Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. Specifications
  • 1.1 Operating specifications
  • 1.2 Capacities
  • 1.3 Engine Data
  • 1.4 Component Data
    • Swing System
    • Auxiliary Power Pump
    • Hydraulic Filters
  • 1.5 Performance Data
    • Function Speeds
    • Dimensions
  • 1.6 Torque Requirements
  • 1.7 Pressure Settings
  • 1.8 Cylinder Specifications
  • 1.9 Major Component Weights
  • 1.10 Serial Number Locations
  • 1.11 Hydraulic Oil
  • 1.12 Operator Maintenance and Lubrication
• 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. Gradall Chassis
  • 3.1 Assembly
  • 3.2 Track tensioning
  • 3.3 Rubber Track Pad Installation
• Section 4. CAT Chassis (Prior to S/N 0300128000)
  • 4.1 Duo-Cone Conventional Seals
    • Installation
    • Assembly and Installation
    • Acceptable Lubricants for Assembly
  • 4.2 System Pressure - Release
    • Procedure for Releasing Pressure
    • Release Of Hydraulic Pressure From A Single Hydraulic Circuit
    • Release Of Hydraulic Pressure From Multiple Hydraulic Circuits
  • 4.3 Track Carrier Roller
    • Removal
    • Installation
  • 4.4 Track Roller
    • Removal
    • Installation
  • 4.5 Track
    • Separation
    • Connection
  • 4.6 Front Idler and Recoil Spring
    • Removal
  • 4.7 Recoil Spring
    • Disassembly
    • Assembly
  • 4.8 Front Idler and Recoil Spring
    • Installation
  • 4.9 Track Adjuster
    • Removal
    • Installation
  • 4.10 Sprocket
    • Removal
    • Installation
  • 4.11 Final Drive and Travel Motor
    • Removal
    • Installation
  • 4.12 Track Adjustment
    • Measuring Track Tension
    • Adjusting Track Tension
    • Track Adjustment - Inspect
• SECTION 5. CAT Chassis (S/N 0300128000 to Present)
  • 5.1 Precautions for use
    • General
    • Installation
    • Hydraulic System
    • Hydraulic Fluid
    • Lubricating Oil for Reduction Gears
    • Operation of Motor
    • Use of Parking Brake
    • Prevention of Overrun
    • Setting of Self-Priming Circuit
    • Cases of Hydraulic Circuit
  • 5.2 gENERAL
    • Description
  • 5.3 Construction and Function
    • Working Principle of Swash Plate Type Axial Piston Motor
    • Working Principle of Shuttle Valve
    • Working Principle of Relief Valve
    • Working Principle of Low Pressure Relief Valve
    • Two-Speed Changeover System
    • Working Principle of Parking Brake
    • Procedures for manually releasing parking brake (This mechanism is optional.)
    • Reduction Gears
  • 5.4 Precautions and warnings
    • Inspection
    • Direction of Rotation
    • Hydraulic Fluid
    • Filters
    • Piping Work
    • Lubricating Oil for Reduction Gears
    • Cautions in Using Parking Brake
  • 5.5 Operating Steps and Precautions
    • Precautions at Startup
    • Hydraulic Fluid Temperature during Operation
    • Maintenance and Inspection
  • 5.6 Periodic Inspection and Change Criteria
    • Hydraulic Fluid
    • Filters
    • Lubricating Oil for Reduction Gears
    • Inspection for Hydraulic Fluid and Lubricant Leaks, and Torque of Bolts and Plugs
  • 5.7 Troubleshooting
    • Troubleshooting for Piston Motor
    • Troubleshooting for Parking Brake
    • Troubleshooting for High Pressure Relief Valve
    • Troubleshooting for Low Pressure Shuttle Valve
    • Troubleshooting for 2-speed Controls
    • Troubleshooting for Low Pressure Relief Valve
  • 5.8 Maintenance and repair procedures
    • Tools for Disassembly and Reassembly
  • 5.9 Precautions for Disassembly
  • 5.10 Disassembly instructions
    • Motor Disassembly
    • Reduction Gear Disassembly
    • Maintenance Standards For Disassembled Parts
  • 5.11 Precautions for Reassembly
  • 5.12 Reassembly
  • 5.13 Quality Check After Reassembly
• Section 6. Turntable
  • 6.1 Swing Hub
    • Adjustment Procedures
  • 6.2 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Replacement
    • Swing Bearing Torque Values.
  • 6.3 Swing Brake - Mico
    • Disassembly
    • Inspection
    • Assembly
  • 6.4 Generator
    • Every 250 hours
    • Every 500 hours
    • Overload Protection
  • 6.5 Spark Arrester Cleaning Instructions
  • 6.6 Deutz EMR 2 (S/N 85110 to Present)
  • 6.7 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS
    • List of Abbreviations in this Section
    • Diagnostic Trouble Codes
    • CAN
    • MIL Output
    • 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 7. Boom & Platform
  • 7.1 Platform
    • Platform Sections Replacement
  • 7.2 Boom Rope Torquing Procedures
    • Torque Procedures
  • 7.3 Wear Pads
    • Main Boom
  • 7.4 Wire Rope
    • Inspection
    • Three Month Inspection
    • Seven Year Inspection
    • Replacement Criteria
  • 7.5 Boom Maintenance
    • Removal
    • Disassembly of Boom Sections
    • Inspection
    • Assembly
    • Installation
  • 7.6 Articulating Jib Boom
    • Removal
    • Disassembly
    • Inspection
    • Assembly
  • 7.7 Limit Switch Adjustment
  • 7.8 Rotator - Helac (Prior to S/N 0300132437)
    • Disassembly
    • Inspection
    • Assembly
  • 7.9 Rotary Actuator (S/N 0300132437 to Present)
    • Theory of Operation
    • Required Tools
    • Disassembly
    • Inspection
    • Assembly
    • Installing Counterbalance Valve
  • 7.10 Foot Switch Adjustment
• Section 8. Hydraulics
  • 8.1 Lubricating O-Rings in the Hydraulic System
    • Cup and Brush
    • Dip Method
    • Spray Method
    • Brush-on Method
  • 8.2 Valves - Theory of Operation
    • Solenoid Control Valve
    • Relief Valves
  • 8.3 Cylinders - Theory of Operation
    • Systems Incorporating Double Acting Cylinders
    • Systems Incorporating Holding Valves
  • 8.4 Cylinder Checking Procedure
    • Cylinders Without Counterbalance Valves
    • Cylinders With Single Counterbalance Valve
    • Cylinders With Dual Counterbalance Valves
  • 8.5 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 8.6 Cylinder Removal and Installation
    • Main Boom Telescope Cylinder Removal
    • Main Boom Telescope Cylinder Installation
    • Main Boom Lift Cylinder Removal
    • Main Boom Lift Cylinder Installation
  • 8.7 Pressure Setting Procedures
    • Main Relief
    • Lift Down
    • Swing
    • Platform Level Up
    • Platform Level Down
    • Jib Up
    • Jib Down
  • 8.8 Hydraulic Pump (Gear)
    • Disassembly
    • Inspect Parts For Wear
    • General Information
    • Reverse Shaft Rotation of Pump
    • Assembly
    • Placing Pump Back Into Service
  • 8.9 Variable Pump
    • Ports and Pressure Gauges
    • NFPE Control
    • Removal and Installation of FNR and NFPE Modules
    • Removal and Installation of FNR and NFPE Control Orifices
    • Charge Relief Valve
    • Shaft Seal and Shaft Replacement
    • Charge Pump
  • 8.10 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication
  • 8.11 Hydraulic Component Start-Up Procedures and recommendations
• Section 9. JLG Control System
  • 9.1 Introduction
  • 9.2 To Connect the JLG Control System Analyzer
  • 9.3 Using the Analyzer
  • 9.4 Changing the Access Level of the Hand Held Analyzer
  • 9.5 Adjusting Parameters Using the Hand Held Analyzer
  • 9.6 Machine Setup
  • 9.7 Level Vehicle Description
  • 9.8 Machine Personality Settings
  • 9.9 Analyzer Diagnostics Menu Structure
• Section 10. Basic Electrical Information & Schematics
  • 10.1 General
  • 10.2 Multimeter Basics
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Voltage Measurement
    • Resistance Measurement
    • Continuity Measurement
    • Current Measurement
  • 10.3 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
  • 10.4 AMP Connector
    • Applying Silicone Dielectric Compound to AMP Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 10.5 Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly