ............................................................................................................. 20

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ELECTRICAL

STARTER CIRCUIT TROUBLESHOOTING The engine does not start. Does the starter engage and turn over the engine?

YES Is there 12 volts at the fuel shut-off solenoid?

NO Is the transmission shift lever in neutral?

YES

NO

Check the fuel system pressure before replacing the fuel solenoid.

Is the fuel shut-off solenoid fuse (Fuse #2) open?

YES Replace the fuel shut-off fuse.

NO Repair or replace the wires between the fuel shut-off solenoid and the fuse.

YES Is the battery fully charged?

NO Move the shift lever to the neutral position.

YES Is the battery properly grounded?

NO Charge or replace the battery.

YES Is the ignition fuse (Fuse #1) open?

NO Replace the battery ground cable.

YES Replace the ignition fuse.

NO Is there 12 volts at the power terminal of the ignition fuse?

YES Is the gear selector fuse (Fuse #2) open?

NO Replace the 60 amp in-line fuse between the battery terminal of the starter relay and the fuse box.

NO With the key switch ON, is there 12 volts at the power terminal of the gear selector fuse (Fuse#2)?

YES Replace the gear selector fuse (Fuse #2).

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ELECTRICAL

STARTER CIRCUIT TROUBLESHOOTING (Cont’d)

NO Is there 12 volts at the battery terminal of the key switch?

YES With the key switch ON, is there 12 volts at the ignition terminal of the key switch?

NO Replace the 60-amp in-line fuse.

YES Replace the ignition relay.

NO Replace the key switch.

YES Use a multimeter to test. Is there 12 volts at the battery terminal of the starter?

YES With the key switch ON and the starter switch depressed, is there 12 volts at the starter terminal of the starter solenoid?

NO Replace the battery cables between the starter and the battery.

YES Repair or replace the starter and/or starter solenoid.

NO With the key switch on, is there 12 volts at the white/blue wire terminal at the starter switch?

YES With the starter switch depressed, is there 12 volts at the white wire terminal of the starter switch?

NO Replace the gear selector switch.

YES Repair or replace the wire between the starter switch and starter solendoid.

NO Replace the starter switch.

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ELECTRICAL

PARK BRAKE CIRCUIT TROUBLESHOOTING The park brake switch is OFF, but the brakes do not release.

Is there 12 volts at the park brake solenoid?

YES Replace the park brake solenoid coil and or the park brake solenoid valve cartridge.

NO Is the park brake fuse (Fuse #2) open?

YES Replace the fuse.

NO Is there 12 volts to the park brake relay terminal #87a (Socket #3)?

YES

NO Is there 12 volts to the park brake relay terminal #30 (Socket #4)?

Repair or replace the wire between the park brake relay and the park brake solenoid.

YES Is there 12 volts at the park brake relay terminal #85 (Socket #2)?

NO Repair or replace the wire from the fuse to the park brake relay.

YES Replace the park brake switch.

NO Replace the park brake relay.

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ELECTRICAL

PARK BRAKE CIRCUIT TROUBLESHOOTING (CONT’D) Park brake switch is ON, but the park brake does not apply.

Is there 12 volts at the park brake solenoid?

YES Is there 12 volts at terminal #85 (Socket #2) of the park brake relay?

NO Replace the park brake solenoid.

YES Replace the park brake relay.

NO Is there 12 volts at terminal #3 of the park brake switch?

YES Repair or replace the wire between terminal #3 of the park brake switch and terminal #85 (Socket #2) of the park brake relay.

NO Replace the park brake switch.

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ELECTRICAL

STEERING MODE CIRCUIT TROUBLESHOOTING Does the steering mode change when the steering mode switch is moved to different mode positions?

YES Is there 12 volts at the a coil in Crab mode and b coil in 4 Wheel steer mode?

NO Replace the steering mode fuse (Fuse #2). Is there 12 volts at the fuse terminals of the steer mode selector switch (terminal #2)?

YES Replace the coil and/or the steer mode control valve.

NO Is there 12 volts at the solenoid terminal of the steer mode selector switch (terminal 3 for Crab, terminal 1 for 4 Wheel)?

YES Repair or replace the wire between the switch and the solenoid.

NO Replace the steer mode selector switch.

YES Is there 12 volts at the solenoid terminals of the steer mode selector switch in Crab or 4 Wheel mode?

NO Repair or replace the wire between the fuse (Fuse #2) and the switch.

YES Is there 12 volts at the steer mode selector valve solenoids?

NO Replace the steer mode selector switch.

YES Repair or replace the steer mode selector valve and/or the valve solenoids.

NO Repair or replace the wire between the switch and the solenoids.

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ELECTRICAL

INSTRUMENT PANEL OR PANEL BULB REPLACEMENT STEP 1

STEP 3

G1007037

G1007041

Pull the instrument panel out from the dash. Mark the position of all connectors on the instrument panel for reassembly. Remove the connectors.

Turn the key switch OFF.

STEP 2 STEP 4 To remove the panel bulbs, turn the bulbs 1/4 turn counterclockwise.

STEP 5 Install the new bulbs and turn 1/4 turn clockwise to lock into the panel.

Reconnect the switch and gauge connectors.

STEP 6

G1007036

Remove the six screws securing the instrument panel.

2

2

2

1 G1007036

Install the instrument panel (1) using the six screws (2).

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ELECTRICAL ELECTRICAL SCHEMATICS

MA08B041

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ELECTRICAL

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ELECTRICAL ELECTRICAL SYSTEM TESTS

NOTE: Use the troubleshooting flow charts for the sequence of component testing and the following steps for test locations and procedures. Always refer to the wiring schematics when doing circuit testing for a better understanding of the circuit.

WARNING If there is no voltage, the battery has an internal open circuit. Connecting a charger or auxiliary battery to a battery with an open circuit can cause a battery explosion.

WARNING When the test involves turning over the engine or starting the engine, use test leads long enough to read the multimeter from the operator’s seat or standing clear of the machine.

If there is voltage, but is less than 12 volts, proceed to the next step.

STEP 2

NOTE: Use a multimeter for all tests. ALWAYS install the ground (-) test lead to a clean, bare metal surface on the engine or frame.

BATTERY TEST

1 2

STEP 1

G1007043

2

Remove the positive (+) battery cable (1) from the battery. Connect the multimeter negative (-) test lead to the positive battery cable (1). Be sure the cable end is not in contact with any metal surfaces.

Connect the positive (+) test lead to the positive (+) post (2) of the battery. The multimeter should read 0 volts.

1 G1007042

Set the multimeter to DC volt s. Connect the multimeter positive (+) test lead to the positive post (1) and the negative (-) test lead to the negative post (2) of the battery. The multimeter should read 12 to 13 volts.

If there is voltage between the positive battery cable (1) and the battery post (2), check the wiring for shorts to ground.

If there is no voltage, recharge or replace the battery.

Install the positive (+) battery cable (1) on the battery.

If there is no voltage, replace the battery.

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ELECTRICAL

FUSE POWER TESTS

STEP 4

STEP 3

1 G1007040

G1007038

Connect the positive (+) test lead to the front (top side) terminal of Fuses 2 through 6. Turn the key switch to the ON position. The multimeter should read 12 to 13 volts.

If there is no voltage, proceed to Step 12.

G1007040

Open the fuse panel cover (1). Connect the positive (+) test lead to the bottom terminal of Fuse 1 to test for battery 12-volt power to the fuse panel. The multimeter should read 12 to 13 volts.

If there is no voltage, replace the 60-amp in-line fuse under the starter relay, or repair or replace the wires between the battery and the fuse panel.

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ELECTRICAL

IGNITION RELAY TESTS

STEP 6

STEP 5

G1007120

G1007120

Connect the positive (+) test lead to the right side terminal (#3) of the relay socket. The multimeter should read 12 to 13 volts.

Connect the positive (+) test lead to the bottom terminal (#2) of the relay socket. Turn the key to the ON position. The multimeter should read 12 to 13 volts.

If there is no voltage, proceed to Step 12.

If there is 12 to 13 volts, but the relay does not work, replace the relay.

STARTER TESTS STEP 7

G0208004

If there is no voltage, replace the 60-amp in-line fuse by the engine, or repair or replace the wires between the relay socket and the battery.

If there is 12 to 13 volts, proceed to the next step.

G1007046

Connect the positive (+) test lead to the battery terminal of the starter. The multimeter should read 12 to 13 volts.

If there is no voltage, clean or replace the positive (+) battery cable between the starter and the battery.

If there is 12 to 13 volts, proceed to the next step.

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ELECTRICAL STEP 9

WARNING When the test involves turning over the engine or starting the engine, use test leads long enough to read the multimeter from the opera tors seat or standing clear of the machine.

STEP 8 G0208005

Connect the positive (+) test lead to the starter terminal (located just below the battery terminal) of the starter solenoid. Turn the key switch to the ON position and press the starter button. The multimeter should read 12 to 13 volts.

If there is no voltage, proceed to the next step.

If there is 12 to 13 volts, and the starter does not turn over the engine, repair or replace the starter and/or the starter solenoid.

G1007055

Remove the wire connector from the fuel shutoff solenoid.

KEY SWITCH AND STARTER SWITCH TESTS STEP 10

1

2 G1007037

Remove the retaining nut from the key switch (1) and the rubber button guard from the starter button (2).

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ELECTRICAL

STEP 11

If there is 12 to 13 volts, proceed to the next step.

STEP 13 1

1

1

2 G1007036

G1007050

Connect the positive (+) test lead to the ignition (blue/ red wire) terminal of the key switch. Turn the key switch to the ON position. The multimeter should read 12 to 13 volts.

If there is no voltage, replace the key switch.

If there is 12 to 13 volts, proceed to Step 18.

STEP 14 G1007041

Remove the six screws (1) from the instrument panel (2). Pull the instrument panel outward to gain access to the wire harnesses and switches.

STEP 12

G1007051

Connect the positive (+) test lead to the white/blue wire terminal of the starter button. Turn the key switch to the ON position. With the transmission lever in neutral the multimeter should read 12 to 13 volts.

If there is no voltage, check the transmission fuse (fuse #2). If the fuse is not open, proceed to the next step.

G1007049

Connect the positive (+) test lead to the battery (red wire) of the key switch. The multimeter should read 12 to 13 volts.

If there is 12 to 13 volts, proceed to the next step.

If there is no voltage, check the ignition fuse (fuse #1) or the wires to the battery.

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ELECTRICAL

STEP 15

STEP 17

G0208001

G1007052

Connect the positive (+) test lead to the black/yellow wire terminal on the transmission control module.

Turn the key switc h to the ON position. The multimeter should read 12 to 13 volts.

Connect the positive (+) test lead to the white wire terminal of the starter button. Place the transmission lever in the neutral position, turn the key switch to the ON position and press the starter switch button. The multimeter should read 12 to 13 volts.

If there is no voltage, replace the wire between the transmission control module and the fuse.

If there is no voltage, replace the starter switch.

If there is 12 to 13 volts, but there was no voltage at the starter solenoid terminal (Step 9), repair or replace the wire between the switch and starter solenoid.

If there is 12 to 13 volts, proceed to the next step.

STEP 16

STEP 18

G0208003

Connect the positive (+) test lead to the white/blue wire terminal of the transmission control module.

Turn the key switch to the ON position. With the transmission lever in neutral the multimeter should read 12 to 13 volts.

1

2 G1007037

Install the key switch (1) and the starter button (2).

If there is no voltage, replace the transmission lever/ switch assembly.

If there is 12 to 13 volts, proceed to the next step.

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ELECTRICAL

STEP 19

STEP 21 2

1

G1007036

Install the instrument panel using the six screws.

G1007057

Check the fuel shut-off solenoid fuse (#2) (1) and test for power to the fuse, refer to (Step 4). Check the ignition relay power (2), refer to (Steps 5 and 6).

If the fuel shut-off fuse and ignition relay are operating properly, repair or replace the red wire between the fuse and the fuel shut-off solenoid.

FUEL SHUT-OFF SOLENOID TEST STEP 20

G1007056

Install the positive (+) test lead to the fuel shut-off solenoid. Turn the key switch to the ON position. The multimeter should read 12 to 13 volts.

If there is no voltage, proceed to the next step.

If there is 12 to 13 volts, but the engine will not start, replace the fuel shut-off solenoid valve.

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ELECTRICAL

PARK BRAKE CIRCUIT TESTS

STEP 24

STEP 22

1 2

G1007045

G1007057

Check the park brake fuse (#2) (1) and test for power to the fuse, refer to (Step 4). Check the ignition relay power (2), refer to (Steps 5 and 6).

If there is 12 to 13 volts at the park brake fuse, proceed to the next step.

Connect the positive (+) test lead to the bottom terminal (#2) of the relay socket (relay terminal 85).

With the key switch and park brake switch in the ON position, the multimeter should read 12 to 13 volts.

If there is no voltage, proceed to Step 30.

If there is 12 to 13 volts, proceed to the next step.

STEP 25 STEP 23

G1007036 G1007044

Remove the park brake relay. Connect the positive (+) test lead to the right side terminal (#3) of the park brake relay socket (relay terminal 30). Turn the key switch to the ON position.

Move the park brake switch to the OFF position. The multimeter should read 0 volts.

If there is no voltage, proceed to the next step.

If there is 12 to 13 volts, proceed to Step 28.

If there is no voltage, repair or replace the wiring between the fuse and the relay.

If there is 12 to 13 volts, proceed to the next step.

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ELECTRICAL STEP 28

STEP 26

G1007058

G1007036

Install park brake relay. Connect the positive (+) test lead and the negative (-) test lead to the park brake solenoid valve wire harness as shown. With the key switch in the ON position and the park brake switch in the OFF position, the multimeter should read 12 to 13 volts.

See Step 13 for instructions to remove the instrument panel to gain access to the park brake switch.

STEP 29

If there is no voltage, replace the park brake relay.

If there is 12 to 13 volts, and the park brake will not release, test the park brake hydraulic circuit before replacing the park brake solenoid valve.

STEP 27

G1007053

Connect the positive (+) test lead to the #2 terminal (brown/yellow wire) of the park brake switch. With the key switch in the ON position, the multimeter should read 12 to 13 volts.

If there is no voltage, repair or replace the wire between the switch and the park brake fuse.

If there is 12 to 13 volts, proceed to the next step.

G1007036

Move the park brake switch to the ON position. The multimeter should read 0 volts.

If there is no voltage and the park brake will not apply, replace the park brake solenoid.

If there is 12 to 13 volts, proceed to the next step.

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ELECTRICAL

STEP 30

STEP 32

2

2

2

1 G1007054

Connect the positive (+) test lead to the relay terminal (tan/red wire) of the park brake switch. With the key switch and park brake switch in the ON position, the multimeter should read 12 to 13 volts.

G1007036

Install the instrument panel (1) using the six screws (2).

If there is no voltage, replace the park brake switch.

If there is 12 to 13 volts, but no voltage at Step 24, replace the tan/red wire between the switch and the relay.

STEP 31

G1007036

Move the park brake switch to the OFF position. The multimeter should read 0 volts.

If there is 12 to 13 volts, replace the park brake switch.

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ELECTRICAL

STEERING MODE CIRCUIT TESTS STEP 33

2 1

G1007060

G1007040

Test for power to the fuse #2 (1) and the ignition relay (2) and check fuse #2 (1).

Install the positive (+) test lead in the orange/white prong of the wire harness. With the key switch in the ON position and the steer mode switch in the crab steer position, the multimeter should read 12 to 13 volts.

If there is no voltage, proceed to Step 35.

STEP 34

G1007059

Set the multimeter to read DC volts. Disconnect the 4-wheel steer wire harness (green and black wires) from the steer mode solenoid connector located under the front cover.

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G1007059

If there is 12 to 13 volts, but the 4-wheel steer mode does not function, replace the solenoid valve.

Connect the wire harness to the 4-wheel steer mode solenoid connector.

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ELECTRICAL STEP 36

STEP 35

G1007061

Disconnect the 4-wheel steer wire harness (green/ blue and black wires) from the steer mode solenoid connector. Install the positive (+) test lead in the green/blue wire prong of the wire harness. With the key switch in the ON position and the steer mode switch in the 4-wheel steer position, the multimeter should read 12 to 13 volts.

G1007062

Complete step 13 to remove the instrument panel.

Connect the positive (+) test lead to the black/yellow wire terminal of the steer mode switch located on the left side of the instrument panel. With the key switch in the ON position the multimeter should read 12 to 13 volts.

If there is no voltage, repair or replace the black/ yellow wire between the switch and the fuse panel.

If there is no voltage, proceed to the next step.

If there is 12 to 13 volts, proceed to the next step.

STEP 37

G1007059

If there is 12 to 13 volts, but the 4-wheel steer mode does not function, replace the solenoid valve.

Connect the wire harness to the 4-wheel steer mode solenoid connector.

G1007063

Connect the positive (+) test lead to the orange/white wire terminal of the steer mode switch. With the key switch in the ON position and the steer mode switch in the CRAB STEER position, the multimeter should read 12 to 13 volts.

If there is no voltage, replace the steer mode switch.

If there is 12 to 13 volts, but no voltage in Step 41, repair or replace the orange/white wire between the switch and the solenoid valve.

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ELECTRICAL

STEP 38

G1007064

Connect the positive (+) test lead to the green/blue wire terminal of the steer mode switch. With the key switch in the ON position and the steer mode switch in the 4-WHEEL STEER position, the multimeter should read 12 to 13 volts.

If there is no voltage, replace the steer mode switch.

If there is 12 to 13 volts, but no voltage in Step 42, repair or replace the green/blue wire between the switch and the solenoid valve.

STEP 39

2

2

2

1 G1007036

Install the instrument panel (1) using the six screws (2).

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GENERAL TABLE OF CONTENTS BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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BATTERY

BATTERY REMOVAL

STEP 1

BEFORE starting any cleaning, lubricating or servicing of this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in the Safety Section of this manual.

G0607022

Open the engine cover.

Engine Cover

STEP 2 G0607021

The battery is located under the engine cover.

WARNING BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL - flush with water. INTERNAL Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a physician immediately.

G0607002

Remove the negative (-) battery cable from the battery.

EYES - Flush with water for 15 minutes and get prompt medical attention. BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame and cigarettes away. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

WARNING Always remove the negative (-) battery cable first so you do not cause a spark at the battery. A spark can cause the battery to explode and cause personal injury or damage to the machine.

WARNING When working around storage batteries, remember that all of the exposed metal parts are LIVE. Never lay a metal object across the terminals because a spark or short circuit will result.

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BATTERY

STEP 3

STEP 5

G0607003

G0607006

Remove the positive (+) battery cable from the battery.

Carefully slide the battery out of the battery compartment and remove.

STEP 4 2 1 1

G0607005

Remove the two wing nuts (1) from the battery holddown rods, then remove the hold-down bar (2).

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BATTERY

BATTERY INSTALLATION

STEP 8

STEP 6

G0607003

Install the positive (+) battery cable on the positive (+) battery post.

G0607006

Carefully slide the battery into the battery compartment.

WARNING

STEP 7

Always install the negative (-) battery cable last so you do not cause a spark at the battery.

A spark can cause the battery to explode and cause personal injury or damage to the machine.

1 2

2

STEP 9

G0607005

Install the hold-down bar (1) and rods and secure with the two wing nuts (2).

G0607002

Install the negative (-) battery cable on the negative (-) battery post.

IMPORTANT: Be sure the cables and battery terminals are clean and tight.

IMPORTANT: Be sure the battery cables are routed correctly and secured away from sharp edges, hot or moving objects.

Close the engine cover.

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Section 401 STEERING CONTROL VALVE REMOVAL AND INSTALLATION 519 Telehandler

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GENERAL TABLE OF CONTENTS STEERING CONTROL VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STEERING CONTROL VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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519 Telehandler

STEERING CONTROL VALVE

STEERING CONTROL VALVE REMOVAL

STEP 5

BEFORE starting any cleaning, lubricating or servicing of this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in the Safety Section of this manual.

STEP 1 Disconnect the battery ground cable.

STEP 2

G0607010

Remove the steering wheel from the steering column.

Loosen the hydraulic oil fill cap to relieve residual pressure on the hydraulic system.

STEP 6

STEP 3

G0607011

G0607007

Unplug the wire harness from the gear selector.

Pry the cap from the center of the steering wheel.

STEP 7

STEP 4

1

2 G0607012

G0607008

Loosen the two bolts (1) and remove the gear selector (2) from the steering column. Mark the position of the gear selector for correct reinstallation.

Loosen and remove the steering wheel nut.

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STEERING CONTROL VALVE

STEP 8

STEP 11

G0607014

G0607031

Remove the six screws from the instrument panel.

Disconnect the wires from the blower.

STEP 12

STEP 9

1

2 G0607016 G0607015

Remove the six screws (1) and remove the blower unit or heater (2).

Reposition the instrument panel in the position shown.

STEP 13

NOTE: Steps 10-12 are for machines equipped with the heater option.

STEP 10

G0607017

NOTE: Place a drip pan under the steering control unit before removing the hoses.

G0607030

Mark the hoses and fittings for correct re-installation.

Loosen and remove the hoses from the steering control valve.

Remove the four screws from the blower unit or heater and position to the side.

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STEERING CONTROL VALVE STEERING CONTROL VALVE INSTALLATION

STEP 14 Install caps and plugs on all hoses and hydraulic fittings to prevent contaminating the hydraulic system.

STEP 16

STEP 15

Remove fittings from the old steering control valve and reinstall in the new one. Replace any fittings that are damaged.

2

Position the steering control valve and steering column together. Make sure the fittings are in the proper position for hose installation. Make sure index hole in the steering column is pointing to the left as shown in Step 14.

STEP 17

2 1 G0607020

Support the steering control valve (1). Loosen and remove the four mounting bolts (2).

Remove the steering control valve assembly.

G0607020

Install the four bolts through the dash and into the steering control valve and tighten.

STEP 18 Remove the caps and plugs from the hoses and fittings.

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STEERING CONTROL VALVE

STEP 19

STEP 22

G0607017

G0607011

Reconnect the hydraulic hoses to the fittings on the steering control valve, as marked in Step 13.

Re-connect the wire harness into the gear selector connector.

STEP 20

STEP 23

2 1

G0607014

G0607010

Re-install the instrument panel (1) and secure with six screws (2).

Re-install the steering wheel.

STEP 24

STEP 21

G0607008

Re-install and tighten the center nut on the steering column shaft and tighten to 35 lb.-ft. (47 Nm).

G0607012

Re-install the gear selector to the steering column using the two bolts. Ensure index pin on the gear selector engages the index hole in the steering column.

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STEERING CONTROL VALVE

STEP 25

STEP 30

2

1 G0707001

G0607016

Re-install the steering wheel center cap.

Re-nstall the heater unit(1) and secure with six screws (2).

STEP 26

NOTE: Steps 31-32 are for machine equipped with the blower option.

Re-connect the battery ground cable.

Tighten the hydraulic tank fill cap.

STEP 31

STEP 27 Start the engine; apply the park brake. Turn the steering wheel in one direction until the wheels reach their travel limits, and then back the other direction to its limit. Repeat this procedure several times until the air is purged from the system.

STEP 28 Shutdown the engine and check for leaks. Correct any leakage found.

G0607031

Reconnect the wires correctly to the blower.

STEP 29 Check the hydraulic fluid level. Add fluid if needed.

STEP 32 2

1 2

G0607030

Re-install the instrument panel (1) and secure with four screws (2).

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Section 501 HYDROSTATIC PUMP REMOVAL AND INSTALLATION 519 Telehandler

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GENERAL TABLE OF CONTENTS HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HYDROSTATIC PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SPECIFICATIONS U.S. Value Metric Value Hydrostatic Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 to 240 lb.-ft. . . . . 298 to 325Nm Flange Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 to 50 lb.-ft. . . . . 61 to 68 Nm

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HYDROSTATIC PUMP

HYDROSTATIC PUMP REMOVAL

STEP 5

BEFORE cleaning, lubricating or servicing this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in the Safety Section of this manual.

STEP 1

G0707013

Disconnect the hydraulic hose from the hydraulic cooler. Install a cap on the fitting and a plug in the hose.

1

STEP 6 G0907021

Drain the hydraulic fluid reservoir by removing the hydraulic fill cap and drain plug (1). Prepare to capture approximately 18 gallons of oil.

1

STEP 2

2

Remove the battery. Complete Steps 1 through 5 of Section 302 for the correct procedure.

STEP 3 Remove the hydraulic pump. Complete Steps 1 through 8 of Section 602 for the correct procedure.

G0707011

Disconnect the hydraulic filter hose (1). Install a cap on the fitting and a plug in the hose. Remove the two mounting bolts (2).

STEP 4 1

STEP 7

2 4

2

3

1

Remove the two lines (1) from the coolant recovery tank. Remove the two mounting bolts (2) and coolant recovery tank (3). Remove the hose P-clamp mounting bolt (4).

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G0707016

Disconnect the hydraulic reservoir fill line.

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HYDROSTATIC PUMP

STEP 8

STEP 10

1

1

1

G0707014

G0607032

Remove the two mounting bolts behind the air filter.

Remove the three front hydraulic cooler mounting bolts (1).

STEP 11

STEP 9 1

1

2

1

2

G0607033

Loosen the two clamps (1) and remove the air filter and hose (2). Install a cap or cover over the turbo inlet.

G0707012

Remove the cooler mounting bolt (1) and with the help of an assistant, remove the hydraulic cooler (2).

Install a cap on the hydraulic reservoir fill fitting and a plug in the line from Step 7.

STEP 12

G0607034

Label and disconnect the solenoid connector.

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HYDROSTATIC PUMP

STEP 13

STEP 15

G0607036

G0607037

NOTE: Place a drip pan under hydrostatic pump before removing hoses.

Label and disconnect the two hoses behind the hydrostatic pump. Install caps on fittings and plugs in hoses.

Label and disconnect the three hydraulic hoses.

Install caps on fittings and plugs in hoses.

STEP 16

STEP 14 1

1 G0607039

2

Install a hoist and lifting strap to support and lift the hydrostatic pump. Remove the mounting bolt (1).

G0607038

Label the supply and pressure line. Remove the fourbolt flange (1) and disconnect the bottom fitting (2).

Install caps on fittings and plugs in hoses.

STEP 17

1

G0607040

Remove the second mounting bolt (1).

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HYDROSTATIC PUMP

STEP 18

G0607041

Pull the hydrostatic pump forward until the input shaft is clear of the engine and lift the pump out of the machine.

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HYDROSTATIC PUMP

HYDROSTATIC PUMP INSTALLATION

STEP 21

Apply a lithium-based grease to the pump splines prior to assembly. Texaco 1912 or equivalent.

STEP 19

G0607039

Install the mounting bolt. Torque both mounting bolts to 220-240 lb.-ft. (298-325 Nm). Remove the hoist and lifting strap.

STEP 22 G0607041

Lower the hydrostatic pump until the input shaft is aligned with the engine crankshaft. Slide the hydrostatic pump fully onto the engine until the mounting flange contacts the engine mount.

STEP 20

G0607037

Remove the caps and plugs and re-connect the two hoses behind the hydrostatic pump.

G0607040

Install the mounting bolt.

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HYDROSTATIC PUMP

STEP 23

STEP 26 1

2 G0607038

G0607033

Remove the caps and plugs and install the four bolt flange (1). Torque to 45-50 lb.-ft. (61-68 Nm).

Reconnect the bottom fitting (2).

Re-install the air filter and hose and tighten the two hose clamps.

STEP 27

STEP 24

G0607032 G0607036

Re-install the two mounting bolts behind the air filter.

Remove the caps and plugs and reconnect the three hoses.

STEP 28

STEP 25 2 1

G0707012

Remove the cap and plug from the hydraulic reservoir fill line and fitting. With the help of an assistant, install the hydraulic cooler (1) and cooler mounting bolt (2).

G0607034

Reconnect the solenoid connector.

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HYDROSTATIC PUMP

STEP 29

STEP 32

1

1

1

G0707014

G0707016

Install the three hydraulic cooler mounting bolts (1).

Tighten the hydraulic reservoir fill line.

STEP 30

STEP 33 3 2 4 2 1 1

2 3

G0707011

G0707049

Install the two mounting bolts (1). Remove the cap and plug and install the hydraulic hose (2).

Install the coolant recovery tank (1) using the two mount bolts (2). Install the two hoses (3) on the tank and install the hose P-clamp bolt (4).

STEP 31

STEP 34 Re-install the hydraulic pump. Complete Steps 11 through 22 of Section 602 for the correct procedures.

STEP 35 Re-install the battery. Complete Steps 6 through 9 of Section 302 for the correct procedure.

STEP 36 Refill the hydraulic reservoir.

STEP 37

G0707013

Remove the cap and plug and install the hydraulic cooler hose.

913302

Start the engine and check for leaks. If no leaks appear, continue to run the engine and test the steering and hydraulic functions for operation. Shut off the engine and check the hydraulic reservoir level.

Add fluid if necessary.

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Section 502 REAR AXLE REMOVAL AND INSTALLATION 519 Telehandler

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GENERAL TABLE OF CONTENTS GENERAL INFORMATION ....................................................................................................................................... 1 REAR AXLE REMOVAL............................................................................................................................................ 1 RELIEVING HYDRAULIC PRESSURE..................................................................................................................... 1 REAR AXLE INSTALLATION.................................................................................................................................... 4

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REAR AXLE

GENERAL INFORMATION

STEP 1

If steering cylinder, brakes or differential repairs are required, the axle assembly must be removed from the chassis. If only the axle steering knuckle or outboard planetary service is required, the axle assembly will not require removal from the chassis.

Procedures used to remove the axle will depend on machine location and the type of lifting equipment available. The following axle removal and installation procedures, using one 10-ton hydraulic floor jack for lifting, can be done in the field or in the shop. The machine must be parked on a solid and level surface.

G0807002

Before starting inspection and repair, move the machine onto a level surface, shut down the engine, and release all hydraulic pressure. Always block the boom securely, or lower it to full ground contact.

Place all controls in neutral.

RELIEVING HYDRAULIC PRESSURE 1. Fully retract and lower the telescoping boom to the ground.

2. Turn the keyswitch to the OFF position to shut down the engine. (See Mandatory Safety Shutdown Procedure.)

WARNING

3. Loosen the hydraulic fill cap to relieve residual pressure in the system.

Tires may be filled with liquid ballast. If filled with liquid ballast, the wheels will be extremely heavy. To prevent injury, remove ballast or use proper wheel handling equipment when dismounting the wheels from the axle hubs.

4. Move the joysticks several times to relieve hydraulic pressure in that circuit.

5. Place chocks or wood blocks around front axle wheels.

STEP 2

REAR AXLE REMOVAL BEFORE cleaning, lubricating, or performing service on this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations).

G0807032

Remove the four bolts that hold the driveshaft to the rear axle assembly. Move the driveshaft to the side.

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REAR AXLE

STEP 3

STEP 6

G0070338

G1107085

Place jack stands in front of the rear axle as shown.

Raise the frame to 16” for clearance to remove the axle.

STEP 4

G1107086

Disconnect both hydraulic steering hoses located on the top side of the axle. Cap and plug fittings.

STEP 7

G0605022

Remove the wheel nuts from the wheel bolts.

STEP 5 Remove each wheel from the axle.

G0807034

Support the axle a s sh own with a 10-ton (or equivalent) floor jack.

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REAR AXLE

STEP 8

STEP 9

1 1 G0807035

G0807039

Lower the axle completely to allow the axle to roll out from under the Telehandler.

2

2

NOTE: If axle repair is required, contact your dealer.

G0807036

Remove the front (1) and rear (2) axle mounting bolts as shown.

NOTE: Locking nuts can be accessed from the bottom of the frame.

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REAR AXLE

REAR AXLE INSTALLATION

STEP 3

STEP 1

G1107085

G0807034

Raise the axle into the frame. Be sure all four alignment bushings fit into the boxes in the frame.

STEP 2

G1107086

Remove the caps and plugs from the hydraulic fittings and connect the steering hoses to the top of the axle.

STEP 4 G0807035

Reinstall each wheel onto the axle.

STEP 5

G0807036

Install the four mounting bolts and nuts. Tighten the bolts to 450 ft.-lb. (607 Nm) torque.

G0605021

Install the wheel nuts on the wheel bolts and hand tighten.

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REAR AXLE

STEP 6

STEP 8

Remove the support stands from under the axle and lower the tires to the floor. Torque all wheel nuts to a final torque of 450 ft.-lb. (607 Nm) torque.

2

STEP 7

1

G1007036

Start the engine, apply the park brake (1). Move the steer mode switch to the 4-wheel steering position (2). Turn the steering wheel in one direction until the wheels reach their travel limits and back the other way to their travel limit. Repeat this procedure several times until the air is removed from the circuit.

G0807032

Reinstall the driveshaft to the axle using the four mounting bolts. Tighten the four bolts to 30 ft.-lb.

(40.5 Nm) torque.

STEP 9 Shut down the engine. Check for leaks. Correct any leakage found. Check fluid level, add fluid if needed.

NOTE: Use Loctite 271 thread lock (or equivalent) on the threads of the bolts.

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GENERAL TABLE OF CONTENTS GENERAL INFORMATION ....................................................................................................................................... 1 FRONT AXLE REMOVAL ......................................................................................................................................... 1 RELIEVING HYDRAULIC PRESSURE..................................................................................................................... 1 FRONT AXLE INSTALLATION ................................................................................................................................. 6

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519 Telehandler

FRONT AXLE

GENERAL INFORMATION

RELIEVING HYDRAULIC PRESSURE

If steering cylinder, brakes or differential repairs are required, the axle assembly must be removed from the chassis. If only axle steering knuckle or outboard planetary service is required, the axle assembly will not require removal from the chassis.

Procedures used to remove the axle will depend on machine location and the type of lifting equipment available. The following axle removal and installation procedures, using one 10-ton hydraulic floor jack for lifting the machine, and to lift and lower the axle assembly, can be done in the field or in the shop.

The machine must be parked on a solid and level surface.

G08-7001

1. Fully retract the telescoping boom.

Before starting inspection and repair, move the machine onto a level surface, shut down the engine, and release all hydraulic pressure. Always block the boom securely, or lower it to full ground contact.

Place all controls in neutral.

2. Raise the telescoping boom far enough to be able to remove the axle from under the frame.

Block the boom using suitable blocking.

3. Turn the keyswitch to the OFF position to shut down the engine. (See Mandatory Safety Shutdown Procedure.)

WARNING

4. Loosen the hydraulic fill cap to relieve residual pressure in the system.

Tires may be filled with liquid ballast. If filled with liquid ballast the wheels will be extremely heavy. To prevent injury, remove ballast or use proper wheel handling equipment when dismounting the wheels from the axle hubs.

5. Move the joysticks several times to relieve hydraulic pressure in that circuit.

STEP 2

FRONT AXLE REMOVAL BEFORE cleaning, lubricating, or performing service on this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations).

STEP 1 NOTE: For ease of service it is recommended that any attachment be removed prior to performing axle service.

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G0605041

Place blocks in front and behind the rear wheels to prevent the machine from rolling when lifted.

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FRONT AXLE

STEP 3

STEP 5

2

2

1

1

G08-7004

G0807006

Remove the four bolts that hold the driveshaft to the front axle.

Remove the front access panel. Remove the window washer reservoir, ground wires (1), hoses (2) and both pump harnesses.

STEP 4

STEP 6

G08-7005 G0807008

Disconnect the hydrostatic drive motor electrical harness.

STEP 7

G1107084

Place a drain pan under the drive motor. Remove the four bolts that hold each drive motor hose to the drive motor.

G0807006

Remove the case drain outlet hose.

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FRONT AXLE

STEP 8

STEP 10

1

G0807020

2

G0807029

Disconnect the case drain inlet hose.

Disconnect the park brake hose (1) and service brake hose (2).

STEP 9

NOTE: If there is insufficient space at the axle, unhook the hoses at the manifold and solenoid.

STEP 11

G0807010

G0807021

Place a floor jack under the front axle and support the frame with a pair of jack stands. Be sure the jack stands are properly rated to support the chassis. Lift the front axle and frame assembly high enough to safely remove the wheels.

G0807009

Disconnect both steering cylinder hoses. Cap fittings and plug hoses.

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FRONT AXLE

STEP 12

STEP 15

1

G0605018

G0807013

Loosen and remove the wheel nuts from the wheel bolts.

Support the drive motor (1) with a lifting strap and a suitable lifting device.

STEP 13

STEP 16

2

1

G0605019

1

G0807013

Remove both wheels and tires from the axle.

Remove the four mounting bolts (1) that hold the drive motor (2) to the front axle. Slide the drive motor rearward away from the front axle and off the drive gear.

STEP 14

STEP 17

G0807024

Remove the four fender nuts. Remove the fender.

G0807022

Remove the four nuts, plates and bolts that hold the axle to the frame.

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FRONT AXLE

STEP 18

G0807016

Carefully lower and roll the axle housing forward with the floor jack. Watch for hose and harness interference during axle removal.

STEP 19 After the axle is removed, have adequate stands and work surface to support the axle safely while performing the repair procedure.

NOTE: If axle repair is required, contact your dealer.

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FRONT AXLE

FRONT AXLE INSTALLATION

STEP 3

STEP 1

2

1

G0807017

Install a new O-ring (1) on the drive motor and carefully align the drive motor with the axle. Be sure the motor shaft slides easily into the top gear of the front axle. Tighten the four drive motor bolts to 158 ft.-lb. (214 Nm) torque.

G0807023

Roll the axle under the front frame. Lift the axle upward being carefull not to pinch any hoses or harnesses.

STEP 4

STEP 2

2

1

G0807029

Re-connect the service brake (1) and parking brake (2) hoses to the front axle.

G0807022

Install and tighten the axle retaining bolts, nuts and plates. Tighten the bolts to 480 ft.-lb. (650 Nm) torque.

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FRONT AXLE

STEP 5

STEP 6 1

G0807020

G0807010

2

2

G0807008

G0807009

Re-connect both hoses (1) (2) to the drive motor.

Re-connect the RH and LH steering cylinder hoses.

STEP 7

G0807007

Re-connect the drive motor harness.

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FRONT AXLE

STEP 8

STEP 10

G0807006

G0605019

Install the window washer reservoir, ground wires (1), hoses and harnesses to both pumps.

Install both wheels and tires onto the axle.

STEP 11

STEP 9

G0605020

Install the wheel nuts and hand tighten.

G0807024

Install the fender. Torque all nuts to 75 ft.-lb. (100 Nm).

STEP 12 Remove the jack stands.

STEP 13 Torque wheel nuts to 450 ft.-lb. (607 Nm) torque.

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FRONT AXLE

STEP 14

STEP 17 Bleed the park and service brakes. See Section 505 of this Service Manual.

STEP 18

2

1

G0807005

G1007036

Start the engine; apply the park brake (1). Move the steer mode switch to the 4-wheel steering position (2). Turn the steering wheel in one direction until the wheels reach their travel limits and back the other way to their travel limit. Repeat this procedure several times until the air is removed from the circuit.

Remove air from the hydrostatic system by cycling the drive forward and backward until the air is removed from the circuit.

G1107084

Install both drive motor hoses.

STEP 19

Tighten the four bolts to 70 ft.-lb. (94.5 Nm) torque.

Shut down the engine. Check for leaks. Correct any leakage found. Check fluid level; add fluid if needed.

STEP 15

G0807004

Install the driveshaft. Torque the four bolts to 30 ft.lb. (40 Nm) torque.

STEP 16 Fill the hydraulic reservoir to the proper level.

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Section 504 BRAKE BLEEDING PROCEDURES 519 Telehandler

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GENERAL TABLE OF CONTENTS BLEEDING SERVICE BRAKE .................................................................................................................................. 1 BLEEDING PARKING BRAKE .................................................................................................................................. 2

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519 Telehandler

BRAKES

BLEEDING SERVICE BRAKE

STEP 3

BEFORE cleaning, lubricating, or performing service on this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information and Decal Locations).

STEP 1

G1107099

Check the brake fluid level. Add Sunco Multi-ATF or equivalent brake fluid if needed.

1

STEP 4 2

Check for proper brake operation.

G1107101

Install one end of a hose (1) onto the bleed screw (2) and place the other end of the hose into a drain pan.

STEP 2

G1107101

With an assistant in the operator’s seat, apply pressure on the brake pedal. Open the bleed screw to relieve air in the system. Close the bleed screw and release pressure on the brake pedal. Repeat the procedure until all air is removed from the system.

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519 Telehandler

BRAKES

BLEEDING PARK BRAKE

STEP 3

BEFORE cleaning, lubricating, or performing service on this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information and Decal Locations).

Turn the engine off and check the hydraulic fluid level. Add hydraulic fluid if needed.

STEP 4 Test for proper park brake operation.

STEP 1

1 2

G1107100

Install one end of a hose (1) onto the bleed screw (2) and place the other end of the hose into a drain pan.

STEP 2

G1107100

Start the engine and de-activate the park brake switch. Open the bleed screw to relieve air in the system. Close the bleed screw and activate the park brake switch. Repeat the procedure until all air is removed from the system.

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Section 601 HYDRAULIC SCHEMATICS, TROUBLESHOOTING TESTING AND ADJUSTMENT PROCEDURES 519 Telehandler

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GENERAL TABLE OF CONTENTS HYDRAULIC SCHEMATICS, TROUBLESHOOTING, TESTING & ADJUSTMENT PROCEDURES ............... 2 INTRODUCTION ............................................................................................................................................... 2 GENERAL TEST PROCEDURES .....................................................................................................................2 HYDRAULIC SPECIFICATIONS ........................................................................................................................... 4 TROUBLESHOOTING.................................................................................................................................... 5 MAIN CONTROL VALVE PRESSURE TROUBLESHOOTING .................................................................... 5 PARK BRAKE PILOT PRESSURE TROUBLESHOOTING ............................................................................ 6 BOOM LIFT TROUBLESHOOTING ................................................................................................................. 7 BOOM EXTEND CYLINDER TROUBLESHOOTING .......................................................................................8 ATTACHMENT TILT CYLINDER TROUBLESHOOTING ............................................................................... 9 BOOM SLAVE CYLINDER/FORK SELF LEVEL TROUBLESHOOTING .................................................. 10 STEERING CIRCUIT TROUBLESHOOTING ................................................................................................ 11 HYDRAULIC SCHEMATICS ................................................................................................................................. 12 HYDRAULIC SYSTEM TESTING ........................................................................................................................ 14 PUMP PRESSURE TEST ............................................................................................................................. 14 LIFT CYLINDER TEST ................................................................................................................................... 15 TILT CYLINDER QUICK TEST ...................................................................................................................... 17 TILT CYLINDER DIRECT TEST .................................................................................................................... 17 TILT CYLINDER COUNTERBALANCE VALVE QUICK TEST ..................................................................... 20 TILT CYLINDER COUNTERBALANCE VALVE DIRECT TEST ................................................................. 21 EXTENSION CYLINDER QUICK TEST ......................................................................................................... 22 EXTENSION CYLINDER DIRECT TEST ...................................................................................................... 22 EXTENSION CYLINDER RELIEF TEST ....................................................................................................... 23 EXTENSION CYLINDER COUNTERBALANCE VALVE QUICK TEST ...................................................... 24 EXTENSION CYLINDER COUNTERBALANCE VALVE DIRECT TEST......................................................25 MAIN CONTROL VALVE PRESSURE RELIEF TEST AND ADJUSTMENT .................................................... 26 JOYSTICK CONTROL PRESSURE TEST ......................................................................................................... 28 STEERING CIRCUIT PRESSURE TEST ........................................................................................................... 30 STEERING CIRCUIT PRESSURE QUICK TEST ......................................................................................... 30 STEERING CIRCUIT PRESSURE DIRECT TEST ....................................................................................... 31 PARK BRAKE PRESSURE TEST ....................................................................................................................... 33

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519 Telehandler

HYDRAULICS

HYDRAULIC SCHEMATICS, TROUBLESHOOTING, TESTING & ADJUSTMENT PROCEDURES GENERAL TEST PROCEDURES

INTRODUCTION This section of the Mustang 519 Telehandler service manual covers the hydraulic schematics, troubleshooting, testing and adjustment procedures.

WARNING

A single-section gear pump attached to the hydrostatic pump provides hydraulic flow for the main control valve. The main control valve directs flow for the steering control valve, joysticks and isolation valve. The hydrostatic pump provides hydraulic flow for the SAHR brake valve. The excess flow from the gear pump is directed back to the hydraulic tank.

NEVER use your hands to search for hydraulic fluid leaks. Instead use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid must be surgically removed by a doctor familiar with this type of injury or gangrene may result.

The joysticks are located on the RH console. They direct the flow from the main control valve for boom functions.

ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid can cause permanent eyesight damage or loss if safety glasses are not worn.

An electrical switch on the right side of the dash is connected to a solenoid that operates the SAHR park brake. When the switch is OFF, the SAHR solenoid is activated and flow from the hydrostatic pump is directed to release the park brake. When the switch is ON, the electrical signal to the solenoid is switched off. The spring on the SAHR valve control spool shifts the spool, blocks the flow from the hydrostatic pump and directs the park brake hydraulic fluid to the reservoir. The spring pressure inside the park brake applies the brake.

WARNING Construction equipment can be dangerous if improperly operated or maintained. This machine should be operated and maintained only by trained and experienced people who have read, understood and complied with the Operator’s Manual.

The steering wheel is connected directly to the Steering Control Valve. When the steering wheel is turned clockwise (right) or counterclockwise (left) the steering control unit directs flow from the priority flow divider to the steering cylinders. The Steering Mode Valve control solenoids are connected to a 3-way switch on the instrument panel. When the switch is in the neutral position, the flow from the priority flow divider is directed to the front steering cylinder. When the switch is in the 4-Wheel Mode or Crab Mode, the Steering Mode Valve directs flow to or from the front cylinder to the rear steering cylinder. The front and rear steering cylinders are in a series hydraulic circuit through the Steering Mode Valve.

WARMING THE ENGINE: Start the engine and run until the coolant temperature gauge is in the normal operating range.

WARMING THE HYDRAULIC OIL: 1. Operate the attachment tilt, boom extend and boom lift cylinders at the end of their stroke for 30 seconds.

2. Repeat Step 1 until the hydraulic oil temperature is at 120°F (49°C).

3. Operate boom functions three to five times in both directions to allow warm oil to enter the circuits.

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519 Telehandler

HYDRAULICS

RELEASE HYDRAULIC OIL PRESSURE:

PRESSURE CHECKING GUIDELINES:

1. Engage the park brake.

1. Use an accurate gauge.

2. Lower equipment to the ground, return the engine to idle for 30 seconds, then shut off the engine.

2. Release hydraulic oil pressure before connecting and disconnecting any gauge.

3. Run the engine at 1000 RPM in the specified Mode Select position.

3. Turn the key switch on. Operate the joystick in each direction. This should ensure there is no residual pressure trapped in the control circuit.

Confirm that there is no attachment or unit movement.

4. As applicable, fully engage the control for the circuit being tested.

5. If adjustment is necessary, obtain each final pressure by bringing the pressure up to the proper setting. Do not bring the pressure to a higher setting and then lower it to the desired setting.

WARNING All trapped hydraulic pressure must be released from the system before installing a gauge in any pressure tap. A sudden release of hot oil could cause burns or other serious injury.

WARNING Relief valves are provided to protect the hydraulic system. Do not increase relief valve pressure settings above specifications or hydraulic system damage may occur.

WARNING To prevent damage and/or personal injury when using an in-line flowmeter for testing, ALWAYS be sure the load valve on the flowmeter is fully OPEN before starting the engine.

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519 Telehandler

HYDRAULICS HYDRAULIC SPECIFICATIONS

Pump Output ............................................................................................................22 gpm (83 L/min) at 2750 RPM Main Control Valve Relief Valve .....................................................................................................3350 psi (230 bar) Steering Relief Valve ......................................................................................................................2400 psi (165 bar) Joystick Relief Valve (Tilt circuit port reliefs) ..................................................................................3500 psi (240 bar) Parking Brake Relief Valve (Charge pump pressure).........................................................................370 psi (25 bar) Hydrostatic Pump Output ...............................................................................................................5800 psi (400 bar) Reservoir Capacity .................................................................................................................... 18 gallons (68 Liters)

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519 Telehandler

HYDRAULICS

MAIN CONTROL VALVE PRESSURE TROUBLESHOOTING Test the pressure at the battery tray test port. Bring engine up to speed then engage a hydraulic function on control valve to force hydraulic oil over the main relief valve. Does the pressure gauge read 3350 psi (230 bar)?

YES Remove the pressure gauge.

NO Adjust the main relief valve on the Main Control Unit. Can 3350 psi, (230 bar) be obtained?

YES Remove the pressure gauge.

NO Replace the main control relief valve. Does the gauge read 3350 psi (230 bar)?

YES Remove the pressure gauge.

NO Repair or replace the main control valve.

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HYDRAULICS

PARK BRAKE PILOT PRESSURE TROUBLESHOOTING Test the pressure at the test port G on the hydrostatic pump.

Does the pressure gauge read 370 psi (25 bar)?

YES

NO

Test the pressure at port 1 on the SAHR brake valve with the park brake switch off. Does the pressure gauge read 370 psi (25 bar)?

Repair or replace the hydrostatic pump.

YES Repair or replace the park brake cylinder.

NO

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Replace SAHR brake valve.

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HYDRAULICS

BOOM LIFT CYLINDER TROUBLESHOOTING NOTE: If the boom will lift but will not lower, replace the counterbalance valve on the lift cylinder.

DANGER

Boom must be properly secured before any work is done on the lift cylinder or boom hydraulics.

Does the boom lift without a capacity load?

NO Follow the Main Control Valve Pressure Pressure Troubleshooting procedure.

Is the problem in the control valve?

YES Test the pressure at the test port on the battery tray. Retract the boom to the end of the cylinder stroke and hold. Does the pressure gauge read 3350 psi (230 bar)?

YES Repair or replace the control components.

YES Use an in-line flowmeter to test the pressure at the lift cylinder extend hose. Does the pressure gauge read 3350 psi (230 bar)?

YES Replace the counterbalance valve.

Does the pressure gauge read 3350 psi (230 bar)?

NO Repair or replace the lift cylinder.

NO Follow the Main Control Valve Pressure Troubleshooting procedure. Does the pressure gauge read 3350 psi (230 bar)?

YES Remove the flowmeter.

YES Adjust the relief valve in the Main Control Valve. Open the load control valve of the flowmeter and hold the joystick in the boom lower position. Does the pressure gauge read 3350 psi (230 bar)?

YES Remove the flowmeter.

NO Remove and bench test the hydraulic gear pump. Does the hydraulic gear pump meet specifications?

NO Repair or replace the relief valve in the Main Control Valve.

YES Remove the flowmeter.

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NO Use an in-line flowmeter to test the pressure at the extend port of the lift cylinder. Does the pressure gauge read 3350 psi (230 bar) when cylinder is fully extended?

NO Repair or replace the hydraulic gear pump.

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519 Telehandler

HYDRAULICS

BOOM EXTEND CYLINDER TROUBLESHOOTING NOTE: If the extend cylinder will extend but will not retract, replace the counterbalance valve on the cylinder.

DANGER

Boom must be properly secured before any work is done on the extend cylinder or boom hydraulics.

Does the boom extend without a capacity load?

NO Follow the Main Control Valve Pressure Troubleshooting procedure.

Is the problem in the control valve?

YES Test the pressure at the test port on the battery tray. Lower the boom to the end of the cylinder stroke and hold. Does the pressure gauge read 3350 psi (230 bar)?

YES Repair or replace the malfunctioning control components.

NO Use an in-line flowmeter to test the pressure at the extend port of the lift cylinder. Does the pressure gauge read 3350 psi (230 bar)?

YES Use an in-line pressure gauge to test the extend pressure at the extend cylinder. Does the pressure gauge read 3350 psi 3350 psi (230 bar)?

YES Replace the counterbalance valve.

Does the pressure gauge read 3350 psi (230 bar)?

NO Repair or replace the extend cylinder.

NO Follow the Main Control Valve Pressure Troubleshooting procedure. Does the pressure gauge read 3350 psi (230 bar)?

YES Remove the flowmeter.

YES Adjust the relief valve in the Main Control Valve. Open the load control valve of the flowmeter and hold the joystick in the boom lower position. Does the pressure gauge read 3350 psi (230 bar)?

YES Remove the flowmeter.

NO Remove and bench test the hydraulic gear pump. Does the hydraulic gear pump meet specifications?

NO Repair or replace the relief valve in the Main Control Valve.

YES Remove the flowmeter.

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NO Repair or replace the hydraulic gear pump.

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HYDRAULICS

ATTACHMENT TILT CYLINDER TROUBLESHOOTING NOTE: If the tilt cylinder will roll back but not lower, replace the counterbalance valve on the cylinder.

DANGER

Boom must be properly secured before any work is done on the tilt cylinder or boom hydraulics.

Does the boom tilt operate without a capacity load?

NO Follow the Main Control Valve Pressure Troubleshooting procedure.

Is the problem in the control valve?

YES Test the pressure at the test port on the battery tray. Lower the boom to the end of the cylinder stroke and hold. Does the pressure gauge read 3350 psi (230 bar)?

YES Repair or replace the malfunctioning control components.

YES Use an in-line pressure gauge to test the extend pressure at the extend cylinder. Does the pressure gauge read 3350 psi 3350 psi (230 bar)?

YES Replace the counterbalance valve.

Does the pressure gauge read 3350 psi (230 bar)?

NO Repair or replace the tilt cylinder.

NO Follow the Main Control Valve Pressure Troubleshooting procedure. Does the pressure gauge read 3350 psi (230 bar)?

YES Remove the flowmeter.

YES Adjust the relief valve in the Main Control Valve. Open the load control valve of the flowmeter and hold the joystick in the boom lower position. Does the pressure gauge read 3350 psi (230 bar)?

YES Remove the flowmeter.

NO Remove and bench test the hydraulic gear pump. Does the hydraulic gear pump meet specifications?

NO Repair or replace the relief valve in the Main Control Valve.

YES Remove the flowmeter.

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NO Use an in-line flowmeter to test the pressure at the extend port of the lift cylinder. Does the pressure gauge read 3350 psi (230 bar)?

NO Repair or replace the hydraulic gear pump.

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519 Telehandler

HYDRAULICS

BOOM SLAVE CYLINDER/FORK SELF LEVEL TROUBLESHOOTING

DANGER

Boom must be properly secured before any work is done on the slave cylinder or boom hydraulics.

Tilt does not self level with boom raise or lower operations. Complete Attachment Tilt Cylinder Troubleshooting, is tilt cylinder functioning normally?

NO Replace the tilt cylinder.

YES Install an in-line pressure gauge on port C of the isolation valve (between main control valve and 65 psi [4.5 bar] check valve) Does the pressure gauge read 65 psi (4.5 bar) or higher?

YES Install an in-line pressure gauge on both slave cylinder ports. Does the pressure gauge read 3500 psi (240 bar) or higher during boom up/down cycles?

NO Replace the 65 psi (4.5 bar) check valve.

YES Repair or replace the Isolation Valve.

NO Repair or replace the Slave cylinder.

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519 Telehandler

HYDRAULICS

STEERING CIRCUIT TROUBLESHOOTING Test the pressure at the test port on the battery tray for the Main Control Valve.

Cramp the steering fully to the right or left. Does the pressure gauge read 2400 psi (165 bar)?

YES Use an in-line flowmeter to test the pressure at port R of the Steer Control Unit. Does the pressure gauge read 2400 psi (165 bar)?

YES Use an in-line flowmeter to test the pressure at the front right steer cylinder. Does the pressure gauge read 2400 psi (165 bar)?

NO Repair or replace the Steering Control Unit.

YES Use an in-line flowmeter to test the pressure at port P of the Steer Valve. Does the pressure gauge read 2400 psi (165 bar)?

NO Repair or replace the front steer cylinder.

NO Repair or replace the Steer Mode Valve.

YES Repair or replace the rear steer cylinder.

NO Test the pressure at the test port on the battery tray. Does the pressure gauge read 3350 psi (230 bar) with a control function bottomed out?

NO Repair or replace the hydraulic gear pump.

YES Use an in-line flowmeter to test the pressure at port PF of the Main Control Valve while adjusting the steering relief valve. Can 2400 psi (165 bar) be obtained?

YES Remove the in-line flowmeter

NO Replace the steering relief valve.

Does the pressure read 2400 psi (165 bar)?

NO Replace the Main Control Valve.

YES Remove the in-line flowmeter.

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HYDRAULICS

MA07N010 913302

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HYDRAULICS

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519 Telehandler

HYDRAULICS HYDRAULIC SYSTEM TESTING

PUMP PRESSURE TEST

STEP 3

NOTE: Before performing any hydraulic test, check for any visible leaks or component damage.

Repair or replace the leaking component before proceeding with the tests.

1

STEP 1 2

G0208017

Loosen the nut (1) and turn the adjustment screw (2) clockwise to increase pressure.

NOTE: One turn is approximately 800 psi (55 bar).

STEP 4 2

G1107004

Connect a 5000 psi (350 bar) pressure gauge to the test port on the battery tray frame. With the engine running at full RPM and a hydraulic function bottomed out the gauge should read 3350 psi (230 bar).

1

WARNING: The hose must be long enough to read the gauge while standing clear of the forklift.

STEP 2 G1107003

If the pressure is still less than 3350 psi (230 bar) shut off the engine and disconnect the pressure gauge (1). Remove the pump from the machine (2).

Repair or replace the gear pump.

G0208014

If the pressure is less than 3350 psi (230 bar) remove the relief valve cap on the main control valve.

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HYDRAULICS

LIFT CYLINDER TEST

STEP 7

DANGER Boom must be properly secured before any work is done on the lift cylinder or boom hydraulics.

2

STEP 5 1

G1107029

1 2

G1107021

3

Start the engine, set the park brake and raise the boom approximately 3 feet (1 meter). Shut off the engine.

NOTE: If the boom lowers while the engine is OFF then replace the counterbalance valve. If the boom still lowers then proceed to next step.

STEP 6

G1107035

Remove the hose (1) from the left port (2) of the lift cylinder. Install a 3350 psi (230 bar) pressure gauge and hose (3) between the hose (1) and the port (2).

WARNING: The hose must be long enough to read the gauge while standing clear of the forklift.

G0907003

Place a support stand under the attachment end of the boom.

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HYDRAULICS

STEP 8

G1107011

Start the engine and remove the support stand.

Watch the pressure gauge and slowly move the joystick to the lower position. The pressure gauge should read 3350 psi (230 bar) when the boom reaches the lowered position.

If the pressure gauge reading steadily drops then replace or repair the cylinder.

If the pressure remains then repeat this process for the other port with the boom in the up position.

Replace of repair the cylinder if it does not hold the pressure.

STEP 9

G0907003

Start the engine and lower the boom onto a support stand. Shut off the engine.

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519 Telehandler

HYDRAULICS

TILT CYLINDER QUICK TEST

STEP 12

STEP 10

G1107011

G107004

Install a 5000 psi (350 bar) pressure gauge and hose on the test port on the battery tray frame.

Tilt the attachment mount up until the tilt cylinder reaches the end of its stroke and hold the joystick in the TILT UP position. The pressure gauge should read 3350 psi (230 bar).

WARNING: The hose must be long enough to observe the pressure gauge from inside the cab or standing clear of the forklift.

If the pressure is at 3350 psi (230 bar), but the tilt cylinder does not work, check the hoses and steel tubes between the control valve and tilt cylinder or check the cylinder barrel for damage.

STEP 11

If the pressure is less than 3350 psi (230 bar) proceed to the next step.

TILT CYLINDER DIRECT TEST STEP 13

3 2 G1107011

Start the engine and run at high idle. Retract the boom until the extend cylinder is at the end of its stroke and hold the joystick in the RETRACT position. The pressure gauge should read 3350 psi (230 bar).

IF the pressure is more or less than 3350 psi (230 bar) proceed to the Main Control Valve Pressure Relief Test and Adjustment section of this manual.

1

G1107023

Shut off the engine. Remove the hose (1) from the piston (tilt up) port (2) of the tilt cylinder. Cap the cylinder port. Install a 5000 psi (350 bar) pressure gauge (3) and hose on the cylinder supply hose.

WARNING: The hose must be long enough to read the gauge while standing clear of the forklift.

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HYDRAULICS

STEP 14

STEP 16

G1107011

G1007024

Start the engine and run at high idle. Hold the joystick into the TILT UP position. The pressure gauge should read 3350 psi (230 bar).

Shut off the engine. Remove the slave cylinder hydraulic hoses. Install plugs in the hose ends and caps on the cylinder fittings.

If the pressure is 3350 psi (230 bar), replace or repair the counterbalance valve. If the cylinder still does not move after reconnecting then repair or replace the tilt cyinder.

STEP 17

If the pressure is less than 3350 psi (230 bar), proceed to the next step.

STEP 15

G1107011

Start the engine and run at high idle. Hold the joystick in the TILT UP position.

If the pressure gauge reads 3350 psi (230 bar), repair or replace the slave cylinder.

G1107102

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If the pressure is less than 3350 psi (230 bar), proceed to the next step.

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HYDRAULICS

STEP 18

STEP 21

2

3

G1107017

Replace the tilt up relief valve located on the bottom of the main control valve.

1

G1107024

Remove the supply hose (1) from the rod (tilt down) port (2) of the tilt cylinder. Cap the cylinder port and install a 5000 psi (350 bar) pressure gauge and hose (3) on the cylinder supply hose.

STEP 19 Repeat Step 15.

If 3350 psi (230 bar) cannot be reached by replacing the relief valve, repair or replace the isolation valve.

WARNING: The hose must be long enough to read the gage while standing clear of the forklift.

STEP 22 STEP 20

2

1

G1107011 G1107023

Shut off the engine. Remove the pressure gauge from the tilt up supply hose (1) and remove the cap from the cylinder port (2). Install the hose on the cylinder.

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Start the engine and run at high idle. Hold the joystick in the TILT DOWN position until the cylinder reaches the end of its stroke. Hold the joystick in the TILT DOWN position. The pressure gauge should read 3350 psi (230 bar).

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519 Telehandler

HYDRAULICS

TILT CYLINDER COUNTERBALANCE VALVE QUICK TEST

STEP 25 Watch the pressure gauge as the attachment mount is slowly tilted down. The pressure gauge should read 3350 psi (230 bar) when the attachment mount reaches the full downward position.

STEP 23

If the pressure is less than 3350 psi (230 bar), proceed to the next step.

G1107004

Install a 5000 psi (350 bar) pressure gauge and hose on the battery tray test port.

WARNING: The hose must be long enough to observe the pressure gauge from inside the cab or standing clear of the forklift.

STEP 24

G1107011

Start the engine and run at high idle. Tilt the attachment mount up until the tilt cylinder reaches the end of its stroke and hold the joystick in the TILT UP position. The pressure gauge should read 3350 psi (230 bar).

If the pressure is less than 3350 psi (230 bar) go to Step 27 of the Tilt Cylinder Direct Test.

If the pressure is 3350 psi (230 bar), proceed to the next step.

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HYDRAULICS

TILT CYLINDER COUNTERBALANCE VALVE DIRECT TEST STEP 26 2 1

3

G1107025

Shut off the engine. Install a 5000 psi (350 bar) pressure gauge and hose (1) between the tilt cylinder rod end (tilt down) port (2) and the supply hose (3).

STEP 27

G1107025

Start the engine and run at high idle. Watch the pressure gauge as the attachment is slowly tilted DOWN. The pressure gauge should read 3350 psi (230 bar) when the attachment mount reaches its full downward tilt position. Shut off the engine.

If the pressure is more or less than 3350 psi (230 bar) replace the counterbalance valve.

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HYDRAULICS

EXTENSION CYLINDER QUICK TEST

STEP 30

STEP 28

G1107011

G1107003

Install a 5000 psi (350 bar) pressure gauge and hose on the test port on the battery tray.

WARNING: The hose must be long enough to observe the pressure gauge from inside the cab or standing clear of the forklift.

Lower the boom until the lift cylinder is at the end of its stroke and hold the joystick in the BOOM LOWER position. The pressure gauge should read 3350 psi (230 bar).

If the pressure is less than 3350 psi (230 bar), proceed to the Main Control Valve Pressure Relief Test and Adjustment section of this manual before proceeding to the next step.

If the pressure is 3350 psi (230 bar), proceed to the next step.

STEP 29

EXTENSION CYLINDER DIRECT TEST STEP 31 2

G1107011

1

Start the engine and run at high idle. Retract the boom until the boom extension cylinder is at the end of its stroke and hold the joystick in the RETRACT position. The pressure gauge should read 3350 psi (230 bar).

If the pressure is more than 3350 psi (230 bar) proceed to the Main Control valve Pressure Relief Test and Adjustment section of this manual.

If the pressure is less than 3350 psi (230 bar), proceed to the next step.

If the pressure is 3350 psi (230 bar), but the extension cylinder is not working properly, check the boom or extension cylinder barrel for damage.

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G1107027

Shut off the engine. Remove the hose (1) from the retract tube fitting. Install a 5000 psi (350 bar) pressure gauge (2) on the hose fitting and plug the retract tube fitting (3).

WARNING: The hose must be long enough to observe the pressure gauge from inside the cab or standing clear of the forklift.

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HYDRAULICS

STEP 32

EXTENSION CYLINDER RELIEF TEST STEP 34 3

2

1 G1107011

Start the engine and run at high idle. Move the joystick into the BOOM RETRACT position and hold.

The pressure gauge should read 3350 psi (230 bar).

If the pressure is 3350 psi (230 bar), repair or replace the counterbalance valve. If cylinder does not work properly once reconnected then replace the cylinder.

If the pressure is less than 3350 psi (230 bar), proceed to the Main Control Valve Pressure Relief Test and Adjusting Section.

G1107026

Remove the hose (1) from the extend tube fitting (2).

Install a 5000 psi (350 bar) pressure gauge (3) on the hose fitting and plug the extend tube fitting.

STEP 35

STEP 33 1 3

2 G1107011

G1107027

Shut off the engine. Remove the pressure gauge (1) from the retract hose fitting (2) and install the retract hose to the retract tube fitting (3).

Start the engine and run at high idle. Move the joystick into the BOOM EXTEND position and hold.

The pressure gauge should read 3350 psi (230 bar) once the boom reaches full extension.

If the pressure is more or less than 3350 psi (230 bar), proceed to the Main Control Valve Pressure Relief Test and Adjustment Section.

WARNING: The hose must be long enough to read the gauge while standing clear of the forklift.

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HYDRAULICS

EXTENSION CYLINDER COUNTERBALANCE VALVE QUICK TEST

STEP 38

STEP 36

G1107011

Retract the boom to the end of the extension cylinder stroke and hold the joystick in the RETRACT position. The pressure gauge should read 3350 psi (230 bar).

G1107003

Install a 5000 psi (350 bar) pressure gauge and hose on the battery tray test port.

If the pressure is less than 3350 psi (230 bar), go to Step 29 of the EXTENSION CYLINDER QUICK TEST.

STEP 37

If the pressure is 3350 psi (230 bar), proceed to the next step.

Start the engine and run at high idle. Extend the boom approximately 6 feet (2 meters). Watch the pressure gauge as the boom is slowly retracted, the gauge should read less than 3350 psi (230 bar).

If the pressure is more than 3350 psi (230 bar), go to the Main Control Valve Pressure Relief Test and Adjustment section of this manual before proceeding to the next step.

If the pressure is less than 3350 psi (230 bar), proceed to the next step.

If the pressure is more than 3350 psi (230 bar), replace the extend cylinder counterbalance valve.

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HYDRAULICS

EXTENSION CYLINDER COUNTERBALANCE VALVE DIRECT TEST STEP 39

2

3

1

G1107028

Shut off the engine. Remove the pressure gauge.

Remove the hose (1) from the retract tube fitting (2).

Install a 5000 psi (350 bar) pressure gauge (3) between the hose (1) and retract tube fitting (2).

WARNING: The hose must be long enough to read the gauge while standing clear of the forklift.

STEP 40 Start the engine and run at high idle. Extend the boom approximately 6 feet (2 meters). Watch the pressure gauge as the boom is slowly retracted. The gauge should read less than 3350 psi (230 bar) as the boom is retracted.

If the gauge is not at 3350 psi (230 bar), replace the extend cylinder counterbalance valve.

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HYDRAULICS

MAIN CONTROL VALVE PRESSURE RELIEF TEST AND ADJUSTMENT MAIN RELIEF VALVE QUICK TEST AND ADJUSTMENT

STEP 43

STEP 41

G1107011

G1107003

Install a 5000 psi (350 bar) pressure gauge and hose on the battery tray test port.

WARNING: The hose must be long enough to observe the pressure gauge from inside the cab or standing clear of the forklift.

Lower the boom until the lift cylinders are at the end of their stroke and hold the joystick in the LOWER position. The pressure gauge should read 3350 psi (230 bar).

If the pressure is 3350 psi (230 bar) go to the Extension Cylinder Direct Test in this manual.

If the pressure is more or less than 3350 psi (230 bar) proceed to the next step.

STEP 42

G1107011

Start the engine and run at high idle. Retract the boom until the boom extension cylinder is at the end of its stroke and hold the joystick in the RETRACT position. The pressure gauge should read 3350 psi (230 bar).

If the pressure is less than 3350 psi (230 bar), proceed to the next step.

If the pressure is more than 3350 psi (230 bar), proceed to Step 48.

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HYDRAULICS

STEP 44

Repeat Steps 46, 47 and 48 until the pressure gauge reads 3350 psi (230 bar).

If the pressure can be adjusted to 3350 psi (230 bar), proceed to Step 49.

1

If the pressure is more than 3350 psi (230 bar) and does not change when the adjusting screw (3) is turned counterclockwise, replace the main relief valve.

1

G1107016

If the pressure is less than 3350 psi (230 bar) and does not increase when the adjusting screw is turned clockwise, go to the Pump Pressure Test in this manual before replacing the relief valve.

STEP 45 2

If the pump, relief valve or any cylinders are repaired or replaced, repeat Steps 46, 47 and 48 to set the main control valve relief pressure at 3350 psi (230 bar).

STEP 46

G1107014

3

G1107003

Remove the pressure gauge from the battery tray test port.

G1107015

Shut off the engine. Remove the four screws securing the joystick panel (1). Remove the main relief valve cap (2) and turn the adjusting screw (3) clockwise to increase and counterclockwise to decrease the pressure.

NOTE: 1 turn of the adjusting screw (3) will change the pressure approximately 800 psi (55 bar).

Install the main relief valve cover.

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HYDRAULICS

JOYSTICK CONTROL TEST

STEP 49

STEP 47 If the forklift does not respond to one of the joystick controller commands, proceed to the next step.

STEP 48 1

2

3

4

G1107011

Start the engine and run at high idle. The park brake must be ON. Hold the joystick in the position of the port to be tested. The pressure gauge should read 3350 psi (230 bar).

G1107020

5

6

7

If the pressure is 3350 psi (230 bar) but there is no response to the joystick command, repair or replace the control spool, or the control valve section, or the entire main control valve.

If the pressure is less than 3350 psi (230 bar), proceed to Step 55.

8

If the pressure is more than 3350 psi (230 bar), proceed to the next step.

STEP 50 Shut off the engine. Replace the main control valve.

Repeat Step 53.

G1107091

Remove the hose from the function to be tested.

Install a 5000 psi (350 bar) pressure gauge and hose between the hydraulic port and the supply hose.

1. Boom (UP) 2. Boom (OUT) 3. Hydraulic Option 4. Tilt (Back)

5. Boom (Down) 6. Boom (IN) 7. Hydraulic Option 8. Tilt (Forward))

WARNING: The hose must be long enough to observe the pressure gauge from inside the cab or standing clear of the forklift.

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HYDRAULICS

STEP 51

STEP 53

2

1

G1207002

G1107020

Shut off the engine. Remove the pressure gauge tee adapter (1) from the hydraulic fitting (2). Install a cap in the hydraulic solenoid and a plug in the tee adapter.

Shut off the engine. Remove the pressure gauge from the hydraulic supply hose and install the supply hose on the valve port.

STEP 52

G1107011

Start the engine and run at high idle. Hold the joystick in the position of the function being tested. The pressure gauge should read 3350 psi (230 bar).

If the pressure is more or less than 3350 psi (230 bar) replace the main control valve.

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HYDRAULICS

STEERING CIRCUIT PRESSURE TEST STEERING CIRCUIT PRESSURE QUICK TEST

STEP 56

STEP 54 1

G0208015

G1107004

3

Install a 5000 psi (350 bar) pressure gauge to the main valve test port on the battery tray.

WARNING: The hose must be long enough to observe the pressure gauge from inside the cab or standing clear of the forklift.

2

STEP 55 G0208016

Remove the cap (1) from the steering relief valve on the main control valve. Loosen the nut (2) and turn the adjustment screw (3) clockwise to increase the pressure or counterclockise to decrease the pressure.

NOTE: One turn is approximately 650 psi (45 bar).

G1007036

Start the engine and run at high idle. Move the Steer Mode Switch (1) to the 4-Wheel Steering position.

Turn the steering wheel in one direction until the wheels reach their travel limits and hold. The pressure gauge should read 2400 psi (165 bar).

If the pressure is more or less than 2400 psi (165 bar), proceed to the next step.

If the pressure is 2400 psi (165 bar), but the steering does not work properly, check the steering linkage and pivot points, and the Steering Mode Valve, before repairing or replacing the steering control unit.

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HYDRAULICS

STEERING CIRCUIT PRESSURE DIRECT TEST

STEP 58

STEP 57 2 1 1

G1107009

G1107096

Remove the supply hose (1) from port P (2) of the Steer Mode Valve. Install the inlet hose from an inline flowmeter on the supply hose (1) and the flowmeter outlet hose on the Steer Mode Valve Port P (2).

STEP 59

2

G1107094

Shut off the engine. Remove the pressure gauge from the PF port (1) and reconnect the hydraulic hose to the PF port fitting (2).

G0805015

OPEN the load control valve (1) of the flowmeter.

Start the engine and run at idle. Turn the steering wheel in one direction until the wheels reach their travel limits and hold. Slowly close the load control valve.

If the pressure is less than 2400 psi (165 bar), repair or replace the steering control unit.

If the pressure is 2400 psi (165 bar), proceed to the next step.

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HYDRAULICS

STEP 60

G0805015

OPEN the flowmeter load control valve and move the Steer Mode Switch to the 2-Wheel Steering position.

If the pressure is less than 2400 psi (165 bar), repair or replace the front steering cylinder.

If the pressure is 2400 psi (165 bar), repair or replace the rear steering cylinder.

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HYDRAULICS

PARK BRAKE PRESSURE TEST

STEP 62

STEP 61 1 1

2 G1107092

G1107005

Connect a 500 psi (35 bar) pressure gauge (1) to test port G (2) on the hydrostatic pump. Start the engine and run at idle, the pressure gauge should read approximately 370 psi (25 bar).

4 3

2

If the pressure is less than 370 psi (25 bar), replace the hydrostatic pump.

G1107093

Remove the hydraulic hose from the B1 port on the SAHR brake valve (1). Install a plug on the hydraulic hose (2). Install a 500 psi (35 bar) pressure gauge (3) to the B1 port on the SAHR brake valve (4).

If the pressure gauge reads 370 psi (25 bar) repair or replace the park brake cylinder.

If the pressure is less than 370 psi (25 bar) replace the SAHR brake valve.

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Section 602 HYDRAULIC PUMP REMOVAL AND INSTALLATION 519 Telehandler

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GENERAL TABLE OF CONTENTS HYDRAULIC PUMP REMOVAL................................................................................................................................ 1 HYDRAULIC PUMP INSTALLATION........................................................................................................................ 3

SPECIFICATIONS Hydraulic Pump U.S. Value Metric Value Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 lb.-ft. . . . . . . . . . . 88 Nm

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HYDRAULIC PUMP

HYDRAULIC PUMP REMOVAL

STEP 4

BEFORE cleaning, lubricating, or servicing this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in the Safety Section of this manual.

STEP 1

G0607024

Disconnect the pressure test hose under the battery tray. Install a cap on the fitting and a plug in the line.

1

STEP 5

G0907021

Drain the hydraulic fluid reservoir by removing the hydraulic fill cap and drainplug (1). Prepare to capture approximately 18 gallons of oil.

1

STEP 2

2

Remove the battery. Complete Steps 1 through 5 of Section 302 for the correct procedure.

1

STEP 3

G0607023

Remove the four bolts (1) and remove the battery tray (2).

STEP 6

1

3 1

2 1

2

G0707008

Remove the eight floor panel mounting bolts (1).

Remove the floor panel (2).

1 G0907018

Remove the eight mounting bolts (1) and remove the front wheel well (2). Install a brace to support the oil cooler (3).

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HYDRAULIC PUMP

STEP 7

STEP 9 1

1 G0907019

G0907020

Disconnect the hydraulic fluid supply line by loosening the hose clamp. Install a cap on the fitting and a plug in the line.

Remove the two hydraulic pump mounting bolts (1).

STEP 10

STEP 8 3 2

1

G0607027

Pull the pump forward until the pump input shaft (1) is clear of the hydrostatic pump (2). Lift the pump out of the machine. Remove the O-ring (3).

G0607026

Disconnect the hydraulic pump pressure line from the hydraulic pump. Install a cap on the fitting and a plug in the line.

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HYDRAULIC PUMP STEP 13

HYDRAULIC PUMP INSTALLATION

1

STEP 11

1 G0907020

Install the two pump mounting bolts (1). Torque the two pump mounting bolts to 65 lb.-ft. (88 Nm).

G0607029

Install a new O-ring on the pump mounting flange.

Position the pump in-line with the rear of the hydrostatic pump.

STEP 14

STEP 12 2

1 G0607026

Remove the caps and plugs and connect the hydraulic pump pressure line to the hydraulic pump.

G0607027

Align the pump input shaft (1) with the hydrostatic pump shaft (2). Slide the pump shaft into the hydrostatic pump until the pump mounting flange contacts the hydrostatic pump flange.

STEP 15

G0907019

Remove the cap and plug and connect the supply line to the hydraulic pump.

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HYDRAULIC PUMP

STEP 16

STEP 19

2

2

1

1 2

2 G0907018

G0707008

Remove the brace supporting the oil cooler and install the wheel well (1) using the eight mounting bolts (2).

Install the floor panel (1) using the eight panel mounting bolts (2).

STEP 20

STEP 17

Re-install the battery. Complete Steps 6 through 9 of Section 302 for the correct procedure.

STEP 21 Refill the hydraulic reservoir.

2 1

STEP 22 Start the engine and check for leaks. If no leaks appear, continue to run the engine and test the steering and hydraulic functions for operation. Shut off the engine and check the hydraulic reservoir level.

Add fluid if necessary.

2 G0607023

Re-install the battery tray (1) using the four mounting bolts (2).

STEP 18

G0607024

Remove the cap and plug and re-connect the pressure test hose under the battery tray.

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Section 603 TILT CYLINDER REMOVAL AND INSTALLATION 519 Telehandler

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GENERAL TABLE OF CONTENTS TILT CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TILT CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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TILT CYLINDER

TILT CYLINDER REMOVAL

STEP 3

BEFORE cleaning, lubricating, or servicing this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations).

1

STEP 1

G1007005

Loosen and remove the retaining bolt and nut.

Remove the pivot pin from the cylinder. Take care to avoid damaging the grease fitting when removing the pin.

NOTE: Thread lock is used on the bolts. Heat may be required for removal.

G1007134

Support the attachment bracket.

STEP 4

STEP 2

G1007004

Mark the hydraulic hoses for correct assembly.

Disconnect the two hydraulic hoses from the tilt cylinder valve block.

G0907004

Move the attachment tilt joystick in all directions several times to relieve pressure from the hydraulic system.

STEP 5 Install caps and plugs on all hydraulic fittings to prevent contaminating the hydraulic system.

NOTE: See Section 605 of this Service Manual for the repair of this cylinder.

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TILT CYLINDER

STEP 6

STEP 8

G1007007

G1007009

Using a chain hoist and lifting strap, position the lifting strap around the tilt cylinder and apply upward force.

Remove the upper pivot pin from the tilt cylinder. Use care not to damage the grease fitting while removing the pivot pin.

STEP 7

IMPORTANT: Protect the chrome finish on the cylinder rod at all times. Damage to the surface of the rod can cause premature seal failure.

STEP 9

G1007008

Remove the retainer bolt and nut from the base pivot pin.

G1007028

Remove the rod end of the cylinder from the bracket first, then lower the chain hoist and floor jack.

Remove the base end of the cylinder.

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TILT CYLINDER

TILT CYLINDER INSTALLATION

STEP 3

STEP 1

G1007008

Install the retainer bolt and nut in the pivot pin and tighten.

G1007028

Using a chain hoist and lifting strap, put the rod end of the cylinder in the bracket first, and then position the base end of the cylinder in the mounting bracket and use a floor jack to apply upward force on the cylinder.

STEP 4 Remove the caps and plugs from the valve block fittings and hydraulic hoses.

STEP 5

STEP 2

G1007004

Reconnect the two hydraulic hoses to the valve block fittings and tighten.

G1007010

Align the pivot pin retainer bolt hole, with the holes in the cylinder mount. Reinstall the upper pivot pin using care not to damage the grease fitting while installing the pin.

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TILT CYLINDER STEP 9

STEP 6

G1007014

G1007005

Install the retainer bolt and nut. Use Loctite ® 271 (red) or equivalent, on the bolts.

Start the engine. The parking brake must be ON. Pull back on the joystick and raise the boom approximately 2 feet. Shut off the engine.

STEP 10

STEP 7

G1007013

With the parking brake on and engine running, fully retract the tilt cylinder by moving the joystick forward.

Then move the joystick back to fully extend. Repeat this procedure several times to remove air from the hydraulic system, and to check for any hydraulic oil leaks.

G1007011

Rotate the bracket and align the rod end of the cylinder with the bracket cylinder mount.

STEP 8

G1007029

Install the lower pivot pin.

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Section 604 HYDRAULIC CYLINDER REPAIR 519 Telehandler

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GENERAL TABLE OF CONTENTS GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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CYLINDER REPAIR

GENERAL INFORMATION

STEP 1 3

Except for some configuration differences, hydraulic cylinder disassembly, repair and assembly procedures will be basically the same for the tilt cylinder, boom lift cylinder, boom slave cylinder and boom extend cylinder. Except where noted differences or procedures are required for special application cylinders, use the following repair procedures for hydraulic cylinders.

1

When backup rings are used with O-ring seals, always note the position of the backup ring (above or below the O-ring) when removing the seals for reassembly reference.

2 G0907024

Select a clean environment. Remove the load check valve (1) slowly to relieve any residual pressure.

Remove the plug (2) from the valve block and caps (3) from the fittings.

One-piece Nylatron® type piston seals can be difficult to install on the piston. Soaking these seals in hot water for a short time prior to installation will make the seals more resilient and easier to install on the piston.

STEP 2

Before installing the piston and rod assembly into the barrel, lubricate the piston seals and wear rings liberally with clean operating fluid. Using an engine piston ring compressor to compress the piston seals tightly for a short period of time will often aid in the assembly procedure.

CYLINDER DISASSEMBLY BEFORE cleaning, lubricating or servicing this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations).

G0907025

Put the base end of the cylinder in a vise. With a drain pan positioned under the cylinder, move the rod in and out slowly to remove the fluid.

WARNING When disassembling hydraulic cylinders, NEVER use pneumatic or hydraulic pressure to aid in removing the piston and rod assembly from the cylinder barrel. To ignore this warning may result in severe injury or death.

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CYLINDER REPAIR

STEP 3

STEP 6

G09070026

G0907028

Loosen and remove the head gland from the cylinder.

Remove and discard the wear ring from the piston.

STEP 7

STEP 4

G0907029

Remove and discard the outer seal from the piston.

G0907027

Remove the rod assembly from the cylinder.

STEP 8

IMPORTANT: Protect the chrome finish on the cylinder rod at all times. Damage to the surface of the rod can cause premature seal failure.

STEP 5 Remove the cylinder barrel from the vise. Put the rod end in the vise. Support the rod on a wood block.

G0907030

Remove and discard the inner seal from the piston.

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CYLINDER REPAIR

STEP 9

STEP 12 1

2

3

G0907031

G0907034

Loosen and remove the nut from the cylinder rod.

Remove and discard the O-ring (1), backup ring (2) and O-ring (3) from the head gland.

NOTE: The nut is retained with thread lock compound and may require heat to remove.

STEP 13

STEP 10

G0907035

Remove the head gland from the cylinder rod.

G0907032

Remove the piston from the cylinder rod.

STEP 14

STEP 11

G0907036

Remove and discard the wiper ring and O-ring from the head gland.

G0907033

Remove and discard the O-ring.

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CYLINDER REPAIR

STEP 15

STEP 17

G0907038

G0907042

Remove and discard the inner seal from the head gland.

If required, remove and discard the bushing from the base end and the rod end of the cylinder.

STEP 16

G0907040

Remove and discard the O-rings and backup rings from the load check valve cartridge.

NOTE: Record the position of the O-rings and backup rings before removing for correct assembly.

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CYLINDER REPAIR

CYLINDER ASSEMBLY

STEP 4

STEP 1 Clean the cylinder rod threads, rod nut and all cylinder parts in solvent and dry with compressed air.

Using compressed air, blow out all passages in the valve block.

Inspect all parts for damage or wear. Replace damaged or worn parts.

STEP 2 G0907042

If needed, install a new bushing in the base end and the rod end of the cylinder.

STEP 5

G0907041

Inspect the cylinder barrel for nicks, scratches or scoring prior to being assembled.

Use crocus cloth to remove minor nicks or scratches.

G0907038

STEP 3

Install a new inner seal (lip to the inside of the barrel) in the head gland.

NOTE: Lubricate all new seals with clean operating fluid or petroleum jelly before installation.

G0907043

Inspect the cylinder rod for any nicks, scratches or scoring. Roll the rod on a hard flat surface to check for straightness.

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CYLINDER REPAIR

STEP 6

STEP 9

G0907036

G0907033

Install a new wiper ring and O-ring in the head gland.

Install the O-ring on the cylinder rod.

Apply a thin coat of oil on the seal, wear ring and wiper in the head gland, prior to installation on the rod.

Push the O-ring against the base. Be sure the O-ring is not twisted.

STEP 10

STEP 7

G0907032

Install the piston on the cylinder rod.

G0907035

Using care, slide the head gland over the threads and onto the cylinder rod.

STEP 11

STEP 8 3

2

1

G0907031

Apply Loctite® #271 Thread Lock (or equivalent) on the threads. Install and tighten the nut on the cylinder rod to 450 ft.- lbs. (610 Nm) torque.

G0907034

Install a new O-ring (1), backup ring (2) and O-ring (3) on the head gland.

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CYLINDER REPAIR

STEP 12

STEP 15 Remove the rod from the vise.

Clamp the base end of the barrel in a vise or other holding fixture.

STEP 16

G0907030

Install the inner seal on the piston. Be sure the seal is not rolled or twisted.

STEP 13 G0907027

Carefully install the rod assembly into the cylinder barrel.

IMPORTANT: Protect the chrome finish on the cylinder rod at all times. Damage to the surface of the rod can cause premature seal failure.

STEP 17

G0907029

Install the outer seal over the inner seal on the piston.

STEP 14

G0907026

Install and tighten the head gland in the cylinder barrel.

G0907028

Install the wear ring on the piston and apply a thin coat of oil on the seal and wear rings prior to installation of the rod assembly.

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CYLINDER REPAIR

STEP 18

G0907040

Lubricate and install new O-rings and backup rings on the load check valve.

STEP 19 3

1

2 G0907024

Install the load check valve (1), plug (2) and fitting caps (3). Torque the load check valve to 10 to 12 ft.lbs. (14 to 16 Nm).

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SLAVE CYLINDER

SLAVE CYLINDER REMOVAL

STEP 3

BEFORE cleaning, lubricating, or servicing this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations).

STEP 1

G1007015

Using a chain hoist and lifting strap, position the lifting strap around the slave cylinder and apply upward force.

STEP 4 2 G1007035

1

Raise the boom enougth to access the slave cylinder retaining plate. Support the boom on a support stand.

Stop the engine.

STEP 2

G100 7016

On the early models remove the two bolts (1) and retaining plate (2).

STEP 5

G1007014

Move the boom joystick in all directions several times to relieve pressure from the hydraulic system.

G1107090

On the late models remove the snap ring.

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SLAVE CYLINDER

STEP 6

STEP 9

G1007021

G1007020

From the right side of the boom, remove the top pivot pin from the slave cylinder.

Remove the bottom pivot pin retainer bolt and nut.

STEP 10

STEP 7

G1007025

Remove the base pivot pin.

G1007023

Lift up on the slave cylinder to access the hydraulic hose. Disconnect the hose. Install a cap and plug on the hose and hydraulic fitting.

STEP 11

STEP 8

G1007027

Remove the slave cylinder.

G1007024

Disconnect the bottom hydraulic hose on the slave cylinder. Install a cap and plug on the hose and hydraulic fitting.

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SLAVE CYLINDER

SLAVE CYLINDER INSTALLATION

STEP 3

STEP 1

G1007020

Install the retainer bolt and nut in the lower pivot pin and tighten.

G1007027

Using a chain hoist and lifting strap, lower the slave cylinder into the base mount.

STEP 4

STEP 2

G1007024

Remove the cap and plug from the lower hydraulic hose and slave cylinder fitting. Reconnect the lower hydraulic hose to the slave cylinder.

G1007025

Install the lower pivot pin into the base of the slave cylinder.

STEP 5

G1007023

Remove the cap and plug from the upper hydraulic hose and slave cylinder fitting. Reconnect the upper hydraulic hose to the slave cylinder.

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SLAVE CYLINDER STEP 8

STEP 6

1 2

G1007022

G1007016

Lower and align the rod end of the slave cylinder into the boom end mount.

On the early models install the retaining plate (1), bolts (2) and then tighten.

STEP 7

STEP 9

G1007031

G1107090

On the late models, install the snap ring.

STEP 10 Remove the chain hoist and lifting strap.

STEP 11 Start the engine. Move the machine to an open area and park on a level surface. Apply the parking brake.

Raise and lower the boom several times until all air is removed from the system. Cycle the tilt circuit back and forth. This will aid in removing air from the circuit.

G1007018

Install the pivot pin into the rod end of the slave cylinder until the half moon end of the pin is positioned as shown.

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STEP 12 Lower the boom and shut off the engine. Check for leaks. Correct any leakage found. Check the hydraulic fluid level. If necessary, fill to the correct level with the specified fluid.

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Section 606 LIFT CYLINDER REMOVAL AND INSTALLATION 519 Telehandler

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LIFT CYLINDER

LIFT CYLINDER REMOVAL

STEP 3

BEFORE cleaning, lubricating or servicing this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations).

STEP 1

G0907005

Using a chain hoist and lifting strap, position the lifting strap to support the weight of the lift cylinder when the upper pivot pin is removed. Apply upward force to remove slack in the lifting strap.

STEP 4 G0907003

Fully retract and lower the telescoping boom onto a support stand. Stop the engine.

STEP 2

G0907007

Remove the snap ring from both sides of the upper pivot pin.

STEP 5 G0907004

Move the boom travel joystick in all directions several times to relieve pressure from the hydraulic system.

NOTE: See Section 605 of this Service Manual for the repair of this cylinder.

G0907009

Remove the upper pivot pin.

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LIFT CYLINDER

STEP 6

STEP 9

G0907011

G0907010

Mark the two cylinder hydraulic hoses for correct assembly. Disconnect the two hydraulic hoses from the lift cylinder.

Reposition the chain hoist and lifting strap to support the full weight of the lift cylinder during removal.

STEP 10

STEP 7 Install caps and plugs on all hydraulic fittings and hoses to prevent contaminating the hydraulic system.

STEP 8

G0907014

Remove the pin from the lift cylinder lower pivot point and remove the lift cylinder.

G0907012

Remove the retaining bolt and nut that secures the lower pivot pin.

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LIFT CYLINDER

LIFT CYLINDER INSTALLATION

STEP 3

STEP 1

G0907014

Install the pin with the bolt hole vertical in the lower pivot point.

G1007002

Position a chain hoist and lifting strap at the balance point of the lift cylinder.

STEP 4

STEP 2

G0907012

Install the retaining bolt and nut to secure the pin.

G1007003

STEP 5

Lower the bottom end of the lift cylinder into position above the lower mounting bracket.

G0907011

Remove the caps and plugs from the lift cylinder hydraulic lines and connect the two hydraulic lines to the lift cylinder.

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LIFT CYLINDER

STEP 6

STEP 9

G0907010

G0907005

Using the chain hoist and lifting strap, position the lift cylinder in the cylinder mount.

Remove the chain hoist and lifting strap.

STEP 10

STEP 7

Start the engine. Move the machine to an open area and park on a level surface. Apply the parking brake.

Raise and lower the boom several times until all air is removed from the circuit.

STEP 11 Lower the boom and shut off the engine. Check for leaks. Correct any leakage found. Check the hydraulic fluid level. If necessary, fill to the correct level with the specified fluid.

G0907009

Install the upper pivot pin.

STEP 8

G0907008

Install the snap ring on both sides of the upper pivot pin.

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Section 607 BOOM EXTEND CYLINDER REMOVAL AND INSTALLATION 519 Telehandler

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GENERAL TABLE OF CONTENTS EXTEND CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 EXTEND CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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BOOM EXTEND CYLINDER

EXTEND CYLINDER REMOVAL

STEP 3

BEFORE cleaning, lubricating, or performing service on this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations.)

STEP 1

G1007068

From the right hand side, disconnect the right hand light wiring harness connector.

STEP 4 1

1 2

G1007071

2

Open the rear access cover.

STEP 2

1

1

1 G1007072

With the boom still raised, remove the rear lighting mounting bolts (1) and plates (2). Remove the rear lights.

1

STEP 5

2 G1007069

Raise the boom to access rear lighting wiring harness. On left side, remove the two zip ties (1).

Then disconnect the harness connector (2).

G1007102

Lower the boom and retract the inner boom all the way. Remove the top left and right side pad bolts from the inner boom. Remove wear pads.

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BOOM EXTEND CYLINDER

STEP 6

STEP 8

2 2 1 1

G1007066

G1007074

Extend the inner boom far enough to access the front rod end pivot pin.

Loosen the hydraulic oil fill cap to release residual pressure in the tank. Relieve hydraulic pressure from the extend cylinder. Disconnect both hydraulic hoses (1) from the hydraulic lines (2).

STEP 7

STEP 9

1

G1007131

G1007075

Cap and plug all hydraulic line fittings.

STEP 10 2

G1007067

Remove both the left and right snap rings from the front pivot pin (1). From the right hand side of the inner boom, remove the rod end pivot pin (2).

G1007073

Disconnect the hydraulic lines from the base end of the extend cylinder.

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BOOM EXTEND CYLINDER

STEP 11

STEP 14

G1007076

G1007079

Cap hydraulic fittings on the extend cylinders.

From the right hand side, remove the base end pivot pin.

STEP 12

STEP 15

G1007074

Remove hydraulic lines mounting block by removing the two nuts. Remove the two hydraulic lines.

G1007080

Pull back on the extend cylinder enough to access the extend cylinder lock valve. Remove the lock valve.

STEP 13

STEP 16

G1007077

Remove the base end pivot pin retaining bolt and nut.

G1007082

Plug the lock valve port.

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BOOM EXTEND CYLINDER

STEP 17

STEP 18

G1007083

G1007127

2

1

G1007118

G1007128

Using a chain hoist and lifting strap, lift up on the extend cylinder and remove the two bolts (1) securing the center wear pad. Remove the wear pad (2).

Using two lifting straps and a chain hoist, lift up on the extend cylinder. Slide the extend cylinder out while rotating the cylinder to clear the hydraulic hoses. Remove the extend cylinder.

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BOOM EXTEND CYLINDER

EXTEND CYLINDER INSTALLATION

STEP 20

STEP 19

G1007083

G1007127

1

2

G1007118

Using a chain hoist and lifting strap, lift up on the extend cylinder and install the wear pad (1) and bolts (2). Tighten the bolts.

G1007128

Install the extend cylinder into the inner boom. Rotate the cylinder enough to clear the hydraulic hoses.

Once past the hoses, rotate the cylinder back into place.

STEP 21

G1007082

Remove the lifting strap and the lock valve plug.

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BOOM EXTEND CYLINDER

STEP 22

STEP 24

2 1

G1007080

G1007077

With the extend cylinder installed far enough so that the lock valve orifice is past the main frame (1), install the lock valve (2) and tighten.

Install the pivot pin retaining bolt and nut. Tighten the nut.

STEP 25

STEP 23

G1007076 G1007078

Remove the caps from the extend cylinder hydraulic fittings.

Using the lifting strap and chain hoist, raise or lower the cylinder to align the base end pivot pin.

STEP 26

G1007073

Install the two hydraulic lines. Do not tighten.

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BOOM EXTEND CYLINDER

STEP 27

STEP 30 2 1 1

2

2

G1007074

G1007074

Install the hydraulic lines mounting block (1) and install the two nuts (2).

Connect the hydraulic hoses (1) to the hydraulic lines (2) and tighten.

STEP 28

STEP 31

G1007073

G1007129

Fully tighten hydraulic lines on the extend cylinder.

Install the rod end pivot pin snap ring on the left side of the inner boom.

STEP 29

STEP 32

G1007075 G1007130

Remove caps and plugs from hydraulic lines and hoses.

913302

From the right hand side, install the rod end pivot pin into the inner boom and extend cylinder.

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BOOM EXTEND CYLINDER

STEP 33

STEP 35

1

G1007131

G1007068

Install the right snap ring.

STEP 34 1

1 2

1

2

2

2

1 1 G1007069

With the boom in the raised position, connect the right and left lighting wire connectors (1). Install zip ties on the left wiring harness (2).

G1007072

Raise the boom high enough to access the rear light mounting points. Install lights and fasten with the mounting bolts (1) and plates (2). Tighten the bolts.

STEP 36 Start the engine and operate the inner boom and check for hydraulic leaks. Check hydraulic fluid reservoir, add hydraulic fluid if needed.

STEP 37

G1007071

Close the rear access cover.

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BOOM ASSEMBLY

BOOM ASSEMBLY REMOVAL

STEP 5

BEFORE cleaning, lubricating, or performing service on this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations.)

STEP 1 Retract the inner boom all the way.

STEP 2 G0907005

Using a chain hoist and lifting strap, position the lifting strap to support the weight of the lift cylinder when the upper pin is removed. Apply upward force to remove the slack in the lifting strap.

STEP 6

G1007138

Raise the boom high enough to access the front lighting rear harness connectors. Disconnect the connectors.

STEP 3 Remove the slave cylinder. See Section 608 of this manual.

G0907008

Remove the snap ring from both sides of the upper pivot pin.

STEP 4 STEP 7

G0907003

Lower the boom onto the support stand.

G0907009

Remove the upper pivot pin.

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BOOM ASSEMBLY

STEP 8

STEP 11

2 2 1 1

G1007145

G1007074

Lower the lift cylinder onto the frame and remove the lifting strap and chain hoist.

Disconnect both hydraulic hoses (1) from the hydraulic lines (2) for the extend cylinder.

STEP 9

STEP 12

G1007071

G1007075

Open the rear access cover.

Cap and plug all hydraulic line fittings.

STEP 10

STEP 13

Loosen the hydraulic fill cap to relieve residual pressure. Relieve hydraulic pressure in the system.

G1007135

Disconnect the hydraulic hoses from the hydraulic lines.

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BOOM ASSEMBLY

STEP 14

STEP 17

G1007149

G1007144

Cap and plug all the hydraulic fittings.

Remove the main boom pivot pin.

STEP 15

STEP 18

G1007143

G1007146

Connect the lifting chains to the lifting points on the main boom. Using a chain hoist remove slack in the lifting chains.

Using the chain hoist, lift the main boom up and forward to remove.

STEP 16

G1007 140

Remove the main boom pivot pin retaining bolt and nut.

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BOOM ASSEMBLY

BOOM ASSEMBLY INSTALLATION

STEP 22

STEP 19

G1007003

Lower the boom onto the support stand.

G1007146

STEP 23

Using the chain hoist, lower the main boom down and back into position.

STEP 20

G1007149

Remove caps and plugs from the hydraulic hoses and lines.

G1007150

STEP 24

Install the main boom pivot pin.

STEP 21

G1007135

Connect the hydraulic hoses to the hydraulic lines.

G1007140

Install the pivot pin retaining bolt and nut.

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BOOM ASSEMBLY

STEP 25

STEP 28

G1007075

G0907009

Remove caps and plugs from the extend cylinder hydraulic lines.

Install the lift cylinder rod end pivot pin.

STEP 29

STEP 26

2 2 1 1 G0907007

Install the snap rings on both sides of the pivot pin.

G1007074

Connect the hydraulic hoses (1) to the hydraulic lines (2).

STEP 30 Install the slave cylinder. See Section 608 in this manual.

STEP 27

G0907010

Using a chain hoist and lifting strap, raise the lift cylinder into the rod end mount.

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BOOM ASSEMBLY

STEP 31

G1007137

Connect the front lighting rear harness connectors.

STEP 32 Start the engine and operate all hydraulic functions and check for hydraulic leaks. Add hydraulic fluid if needed.

STEP 33

G1007071

Close the rear access cover.

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GENERAL TABLE OF CONTENTS INNER BOOM REMOVAL.........................................................................................................................................1 INNER BOOM INSTALLATION.................................................................................................................................4

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INNER BOOM

INNER BOOM REMOVAL

STEP 5

BEFORE cleaning, lubricating, or performing service on this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations.)

STEP 1 Fully retract the inner boom.

STEP 2 G1007074

Disconnect hydraulic hoses from the hydraulic lines.

Cap and plug the hydraulic fittings.

STEP 6

G1007071

Open the rear access cover.

STEP 3 G1007073

Disconnect hydraulic lines from the extend cylinder.

Cap and plug the hydraulic fittings.

STEP 7

G1007102

Remove the two bolts from the top left wear pad on the inner boom. Remove the wear pad.

STEP 4 Fully extend the inner boom. Relieve hydraulic pressure from the extend cylinder.

913302

G1007074

Remove the two nuts from the hydraulic lines retainer block. Remove the hydraulic lines.

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INNER BOOM

STEP 8

STEP 10 2

2

1

1 G1007113

G1007086

Raise the main boom to access the tilt cylinder and auxiliary hydraulic line fittings. Relieve the hydraulic pressure from the lines. Disconnect the hydraulic fittings. Cap and plug all fittings.

Disconnect the front lights wiring harness connectors (1). Remove the two mounting bolts (2) from the light bar. Remove the lights.

STEP 11

STEP 9 2

1

G1007095

Mark all inner boom wear pads for reassembly.

G1007108

Lower the boom onto the support stand (1). Using a chain hoist and lifting strap apply upward pressure on the front of the inner boom (2).

NOTE: Some pads may have shims.

STEP 12

G1007096

Remove the six top wear pad retaining bolts.

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INNER BOOM

STEP 13 2

2 1

1 1

1

G1007100

G1007097

Remove the top wear pads and shims.

Using a chain hoist and lifting strap, raise the boom enough to take weight off the bottom wear pads.

Remove the eight wear pad bolts (1) and remove the wear pads and shims (2).

STEP 14 2

STEP 16 1

2

G1007093

Remove the side wear pad bolts from both sides of the main boom. Remove the wear pads.

G1007101

Remove the boom angle indicator bolts (1) and remove the boom angle indicator (2).

NOTE: The lighting harness clamp bolt is longer (2).

STEP 15

STEP 17

G1007098 G1007106

With the inner boom well supported, start the engine and back the machine away from the inner boom.

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INNER BOOM

INNER BOOM INSTALLATION

STEP 20

STEP 18

1

G1007122

G1007105

Make sure the tilt cylinder and auxiliary hoses are routed correctly.

2

STEP 19

G1007124

3 G1007106

Apply grease to the wear pads. Start the machine and slowly drive forward allowing the inner boom to align with the main boom.

G1007123

Attach one end of a Come-along to the front point on the inner boom (1). Attach the other end of the Come-along to the mounting point (2). Ratchet the Come-along (3) to allow the inner boom to move into the main boom.

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INNER BOOM

STEP 21

STEP 24 1 2 1

1

G1007099

G1007093

Install the bottom wear pads and tighten the bolts.

Install the right and left wear pad mounting bolts (1).

Tighten the bolts.

STEP 22

NOTE: The wiring harness clamp bolt is longer (2).

STEP 25 1

G1007088

2

Install the top and side wear pads.

2 G1007086

STEP 23

Install the light bar and tighten the mounting bolts (1).

Connect the light wiring connectors (2).

G1007096

Install the six top wear pad bolts and tighten.

913302

702-5

PRINTED IN U.S.A.

Template Name: OML_2_col Template Date: 1997_02_12

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519 Telehandler

INNER BOOM

STEP 26

STEP 28

G1007113

G1007073

Raise the boom enough to access the tilt cylinder and auxiliary hydraulic line connectors. Remove the caps and plugs from the hydraulic connectors.

Connect the hydraulic lines and tighten.

Remove the caps and plugs from the extend cylinder hydraulic lines. Install the hydraulic lines to the extend cylinder.

NOTE: Do not tighten.

STEP 27

STEP 29 1 1 2 2

G1007102

With the main boom lowered and the inner boom fully retracted from the back of the machine, install the top left wear pad and bolts. Tighten the bolts.

913302

G1007074

Install the hydraulic lines mounting block and tighten the nuts (1). Connect the hydraulic hoses (2) and tighten.

702-6

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Template Name: OML_2_col Template Date: 1997_02_12

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519 Telehandler

INNER BOOM

STEP 30

STEP 32 Start the engine and operate the inner boom. Check for hydraulic leaks; add hydraulic fluid if needed.

STEP 33

G1007073

Tighten the extend cylinder hydraulic line fittings.

STEP 31 G1007071

Close the rear access cover.

2 1

G1007101

Install the boom angle indicator (1) and tighten the bolts (2).

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PRINTED IN U.S.A.

Section 800 HOOD AND COVER REMOVAL AND INSTALLATION 519 Telehandler

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913302

Template Name: OML_2_col Template Date: 1997_02_12

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GENERAL TABLE OF CONTENTS HOODS AND COVERS............................................................................................................................................. 1 ENGINE COVER REMOVAL .................................................................................................................................... 1 ENGINE COVER INSTALLATION ............................................................................................................................ 2 FRONT COVER ACCESS......................................................................................................................................... 2 RADIATOR COVER REMOVAL................................................................................................................................ 3 RADIATOR COVER INSTALLATION........................................................................................................................ 3 REAR COVER ACCESS ........................................................................................................................................... 4

Template Name: OML_2_col Template Date: 1994_04_22

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519 Telehandler

HOODS AND COVERS

HOODS AND COVERS

STEP 3

BEFORE cleaning, lubricating, or performing service on this equipment, refer to the MANDATORY SAFETY SHUTDOWN PROCEDURE in Section 100 (Personal Safety Information And Decal Locations).

2

STEP 1 1

1

G0707002

Remove the four bolts (1) on the engine hood hinges.

With the help of an assistant, remove the engine hood (2).

G0607021

Open engine hood.

ENGINE HOOD REMOVAL STEP 2

1

G0707003

Temporarily install a support to prevent the engine hood from closing when the gas cylinder bracket is removed. Remove the two bolts (1) on the gas cylinder bracket.

913302

800-1

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Template Name: OML_2_col Template Date: 1994_04_22

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519 Telehandler

HOODS AND COVERS

ENGINE HOOD INSTALLATION

FRONT ACCESS COVER

STEP 1

STEP 1

1

1

G0707002

G0707042

Turn the quarter-turn latch counterclockwise and lift, slide toward cab, pull out.

With the help of an assistant, place the engine hood hinges in place and install the four mounting bolts (1).

STEP 2

1

G0707003

Temporarily install a support to prevent the hood from closing. Install the gas cylinder bracket with the two mounting bolts (1).

STEP 3 Remove the support and close the engine hood.

PRINTED IN U.S.A.

800-2

913302

Template Name: OML_2_col Template Date: 1994_04_22

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519 Telehandler

HOODS AND COVERS

RADIATOR COVER REMOVAL

RADIATOR COVER INSTALLATION

STEP 1

STEP 1

Open the engine hood.

STEP 2

G0707005

Place the radiator cover down into place from the rear.

STEP 2

G0707004

Turn the two quarter-turn latches counterclockwise to unlock the radiator cover.

STEP 3

G0707004

Turn the two quarter-turn latches clockwise to lock the cover into place.

G0707005

Remove the cover by lifting up and to the rear.

913302

800-3

PRINTED IN U.S.A.

Template Name: OML_2_col Template Date: 1994_04_22

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519 Telehandler

HOODS AND COVERS

REAR ACCESS COVER STEP 1

G0707040

Turn the quarter-turn latch counterclockwise to open.

PRINTED IN U.S.A.

800-4

913302

Mustang Manufacturing Co., Inc. www.mustangmfg.com

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