Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
  • Section 1. SPECIFICATIONS
    • 1.1 Capacities
    • 1.2 Engine Specifications
    • 1.3 Tires
    • 1.4 Specifications and Performance Data
    • 1.5 Torque Requirements
    • 1.6 Critical Stability Weights
    • 1.7 Major Component Weights
    • 1.8 Function Speeds
    • 1.9 Pressure Settings - PSI (Bar)
    • 1.10 Cylinder Specifications
    • 1.11 Lubrication
      • Hydraulic Oil
    • 1.12 Welder, Hydraulic (option)
    • 1.13 Serial Number Location
    • 1.14 Operator Maintenance and Lubrication
      • Draining Oil Build Up From The Propane Regulator
      • Propane Fuel Filter Replacement
      • Propane Fuel System Pressure Relief
  • Section 2. GENERAL
    • 2.1 Machine Preparation, Inspection, and Maintenance
      • General
      • Preparation, Inspection, and Maintenance
      • Pre-Start Inspection
      • Pre-Delivery Inspection and Frequent Inspection
      • Annual Machine Inspection
      • Preventative Maintenance
    • 2.2 Service and Guidelines
      • General
      • Safety and Workmanship
      • Cleanliness
      • Components Removal and Installation
      • Component Disassembly and Reassembly
      • Pressure-Fit Parts
      • Bearings
      • Gaskets
      • Bolt Usage and Torque Application
      • Hydraulic Lines and Electrical Wiring
      • Hydraulic System
      • Lubrication
      • Battery
      • Lubrication and Servicing
    • 2.3 Lubrication and Information
      • Hydraulic System
      • Hydraulic Oil
      • Changing Hydraulic Oil
      • Lubrication Specifications
    • 2.4 Cylinder Drift Test
      • Platform Drift
      • Cylinder Drift
    • 2.5 Pins and Composite Bearing Repair Guidelines
    • 2.6 Welding on JLG Equipment
      • Do the Following When Welding on JLG Equipment
      • Do NOT Do the Following When Welding on JLG Equipment
  • Section 3. CHASSIS & TURNTABLE
    • 3.1 Tires & Wheels
      • Tire Inflation
      • Tire Damage
      • Tire Replacement
      • Wheel Replacement
      • Wheel Installation
    • 3.2 Drive Hub Part No. 2780243 (2wd Rear) Part No. 2780244 (4wd Rear)
      • Disassembly
      • Disassembly of Cover Unit (8)
      • Disassembly of First Stage Planetary Assembly
      • Disassembly of the Second Stage Planet Gears (1)
      • Assembly of First Stage Planetary Assembly (7)
      • Assembly Of End Cover Unit (8)
      • Final Assembly
    • 3.3 Drive Hub Part No. 2780246 (4wd steer axle Prior to S/N 0300076633)
      • Disassembly
      • Disassembly of Cover Unit (8)
      • Disassembly of First Stage Planetary Assembly
      • Disassembly of the Second Stage Planet Gears (1)
      • Assembly of First Stage Planetary Assembly (7)
      • Assembly of End Cover Unit (8)
      • Final Assembly
    • 3.4 Torque Hub - 4WD (Machines built after S/N 0300076633)
      • Roll and Leak Testing
      • Tightening and Torquing Bolts
      • Oil Information
      • Main Disassembly for ”B” Drives
      • Hub-Spindle Disassembly
      • Cover Disassembly
      • Carrier Disassembly
      • Assembly of the Carrier
      • Cover Sub-Assembly
      • Hub-Spindle Sub-Assembly
      • Main Assembly
      • Tool List
    • 3.5 Re-Aligning Torque Hub Input Coupling
      • Equipment Required
      • Procedure
    • 3.6 Drive Brake
      • Pre-Installation Checks
      • Installation
      • Maintenance
      • Disassembly
      • Examination
      • Assembly
    • 3.7 Drive Motor
      • Description
      • Shaft Seal Replacement
      • Loop Flushing Valve
      • Troubleshooting
      • Disassembly
      • Inspection
      • Assembly
      • Initial Start-up Procedures
    • 3.8 Adjustment Procedure For Lockout Valve
    • 3.9 Toe-In Adjustment
    • 3.10 2WD Hub
      • Removal & Disassembly
      • Cleaning & Inspection
      • Assembly & Installation
    • 3.11 Oscillating Axle Bleeding Procedure
    • 3.12 Oscillating Axle Lockout Test
    • 3.13 Swing Bearing
      • Turntable Bearing Mounting Bolt Condition Check
      • Wear Tolerance
      • Replacement of Swing Bearing
      • Swing Bearing Torque Value
      • Swing Drive Installation
    • 3.14 Swing Brake (Prior to S/N 64802)
      • Installation
      • Brake Disassembly
      • Assembly Information
    • 3.15 Swing Brake S/N 64802 to Present
      • Disassembly
      • Assembly
    • 3.16 Swing Drive Torque Hub
      • Disassembly Procedure
      • Hub Shaft Sub-Assembly Procedure
      • Carrier Sub-Assembly Procedure
    • 3.17 Semi-Track
      • Testing the Track
      • Removing the Track
      • Assuming Normal Wear
      • Adjustment
    • 3.18 Generator
      • Every 250 hours
      • Every 500 hours
      • Overload Protection
      • Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
    • 3.19 Ford EFI Engine
      • Performing Diagnostics
      • Visual/Physical Engine Inspection Check
      • EFI Diagnostics (Prior to S/N 61718)
      • ECM AND SENSORS
      • Fuel System
    • 3.20 Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61718)
      • General
      • Procedure
      • Controller Status
      • Failure Modes
    • 3.21 Tilt Alarm Switch (Prior to S/N 61718)
      • Manual Adjustment
    • 3.22 Hydraulic Welder (225-4)
      • Replacement of Weld Transformer
      • Replacement of Hydraulic Motor
      • Replacement of Fine Control
      • Rotor Replacement
      • Replacement of Flow Regulator
      • Replacement of Exciting Rectifier Bridge
      • Replacement of Weld Rectifier Bridge
      • Replace Brushes on Sky Welder
      • Replacing Range Switch
      • Replacing Selector Switch
      • Replacement of Couplings
      • Voltage Change Over - 120/240 Volt
    • 3.23 Troubleshooting of the Sky Welder
      • Low Sky Welder Speed
      • Low Welding Amps
      • No Output on Weld Receptacles or AC Receptacles
      • No Ac Output but Weld Output
      • No Output on Weld Receptacle but AC Receptacle Output OK
      • Welder Completely Dead - No AC or Weld Power
      • Intermittent Welder Operation
    • 3.24 Deutz EMR 2 (S/N 77682 to Present)
    • 3.25 GM Engine General Maintenance
      • Maintenance of the Drive Belt
      • Engine Electrical System Maintenance
      • Checking/Filling Engine Oil Level
      • Changing The Engine Oil
      • Coolant Fill Procedure - Dual Fuel Engine
    • 3.26 GM Engine Dual Fuel System
      • Fuel Filter
      • Electric Lock Off
      • EPR Assembly
      • Low Pressure Regulator (LPR)
      • Air Fuel Mixer
      • Electronic Throttle Control (ETC)
      • Engine Control Module
      • Heated Exhaust Gas Oxygen Sensor
      • Gasoline Multi Point Fuel Injection System (MPFI)
      • Gasoline Fuel Pump
      • Gasoline Pressure And Temperature Sensor Manifold
      • Fuel Filter
      • Fuel Injector Rail
      • Fuel Injector
    • 3.27 GM Engine Fuel System Repair
      • Propane Fuel System Pressure Relief
      • Propane Fuel System Leak Test
      • Propane Fuel Filter Replacement
      • Electronic Pressure Regulator (EPR) Assembly Replacement
      • Temperature Manifold Absolute Pressure (TMAP) Sensor
      • Electronic Throttle Control Replacement
      • Mixer Replacement
      • Coolant Hose Replacement
      • Vapor Hose Replacement
      • Engine Control Module Replacement
      • Heated Exhaust Gas Oxygen Sensor Replacement
    • 3.28 GM Engine LPG Fuel System Diagnosis
      • Fuel System Description
      • Diagnostic Aids
    • 3.29 Perkins Engine General Maintenance
      • Replacing the Engine Crankcase Breather
      • Engine Oil Level - Check
      • Engine Oil and Filter - Change
      • Fuel Filter/Water Separator
      • Setting the Actuator
      • Speed Sensor Installation
    • 3.30 Engine Radiator Fill Procedure - Perkins & Caterpillar
    • 3.31 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS
      • Section Layout
      • List of Abbreviations in this Section
      • Fault Code Broadcast
      • Diagnostic Trouble Codes
      • CAN
      • MIL Output
      • Diagnostic Calibration Configuration and Corrective Actions
      • Fault/Diagnostic Trouble Code Interaction
      • DBW Diagnostic Test
    • 3.32 Diagnostic Trouble Code Fault Descriptions
      • DTC 116- ECT Higher Than Expected Stage 1
      • DTC 117- ECT/CHT Low Voltage
      • DTC 118- ECT/CHT High Voltage
      • DTC 122- TPS1 Signal Voltage Low
      • DTC 123- TPS1 Signal Voltage High
      • DTC 217- ECT Higher Than Expected 2
      • DTC 219- RPM Higher Than Max Allowed Governed Speed
      • DTC 336- Crank Signal Input Noise
      • DTC 337- Loss of Crank Input Signal
      • DTC 521- Oil Pressure Sender/Switch High Pressure
      • DTC 524- Oil Pressure Low
      • DTC 562- Battery Voltage (VBat) Low
      • DTC 563- Battery Voltage (VBat) High
      • DTC 601- Microprocessor Failure - FLASH
      • DTC 604- Microprocessor Failure - RAM
      • DTC 606- Microprocessor Failure - COP
      • DTC 642- 5 Volt External Low Voltage
      • DTC 643- 5 Volt External High Voltage
      • DTC 1612- Microprocessor Failure - RTI 1
      • DTC 1613- Microprocessor Failure - RTI 2
      • DTC 1614- Microprocessor Failure - RTI 3
      • DTC 1615- Microprocessor Failure - A/D
      • DTC 1616- Microprocessor Failure - interrupt
      • DTC 1625- CAN J1939 Shutdown Request
      • DTC 1626- CAN J1939 Transmit (Tx) Fault
      • DTC 1627- CAN J1939 Receive (Rx) Fault
      • DTC 1628- CAN Address Conflict Failure
      • DTC 1629- J1939 TSC1 Message Reciept Loss
      • DTC 1652- TPS1 Loss of Communications
      • DTC 2111- Unable to Reach Lower TPS
      • DTC 2112- Unable to Reach Higher TPS
      • DTC 9999- Throttle Actuator Failsafe Spring Failure
      • DTC to SPN/FMI Table
  • Section 4. BOOM & PLATFORM
    • 4.1 Boom
      • Removal
      • Disassembly
      • Inspection
      • Assembly
      • Installation
    • 4.2 Articulating jib
      • Removal
    • 4.3 Limit Switch Adjustments
      • Boom Horizontal Limit Switch
      • Dual Capacity Angle Limit Switch
      • Boom Length Limit Switch
    • 4.4 Drive Card Setup Procedures
      • Machine Orientation When Doing Speed Tests
      • Test Notes
      • Lift, Swing, and Drive Cards
      • Flow Control Card
    • 4.5 Helac Rotary actuator
      • Theory Of Operation
      • Tools Required for Assembly/Disassembly
      • Disassembly
      • Inspection
      • Assembly
      • Installing Counterbalance Valve
  • Section 5. HYDRAULICS
    • 5.1 Cylinders - Theory of Operation
      • Systems Incorporating Double Acting Cylinders
      • Systems Incorporating Holding Valves
    • 5.2 Cylinder Repair
      • Cylinders Without Counterbalance Valves
      • Cylinders With Dual Counterbalance Valves
      • Disassembly
      • Cleaning and Inspection
      • Assembly
    • 5.3 Valves - Theory of Operation
      • Solenoid Control Valve
      • Relief Valves
    • 5.4 Pressure Setting Procedures
      • 1. Bang-Bang Main Relief Valve;
      • 2. Steer;
      • 3. Platform Level Up;
      • 4. Platform Level Down;
      • 5. Articulating Jib Up;
      • 6. Articulating Jib Down;
      • 7. The Bang-Bang Main Relief Valve;
      • 8. The Proportional Main Relief Valve;
      • 9. Lift Down;
      • 10. Swing;
    • 5.5 Hydraulic Motor Repair (H Series Char-lynn)
      • Disassembly
      • Reassembly Shaft End
      • Gerotor End
      • Timing Procedure
      • Standard Rotation
      • Reverse Rotation
    • 5.6 Hydraulic Pump “Neutral” Or Null Adjustment
    • 5.7 Non-feedback, Proportional Electrical Control - NFPE
      • Features and Benefits of the NFPE Control
      • Input Signal requirements
    • 5.8 Hydraulic Component Start-Up Procedures and Recommendations
  • Section 6. JLG CONTROL SYSTEM (S/N 61718 to Present)
    • 6.1 Introduction
    • 6.2 To Connect the JLG Control System Analyzer
    • 6.3 Using the Analyzer
    • 6.4 Changing the Access Level of the Hand Held Analyzer
    • 6.5 Adjusting Parameters Using the Hand Held Analyzer
    • 6.6 Machine Setup
    • 6.7 Level Vehicle Description
    • 6.8 Machine Personality Settings
    • 6.9 System Test
      • Test from the Platform
      • Test from the Ground Station
    • 6.10 Analyzer Diagnostics Menu Structure
  • Section 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS
    • 7.1 General
    • 7.2 Multimeter Basics
      • Grounding
      • Backprobing
      • Min/Max
      • Polarity
      • Scale
      • Voltage Measurement
      • Resistance Measurement
      • Continuity Measurement
      • Current Measurement
    • 7.3 Checking Switches
      • Basic Check
      • Limit Switches
      • Automatic Switches
      • Switch Wiring - Low Side, High Side
    • 7.4 Applying Silicone Dielectric Compound to Electrical Connections
      • Installation of Dielectric Grease
      • Deutsch HD, DT, DTM, DRC Series
      • AMP Seal
      • AMP Mate-N-Lok
      • DIN Connectors
      • Exclusions
    • 7.5 AMP Connector
      • Applying Silicone Dielectric Compound to AMP Connectors
      • Assembly
      • Disassembly
      • Wedge Lock
      • Service - Voltage Reading
    • 7.6 Deutsch Connectors
      • DT/DTP Series Assembly
      • DT/DTP Series Disassembly
      • HD30/HDP20 Series Assembly
      • HD30/HDP20 Series Disassembly